Baker Masoneilan 21000 series User manual

Baker Hughes Data Classication: Public

21000 Series

Top Guided Globe Valve

with Lo-dB™/Anti-cavitation capabilities

Instruction Manual (Rev.E)

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-

SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S

NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND

MAINTENANCE PHILOSOPHIES VARY, BAKER HUGHES COMPANY (AND ITS SUBSIDIARIES

AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO

PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT

PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL

UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND

ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE,

THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH

THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR

REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN

EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN

CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER

INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT

COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER

SHOULD BE REFERRED TO BAKER HUGHES.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE CUSTOMER/

OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT

RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR

WARRANTIES BY BAKER HUGHES REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN

OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO

ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE

EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN

PART WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | iii

Table Of Contents

Important: Safety Warning............................................................................................................. 1

1. Introduction................................................................................................................................. 2

2. General ........................................................................................................................................ 2

3. Unpacking ................................................................................................................................... 2

4. Installation................................................................................................................................... 2

5. Air Piping..................................................................................................................................... 3

6. Body Disassembly...................................................................................................................... 3

6.1 Threaded Trim ....................................................................................................................... 3

6.2 Quick-Change Trim ............................................................................................................... 3

7. Maintenance/Repair.................................................................................................................... 4

7.1 Threaded Seat Ring Removal ............................................................................................... 4

7.2 Bushing Removal .................................................................................................................. 4

7.3 Lapping Seats ....................................................................................................................... 4

7.3.1 Threaded Trim .............................................................................................................. 4

7.3.2 Quick-Change Trim ....................................................................................................... 5

7.4 Lo-Db Plug ............................................................................................................................ 5

7.5 Plug Stem Pinning................................................................................................................. 5

7.6 Packing Box .......................................................................................................................... 6

7.6.1 Kevlar/Ptfe Pack. Ring (Standard) ................................................................................ 6

7.6.2 Expanded Graphite P. Ring (Option) ............................................................................ 7

7.6.3 Le Packing (Low Emission) (Option) ............................................................................ 7

7.7 Soft Seat Plug ....................................................................................................................... 8

8. Valve Body Reassembly ............................................................................................................ 9

8.1 Threaded Trim ....................................................................................................................... 9

8.2 Quick-Change Trim ............................................................................................................... 9

8.3 High Pressure & Angle Design .............................................................................................. 9

9. Actuators................................................................................................................................... 10

9.1 Types 87/88 Actuators ......................................................................................................... 10

10.Bellows Seal Assembly .......................................................................................................... 10

10.1 Bellows Valve Disassembly ............................................................................................... 15

10.1.1 Threaded Trim .......................................................................................................... 15

10.1.2 Quick-Change Trim ................................................................................................... 15

10.2 Repair................................................................................................................................ 16

10.2.1 Plug / Stem Bellows / Bonnet Extension S/A ............................................................ 16

10.3 Plug And Seat Ring Seating Surfaces .............................................................................. 17

10.4 Bonnet Reassembly .......................................................................................................... 17

10.5 Valve Body Reassembly ................................................................................................... 17

10.6 Actuator To Body S/A And Plug Stem Adjustment ............................................................. 17

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 1

Safety Information

Important - Please read before installation

These instructions contain DANGER, WARNING, and CAUTION

labels, where necessary, to alert you to safety related or other

important information. Read the instructions carefully before

installing and maintaining your control valve. DANGER and

WARNING hazards are related to personal injury. CAUTION

hazards involve equipment or property damage. Operation

of damaged equipment can, under certain operational

conditions, result in degraded process system performance

that can lead to injury or death. Total compliance with all

DANGER, WARNING, and CAUTION notices is required for

safe operation.

This is the safety alert symbol. It alerts you to potential personal

injury hazards. Obey all safety messages that follow this symbol

to avoid possible injury or death.

Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,

could result in serious injury.

Indicates a potentially hazardous situation which, if not avoided,

could result in minor or moderate injury.

When used without the safety alert symbol, indicates a

potentially hazardous situation which, if not avoided, could result

in property damage.

Note: Indicates important facts and conditions.

About this Manual

• The information in this manual is subject to change without

prior notice.

• The information contained in this manual, in whole or part,

shall not be transcribed or copied without Baker Hughes’s

written permission.

• Please report any errors or questions about the information

in this manual to your local supplier.

• These instructions are written specifically for the 21000

Series control valves, and do not apply for other valves

outside of this product line.

Useful Life Period

The current estimated useful life period for the 21000 Series

control valves is 25+ years. To maximize the useful life of the

product, it is essential to conduct annual inspections, routine

maintenance and ensure proper installation to avoid any

unintended stresses on the product. The specific operating

conditions will also impact the useful life of the product. Consult

the factory for guidance on specific applications if required prior

to installation.

Warranty

Items sold by Baker Hughes are warranted to be free from

defects in materials and workmanship for a period of one

year from the date of shipment provided said items are used

according to Baker Hughes recommended usages. Baker

Hughes reserves the right to discontinue manufacture of any

product or change product materials, design or specifications

without notice.

Note: Prior to installation:

• The valve must be installed, put into service and maintained

by qualified and competent professionals who have

undergone suitable training.

• All surrounding pipe lines must be thoroughly flushed to

ensure all entrained debris has been removed from the

system.

• Under certain operating conditions, the use of damaged

equipment could cause a degradation of the performance

of the system which may lead to personal injury or death.

• Changes to specifications, structure, and components

used may not lead to the revision of this manual unless

such changes affect the function and performance of the

product.

Figure 1 – Numbering System

The 21800 Series double stage anti-cavitation valve is derived

from the 21700 single stage anti-cavitation valve through a

modification to the cage and plug. Substitution of the standard

cage with an anti-cavitation cage permits the pressure drop to be

split between the two stages efficiently.

The 21900 Series double stage Lo-dB valve is also derived from

the 21700 single stage Lo-dB valve through a modification to

the cage and plug. Substitution of the standard cage, with a Lo-

dB cage permits the pressure drop to be split between the two

stages efficiently.

In the 21800/21900 Series designs, enlargement of the plug

head up to the cage diameter permits simultaneous throttling of

the plug Cv and the cage Cv. It also provides optimum allocation

of the pressure drop between the two stages along the entire

plug travel.

Recommended spare parts required for maintenance are listed

in the Parts Reference table on page 17. The model number,

size, rating and serial number of the valve are shown on the

identification tag located on the actuator. Refer to Figure 1 for the

21000 series numbering system.

3. Unpacking

Care must be exercised when unpacking the valve to prevent

damage to the accessories and component parts. Contact the

local Baker Hughes Sales office or Service Center with any

issues or problems. Be sure to note the valve model number and

serial number in all correspondence.

4. lnstallation

4.1 Piping Cleanliness

Before installing the valve in the line, clean piping and valve of

all foreign material such as welding chips, scale, oil, grease or

dirt. Gasket surfaces should be thoroughly cleaned to ensure

leak-proof joints.

4.2 Isolation Bypass Valve

To allow for in-line inspection, maintenance or removal of the

valve without service interruption, provide a manually operated

1. Introduction

The following instructions should be thoroughly reviewed

and understood prior to installing, operating or performing

maintenance on this equipment. Throughout the text, safety

and/or caution notes will appear and must be strictly adhered to,

otherwise, serious injury or equipment malfunction could result.

Baker Hughes has a highly skilled After Sales Department

available for start-up, maintenance and repair of our valves and

component parts.

Arrangements for this service can be made through your local

Baker Hughes's representative or sales department. When

performing maintenance use only Masoneilan™ replacement

parts. Parts are obtainable through your local representative or

spare parts department. When ordering parts, always include

Model and Serial Number of the unit being repaired.

2. General

These installation and maintenance instructions apply to all sizes

and ratings of the 21000 Series control valves regardless of the

type of trim used.

21000 Series single ported top guided control valves are designed

with built in versatility making them well-suited to handle a wide

variety of process applications.

Standard construction offers a contoured plug (21100 Series)

with a threaded seat ring or a quick change seat ring. The heavy

top plug guiding provides maximum support to ensure plug

stability.

A series of reduced area trim is available to provide wide flow

range capabilities in all valve sizes.

Tight Shutoff Class IV leakage is standard. Optional constructions

(one of which is the 21600 Series soft seat plug) meet IEC 534-4

and ANSI/FCI 70.2 Class V and Vl requirements.

An optional Low Emission LE™ Packing is available to assure

compliance with the fugitive emission containment requirements.

Replacing the conventional plug with the single stage Lo-dB

design (21700 Series) provides excellent noise attenuation or

anti-cavitation performance.

2nd

Flow

Characteristics

0. Undefined

1. Linear

2. Equal

Percentage

3. Modified

Percent

2nd 5th

4th

3rd

87 Spring Diaphragm

Air to Close

88 Spring Diaphragm

Air to Open

1st

Plug Type

0. Undefined

1. Contoured

6. Soft Seat

7. Single Stage

Lo-dB/

Cavitation

Containment

8. Double Stage

Cavitation

Containment

9. Double Stage

Lo-dB

Actuator Type Seat Type

0. Undefined

4. Quick Change

5. Threaded

6th

Optional

Configuration

A Angle Body

BS Bellows

Seal

EB Extension

Bonnet

C Cryogenic

Extension

Bonnet

Body

Series

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 3

CAUTION

WARNING

DANGER

Do not exceed supply pressure indicated on serial plate

located on the yoke of the actuator.

6. Body Disassembly

Access to the internal components of the body should be

accomplished with the actuator removed. To remove the actuator

from the body, refer to the actuator instruction Ref. 19530 for a

type 87/88 multispring actuator.

CAUTION

WARNING

DANGER

Prior to performing maintenance on the valve, isolate the

valve and vent the process pressure. Shut off the supply

air line and the pneumatic or electric signal line.

6.1 Threaded Trim (Figure 12 or 14)

After removing the actuator, disassemble the body using the

following procedure :

A. If there is a leak detector connection on the lateral NPT port

of the bonnet, disconnect this piping as well.

B. Remove body stud nuts (10).

C. Remove bonnet (8), and plug stem (1) and plug (16) sub-

assembly together as one unit.

Note: Spiral wound body gaskets (11) are standard in

the 21000 Series design and it is imperative that a new

gasket be installed each time the valve is disassembled.

D. Remove packing flange stud nuts (3), packing flange (4) and

packing follower (5).

E. Remove plug (16) and plug stem (1) sub-assembly from the

bonnet (8).

CAUTION

WARNING

DANGER

Care must be taken to avoid damage to the plug and

plug guide.

F. Remove old packing (6) [and optional lantern ring (7) if a

leak detection connection has been installed]. Refer to

Figure 5.

G. Bonnet (8), plug (16), bushing (12) and seat ring (14) may

now be inspected for wear and service damage. After

determining the maintenance required, proceed to the

appropriate Section of this instruction manual.

6.2 Quick-Change Trim (Figure 13 or 15)

After removing the actuator, disassemble the body using the

following procedure:

A. If there is a leak detection connection on the lateral NPT port

of the bonnet, disconnect this piping as well.

B. Remove body stud nuts (10).

stop valve on each side of the 21000 Series valve with a manually

operated throttling valve mounted in the by-pass line (See Figure

2).

4.3 Flow Direction

The valve must be installed so that the process fluid will flow

through the valve in the direction indicated by the flow arrow

located on the body.

• With contoured plug (21100/21600) or Lo-dB plug

(21700/21900) flow-to-open

• On anti-cavitation design (21700/21800) flow-to-close

4.4 Heat Insulation

For heat-insulated installation, do not insulate the valve bonnet.

Take necessary protective measures relate to personal safety.

Welded Connections

CAUTION

WARNING

DANGER

Carefully review the information in this section prior to

welding any valves inline. Refer any additional ques-

tions to the local Baker Hughes Sales Office or Service

Center.

Pre-Weld Preparation

Carefully follow the installation steps defined in the sections

noted above prior to performing weld procedures.

Welding Process

Perform welding process in accordance with the standard

requirements for the materials and weld construction of the

specific valve. Apply post weld heat treatment if required.

CAUTION

WARNING

DANGER

Internal valve components should be removed prior

to performing welding or pre/post weld heat treatment

weld heat treatment in order to prevent damaging any

soft goods (such as PTFE seals). If unable to remove

the elastomeric components, then other methods must

be employed to prevent the local temperature around

the seals from exceeding the maximum material limits

(typically 450°F / 232°C for PTFE based materials).

Post Weld Cleaning & Assembly

Inspect the body, bonnet, and trim components for cleanliness

and surface condition. Remove any foreign materials, such as

weld chips, slag or scale. Make sure there are no nicks, scratches,

burrs or sharp corners on sealing and sliding surfaces. Clean all

gasket interface surfaces and reassemble using new gaskets to

ensure sealing integrity.

5. Air Piping

The actuators are designed to accept 1/4" NPT air supply piping.

Use 1/4" OD tubing (4 x 6 mm) or equivalent for all air lines. If the

supply air line exceeds 25 feet in length (7 meters) or if the valve

is equipped with volume boosters, then 3/8" tubing (6 x 8 mm) is

preferred. AII connections must be free of leaks.

narrow as possible. This may require dressing both parts in a

lathe. The seating surface angle of the plug is 28 degrees and

the seat ring is 30 degrees (relative to the centerline axis). A

good grade of fine grinding compound is required for the lapping

operation.

The compound should be mixed with a small quantity of lubricant

such as graphite. This will slow the cutting rate and prevent

tearing of the seating surfaces. The amount of lapping required

depends on the materials, condition of seating surfaces, and

accuracy of machining. lf a short period of lapping does not visibly

improve seating, there is usually no advantage in continuing as

excessive lapping may result in rough seats. The only remedy is

replacement or re-machining of one or both parts. When lapping

new plugs and seat rings, begin with a medium fine (240 grit) and

finish with a finer grade (600 grit).

Note: Lapping should produce a line contact area, not the

entire surface, due to the difference in seat angles.

CAUTION

WARNING

DANGER

Before lapping, the plug and stem sub-assembly must

be concentric. (See pinning operation, section 7.5).

7.3.1 Threaded Trim (Figure 12 or 14)

1. CIean body gasket surface areas.

2. When seat has been removed, ensure that the sealing

surface in the body bridge and the threads are thoroughly

cleaned.

Note: A sealant compatible with the process should be

applied sparingly to the seat ring threads and sealing

shoulder.

3. lnstall and tighten seat ring using fabricated wrench used for

removal.

CAUTION

WARNING

DANGER

Do not over-tighten. Do not strike seat ring lugs

directly. This could distort the seat ring resulting in

seat leakage.

4. Apply lapping compound on the plug at several spots equally

spaced around the seating area.

5. lnsert the stem and plug sub-assembly carefully into the

body until it is seated.

6. Place bonnet (8) on the body and fasten the bonnet to the

body using four body stud nuts (10) spaced equally apart.

Apply slight pressure and tighten evenly.

CAUTION

WARNING

DANGER

Do not tighten nuts to nal torque specications at

this time. The bonnet is used temporarily for guiding

purposes only.

7. lnsert two or three pieces of packing (6) into the packing box to

assist in guiding the stem and plug during lapping.

8. Screw a drilled and tapped rod with a T-handle onto the plug

stem and secure with a locknut (see Figure 4).

Note: As an alternative, drill a hole through a flat steel

plate and fasten to the plug stem using two locknuts.

C. Remove bonnet (8), and plug stem (1) and plug (16) sub-

assembly together as one unit.

D. Since the cage (13), seat ring (14) and seat ring gasket (15) are

held in place by the bonnet, they may now be removed.

Note: Spiral wound gaskets (11 & 15) are standard in the

21000 Series design and it is imperative that new gaskets

be installed each time the valve is disassembled.

E. Remove packing flange stud nuts (3), packing flange (4) and

packing follower (5).

F. Remove plug (16) and plug stem (1) sub-assembly from the

bonnet (8).

CAUTION

WARNING

DANGER

Care must be taken to avoid damage to the plug and

plug guide.

G. Remove old packing (6) [and optional lantern ring (7) if a

leak detection connection has been installed]. Refer to

Figure 5.

H. All components may now be inspected for wear and service

damage. After determining the maintenance required,

proceed to the appropriate Section of this instruction manual.

7. Maintenance & Repair

The purpose of this section is to provide recommended

maintenance and repair procedures. These procedures assume

the availability of standard shop tools and equipment.

7.1 Threaded Seat Ring Removal

(Figure 12 or 14)

Threaded seat rings (14) are installed tightly by the manufacturer,

and after years of service they may be difficult to remove.

To facilitate removal, seat ring wrenches can be fabricated to

engage the seat ring lugs and adapted to a standard wrench. If

the seat ring is exceptionally resistant to removal, the application

of heat or penetrating oil should be helpful.

CAUTION

WARNING

DANGER

When using heating devices, ensure that proper

safety practices are observed. Flammability and

toxicity of the process uid must be considered and

proper precautions taken.

7.2 Bushing Removal

The bushing (12) is press fit into the bonnet and does not normally

require replacement. If necessary, it may be pulled or machined

out. When machining the bushing out, care must be taken to

maintain proper dimensions and tolerances in the bonnet. These

will be furnished upon request.

7.3 Lapping Seats

Lapping is the process of working the valve plug against the

seat ring with an abrasive to produce a close fit. If valve leakage

is excessive, lapping becomes necessary. The plug and seat

ring seating surfaces should be free of large scratches or other

defects, and the contact surfaces of the seats should be as

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 5

10. Apply slight pressure on the stem, and rotate the stem in

short oscillating strokes (around 8 to 10 times). Repeat this

step as necessary.

Note: The plug should be lifted and turned 90° each

time before repeating Step (10). This intermittent lifting

is required to keep the plug and seat ring concentric

during lapping.

11. After completion of the lapping operation, remove bonnet

and internal parts. The seating area of the seat ring and the

plug must be cleaned of all lapping compound in preparation

for reassembly.

7.4 Lo-dB PIug (Figure 8, 14 or 15)

The procedures used for performing maintenance on a valve

equipped with Lo-dB plugs (21700/21800/21900 Series) are the

same as those used for Threaded or Quick Change Trim.

CAUTION

WARNING

DANGER

Maintenance of the plug should be limited to cleaning

of the ports and the procedures dened under

Sections 7.3 (Lapping) and 7.5 (Pinning) as required.

7.5 PIug Stem Pinning

Plug stem pinning in the field may be required for the following:

- Replacing existing plug and stem, or

- Replacing existing stem only

Replacing Plug and Stem

If it is necessary to replace the plug, then the plug stem must be

replaced at the same time. The original pin hole in an existing

stem will not provide the necessary fit, and might seriously impair

the strength of the assembly.

A. Reference Marking on the Plug Stem

Measure the depth of the pilot recess in the plug (Dimension

X in Figure 9), and make a reference mark on the plug stem

at the same distance from the thread.

Note: While pinning is being performed, care must

be taken not to damage the seating surface or plug

guide. Always use a soft metal or plastic vice jaws with

cylindrical features to hold the plug guide area (see

Figure 9).

B. Screwing Stem to Plug

•

Hold the plug (with vise jaw assembly) in a vise.

•

Lock two nuts against each other on the end of the new

plug stem, and screw the stem solidly into the plug using

a wrench on the upper nut.

When properly assembled, the reference mark (see

Section A above) should be flush with the end of the plug

guide.

C. Drilling the New Parts

• If the plug is already fully drilled (typical for 440 C

hardened stainless steel material or solid Stellite or

Equivalent), then drill the stem to the same diameter

(Diameter C in Figure 9) as the plug shank hole.

9. Apply slight pressure on the stem, and rotate the stem in

short oscillating strokes (around 8 to 10 times). Repeat this

step as necessary.

Note: The plug should be lifted and turned 90° each

time before repeating Step (9). This intermittent lifting

is required to keep the plug and seat ring concentric

during lapping.

CAUTION

WARNING

DANGER

Avoid over-lapping as this can cause damage to

the seating surface rather than improve leakage

performance.

10. After completion of the lapping operation, remove bonnet

and plug. The seating area of the seat ring and the plug

must be cleaned of all lapping compound in preparation for

reassembly. Do not remove seat ring.

7.3.2 Quick-Change Trim (Figure 13 or 15)

1. CIean body gasket surface areas.

2. Install a new seat ring gasket (15) and insert seat ring (14)

in the body.

Note: Gasket (15) is temporarily placed to hold the seat

ring during lapping. It is imperative to use a new gasket or

a test part having the same geometrical characteristics

in order to ensure the correct position of the seat ring

during lapping. This gasket (or similar part) can be kept

after lapping for future use. The gasket used for lapping

must not be reused for the body reassembly.

3. Apply lapping compound at several spots equally spaced

around the seating area of the seat ring.

4. Insert the cage (13) into the body.

5. lnsert the stem and plug sub-assembly carefully into the

body until it is seated.

6. PIace bonnet (8) on the body.

CAUTION

WARNING

DANGER

Ensure that the seat ring (14), cage (13) and bonnet

(8) are properly aligned.

7. Fasten the bonnet to the body using four body stud nuts

(10) spaced equally apart. Apply slight pressure and tighten

evenly.

CAUTION

WARNING

DANGER

Do not tighten nuts to nal torque specications at

this time. The bonnet is used temporarily for guiding

purposes only.

8. Insert two or three pieces of packing into the packing box to

assist in guiding the stem and plug during lapping.

9. Screw a drilled and tapped rod with a T-handle onto the plug

stem and secure with a locknut (see Figure 4).

Note: As an alternative, drill a hole through a flat steel

plate and fasten to the plug stem using two locknuts.

D. Pinning

Select the correct size pin based on the plug guide diameter and

pin hole diameter. Proceed as described in part D of the previous

section, taking care not to damage the plug guide area.

Ensure plug stem alignment following the pinning operation.

7.6 Packing Box (Figures 12 to 15)

Packing box maintenance is one of the principle action items of

routine servicing. Tightness of the packing is maintained by packing

compression. Compression is achieved by evenly tightening the

packing flange nuts (3) against the packing flange (4). Care must

be taken not to over tighten as this could prevent smooth operation

of the valve. If all compression is used up and the valve leaks, then

new packing is required.

CAUTION

WARNING

DANGER

Valve must be isolated and the pressure vented

before performing packing box maintenance.

Proceed as follows :

7.6.1 Braided PTFE with Carbon or Aramid Core (Standard)

(Figures 12 to 15)

Note: The Braided PTFE/Carbon or Aramid packing rings

have a skive cut allowing packing replacement without

disconnecting the plug stem from the actuator connector

or actuator stem.

A. Loosen and remove packing flange nuts (3).

B. Lift the packing flange (4) and packing follower (5) up the

valve stem.

Note: They may be taped in place to keep them out of

the way before proceeding.

C. By means of a hooked instrument, remove packing (6)

ensuring not to damage the sealing surfaces of the packing

box or plug stem.

Note: On valves equipped with an optional lubricator

connection, the lantern ring (7) must also be removed to

gain access to lower packing rings.

D. Replace packing rings (6).

Note: Assemble and compress rings one at a time into

packing box. The skive cut of each packing ring must

be placed about 120 degrees apart.

Note: On valves equipped with an optional lubricator

connection, refer to Figure 10 for correct amount of

rings to place under the lantern ring (7).

E. Replace packing follower (5) and packing flange (4).

F. Replace and tighten packing stud nuts (3).

CAUTION

WARNING

DANGER

Do not overtighten.

G. Place valve back in service and only tighten packing as

necessary to stop external leakage.

Note: In an emergency, string packing may be used as

a temporary repair only. It must be replaced with the

correct packing as soon as possible.

• If the plug guide area has a center mark,

PIace the plug guide on a V-block and use a suitable

drill size to either:

- Match the hole size in the plug, or

- Match Diameter C (see Figure 9)

Drill through the plug-stem assembly.

• If the plug guide area does not have any hole or any

center mark,

- Measure Dimension D based on the plug guide diameter

and stem diameter (see Figure 9).

- PIace the plug guide on a V-block, and make a center

mark on the plug guide area using a center punch.

- Drill through the plug-stem assembly using a suitable

size drill bit.

In all cases after drilling: Remove any burrs from the

plug guide hole by making a slight chamfer.

D. Pinning the Plug-Stem Assembly

Select the correct size pin based on the plug guide diameter

and stem diameter (see Figure 9). Apply a small amount of

grease on the pin and hand assemble it into the hole in the

plug.

2. Press fit the pin into the hole using a hammer. Complete

the pinning operation by taking care to ensure that the pin is

recessed by the same amount at both sides (see Figure 9).

3. After the plug has been pinned, it should be placed in a lathe

to ensure it is concentric with the stem.

If the assembly is not running true, then the stem should be

placed in a collet with the plug guide against it and the plug

should be adjusted. Alignment of plug stem can be performed

by means of a soft faced mallet.

Replacing Existing Stem Only

A. Removing Existing Pin and Stem

Place the plug guide on a V-block and use a drift punch to

drive out the old pin.

Note: If it is necessary to drill out the pin, use a drill bit

slightly smaller than the pin diameter.

2. Hold the plug guide in a vise (see note on opposite side of

page).

3. Lock one nut against another at the end of the plug stem. Using

a wrench on the lower nut, unscrew the stem from the plug. The

stem is removed by turning it counter-clockwise.

B. Screwing Stem to Plug

Refer to step B of the previous section on “REPLACING

PLUG AND STEM”.

C. Drilling the New Stem

PIace the plug guide on a V-block and use a suitable size

drill bit to drill the stem (use the hole in the plug as a guide).

Note: If the hole in the plug guide has been slightly

damaged while removing the old pin, choose a drill bit

and a pin with a slightly larger diameter than the normal

pin.

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 7

7.6.3.1 Preparation

7.6.3.1.1 Stem

Inspect stem for any nicks or scratches on the surface

finish. Reject the stem for any of these reasons as they may

damage packing.

Note: A properly etched part number on the stem in

the packing area will have no adverse effect on the

performance of the packing.

Stem finish should be 3-7 AARH (Ra 0,1/0,2).

7.6.3.1.2 Packing Box

Note: Bonnets that have a lube hole or leak detection

port are unacceptable for use with the packing

arrangement shown in Figure 7.

CAUTION

WARNING

DANGER

Packing box should be clean and free of burrs, rust,

and any foreign matter. Parts can be cleaned with

denatured alcohol.

Note: Packing box finish should be 125 AARH (Ra 3,2)

or better.

The packing box may be bored or honed oversize by up to

0.015" (0.38 mm) above the nominal diameter to improve the

finish. For instance, a nominal 0.875" (22.22 mm) packing box

may be bored or honed up to 0.890" (22.60 mm) and the LE

Packing will still seal properly.

Packing box must be finished to the bottom of the bore.

7.6.3.1.3 Packing

Inspect packing rings. Do not use packing if any nicks or

scratches on packing are observed. Check packing and

ensure that it is in the proper arrangement (see Figure

below). PFE material can be identified by the gloss black

molded finish. PTFE material has a dull black machined

finish.

PTFE - female adapter

PTFE - V -Ring

PTFE - male adapter

PFE - V-Ring

7.6.3.1.4 Spring Loaded Follower

The spring loaded follower consists of an upper and lower

follower and eight (8) disc springs (see Figure below). The

springs are installed inside the lower follower and positioned

alternately. The assembly is held together by tape, which

must be removed before installation.

Upper

Follower

Lower

Follower

Disc

Springs

Scribe

Mark

7.6.2 Flexible Graphite Rings (Optional – See Figure 6)

Note: Flexible graphite packing rings replacement may require

disconnecting the plug stem from the actuator stem and

removal of the actuator if rings are not skive cut.

A. Remove actuator from the body S/A. Refer to actuator

instruction Ref. 19530 for a type 87/88 actuator.

B. Loosen and remove packing flange nuts (3).

C. Remove packing flange (4) and packing follower (5) from

the plug stem.

D. By means of a hooked instrument, remove packing (6)

ensuring not to damage the sealing surfaces of the packing

box or plug stem.

Note: On valves equipped with an optional lubricator

connection, the lantern ring (7) must also be removed to

gain access to lower packing rings.

E. Replace new packing set (6); first assemble a back-up ring

(Graphite Filament Yarn braided ring), then the flexible

graphite rings (smooth rings), and finally another braided

back-up ring (refer to Figure 6).

Note: Assemble and compress rings one at a time into

packing box.

Note: On valves equipped with an optional lubricator

connection, refer to Figure 10 for correct arrangement

according to valve size.

F. Assemble packing follower (5) and packing flange (4).

G. Assemble and tighten packing stud nuts (3).

CAUTION

WARNING

DANGER

Do not overtighten.

H. Proceed to appropriate instructions for actuator and valve

assembly adjustment.

I. Place valve back in service and only tighten packing as

necessary to stop external leakage.

7.6.3 LE Packing (Optional – See Figure 7)

The Masoneilan LE (Low Emissions) Packing from Baker

Hughes is a high performance packing system capable of

containing fugitive emissions well below the specifications of the

most severe recommendations. It is also available in a firesafe

configuration.

The packing is provided as a set of five pieces. It consists of

two adapter rings and three V-rings. An alternating pattern of

Perfluoroelastomer (PFE) and long carbon fiber filled Teflon

(PTFE) V-rings are used.

Applied properly, this packing exhibits very little cold flow (or creep).

Consequently, it can effectively prevent fugitive emissions leaks

from a control valve. The LE Packing system can directly replace

conventional packing, requiring no modification to the control

valve or actuator.

A spring loaded, two-piece follower assembly is used to maintain

a constant load on the packing, and is necessary for thermal

cycling applications. As the definition of thermal cycling can vary,

and processes are potentially subject to unpredicted thermal

gradients, LE Packing is only available with the spring loaded

follower.

Installation should be performed as detailed in the following

paragraphs.

B. Carefully place plug sub-assembly into a soft jaw vise,

holding the plug by the flats provided on the upper end of

the shank.

CAUTION

WARNING

DANGER

When using a vise to hold the plug, extreme care

must be taken not to damage the plug shank.

C. Using the appropriate tool, unscrew plug tip (counter-

clockwise) from the shank sub - assembly.

D. Remove insert O-ring (for valve sizes 3"- 8" only) and insert

retainer. Discard existing insert and O-ring.

E. Thoroughly clean all remaining metallic components

and install new insert and O-ring as follows (according to

valve size):

For 3/4"- 2" valves :

a. Place new insert on shank and insert retainer as

shown in Figure 3.

b. lnstall plug tip into shank sub-assembly. Hand tighten

and ensure plug tip seats evenly against insert.

For 3" – 8" valves:

a. Apply a light coat of lubricant to the O-ring and install on

insert retainer.

CAUTION

WARNING

DANGER

Ensure any lubricant used is compatible with service

conditions.

b. Install new insert on insert retainer and assemble as

shown in Figure 3.

c. Install plug tip into insert retainer sub-assembly insuring

the plug tip seats evenly on the insert.

F. Carefully place the plug sub-assembly into a soft jaw vise,

holding the plug by the flats provided on the upper end of the

shank.

CAUTION

WARNING

DANGER

When using a vise to hold the plug, extreme care

must be taken not to damage the plug shank.

G. Using the appropriate tool used during disassembly, firmly

tighten the plug tip.

CAUTION

WARNING

DANGER

The plug tip must be tightened, allowed to set for

approximately 4 hours, re-tightened, allowed to set

another 4 hours, then tightened one more time. The

purpose of this tightening sequence is to allow the

insert material to “cold ow” into place on the plug

sub-assembly.

H. Following the above tightening sequence, securely tighten

the set screw down into the plug. Plug is ready for assembly

into the valve.

7.6.3.2 Packing Installation

a. The packing must be lubricated with Krytox ® fluori-

nated grease prior to installation (Krytox GPL206 or

equivalent).

b. Packing should be lubricated as a set (not

individually) to minimize getting lubricant between

the rings.

c. Packing should be lubricated with a generous application

to the O.D. and I.D. of the packing set.

Note: All exposed surfaces of the packing set must

be covered with the lubricant.

d. PFE/PTFE is to be installed as a set. Carefully slide the

packing set down the stem. Do not cock or force the

packing on the threads.

If the packing set separates while on the stem, do not

remove. Continue installing the remaining pieces to put

the set back together.

e. Gently press the packing into the packing box. Do not

tap the packing down into the box.

f. The spring loaded follower is installed on top of the

packing. This follower is installed as an assembly held

together by tape. This tape should be removed after

assembly. Proper assembly of the packing box will leave

the top of the Lower Follower 0.25 – 0.50 inches (6 to

13 mm) above the bonnet.

A groove is scribed into the O.D. of the upper follower.

The packing flange is tightened evenly until the top of

the Lower Follower aligns with the scribe mark (groove)

in the Upper Follower.

Note: This is the optimum loading for this packing.

Further tightening will shorten life of the packing.

Thread locking compound can be used on packing

nuts.

g. The packing should be checked for leakage.

h. Packing load should be checked after the valve has

cycled approximately 500 times. Adjust if necessary. No

further adjustment should be required for the life of the

packing.

7.7 Soft Seat Plug (Figure 3)

The soft seat plug used in the 21000 Series valve has a

replaceable insert. To remove and replace the insert, proceed

as follows.

CAUTION

WARNING

DANGER

The shank OD is the plug guide. Extreme care must

be taken to prevent scoring or marring this surface.

Failure to do so could result in damage to the guide

bushing and destruction of the plug. Two ats are

provided for holding.

A. Loosen set screw until the head of the set screw is flush with

the OD of the shank.

Note: On 3/4"‑ 2" size valves, the plug tip has a machined

slot into which a bar can be inserted for removal. On

3"‑ 6" size valves, the plug tip has two machined holes

into which a tool (fabricated with appropriate size pins)

can be inserted for removal.

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 9

8.2 Quick-Change Trim

(Figure 13 or 15)

A. CIean all gasket mating surfaces.

B. Install seat ring gasket (15) and seat ring (14).

Note: Spiral wound gaskets (11 & 15) are standard in the

21000 Series design. It is imperative that a new gasket

be installed each time the valve is disassembled.

C. Install cage (13).

D. Carefully install plug and stem assembly.

Note: Valve should be lapped before final assembly.

See Section 7.3.

Note: For 2" valves with Cv30 Lo‑dB / Anti‑Cavitation

trim only, steps C and D must be reversed such that the

plug and stem assembly is installed prior to the cage.

E. Install body gasket (11).

F. Assemble bonnet (8) and body stud nuts (10) and tighten.

Bonnet must be positioned so the packing flange studs are

at 90° to the flow center line.

CAUTION

WARNING

DANGER

Care must be taken to ensure that the cage, seat,

and bonnet are properly aligned in the body. Cage

should be installed with parts at lower end, near seat

ring. Tighten nuts (10) until metal to metal contact

is obtained with proper bolt torque. Refer to Figure

11 for proper bolt torque and tightening sequence

specications.

G. lnsert packing (6) [and lantern ring (7) on valve equipped

with an optional lubricator or leak detection connection].

Refer to Section 7.6 for proper packing assembly procedure

for standard or optional designs.

H. Install packing follower (5) and packing flange (4).

I. Install packing flange stud nuts (3).

CAUTION

WARNING

DANGER

Do not overtighten (See Section “7.6. Packing Box”).

J. If a leak detection connection was installed, connect it on

the lateral NPT port in the bonnet. If not, ensure that the 1/4"

NPT plug remained in place (Figure 5).

K. For actuator assembly and plug stem adjustment, proceed

to the actuator instruction Ref. 19530 for a type 87/88

multispring actuator.

8.3 High Pressure & Angle Design

(Figures 16 & 17)

Standard trim is used within these optional body configurations.

Refer to the applicable sections within this instructions manual.

8. Valve Body Reassembly

After completion of the required maintenance, the valve should

be reassembled using the following procedures:

Note: If any of the following steps were completed during

maintenance, then proceed to the next step.

8.1 Threaded Trim (Figure 12 or 14)

A. CIean all gasket mating surfaces.

B. Apply a small amount of sealant to the seat ring threads and

sealing shoulder. Install seat ring into valve body.

Note: A sealant compatible with the process should be

applied sparingly.

C. lnstall and tighten seat ring using wrench used for removal.

CAUTION

WARNING

DANGER

Do not over-tighten. Do not strike seat ring lugs

directly. This could distort the seat ring resulting in

unwarranted seat leakage.

D. Carefully install plug and stem assembly.

Note: Valve should be lapped before final assembly.

See Section 7.3.

E. Install body gasket (11).

Note: Spiral wound body gaskets (11) are standard in

the 21000 Series design. It is imperative that a new

gasket be installed each time the valve is disassembled.

F. Assemble bonnet (8) and body stud nuts (10). Bonnet must

be positioned so the packing flange studs are at 90° to the

flow center line.

CAUTION

WARNING

DANGER

Tighten nuts (10) until metal to metal contact is

obtained with proper bolt torque. Refer to Figure

11 for proper bolt torque and tightening sequence

specications.

G. lnsert packing (6) [and lantern ring (7) on valve equipped

with an optional lubricator connection]. Refer to Section

7.6 for proper packing assembly procedure for standard or

optional designs.

H. Install packing follower (5) and packing flange (4).

I. lnstall packing flange stud nuts (3).

CAUTION

WARNING

DANGER

Do not overtighten (See Section “7.6. Packing Box”).

J. If a leak detection connection was installed, connect it on

the lateral NPT port in the bonnet. If not, ensure that the 1/4"

NPT plug remained in place (Figure 5).

K. For actuator assembly and plug stem adjustment, proceed

to the actuator instruction Ref. 19530 for a type 87/88

actuator.

Figure 5 – Lubricator Connection (Optional)

Figure 7

LE (Low Emission) Packing Arrangement (Optional)

9. Actuators

9.1 Types 87/88 Actuators

Assemble the pneumatic actuator onto the control valve using the

appropriate instructions for the specific actuator model and type.

Connect air pressure lines to the actuator ports to meet intended

operating mode (i.e., air-to-extend, air-to-retract, or double-

acting). For further details dealing with removal, maintenance,

assembly and adjustment, please refer to Instruction Manual

19530.

10. Bellows Seal Assembly

CAUTION

WARNING

DANGER

Since this is a sealing bellows, the plug stem should

never be turned under any circumstances.

There is a built-in anti-rotation feature, consisting of a double flat

surface machined on the plug stem that slides into a rectangular

slot machined in the upper bushing (30) of the bellows (see

Figure 19 – Section a).

Figure 2 – Typical Installation

Insert

3/4" - 2" Valve Sizes 3" - 8" Valve Sizes

Insert

Retainer Plug

Tip

Plug Tip O-ring

Shank

Skirt &

Insert

Retainer

Set

Screw

Set

Screw

Flats Flats

Figure 3 – Soft Seat Plugs (Optional)

CAUTION

WARNING

DANGER

IT IS IMPORTANT TO DISCONNECT THE ACTUATOR

FROM THE VALVE BEFORE CHANGING THE

ACTUATOR ROTATIONAL POSITION.

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 11

T-Handle

Lock Nut

Figure 4 – Seat Lapping Device

Figure 6 – Braided Flexible Graphite Configuration

Figure 8

Lo-dB (Type 21900) and Anti-cavitation (Type 21800) Double Stage Trim (Optional)

Plug Stem

Dia. “B” Pin Hole

Dia. “C” “D” “X”

Plug Guide

Dia. “A”

Soft metal

or plastic

vise jaws

Cylindrical machining

diameter of the jaws =

plug guide diameter “A

”

C Dia.

Reference Mark

in.

.87

1.50

2.38

2.75

22.22

38.10

60.32

69.85

12.70

19.05

in.

1/2

3/4

3.50

5.00

in.

.138

.197

47.5

in.

1.25

1.88

1.25

1.88

in.

.50

.75

Figure 9 – Plug Stem Pinning

Valve

Size

Total

200 88

Quantity of Packing Rings (6)

Packing box with Kevlar

PTFE

packing rings

Lantern

Ring

(7)

Packing box with

Flexible Graphite packing rings

and Back-up rings

Braided

Back-up Rings

Flexible

Graphite Rings

Lantern

Ring

(7)

Total

in.

3/4 to4

6 to8

20 to 100

150 to 200

Figure 10 – Packing Ring Arrangements with Optional Lubricator Connection

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 13

Assembly Torque Requirements

Valve Size ANSI Class Bolting Requirements Torque Requirements

Minimum Maximum Pre-Load

inch mm Qty. Size (inch) Lbs.Ft N.m Lbs.Ft N.m Lbs.Ft N.m

.75

& 1

20 &

150 & 300 41/2"-13NC-2A 25 34 66 89 5 7

600 41/2"-13NC-2A 25 34 66 89 5 7

900 & 1500 41"-8NC-2A 125 169 560 759 45 61

2500 41"-8NC-2A 125 169 560 759 45 61

1.5

& 2

40 &

150 & 300 81/2"-13NC-2A 25 34 66 89 5 7

600 81/2"-13NC-2A 25 34 66 89 5 7

900 & 1500 8 7/8"-9NC-2A 100 136 300 407 30 41

1.5 40 2500 8 7/8"-9NC-2A 100 136 300 407 30 41

2 50 2500 81-1/8"-7NC-2A 160 217 640 868 60 81

380

150 & 300 6 5/8"-11NC-2A 45 61 132 179 10 14

600 8 3/4"-10NC-2A 80 108 230 312 20 27

900 & 1500 81-1/8"-8NC-2A 225 305 830 1125 75 102

4100

150 & 300 8 5/8"-11NC-2A 45 61 132 179 10 14

600 81"-8NC-2A 125 169 560 759 45 61

900 & 1500 81-1/2"-8NC-2A 400 542 2100 2847 115 156

6150 150 & 300 12 5/8"-11NC-2A 45 61 132 179 10 14

600 12 1"-8NC-2A 125 169 560 759 45 61

8200 150 – 600 12 1-1/4"-8NC-2A 235 319 1200 1627 100 136

Notes: 1. Do not exceed Maximum Torque values listed.

2. Tighten in increments until required torque levels are reached.

3. Reject assembly if metal-to-metal contact is not achieved after reaching Maximum Torque.

4. Torque requirements shown are for standard B7 studs and 2H nuts.

Bellows Bonnet Assembly Torque Requirements

Bolting Requirements Torque Requirements

Minimum Maximum Increments Pre-Load

Qty. Size (inch) Lbs.Ft N.m Lbs.Ft N.m Lbs.Ft N.m Lbs.Ft N.m

81/2"-13NC-2A 20 27 30 41 5757

8 5/8"-11NC-2A 25 34 55 75 10 14 5 7

Notes: 1. Do not exceed Maximum Torque values listed.

2. Tighten in increments noted until required torque levels are reached.

3. Torque requirements shown are for standard B7 studs and 2H nuts.

Valve

Size

mm in.

1-1/2

900

230 250

Min.

daN.m

Carbon Steel Bolting

Max.

Ft.Lbs.

daN.m

Ft. Lbs.

ANSI Class Stud(9)

20to50 3/4to2 150 -300

600

4,5

33 37

1/2”-13NC-2A

200 8 150 -300

192 207

1-1/4”-8NC-2A

Size Qty

1500

260 295

1” -8NC-2A 4

2500

295 370

5,5

40 48

6,5

80 3

150

300

600

60 63

8,5

5/8”-11 NC-2A 6

140 148

3/4”-10NC-2A 8

100 4 150 -300

600

8,5

63 70

9,5

5/8”-11 NC-2A 8

207 220

1” -8NC-2A 8

150 6 150 -300

600

8,5

63 66

5/8”-11 NC-2A 12

207 221

1” -8NC-2A 12

60 63

8,5

5/8”-11 NC-2A 6

170 184

Min.

daN.m

Stainless Steel Bolting

Max.

Ft. Lbs.

daN.m

Ft.Lbs.

3,5

26 30

192 207

4,5

33 37

23*

170 * 184 *

25*

52 59

207 221

66 74

Req’d. Torque

207 221

Only on 21000 threaded trim valves. For quick-change trim valve s, use fo llow ing torques.........

Figure 11 – Bolting Torques and Tightening Sequence

Figure 14

Threaded Seat Ring - Lo-dB Plug

Figure 15

Quick Change Trim - Lo-dB Plug

Figure 12

Threaded Seat Ring - Contoured Plug - Full Capacity

Figure 13

Quick Change Trim - Contoured Plug - Full Capacity

 Recommended spare parts * Only on Quick Change Trim

Ref. Part Name Ref. Part Name Ref. Part Name

PARTS REFERENCE

 1 Plug Stem

2 Packing Flange Stud

3 Packing Flange Stud Nut

4 Packing Flange

5 Packing Follower

 6 Packing

7 Lantern Ring (optional)

8 Bonnet

9 Body Stud

10 Body Stud Nut

11 Body Gasket

12 Plug Guide Bushing (Incl. w/ref. 8)

13 Cage *

14 Seat Ring

15 Seat Ring Gasket *

16 Plug

17 Plug Pin

18 Body

19 Drive Nut

Masoneilan 21000 Series Top Guided Globe Valve Instruction Manual | 15

10.1 Bellows Valve Disassembly

(Figure 19)

Note: Spiral wound gaskets are standard in the 21000

BS Series design. IT IS RECOMMENDED THAT NEW

GASKETS ARE INSTALLED EACH TIME THE VALVE IS

DISASSEMBLED.

10.1.1 Threaded Trim

After removing the actuator, disassemble the body S/A using the

following procedure:

• Disconnect the leak-off circuit from the bonnet (if this option

is included). Remove nuts (27) and bonnet studs (26) from

the bonnet (25).

• Remove packing flange stud nuts (3), packing flange (4)

and packing follower (5). Remove bonnet (25).

• Remove existing packing (6).

• Remove body stud nuts (10).

• Remove bonnet extension (29), stem bellows S/A (30) and

plug (16) at the same time.

• Remove the plug pin (17), then remove the plug (16) from

the plug stem (30). (See section 10.2.1.1 for unpinning the

plug stem).

Figure 16 - 21000 Series

3/4" to 2" Valve Sizes ANSI Class 900 to 2500

Figure 17 - Angle Body Design

3/4" to 6" Valve Sizes ANSI Class 150 to 600

3/4" to 2" Valve Sizes ANSI Class 900 to 2500

• Remove stem bellows S/A (30) by the top of the bonnet

extension (29). If necessary, disengage the upper bushing of

assembly (30) using a screwdriver in the groove provided for

this purpose.

CAUTION

WARNING

DANGER

Be careful not to damage the seating surfaces of the

bellows bushing.

• Remove the bonnet and spacer gaskets (28) and the body

gasket (11).

• Bonnet extension (29), plug (16), guide bushings and seat

ring (14) may now be inspected for wear and service damage.

After determining the maintenance required, proceed to the

appropriate section of these instructions.

10.1.2 Quick-Change Trim

Removal of the quick-change trim is accomplished using the

same procedures as removal of the threaded trim.

However, after the bonnet extension (29) has been removed

from the body, remove the cage (13), the seat ring (14) and the

seat ring gasket (15).

10.2 Repair

The purpose of this section is to provide recommended

maintenance and repair procedures. These procedures assume

the availability of standard shop tools and equipment.

10.2.1 Plug/Stem Bellows/Bonnet Extension S/A

Plug stem pinning in the field may be required for:

• Replacing existing plug and stem-bellows S/A

• Replacing stem-bellows S/A only

Note: If the plug needs replacing, the stem‑bellows

sub‑assembly should be replaced at the same time.

The original pin hole in a stem which is being reused sometimes

prevents a satisfactory result being obtained and can also

weaken the plug-stem assembly.

If the stem-bellows sub-assembly is being replaced, the

new assembly can be fitted on an existing plug as long as it

is in good condition and the removal of the pin has not

deformed the hole or damaged it in any other way.

Note: Always use soft metal vise jaws to hold the plug

guide surface. Failure to take this precaution could

result in damage to the plug guide surface during

pinning (see Figure 18).

Be careful not to damage the plug seating surface during pin

removal and assembly operations.

10.2.1.1 Unpinning the Plug Stem

• Pull and hold the plug (16) out of the bonnet extension (29)

to allow access to the plug pin (17). Place the plug guide on

a V-block.

Note: A lower mechanical stop has been provided to

prevent damage of the bellows during this step.

• Using a drift punch, drive out the existing pin (17).

Note: If it is necessary to drill out the pin, use a drill bit

slightly smaller than the pin diameter. Be careful not to

damage the hole of the plug guide.

• Lock two nuts against each other on the end of the plug

stem, and use a flat spanner on the lower nut to prevent

rotation while unscrewing the plug from the stem. The plug

is removed by turning it counter-clockwise.

• Remove the two nuts from the plug stem. Complete step

10.1.1.

• Inspect the parts and carry out any necessary repairs, then

reassemble the stem-bellows sub-assembly (30) through

the upper hole in the bonnet extension (29) (see section

10.2.1.2).

10.2.1.2 Mounting of the Plug-Stem/Bellows S/A into the

Bonnet Extension

• Clean all contact surfaces of the bonnet extension (29) and

the plug-stem/bellows S/A.

• Assemble a new gasket (28) on the upper flange of the

bonnet extension.

• Insert the new stem-bellows S/A through the top hole into

the bonnet extension (29).

• Pin the plug on the stem (See section 10.2.1.3).

10.2.1.3 Plug Stem Pinning

Replacing Plug and Stem/Bellows S/A

A. Screw Stem into Plug

- Lock two nuts against each other on the end of the plug

stem and use a flat spanner on the upper nut to prevent

rotation of the stem-bellows S/A. Screw the plug onto the

lower part of the stem while inserting the plug shank into the

guide bushing (12) in the bonnet extension (29).

- Pull and hold the plug (16) out of the bonnet extension (29)

to allow access to the plug pin (17).

B. Drilling the New Parts

• If the plug is already fully drilled, (typical for 440C hardened

stainless steel material or solid Stellite or Equivalent), then

drill the stem to the same diameter (Diameter C in Figure 18)

as the Plug Shank Hole.

• If the plug guide area has a center mark, Place the plug

guide on a V-block and use a suitable size drill to either:

- Match the hole size in the plug, or

- Match Diameter C (see Figure 18),

- Drill through the plug-stem assembly.

• If the plug guide area has no hole or any center mark,

- Measure Dimension D based on the plug guide diameter

and stem diameter (see Figure 18).

- Place the plug guide on a V-block, and make a center mark

on the plug guide area using a center punch.

- Drill through the plug-stem assembly using a suitable size

drill bit.

In all cases after drilling: Remove any burrs from the plug

guide hole by making a slight chamfer.

C. Pinning the Plug-Stem Assembly

- Select the correct size pin based on the plug guide diameter

and stem diameter (see Figure 18). Apply a small amount of

grease on the pin and hand-assemble it into the hole in the

plug.

- Press fit the pin into the hole using a hammer. Complete the

pinning operation by ensuring that the pin is recessed by the

same amount from both sides (see Figure 18).

Replacing Stem/Bellows S/A Only

A. Screw Stem into Plug

- Refer to paragraph A of the previous section “REPLACING

PLUG AND STEM/BELLOWS S/A”.

B. Drilling the New Stem

- Place the plug guide on a V-block and use a suitable

size drill bit to drill the stem (use the hole in the plug as a

guide).

Note: If the hole in the plug guide has been slightly

damaged while removing of the old pin, choose a drill bit

and a pin with a slightly larger diameter than the normal

pin.

C. Pinning

- Select the correct size pin based on plug guide diameter

and pin hole diameter. Proceed as described in Paragraph

C above, taking care not to damage the plug guide area.

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