cashco 521 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
Model 521
with ATO - FC Actuator
SECTION II
ABBREVIATIONS
SST.......... Cast or Wrought Stainless Steel
HC ........... Wrought Hastelloy C-276
ATO-FC ... Air-to-Open, Fail Close
ATC-FO ... Air-to-Close, Fail Open
CCW........ Counter Clockwise
CW........... Clockwise
D or DIR... Direct Acting
R or REV.. Reverse Acting
IAS........... Instrument Air Supply
IOM.......... Installation, Operation and Maintenance
Manual
SIG .......... Output Signal from Instrument
LOAD....... Positioner Output Air Pressure
V .............. Vent
IOM-521
02-20
MODEL 521
TOTAL TFE, GLOBE-PATTERN CONTROL VALVE
BODY IOM
SECTION I
I. DESCRIPTION AND SCOPE
The Model 521 is a bellows sealed, globe-style control
valve fabricated from a tee-block of isostatically
compacted virgin TFE. Sizes are 1/2", 1", 1-1/2" and
2". The split body jacket is CF8 (304 SST) material.
All wetted internal parts are of isostatically compacted
TFE material. The standard stem material is of 316
SST; two optional Hastelloy C-276 stem material
constructions are available.
End connections are available to mate with 150#,
300# or DIN PN16, 25 or 40 flanges. Each flange
is drilled and tapped to receive stud bolting only.
The valve is designed for chemical service with fluids
that are normally corrosive to metallic materials.
For application pressure vs. temperature zone refer
to Model 521-TB, Graph No. 1 (pg. 3).
Actuators that may be mounted to a Model 521
body are Cashco Model C27 or Model C53, both
field reversible.
II. REFERENCES
Refer to Technical Bulletin 521-TB for complete
technical specifications of a Model 521 coupled with
either Cashco Actuator C27 or C53.
www.cashco.com/techbulletins/521.pdf
Refer to following Installation, Operation &
Maintenance Manuals (IOM’s) for either actuator
and/or devices that maybe mounted to a Model 521:
Actuators: www.cashco.com/IOM/C27-C53.pdf
Positioners:
P/P: www.cashco.com/techbulletins/9540l.pdf
I/P: www.cashco.com/techbulletins/srd991.pdf
I/P: www.cashco.com/iom/PS2iom.pdf
ISO Registered Company

IOM-5212
III. INSTALLATION
A. Orientation
1. Recommended orientation when installed
is in a horizontal pipeline with the stem
vertical. Valves may be installed in a vertical
or horizontal pipeline with the stem between
vertical and horizontal.
2. Outdoors, all installations may be oriented
at any angle from horizontal-to-vertical, as
per A.1. above.
3. Model 521 valves should not be installed
with the stem oriented below horizontal/
downwards.
4. In no case is additional weight to be applied
to the actuator assembly when installed in
an orientation other than vertical.
8. Undue piping stress/strain or bending
torques may not be transmitted through
the control valve body. One pipe (inlet
or outlet) should be anchored rigidly for
piping that is “hot” or “cold” with respect to
SECTION III
Figure 2: Body Insulation
B. Piping System
1. It is recommended that the control valve
unit be installed with a double-block and
bypass as indicated in Figure 1. This
arrangement is recommended especially
where maintenance will be done on the valve
body while still installed in the pipeline.
2. If pipe reducers are located before and/or
after the valve body, keep the reducers as
close as practical to the valve body; this is
especially important where the reducers are
more than one line size larger than the valve
body size, which is common in gaseous
service.
3. Clean the piping of all foreign debris,
including chips, weld scale, weld splatter,
oil, grease, sand or dirt prior to installing
the control valve; THIS IS AN ABSOLUTE
REQUIREMENT.
4. Field hydrostatic testing the completed
piping system, including the Model 521,
to 1-1/2 x CWP indicated on Model 521
nameplate is acceptable. If hydro test
pressure exceeds the 1-1/2 x CWP limit,
the 521 must be removed for such testing.
Before pressurization, the valve plug should
be lifted from the seat if of reverse, ATO-FC
action.
5. Flow Direction: Install so the flow direction
matches the arrow cast on the valve body.
6. Valves are not to be direct buried
underground.
7. Insulation may be applied as indicated in
Figure 2. Drainage from the packing area
must be ensured when fully installed, sealed
and lagged for outdoors installation. Vented
pipe plug (12) should not be covered.
WARNING
The valve/actuator unit should not be used as a
“step” to support personnel. Failure to comply
may cause leakage at the bonnet/body joint,
allowing possible contact with harmful fluids.
Figure 1: Typical Control Valve Station

IOM-521 3
12. Tighten flange stud nuts uniformly in a
crossing pattern. Ensure flange facing
alignment. Do not use flange bolting to “pull”
flanges into alignment. Tighten flange bolting
to torque levels of Table 2 in increments of
1/2 revolution to ensure uniform loading of
valve’s raised facing.
ambient temperature; the remaining pipe
(inlet or outlet) should be supported and
guided to ensure unidirectional expansion/
contraction. Properly align prior to installing
valve with required flange bolting.
9. The Model 521 is designed for a flanged
connection that is gasketless. The raised
face portion of end connection flange serves
as the gasket.
10. An ANSI/DIN adapter gasket (17) is supplied
with all Model 521 valves provided with DIN
16/25/40 end connections. See Figure 3.
The purpose of this adapter gasket (17) is
to ensure proper compression of the body’s
TFE core (1.2) when used with DIN piping.
To assist during installation, place pipe
thread sealant on one side of adapter gasket
(17), and press the sealant covered side of
the adapter gasket over the exposed TFE
of the body core (1.2) end connection. The
sealant will hold the adapter gasket (17)
to its proper location prior to joining with a
piping flange.
NOTE: If the installed Model 521 has had
the flange bolting over-torqued, distortion
of TFE core (1.2) will occur. If dimension
“X” in Figure 4 is 0.040" (1 mm) or less, a
gasket is recommended upon reinstallation.
If dimension “X” is less than 0.020" (0.5 mm),
body replacement is recommended.
Figure 3: ANSI/DIN Adapter Gasket
11. Flange bolting must be of the stud-type. Each
flange is drilled and tapped to accept studs.
The studs should be of a length to penetrate
the full depth of the bolt hole through the
flange; DO NOT USE STUDS/BOLTS OF
TOO SHORT LENGTH. See Table 1 for
stud size/thread/length requirements.
TABLE 1
Body Size End Connection Flange Bolting
In. (DN) 150# 300# DIN 16/25/40
1/2" DN15 1/2" Ø - 1-3/4"
13 UNC-2B
1/2" Ø - 1-3/4"
13 UNC-2B
14 mm Ø - 45 mm
M12x1.75-6H
1" DN25 1/2" Ø - 2"
13 UNC-2B
5/8 Ø - 2"
11 UNC-2B
14 mm Ø - 52 mm
M12x1.75-6H
1-1/2" DN40 1/2" Ø - 2-1/2"
13 UNC-2B
3/4" Ø - 2-3/4"
10 UNC-2B
18 mm Ø - 70 mm
M16x2.0-6H
2" DN50 5/8" Ø - 2-1/2"
11 UNC-2B
5/8" Ø - 2-3/4"
11 UNC-2B
18 mm Ø - 70 mm
M16x2.0-6H
No. Bolt Holes 4 4 or 8 * 4
* 2" - 300 # requires 8 bolt holes; all others 4.
TABLE 2
Body Size End Connection Flange Bolting
In. (DN) ANSI-150 ANSI-300 DIN 16/25/40
1/2" DN15 10 - 12 ft-# 10 - 12 ft-# 15 - 18 N-m
1" DN25 10 - 12 ft-# 12 - 14 ft-# 21 - 25 N-m
1-1/2" DN40 10 - 12 ft-# 14 - 17 ft-# 18 - 22 N-m
2" DN50 35 - 40 ft-# 17 - 20 ft-# 50 - 60 N-m
Figure 4: End Connection - Partial Section

IOM-5214
SECTION IV
IV. STARTUP
A. General:
1. Ensure that the Model 521 unit has been
properly adjusted and calibrated, including
the positioner, if installed.
2. Recommend startup to be in “manual”
mode. This procedure assumes double
block (isolation) and bypass valves for the
“control valve station" per Figure 1.
3. Start with either of the two block valves
closed, with the other open. The bypass
valve should be closed. Pressurize system
if possible/practical.
4. Back out the airset’s adjusting screw until
loose.
5. Turn on air supply pressure.
6. Adjust the air supply airset (filter-regulator) to
the proper level as indicated in the technical
bulletin 521-TB. DO NOT STROKE THE
CONTROL VALVE WITH AN AIR SUPPLY
PRESSURE SETTING GREATER THAN
RECOMMENDEDMAXIMUMPRESSURE!
7. Place loop controller into “manual” mode.
Vary setting from minimum – mid-range—
maximum SIG output. Observe response of
control valve unit to these changes of input
SIG. The valve should fully stroke at the
variation from minimum SIG to maximum
SIG; the mid-range SIG should have the
valve stem travel at/near 1/2 open.
8. Confirm that action of controller and
positioner – direct or reverse – are producing
the desired response in the control unit.
Confirm that the control valve “fail” position
is as required.
9. Hereafter, the procedure assumes that
actual fluid flow may be established. This
may not be practical/possible in all cases;
if so, vary procedure as required.
Always “heat” or “cool” down the system
piping SLOWLY by opening the control valve
station bypass valve in small increments.
10. With one of the control valve station block
valves still closed, and the loop controller
still in “manual” mode, open bypass valve
and vary flow rate manually to observe the
response of the controller and control valve
unit together.
11. Attempt to develop manual control of the
loop by opening/closing the manual bypass
as required, or by manually controlling
mainstream flow as required.
12. When the control valve is partially open,
crack open, slowly, the closed block valve
while simultaneously closing the bypass
valve; it may be necessary/desirable to
vary the manual output SIG from the
controller simultaneously also. Continue
this procedure until the bypass is closed
and the block valves are both fully open.
The system is still under “manual” mode
control, but all flow is passing through the
control valve.
C. Auxiliary Detection:
1. When a fluid is known to permeate TFE over
a finite time period and the fluid is lethal
or is subject to stringent limits of fugitive
emissions, the vented pipe plug (12) should
be removed and one of, or a combination of,
the following methods should be considered
to monitor the integrity of the internal primary
stem (9) seal – the bellows sub-assembly
(8):
a. gas detector with alarm
b. pressure indicating gauge
c. pressure switch with alarm
d. inert gas, constant flow purge.
CAUTION
DO NOT WALK AWAY AND LEAVE A MANUALLY
CONTROLLED CONTROL VALVE UNATTENDED!
13. Vary controller “manual” SIG output until
matching the “automatic” SIG output, then
change the mode of the controller over to
“automatic”, and the loop will experience a
minimum of upset conditions, and will be in
automatic control.

IOM-521 5
A. General:
1. Once fluid pressure has been isolated by
block valves, and piping flange bolting has
been only loosened, carefully remove vented
pipe plug (12) from the bonnet (2), applying
the detection procedures of C. 1. above, as
a small quantity of fluid may be “trapped” in
the void space of the bellows (8) interior due
to permeation. The plug (12) has a “groove”
notched in its threads to assure venting prior
to the threads fully disengaging. Once fully
vented and/or purged as required by safety
procedures, reinstall the plug (12) using a
fluid compatible lubricant . DO NOT USE
THREAD SEALANT FOR VENTED PIPE
PLUG (12) ON REINSTALLATION.
2. Maintenance procedures hereinafter are
based upon removal of the valve/actuator
unit from the pipeline where installed.
3. Owner should refer to Owner’s procedures
for removal, handling and cleaning of
nonreusable parts and suitable solvents,
etc.
4. Valves supplied from the factory do not
use any sealing aids for the gasket such
as oil, sealant, or pipe dope in the wetted
portions of the valve body assembly. Sealing
aids should not be required and are not
recommended.
5. All indicated Item Numbers that are with
respect to actuator assembly (AA) will be in
parenthesis and underscored; i.e. (20). All
Item Numbers that are with respect to the
body assembly (BA) are not underscored;
i.e. (32). Reference with respect to the
positioner is in double parentheses; i.e.
((AP)).
V. MAINTENANCE
WARNING
Model 521 control valves frequently are installed
in hazardous/lethal fluid services. Before removal
from pipeline or any level of disassembly,
consult the Owner’s safety procedures for
proper flushing, cleaning and handling of a
valve exposed to potentially hazardous fluids
during de-pressurization and removal. Owner's
safety procedures preempt any statements or
recommendations contained in this IOM.
Figure 5: Pressure Boundry Testing Configuration
SECTION V
6. The stem sub-assembly (9) is designed
for non-rotation when installed. DO NOT
ATTEMPT TO ROTATE WITH THE STEM
SUB-ASSEMBLY INSTALLED; FAILURE
TO HEED MAY CAUSE DAMAGE TO THE
STEMSUB-ASSEMBLY(9),THEBELLOWS
SUB-ASSEMBLY (8), THE PLUG (3) AND/
OR THE BODY ASSEMBLY(1). Exhibit
special care when handling the stem (9)
surface where it contacts the packing (6).
B. Pressure Boundary Leakage Shop Test:
1. Secure the body assembly (BA) in a vise
with the valve stem (9) oriented vertically.
2. Remove vented pipe plug (12).
3. Install a pipe nipple, test pressure gauge and
isolation valve into the 1/8"-NPT (female)
opening. (See Figure 5.)
4. Place a suitable adhesive tape (“duct tape”)
around the perimeter of the bonnet/body
flange. Place tape on the “joint lines” of the
shell halves (1.1) (see Figure 10). Place blind
flanges over the flanged end connections
and bolt down; one of the blind flanges must
have a hole through the face; place tape
over the opening of the blind flange.
5. Using a source of acceptable fluid such as
nitrogen gas, pressurize the bellows “void
zone” to 30 psig (2.1 Barg). Tightly close off
the isolation valve of 3. above. Disconnect
the pressure source.
6. Poke small holes in the tape at the bonnet/
body flange and at the opening in the blind
flange.

IOM-5216
6. Loosen stem nut (20) by rotating nut CW
(viewed from above) to base of threads.
7. Loosen packing (6) by turning packing gland
nut (5) CCW 2-3 revolutions.
8. Rotate yoke nut (15) CCW to fully loosen
nut.
9A. For ATO-FC Reverse Action Actuators:
a. Connect a temporary air source
to the actuator and pressurize the
actuator to upper limit of the bench
range specified on the valve name
plate. (Pressure will lift the plug head
(3) away from the body's (1) integral
seat until the plug (3) is 100% open.)
b. Place a wrench on the hex surface
of the swivel lower knuckle (44) and
rotate knuckle CCW (viewed from
above actuator) until lower knuckle dis-
engages from stem (9). Keep track of the
number of full revolutions to dis-engage
and record here. _______________
c. Maintain lift support from above the
7. For units with Reverse Action (ATO-FC)
actuators pressurize to a level sufficient to
initiate travel to approximately mid-stroke
to hold the plug (3) away from the body (1)
seat.
8. Apply leak detection fluid to all the potential
leak paths:
a. Packing gland nut (5). (Tighten as
necessary.)
b. Body (1)-to-bonnet (2) flange tape hole.
c. Body (1) and bonnet (2) bolting (13, 14,
1.3, 1.4, 1.5).
d. End connection blind flange tape hole.
e. Test pressure piping connections.
9. If leakage occurs at:
a. a. above, there is a packing (6) or a
packing (6) /stem sub-assembly (9)
failure.
b. b. above, there is a bonnet gasket (11)
failure.
c. c. above, there is a bonnet gasket (11),
or TFE core (1.2) failure.
d. d. above, there is a bellows sub-assembly
(8) failure.
10. Following this test procedure may help
to solve maintenance problems when
combined with visual examination of
disassembled body assembly (BA).
C. Separation of Body/Actuator:
1. Reference the Actuator IOM-C27-C53 for
item number call outs and drawings for
actuator.
2. Secure the body in a vise with the actuator
assembly (AA) oriented vertically. Place
matchmarks between the body (1) bonnet
flange, the bonnet (2) flange, and the yoke
(3) to assist in final orientation when the
body is disassembled and/or the actuator
removed. If actuator has handwheel - see
Actuator IOM for removal instructions.
3. Secure and rig the actuator assembly (AA)
for a vertical lift using an overhead hoist.
Remove slack from rigging.
4. This procedure assumes that the body
assembly (BA) has been fully assembled
through the bonnet (2), including the packing
gland nut (5) and packing (6).
5. Remove vented pipe plug (12) from body.
Figure 6: Swivel-Type Connector
actuator assembly (AA). Dis-engage
(slide) the swivel lower knuckle (44) out
of the upper knuckle (43) slot.
9B. For ATC-FO Direct Action Actuators:
a. Place a wrench on the hex surface
of the swivel lower knuckle (44) and
rotate knuckle CCW (viewed from
above actuator) until lower knuckle dis-
engages from stem (9). Keep track of the
number of full revolutions to dis-engage
and record here. ________________
b. Maintain lift support from above the
actuator assembly (AA). Dis-engage
(slide) the swivel lower knuckle (44) out
of the upper knuckle (43) slot.

IOM-521 7
The valve body (1) is machined after the
shell halves (1.1) have been bolted (1.3, 1.4,
1.5) around the TFE core (1.2). Disassembly
of the body sub-assembly (1) will create
alignment problems during reassembly. The
TFE core (1.2) is not replaceable, except as
a body sub-assembly (1).
10. Make a visual inspection of the trim portions
still interconnected to the actuator assembly
(AA) for obvious problems.
11. Hand-grasp the bellows sub-assembly
(8) and rotate CCW (viewed from plug (3)
end) to removal. Do not use any wrench,
vise, etc., for grasping the bellows sub-
assembly (8)! The bellows (8) should only
be hand-tight.
12. Loosen packing gland nut (5) 2-3 revolutions
out of the bonnet (2) by rotating CCW (viewed
from stem (9) end).
13. Loosen jam nut (20) 1-2 revolutions.
14. Grasp the valve’s stem sub-assembly (9)
in the lower area (normally surrounded by
the bellows (8.1)) using soft jawed pliers
to prevent marring stem surface. Place
a wrench on the hex surface of the swivel
lower knuckle (44) and rotate knuckle CW
(viewed from plug (3) end) until lower knuckle
dis-engages from stem (9). Keep track of
the number of full revolutions to dis-engage
and record here. _______________
15. Retract the stem sub-assembly (9)
downwards through the bonnet (2) until
stopped by locknut (20). Rotate locknut (20),
CCW until it is removed.
16. Fully withdraw stem sub-assembly (9).
17. Visually inspect parts for wear, general
corrosion, localized corrosion, dirty service
fluid, uneven alignment, seat leakage wire
drawing, excess plug-to-seat loading,
flange facings, looseness of plug-to-bellows
connection, primary seal at TFE Core (1.2)
-to-bellows (8.1) joint, secondary seat at
bonnet gasket (11) (See Figure 9), blisters
on TFE surfaces, etc.
18. Attempt to determine the reason for a
failure. Evaluate if process conditions need
correction, if alternate materials are required
for the stem sub-assembly (9), or if effects
10. Raise the actuator assembly (AA) over stem
(9). Release any actuator air pressure. Lay
actuator assemby aside on work surface.
D. Body Disassembly:
1. Access to body assembly (BA) internals may
be accomplished with the actuator assembly
(AA) intact with the bonnet (2) (i.e. locknut
(15) is still fully tightened), or with the body
assembly (BA) separated as per above
paragraph V.C. Steps 1-10.
2. Maintenance procedures hereinafter are
based upon the actuator assembly (AA) fully
interconnected with the valve stem assembly
(9) during disassembly.
3. Secure the body in a vise with the actuator
assembly (AA) oriented vertically upwards.
Place matchmarks between the body (1)
bonnet flange and the bonnet (2) flange to
assist in final orientation when the body is
disassembled and/or the actuator removed.
4. Secure and rig the actuator assembly (AA)
for a vertical lift using an overhead hoist.
Remove slack from rigging.
5. Loosen all bonnet cap screws (14)
approximately 1/4" (6 mm) by rotating CCW
(viewed from above).
6. Raise actuator assembly (AA) with overhead
hoist approximately 1/8" (3 mm).
7. Continue to loosen and remove bonnet cap
screws (14 and lockwashers (13).
8. Using overhead hoist, lift the actuator
assembly (AA) with the interconnected
valve stem sub-assembly (9), bellows sub-
assembly (8), bonnet (2), bonnet spacer
(19), locknut (15), packing gland nut (5),
packing rings (6), Belleville spring washers
(7), bonnet gasket (11), plug (3) and plug
retainer (4). Lay this assembly down on a
horizontal work surface carefully, so as to
not damage the valve’s internals.
9. Make a visual inspection of the body sub-
assembly (1) exterior, which includes two
shell halves (1.1), TFE core (1.2), and four
body cap screws (1.3) with body nuts (1.4)
and lockwashers (1.5).
NOTE: DO NOT DISASSEMBLE THE PARTS
OF THE BODY SUB-ASSEMBLY (1)!

IOM-5218
F. Packing Ring Replacement:
1. Disassemble the body assembly (BA) per
V.C. previous, including separation of body
assembly (BA) from actuator assembly (AA).
2. Loosen packing gland nut (5) until fully
dis-engaged from bonnet (2) by rotating
CCW (viewed from stem (9) end). Remove
packing rings (6) from packing box (recess)
in bonnet (2).
3. Examine wall surface inside the bonnet (2)
for any sign of corrosion.
4. Hone the bonnet’s (2) packing box to a #16
RMS finish. Burnish the stem sub-assembly
(9) to a #4 RMS finish in the packing (6)
contact area.
G. Reassembly of Body Assembly:
1. Place body assembly (BA) (1) in a vise with
the bonnet (2) end directed upwards.
2. Join the stem sub-assembly (9) to the
bellows sub-assembly (8) (with new plug
head (3) already installed) by rotating the
stem's (9) lower end into embedded nut (8.2)
CW (viewed from bellows (8.1) open end).
Rotate the stem sub-assembly (9) as far as
possible while hand-grasping the bellows
(8.1) DO NOT USE A WRENCH IN THIS
OPERATION. A light coat of Fluorolube
(™ of Occidental Chemical Co.) lubricant
may be applied to the engaged (threaded)
end of the stem sub-assembly (9) if fluid
compatible.
3. Place spacer washer (10) over the threaded
upper end of stem sub-assembly (9).
4. Referring to Figure 7 for proper orientation
and quantity of Belleville spring washers (7),
place the spring washers (7) over the upper
end of stem sub-assembly (9).
5. Position a new bonnet gasket (11) into recess
of body sub-assembly (1).
6. Observe the underneath side of bonnet (2)
where square recess is located. Position
combined bellows sub-assembly (8) and
stem sub-assembly (9) so that the anti-
rotation "stop" (square part of stem)is aligned
to slip into the bonnet’s (2) square recess.
of possible permeation need considerations
similar to those outlined in Section III.C.1.
E. Plug, Bellows, or Both Replacement:
1. Disassemble the body assembly (BA) per
V.D.1.-11. previous.
2. Hand-grasp the bellows sub-assembly (8)
and hand-rotate the plug head (3) until the
plug retainer strip (4) ends come into view
through the slot located on the side of the
plug head (3).
3. Using a pointed end pick tool, get under one
end of the plug retainer strip (4) and extract
through the plug’s (3) slot. Manually rotate
the plug head (3) end to allow more of the
plug retainer strip (4) to be extracted. When
able to grasp with needle nose pliers, lightly
pull the plug retainer strip (4) and rotate the
plug head (3) as necessary until the strip
(4) is fully removed.
4. Slide plug head (3) off the stub-end of the
bellows sub-assembly (8).
5. Discard the plug head (3), if worn. Always
discard the plug retainer strip (4); only use
a new plug retainer strip (4) at reassembly.
6. Do not attempt to field remove embedded
nut (8.2) from inside the bellows (8.1); these
parts are only available as a sub-assembly
(8). If embedded nut (8.2) is badly corroded,
replace the entire bellows sub-assembly (8)
and give strong consideration to alternate
materials for stem sub-assembly (9) and
bellows nut (8.2). If embedded nut (8.2)
is “loose”, consider potential causes and
replace bellows sub-assembly (8).
7. If bellows sub-assembly (8) is to be reused,
thoroughly clean the valleys of the bellows
(8.1) convolutions (inside and outside) for
the smallest of debris. Clean the grooves
of the bellows (8.1) and the plug head (3)
where the plug retainer strip (4) locates.
8. Place the plug head (3) over the bellows
sub-assembly (8) end. Insert a new TFE
plug retainer strip (4) into the slot/groove.
Rotate the plug head (3) as necessary while
feeding the strip (4) until the strip (4) is fully
located into the groove. (No cutting of the
strip (4) should be required.)

IOM-521 9
and alignment of parts (10) (8) (11) (7),
remove temporary spacer while continuing
downward force on the stem (9) while
simultaneously holding the bonnet (2) from
dropping downwards.
13. Lower bonnet (2) carefully downwards into
the recess of the body sub-assembly (1)
while continually applying downward force
on the stem (9).
14. At this point, downward force on stem (9)
may be exchanged for downward force on
the bonnet (2). Hand-tighten all bonnet cap
screws (14); relax downward force on bonnet
once cap screws have taken up all slack.
15. Using a torque wrench, tighten bonnet cap
screws (14) in alternating cross-pattern in
1/4 revolution increments to 40 ft-# (55 N-M).
7. Center the loose parts (10) (7) surrounding
the stem (9) as close as possible.
8. Position the bonnet (2) over the exposed
upper stem sub-assembly (9), ensuring
that the anti-rotation "stop" (square or flat
surface of the stem) is properly engaged
into the bonnet (2) square recess.
9. Placeatemporaryspacerdevice(screwdriver
blade, nuts, plain washers, etc.) equally
spaced on the body (1) flange to hold the
bonnet (2) up, as bonnet is lowered into
the body, maximizing the gap between the
bonnet flanges (1) (2).
10. Place anti-seize thread lubricant on bonnet
cap screws (14). Engage all bonnet
cap screws (14) with lockwashers (13)
approximately 1-1/2 revolutions.
11. Visually observing the gap between the
bonnet (2) lower flange surface and the
body sub-assembly (1) bonnet flange, apply
downward force tending to seat the plug
end (3). This will pull the bellows (8.1) into
proper position for the primary bonnet seal.
12. When visually satisfied of concentricity
Figure 7: Belleville Spring Washer Orientation
1/2" (DN 15) & 1-1/2" (DN 40) Body Sizes
1" (DN 25) Body Size
2" (DN 50) Body Size
CAUTION
Improper bonnet bolting torques may lead to
premature failure of the primary and secondary
bonnet seals.
16. Engage threaded, vented pipe plug (12) into
the 1/8" NPT tap on the bonnet (2) if it was
removed. If a lubricating oil is compatible with
the fluid, a light coating will aid in preventing
galling of the plug (12). Ensure that the tip
of the notch on the threads is in the bonnet
(2) at least 1-1⁄2 revolutions. Do not over-
tighten to minimize chances of galling.
Do not use thread sealing compound that
might “fill in” the notch and negate the purpose
of the notch.
17. The packing ring set (6) design is identical for
all unit body sizes. It consists of seven V-rings
(6.1) and one each male (6.2) and female
(6.3) adapter. (See Figure 8.) The purpose of
the packing rings (6) is to minimize moisture
ingress, and to serve as a secondary stem
seal in the event of bellows sub-assembly
(8) failure.
Carefully install rings (6) as indicated in
Figure 8, one at a time, using a hollow tool
to press the rings (6) to their final position.
Take care in slipping the rings (6) over the
threaded end of the stem (9) so as to not
mar the ring’s (6) internal surfaces. Do not
reverse orientation for vacuum service. Do
not “split” rings (6) for ease in replacement.
Do not reuse removed packing rings (6).

IOM-52110
4. This procedure assumes that bonnet (2) has
been bolted to the body sub-assembly (1).
5. Engage stem jam nut (20) to body assembly’s
stem (9) by rotating CW (viewed from valve
stem (9) end). Rotate jam nut (20) all the
way to root of the stem (9) threads.
6. Lower actuator assembly (AA) until the
opening of the actuator yoke (1) is at the
level of jam nut (20).
7. Place yoke nut (15) over valve stem (9) and
lower the nut to rest upon the yoke (3).
8. Push valve stem (9) downward towards
seating position. NOTE: The valve bellows
(8) may give “spring action” to keep the plug
(3) partially away from the seat.
9. For Direct Action ATO-FC Only: Connect
a temporary air supply hose that has an
adjustable airset with gauge connected at
the lower actuator inlet. Pressurize actuator
to a sufficient level to the upper pressure
level of the bench setting; i.e. for 5–15 psig
(.34–1.03 Barg) range, set pressure at 15
psig (1.03 Barg).
10. Apply Loctite Nickel Anti-Seize to grove and
top surface of swivel lower knuckle. Engage
(slide) the lower knuckle (44) into the upper
knuckle (43) saddle.
11. Continue lowering the actuator assembly
(AA) until the swivel lower knuckle (44)
connector and the valve's stem (9) just
touch. NOTE: For ATO-FC may need to
slowly reduce air pressure in the actuator
to connect the stem and knuckle.
12. Thread yoke nut (15) onto bonnet (2) threads
by hand as far as possible to help stabilize
topworks. Wrench-tighten one-half (1/2)
extra revolution.
13. Engage valve stem (9) threads to swivel
lower knuckle (44). Rotate swivel knuckle
(44) CW (viewed from actuator end) to
engage with valve stem (9), refer to V.C.
Steps 9A or 9B for the number of revolutions
recorded to dis-engage the lower knuckle.
14. Remove overhead rigging to allow actuator
assembly (AA) to fully rest on the bonnet (2).
Refer back to V.C. Step 2 for alignment of
match marks. Hand-tighten yoke nut (15).
18. Place anti-seize thread lubricant on threads
of packing gland nut (5). Place gland nut
(5) over the stem (9) end and engage with
the bonnet (2) by rotating CW (viewed from
exposed stem (9) end); continue finger-
tightening to the point of resistance. Wrench
tighten gland nut (5) 1/8 revolution past the
manual tightening resistance point.
19. Place bonnet spacer (19) down over
threaded portion of the bonnet (2).
20. Valve body assembly (BA) is completed, and
may be pressure tested up to 275 psig x 1.5
= 413 psig (19.0 Barg x 1.5 = 28.5 Barg) at
ambient temperature. Before pressurizing
for hydro, ensure that plug (3) is away from
body (1) seat. NOTE: Use soft gaskets on
body assembly (BA) end flanges to prevent
distortion of TFE flange facings.
H. Mounting Actuator Assembly to Body
Assembly:
1. Reference Actuator IOM-C27-C53 for item
number call outs and drawings for actuator.
This procedure assumes that accessory
plate ((AP)) or indicating washer (51) was
not removed or has been secured to the
actuator stem(6) by the swivel upper knuckle
(43) - tighten with 20-30 ft.lbs. (27-40 N M).
DO NOT allow actuator stem (6) to rotate.
Secure flats on bottom of stem (6) when
rotating knuckle (43).
2. Secure the body assembly (BA) in a vise
with the valve stem (9) oriented vertically.
3. Rig actuator assembly (AA) to be supported
from above.
Figure 8:Packing Ring Set