cashco 988 Installation guide

I. DESCRIPTION AND SCOPE
Model 988’s and 989’s are pneumatically actuated, globe-
style control valves. Sizes are 3/4", 1", 1-1/2" and 2".
Materials are available in cast carbon steel, Grade WCB
(CS); cast 316L SST, Grade CF3M (SST); and cast CW-
12MW, similar to Hastelloy C (H-C).
Failure position is determined by actuator for:
"D" = Direct action; on increasing air loading pressure, the
actuator stem extends. Fail-safe position is with the stem
retracted.
"R" = Reverse action; on increasing air loading pressure, the
actuator stem retracts. Fail-safe position is with the stem
extended.
These valves are designed for chemical service and most
common liquid, gaseous, or steam services.
Models 988 and 989 differ only in the face-to-face dimensions
of flanged units; 988’s have a “regular” (“long”) body pattern,
and the 989’s have a “short” body pattern.
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-988/989
02-16
MODELS 988 and 989
GLOBE-STYLE PNEUMATIC CONTROL VALVE BODY
SECTION I
SECTION II
II. REFERENCE
Refer to Technical Bulletin 988-TB or 989-TB for complete
technical specifications coupled with either Cashco Actuator
Model C27 or C53.
www.cashco.com/techbulletins/988.pdf
www.cashco.com/techbulletins/989.pdf
Refer to following Installation, Operation & Maintenance
Manuals (IOM’s) for either actuator and/or devices that
maybe mounted to a Model 988 or 989:
Actuators: www.cashco.com/iom/C27-C53.pdf
ABBREVIATIONS
ATO-FC ............. Air-to-Open, Fail Closed
ATC-FO ............. Air-to-Close, Fail Open
CCW.................. Counter Clockwise
CW..................... Clockwise
D or DIR............. Direct Acting
HC ..................... Cast CW-12MW or Wrought Hast C-22
IAS..................... Instrument Air Supply
LOAD................. Positioner Output Air Pressure
R or REV ........... Reverse Acting
SIG .................... Output Signal from Instrument
SST.................... Cast or Wrought 316L Stainless Steel
V ........................ Vent
Model 988
with ATC - FO Actuator
Shown with Internal Live-Loaded Packing
ISO Registered Company

2IOM-988/989-BODY
III. INSTALLATION
A. Orientation:
1. Recommended orientation when installed in a
horizontal pipeline is with the stem vertical. Valves
may also be installed in vertical pipelines with
stems horizontal.
2. Outdoors, all installations may be oriented any
angle from horizontal-to-vertical. (Orient actuator
vent cap, if supplied, to not collect rainwater that
might freeze.)
3. Model 988/989 valves with actuators are not
recommended for installation with the actuator
oriented downwards.
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.
5. Clean piping of all foreign debris, including chips,
weld scale, weld spatter, oil, grease, sand or
dirt prior to installing the control valve. This is
an absolute requirement for valves supplied
with composition soft seats. System startup
strainers for removal shortly after initial startup are
recommended.
6. Field hydrostatic testing the completed piping
system to 1-1/2 x CWP in psig indicated on
the nameplate including the Model 988/989 is
acceptable. If hydro test pressure exceeds the
1-1/2 x CWP limit, the 988/989 must be removed
for such testing. Before pressurization, the valve
plug should be lifted from the seat if of reverse,
ATO-FC action. Tighten packing as required.
7. In placing thread sealant on pipe ends prior to
engagement, ensure that excess material is
removed and not allowed to enter the valve upon
startup.
8. Flow Direction: Install so the flow direction matches
the arrow on the valve body.
9. For best performance, install in well drained
horizontal pipe, properly trapped if a steam service
application.
10. Valves are not to be direct buried underground.
11. Insulation may be applied as indicated in Figure
2. Drainage away from the packing area must be
ensured when fully installed, sealed and lagged for
outdoors installation.
12. 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 ambient temperature; the remain
ing pipe (inlet or
SECTION III
2. Pipe unions are recommended for NPT screwed
or socket welded installations to allow complete
removal from system. If removal for maintenance
is by cutting torch for socket welded valves, leave
sufficient pipe nipple space between the body and
the next piping component up or downstream to
allow socket weld couplings for reinstallation.
3. 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.
Figure 1: Typical Control Valve Station
Recommended Maximum Flange Bolting Torque (ft-lbs.)
Body Size Body Material 150# Flange 300# Flange
3/4"
CS
23 28
1" 29 36
1-1/2" 43 43
2" 66 33
3/4"
SST
19 25
1" 24 30
1-1/2" 36 36
2" 54 27
3/4"
HC
26 32
1" 32 40
1-1/2" 48 48
2" 72 36
4. For split-ring flanged end connections, install flange
bolting to following torque values.
Drain Drain

3
IOM-988/989-BODY
outlet) should be supported and guided to ensure
unidirectional expansion/contraction.
C. Removal From Piping System:
1. Care should be taken in removal of separable
flanged units. Run wire across the flange face
and through bolt holes in 180° crossing pattern to
prevent flanges from coming loose during handling.
IV. STARTUP
A. General:
1. Ensure that the Model 988/989 unit has been
properly adjusted and calibrated, including the
positioner if installed.
2. Recommend startup to be in a “manual” mode.
This procedure assumes double block (isolation)
and bypass valves for the “control valve station”.
See 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 as follows:
Bench Setting Airset Output
psig (Barg) psig (Barg)
5–15 (.34–1.0) 20 (1.4)
15–60 (1.0–4.1) 75 (5.2)
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 at/near 1/2 travel.
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, slowly crack
open the closed block valve while simultaneously
closing the bypass valve. 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.
13. Vary controller “manual” SIG output until matching
the “automatic” SIG output, then change the mode
of the controller over to “automatic”. The loop will
experience a minimum of upset conditions, and will
be in automatic control.
CAUTION
DO NOT WALK AWAY AND LEAVE A MANUALLY
CONTROLLED CONTROL VALVE UNATTENDED!
SECTION IV
CAUTION
Exhibit care in handling flanged units to prevent separable
flanges from coming loose, falling to floor and smashing
feet/toes.
Figure 2: Body Insulation

4IOM-988/989-BODY
V. MAINTENANCE
A. General:
1. Maintenance procedures hereinafter are based
upon removal of the valve/actuator unit from the
pipeline where installed.
2. Owner should refer to Owner’s procedures for
removal, handling and cleaning of non-reusable
parts, i.e. gaskets, suitable solvents, etc.
3. Valves supplied from the factory do not use any
aid to assist in gasket sealing such as oil, sealant
or pipe dope. Owner may use such aids provided
the aids are compatible with the Owner’s fluid.(See
below for “oxygen cleaned” valves.)
4. Valves originally supplied per Option-55 require
special cleaning procedures. Refer to Cashco
Specification No. S-1134 for details. When in
compliance with/to Spec. No. S-1134, the valve
is suitable for oxygen service. This procedure is
limited to bodies of SST or HC only.
5. All indicated Item Numbers that are with respect to
the 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).
6. Special care must be exhibited when rotating
the plug/stem (3) of the valve to not mar that
portion of the surface of the stem where it
contacts with the packing (6). To rotate the
plug/stem use the jam nuts (52) or a soft jawed
pliers. NOTE: When using the jam nuts to rotate
the plug/stem, use the upper jam nut to rotate the
stem CW, and the lower jam nut to rotate the stem
CCW, when viewed from above valve plug/stem.
7. Hereafter, whenever text has the following notation,
"(Note PA.)", the following text is to be applied:
"For ATO-FC units ONLY, connect a
temporary air source with gauge to the actuator
and pressurize to a level sufficient to initiate
travel to approximately mid-stroke."
8. Hereafter, whenever text has the following notation,
"(Note RP.)", the following text is to be applied:
"For ATO-FC units ONLY, release all
temporary air pressure."
B. Actuator Assembly Removal:
1. Refer to the correct actuator IOM for this procedure.
2. Secure the (BA) in vise with (AA) oriented vertically.
3. Rig (AA) to be supported above the (BA). Place
matchmarks between the bonnet/yoke and yoke/
accessory plate.
4. This procedure assumes that the (BA) is fully
assembled through the bonnet (2), including the
packing flange (4), follower (5), and packing (6).
5. (Note PA.) Securing the “flats” of the actuator
stem (6) by wrench, loosen stem jam nuts (52) by
rotating CW (viewed from above) one-at-a-time.
6. Fully loosen any accessory devices that are
connected to/with the stems (6), (3), such as
accessory plate ((AP)) for limit switch or positioner.
If actuator has handwheel - see Actuator IOM for
removal instructions.
7. Using a blunt end tool, hammer rap the tool to
loosen yoke nut (25), turning CCW (viewed from
above) approximately 1/2 revolution.
8. If the actuator is to be reinstalled, put paint or dye
marker between the plug/stem (3) and the actuator
stem (6), to serve as matchmarks.
9. Loosen packing (6) by rotating nuts (15) CCW 2-3
revolutions. (Note RP).
NOTE: To fully disengage the actuator stem (6) from
the plug/stem (3) is a two-step procedure. Be aware
of the valve’s stroke length as indicated on the
nameplate (40) before beginning disengagement.
During the disengagement, measure the distance
extended and attempt to make each step about
half of full stroke. Keep track of the number of
revolutions for each step in the box below.
10A. For ATO-FC Reverse Action Actuators:
a. (NOTE PA).
b. Step A. Rotate plug/stem (3) CW (viewed from
above the valve) to disengage the actuator
stem from the plug/stem. Record number of
plug/stem revolutions for Step A in box above.
When disengagement reaches approximately
50% of full stroke travel, Step A is complete.
For Steps 10A and 10B: Count the Number
of revolutions to disengage plug/stem from actuator stem:
Step A. __________ Step B. _________
TOTAL ________
SECTION V
WARNING
SYSTEM UNDER PRESSURE. Prior to performing any
maintenance, isolate the valve/actuator from the system
and relieve all pressure. Failure to do so could result in
personal injury.

5
IOM-988/989-BODY
c. Step B. Support the (AA) from above. Fully
loosen yoke nut (25) to removal. Lift the (AA)
upwards approximately 1/4"–3/8" (6–8 mm).
Again, rotate plug/stem (3) CW (viewed from
above) until disengagement from actuator
stem (6). Record number of plug/ stem
revolutions for Step B in box on previous page.
NOTE: Take notice of the parts “dangling loosely”
about the stem, the order of their location and their
proper orientation.
d. Fully raise (AA) above (BA). Remove carefully
to prevent "dangling parts" (position indicating
washer (51), accessory plate ((AP)), yoke nut
(25)) from falling. (Note RP).
10B. For ATC-FO Direct Action Actuators:
a. Step A. Rotate plug/stem (3) CW (viewed from
above the valve) to disengage the actuator
stem from the plug/stem. Record number of
plug/stem revolutions for Step A in box on
previous page When disengagement reaches
approximately 50% of full stroke travel, Step
A is completed.
b. Step B. Support the (AA) from above. Fully
loosen yoke nut (25) to removal. Lift the
(AA) upwards approximately 1/4"–3/8" (6–8
mm). Again rotate plug/stem (3) CW (viewed
from above valve) until disengagement from
actuator stem (6). Record the number of valve
stem revolutions for Step B in box on previous
page.
NOTE: Take notice of the parts “dangling loosely”
about the stem, the order of their location and their
proper orientation.
c. Fully raise (AA) above (BA). Remove carefully
to prevent “dangling parts” (position indicating
washer (51), accessory plate ((AP)), yoke nut
(25) from falling.
C. Mounting Actuator Assembly to Body Assembly:
1. Refer to the correct actuator IOM for completion of
this procedure.
2. Secure the (BA) in a vise with the plug/stem (3)
oriented vertically. Push stem down until plug
touches the seating surface in the body.
3. Rig (AA) to be supported above the (BA).
4. This procedure assumes that the packing assembly
and bonnet (2) have been bolted to the body (1).
5. Engage stem jam nuts (52) one-at-a-time to the
plug/stem (3) by rotating CW (viewed from above
stem end). Rotate jam nuts all the way down to the
root of the stem threads.
6. Lower (AA) until the opening of the actuator yoke
(3) is at the level of upper jam nut (52).
7. Place yoke nut (25) over the plug/stem (3) and
lower the nut to rest upon the yoke.
8. Place travel indicator washer (51) and accessory
plate ((AP)) over stem (3) and allow to rest upon
upper stem jam nut (52).
9. Align matchmarks between body/bonnet, bonnet/
yoke and yoke/accessory plate. Continue to lower
(AA) until two stems are approximately 3/8" (8mm)
apart.
10. Ensure that plug/stem (3) is resting on seat ring.
11A. For ATC-FO: Hook up a temporary air supply
hose that has an adjustable airset connected at
the actuator inlet to allow pressurization. Slowly
pressurize actuator to bring the actuator stem to
within 1/8" (3mm) of touching the plug/stem.
11B. For ATO-FC: Continue lowering (AA) until
actuator’s stem (6) and valve’s stem (3) almost
touch.
12. Rotate yoke nut (25) onto bonnet (2) threads as far
as able to help stabilize topworks. Wrench-tighten
one-half (1/2) extra revolution.
13. Use hand to lift plug/stem (3) upwards to engage
with actuator stem (6). Rotating plug/stem CW
(viewed from plug end) the same number of
revolutions recorded to disengage the stem per B
Step 10A.
14. For ATC-FO: Release air pressure from (AA).
For ATO-FC: (NOTE PA).
15. Fully lower the (AA) downwards until the yoke (3) is
properly positioned on the valve bonnet (2). Hand-
tighten yoke nut (25).
16. Complete the engagement of plug/stem into the
actuator stem the same number of revolutions
recorded to disengage the stems per B Step 10B.
(NOTE RP)
17. Connect “dangling parts” – accessory plate (AP)
and travel indicator disc (51) – to actuator stem (6)
with stem jam nuts (52).
18. Retighten packing flange nuts (15).
19. Hammer rap yoke nut (25) with a blunt end tool
until tight.
20. Check valve stem stoke by alternately pressurizing
and then depressurizing the actuator. Repeat
several times. DO NOT OVER PRESSURIZE.
21. Release all air pressure from (AA) and remove
temporary air supply hook up.

6IOM-988/989-BODY
D. Trim and Packing Removal and Replacement for
Units with Internal Live-Loaded Packing; Opt-STD
or Opt-KRI: (See pg. 19 for Item # identification.)
1. Remove (AA) as described in Sub-Section V.B.
Leave (BA) in vise with plug/stem (3) upwards.
2. Continue to loosen stem packing (6) by
rotating packing nuts (15) CCW to just short of
disengagement from packing studs (14). DO NOT
REMOVE PACKING NUTS (15).
3. Remove all bonnet stud nuts (17).
4. Lift bonnet (2), plug/stem assembly (3), cage (10)
and all packing zone parts up and out of the body
- grasp stem (3) to prevent from falling. Lay these
parts down horizontally on a workbench. NOTE:
Seat ring (11) (and seat retainer (23) and soft seat
insert (24) for composition/soft seated designs)
may also pull out with the above parts assembly.
5. Remove both stem nuts (52).
6. Withdraw plug/stem (3) out through bottom of the
bonnet (2) and packing (6). Hold cage (10) to
prevent from dropping. Set parts (3, 10) aside.
7. Place bonnet (2) into a second vise with the packing
zone on top.
8. Remove the packing nuts (15).
9. Remove packing flange (4) and follower (5).
14. Examine plug/stem (3) in critical finish zone where
contact is made with the packing (6). It is desirable
to restore the surface of the stem (3) to a #4 Ra μ-in
surface finish; metal removal should not exceed
0.001 inch material. A deeply scratched or pitted
stem should be replaced.
15. Examine plug/stem (3) for wear around the seating
area. Examine seat ring (11).
a. Plug head of stem assembly (3) for metal
seated design may be hand lapped using
suitable lapping compound. If hand lapping will
not restore surfaces to an acceptable degree,
then replacement of plug/stem assembly is
recommended.
b. For composition seated design, if plug/stem
assembly is wear damaged, the stem should
be replaced.
16. Examine the inner surface of the bonnet’s (2)
stuffing box. It is desirable to restore the surface
of stuffing box to a #8 Ra μ-in surface finish; metal
removal should not exceed 0.001 inch material. A
deeply scratched or pitted bonnet (2) should be
replaced.
17. Examine packing follower (5) for corrosion.
Replace if corroded:
a. Replace follow bushing (26) with new bushing.
b. Replace wiper ring (22) with new wiper ring.
18. Turn attention to the body (1) and remaining
parts yet therein. Remove seat ring (11) (and
seat retainer (23) and soft seat insert (24) for
composition/soft seated design) if not already
removed. Discard used soft seat insert (24); always
use a new soft seat insert upon reassembly. If
seat ring (11) or seat retainer (23) are damaged,
replace.
19. Examine gaskets (12,13) to see if leakage
occurred. Remove and discard both the seat ring
gasket and bonnet gasket. Always use new gaskets
upon reassembly.
20. Remove body (1) from vise. Solvent clean all loose
parts with suitable solvent. Determine parts to be
replaced due to wear and/or corrosion. Clean seat
ring (11), cage (10), and seat retainer (23).
21. Place body (1) into vise with body/bonnet flange
face up.
22. Place a new seat ring gasket (13) into position.
23. Note correct orientation of seat ring (11) and place
inside the body (1).
24. For composition/soft seat design, position a new
soft seat insert (24) and the seat retainer (23) into
position on top of seat ring (11).
25. Place new bonnet gasket (12) on the body’s bonnet
flange face.
10. Using a sharp, hooked-end, pick-type tool, hook and
pull the packing rings (6) up and out of the bonnet’s
(2) stuffing box individually. Examine for excessive
wear. Discard old packing.
11. Remove bonnet (2) from vise and invert to allow
packing washer (7), packing spacer (9) and packing
spring (21) to slide out of the bonnet’s stuffing box.
12. Solvent clean all parts to be reused, including
bonnet (2). Examine any parts for wear and
corrosion. Replace any corroded or warn parts.
13. Examine plug/stem (3) at lower guide bushing (8)
area for wear. If there are signs of excess wear,
guide bushing (8) should be replaced:
a. Place the bonnet (2) on a bench press. Press
the guide bushing (8) out of the bonnet and
discard.
b. Rotate bonnet (2) end-for-end. Place a new
guide bushing (8) into position and press fully
into the bonnet.
c. Reclean bonnet with suitable solvent.
CAUTION
Take extreme care to not mar internal wall surface of the
bonnet (2).

7
IOM-988/989-BODY
26. With the cage (10) oriented correctly on the stem
assembly (3), set plug head down into the seat
ring (11). Keep firm hold of the plug/stem with
one hand; use other hand to push cage down into
proper alignment.
27. Lift bonnet (2) over threaded end of plug/stem
(3) and carefully lower bonnet down over stem,
ensuring that the critical finish zone of the bonnet’s
stuffing box is not scratched by the stem’s threads.
Align body (1)-to-bonnet (2) flanges to matchmarks
as bonnet comes down over bonnet studs (16).
Carefully release plug/stem (3) only when bonnet
is completely resting on the body.
28. Install bonnet nuts (17) on studs (16) finger-tight.
29. Place packing spacer (9) over end of plug/stem (3)
and carefully lower into stuffing box.
30. Place packing spring (21) over end of plug/stem
(3) and carefully lower down into stuffing box.
37. Install packing stud nuts (15), finger-tight, on top
of the packing flange (4).
38. Continue tightening nuts (15) evenly in 1/2
revolution increments, until the shoulder of packing
follower (5) is resting evenly on the upper edge of
the bonnet (2) at the stuffing box.
39. Thread the two stem jam nuts (52) onto the stem (3)
and rotate as far down the plug/stem as possible.
40. Push valve stem (3) down into the seat ring
(11). Wiggle the loose assembly to ensure initial
alignment/stacking.
41. Tighten bonnet bolting (16,17) in an alternating
cross-pattern in 1/4 revolution increments to the
following torque levels:
Size Torque
3/4”, 1”, 1-1/2” 70-75 ft-lbs (95-102 N-M)
2” 50-55 ft-lbs (68-75 N-M)
WARNING
Failure to ensure proper release of forces from Belleville
spring washers can cause flying parts that might cause
bodily injury.
42. Reinstall the (AA) as recorded in Sub-Section V.C.
43. Position suitable end closures – plugs, blind flanges,
etc., – and leak test with 100 psig air pressure
minimum. No packing (6) adjustment should be
required to get a tight seal.
44. Recalibrate per Section VI.
E. Trim and Packing Removal and Replacement for
Units With External Live-Loaded Packing; Opt-EXT,
Opt-KRE, Opt-HTE-Hi, or Opt-HTE-Lo: (See pg. 20
for Item # identification.)
1. Remove (AA) as described in Sub-Section V.B.
Leave (BA) in vise with plug/stem (3) upwards.
2. Place thread penetrating lubricant on bonnet
bolting (16,17) and packing bolting (14,15).
3. Loosen both packing stud nuts (15) until clearance
exists between the bottom of the nuts (15) and the
upper retainers (39). See Figure 4.
4. Spacer rings (40) should “spin freely”. If stacked
mechanism (39,40,41) is not “loose” due to
corrosion, debris, packed dirt, etc., tap the spacer
rings lightly with a hammer while attempting to pry
up the spacer ring /lower retainer with a flat tool.
DO NOT REMOVE PACKING NUTS (15).
5. Continue to loosen packing stud nuts (15) to just
short of disengagement from packing studs (14).
DO NOT REMOVE PACKING NUTS.
Figure 3: “STD” and “KRI” Packing Orientation
31. Place packing washer (7) over end of plug/stem (3)
and carefully lower into stuffing box. See Figure 3
for proper packing orientation.
32. Carefully place lower adapter (6.3) of packing ring
set (6) over plug/stem’s (3) end, properly oriented.
Using the packing follower (5), push the lower
adapter into the bonnet’s (2) stuffing box.
33. Carefully place a packing ring (6.2) properly
oriented over the plug/stem’s (3) end and push
into the stuffing box similar to the adapter (6.3).
Repeat for each of the four rings (6.2).
34. Place upper adapter (6.1) over the stem 3)
35. Place packing follower (5) with new wiper ring (22)
and new follower bushing (26) tape over the end
of the plug/stem (3).
36. Place packing flange (4) over end of plug/stem (3)
and over packing studs (14).

8IOM-988/989-BODY
6. Remove all bonnet stud nuts (17).
7. Lift bonnet (2), plug/stem assembly (3), cage (10),
and all packing zone parts up and out of the body
(1) - grasp stem to prevent from falling. Lay these
parts down horizontally on a workbench. NOTE:
Seat ring (11) (and seat retainer (23) and soft seat
insert (24) for composition/soft seated designs)
may also pull out with above parts assembly.
8. Remove both stem nuts (52).
9. Withdraw plug/stem assembly (3) from within the
bonnet (2) and packing (6). Hold cage (10) to
prevent from dropping. Set parts (3,10) aside.
10. Place the bonnet (2) into a second vise with the
packing zone on top. Remove packing nuts (15).
11. Grasp the lower retainers (39) from its underneath
side and lift the lower retainers, spacer rings (40),
Belleville spring washer stacks (41), and upper
retainers(39) together up and over the packing
studs (14). Set these parts (39,40,41) aside without
disturbing the orientation.
12. Remove packing follower (5) together with follower
bushing (26 or 5.2). Discard Rulon tape bushing
(26) if supplied.
15. Solvent clean all parts to be reused including
bonnet (2). Examine all parts for wear and
corrosion. Replace any corroded or worn parts.
Belleville spring washers (41), studs (14,16), nuts
(15,17) and retainers (39) should be replaced in
sets.
16. Examine plug/stem (3) at lower guide bushing area
(8) for wear. If there are signs of excess wear, guide
bushing should be replaced:
a. Place the bonnet (2) on a bench press. Press
the guide bushing (8) out of the bonnet and
discard.
b. Rotate bonnet (2) end-for-end. Place a new
guide bushing (8) into position and press fully
into the bonnet.
c. Reclean bonnet with suitable solvent.
17. Examine plug/stem (3) in critical finish zone where
contact is made with the packing (6). It is desirable
to restore the surface of the stem to a #4 Ra μ-in
surface finish; metal removal should not exceed
0.001 inch material. A deeply scratched or pitted
stem should be replaced.
18. Examine plug/stem (3) for wear around the seating
area. Examine seat ring (11).
a. Plug head of stem assembly (3) of metal
seated design may be hand lapped using
suitable lapping compound. If hand lapping will
not restore surfaces to an acceptable degree,
then replacement of plug/stem assembly is
recommended.
b. For composition seated design, if plug/stem
assembly (3) is wear damaged, the stem (3)
should be replaced.
19. Examine inner surface of the bonnet’s (2) stuffing
box. It is desirable to restore the surface of stuffing
box to a #8 Ra μ-in surface finish; metal removal
should not exceed 0.001 inch material. A deeply
scratched or pitted bonnet (2) should be replaced.
20. Examine packing follower (5) for corrosion.
Replace if significantly corroded:
a. Place new follower bushing tape (26) into
follower’s (5) interior groove.
b. If packing Opt-HTE-Hi or Opt-HTE-Lo is
supplied, the packing follower (5) contains
carbon bushing (5.2) that is pressed into the
follower (5.1). This bushing (5.2) is not field
replaceable and must be supplied as a packing
follower sub-assembly (5). Examine the car
bon
bushing (5.2) for wear or corrosion. Replace
follower sub-assembly when necessary.
21. Turn attention to the body (1) and the remaining
parts yet therein. Remove seat ring (11) (and
seat retainer (23) and soft seat insert (24) for
composition/soft seated design). Discard used soft
seat insert (24); always use a new soft seat insert
upon reassembly, If seat ring(11) or seat retainer
(23) are damaged, replace.
Figure 4: External Live Loaded Packing Orientation
CAUTION
Take extreme care to not mar internal wall surface of the
bonnet (2).
13. Using a sharp, hooked-end, pick-type tool, hook
and pull the packing rings (6) up and out of the
bonnet’s (2) stuffing box individually. Examine for
excessive wear. Discard packing.
14. Remove bonnet (2) from vise and invert to allow
packing spacer (9) to slide out of the bonnet’s
stuffing box.

9
IOM-988/989-BODY
22. Examine gaskets (12,13) to see if leakage occurred.
Remove and discard both gaskets. Always use new
gaskets upon reassembly.
23. Remove body (1) from vise. Solvent clean all loose
parts with suitable solvent. Determine parts to be
replaced due to wear and/or corrosion. Clean seat
ring (11), cage (10), and seat retainer (23).
24. Place body (1) into vise with body/bonnet flange
up. Install a new seat ring gasket (13) inside body
25. Note correct orientation of seat ring (11)and place
inside the body (1).
26. For a composition/soft seat design, position a new
soft seat inset (24) and the seat retainer (23) into
position on top of seat ring (11).
27. Place a new bonnet gasket (12) on the body’s (1)
bonnet flange face.
28. With cage (10) oriented correctly on the stem
assembly (3), set plug head down into the seat
ring (11). Keep firm hold of stem with one hand;
use other hand to push cage down into proper
alignment.
29. Lift bonnet (2) over threaded end of plug/stem
(3) and carefully lower bonnet down over stem,
ensuring that the critical finish zone of the bonnet’s
stuffing box is not scratched by the stem’s threads.
Align body (1) to-bonnet (2) flanges to matchmarks
as bonnet comes down over bonnet studs (16).
Carefully release stem (3) only when bonnet is
completely resting on the body.
30. Install bonnet nuts (17) onto bonnet studs (16) and
finger -tighten.
31. Place packing spacer (9) over end of plug/stem (3)
and carefully lower into stuffing box.
32A. For Opt-EXT and Opt-KRE Packing option –
(Reference Figure 3 for proper packing orientation) –
a. Carefully place lower adapter (6.3) of the new
packing ring set (6) over plug/stem’s (3) end,
properly oriented. Using the packing follower
(5), push the lower adapter into bonnet’s (2)
stuffing box.
b. Carefully place a packing ring (6.2) properly
oriented over the plug/stem’s end and push
into the stuffing box similar to the adapter (6.3).
Repeat for each of the four rings (6.2).
c. Carefully place upper adapter (6.1) similar to
lower adapter (6.3). Leave packing follower
(5) in position, properly oriented.
d. Place lower retainers (39) over each packing
stud (14). See Fig. 4 for proper orientation.
e. Orient spring washers (41) stacks per Figure
5. Lower spring washer stacks over studs and
down onto the lower retainers (39).
f. Place spacer rings (40) over studs and onto
ledge of lower retainers (39).
g. Place upper retainers (39) over the packing
studs (14), and onto the ledge of the spacer
rings (40). Ensure the upper retainers (39) are
properly positioned around its circumference.
h. Install packing stud nuts (15), finger-tight, on
top of the upper retainers (39). (See Fig. 4.)
i. Ensure that nuts (15) are drawn down evenly
such that the upper retainers (39) are level.
Wrench tighten packing nuts in 1/2 revolution
increments. Continue to tighten nuts until the
spacer rings (40) can no longer be manually
rotated by use of fingers; add 1/2 revolution of
additional draw-down to each nut to properly
load the packing (6).
32B. For Opt-HTE-Hi and Opt-HTE-Lo packing options
(Refer to Fig. 6 for proper packing orientation) –
Figure 5: Belleville Spring Washers Orientation
Figure 6: Packing Orientation for Opt-“HTE-Hi & Lo”
a. Carefully place the lower braided ring (6.4)
over the plug/stem’s (3) end. Using the packing
follower (5) push the lower braided ring (6.4)
into the bonnet’s (2) stuffing box.
b. Carefully place lower adapter (6.3) properly
oriented over the plug/stem's end and push
into the stuffing box similar to the lower braided
ring.
c. Carefully place a packing ring (6.2) properly
oriented over the plug/stem’s end and push
into the stuffing box similar to the lower braided
ring . Repeat for each ring.
d. Carefully place the upper adapter (6.1) similar
to the lower adapter (6.3). Leave packing
follower (5) in position, properly oriented.
e. Place one of the lower retainers(39) over each
of the packing studs (14). Install packing nuts
(15) and finger-tighten.

10 IOM-988/989-BODY
f. Wrench-tighten the packing stud nuts (15)
evenly and in 1/2 revolution increments until
the “upper groove on the packing follower (5),
identified as “Line A” (Fig. 4), is flush with the
top edge of the bonnet’s (2) stuffing box.
g. Remove the packing nuts (15), lower retainers
(39) and packing follower (5).
h. Carefully place the upper braided ring (6.4)
over the plug/stem’s (3) end and push into the
stuffing box similar to the lower braided ring
(6.4). Leave the packing follower in position,
properly oriented.
i. Place lower retainers (39) over each of the
packing studs (14). Install packing stud nuts
(15) and finger-tighten.
j. Repeat Step f. with the exception that the
packing set (6) is to be compressed into the
stuffing box until the “lower groove” identified
as “Line B” on the packing follower (5) is flush
with top edge of the bonnet’s (2) stuffing box.
k. Remove the packing nuts (15). Leave the
follower (5) and lower retainers in place.
l. Orient spring washer (41) stacks per Figure
5. Lower stacks over studs and onto ledge of
lower retainers (39).
m. Place spacer rings (40) over studs and onto
ledge of lower retainers (39).
n. Place upper retainers (39) over packing studs
(14), and onto the ledge of the spacer rings
(40). Ensure the upper retainers (39) are
properly positioned around its circumference
and that the inversion is correct for HTE-Hi
versus HTE-Lo options.
o. Install packing stud nuts (15), finger-tight, down
to the upper retainers (39).
p. Manually stroke the plug/stem (3) a minimum
of fifty full strokes.
q. Ensure that packing stud nuts (15) are drawn
down such that the upper retainers (39) are
level with top of spacer rings (40). Wrench-
tighten packing stud nuts in 1/2 revolution
increments. Continue to tighten nuts until
the spacer rings can no longer be manually
rotated by use of fingers; add 1/2 revolution of
additional draw-down to each nut to properly
load the packing (6).
33. Reinstall the two stem jam nuts (52) onto the plug/
stem (3) and rotate as far down the as possible.
34. Push valve stem (3) down into the seat ring
(11). Wiggle the loose assembly to ensure initial
alignment/stacking.
35. Tighten bonnet bolting (16, 17) in an alternating
cross-pattern in 1/4 revolution increments to the
following torque lev
els:
37. Position suitable end closures – plugs, blind
flanges, etc., – and leak test with 100 psig air
pressure minimum. No packing (6) adjustment
should be required to get a tight seal.
38. Recalibrate per Section VI.
F. Trim and Packing Removal and Replacement for
Units with Jammed Packing; Opt-38J, Opt-34A, Opt-
34B, Opt-34C:(See pg. 11 & 19 for Item # identification.)
1. Remove (AA) as described in Sub-Section V.B.
Leave (BA) in vise with plug/stem (3) upwards.
2. Continue to loosen stem packing (6, 47) by
rotating packing stud nuts (15) CCW to just short
of disengagement from packing studs (14).
3. Remove all bonnet stud nuts (17).
4. Lift bonnet (2), plug/stem assembly (3), cage (10)
and all packing zone parts up and out of the body
- grasp stem (3) to prevent from falling. Lay these
parts horizontally on a workbench. NOTE: Seat ring
(11) (and seat retainer (23) and soft seat insert (24)
for composition/soft seated designs) may also pull
out with the above parts assembly.
5. Remove both stem nuts (52).
6. Withdraw plug/stem assembly (3) from within the
bonnet (2) and packing (6, 47). Holding cage (10)
to prevent from dropping. Set parts (3, 10) aside.
7. Place bonnet (2) into a second vise with the packing
zone on top. Remove the two packing nuts (15).
8. Remove packing flange (4), packing follower (5),
wiper ring (22) and TFE bias tape follower bushing
(26).
Size Torque
3/4”, 1”, 1-1/2” 70-75 ft-lbs 95-102 N-M)
2 50-55 ft-lbs (68-75 N-M)
36. Reinstall the actuator assembly (AA) as recorded
in Sub-Section V.C.
9. Using a sharp, hooked-end, pick-type tool, hook
and pull the packing rings (47) up and out of the
bonnet’s (2) stuffing box individually. Examine for
proper orientation (see Figures 7, 8, 9 and 10).
10. Remove bonnet (2) from vise and invert to allow
lantern ring (27) or packing spacer (9) to slide out
of the bonnet’s stuffing box.
For Opt-34 –
a. Invert bonnet (2) again and place back in vise
with packing zone on top.
CAUTION
Take extreme care to not mar internal wall surface of the
bonnet (2).
CAUTION
Take extreme care to not mar internal wall surface of the
bonnet (2).