Chromatic HCV Valve User manual

General Information
The HCV valve is a quarter-turn valve with a segmented sphere or Hemi and a top entry
cartridge design that fits within the valve housing while supporting opposed upstream and
downstream sealing components. The Hemi rotates around a stationary core which directs the
flow through the valve. The Hemi sealing area, seat ring, and internal trim parts are not directly
exposed to the flow stream when the Hemi is in the open position. The spherical offset Hemi
design provides low pressure and low differential pressure sealing characteristics as well as
increased capability to seal at high pressure. This design will increase the life of the seat insert
by reducing its mechanical load in the full open position. The spherical offset of the Hemi
increases the sealing forces mechanically in the closed position in addition to the pressure
energized piston sealing characteristic. The valve is bi-directional. There is a preferred or
normal flow direction which provides optimum sealing performance and seal life, especially in
dirty or contaminated fluids. If flow and pressure are in the non- preferred direction, the
pressure energized seat ring provides sealing. The valve internal components, such as the
seat, Hemi, core, seals, and bearings are all contained in the cartridge assembly and the
parallel machined body allows for easy installation and removal of the cartridge in the field with
minimal time and effort. The valve can be provided with the operating options illustrated below.
Other options are available upon request. Gears, actuators, and levers are referred to as
operators in the manual.
Storage
Inspect for any damage that may have occurred during shipment prior to storage and contact
your shipper immediately if damages exist. Valves are drained and flange faces are coated with
rust inhibitor and flange protectors are installed. Valves and actuation equipment protective
covers should remain in place until the valve is ready to be installed in the line. Valves and
actuation equipment should be stored inside to protect them from harsh environment
including humidity and dust. Valves are shipped in the opened position, with the exception of
Fail-Close systems, and should be stored in the as shipped condition. For special long term
storage requirements on actuation equipment refer to applicable actuation manuals.
Unpacking
Remove any packing material, valve flange protectors, and protective covers from actuation
equipment. Inspect the valve bore for foreign objects and, if necessary, clean the valve body.
Handling equipment must be provided which is appropriate for lifting the valve and actuator
assembly safely into position. Use slings, end flanges or eyebolts in the provided tapped holes
on the valve. Do not use the lifting lugs or eyebolts on the actuator to lift the total assembly. Pay
attention that slings or braces do not damage the actuator or gear.
Pre-installation Safety Information
The valves shall be installed, operated, and maintained in accordance with these procedures.
Always follow standard safety procedure set forth by the law and regulations required by your
employer, end-users, and jurisdiction authorities. Any transportation, unpacking, lifting,
installation, operation, and maintenance of the system shall be made by expert, trained, and
qualified personnel.
HCV Valve Installation,
Operation, and
Maintenance Manual
WARNING: When lifting a valve with an attached actuator assembly, be aware that the center of
gravity may be above the lifting point. Additional support must be provided to prevent the valve and
actuator assembly from flipping or rotating. Failure to do so can cause serious injury to personnel
and/or damage to the equipment.
Lever Operated
Adapted for Actuator
Gear Operated
Pneumatic/Electric Actuator
IOM HCV 001 09-2019A

Installation
Identify the valves with the packing list and applicable
documents against the name plate for proper identification.
Check the total equipment weight and use suitable handling
devices to safely install the valves.
Prior to installation, ensure the valve drain and bleed plugs are
installed and tightened securely and the valve is in the full open
position.
Valves shall be installed in a manner that will not support the
weight of the line and line expansion and strain is isolated
external to the valve. Install the valve with the preferred inlet,
marked by the red flange and marking on the valve body,
toward the pump or pressure source. Position the valve in
piping to allow clearance and access to the operator. The valve
should be installed that the drain and bleed plugs are
accessible and cartridge removal is possible for in-line service
and maintenance. The preferred orientation is with the drain
plug to be at the lowest point of the valve.
Flanged valves should be installed using the proper gasket (not
supplied) and procedure recommended by National and
International Standards/Codes specified for the installation.
Butt Weld ends shall be welded in accordance to proper
Standard Code welding procedures.
Piping should be thoroughly flushed with the valve in the open
position prior to valve operation and the body drained after
testing to remove test fluid and debris that may have
accumulated in the body during testing.
Install the valve operator according to the manufacturer’s
guidelines. Refer to pneumatic, hydraulic or electric actuators
section for setting or adjusting the open and close stops for the
operator.
Operate (dry run) the valve by cycling from open to closed
position several times to test and ensure the proper operation
of the valve.
Operations
Prior to valve operation, make sure that the valve has been
installed in the pipeline with the preferred inlet upstream in the
normal flow direction. The valve is bi-directional and will seal in
either direction. Operating the valve in a preferred or normal
flow direction will provide optimum sealing performance and
seal life, especially in dirty or contaminated fluids.
The valve operates 90° from the full open to full closed
position. The valve is a torque seated valve with the maximum
closing torque for the appropriate pressure is applied at the
end of the close cycle. Under high differential pressures, the
un-seating torque may be as high as the seated torque.
Pneumatic, Hydraulic or Electric Actuators
In the case when the actuator has been installed prior to
receipt or installation, check that air, hydraulic and electrical
supply lines are connected per the manufacturer’s
specifications and instructions. Using the manual override,
place the valve in the mid open position. Verify that the
actuator mounting bolts are securely tightened. Activate the
OPEN button or switch and make sure that the actuator travel
counterclockwise towards the open position. If it does not,
make the appropriate piping or wiring changes and/or
adjustments.
In the case when an actuator has not been previously installed
on the valve, mount the actuator and tighten the nuts on the
studs securely to the proper torque specification per Table 1.
Install the pneumatic or electrical wiring and cable to the
actuator according to the manufacturer’s instructions. After
installation of the operator on to the valve, rotate the position of
the ball approximately 1⁄4 turn to determine if the ball moves to
the closed position. If the ball does not completely close the
port, adjust the actuator stop to reposition the valve’s closed
position. Turn the actuator to the open position and observe if
the Hemi moves completely to the open position. A full port
opening should be visible. If the Hemi does not completely
move to the open position, adjust the actuator stop to
reposition the valve’s open position. The Hemi should be in the
full open position at zero degrees.
Maintenance
The valve does not require periodic lubrication or maintenance
to provide continuous trouble-free service. The valve is a
torque seated valve and maximum rated torque must be
applied in the closed position. If the valve does not seal
properly, or if there are difficulties opening or closing the valve,
it may be due to foreign material deposits within the cartridge
of the valve body. Cleaning may be required in order to remove
the debris or foreign objects.
HCV Valve
CAUTION: Do not attempt to operate the valve past the full open
and closed position. Adjust the operator stops to engage prior to
the valve integral stops, as the integral stops in the valve are not
intended to be used as the operator stops.
NOTE: Do not over torque in the closed position. Over torque
may cause damage to the valve and void the warranty.
2 IOM HCV 001 09-2019A

Cartridge Removal and Installation
The following steps should be taken:
1. Isolate the valve section and depressurize and drain the pipeline.
2. Release any pressure which may be trapped in the valve body cavity by opening the
bonnet’s bleed plug and venting to the atmosphere.
3. Operate the valve to the open position. Remove the bottom drain plug and flush from
the vent through the drain plug.
4. Remove the valve operator.
• If an actuator is installed on the valve, reverse the steps described in the
pneumatic, hydraulic or electric actuators section for the removal of the actuator.
• If a manual lever is installed, back off on the set screw and remove the lever or
handle.
5. Loosen and remove bonnet bolting. Remove the cartridge from the valve body,
Figure 1. If the cartridge is difficult to remove, attach a lifting device to the two eye
bolts or jack screws located on top of the bonnet. The cartridge must be pulled
straight out from the body to ensure easy removal.
6. Inspect the cartridge for signs of damage to any internal parts.
• Clean the cartridge by flushing all the inside surfaces of the cartridge with clean
water. Flush several times with the Hemi in the open and closed positions to
remove any deposited debris. Make sure that no foreign objects is between the
Hemi and the cartridge’s side plates.
• If damaged, replace with a new cartridge. Remove the protective covering from
the new cartridge assembly. The replacement cartridge unit has been attached to
the bonnet for easy installation into the body.
7. Prior to installing the new cartridge, clean the inside of the valve body and apply
grease to the machined areas of the body.
8 Remove and replace the old bonnet seal from the upper flange of the valve. Replace
with a new bonnet seal by pressing the seal into the groove on valve body’s upper
flange. The replacement bonnet seal is shipped loose with the new cartridge.
9. [Flow Control cartridge only] Attached the installation tool to the replacement
cartridge as shown in Figure 2. Tighten the nuts onto the threaded shaft until the
cartridge assembly is compressed by approximately .060” (1.50 mm).
10. Install the cartridge unit by matching the wide portion of the cartridge (seat side) to the valve body’s
downstream flange (unmarked - none Red) and gently lower the cartridge into the valve body.
11. [Flow Control cartridge only] Once the cartridge is installed about halfway into the valve body and
both retaining plates have firmly engaged with the valve body, remove the installation tool. Then
slide the cartridge completely into the valve body.
12. Replace the nuts on each stud and torque securely to the proper torque specification in a cross
pattern method in 25% increment per Table 1.
13. Reinstall the valve operator.
• Reinstall the actuator according to the steps described in the pneumatic, hydraulic or electric
actuators section.
• Reinstall the manual lever on the valve by tightening the set screw to the valve stem.
14. Open and close the valve several times to assure proper sealing and operation.
HCV Valve
IOM HCV 001 09-2019A 3
Figure 1: Cartridge Removal/Installation
Figure 2: Installation Tool
SIZE (inches) 1/2 5/8 3/4 7/8 1 1 - 1/8 1 - 1/4 1 - 3/8 1 - 1/2
Torque (lbf.ft) 68 136 242 390 584 856 1204 1632 2154
Torque (N.m) 92 184 328 528 792 1160 1632 2212 2920
Table 1: Bolt Torques

IOM HCV 001 09-2019A Copyright © 2019 Chromatic Industries LLC. All rights reserved. Specifications may change without notice.
Chromatic Industries, LLC
16400 Air Center Blvd. Suite 200, Houston, TX 77032
Tel: [phone] www.chromaticindustries.com
HCV Valve
Bill Of Material
ITEM NO. DESCRIPTION
1 Body
2 (1) Bearing
3 Hemi
4 Bonnet Seal
5 (1) Bearing
6 Stem
7 Washer
8 (2) O-Ring
9 (2) Weather Seal
10 Bonnet
11 Stud
12 Nut
13 Seat Assembly
14 Seat Retainer
15 Screw
16 Core Assembly
17 Core Retainer
18 Key Square
19 Drain Plug
20 Bleed Plug
21 (3) Bottom Retainer
22 (3) Screw
23 (4) Stud
24 (4) Stem Packing
25 (4) Stem Bearing
26 (4) Follower
27 (4) Gland Plate
28 (4) Belleville Washer
29 (4) Nut
(1) Trunnion Valve Only
(2) O-Ring Stem Seal Only
(3) 6” and Larger Valves Only
(4) Outside Packing Gland Only