Circor D Series User manual

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INSTALLATION, OPERATING
AND MAINTENANCE INSTRUCTIONS
D SERIES
TABLE OF CONTENTS
GENERAL INFORMATION
TERMS CONCERNING SAFETY
UNPACKING
INSTALLATIONS
VALVE MAINTENANCE
VALVE DISASSEMBLY AND REASSEMBLY
PLUG STEM PINNING
ILLUSTRATION INDEX
Figure 1 – Typical bolting torque sequence
Figure 2 – Exploded drawing
Figure 3 – Installation of carbon filled energized seal ring
Figure 4 – Installation of Grafoil seal ring
Figure 4.1 – Grafoil seal ring
Figure 5 – Plug stem pinning
Figure 5.1 – Plug
Figure 6 – End to End dimensions
Figure 7 – Trim types
Figure 7.1 – Single stage Balanced Trim
Figure 7.2 – Two stage Balanced Trim
Figure 7.3 – Standard Trim

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1 General Information
The following instructions are designed to assist in
unpacking, installing and performing maintenance
as required on Circor D-series control valves.
Product users and Maintenance personnel should
thoroughly review this bulletin prior to installing,
operating or performing any maintenance on the
valve.
To avoid possible injury to personnel or damage to
valve parts, WARNING and CAUTION notes must
be strictly followed. Modifying this product,
substituting non-factory parts or using maintenance
procedures other than outlined could drastically
affect performance and be hazardous to personnel
and equipment and may void existing warranties.
WARNING: Standard industry safety practices
must be adhered to when working on this or any
other process control product. Specifically, personal
protective and lifting devices must be used as
warranted.
2 Terms Concerning Safety
The safety terms DANGER, WARNING,
CAUTION and NOTE are use in these instructions
to highlight particular dangers and/or to provide
additional information on aspects that may not be
readily apparent.
DANGER: indicates that death, severe
personal injury and/or substantial property
damage will occur if proper precautions are
not taken.
WARNING: indicates that death, several
personal injury and/or substantial property
damage can occur if proper precautions are not
taken.
CAUTION: indicates that minor personal
injury and/or property damage can occur if proper
precautions are not taken.
NOTE: indicates and provides additional technical
information, which may not be very obvious even
to qualified personnel.
3 Unpacking
1. While unpacking the valve, check the packing
list against materials received. Lists describing
valve and accessories are in each
shipping container.
2. When lifting the valve from shipping container,
use the lifting lugs attached to the bonnet bolting.
Take care to position lifting straps to avoid damage
to the tubing and mounted accessories.
WARNING: When lifting a valve using the
lifting lugs, be aware that the center of gravity may
be above the lifting point. Therefore, support must
be given to prevent the actuator from rotating.
Failure to do so can cause serious injury to
personnel, damage to the valve or nearby
equipment.
3. Contact your shipper immediately if there is
shipping damage.
4. Should any problem arise, contact your Circor
representative.

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Page 3 of 15
4 Installations
1. Before installing the valve, clean the line of dirt,
welding chips, scale or other foreign material.
2. Whenever possible, the valve should be installed
in an upright position. Vertical installation permits
easier valve maintenance.
3. Be sure to provide proper overhead clearance for
the actuator to allow for disassembly of the plug
from the valve body
4. Double-check flow direction to be sure the
valve is installed correctly. Flow direction is
indicated by the arrow attached to the body.
5. If welding the valve into the line, use extreme
care to avoid excess heat buildup in the valve.
6. Connect the air supply and instrument signal
lines. Throttling control valves are equipped with a
valve positioner. Refer to the appropriate positioner
bulletin for connections, maximum air supplies, and
maintenance instructions.
4.1 Quick-check
Prior to start-up, check the control valve by
following these steps:
1. Stroke the valve and observe the plug position
indicator on the stem clamp compared to the stroke
indicator plate. The plug should change position in
a smooth, linear fashion.
NOTE: Due to excessive friction, graphite packing
can cause the plug stem to move in a jerky fashion.
2. Check for full stroke by making appropriate
instrument signal change.
3. Check all air connections for leaks.
4. Check packing box bolting for the correct
adjustment.
CAUTION: Do not over tighten
packing. This can cause excessive packing
wear and high stem friction that may impede
plug movement.
5. Make sure the valve fails in the correct
direction in case of air failure. This is done
by turning off the air supply and observing
the failure direction.
6. After a temperature excursion has
occurred, bonnet flange bolting should be re-
torqued to ensure bonnet gaskets do not leak.
(Refer table 1)
Table 1
SIZE
OF THE
VALVE CLASS
SIZE
OF
THE
NUT
(in)
NO.
OF
NUTS
TORQUE
Nm
2"
150 ~ 600
0.75
6
152
900 ~ 1500
0.875
8
220
3"
150 ~ 600
0.875
8
233
900 ~ 1500
1.25
8
583
4"
150 ~ 600
0.875
8
307
900 ~ 1500
1.5
8
922
6"
150 ~ 600
1
12
391
900
1.25
12
856
1500
1.75
8
1798
8"
150 ~ 600
1
12
573
900
1.75
8
2631
1500
1.625
12
1629
10"
150
1
8
879
300
1
12
586
600
1.25
16
550
12"
150
1
12
873
300
1.25
12
1091
600
1.5
16
982
16"
150
1.25
12
1605
300
1.5
12
1926
600
1.75
16
1685

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Typical Bolting torque sequence
Figure 1

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5 Valve Maintenance
At least once every six months, check for
proper operation by following the
preventative maintenance steps outlined
below. These steps can be performed while
the valve is in-line and, in some cases
without interrupting service. If an internal
problem is suspected, refer to the “Valve
Disassembly and Reassembly” section.
1. Look for signs of gasket leakage through
the end flanges and bonnet. Re-torque flange
and bonnet bolting (if required).
2. Check for fluid leakage to the atmosphere
through the body drain plug, if applicable.
3. Examine the valve for damage caused by
corrosive fumes or process drippings.
4. Clean valve and repaint areas of severe
oxidation.
5. Check packing box bolting for proper
tightness.
6. If the valve is supplied with a lubricator
fitting, check lubricant supply and add
lubricant if necessary.
7. If possible, stroke the valve and check for
smooth, full-stroke operation. Unsteady stem
movement could indicate an internal valve
problem.
NOTE: Due to excessive friction, graphite
packing can cause the plug stem to move in a
jerky fashion.
WARNING: Keep hands, hair and
clothing away from all moving parts when
operating the valve. Failure to do so can
cause serious injury.
8. Ensure all accessories, brackets and
bolting is securely fastened.
9. If possible, remove air supply and observe
actuator for correct fail-safe action.
10. Clean any dirt and other foreign material
from the plug stem.
11. If an air filter is supplied, check and
replace cartridge if necessary.

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Figure 2: Exploded Drawing
Table 2
Parts List
Part
Item
Body
1
Bonnet
2
Seat ring
17
Plug stem assy 15
Cage 18
Seat Gasket
5
Bonnet Gasket
4
Seal ring
16
Gland flange stud
13
Nut
14
Bonnet studs
6
Heavy Hex nut 7
Packing Ring 8
Guide Bush
9
Lantern Ring
10
1/4 NPT Plug
3
Gland Bush
11
Gland Flange
12
Plug stem assy has the following
Integral parts (Refer section 7)
15- Plug
19- Pin
20- Stem

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6. Valve Disassembly and Reassembly
6.1 Disassembling the Body
To disassemble the valve body, refer to
Figure 2 then proceed as follows:
WARNING: Depressurize line to
atmospheric pressure and drain all fluids
before working on the valve. Failure to do so
can cause serious injury. Remove all
compression from adjusting springs
For Normally open valve, relieve air pressure
from the actuator. Remove the tubing from
upper diaphragm case.
For Normally closed valve, apply sufficient
air to the actuator diaphragm to keep valve
plug from touching seat while disengaging
valve plug stem from actuator stem
1. Loosen valve stem nut. Use wrench on
plug stem flats and turn valve plug (15) put
of actuator stem until stems separate.
Remove the tubing from lower diaphragm
case. Do NOT grasp the stem with pliers.
2. Remove cap screws holding actuator to
bonnet (2) and lift off actuator. Use caution
not damage the valve stem with yoke.
3. Remove the stem nut, travel indicator,
packing flange Studs & nuts (13, 14),
packing flange (12), and packing follower
(11).
4. Remove bonnet nuts and lift bonnet (2)
straight up until it clears valve plug stem (15)
being careful not to damage threads. Take
out bonnet gasket (4).
5. Lift out valve plug (15) assembly and cage
(18).
6. Remove seat ring (17) and seat ring gasket
(5)
7. Hold plug assy (15) with a wrench on stem
flats and remove the pin holding the plug
head. Loosen the plug stem from the plug
head.
6.2 Cleaning
Remove the old packing from the bonnet and
clean and polish the stuffing box. Clean all
parts with solvent.
Polish the parts with a fine aluminium oxide
cloth to remove any foreign matter. Replace
any worn or damaged parts. Be sure all
gasket seating surfaces are clean and smooth.
If any of the gasket faces are steam cut and
remachining is needed, it is recommended
that the valve be sent to Leslie controls
rebuilding department fro repair. ALL
CRITICAL dimensions must be maintained
during machining process.
6.3 Lapping-in of valve plug and seat
ring
1. Place seat ring (17) in body recess with
seating surface upward. Lower cage (18) into
body with window opening downward. Make
sure cage fits into body with window
openings downward. Make sure cage fits
over raised face of seat ring (17).
2. Use a small amount of Carborundum grade
“CF” lapping compound (or equal) evenly
spread around valve plug seating surface.
Carefully insert valve plug (15) into body
until plug contacts seat ring (17). Lower
bonnet (2) over valve stem making sure stem
threads are not damaged. Place one metal
packing ring (8) over valve stem and into
bottom of stuffing box to act as a guide while
lapping plug. Lightly lap plug to seat ring
(15) using weight of plug only and by
rotating the plug in ¼ turn increments. Lift
and rotate plug 90 deg., three or four times
during lapping procedure. This will ensure
even distribution of compound. DO NOT lap
excessively- 10 to 12 turns should be
sufficient. Remove the parts and clean them
thoroughly after lapping. Plug (15) and seat
ring (17) contact may be checked by the
bluing method before assembly.

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6.4 Reassembling the Body
To reassemble the valve body, refer to Figure
2 then proceed as follows:
1. Install new bonnet (2) and seat gaskets (5)
with the bevelled edge up
NOTE: All gaskets should be replaced
whenever the valve is disassembled.
2. Relocate the seat ring (17). Carefully
install the cage (18), taking care to ensure
they installed with the correct ends up.
3. Replace the plug seals (16) on the plug,
referring to Figure 3and observing the
following directions:
WARNING: Gloves should be worn to
protect the hands from being burned.
PTFE Seals:Heat the seal to 300°F (150°C)
and slip it over the plug into the seal groove.
Thermal expansion causes the ring to stretch,
thereby making it relatively easy to slide
over the plug head. Care must be taken to
prevent the seal from rolling, rather than
sliding over the plug.
Figure 3: Installation of Carbon filled
Teflon energised seal ring
FTC
FTO
By hand, evenly exert a sufficient thrust to
constrain seal ring to slide until its groove.
Take care not to damage seal ring during this
step. Ensure seal ring is completely and
correctly inserted before perform next
assembly step.
NOTE: To easy introducing plug with its
seal ring into the cage, it is recommended to
apply a small amount of grease such as
Bardhal® (or equivalent) around the seal ring
(17).
Figure 4: Installation of Grafoil seal
ring

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Figure 4.1 Grafoil seal ring
CAUTION: Graphite seal rings are brittle
parts, so care must be taken to avoid
damage during following steps.
•Using a sharp knife, score the
graphite ring in one location.
•Hold each side of the ring around the
score mark between thumbs and
forefingers and bend the ring to
break at the scribe mark.
•By means of a very fine file, adjust
each broken end so that the external
ring circumference equal the proper
internal circumference of the cage
(18).
•Remove seal ring from the cage.
Open the seal ring sufficiently to
place it around the top of the plug.
Slide the ring along the plug and
insert into groove.
Graphite seal ring:
The seal ring cut location shall be placed at
180° apart when both the seal rings are
inserted into plug groove.
4. Lower the plug (15) into the body and
cage (18). Care should be taken with the plug
(16) seals to avoid scoring or galling the
sealing surface while fitting them into the
cage bore.
5. Lower the bonnet (2) onto the plug (15)
and body, taking great care to avoid scoring
the plug stem.
6. Once the bonnet is resting squarely in the
valve body, finger tighten the bonnet flange
bolting.
7. Reinstall the packing (8), guide bush (9)
and Lantern ring (10) referring to the
appropriate packing installation manual and
reinstalling new packing exactly as shown.
Make sure at least 1⁄8" is left at the top of
packing box for the top guide to enter
8. Replace and tighten the packing gland
(12) and bolting (13, 14).
9. Turn actuator back onto the body
assembly, without turning the plug inside the
bonnet. Leave a 3⁄32" to 1⁄8" (2 mm to 3
mm) gap between the mating surfaces of the
bonnet and yoke. Tighten
Yoke bolting to close this gap. Firmly tighten
the yoke bolting.
10. Using the actuator, seat the plug two or
three times to centre the seat ring (17) using
pressure on the top of the actuator.
11. Tighten the body bolting, following the
bolting sequence outlined in Figure 1. Use a
minimum of four steps to reach the
suggested bolt torque values shown in Table
1. Never exceed more than 30% of the
suggested bolt torque value in a single step.
12. Slowly stroke the plug up and down to
check the alignment of the plug with the
cage.
13. Perform a Quick Check as described in
section 4.1.

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7. Plug Stem Pinning
Shouldered Plug stem
Standard Plug stem
Plug pin
Figure 5- Plug stem pinning
Table 3
Plug Head Plug head Assy.
in mm in mm in mm in mm in mm in mm in mm Ft.Lbs daN.M in mm
2" 50 0.79 20 1/2 12.7 0.248 6.3 0.75 19.05 0.63 16 0.24 644 611/16 17
7/8 22
1 1/16 27
4" 100 1.06 27 5/8 15.87 0.248 6.3 125.4 0.87 22 1 1/16 27
6" 150 1.5 38 3/4 19.05 0.248 6.3 1.5 38.1 1.38 35 0.59 15 1 1/16 27
1 1/4 30
1 7/16 36
12" & 16" 300 & 400 2.76 70 1 1/4 1.25 0.394 10 2.56 65 1.97 50 1 7/16 36
Plug Shank
Dia. ''A"
Plug Stem
Dia. ''B''
Pin Hole
Dia. ''C''
Pin Length
''F''
"D''
"X''
Torque on
Plug Stem
Wrench
Size ''E''
0.98
25
5/8
15.87
0.248
6.3
1
25.4
0.87
22
0.31
8
118
16
35
0.79
20
1.97
50
1
25.4
0.248
6.3
Valve size
184
25
80
200 & 250
3"
8" & 10"
2
50.8
1.38

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Plug stem pinning during field assembly
may be divided into two parts:
— Replacing old plug and old stem,
— Replacing only old stem.
Replacing Plug and Stem
The plug (15) and stem (20) assembly
consists of a shaft threaded into the plug and
pinned in place. To replace the stem (20) it is
necessary to drill or drive out the pin (19)
and unscrew the stem (20) from the plug
(15).
If it is necessary to replace the plug, it is
necessary to replace the plug stem at the
same time. Indeed, the original pin hole in an
old stem prevents satisfactory results and
might seriously impair strength of the
assembly.
A. Reference Marking on the Plug Stem
Measure the depth of the pilot recess in the
plug (X in Figure 5) and make a reference
mark to the plug stem at the same distance,
from the thread.
B. Screwing Stem into Plug
1. Hold the plug in a vise.
2. Apply a small amount of grease such as
Gripcott® (or an equivalent compatible with
the fluid process) on the threaded part of the
plug stem.
3. Lock one nut against another one to the
end of the new plug stem and, using a
wrench on the upper nut, screw the stem
solidly into the plug. When properly
assembled, the reference mark should be
flush with the end of the plug shank.
C. Drilling the New Parts
1. Measure the “D” dimension,
(See Table 3).
2. Place the plug shank on a V-block and, by
means of a centre punch, make a centre mark
on the plug shank area.
3. Using a suitable size drill bit, drill the
plug-stem assembly. After drilling, remove
any burrs from the plug shank by making a
slight chamfer.
D. Pinning the Plug-Stem Assembly
1. Select the correct size pin according to
plug shank diameter and stem diameter, (see
Table 3). Apply a small amount of grease on
it, and hand place the pin to the hole inlet.
2. By means of an hammer, introduce the pin
into the hole. Use a flat-ended punch to
ensure the pin is recessed by the same
amount at both sides, (see Figure 5).
3. After the plug has been pinned, it should
be placed in a lathe to insure it is running
“true.” The stem should be placed in a collet
with the plug shank against it and the plug
should be struck on the non guiding surface
of the plug using a mallet / nylon hammer
without causing mechanical damage to the
surface. Alignment of plug stem can be
performed using appropriate means.
Note: While pinning is being performed, care
must be taken not to damage the seating
surface or plug guide. In holding plug in
order to tightening the plug stem, always
tighten the jaws of the vise on a non-guiding
surface of the parts. Always use a soft metal
vise jaw with a special machining to hold the
shank of the plug (see Figure 5.1).
Figure 5.1 – Plug
Non-guiding
Surface

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Replacing Only Old Stem
A. Removing Old Pin and Stem from the
Plug
1. Place the plug shank on a V-block, and
using a drift punch, drive out the old pin.
Note: If it is necessary to drill out the pin, a
drill bit somewhat smaller than the pin
should be used and the remainder of the pin
driven out.
2. Hold the plug shank in a vise, (see
bordered note in the paragraph A on previous
page).
3. Lock one nut against another one to the
end of the plug stem and, using a wrench on
the lower nut, unscrew the stem from the
plug. The stem is removed by turning it anti-
clockwise.
Note: In case of great sizes and/or high
temperature service and some other cases,
the plug stem has a shoulder which allows to
unscrew plug stem without using of the two
nuts, (see Table 3 for the required
Wrench sizes).
B. Screwing Stem to Plug
Refer to paragraph B of the above section
“REPLACING PLUG AND STEM”.
C. Drilling the New Stem
Place the plug shank on a V-block and, using
a suitable size drill bit, drill the stem using
the hole in the plug as a guide.
Note: If the hole in the plug shank has been
slightly damaged while removing of the old
pin, choose a drill bit and a pin with a
diameter somewhat larger than the normal
Pin.
D. Pinning
Select the correct size pin according to plug
shank diameter and pin hole diameter, (see
Figure 5). Proceed as described in the above
paragraph D2, taking care not to damage the
plug shank area.
Ensure plug stem alignment as indicated in
the above paragraph D3.

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Assembly Dimensional Details
Figure 6
Table 4

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Table 5
Table 6
Dimensions are in Inches (mm).

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Trim Types
Single stage Balanced Trim
Figure 7.1
Two stage Balanced Trim
Figure 7.2
Standard Trim
Figure 7.3