Dover Midland A-547PL Series Instruction manual

P/N: A-547PL, Rev. 1
Issue Date: January 12, 2021
Supersedes: Rev 0
Bottom-Outlet Plug Valve
A-547PL Series
Installation, Operation & Maintenance (IOM) Manual
Manual content is subject to change.
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A-547PL, Rev. 1
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Table of Contents
1!Regulations and Safety Requirements ...............................................................................................3!
!Regulations.................................................................................................................................. 3!1.1
!Safety Warnings and Precautions ...............................................................................................3!1.2
2!Introduction ......................................................................................................................................... 6!
!Valve Features............................................................................................................................. 6!2.1
!Valve Details................................................................................................................................6!2.2
!Component Identification and Parts Listings ............................................................................... 8!2.3
3!Operating Procedure ........................................................................................................................10!
!Opening the Valve ..................................................................................................................... 10!3.1
!Closing the Valve.......................................................................................................................10!3.2
4!Valve Installation...............................................................................................................................11!
!Installation Procedure and Required Tools................................................................................ 11!4.1
!Leak Inspection.......................................................................................................................... 12!4.2
5!Valve Qualification ............................................................................................................................13!
!Valve Disassembly and Required Tools ....................................................................................13!5.1
!Valve-Disassembly Procedure................................................................................................... 13!5.2
!Component Inspection...............................................................................................................19!5.3
!Valve Reassembly and Required Tools..................................................................................... 24!5.4
!Testing Process .........................................................................................................................31!5.5
6!Routine Maintenance........................................................................................................................ 32!
!Maintenance Procedure............................................................................................................. 32!6.1
!Shaft Packing Gland Leakage ................................................................................................... 33!6.2

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1Regulations and Safety Requirements
Regulations1.1
Midland bottom-outlet plug valves are used in contact with a variety of products, many of which are hazardous materials
and could cause serious injury or damage if mishandled. The acceptance and transportation of products are regulated
by the DOT and AAR in the U.S.A., and in Canada by CTC and Transport Canada. Regulations of other governmental
bodies must be complied with for stationary and mobile applications. All personnel should be familiar with and follow
these regulations. Nothing in these instructions is intended to conflict with or supersede these regulations. The
information in this document was gathered from knowledgeable sources. However, Midland Manufacturing Corporation
makes no representations or guarantees about its accuracy or completeness, and assumes no liability for this
information.
Specifications are subject to change without notice.
This valve should only be installed, operated and maintained by qualified personnel. Read all of these instructions
carefully before proceeding.
Operation of the valve must conform to all applicable specifications from TC, AAR, DOT, CFR (Parts 173.31, 174.67,
etc.) and other governmental bodies, along with the operating instructions of your company.
Safety Warnings and Precautions1.2
Please carefully read each of the following warnings and cautions prior to performing any work.
WARNING: Toxic Hazard. Always use extreme caution and proper equipment when involved with hazardous
materials. To avoid exposure to toxic or hazardous materials, make sure the tank car is empty and clean, and
that the work area is free of hazardous chemicals before removing or installing any valve.
•Wear protective clothing and equipment suitable for withstanding the materials to which you
may be exposed
•Position yourself on the upwind side of the valve when possible
•Work in a well-ventilated area
•Work with a partner who can help you in the event of an emergency
•Follow approved safety precautions for hazardous or toxic materials
•Obtain MSDS sheets for all the commodities used with the associated valve
NOTICE: Consult gasket manufacturer and Midland Manufacturing for torque requirements as max
torque may vary by valve model. Do not exceed 200 ft-lb.
CAUTION: Be sure the car is empty and clean, and that the work area is free of hazardous chemicals
that may have been in the car, before removing a valve or installing a new one.
WARNING
NOTICE
CAUTION

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NOTICE: Repair work is limited to cleaning and polishing. See Paragraph A3.11.1 of the Tank-Car
Specifications.
WARNING: Machining Not Allowed. Machining, grinding, welding or other alterations to the valve seat
or stem seat is not allowed per AAR M1002, Paragraph A3.11 of the Tank-Car Specifications.
NOTICE: To ensure best practice and consistency of your qualification procedure, O-rings, gaskets and
wire seals should always be replaced.
Nuts, washers and studs must be closely inspected before re-use or replaced regularly.
Valve components such as the top guide, stem, retainer, body and spring must be thoroughly inspected.
NOTICE: Procedures may not cover all conditions encountered in the field. Therefore, it is the
responsibility of the repair agency to obtain approval from Midland for inspection, evaluation, repair and
maintenance procedures not covered herein.
Evaluation of critical component metal surfaces of the valves after cleaning, inspection and specialized
testing performed by agencies other than the repair facility are the responsibility of the repair facility.
Where numerical tolerances cannot be provided, the disposition of the internal integrity and surface
quality of parts is under the jurisdiction of the repair facility and dependent on its experience and
judgment.
NOTICE: Without consent from the valve manufacturer or car owner, repair work is limited to
cleaning and polishing. See AAR M1002, Paragraph A3.11.1 of the Tank-Car Specifications.
WARNING: Machining Not Allowed. Without consent from the valve manufacturer or car owner,
machining, grinding, welding or other alterations to the valve seat or stem seat is not allowed per AAR
M1002, Paragraph A3.11.1 of the Tank-Car Specifications.
CAUTION: Safety Protection. Wear appropriate safety glasses or face shield and protective clothing
when conducting this procedure. Valve testing involves high-velocity air and water flow that can cause
injury.
CAUTION: Do not use an extension or cheater on the valve handle. If it does not move freely, report this
to the tank car supervisor. The tank may be pressurized, contain solidified product, or the valve may be
jammed.
NOTICE
WARNING
NOTICE
NOTICE
NOTICE
WARNING
CAUTION
CAUTION

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NOTICE: Routine Maintenance involves valve inspection and component replacement for valves in-
service on tank cars in accordance to the car owner’s standard maintenance program to ensure the
valve performs the intended function without failure until the next qualification, or for the design life.
Routine maintenance may be done with the valve installed on the rail car.
NOTICE:It is essential to establish a periodic retesting and preventive maintenance program for
pressure relief valves. The DOT and AAR have set forth a retesting interval that should be considered
the maximum length of time between tests. If your company’s experience indicates that a shorter interval
is advisable, a program with more frequent retesting should be implemented.
NOTICE: It is an AAR requirement (refer to D3.4) that new O-rings be installed when a valve is retested.
CAUTION: Do not premit the top guide to fly up. About 50 ft-lb of force is necessary to restrain the
spring.
CAUTION: Do not scratch the O-ring groove, as a scratch could cause a leak path around the O-ring.
NOTICE: Emergency Response is the temporary remediation to a valve observed to be emitting product
in an unintended manner. It is possible to replace O-rings on an internal style valve installed on a
pressurized tank car. Since leak repair is a temporary measure, once the car is unloaded and pressure
is relieved, the valve should be removed for complete inspection, repairs, and full qualification in
accordance to the car owner’s standard qualification and maintenance program. Leak repair is
unscheduled maintenance and is not part of scheduled maintenance.
NOTICE
CAUTION
CAUTION
NOTICE

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2Introduction
The Midland A-547PL Series Modified Bottom Outlet Plug Valves are cavity free, corrosion-resistant devices designed
for the containment of product in tank cars requiring superior product containment.
•High-quality steel construction with an optional integrated steam jacket
•Meets Level A protection per AAR
•Triple-seal design for exceptional sealing capabilities
Valve Features2.1
Superior Construction & Features:
•304 stainless steel wetted-parts
•Optional integrated steam jacket
Configuration Options:
•Integrated 304 stainless steel cap and chain
•Standard and specialty elastomers available
Safety & Performance:
•Spring-loaded plug ensures valve remains closed in the event of an accident
•Triple-seal design on plug provides exceptional redundant sealing
•Self-cleaning, cavity-free design prevents entrapment or isolation of media inside valve body
Valve Details2.2
Figure 2-1 A-547PL Dimensions (Section A-A)

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Figure 2-2 A-547PL Dimensions (Section B-B)
Figure 2-3 A-547PL Dimensions (Top View)

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Component Identification and Parts Listings2.3
ITEM
QTY.
PART NAME
A-547PL-02-MO-S01
MATERIAL
PART NO.
1
1
TOP GUIDE
STAINLESS STEEL
547PL-1-MO
2
1
SHAFT
STAINLESS STEEL
547PL-22-SS
3
1
PLUG ASSEMBLY
STAINLESS STEEL
547PL-3-MO
4
1
BODY
STAINLESS STEEL
549-4-SS 2
5
1
SPRING
STAINLESS STEEL
545-5-MO
6
1
RETAINER COVER ASSEMBLY
STAINLESS STEEL
549-61-SS
7
–
–
–
–
8
2
PACKING FLANGE
STEEL, PLATED
549-8-CS
9
1
NAMEPLATE
STAINLESS STEEL
547PL-96-SS
10
1
SEAT O-RING
BUNA-N 1
545-10-BN
11
1
BORE O-RING
BUNA-N 1
545-11-BN
12
2
SAHFT O-RING
BUNA-N 1
545-12-BN
13
2
BUSHING O-RING
BUNA-N 1
545-13-BN
14
1
WIPER RING
PTFE
545-14-TF
15
1
CAM LEVER
STAINLESS STEEL
548-15-SS
16
1
CAM
STAINLES STEEL
545-16-SS
17
1
CAM BOLT
NITRONIC 60
545-17-N60
18
2
RETAINER RING
STAINLESS STEEL
545-18-MO
19
–
–
–
–
20
2
PAKCING BUSHING
NITRONIC 60
545-20-N60
21
2
PACKING SET
PTFE
549-21-TF
22
2
PACKING SPRING
STAINLESS STEEL
549-22-SS
23
2
PACKING RING
PTFE
549-211-TF
24
1
RETAINER RING
STAINLESS STEEL
549-24-MO
25
8
PACKING BOLT/LOCKWASHER
STAINLESS STEEL
545-25-MO
26
4
RETAINER BOLT/LOCKWASHER
STAINLESS STEEL
545-26-MO
27
1
CAM STEM NUT
STAINLESS STEEL
724-20-SS
28
1
CAM STEM PIN
STAINLESS STEEL
545-28-MO
29
1
CAM PIN
STAINLESS STEEL
545-29-MO
30
–
–
–
–
31
1
BASE
STAINLESS STEEL
547PL-31-MO
32
4
STUD
STAINLESS STEEL
547PL-41-SS
33
3
BASE O-RING
BUNA-N 1
547-33-BN
34
–
–
–
–
35
1
PIN
NITRONIC 60
549-35-N60
36
8
BODY BOLT
STEEL, PLATED
363-22-AS
37
8
LOCKWASHER
STEEL, PLATED
363-21-AS
38
4
LOCKWASHER
STAINLESS STEEL
566-322-SS
39
–
–
–
–
40
1
ADAPTER FLANGE
STAINLESS STEEL
547PL-40-SS
41
4
NUT
STAINLESS STEEL
566-321-SS
Table 2-1 Valve Components
NOTES:
1. Alternative material available.
2. 549-4-MO bodies currently not available; 549-4-SS is a substitution.

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Figure 2-4 A-547PL Component Identification (Section A-A)
Figure 2-5 A-547PL Component Identification (Section B-B)

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3Operating Procedure
Opening the Valve3.1
Conform with all applicable TC, AAR, and DOT regulations (Parts 173.31, 174.67, Pamphlet 34, etc.)3.1.1
CAUTION: When loading or unloading, the vacuum relief valve’s proper orientation must be verified, and
the vent valve or manway cover opened to avoid either compressing air in loading, or drawing a vacuum
when unloading.
CAUTION: Do not use an extension or cheater on the valve handle. If it does not move freely, report this
to the tank car supervisor. The tank may be pressurized, contain solidified product, or the valve may be
jammed.
For unloading, the valve handle must be secured in the open position. If it is not properly pinned open in the3.1.2
bracket, the handle will automatically swing toward the closed position.
Closing the Valve3.2
CAUTION: Do not use an extension or cheater on the valve handle. If it does not move freely, report this
to the tank car supervisor. The outlet may be filled with trapped incompressible liquid. Release liquid
pressure prior to closing the valve.
Remove the pin from the bracket that keeps the handle in the open position. Rotate the handle to close. The3.2.1
handle must then be secured in the closed position with a pin and swivel that has a slot for a car seal, or by a
lock, to prevent unauthorized opening later.
CAUTION
CAUTION
CAUTION

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4Valve Installation
Prior to installation, ensure that the valve remains clean and the gasket-sealing surfaces are not damaged.
Installation Procedure and Required Tools4.1
SAE Wrench
Component(s)/Description
3/4” Wrench
Body Bolt (item 36)
Torque Wrenches (0 – 200 ft-lb)
Other Tools, Supplies, and Equipment:
Lint-free Cloth
Emery Paper (400 grit, cut in 1" strips)
Wire Brush
Lift or Jack
Table 4-1 Required Tools for Valve Assembly
NOTICE: Consult gasket manufacturer and Midland Manufacturing for torque requirements as max
torque may vary by valve model. Do not exceed 200 ft-lb.
CAUTION: Be sure the car is empty and clean, and that the work area is free of hazardous chemicals
that may have been in the car, before removing a valve or installing a new one.
Thoroughly clean the sealing surfaces on mounting saddle. Be sure there are no nicks, burrs, grit, paint,4.1.1
coatings, or any other residue on this surface. Saddle sealing surfaces should be flat within 0.030 inches
TIR. This valve mounts to a Midland Saddle B-363 or equivalent.
Make sure base O-ring (item 33) is in the groove.4.1.2
Align holes in base flange with 3/8” threaded holes in saddle. Make sure stem end is perpendicular to4.1.3
longitudinal axis of tank car.
Install bolts (item 36) and lock washers (item 37). Gradually apply torque in cross-pattern to 30 ft-lb.4.1.4
NOTICE
CAUTION

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Leak Inspection4.2
Test all newly installed valves to conform to car-owner specifications. No leaks should be present.4.2.1
Special Inspection Considerations4.2.2
4.2.2.1 Previous procedures may not cover all conditions encountered in the field. Therefore, it is the
responsibility of the repair agency to obtain approval from Midland for inspection, evaluation, repair and
maintenance procedures not covered herein.
4.2.2.2 Facilities performing recommended dye-penetration and magnetic-particle testing must carry out such
testing according to a qualified procedure conducted by certified trained personnel.
4.2.2.3 Evaluation of critical component metal surfaces of the valves after cleaning, inspection and specialized
testing performed by agencies other than the repair facility are the responsibility of the repair facility.
4.2.2.4 Where numerical tolerances cannot be provided, the disposition of the internal integrity and surface
quality of parts is under the jurisdiction of the repair facility and dependent on its experience and
judgment.

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5Valve Qualification
NOTICE: To ensure best practice and consistency of your qualification procedure, O-rings, gaskets and
wire seals should always be replaced.
Nuts, washers and studs must be closely inspected before re-use or replaced regularly.
Valve components such as the top guide, stem, retainer, body and spring must be thoroughly inspected.
Valve Disassembly and Required Tools5.1
SAE Wrenches
Component(s)/Description
Item #
7/16” Socket Wrench
Retainer Bolts
26, 25
1” Wrench
Nuts
41
5/8” Wrench
Cam Bolt
17
Other Tools, Supplies, and Equipment:
Hammer/Pin Pusher
Cam Assembly Pin
29
Flat-Head Screw Driver
Retainer Ring
18
Non-Scratching Tool to Remove O-Rings
O-Rings
12, 13
Table 5-1 Required Tools for Valve Disassembly
NOTICE: Valve disassembly should only be done by trained personnel with access to the proper
machines, tools, procedures and personal-protective equipment (PPE).
Valve-Disassembly Procedure5.2
NOTICE: Please note that following instructions are based on the A-547PL-02-XX valve model. Your
specific valve model may vary from configuration shown; however, valve-disassembly procedure will be
the similar.
Remove four retainer bolts (item 26) from retainer cover assembly with5.2.1
lockwashers (item 6).
TIP:Use a 7/16” wrench to remove retainer bolts (item 26).
Figure 5-1 Remove Bolts
NOTICE
NOTICE
NOTICE
26

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Remove four nuts (item 41) and lockwashers (item 38) from the body studs5.2.2
(item 32).
TIP:Use a 1” wrench to remove nuts (item 41).
Figure 5-2 Remove Nuts and
Lockwashers
Remove base (item 31) and O-ring (item 33)5.2.3
and remove adapter flange (item 40) and O-
ring (33). Remove O-rings.
Figure 5-3 Remove Base, Adapter Flange and O-Rings
To start the top section of the valve disassembly, remove four studs (item 32)5.2.4
from the valve body (item 4).
Figure 5-4 Remove Studs
Place valve in fixture to compress the spring (item 5) and remove spring force5.2.5
from the top guide (item 1).
Remove top guide retainer ring (item 24) and top guide (item 1) from body5.2.6
(item 4).
TIP:Use a screw driver to pry retainer ring (item 24) loose.
Slowly release press until the spring (item 5) force is relaxed.5.2.7
Figure 5-5 Remove Top Guide and
Ring
40
31
33
33
32
1
24
4
32
38
41

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Remove the top guide (item 1) and the spring (item 5) from the body (item 4).5.2.8
Figure 5-6 Remove Top Guide and
Spring
To complete the top section of the valve disassembly, remove the plug5.2.9
assembly with O-rings and wiper (items 3, 10, 11 and 14) from the body (item
4) and remove the O-rings and wiper. (See Section 5.2.20 for disassembly of
plug assembly.)
Figure 5-7 Remove Plug Assembly
To start bottom actuator disassembly, remove cam stem pin (item 28).5.2.10
Figure 5-8 Remove Cam Bolt
Loosen the cam stem nut (item 27) and remove the nut and cam bolt (item5.2.11
17).
TIP:Use two wrenches 7/16” and 5/8”.
Figure 5-9 Remove Cam Stem Pin
4
5
3
10
11
14
17
27
28
1

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Remove cam5.2.12
lever assembly
(items 15 and
6) and remove
the pin (item
35) to remove
the retainer
cover assembly
(item 6) from
the cam lever
(item 15).
Figure 5-10 Remove Cam Lever, Pin and Retainer Cover Assembly
Rotate the shaft (item 2) to locate and remove the cam assembly pin (item5.2.13
29).
TIP:Use a pin pusher and hammer to dislodge cam assembly pin (item
29).
Figure 5-11 Remove Cam Assembly
Pin
Remove the four packing bolts and lockwashers (item 25) from first side of5.2.14
the double-ended shaft assembly.
TIP:Use a 7/16” wrench to remove packing bolts (item 25).
Figure 5-12 Remove Packing Bolts
Remove the packing flange (item 8) from the shaft (item 2).5.2.15
Figure 5-13 Remove Packing
Flange
6
29
8
35
6
15
15
15
25
2
2

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Remove the retainer ring (item 18) from the shaft (item 2).5.2.16
TIP:Use a small flat-head screw driver to pry retainer ring (item 18)
loose.
Figure 5-14 Remove Retainer Ring
Repeat steps5.2.17
5.2.12 through
5.2.14 for the
oppposite end of
the double-
ended shaft
assembly (item
2).
Figure 5-15 Remove Packing Bolts, Packing Flange and Retainer Ring
Pull the shaft assembly (item 2) from out of the base (item 31). In the same5.2.18
motion, remove the cam (item 16) from the back end of the shaft (item 2).
NOTICE: The opposite set of shaft packing components (items 22, 21,
20, 12 and 13) remain in the base for later disassembly.
Figure 5-16 Remove Shaft
Assembly
From the shaft (item 2), remove the packing set (item 21), packing ring (item5.2.19
23) and packing spring (item 22).
Figure 5-17 Remove Packing Set,
Ring and Spring
NOTICE
18
18
8
25
31
2
22
21
23
16
2
20
13
21
12
22

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From the shaft (item 2), remove the packing bushing (item 20) and O-rings5.2.20
(item 12 and 13).
TIP:Use non-scratching tool to remove O-rings.
Figure 5-18 Remove Packing
Bushing
From base, remove packing bushing and O-5.2.21
ring set (items 20, 12, and 13). Next, remove
packing spring (item 21) and packing set
(items 22 and 23).
Figure 5-19 Remove Packing Bushing and O-Rings, then Remove
Packing Spring and Packing Set
From the plug assembly (item 3) with rings, remove the wiper ring (item 14),5.2.22
bore O-ring (item 11) and seat O-ring (item 10).
TIP:Use non-scratching tool to remove wiper ring and O-rings.
Figure 5-20 Remove Wiper Ring
and O-Rings
2
20
13
14
12
3
13
12
21
22
23
20
13
12

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Component Inspection5.3
Key components must be thoroughly inspected during the qualification process. These components include the top
guide, shaft, retainer, valve body, spring and plug assembly.
Figure 5-21 Component Inspection
Facilities performing recommended liquid dye-penetration and magnetic-particle testing must carry out such testing
according to a qualified procedure conducted by certified trained personnel. In some instances, a component can be
properly evaluated for damage or cracks only with the use of specialized techniques, such as liquid dye-penetration or
magnetic-particle testing according to a qualified procedure by certified and trained personnel. Such testing is indicated
within this document where mandatory.
O-Rings, gaskets and wire seals must always be replaced during this step.
NOTICE: Procedures may not cover all conditions encountered in the field. Therefore, it is the
responsibility of the repair agency to obtain approval from Midland for inspection, evaluation, repair and
maintenance procedures not covered herein.
Evaluation of critical component metal surfaces of the valves after cleaning, inspection and specialized
testing performed by agencies other than the repair facility are the responsibility of the repair facility.
Where numerical tolerances cannot be provided, the disposition of the internal integrity and surface
quality of parts is under the jurisdiction of the repair facility and dependent on its experience and
judgment.
NOTICE
Spring (item 5)
Base (item 31)
Cam Lever (item 15)
Cam (item 16)
Top Guide (item 1)
Adapter Flange (item 40)
Plug Assembly (item 3)
Shaft (item 2)

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NOTICE: Without consent from the valve manufacturer or car owner, repair work is limited to
cleaning and polishing. See AAR M1002, Paragraph A3.11.1 of the Tank-Car Specifications.
WARNING: Machining Not Allowed. Without consent from the valve manufacturer or car owner,
machining, grinding, welding or other alterations to the valve seat or stem seat is not allowed per AAR
M1002, Paragraph A3.11.1 of the Tank-Car Specifications.
Shaft Inspection5.3.1
Visually inspect the shaft (item 2) paying close attention to two packing areas.
The shaft should be free of corrosion, nicks, dents, scratches and pits.
Clean and inspect by sanding lightly with emery paper (400-grit). If this does
not effectively clean the part, replace this part.
Figure 5-22 Inspect Shaft
Cam Lever Inspection5.3.2
Visually inspect the cam lever (item 15). The cam lever should be free of
corrosion, nicks, dents, scratches and pits.
Clean and inspect by sanding lightly with emery paper (400-grit). If this does
not effectively clean the part, replace this part.
Figure 5-23 Inspect Cam Lever
Cam Inspection5.3.3
Visually inspect the cam lever (item 16). The cam should be free of corrosion,
nicks, dents, scratches and pits.
Clean and inspect by sanding lightly with emery paper (400-grit). If this does
not effectively clean the part, replace this part.
Figure 5-24 Inspect Cam
NOTICE
WARNING
15
2
16
Inspect
Inspect