Flowserve Valdisk 150 Manual

37-1Orig. 5/97 Valtek No. 35190
Valdisk 150
Control Valves
NOTE: Selecting the proper fastener material is the
responsibility of the customer. Typically, the supplier
does not know what the valve service conditions or
environment may be. ValtekÔs standard bolting material
is B7/2H. B8 (stainless steel) is optional for applications
above 800
O
F and with stainless steel or alloy body
valves. The customer therefore must consider the
materialÕs resistance to stress corrosion cracking in
addition to general corrosion. As with any mechanical
equipment, periodic inspection and maintenance is
required. For more information about fastener materi-
als, contact your local Valtek representative or factory.
Unpacking
1. While unpacking the valve, check the packing list
against the materials received. Lists describing the
valveandaccessoriesareincludedineachshipping
container.
2. When lifting the valve from the shipping container,
position lifting straps to avoid damage to tubing and
mounted accessories. Most Valdisk 150 valves
may be lifted by the actuator lifting ring. If no lifting
ring is provided, lift the valve using lifting straps or
hook through the yoke legs and outer end of the
body.
3. In the event of shipping damage, contact your ship-
per immediately.
4. Should any problem arise, contact your Valtek rep-
resentative.
GENERAL INFORMATION
The following instructions are designed to assist in
unpacking, installing, operating and performing mainte-
nance as required on Valdisk 150 butterfly valves.
Product users and maintenance personnel should thor-
oughly review this bulletin prior to working on the valve.
Separatemaintenanceinstructionscoveradditionalfea-
tures (such as positioners, special accessories, fail-
safe systems,etc.)
This publication does not contain information on install-
ing, maintaining, troubleshooting, calibrating, and oper-
ating Valtek actuators or positioners. Refer to the
appropriateValtekInstallation,Operation, Maintenance
Instructions when this information is required.
Toavoidpossible injury to personnel or damage
to valve parts, WARNING and CAUTION notes
mustbestrictlyadheredto. Modifyingthisprod-
uct, substituting nonfactory parts, or using
maintenance procedures other than outlined
coulddrasticallyaffect performance, be hazard-
ous to personnel and equipment, and may void
existing warranties.
WARNING:Standardindustrysafetypracticesmust
be adhered to when working on this, or any other,
process control product. Specifically, personal
protective and lifting devices must be used as war-
ranted.

37-2
TABLE I:
Flange Bolting Torques* (Class 150)
Torque Values
(ft-lbs) (newton-meter)
2, 3, 4 118 160
6, 8 209 282
10, 12 337 455
* For intermediate strength bolting, per ASME/ANSI B16.5 – 1988.
Quick-check
Prior to start-up, check the control valve by following
these steps.
1. Check for full stroke by making the appropriate in-
strument signal change. Observe the disc position
indicator plate mounted on the actuator transfer
case cover plate. The disc should change position
in a smooth, rotary fashion.
2. Check all air connections for leaks. Tighten or re-
place any leaking lines.
3. Evenly tighten the packing nuts on the valve to fin-
ger tight plus 1/2to one full turn (Teflon only).
CAUTION:Donotovertightenpacking. Thiscan
cause excessive packing wear and high shaft
friction, which may impede shaft rotation.
Afterthevalvehasbeeninoperationforashorttime,
check the packing nuts to make sure they are just
over finger-tight (readjust if necessary). If packing
box leaking occurs, tighten the packing nuts only
enough to stop leakage.
4. Toobservethevalvefailuremodeincaseofairfail-
ure,positionthevalvetomid-strokeandshutoffthe
air supply or disconnect the instrument signal. By
observingthe indicator plate, thediscshouldeither
failopenorclosed. Ifincorrect,refertothe“Revers-
ingtheActuator”sectionintheappropriateActuator
MaintenanceInstructions.
PREVENTIVE MAINTENANCE
Atleast onceeverysix months,checkforproper opera-
tion by following the preventative maintenance steps
outlinedbelow. Thesestepscanbeperformedwhilethe
valve is in line and, in some cases, without interrupting
service. Ifaninternalproblemissuspected,refertothe
“Disassembly and Reassembly” section.
1. Look for signs of gasket leakage through the body
and line flanges. Tighten flange bolting if necessary.
2. Note if any corrosive fumes or process drippings
are damaging the valve.
Valve Size
(inches)
Installation
1. Before installing the valve, clean the line of dirt,
scale, welding chips, and other foreign material.
Clean gasket surfaces thoroughly to insure leak-
proof joints.
2. Check flow direction to be sure valve is installed
correctly. Fail-closed valves should be installed
with the shaft upstream only in gas service. It
is preferred that liquid service valves be installed
with the shaft downstream regardless of air fail-
ure action. However, under certain flow condi-
tions the valve can flow shaft upstream. Consult
the factory if the valve must be mounted with the
shaftupstreaminliquidservice. Fail-openvalves
should be installed with the shaft downstream.
3. Fully close the valve before and during the instal-
lation process.
WARNING: Keephands,hair,clothing,etc.away
from the rotating disc and the seat when operat-
ing the valve. Failure to do so could cause seri-
ous injury.
WARNING: When valve is installed for end-of-
line service, retainer ring must be supported by
the mating pipe flange.
CAUTION: Because of Valdisk 150’s self-cen-
tering seat, there is no reason to open the
valve at any time during installation. There-
fore, the valve should remain closed until the
valve is fully installed.
4. Connect the air supply and instrument signal.
Throttling valves are usually equipped with valve
positioners. Two connections are marked for the
air supply and for the instrument signal. Both
cylinderandpositioneraresuitablefor150psi air
supply. Anairregulatorisnotrequiredunlessthe
supply pressure exceeds 150 psi. An air filter is
recommended unless the supply air is unusually
clean and dry. All connections must be free of
leaks.
NOTE: In some rare cases, the air supply must
be limited to 80 psi rather than 150 psi. In this
case,astickerfoundneartheupperairportonthe
cylinderwillindicate this and anairregulator may
needto be installed to insure the supplypressure
does not exceed 80 psi.
5. Make sure proper clearance exists internally in
the mating piping to permit proper disc rotation.
6. Apply the recommended torque values to the line
flange bolting for proper sealing (see Table 1).

37-3
Body
Packing Retainer (Item No. 85)
Packing (Item No. 88)
Shaft (Item No. 51)
Packing Box Nut
(Item No. 117)
Gland Flange
(Item No. 80)
Packing Box Stud
(Item No. 109)
Packing Follower
(Item No. 87)
Shaft Bearing
(Item No. 83)
Thrust Washer
(Item No. 82)
Disc
(Item No. 50)
Disc Stop
Thrust
Washer
(Item No. 82)
Shaft
Bearing
(Item No. 84)
Taper Pin
(Item No. 1)
(Item No. 52)
Figure 1: Body Assembly
NOTE: Item numbers correspond directly to the valve’s bill of material. Refer to it for specific part numbers.
3. Cleanvalveandre-paint areasofsevere oxidation.
4. Check packing box bolting for proper tightness.
Packing nuts should be slightly over finger-tight;
however, tighten as necessary to prevent stem
leakage.
CAUTION: Do not overtighten packing.
5. Ifthevalveissuppliedwithalubricator,checklubri-
cant supply and add lubricant if necessary.
6. If possible, stroke the valve and check for smooth,
full-stroke operation by observing the disc position
indicator plate mounted on the transfer case. Un-
steadymovementofthedisccouldindicateaninter-
nalvalveproblem(jerkymotionisnormalwhenever
Grafoil packing is used).
7. Check positioner calibration by observing the
gaugesanddiscpositionindicatorplate. Makesure
positioner is calibrated to the correct range. Refer
topositionerinstructionsforadditionalpreventative
maintenance.
8. If possible, depressurize the actuator, and remove
the actuator transfer case cover plate, and make
sure the positioner linkage is securely fastened.
CAUTION: Never apply air to the actuator with-
out the cover plate installed; otherwise, the un-
supported shaft may sustain damage.
9. Becertainall accessories,bracketsandboltingare
securely fastened.
10. If possible, remove the air supply and observe the
position indicator plate for correct fail-safe action.
11. Spray soap solution around the cylinder retaining
ring and the adjusting screw to check for air leaks
through the O-rings.
12. Clean any dirt or other foreign material from the
exposed portion of the shaft.
13. If an air filter is supplied, check and replace the
cartridge if necessary.

37-4
SafeGuard / SureGuard
Fire-safe Option
(live-loading omitted)
SureGuard
Standard Square Standard Single "V" Twin "V"
SafeGuard
(packing studs rotated 45 degrees)
Twin "V" with
Lubricator
Figure 2: Typical Packing Configuration
4. Slide the valve carefully from the line. To avoid
damage to gasket surfaces, do not twist the valve.
5. Afterthevalveiscompletelyremovedfromtheline,
slowly relieve air pressure from the actuator.
CAUTION: On valves with fail-open action, the
actuator spring will cause the disc to open.
Make sure the disc will not strike any object
upon opening. Protect disc edges from damage.
Removing Actuator From Body
Inmostcases,boththebodyassemblyandtheactuator
are easier to disassemble with the actuator removed
from the body. To do so, proceed as follows:
1. Supporttheactuatorassemblybytheliftingringbe-
fore disconnecting it from the body sub-assembly.
2. Depressurizeactuatorandallowittomovetoitsfail
position.
3. Removetheboltsconnectingtheyoketotheactua-
tor subassembly.
4. Slide the entire actuator assembly off the valve
shaft.
DISASSEMBLY AND REASSEMBLY
Removing Valve From Line
If an internal problem is suspected with the valve and
disassemblyis required, removethevalvefrom the line
by proceeding as follows:
WARNING: Depressurize line to atmospheric pres-
sure,drainallprocessfluidsanddecontaminatethe
valve (if caustic or hazardous materials are
present). Failure to do so can cause serious injury.
1. Make sure the valve is fully closed.
CAUTION: On valves with fail-open action, the
air pressure must be supplied under the piston
to close the valve. If the valve is supplied with
a handwheel, it can be used to close the valve.
Failuretodosowilldamagethevalvediscupon
removal from the line.
2. Attach a hoist or some means to support the valve.
3. Remove the line bolting. Do not attempt to pry the
lineflangesapartby pushingorpulling onthevalve
or actuator.

37-5
Disassembling the Body
To disassemble the Valdisk 150 body, refer to Figures
1 and 3 and proceed as follows:
1. Lay the valve body on a flat surface with the seat
surface up. Carefully insert a flat screwdriver into
the groove behind the seat retainer and pry the
retainer out of the body. The seat insert will now
easily lift out of the body.
2. Turn the body over so its backside is up and mark
the location of the thin end of the taper pin on the
disc. (This mark will be used during reassembly.)
Grindoffthetackweldholdingthetaperpininplace.
Drive the taper pin out of its slot using a punch and
hammer.
3. Placethevalvebodyintoavisewiththeshaftpoint-
ing up. Use brass jaws or wood blocks to prevent
damage to the body surfaces.
4. Removethetwo packingboxnutsandgland flange
from off the shaft.
5. Pull the shaft out of the body, noting that the disc
may fall out of body. Use caution to prevent it from
striking any hard objects or personnel. Next, re-
movethepackingfollower,packingsetandpacking
retainer.
6. The disc can now be removed from the body, fol-
lowed by the thrust and shaft bearings.
Reassembling the Body
To reassemble the Valdisk 150 body sub-assembly,
refer to Figures 1, 2, and 3 and proceed as follows:
1. Clean or replace all parts. The O-ring and packing
setshouldbereplacedeachtimethevalveisdisas-
sembled.
2. Check the disc seating surface to make sure it is
smooth and free of excessive wear, scoring and
scratches.
CAUTION: Damaged or dirty seat surfaces can
cause excessive seat wear and high torque re-
quirements. Damaged discs should be re-
placed.
3. Inspect the shaft for scratches or galled surfaces.
Formaximum performance, Valdisk 150shafts are
machinedtoaverysmoothfinish. Ifdamageexists,
replacetheshaftorcontactthefactoryrepresentative.
NOTE: Disc and shaft are interchangeable. Re-
placingthediscdoesnotrequirereplacingtheshaft
and vice versa.
4. Placethe valve body in a vise with shaft bore point-
ing up. Brass jaws or wood blocks are recom-
mended to prevent damage to the valve surfaces
while being held in the vise.
5. Placeoneshaftbearingintothelowerbearingbore,
followed by a thrust bearing.
6. Place the disc into the body from the backside with
the taper pin slot on top. Do not dislodge the thrust
bearing.
7. Insert the second thrust bearing between the disc
andthevalvebody. Alignbothbearingswiththedisc.
8. Insert the shaft into the body with the taper pin slot
end first. Slowly insert it through the body, upper
thrust bearing, disc, lower thrust bearing and into
the shaft bearing.
9. Inserta new taperpinintotheslot in the back of the
disc and in the shaft. Refer to the mark on the disc
made during disassembly and make sure the pin
does not go beyond it. Be certain the pin is flat
against the disc. Set in place with a punch and
hammer.
10. Place the remaining shaft bearings* over the shaft
andinto the bearing bore. (*Refer to the valve’s bill
of materials for the number of shaft bearings re-
quired.) Next, place the packing retainer, followed
by the packing set into the packing bore. (See Fig-
ure2. Teflonpackingchevronspointawayfromthe
disc.) Be careful to not damage the packing rings
while inserting them over the shaft.
11. The packing follower is next inserted into the pack-
ing bore with machined lip end up.
12. If the packing box studs were removed, re-install
them using anti-seize lubricant. Tighten until they
bottomout. Placeawasher overeachstudandse-
cure in place with a jam nut tightened until snug
(valve sizes 1 thru 6-inch).
13. Place the gland flange over the shaft and onto the
studsbeingcertaintherockerknobisfacingtoward
thedisc. Placethepackingboxnuts ontothe pack-
ing box studs and tighten finger tight plus 1/2to one
fullturn with Teflonpacking. (Ropepacking should
betorquedto14foot-poundsor19newton-meters.)
14. Installtheseatassemblyintothevalvebodybyfirst
insertingseatgasketintoouterseatretainergroove.
Next, remove the body from the vise and lay it on a
flat surface with the seat side up. Proceed as fol-
lows.
Softor metalseat design- Laytheseatinsertinto
thevalvebody. Next,inserttheseatretainerintothe
body seat counter bore. Use a rubber mallet or
press to press the seat retainer into the body.
Fire-safe seat design - Place one Grafoil gasket
into the retainer ring groove. Place two additional
Grafoil gaskets on either side of the seat insert.
Place the metal seat on top of the seat/gasket as-
sembly and then place the entire assembly into the
retainer ring in the body. Next, insert the seat re-
tainerintothebodyseatcounterbore. Usearubber
mallet or press to press the seat retainer into the
body.

37-6
15. Rotate disc several times to allow seat to self-cen-
terinthebody.Again,checkpackingboxnutstobe
certain they are tight, per step number 13. Do not
overtighten.
CAUTION: Do not over tighten packing box
nuts. This can cause excessive packing wear
andhighshaftfriction,whichmayimpedeshaft
rotation.
16. After the valve is fully assembled and seat leak
tested, use a compatible welding rod to tackweld
the taper pin to the disc at its thickest end. Later,
this will allow the taper pin to be removed after the
weld has been ground off.
Remounting Valve to Actuator
Beforemounting a Valdisk 150 valve to a Valtek actua-
tor, verify that the disc rotation matches the actuator
rotation and complies with the air failure requirements.
Procedures for mounting the actuator are as follows.
1. Slide the entire actuator assembly onto the shaft.
To ensure full rotation of the disc, marks provided
on the end of the valve shaft and on the actuator
lever arm should be aligned.
2. Bolttheactuatoryoketothevalvebody. Becertain
the stroke indicator plate is positioned properly to
accurately indicate the valve’s rotation.
3. Adjusttheactuatorstrokestopboltsuntilthediscis
parallel to the seat surface.
CAUTION: Actuator stroke stop bolts must be
properlyadjustedtopreventthevalvediscfrom
overstroking. If incorrectly adjusted the valve
shaft may be twisted or sheared off.
4. Install the valve in line as outlined in the “Installa-
tion” section.
82
83
50
82
84
52
117 80
87
109 113*
114*
88
85
51
1
25
21
22
26
26 26
27
Figure 4: Exploded Body Sub-assembly
Item No. Description
1 body
21 seat insert
22 seat retainer
25 retainer O-ring
26 fire-safe gasket**
27 fire-safe seal**
50 disc
51 shaft
52 taper pin
80 gland flange
82 thrust washer
83 shaft bearing
84 shaft bearing
85 packing retainer
87 packing follower
88 packing
109 packing box stud
113 jam nut*
114 washer*
117 packing box nut
* 1 thru 6-inch only
** Fire-safe designs only

37-7
Failure Probable Cause Corrective Action
Valve moves to failure 1.Failure of actuator O-ring 1.Replace actuator stem O-ring
position, excessive air 2.Failure of sliding seal assembly 2.Repair or replace sliding seal assembly
bleeding from transfer case
Jerky shaft rotation 1.Overtightened packing 1.Retighten packing box nuts to slightly over
finger-tight for V-ring packing, 14 ft-lbs for
braided packing
2.Improper adjustment of lever arm on 2.Readjust lever arm (see step 1 in the
shaft causing arm to contact transfer case “Remounting Actuator” section)
3.Cylinder wall not lubricated 3.Lubricate cylinder wall with silicone lubricant
4.Worn piston O-ring allowing piston to 4.Replace O-ring; if galling has occurred
gall on cylinder wall replace all damaged parts
5.Worn actuator stem O-ring causing 5.Replace O-ring; if actuator stem is galled
actuator stem to gall on stem collar replace it
6.Worn (or damaged) thrust bearings, shaft 6.Disassemble and inspect parts; replace
bearings or packing followers any worn or damaged parts
Excessive leakage 1.Improper adjustment of external stroke 1.See “Remounting Valve to Actuator”
stops section
2.Worn or damaged seat 2.Replace seat
3.Damaged disc seating surface 3.Replace disc
4.Improper handwheel adjustment acting 4.Adjust handwheel until disc seats properly
as limitstop
Leakage through line 1.Dirty line gasket surfaces 1.Clean gasket surfaces and reinstall valve
2.Improper sealing of line flanges 2.Tighten line flanges evenly and
completely (see Table 1 for proper torque)
3.Flange or pipe misalignment 3.Clean body bore and stem, replace packing
Leakage through 1.Loose packing box nuts 1.Tighten packing box nuts to slightly over
packing box finger-tight for V-ring packing, 14 ft-lbs for
braided packing
2.Worn or damaged packing 2.Replace packing
3.Dirty or corroded packing 3.Clean body bore and stem, replace packing
Disc interferes with body 1.Disc installed upside down 1.Reinstall disc
2.Worn thrust bearings 2.Replace thrust bearings
Disc interferes with line 1.Cement lining or heavy schedule pipe 1.Modify line to allow proper disc clearance
Valve slams, won’t open, 1.Improper valve installation 1.See step 2 in “Installation” section and
or causes severe water correct flow direction
hammer
Shaft rotates, disc remains 1.Missing or broken taper pin 1.Replace taper pin
open or closed 2.Broken shaft 2.Replace shaft, make sure disc does not
overstroke and contact disc stop
Actuator operates, shaft 1.Broken internal actuator parts 1.Refer to appropriate actuator Maintenance
does not rotate Instructions
Troubleshooting Valdisk 150 Valves

37-8
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this
Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve
products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial service
conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all
possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installa-
tion, operation and maintenance of Flowserve products. The purchaser/user should read and understand the Installation Operation
Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in
connection with the specific application.
While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative purposes
only and should not be considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained herein is to be
construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve is
continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to
change without notice. Should any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation
at any of its worldwide operations or offices.
For more information, contact:
For more information about Flowserve and its products,
contact www.flowserve.com or call USA 972 443 6500
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Flowserve and Valtek are registered trademarks of Flowserve Corporation.
©1998 Flowserve Corporation. Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611