Flowserve Valtek Mark 100 User manual

Experience In Motion
Valtek®Control Products
Mark 100™and Mark 100SC™
Control Valves
USER INSTRUCTIONS

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves
Sections
1General information ........................... 3
2Terms concerning safety ...................4
3Unpacking .........................................5
4Installation..........................................6
5Valve maintenance ............................8
6Valve disassembly
and reassembly ...............................10
7Severe service trim options .............14
Tables
1 Valve disassembly clearance.............6
2 Recommended body
bolt torque values...............................7
3 Common packing lubricants..............7
4 Troubleshooting chart.......................17
Figures
1 Exploded drawing..............................9
2 Cutaway drawing .............................10
3 Seal designs.....................................12
4 PTFE seal cutting detail ...................12
5 Actuator stem / stem
clamp alignment...............................12
6 Bolt patterns .....................................13
7 Mark One with CavControl
trim body assembly..........................14
8 Mark One with ChannelStream
trim body assembly..........................15
9 DiamondBack trim body
assembly ..........................................15
10 Mark One with MegaStream
trim body assembly..........................16
11 Mark One with Stealth trim
body assembly.................................16

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves
The following instructions are designed to assist in unpacking,
installing and performing maintenance as required on Valtek
Mark 100 and Mark 100SC control valves. Product users and
maintenance personnel should thoroughly review this bulletin
prior to installing, operating or performing any maintenance on
the valves. Separate Installation, Operation and Maintenance
instructions cover additional features (such as actuators,
handwheels, packing and positioners).
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, be hazardous to personnel and equipment,
and may void existing warranties.
cWARNING: 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.
NOTE ON FASTENERS: 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. Flowserve’s standard body bolting material is B7/2H. B8
(stainless steel) is optional for applications more than 425°C
(800°F) and with stainless steel or alloy-body valves. The
customer, therefore, must consider the material’s resistance
to stress corrosion cracking in addition to general corrosion.
As with any mechanical equipment, periodic inspection and
maintenance are required. For more information about fastener
materials, contact your Flowserve representative.
1
General
information
1.2 Applicability
The following instructions are applicable to the maintenance
and installation of Valtek Mark 100 and Mark 100SC globe
and angle body design control valves. These instructions
cannot claim to cover all details of all possible product
variations, nor can they provide information for every possible
example of installation, operation or maintenance. This means
that the instructions normally include only the directions to
be followed by qualified personnel using the product for its
defined purpose. If there are any uncertainties in this respect,
particularly in the event of missing product-related information,
clarification must be obtained via the appropriate Flowserve
sales office. All Flowserve User Manuals are available at
www.flowserve.com.

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves
2
Terms concerning
safety
The safety terms DANGER,WARNING, CAUTION and NOTE
are used in these instructions to highlight particular dangers
and/or provide additional information on aspects that may
not be readily apparent.
bDANGER: indicates that death, severe personal injury
and/or substantial property damage will occur if proper
precautions are not taken.
cWARNING: indicates that death, severe personal injury
and/or substantial property damage can occur if proper
precautions are not taken.
a 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.
Compliance with other, not particularly emphasized notes, with
regard to transport, assembly, operation and maintenance and
with regard to technical documentation (e.g., in the operating
instructions, product documentation or on the product itself) is
essential, in order to avoid faults, which in themselves might
directly or indirectly cause severe personal injury or property
damage.

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Valtek®Control Products Mark 100™ and Mark 100SC Control Valves
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.
cWARNING: 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 valve assembly 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, call your Flowserve
representative.
3
Unpacking

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4
Installation
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.
a CAUTION: Do not insulate extension bonnets that are
provided for hot or cold services.
3. Be sure to provide proper overhead clearance for the
actuator to allow for disassembly of the plug from the valve
body. Refer to Table 1 for the necessary clearance needed
for valve disassembly.
Table 1: Valve disassembly clearance
Valve Size
(in)
Clearance
in mm
610 254
813 330
10 14 356
12 16 406
14 18 457
16 20 508
18 23 584
20 25 635
24 31 787
30 37 940
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.
a CAUTION: On valves equipped with air filters, the air
filter drain must point down to perform properly.
NOTE: In some rare cases, the air supply must be limited
to less than 150 psi (10.3 bar). This is indicated on a sticker
found near the upper air port on the actuator cylinder. An air
pressure regulator should be installed to ensure the supply
pressure does not exceed the line pressure indicated on
the sticker.
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 slip/stick 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. Refer
to the packing installation manual for specific details on
maintaining the style of packing supplied.
a CAUTION: Do not overtighten packing. This can cause
excessive packing wear and high stem friction that may
impede plug movement.

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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 retorqued to ensure bonnet gaskets do
not leak. See Table 2.
Table 3: Common packing lubricants
Lubricant Manufacturer Temperature Range Applications, Description
Krytox 206 E.I. DuPont -20°C to 285°C
(-5°F to 550°F) Fluorinated general purpose grease; handles common liquids and gases; good lubricity in harsh mediums; nonflammable, chemically
inert; will not harm plastic or metal parts
GP 460 Graphite Products Co. 0°C to 540°C
(32°F to 1,000°F) Graphite in petrolatum; high pressures; anti-galling, graphite remains above 316°C (600°F)
Aeroshell Grease 7 Shell Oil Co. -75°C to 150°C
(-100°F to 300°F) Synthetic oil-based; low-temperature applications
Garlock Luball Garlock Inc. 0°C to 260°C
(32°F to 500°F) General purpose molybdenum disulfide lubricant economical; good in water, steam and common chemicals; not good in harsh mediums
where Krytox 206 is recommended
Table 2: Recommended body bolt torque values
Bolt Size Bolt/Stud Material
B7 Studs, 2H Nuts B8 Studs and Nuts
(in) ft-lb N m ft-lb N m
7⁄8230 312 150 203
1350 474 220 298
11⁄8510 691 330 447
1¼ 730 990 460 624
13⁄81,000 1,356 630 854
1½ 1,320 1,790 840 1,139
15⁄81,710 2,318 1,080 1,464
13⁄42,170 2,942 1,400 1,898
17⁄82,700 3,660 1,700 2,305
23,350 4,542 2,100 2,847
21⁄44,050 5,491 2,530 3,430
21⁄24,850 6,575 3,010 4,081

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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. Retorque flange and bonnet bolting (if
required). See Table 2.
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. Refer to the
packing installation manual for specific details on main-
taining the style of packing supplied.
a CAUTION: Do not overtighten packing. This can cause
excessive packing wear and high stem friction that may
impede stem movement.
6. If the valve is supplied with a lubricator fitting, check
lubricant supply and add lubricant if necessary. See Table 3
for common lubricants.
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 slip/stick fashion.
cWARNING: Keep hands, hair and clothing away from all
moving parts when operating the valve. Failure to do so
can cause serious injury.
8. Make sure positioner linkage and stem clamp are securely
fastened. If the stem clamp is loose, check plug thread
engagement (refer to the “Reassembling the actuator”
section for the correct procedure on aligning the plug with
the seat.) Tighten stem clamp nut.
9. Ensure all accessories, brackets and bolting are securely
fastened.
10. If possible, remove air supply and observe actuator for
correct fail-safe action.
11. Check rubber actuator bellows for splits, cuts or wear.
12. Spray a soap solution around the cylinder actuator retaining
ring, adjusting screw and actuator stem guide to check
for air leaks through the O-rings.
13. Clean any dirt and other foreign material from the plug stem.
14. If an air filter is supplied, check and replace cartridge
if necessary.

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Parts list
Part Item
Body 1
Seat Ring* 20
Plug* 50
Plug Stem* 51
Cage 30
Pressure-Balanced Sleeve 31
Bonnet 40
Seat Gasket* 55
Sleeve Gasket* 56
Bonnet Gasket* 58
Seal Types*
O-ring Seal 65
66
PTFE Seal 65
Metal Multi-Seal 65
Carbon Single Seal 65
Carbon Triple Seal 65
Gland Flange 80
Gland Flange Bolting 109, 117
Lower Guide* 83
Upper Guide* 87
Packing* 88
Anti-Extrusion Spacer* 93
Body Bolting 108, 114
Packing Spacers 94 to 99
(1) Body
(55) Seat Gasket
(20) Seat Ring
(30) Cage
(31) Pressure-Balanced Sleeve
(50) Plug
(65, 66) Pressure-Balancing Seals
(58) Bonnet and (56) Sleeve Gasket
(40) Bonnet
(108, 114) Body Bolting
(83, 87, 88, 93, 94 to 99)
Packing, Guides and Spacers
(80) Gland Flange
(109,117) Gland Flange Bolting
Figure 1: Exploded drawing
* Recommended spare parts

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6
Valve disassembly
and reassembly
6.1 Disassembling the body
To disassemble the valve body, refer to Figures 1 and 2, then
proceed as follows:
cWARNING: Depressurize line to atmospheric pressure
and drain all fluids before working on the valve. Failure
to do so can cause serious injury.
1. Fully retract the plug until the stem clamp indicator points to
the open position.
2. Remove the bonnet flange bolting and lift the actuator,
bonnet and plug out of the valve body.
cWARNING: Danger exists in removing the actuator,
bonnet and plug, especially if PTFE plug seals are used.
The sleeve may stick to the plug and fall during disas-
sembly, causing possible serious injury and damage
to the valve or nearby equipment. If sleeve is observed
sticking to the plug, steps 3 to 5 should be consulted.
aCAUTION: Heavy actuators may require a hoist. Lift the
actuator with the yoke legs using a lifting strap and a
hoist. Great care should be taken to lift the actuator and
plug straight out of the body to avoid damage to the
plug and seat.
3. If the sleeve is observed sticking to the plug during
removal, fully extend the plug by applying air above the
piston, allowing the sleeve to remain in the body and the
bonnet to rise above the body.
4. In the gap between the top of the sleeve and the bottom of
the bonnet, place wooden blocking of equal thickness in at
least three places. The wooden blocks must not extend in
far enough that they interfere with plug movement. The plug
must be allowed to stroke up to the bonnet.
5. By applying air below the piston, retract the plug until the
plug head is freed from the sleeve. Once the plug is free
from the sleeve, remove the plug and bonnet assembly from
the body.
6. Lift the sleeve out of the valve body using lifting points on
the top of the sleeve.
7. Remove cage, seat ring and gaskets from the valve body.
Figure 2: Cutaway drawing
8. Remove the pressure-balancing seals from the plug head.
9. Check to see the seating surfaces on both the seat ring
and plug are free of damage to ensure tight shutoff. Make
sure the gasket surfaces on the seat ring, bonnet and body
are clean and undamaged. Inspect the pressure-balanced
sleeve for scratches, wear or other damage.