Flowserve Valtek Valdisk Guide

10-1
Valtek Valdisk
Control Valves
Valtek No. 49020
GENERAL INFORMATION
The following instructions are designed to assist in
unpacking, installing and performing maintenance as
required on Valdisk rotary valves. Product users and
maintenance personnel should thoroughly review this
bulletin prior to installing, operating, or performing any
maintenance on the valve.
Separate maintenance instructions cover additional
features(suchasactuators,positioners,specialacces-
sories, fail-safe systems, etc.) Refer to the appropriate
FlowserveInstallation,Operation,MaintenanceInstruc-
tions when information on installing, maintaining, trou-
bleshooting, calibrating, and operating Valtek®actua-
tors or positioners is required.
Toavoidpossibleinjurytopersonnelordamage
to valve parts, WARNING and CAUTION notes
must be strictly adhered to. Modifying this
product,substitutingnonfactoryparts,orusing
maintenance procedures other than outlined
could drastically affect performance, be
hazardous 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
warranted.
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. Valtek's standard body bolting
material is B7/2H. B8 (stainless steel) is optional for
applications above 800 ° F and with stainless steel or
alloybodyvalves. Thecustomerthereforemustconsider
thematerial'sresistancetostresscorrosioncrackingin
addition to general corrosion. As with any mechanical
equipment,periodic inspection and maintenance is
required. For more information about fastener
materials, contact your local Valtek representative or
factory.
Unpacking
1. While unpacking the valve, check the packing list
againstthematerialsreceived. Listsdescribingthe
valve and accessories are included in each ship-
ping container.
2. When lifting the valve from the shipping container,
positionliftingstrapstoavoiddamagetotubingand
mounted accessories. Valves up through 14-inch
may be lifted by the actuator lifting ring. On larger
valves, 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
shipper immediately.
4. Should any problem arise, contact your Valtek
representative.

10-2
WARNING: Keep hands, hair, clothing, etc.
away from the rotating disc and the seat when
operating the valve. Failure to do so could
cause serious injury.
CAUTION: Because of Valdisk’s self-centering
seat,thereisno reason to openthevalveatany
time during installation. Therefore, the valve
should remain closed until the valve is fully
installed.
4. Connect air supply and instrument signal. Throt-
tling valves are usually equipped with valve
positioners.Twoconnectionsaremarkedfortheair
supplyand forthe instrumentsignal. Both cylinder
andpositioneraresuitablefor150psiairsupply.An
air regulator is not required unless the supply
pressure exceeds 150 psi. An air filter is recom-
mended unless the supply air is unusually clean
and dry. All connections must be free of leaks.
CAUTION: On valves equipped with air filters,
the air filter bowl must point down; otherwise,
the air filter will not perform properly.
NOTE: In some rare cases, the air supply must be
limited to 100 psi rather than 150 psi. In this case,
a sticker found near the upper air port on the
cylinderwillindicatethisandanairregulatorshould
be installed to insure the supply pressure does not
exceed 100 psi.
5. Make sure proper clearance exists internally in the
mating piping to permit proper disc rotation.
6. Apply recommended torque values to line flange
bolting for proper sealing (see Table I).
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 disc position
indicator plate mounted on the transfer case. The
disc should change position in a smooth, rotary
fashion.
2. Check all air connections for leaks. Tighten or
replace any leaky lines.
3. Evenly tighten the packing nuts to slightly over
finger-tight.
CAUTION: Do not overtighten packing. This
can cause excessive packing wear and high
shaftfriction, whichmayimpede shaftrotation.
After the valve has been in operation for a short
time,checkthe packingnutstomake suretheyare
just over finger-tight (readjust if necessary). If
packing box leaking occurs, tighten the packing
nuts only enough to stop leakage.
4. To observe the valve failure mode in case of air
failure,positionthevalvetomid-strokeandshutoff
Table I: Flange Bolting Torques
Valve Rating Torque
Size (inches) (ft./lbs.)
150 118
2 300 118
600 118
150 118
3 300 209
600 209
150 118
4 300 209
600 337
150 209
6 300 209
600 505
150 209
8 300 337
600 728
10 150 337
300 505
12 150 337
300 728
14 150 505
16 150 505
18 150 728
20 150 728
24 150 1009
30 150 1009
Installation
1. Before installing the valve, clean the line of dirt,
scale, welding chips, and other foreign material.
Clean the 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 on gas service. It
is preferred that liquid service valves must be
installed with the shaft downstream regardless of
air failure action. However, under certain flow
conditionsthevalvecanflowshaftupstream. Con-
sult factory if the valve must be mounted with the
shaft upstream in liquid service. Fail-open valves
should be installed with the shaft downstream.
WARNING: When installing the valve in-line
between flanges, make certain the flange face
gasket covers both seat retainer and body and
surface. Failure to do so will cause excessive
leakagedownstream.Referto“SeatInsert/Snap-
ring Configuration” in Figure 1.
3. Fullyclosethevalvebeforeandduring the installa-
tion process.

10-3
the air supply or disconnect the instrument signal.
By observing the indicator plate, the disc should
either fail open or closed. If incorrect, refer to the
Reversing the Actuator section in the appropriate
Actuator Maintenance Instructions.
PREVENTIVE MAINTENANCE
Atleastonceeverysixmonths,checkforproperopera-
tion by following the preventive maintenance steps
outlined below. These steps can be performed while
thevalveisinlineand,insomecases,withoutinterrupt-
ingservice. Ifaninternalproblemissuspected,referto
the Disassembly and Reassembly section.
1. Lookfor signs of gasket leakage through bodyand
line flanges. Tighten flange bolting if necessary.
2. Note if any corrosive fumes or process drippings
are damaging the valve.
3. Clean valve andpaint anyareas of severeoxidation.
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. Ifvalveissuppliedwithalubricator,checklubricant
supply and add lubricant if necessary.
6. Ifpossible, strokevalve andcheck forsmooth, full-
stroke operation by observing the disc position
indicator plate mounted on the transfer case. Un-
steady movement of the disc could indicate an
internalvalveproblem(jerkymotionisnormalwhen-
ever Grafoil packing is used).
7. Check positioner calibration by observing the
gaugesand the discpositionindicator plate. Make
sure the positioner is calibrated to the correct
range. Pushthepositionercleanoutplunger(Model
80R positioner only) several times to clear any
possible restrictions.
8. Remove transfer case cover plate and make sure
the positioner linkage and internal actuator parts
are securely fastened. Also, check for air leaks
through actuator stem seal, using a soap solution.
CAUTION: Never apply air to the actuator with-
out the cover plate installed; otherwise, the
unsupported shaft may sustain damage.
9. Be sure that all accessories, brackets and bolting
are securely fastened.
10. If possible, remove air supply and observe stroke
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 car-
tridge if necessary.
DISASSEMBLY AND REASSEMBLY
Removing Valve From Line
If an internal problem is suspected with the valve and
disassemblyisrequired,removethevalvefromtheline
by proceeding as follows:
WARNING: Depressurize line to atmospheric
pressure, drain all process fluids and decon-
taminatethevalve(ifcausticorhazardousmaterials
are present). Failure to do so can cause serious
injury.
1. Make sure valve is fully closed.
NOTE: On valves with fail-open action, air pres-
sure must be supplied under the actuator piston to
close the valve. If the valve is supplied with a
handwheel, it can be used to close the valve.
Figure 1: Seat Retainer Configurations
NOTE: Item numbers correspond directly to the bill of material. Refer to the bill of material for specific part numbers.
A – Dual Seat B – Metal Seat C – Soft Seat D – Seat Insert /
Snap-ring

10-4
Figure 2: Body Assembly
NOTE: Item numbers correspond directly to the valve's bill of material. Refer to it for specific part numbers.
Body
(Item No. 1)
Taper Pins (Item No. 52)
Shaft Bearing (Item No. 83)
Shaft (Item No. 51)
Inner Packing (Item No. 88)
Outer Packing (Item No. 88)
Packing Follower (Item No. 87)
Packing Spacer(s) (Item No. 93 - 95)
Packing Retainer (Item No. 85)
Seat Retainer Clip (Item No. 123)
Shaft
Plug
(Item No. 122)
Disc
(Item No. 50)
O-ring
(Item No. 61)
Seat
Shaft
Bearing
(Item No. 83) Disc Stop
Seat Retainer Bolt (Item No. 124)
2. Attacha hoistor some meansto supportthe valve.
3. Remove the line bolting. Do not attempt to pry line
flangesapartbypushingorpulling on valveactuator.
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.
Removing Actuator From Body
Inmostcases,boththebodyassemblyandtheactuator
are easier to disassemble with the actuator removed
from the body. To do so, proceed as follows:
1. Supportactuatorassemblybytheliftingringbefore
disconnecting it from the body assembly.
2. Remove the transfer case cover bolts. Carefully
pryorslidethecoverplatefromtheendoftheshaft.
3. On Valtek actuators with a clamping lever arm
design, loosen the linkage bolt.
4. Loosen the actuator adjusting screw to release
spring pressure.
5. Remove the bolts connecting yoke to the actuator
subassembly.
6. Slide entire actuator assembly off the shaft. For
Valtekactuatorswithaclamping lever-arm design,
itmaybenecessarytowedgethehalvesof splined
lever arm apart to loosen it from the shaft splines.
Disassembling the Body
To disassemble the body, refer to Figures 1, 2 and 5
and proceed as follows:
1. On Valdisk valves supplied with seat retainer
screws, remove the seat retainer screws and re-
tainer clips. Lift the seat retainer out of the valve
body. (Refer to Figures 1A, B, C).
2. Onvalvessuppliedwithretainersnap-ringconfigu-
ration, carefully insert a screwdriver in the key slot
provided in the retainer; pry the retainer and snap
ring out of the valve body. (Refer to Figure 1D).
3. Removetheglandflangebyremovingbothpacking
nuts. It is not necessary to remove the studs.
4. Drivethetaperpinsoutofthediscbytappingonthe
small end of the pins using a punch and hammer.
5. Remove the end plug (optional bolted flange and
seal if applicable).
6. Removeshaftbyinsertingapressoranylonrod(or
similar material) into body’s blind end, and using a
hammer, carefully tap the shaft through the body.
CAUTION: Take special care not to damage the
splined end of the shaft during disassembly.
To prevent scratching the sealing surface of the
discwhileremovingtheshaft,placesupportsunder-
neath the disc. This also prevents the shaft from
binding in the body as the shaft comes off the
bearing surfaces.

10-5
side of the disc and insert the shaft through the
body, bearings and disc.
5. Position the disc in the body, making sure it will
rotate in the proper direction with respect to the
body’s internal disc stop. Slide the shaft through
the body, bearings and disc.
CAUTION:Exercise care while slidingthe shaft
into the sliding stem shaft bearings to avoid
damage to both the shaft and bearings.
6. Insert new taper pins and drive them firmly into
place in the side opposite the stop.
7. Slide the packing retainer, lower packing, packing
spacer, upper packing, and packing follower over
splined end of the shaft and into the body. Typical
packing configurations are shown in Figure 3.
NOTE: Alwaysusenewpackingwheneverrebuild-
ing the packing box.
CAUTION: Since the sealing on V-ring packing
takesplaceatthefeatheredge,itisimportantto
avoid damage to that edge.
8. Reinstall the end plug (or replace the end seal and
reinstall the bolted flange).
9. Reinstalltheglandflangeandpackingnuts. Tighten
packing evenly to slightly over finger-tight.
CAUTION: Donot overtighten packing. This can
cause excessive packing wear and high shaft
friction, which may impede shaft rotation.
7. Push the packing and bearings out of the body
using a dowel of appropriate diameter. Push the
packing from the center of the valve.
Reassembling the Body
Toreassemblethebodysub-assembly,refertoFigures
1, 2, 3, and 5 and proceed as follows:
1. Clean all parts.
2. Check the disc seating surface to make sure it is
smooth and free of scoring and scratches.
CAUTION: Damaged or dirty seat surfaces can
cause excessive seat wear and high torque
requirements. Damaged discs should be re-
placed.
3. Inspect shaft for scratches or galled surfaces. For
maximum performance, Valdisk shafts are ma-
chined to a very smooth finish. If damage exists,
replacethe shaft orcontact factoryrepresentative.
NOTE: Disc and shaft are interchangeable in re-
cent designs. Replacing the disc does not require
replacingtheshaft. Earlierdesignsrequirethatthe
disc and shaft be machined together. Contact the
factory for matched disc and shaft.
4. Insert new sliding stem shaft bearings into the body.
(A press may be required with some designs.)
NOTE: Earlier Valdisk designs require the disc to
be aligned in the body in such a way that it can
rotate properly. Align the shaft bearings on either
Figure 3: Typical Packing Configurations
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

10-6
10. All seat configurations with screw/clip retainers
require a gasket (item No. 55) installed in the
appropriategroove. Thisisaccomplishedbypress-
ing the gasket into the appropriate groove.
11. If the seat retainer is the screw/clip type and has a
soft or dual seat, press the soft seat into the soft
seat retainer or metal seat. (There should be an
interference between the soft seat and the re-
tainer.) With the valve in the closed position,
secure the retainer or metal seat in place by tight-
eningtheretainerclipsandscrews. Thisallowsthe
seat to align with the disc, permitting tight shutoff.
12. If the seat retainer is the screw/clip type with a
metalseatdesign,agasketwillneedtobeinstalled
in the metal seat prior to clipping the seat in place
with the seat clips and screws.
NOTE: Valdisk valves of earlier design may re-
quire that the disc be open while installing the soft
seat into the body. (Refer to Figure 1D.)
13. If an early design Valdisk seat retainer has an
indexing groove to accept a soft seat, press the
correspondingseatintotheretainergroove. Install
the seat retainer subassembly into the body.
14. On valves supplied with the retainer snap-ring con-
figuration,installthesnap-ringintothegroovearound
theretainer(ormetalseat). Starttheretainerinto the
Figure 4: Transfer Case Mounting
O
SS
O
SS
O
SS
O
SS
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
Style A
Fail-closed
Air-to-open
Shaft Upstream
Style B
Fail-open
Air-to-close
Shaft Upstream
Style C
Fail-open
Air-to-close
Shaft Downstream
Style D
Fail-closed
Air-to-open
Shaft Downstream
NOTE: Styles B and D may
require a heavy-duty spring
to achieve failure.
Right-hand Mounting
Facing Downstream
Left-hand Mounting
Facing Downstream
Style C Style D Style B Style A
Left-hand
Mounting Right-hand Mounting
NOTE: Orientation 1 is standard. Orientation positions
2 and 4 are not available in some actuator sizes.
Contact factory.
FLOW

10-7
85
88 93
88
87 80
109
117
51
83
50 83
52
122 61
1
21
55
20/22 123
124
rotationofthedisc,marksprovidedontheendofthe
shaft and on the lever arm should be aligned.
2. Bolttheactuator yoketothe valve body. Becertain
the stroke indicator plate is positioned properly to
accurately indicate the valve's rotation.
3. Position the actuator lever arm on the shaft so the
actuator stem is centered in the transfer case.
Firmly tighten the linkage bolt, on clamping lever
arm actuators.
CAUTION: On clamping lever-arm actuators,
do not apply air to the actuator without the
cover plate installed; otherwise, the unsup-
ported shaft may sustain damage.
4. Adjustthe actuator strokestop boltsuntilthe discis
parallel to the seat surface, but not resting on body
disk stop.
CAUTION: Actuator stroke stop bolts must be
properlyadjustedtopreventthevalvediscfrom
overstroking. If incorrectly adjusted the valve
shaft may be twisted or sheared off.
5. Install valve in line as outlined in Installation section.
Figure 5: Exploded Body Sub-Assembly
NOTE: Item numbers correspond directly to the bill of material. Refer to it for specific part numbers.
Item No. Description
1 body
20 hard seat
21 seat insert
22 seat retainer
50 disk
51 shaft
52 taper pins
55 seat gasket
61 O-ring
80 gland flange
83 shaft bearing
85 packing retainer
87 packing follower
88 packing
93 packing spacer
109 packing box stud
117 packing box nut
122 shaft plug
123 clip
124 screw
body with the open ends of the snap-ring in the
body groove. Gently press the snap-ring into the
retainer until both the retainer and snap-ring slip
into the body. (Refer to Figure 1D.)
15. On early design Valdisk valves supplied with seat
retainer screws, install the insert and retainer into
the body with the disc open. Loosely install the
retainer screws, then close the disc. Tighten the
screwsafter the closeddischas centeredtheseat.
Thisallowstheseattoalignwiththedisc,permitting
tight shutoff.
Remounting Actuator to Valve
Before mounting a Valtek actuator on the valve body,
verify that the disc rotation matches the actuator rota-
tion and complies with the air failure requirements.
Procedure for mounting the actuator is as follows:
1. Slide the entire actuator assembly onto the shaft. If
necessary on Valtek actuator designs with clamp-
ing lever arm design, wedge the splined lever arm
apart to loosen it on the shaft splines. For full

10-8
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
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) shaft 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 Adjusting External Stroke Stops
stops section
2. Worn or damaged seat 2. Replace seat
3. Damaged disc seating surface 3. Replace disc and shaft
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 I 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
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 shaft bearings 2. Replace shaft 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, or 1. Improper valve installation 1. See step 2 in
Installation section and
causes severe water hammer correct flow direction
Shaft rotates, disc remains 1. Missing or broken taper pins 1. Replace taper pins
open or closed 2. Broken shaft 2. Replace shaft, make sure shaft is not
overstressing on external stroke stop
Actuator operates, shaft 1. Broken internal actuator parts 1. Refer to appropriate actuator Maintenance
does not rotate Instructions
Troubleshooting Valdisk Valves
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, installation, 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
Manufacturing Facilities
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©2001 Flowserve Corporation. Flowserve, Valtek and Kammer are registered trademarks of Flowserve Corporation.
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FCD VLAIM010-04