GE 10000 User manual

GE Oil & Gas
10000 Series
Masoneilan* Double Ported Globe Valve
Instruction Manual
GE Data Classification : Public

b | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-
SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL
OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE
PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES)
DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS
AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING
OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT
IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE
INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS
APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER
EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT
NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH
INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED
OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE
CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD BE REFERRED TO GE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE
STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY
OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE REGARDING
THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST
IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT
DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART WITHOUT
THE WRITTEN APPROVAL OF GE.

Masoneilan 10000 Series Globe Valve Instruction Manual | c
© 2015 General Electric Company. All rights reserved.
Contents................................................................................................................................... Page
1. Introduction........................................................................................................................................... 2
2. Unpacking................................................................................................................................................. 2
3. Installation................................................................................................................................................ 2
4. Air Piping................................................................................................................................................... 2
5. Body Disassembly (Refer to Figure 9) ................................................................................................. 3
6. Maintenance/Repair............................................................................................................................... 3
6.1 Seat Ring Removal............................................................................................................................................3
6.2 Bushing Removal...............................................................................................................................................3
6.3 Lapping Seats......................................................................................................................................................3
6.4 Plug Stem Pinning .............................................................................................................................................4
6.5 Packing Box..........................................................................................................................................................5
6.6 Packing Box (Optional Lubrication Figure 7)........................................................................................5
7. Valve Body Reassembly ......................................................................................................................... 6

1 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
Safety Information
Important - Please Read Before Installation
Masoneilan 10000 Series Control Valve instructions contain
DANGER, WARNING, and CAUTION labels, where necessary,
to alert you to safety related or other important information.
Read the instructions carefully before installing and maintaining
your control valve. DANGER and WARNING hazards are
related to personal injury. CAUTION hazards involve equipment
or property damage. Operation of damaged equipment can,
under certain operational conditions, result in degraded process
system performance that can lead to injury or death. Total
compliance with all DANGER, WARNING, and CAUTION
notices is required for safe operation.
This is the safety alert symbol. It alerts you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
could result in serious injury.
Indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury.
When used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, could result
in property damage.
Note: Indicates important facts and conditions.
About this Manual
• Theinformationinthismanualissubjecttochangewithoutprior
notice.
• Theinformationcontainedinthismanual,inwholeorpart,shall
not be transcribed or copied without GE’s written permission.
• Please report anyerrorsorquestions about the information in
this manual to your local supplier.
• These instructions are written specifically for the 10000 Series
Control Valve, and do not apply for other valves outside of this
product line.
Life Period
The current estimated useful life period for the Masoneilan 10000
Series control valve is 25+ years. To maximize the useful life of
the product it is essential to conduct annual inspections, routine
maintenance and ensure proper installation to avoid any unintended
stresses on the product. The specific operating conditions will also
impact the useful life of the product. Consult the factory for guidance
onspecificapplicationsifrequiredpriortoinstallation.
Warranty
Items sold by General Electric are warranted to be free from
defects in materials and workmanship for a period of one year
from the date of shipment provided said items are used according
to GE recommended usages. GE reserves the right to discontinue
manufacture of any product or change product materials, design
or specifications without notice.
This instruction manual applies to the Masoneilan 10000 Series
Control Valve.
The Control Valve and Actuator:
• MUST BE installed, put into service and maintained by
qualifiedandcompetentprofessionalswhohaveundergone
suitable training.
• Under certain operating conditions, the use of damaged
equipmentcouldcauseadegradationoftheperformanceof
the system which may lead to personal injury or death.
• Changes to specifications, structure, and components used
may not lead to the revision of this manual unless such
changes affect the function and performance of the product.
• Allairsupplytotheactuatormustbeturnedoff.
• All surrounding pipe lines must be thoroughly flushed
to ensure all entrained debris has been removed from
the system.

Masoneilan 10000 Series Globe Valve Instruction Manual | 2
© 2015 General Electric Company. All rights reserved.
1. Introduction
The following instructions are designed to assist maintenance
personnelinperformingmostofthemaintenancerequiredonthe
10000 Series valve.
GE has highly skilled service people around the world available
for startup, maintenance and repair of our valves and component
parts. In addition, a regularly scheduled training program is
conducted to train customer service and instrumentation personnel
in the operation, maintenance and application of our control valves
and instruments. Arrangements for these services can be
made through your local GE Representative. When performing
maintenance use only GE replacement parts. Parts are obtainable
through your local Masoneilan Representative. When ordering
parts always include Model and Serial Number of the unit being
repaired. These installation and maintenance instructions apply
to all sizes and ratings of the Masoneilan 10000 Series control
valves, regardless of the type of trim used. The model number,
size and rating of the valve are shown on the identification
tags located on the actuator. Refer to Figure 1 to identify
valve nomenclature.
2. Unpacking
Care must be exercised when unpacking the valve to prevent
damage to the accessories and component parts. Should any
problems arise, contact your GE Representative or Sales Office.
3. Installation
The valve must be installed with the flow entering between the
seats. In addition, the upper plug must be installed so that the larger
of the two V-notches in the plug is oriented to face the inlet of the
valve.
3.1 Before installing the valve in the line, clean piping and valve of
all foreign materials, such as welding chips, scale, oil, grease or
dirt. Gasket surfaces should be thoroughly cleaned to ensure
leak-proof joints.
3.2 To allow for in-line inspection, maintenance and removal of
the valve without service interruption, provide a manually
operated stop valve on each side of the 10000 Series valve with
a manually operated throttling valve mounted in the bypass
line (See Figure 2).
Figure 2
3.3 The valve must be installed so that the control substance
will flow through the valve body in the direction indicated by
the flow arrow located on the body or the words in and out
stampedonendconnections.Inaddition,seeCAUTIONabove.
3.4Whereinsulationofthevalvebodyisrequired,donotinsulate
the valve bonnet.
4. Air Piping
Theactuatorisdesignedtoaccept1/4"NPTairsupplypiping.Use
1/4"ODtubingorequivalentforallairlines.Iftheairlineexceeds25
feetinlengthorifthevalveisequippedwithvolumeboosters,3/8"
tubing is preferred. All connections must be free of leaks.
Do not exceed loading pressure indicated on the warning tag
located on the diaphragm cover. If no tag is present please consult
the actuator instruction manual or consult the factory.
2nd 2nd
0
5th
4th
3rd
1st
1
1st
8
Control Characteristics
3.EqualPercentage
6. Quick Opening
7. Linear
Body Series
10
87SpringDiaphragm:
direct, Air to close
(fail open action)
88SpringDiaphragm:
reverse, Air to open
(fail close action)
Actuator Type(1) Seat Type
2. Down
seating
Plug Type
1. Double Seat
(1)ForValveTravel>2.5"useActuatorModel37/38.
Figure 1
Numbering System

3 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
5. Body Disassembly (Refer to Figure 9)
Access to the internal components of the body should be
accomplished with the actuator removed. To remove the actuator
from the body, refer to the appropriate actuator instruction
GEA19530.
Prior to performing maintenance on the valve, isolate the valve,
vent the process pressure, shut off supply and signal air lines to
the actuator. In addition, it is recommended that the bonnet, body
and bottom flange be marked in relation to each other so the same
orientation can be maintained during reassembly.
A. Remove stem lock nuts and travel indicator if applicable.
B. Remove packing flanged nuts (2), packing flange (3), packing
follower (19) from the bonnet.
C. Remove body stud nuts (11) from around the bonnet and bottom
flange.
D. Remove bonnet (6) bottom flange (10) gaskets (13) and plug and
stemsubassembly(9,1and8)fromthebody.
Note: Ifanew body gasket(13) is notavailable,care must betaken
topreserve the old gasketforreuse.Spiralwoundflexitallic gaskets
are standard in the 10000 Series design, and it is recommended
thatanewgasketbe installed each time the valve is disassembled.
E.Removepacking(17)andpackingspacer(18)fromthebonnet.
F. Inspect all parts for wear and service damage. If bushings (14) must
be removed from the bonnet or bottom flange, refer to Section
6.2. After determining the maintenance required, proceed to the
appropriate section of these instructions.
6. Maintenance / Repair
The purpose of this section is to assist maintenance personnel by
suggesting methods of component maintenance which is largely
dependent on the tools and machine shop equipment available.
Each section should be read and understood before proceeding.
6.1 Seat Ring Removal
Threaded seat rings (15 and 16) are installed tightly at the point of
manufacture and after years of service they are often difficult to
remove. To facilitate removal, seat ring wrenches can be fabricated
to engage the seat ring lugs and adapted to a shock wrench
(see Figure 3). If the ring is exceptionally resistant to removal the
application of heat or penetrating oil should be helpful.
Figure 3
When using heating devices, ensure that proper safety practices are
observed. Such items as flammability and toxicity of the controlled
substance must be considered and proper precautions taken.
6.2 Bushing Removal
The bushings (14) are press fit into the bonnet and bottom
flange,anddonotnormallyrequirereplacement.However,should
replacement be required, they can be pulled or machined out.
When machining the bushings out, care must be taken to maintain
proper dimensions and tolerances. These will be furnished upon
request.
6.3 Lapping Seats
Lapping is the process of working the valve plug against the seat
ring with an abrasive to produce a close fit. When valve leakage
becomes excessive, lapping becomes necessary.
The plug and seat ring seating surfaces should be free of large
dents, scratches and the contact surfaces of the seats should be as
narrowaspossible.Thismayrequiredressingbothpartsinalathe.
Both surfaces make an angle of 30˚ with the axis of the plug (see
Figure 4).
Figure 4
For the lapping operation, a good grade of fine grinding compound
isrequired.The compound would be mixedwitha small quantity
of lubricant, such as graphite. This will slow the cutting rate and
prevent tearing of the seating surfaces. The amount of lapping
required depends on the materials, condition of seating surfaces
and accuracy of machining. If a short period of lapping does not
visibly improve seating there is usually no advantage in continuing,
as too much lapping may result in rough seats. The only remedy is

Masoneilan 10000 Series Globe Valve Instruction Manual | 4
© 2015 General Electric Company. All rights reserved.
replacement or re-machining of one or both parts. When lapping
new plug and seat ring, begin with medium compound and finish
with fine.
Before lapping plug and stem must be true (see pinning operation,
section 6.4).
Note: Seat repair in a double seated valve is critical. In a new
valve the distance between the upper and lower seat ring seats is
establishedinmanufacturingandonlylappingisrequiredtomake
both parts close simultaneously. In the field, it is best to lap the
seats first. If one of the seats is damaged beyond what is repairable
by lapping, care must be taken to maintain the original distance
between the seats on both the plug and seat rings. Therefore, when
machining one seat of the plug or one seat ring the other must be
machined in exactly the same way.
A. Clean body gasket surface areas.
B. When the seats have been removed, ensure that the sealing
surfaces in the body bridge and the threads are thoroughly
cleaned.
Note: A lubricant such as Chesterton 725 or a sealant compatible
with the process should be applied sparingly, to the seat ring
threads and sealing shoulder.
C. Install and tighten seat rings using fabricated wrench used for
removal. (See Figure 3).
Do not over tighten. Do not strike seat ring lugs, this could distort
the seat ring resulting in unwarranted seat leakage.
D. Install bottom flange (10), ensuring bottom bushing (14) is in
place and secure to the body using body stud nuts (12) spaced
equallyapart.Fastenthebottomflangetothebodyusingonly
slight pressure and tighten evenly.
Do not tighten nuts to torque specifications at this time. The
bottom flange is used temporarily for guiding purposes.
E. Applylappingcompoundatseveralspotsequallyspacedaround
the seating areas of the plug.
F. Insert the stem and plug assembly carefully into the body until
it is seated.
G. Place bonnet (6) on the body and using body stud nuts (12),
spaced equally apart, fasten to the body using only slight
pressure and tighten evenly.
Do not tighten nuts to torque specifications at this time. The
bonnet is used temporarily for guiding purposes.
H. Insert two or three pieces of packing (17) into the packing box to
assist in guiding the stem and plug during lapping.
I. Screw a drilled and tapped rod with a tee handle onto the plug
stem and secure with a lock nut. (See Figure 5).
Note: As an alternative, drill a hole through a flat piece of steel
and fasten to the plug stem using two lock nuts.
Figure 5
J. Apply a slight pressure on the stem, rotating the stem in short
oscillating strokes eight to ten times.
Note: The plug should be lifted and turned 90˚ before repeating
step10.Thisintermittentliftingisrequiredtokeeptheplugand
seat ring concentric during lapping. After completion of the
lapping operation, remove body stud nuts (12) from the bonnet
(6) and bottom flange (10).
K. Remove bonnet (6) and bottom flange (10).
L. The seat rings, plug and internal components of the valve must be
cleaned of all lapping compound in preparation for reassembly.
6.4 Plug Stem Pinning
Valve plug and stem assemblies are normally furnished as a
complete assembly in which case the installation involves no
problem. It is only necessary to lap the plug and seat ring and
assemble the valve. If it is necessary to replace the plug it is
recommended that a new stem be used. If the old stem must be
used, it is necessary to determine if the stem will be long enough
sincethestemwillrequirecutting.Ifthestemdoesnotengagethe
actuator stem by a minimum of one stem diameter, the old stem
should not be used. If it does not engage a minimum of one stem
diameter, proceed as follows.
Note: While pinning is being performed, care must be taken not to
damage the seating surface and plug guides.
A. Usingadriftpunch,driveouttheoldpin(8).
Note: If it is necessary to drill out the pin, a drill somewhat
smaller than the pin should be used and the remainder of the
pin driven out.
B. Unscrewtheplugfromthestem(counterclock-wise).
Figure 6

5 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
Figure 7
C. Cut off the stem directly above the pin hole. (See Figure 6).
D. Rethread the stem the original amount.
Note: TheareaoftheplugstemmarkedXinFigure8,servesasa
guide and must be checked to ensure a close fit in the valve plug.
Stem
Dia.
Hole
Dia. "A" "B" "X"
Inches in mm in mm in mm
½0,188 4,78 1,250 31,75 0,50 12,7
5
/80,219 5,56 1,562 39,67 0,62 15,7
¾0,250 6,35 1,875 47,63 0,75 19,1
10,312 7,92 2,500 63,50 1,00 25,4
Figure 8
E. Screw the stem solidly into the plug.
Note: This can be checked by measuring the depth of the pilot
recessintheplug(XinFigure8),andmakingareferencemark
on the stem the same distance from the thread. When properly
assembled, the reference mark should be flush with the end of
the guide section.
F. Place the plug guide on a V block and using a suitable size drill,
drill the stem using the hole in the plug as a guide.
G. Remove any burrs from the plug guide by making a slight
counter bore.
H. Select the correct size pin, apply a small amount of grease on it
and press into the hole.
Note: The pin must be recessed approximately 1/16" below the
plug guide surface.
I. After the plug has been pinned it should be placed in a lathe to
ensure it is running true. If it is not, strike the plug with a soft
faced mallot to straighten.
Note: The plug should be placed in a collet with the plug guide
against it and the plug should be struck.
6.5 Packing Box
Packing box maintenance is one of the principle chores of routine
servicing. Tightness of the packing is maintained by packing
compression. Compression is achieved by evenly tightening the
packing flanged nuts (2) against the packing flange (3). Care
must be taken not to over tighten, as this could prevent smooth
operations of the valve. If all compression is used up and the valve
leaks,newpackingisrequired.
Valve must be isolated and pressure vented before performing
packing box maintenance.
Proceed as follows:
A. Loosen and remove packing flange nuts (2).
B. Raise packing flange (3) and packing follower (19) up the valve
stem.
C. Remove packing (17).
Note: Only the top pieces of the old packing are removable by
pulling them out the top of the bonnet. To remove all the packing
the bonnet must be removed. (See appropriate section)
D. Replace packing. As a rule, 2/3 of the packing rings are placed
below the packing spacer, and 1/3 above.
Note: Ensure packing is inserted with skives 90˚ apart on
successive rings.
E. Replace packing follower (19) and packing flange (3).
F. Replace and tighten packing flange nuts (2).
Do not over tighten.
G. Put valve back in service and tighten packing only as much as is
necessary to stop leaking.
Note: In an emergency, string packing may be used as a
temporary repair only and must be replaced with the correct
packing as soon as possible.
6.6 Packing Box (Optional Lubrication Figure 7)
In some applications, packing boxes are designed for use with
a lubricator. The lubricator is provided with a ball check valve to
present backflow of the process fluid. On some valves, an isolating
valve (67) is added for positive protection against backflow. The
lubricator (66) should be kept filled with the specified lubricant and
turned in firmly but not tightly. One or two turns of the lubricator
once every two weeks should suffice to provide the desired seal.
Lubricants are available through your GE Representative or District
Office. Replacement of the packing (17) is accomplished in the
same manner as the standard lubricator box. Care must be taken
toensurethatthelaternring(18)isinlinewiththelubeholelocated
in the bonnet. As a rule, 2/3 of the packing rings are inserted below
the lantern ring and 1/3 above.

Masoneilan 10000 Series Globe Valve Instruction Manual | 6
© 2015 General Electric Company. All rights reserved.
7. Valve Body Reassembly
It is possible to change the valve from down seating to up seating
or vice versa.  However, the plug stem must be re-pinned to the
opposite end of the plug. (If at all possible, a new stem should be
used.) Then, simply invert the valve body and reassemble. The
tolerances and clearances explained in this instruction apply to
either seating direction.
Aftercompletionoftherequiredmaintenance,thevalveshouldbe
reassembled using the following procedures.
Note: If any of the following steps were completed during
maintenance proceed to the next step. If the bonnet, body and
bottom flange were marked in relation to each other, remember to
align these marks to obtain the same orientation.
A. Clean all gasket surfaces.
B. Apply a small amount of lubricant to the seat ring threads and
sealing shoulder and install.
C. Usingseatringwrench,fabricatedforremoval,tightenseatring
only enough to ensure a seal.
Do not over tighten. Do not strike the seat ring lugs.
This could distort the seat ring, resulting in unwarranted seat
leakage.
Note: Valve seats must be lapped before final assembly (See
section 6.3).
D. Install bottom flange gasket (13) bottom flange (10) and loosely
installbodystudnuts (11).Installstemandplugassembly(1,8
and 9).
The upper plug must be installed so that the larger of the two V
notches in that plug is in line with the inlet of the valve. Placement
of a witness mark on the stem may be helpful.
E. Install bonnet gasket (13), bonnet (6) and loosely install body stud
nuts (11).
Note: For ease of accessibility the bonnet should be positioned
so that the packing flange studs are at right angles to the flow
center line.
RefertoFigure10forproperbolttorqueandtighteningsequence
specifications. Additionally the plug must be stroked manually
while evenly tightening the body stud nuts (11) around both
bonnet and bottom flange to ensure proper alignment and
prevent binding between the plug guides and the bushings.
F. Insertpacking(17)andpackingspacer(18).
G. Install packing follower (19) and packing flange (3).
H. Install packing flange stud nuts (2).
Do not tighten at this time. When placed in service they should
be tightened only enough to stop leaking.
I. Install stem lock nuts and travel indicator on plug stem.
J. Proceed to the appropriate actuator instructions for actuator to
body assembly.
(1)Itisextremelyimportanttotightenstudnutsevenlyandinthesequenceshownotherwisedamagetotheguidesor
bushings could occur.
Valve Size ANSI Class Studs Maximum Torque(1)
in mm Qty Size (in) ft. lbs. m.daN
¾ 20 600 6 ½-13 55 7,5
1 25 600 6 ½-13 55 7,5
1½ 40 600 6 ½-13 55 7,5
2 50 600 8½-13 55 7,5
380 600 85 /8-11 89 12
4 100 600 8¾-10 170 23
6 150 600 12 ¾-10 170 23
8200 300 16 5
/8-11 89 12
600 20 ¾-10 170 23
10 250 300 16 ¾-10 170 23
600 16 11 /8-8 428 58
12 300 300 16 7
/8-9 236 32
600 16 1½-8 789 107
14 350 - - - - -
16 400 300 16 1¼-8 332 45
600 16 11 /5-8 789 107
Bolt Torque and Tightening Sequence(1)

7 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
Figure 9
Note: V-Port is shown 90° out of position. It must be installed as explained in Section 3.
Figure 10
Ref. No. Description
1 Plug Stem
2 Packing Flange Nut
3 Packing Flange
4 Packing Flange Stud
5 Drive Nut
6 Valve Bonnet
7 Valve Body
8Plug Pin
9 Plug
10 Lower Flange
11 Body Stud Nut
12 Body Stud
13 Body Gasket
14 Guide Bushing
15 Lower Seat Ring
16 UpperSeatRing
18 Lantern Ring (Optional)
19 Packing Follower
10000 Series Globe Valve - Parts Reference List

Masoneilan 10000 Series Globe Valve Instruction Manual | 8
© 2015 General Electric Company. All rights reserved.
Notes

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