ITT Engineered Valves 903 User manual

Installation, Operation, and
Maintenance Manual
Handwheel Operated Valves (903, 913, 963)

Table of Contents
1 Introduction and Safety ....................................................................................................................................2
1.1 Safety message levels .............................................................................................................................. 2
1.2 User health and safety .............................................................................................................................. 2
2 Transportation and storage .............................................................................................................................. 5
2.1 Handling and unpacking guidelines........................................................................................................... 5
2.2 Storage, disposal, and return requirements ..............................................................................................5
3 Product Description ..........................................................................................................................................6
3.1 Topworks identification ..............................................................................................................................6
3.2 Bonnet description..................................................................................................................................... 6
3.3 Valve diaphragm identification...................................................................................................................6
4 Installation..........................................................................................................................................................8
4.1 Install the valve and topworks ...................................................................................................................8
4.2 Tighten the bonnet fasteners..................................................................................................................... 8
4.2.1 Fastener torque table for valve body to topworks ........................................................................... 9
4.3 Set the travel stop ................................................................................................................................... 10
5 Operation.......................................................................................................................................................... 11
5.1 Topworks operation ................................................................................................................................. 11
5.2 Operate the Adjustable Open Stop ......................................................................................................... 11
6 Maintenance.....................................................................................................................................................13
6.1 Precautions ............................................................................................................................................. 13
6.2 Inspection ................................................................................................................................................ 13
6.3 Lubrication requirements......................................................................................................................... 13
6.4 Disassemble the valve ............................................................................................................................ 14
6.5 Replace the valve diaphragm.................................................................................................................. 14
6.6 Change the diaphragm type .................................................................................................................... 16
6.7 Replace the o-rings .................................................................................................................................16
7 Parts Listing and Cross-Sectional Drawings................................................................................................ 19
7.1 963 PAS plastic bonnet ........................................................................................................................... 19
Table of Contents
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 1

1 Introduction and Safety
1.1 Safety message levels
Definitions
Safety message level Indication
DANGER:
A hazardous situation which, if not avoided, will result in death or
serious injury
WARNING:
A hazardous situation which, if not avoided, could result in death
or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result in minor
or moderate injury
ELECTRICAL
HAZARD:
The possibility of electrical risks if instructions are not followed in a
proper manner
NOTICE:
• A potential situation which, if not avoided, could result in an
undesirable result or state
•A practice not related to personal injury
1.2 User health and safety
General precautions
This product is designed and manufactured using good workmanship and materials, and meets all appli-
cable industry standards. This product should be used only as recommended by ITT.
WARNING:
•Misapplication of the valve can result in injury or property damage. Select valves and
valve components of the proper materials and make sure that they are consistent with
your specific performance requirements. Incorrect application of this product includes but
is not limited to:
• Exceeding the pressure or temperature rating
• Failing to maintain this product according to the recommendations
• Using this product to contain or control media that is incompatible with the materials
of construction
• Proper containment or protection from hazardous media must be provided by the
end user to protect employees and the environment from valve discharge.
• If the product exhibits any indication of leakage, do not operate. Isolate the product and
either repair it or replace it as outlined within this manual.
1 Introduction and Safety
2 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual

Qualifications and training
The personnel responsible for the assembly, operation, inspection, and maintenance of the valve must
be appropriately qualified. The operating company must do the following tasks:
• Define the responsibilities and competency of all personnel handling this equipment.
• Provide instruction and training.
• Ensure that the contents of the operating instructions have been fully understood by the personnel.
Instruction and training can be carried out by either ITT or the reseller of the valve by order of the operat-
ing company
WARNING:
California Proposition 65 Cancer http://www.P65Warnings.ca.gov. Plastics in product contain
Glass Wool Fibers, known to the State of California to cause cancer. Wash hands after han-
dling.
Non-compliance risks
Failure to comply with all safety precautions can result in the following conditions:
•Death or serious injury due to electrical, mechanical, and chemical influences
• Environmental damage due to the leakage of dangerous materials
• Product damage
• Property damage
• Loss of all claims for damages
Operational safety precautions
Be aware of these safety precautions when operating this product:
• Do not remove the contact guard for moving parts when the product is in operation. Never operate
the product without the contact guard installed.
• Do not hang items from the product. Any accessories must be firmly or permanently attached.
• Do not use the product as a step or hand hold.
• Do not paint over the identification tag, warnings, notices, or other identification marks associated
with the product.
Maintenance safety precautions
Be aware of these safety precautions when performing maintenance on this product:
• You must decontaminate the product if it has been exposed to harmful substances such as caustic
chemicals.
Use of unauthorized parts
Reconstruction or modification of the product is only permissible after consultation with ITT. Genuine
spare parts and accessories authorized by ITT serve to maintain safety. Use of non-genuine ITT parts
can annul liability of the manufacturer for the consequences. ITT parts are not to be used in conjunction
with products not supplied by ITT as this improper use can annul all liability for the consequences.
Unacceptable modes of operation
The operational reliability of this product is only guaranteed when it is used as designated. The operating
limits given on the identification tag and in the data sheet may not be exceeded under any circumstan-
ces. If the identification tag is missing or worn, contact ITT for specific instructions.
1.2 User health and safety
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 3

Do not use "cheater bars" to operate manual valves. Damage to the valve or personal injury could result.
1.2 User health and safety
4 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual

2 Transportation and storage
2.1 Handling and unpacking guidelines
CAUTION:
Always observe the applicable standards and regulations regarding the prevention of accidents
when handling the product.
Handling guidelines
Follow these guidelines when handling the product to prevent damage:
•Use care when handling the product.
• Leave protective caps and covers on the product until installation.
Unpacking guidelines
Follow these guidelines when unpacking the product:
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. Do not lift or pull on the electrical conduit lines. Doing so may cause the POC switches to come
out of calibration.
2.2 Storage, disposal, and return requirements
Storage
If you are not immediately installing the product after delivery, store it as follows:
• Store the product in a dry room that maintains a constant temperature.
• Make sure that the products are not stacked on top of one another.
Disposal
Dispose of this product and associated components in compliance with federal, state, and local regula-
tions.
Return
Ensure these requirements are met before you return a product to ITT:
• Contact ITT for specific instructions on how to return the product.
• Clean the valve of all hazardous material.
• Complete a Material Safety Data Sheet or Process Data Sheet for any process fluid that could re-
main on the valve.
• Obtain a Return Material Authorization from the factory.
2 Transportation and storage
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 5

3 Product Description
3.1 Topworks identification
Model number
Code Description
903 Cast iron bonnet with rising stem and travel stop
903S Cast iron sealed bonnet with rising stem and travel stop
913 Stainless steel bonnet with rising stem and travel stop
913S Stainless steel sealed bonnet with rising stem and travel stop
963 PAS plastic bonnet with rising handwheel and travel stop
963S PAS plastic sealed bonnet with rising handwheel and travel stop
3.2 Bonnet description
Non-Sealed bonnet
The non-sealed bonnet has a weep hole that indicates a diaphragm failure by allowing process fluid that
accumulates in the bonnet to pass through the hole.
Sealed bonnet
The sealed bonnet uses a special “V-notch” vent plug, which permits leak detection.
Bonnet
weep hole
V-notch vent plug
(Sealed bonnet only)
Figure 1: Weep hole and V-notch vent plug
3.3 Valve diaphragm identification
Diaphragm tab codes
All diaphragm materials and physical properties are batch traceable via permanent codes molded into
the diaphragm tabs. The molding date, grade of diaphragm, and size provide traceability to original batch
records.
3 Product Description
6 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual

1. Date code
2. Supplier code
Figure 2: Elastomer diaphragm front
1. Valve size
2. Grade of diaphragm
Figure 3: Elastomer diaphragm back
1. Material code
2. Date code
Figure 4: PTFE diaphragm
3.3 Valve diaphragm identification
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 7

4 Installation
4.1 Install the valve and topworks
NOTICE:
The topworks size and configuration can limit the actual operating pressure. Consult the Pure-
Flo catalog for pressure limitations. Consult the factory or engineering catalog for vacuum op-
eration.
1. If you have a weld end valve, then consider the following:
If you are welding ... Then ...
Manually Remove the topworks.
Remove the diaphragm.
In line for schedule 10 or
heavier pipe
Remove the topworks.
Remove the diaphragm.
In line for schedule 5 or light-
er pipe and tubing
You can weld with automatic equipment. Before you perform the
weld:
1. Remove the topworks (optional).
2. If left installed, set the valve to the open position.
3. Properly purge the valve with an inert gas.
2. Install the valve.
Install with the raised hash marks (castings) or small machined dots (forgings) on the valve body at
the 12 o'clock position to achieve the optimum drain angle.
3. Prior to pressurization (with the valve slightly open), tighten the bonnet fasteners.
For more information, see 4.2 Tighten the bonnet fasteners on page 8.
4. Cycle the valve two to three times to verify smooth operation.
5. Set the travel stop.
For more information, see 4.3 Set the travel stop on page 10.
4.2 Tighten the bonnet fasteners
CAUTION:
Do not tighten fasteners while the system is pressurized or at elevated temperatures (greater
than 38°C | 100°F).
1. Depressurize the system.
2. Position diaphragm so that valve is slightly open.
For valves with an actuator, you may need to use regulated air pressure to actuate the valve.
4 Installation
8 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual