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

3. Tighten the bonnet fasteners in a crisscross pattern.
For more information, see 4.2.1 Fastener torque table for valve body to topworks on page 9.
4. Make multiple crisscross passes to build up torque to the final table value. Make additional criss-
cross passes using final table values to evenly tighten each fastener to within 5% of torque value.
5. Retighten the bonnet fasteners as noted above at ambient conditions after the system has cycled
through operating pressure and temperature.
6. Monitor the valve for leakage:
If leakage ... Then ...
Occurs at the body/bonnet
flange sealing area
Depressurize the system and retighten the bonnet fasteners as noted
above.
Continues Depressurize the system and retighten the bonnet fasteners as noted
above. (maximum 3rd re-torque)
Continues Replace the valve diaphragm.
For more information, see 6.5 Replace the valve diaphragm on page 14.
4.2.1 Fastener torque table for valve body to topworks
Table 1: PAS bonnet (963)
Values given are for lubricated fasteners.
Valve size, inches (DN) PTFE diaphragm Elastomer diaphragm
Inches DN in-lb N-m in-lb N-m
0.50 15 20-50 2.3-5.7 20-40 2.3-4.5
0.75 20 40-70 4.5-7.9 20-50 2.3-5.7
1.00 25 45-80 5.1-9.1 25-70 2.8-7.9
1.50 40 145-170 16-19 75-130 8.5-14.7
2.00 50 225-275 25-31 100-180 11-20
2.50 65 500-830 57-94 300-420 34-48
3.00 80 500-830 57-94 300-420 34-48
4.00 100 200-575 23-65 180-220 20-25
Table 2: Metal bonnet (903, 913)
Values given are for lubricated fasteners.
Valve size PTFE diaphragm Elastomer diaphragm
Inch DN in-lb N-m in-lb N-m
0.50 15 25-80 2.8-9.1 20-40 2.3-4.5
0.75 20 50-80 5.7-9.1 20-50 2.3-5.7
1.00 25 65-120 7.4-13.6 45-70 5.1-7.9
1.25 and 1.50 32 and 40 200-225 23-25 75-130 8.5-14.7
2.00 50 225-300 25-34 100-180 11-20
2.50 65 750-1000 85-113 300-420 34-48
3.00 80 750-1000 85-113 300-420 34-48
4.00 100 540-600 61-68 190-230 22-26
NOTICE:
1. Make multiple criss-cross passes to build up torque to final table values. Make addition-
al criss-cross passes using table vales to evenly tighten each bolt to within 5% of stated
torque.
4.2 Tighten the bonnet fasteners
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 9

2. Values given are for lubricated fasteners.
3. Minimum values given will provide longer diaphragm cycle life for valves in non-auto-
clave and low thermal cycle conditions.
4. Maximum values given will be required for autoclave conditions and for high thermal
cycle conditions.
5. Torques should be applied at or near ambient conditions <38°C |100°F.
4.3 Set the travel stop
1. Do you have a test fixture?
• If Yes: Follow steps 2 through 6.
• If No: Proceed to step 7.
2
3
4
1
1. Stop nut
2. Air supply
3. Tubing
4. Beaker of water
2. Supply air pressure equal to the system operating pressure to one side of the valve.
3. Cap the other side of the valve and install a venting rubber or plastic tube.
4. Hold the tube in a container of water.
5. Turn the handwheel closed until the leakage stops.
Air bubbles indicate leakage.
6. Adjust the travel stop nut tight against the spacer.
7. If you do not have a fixture, then follow the steps below:
a) Loosen the lock nut.
b) Turn the handwheel clockwise until you feel the initial resistance of the diaphragm seating.
From this point, turn the handwheel another 5/8 turn.
c) Turn the lock nut down until it bottoms on the spacer.
4.3 Set the travel stop
10 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual

5 Operation
5.1 Topworks operation
WARNING:
For a sealed bonnet, the bonnet intervals and seals should be constructed of materials suitable
for exposure to the process fluid or gas. If in doubt, contact ITT for evaluation.
The valve is closed with a clockwise rotation of the handwheel.
Valve size Stem travel Number of turns
Inch DN Inch mm
0.50 15 0.25 6.4 2
0.75 20 0.38 9.5 3
1.00 25 0.50 13 4
1.25 and 1.50 32 and 40 0.81 21 4.88
2.00 50 1.12 29 6.75
2.50 65 1.61 41 8.12
3.00 80 1.61 41 8.12
4.00 100 2.12 54 10.62
5.2 Operate the Adjustable Open Stop
1
2
3
4
5
Item Description
1 Bonnet assembly
2 Handwheel
3 Cap
4 Nut
5 Capscrew
1. Bonnet assembly should be installed to a body.
2. Loosen nut and turn counter clockwise until it is next to the head of the capscrew.
3. Back out capscrew turn counter clockwise until the lower end is flush with the underside of cap.
5 Operation
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 11

4. Turn handwheel until it is in the desired open position.
5. Turn capscrew clockwise until its lower end is in contact with the top of the stem of the bonnet as-
sembly.
6. Turn the nut clockwise tight against the top of the cap.
Opening stop is now set.
5.2 Operate the Adjustable Open Stop
12 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual

6 Maintenance
6.1 Precautions
WARNING:
•All procedures must be performed by qualified personnel.
• When the process fluid is hazardous, thermal (hot or cold), or corrosive, take extra pre-
cautions. Employ the appropriate safety devices and be prepared to control a process
media leak.
• Always wear protective clothing and equipment to safeguard the eyes, face, hands, skin,
and lungs from the fluid in the line.
6.2 Inspection
Inspection area What to look for Action if problem is found
External valve parts Excessive wear or corrosion • Replace the affected parts
•Contact ITT to obtain replace-
ment parts or for specific in-
structions
Non sealed bonnet Fluid weeping from the weep hole Replace the valve diaphragm
Sealed bonnet Fluid weeping from the plug
Loosen the v-notch vent plug 2-3
turns to check
Replace the valve diaphragm
Topworks Spindle binding, excessive noise, or
dried lubricant
Lubricate the topworks
Diaphragm and valve body Leakage between the diaphragm and
valve body
Tighten the bonnet fasteners
For more information, see:
•6.5 Replace the valve diaphragm on page 14
•6.3 Lubrication requirements on page 13
•4.2 Tighten the bonnet fasteners on page 8
6.3 Lubrication requirements
Lubrication schedule
Remove residual grease prior to re-lubrication. Lubricate the spindle threads, thrust bearing, lower spin-
dle face and neck where it interfaces with the compressor, and o-ring whenever the topworks is disas-
sembled. Bonnets are not equipped with grease fittings and must be disassembled to be lubricated.
Acceptable lubricants
Brand Lubricant type
Chevron FM ALC EP 2 (FDA Compliant)
Fuchs Cassida FM CSC EP2 (FDA Compliant)
6 Maintenance
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 13

6.4 Disassemble the valve
1. Remove all line pressure.
2. Turn the valve to the open position counter clockwise at least one turn.
3. Remove the bonnet fasteners.
4. Lift the topworks assembly from the valve body.
6.5 Replace the valve diaphragm
1. Disassemble the valve.
For more information, see 6.4 Disassemble the valve on page 14.
2. Unscrew the diaphragm from the compressor by turning the diaphragm counterclockwise.
The replacement diaphragm should be identical in size and grade to the original diaphragm.
3. If replacing a PTFE diaphragm, then follow these steps.
a) Install the new elastomer backing cushion over the tube nut.
b) Invert the PTFE diaphragm by pressing the center of the diaphragm face with your thumbs
while holding the edge of the diaphragm with your fingers.
c) Engage the threads of the diaphragm into the tube nut by rotating clockwise.
d) Continue rotating the PTFE diaphragm clockwise into the compressor while securing the back-
ing cushion from rotating.
6.4 Disassemble the valve
14 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual

4. Rotate the diaphragm until hard stop or heavy resistance is achieved and additional force does not
significantly rotate the diaphragm into the compressor.
5. If replacing a PTFE diaphragm, re-invert the diaphragm.
6. Back off (no more than half turn) until the bolt holes in diaphragm and the bonnet flange align.
7. Rotate the handwheel counterclockwise just enough to permit the flange area of the diaphragm to
rest flat against the flange area of the bonnet.
8. Replace the topworks assembly on the body and tighten the bonnet fasteners.
For more information, see 4.2 Tighten the bonnet fasteners on page 8.
9. Set the travel stop.
For more information, see 4.3 Set the travel stop on page 10.
6.5 Replace the valve diaphragm
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 15

6.6 Change the diaphragm type
1. Remove the bonnet nuts and lift off the bonnet.
2. Remove the plastic cap and travel stop nut.
3. Loosen the handwheel setscrew(s) and remove the handwheel from the bonnet.
4. Remove the diaphragm, spindle and bushing assembly by withdrawing it through bottom of bonnet.
5. Remove the compressor.
If the compressor to spindle connection is a ... Then ...
Spring pin Drive out the spring pin that retains the compressor
"T" slot Slide the compressor off the spindle
6. Change to the new compressor.
If you are changing ... Then ...
From an elastomer to a PTFE diaphragm Install a tube nut into the hexagonal hole in the new com-
pressor
From a PTFE to an elastomer diaphragm Change to the new compressor.
7. Install the new compressor.
If the compressor to spindle connec-
tion is a ...
Then ...
Spring pin Locate the new compressor on the spindle and drive in the
spring pin
“T” slot Slide the new compressor onto the spindle
6.7 Replace the o-rings
1. Disassemble the topworks:
a) Remove the bonnet nuts and lift off the bonnet.
b) Remove the plastic cap and travel stop nut.
c) Loosen the handwheel setscrews and remove the handwheel from the bonnet.
d) Remove the diaphragm, spindle, and bushing assembly by withdrawing it through the bottom of
the bonnet.
2. Remove o-ring 1 from the groove in the bushing outside diameter.
2
3
1
Figure 5: O-rings for 0.50–2.00
inch (DN 15–50) valve
1. O-ring 1
2. O-ring 2
3. O-ring 3
2
3
4
1
Figure 6: O-rings for 2.50–4.00 inch
(DN 65–100) valve
1. O-ring 1
2. O-ring 2
3. O-ring 3
4. O-ring 4
6.6 Change the diaphragm type
16 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual

3. Unscrew the diaphragm and spindle assembly from the handwheel bushing.
4. Remove o-rings:
Valve size (in) Valve size (DN) Action
.5–2 15–50 Remove o-ring 2 from the
groove in spindle outside diame-
ter.
2.5–6 80–150 Remove o-rings 2 and 4 from
the spindle plug.
5. Install the thrust bearing or washer:
a) Lubricate the thrust bearing or washer.
For more information, see 6.3 Lubrication requirements on page 13.
b) Install the thrust bearing or washer on the shoulder of the bushing.
6. Cover the stem threads with masking tape to protect the o-rings during installation.
7. Lubricate o-rings.
For more information, see 6.3 Lubrication requirements on page 13.
Valve size (in) Valve size (DN) Action
.5–2 15–50 Lubricate o-rings 1 and 2 and
insert them into the grooves in
the bushing and spindle.
2.5–6 80–150 Lubricate o-rings 2 and 4 and
insert them into the grooves in
the spindle plug.
Select the proper o-rings for the valve size.
Valve size, inches
(DN)
O-ring 1 O-ring 2 O-ring 4
0.50 (15) .445 x .063 #107 –
0.75 (20) .571 x .063 #109 –
1.00 (25) .634 x .063 #110 –
1.25 (32) #119 #112 –
1.50 (40) #119 #112 –
2.00 (50) #119 #112 –
2.50 (65) #218 #209 #212
3.00 (80) #218 #209 #212
4.00 (100) #220 #210 #214
8. Remove the masking tape from the stem threads.
9. Screw the diaphragm and spindle assembly into the bushing.
10. Install the diaphragm, spindle, and bushing assembly into the bonnet.
Verify that the shim washer is installed.
11. Install the handwheel:
a) Tighten the setscrews, ensuring the setscrew ends engage the bushing holes.
b) If you do not have a plastic handwheel, then use a thread locking compound.
12. Install o-ring 3 and screw the cap onto the bushing hand tight.
6.7 Replace the o-rings
Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual 17

Select the proper o-ring for the valve size.
Valve size, inches (DN) O-ring 3
0.50 (15) #118
0.75 (20) #119
1.00 (25) #121
1.25 (32) #122
1.50 (40) #122
2.00 (50) #122
2.50 (65) #128
3.00 (80) #128
4.00 (100) #130
6.7 Replace the o-rings
18 Handwheel Operated Valves (903, 913, 963) Installation, Operation, and Maintenance Manual