KSB MIL 10000 User manual

The following instructions should be thoroughly
reviewed and understood prior to installing, operating
or performing maintenance on this equipment.
Throughout the text, safety and/or caution notes will
appear and must be strictly adhered to, otherwise, serious injury
or equipment malfunction could result.
Instruction Manual
Purchase Order No : ___________________________________________
MIL 10000
Double Ported Top & Bottom Guided
Control Valves

1. Introduction........................................................................................................................2
2. General................................................................................................................................3
3. Unpacking...........................................................................................................................3
4. Installation..........................................................................................................................3
5. Air Piping.............................................................................................................................4
6. Body Disassembly................................................................................................................4
7. Maintenance / Repair..........................................................................................................4..
8. Valve Body Reassembly.......................................................................................................7
Parts List.............................................................................................................................9
10
Note: Easily replaceable Pressure gauges for Air sets and externally mounted Pressure
gauges of positioners are normally dismantled, separately packed and bound to the
actuator yoke as a precaution against transit damages. This may be noted while
opening the boxes.
Warning: Do not lift large size valves by the actuator. Lifting lugs provided on the
actuators are for lifting the actuator alone.
The following instructions should be
thoroughly reviewed and understood prior to
installing, operating or performing maintenance
1. Introduction
on this equipment. Throughout the text, safety
and/or caution notes will appear and must be
strictly adhered to, otherwise, serious injury or
2

equipment malfunction could result.
MIL has a highly skilled Aftermarket
department available for start-up, maintenance
and repair of our valves and component parts.
Arrangements for availing their service can be
made through your local representative or
Aftermarket department. In addition, a
regularly scheduled training program is
conducted at our plant, to train customer
service and instrumentation personnel in the
operation, maintenance and application of MIL
Control Valves and Accessories. Also when
Caution: Skilled service personnel to be
engaged for start up, maintenance and
repair of the valve.
Caution: Always use original MIL
replacement parts while performing
maintenance.
performing maintenance, please ensure that
only original MIL replacement parts are used.
When specifying parts, always include Serial
Number of the valve.
2. General
The 10000 Series double ported control valves
are designed to handle a wide variety of process
applications. Construction features have been
carefully selected to provide optimum
performance. The concept of the top and
bottom guided single seat valve was developed
to improve the rigidity of the standard top
guided valve for use at higher flow rates and
pressure drops. The additional guiding reduces
the vibration of the plug, which if severe
enough, can use failure in valves with top
guiding only. Double seated valves are
inherently balanced and therefore enable
economical actuation of larger valves than with
3. Unpacking
a single seated design.
All 10000 series bodies and plugs are invertible,
so either air-to-open or air-to-close action can be
obtained with the same spring diaphragm
actuator.
These installation and maintenance instructions
apply to all sizes and ratings of the MIL 10000
series control valves regardless of the type of
trim used. Recommended spare parts required
for maintenance are listed in parts reference of
page 15. The model number, size, rating and
serial number of valve are shown on the
identification tag located on the actuator. Refer
to Figure 1 to identify valve nomenclature.
Warning: Care must be exercised when unpacking the valve to prevent damage to the
accessories and component parts. Should any problems arise, contact your local
representative or MIL Aftermarket department. Do not remove end protection cover
before installation.
4. Installation
To allow in-line inspection, maintenance or
removal of the valve without service
interruption, provide a manually operated
stop valve on either side of the MIL 10000
series valve with a manually operated
throttling valve mounted in the by-pass line.
(See figure 2)
Caution: Before installing the valve in
the line, clean piping and flush the line
to remove all foreign material such as
welding chips, scale, oil, grease or dirt.
End flange gasket surfaces must be
thoroughly cleaned to ensure leak
proof joints.
Main Line
By-Passs Line
By-Passs Valve
Control Valve
Isolation Valve Isolation Valve
Figure 2
Caution: The valve must be installed so
that the controlled substance will flow
through the valve in the direction
indicated by the flow arrow located on
the body.
3

Caution: Where insulation of the valve body is required, do not insulate the valve
bonnet. Takenecessary protective measures for personal safety.
5. Air Piping
Unless otherwise specified, the connection to
the actuator tubing shall be 1/4" NPT or ½"
NPT. Use the tubing equivalent or higher to the
connection size. Refer MIL valve specification
sheet of respective valves for more details. All
connection joints should be free of leaks.
Warning : Do not exceed supply pressure
indicated on tag plate located on the
yoke of the actuator.
Numbering System
th
5th
6th 7
ACTUATOR TYPE BODY SERIES PLUG TYPE TRIM
CHARACTERISTICS TRIM TYPE
st
1nd
2
-
rd
3th
4
1 0
37. Direct Spring
Diaphragm 10.
Top and Bottom
Guided Control
Valves
Double Ported
0. Undefined
1. Double Seat (Std)
2. Double Seat
(Special)
0. Undefined
3. Equal %
6. On-Off
7. Linear
8. Lo-dB Linear
0. Undefined
2. Down Seating
4 Up Seating
6. Down Seating
(Soft Seat)
(1)
(1) : For soft seated valves requiring “Air fail close action”. Soft seat is applicable only for linear and on-off characteristics.
-- - -
38. Reverse Spring
Diaphragm
67. Direct Piston
Cylinder
68. Reverse Piston
Cylinder
90. Electrical Actuator
20. Hand Operated
6. Body Disassembly
Caution: New packing & gaskets sets
should be on hand before disassembling
the valve, since it is recommended that
new packing & gaskets be used during
reassembly.
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
instructions.
Warning: 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 that the
same orientation can be maintained
during reassembly.
A. Remove Stem lock nuts and travel
indicator
B. Remove packing flange nuts (2), packing
flange (3), packing follower (18) from the
bonnet
C. Remove body stud nuts (6, 7) from
around the bonnet and bottom flange.
D. Remove bonnet (5) bottom flange (11)
gaskets (12) and plug and stem sub-
assembly (1, 9) from the body.
Note : If a new body gasket 12, is not
available, care must be taken to
preserve the old gasket for reuse.
E. Remove packing (17) and packing spacer
(16) from the bonnet.
F. Inspect all parts for wear and service
damage. If bushings (15) must be removed
from the bonnet or bottom flange, refer to
section 7.2. After determining the
maintenance required, proceed to the
appropriate section of these instructions.
4

7. 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.
7.1 Seat Ring Removal
Threaded seat rings (13, 14) 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
seat ring is exceptionally resistant to removal
the application of heat or penetrating oil should
be helpful.
Caution: 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.
7.2 Bushing Removal
The bushings (15) are press fitted 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.
7.3 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. The
seating surfaces make an angle of 30 degrees
with the axis of the plug (See figure 4), For
the lapping operation, a good grade of fine
grinding compound is required. The
compound should 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
replacement or re-machining of one or both
parts. When lapping new plug and seat ring,
begin with medium compound and finish
with fine.
figure 4
Caution : Before lapping plug and stem
must be true (see pinning operation,
section 7.4).
5
figure 3

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 with a
special reamer, and only lapping is
required to make both ports 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 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).
Caution: not over tighen. Do not
strike seat ring lugs, this could distort
the seat ring resulting in unwarranted
seat leakage.
D. Install bottom flange (11), ensuring
bottom bushing (15) is in place and secure
to the body using 4 body stud nuts (6, 7)
spaced equally apart. Fasten the bottom
flange to the body using only slight
pressure and tighten evenly.
Note : As an alternative, drill a hole
through a flat piece of steel and fasten
to the plug stem using two lock nuts.
Note : The plug should be lifted and
turned 90 degrees 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
(6, 7) from the bonnet (5) and bottom
flange (11).
Caution : 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 (5) on the body and using 4
body stud nuts (6, 7), spaced equally
apart, fasten to the body using only slight
pressure and tighten evenly.
Caution: 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).
J. Apply a slight pressure on the stem,
rotating the stem in short oscillating
strokes eight to ten times.
K. Remove bonnet (5) and bottom flange (11)
L. The seat rings, plug and internal
components of the valve must be cleaned
of all lapping compound in preparation for
reassembly.
6
figure 5

7.4.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 engage a
minimum of one stem diameter, proceed as
follows.
A. Using a drift punch, drive out the old pin
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.
(8).
B. Unscrew the plug from the stem (counter
clock-wise).
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 in figure 8, serves as a guide
and must be checked ensure a close fit
in the valve plug.
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.
Note: While replacing packing, replace the
upper packing set completely
Caution : Valve must be isolated and the
pressure vented before performing
packing box maintenance.
Proceed as follows :
A. Disconnect the actuator stem from the
valve to maintain a gap to insert the
packing set
B. Loosen and remove packing flange nuts
(2).
C. Raise packing flange (3), and packing
follower (18) up the valve stem.
Note: They may be taped in place to
keep them out of the way before
proceeding.
D. By means of a hooked instrument, remove
packing (17) ensuring not to damage the
sealing surfaces of the packing box or
plug stem.
E. Replace packing (17) referring to Figure 9
for correct amount of packing to place
above the spacer.
Note : Assemble and compress rings one
at a time into packing box. If rings are
skive cut, the skive cut of each packing
ring must be placed about 120 degrees
apart.
figure 6
figure 7
figure 8
Stem
Dia
Hole Dia.
"A" "B" "X"
½
½
0.188
0.219
1.25 0.50
0.62
1.562
7

Note: For any type packing do not change
the sequence of packing arrangement. Use
the packing as a set only.
F. Replace packing follower (18) and
packing flange (3).
G. Replace and tighten packing stud nuts.
Caution: Do not over-tighten.
Caution: For Eco-lock packing, inner and
outer packing to be replaced as a set
only.
Note: MIL Ecolock packing (Fig 10) is a
high performance system to keep
fugitive emissions within allowable
limits. The packing is provided with the
inner packing and outer packing as a
set. It consists of V and double V
packing rings with varying density,
which is designed to prevent fugitive
emission from the packing effectively.
H. Put valve back in service and tighten
packing only as much as is necessary to
stop leaking.
Note: A spring loaded follower assembly
is used to maintain a constant load on
the packing, and is necessary for thermal
cycling applications. As the definition of
thermal cycling can vary, and processes
are potentially subject to unpredicted
thermal gradients. Both standard and
Eco-Lock systems are available with the
spring loaded follower (Figure 11).
Caution: Packing box should be clean
and free of burrs, rust, and any foreign
matter. Parts can be cleaned with
denatured alcohol.
Note: In an emergency, string packing
may be used as a temporary repair only.
It must be replaced with the correct
packing as soon as possible.
For valves with leakage class III and above, an
adjustable type plug is provided. This is to
overcome the difficulty in simultaneous closure
of both the ports.
The upper plug is maintained in the closed
position and lower plug is adjusted such that the
lower plug seats in the lower port and then the
lower plug is locked using the lock nut (Figure
11). Only down seating is provided for such
construction, to facilitate the adjustments from
bottom. Hence, for air-to-open action, Reverse
type actuator is opted and for air to close
action, direct actuator is opted.
7.6 Special Plug construction
(For class III and above leakage)
7.5 Packing Box
Packing box maintenance is one of the principal
actions in routine servicing. Tightness of the
packing is maintained by packing compression.
Compression is achieved by evenly tightening
the packing flange nuts (2) against the packing
flange (3). Care must be taken not to over
tighten as this could prevent smooth operation
of the valve. If all compression is used up and
the valve leaks, then new packing is required.
The packing is available as a set of lower and
upper packing. The height of the lower and
upper packing set is same for standard packing.
Due to the difference in the height for Eco-lock
packing, the packing sets are labeled as lower
packing and upper packing. The upper packing
set will be larger than lower packing set for
Eco-lock.
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
Note : The pin must be recessed
approximately 1/16" below the plug
guide surface.
Note : The plug should be placed in a
collet with the plug guide against it and
the plug should be struck.
amount of grease on it and press into the
hole.
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 mallet to straighten.
8

D. Install bottom flange gasket (12) bottom
flange (11) and loosely install body stud
nuts (6, 7). Install stem and plug assembly
(1, 9).
Caution: 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.
E. Install bonnet gasket (12), bonnet (5) and
loosely install body stud nuts (6, 7).
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.
Caution: Refer to figure 10 for proper
bolt torque and tighening sequence
specifications. Additionally the plug
must be stroked manually while
evenly tightening the body stud nuts
(6, 7) 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
(16).
G. Install packing follower (18) and packing
flange.
H. Install packing flange stud nuts (2).
Caution: 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.
Valve Size
(Inch)
ASME
Rating Class Stud Size Torque
(Nm)
¾ to 2½
3
3 to 8
10
12
600
300
600
600
600
½ - 13
½ - 13
5/8 - 13
7/8 - 13
11/8 - 13
31
31
60
168
344
Bolting Torques And Tightening Sequence
A. Clean all gasket surfaces.
B. Apply a small amount of sealant 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.
Caution : 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).
9
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.
It is possible to change the valve from down
seating to up seating or vice versa. However, the
plug stem must be repinned to the opposite end
of the plug. (If at all possible, a new stem
should be used). Then, simply invert the valve
body and re-assemble. 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.
8. VALVE BODY REASSEMBLY (For Valve <= Class II leakage)

1
3
4
5
8
9
10
11
7
18
17
16
15
14
13
12
2
6
Parts Reference
PART NAME
Blind Flange
Body Gasket
Guide Bush
Lower Seat Ring
Upper Seat Ring
Packing
Packing Spacer
Packing Follower
10
PART NAME
DRAWING Ref No. DRAWING Ref No.
1Plug Stem
2Packing Flange Nut
3Packing Flange
4Packing Flange Stud
5,10 Bonnet, Body
6
7
8
Plug
9
Body Nut
Body Stud
11
12
15
13
14
17
16
Plug Pin 18

INS/10000/REV-F/05-2018/ © KSB MIL Controls Limited 2018. Subject to technical modification without prior notice.
KSB MIL Controls Limited
Meladoor, Annamanada, Pin - 680741
Thrissur District, Kerala, India
Tel. [phone], Fax. [phone]
E-mail: [email protected], www.ksb-mil.com
You can also visit us at:
www.ksb.com/socialmedia
IMPORTANT
In normal process control applications, expected life cycle of a control valve is 25 years with periodic
maintenance and replacement of wear parts. We recommend inspection of valves in critical loops
during all plant shutdowns.
Soft parts like gland packing, gaskets, seal rings etc are recommended to be replaced with OEM parts
every time valve is opened for maintenance. Metallic Wear parts like plug, seat ring, cages etc are to
be inspected in the event of performance deterioration and should be replaced if found necessary.
Damage, if any, noticed to valve body and bonnet also should be replaced or repaired.
After the life-cycle, we recommend to dispose the parts as per your established procedures, through
approved agencies only.