KSB MIL 77000 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 77000
Control Valves

TABLE OF CONTENTS
1. Introduction.........................................................................................................................2
2. General............................................................................................................................... 3
3. Unpacking...........................................................................................................................3
4. Installation ..........................................................................................................................3
5. Air Piping.............................................................................................................................4
6. Maintenance .......................................................................................................................4
6.1 Valve Disassembly.................................................................................................4
6.2 Valve Reassembly.................................................................................................4
6.3 Plug Stroke Adjustment .......................................................................................5
6.4 Mounting and Adjustment of Actuator ..............................................................6
6.4.1 No. 37 Direct Actuator (Air-to-open)....................................................6
6.4.2 No.38 Reverse Actuator (Air-to-close) ..................................................7
6.4.3 67 and 68- Piston Cylinder Double Acting Actuator .............................8
6.5 Standard Packing..................................................................................................9
6.6 Grinding Plug to Seat Ring ...................................................................................9
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.
1. Introduction
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.
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
Caution: Skilled service personnel to be
engaged for start up, maintenance and
repair of the valve.
Control Valves and Accessories. Also when
performing maintenance, please ensure that only
original MIL replacement parts are used. When
specifying parts, always include Serial Number
of the valve.
2
Caution: Always use original MIL
replacement parts while performing
maintenance.

2. General
The MIL 77000 Series is part of MIL’s severe
service portfolio, and may be custom designed
to fit our customer’s most difficult applications.
The plug and seat ring design provides an
expanding labyrinth passage in which the fluid
flows through a succession of variable sections.
These sections create a pressure drop by
molecular friction comparable to the Fanno
flow effect which occurs in long straight pipe
but with one important consideration.
The increase in volume of the fluid, due to the
pressure drop is counteracted by a progressive
increase of flow area within the trim. This
ensures a nearly constant fluid velocity
Numbering System
Body Series Plug Type Trim
Characteristic
77. Multi-stage
Labyrinth
Lo-dB
Control Valve
0. Undefined
7. Labyrinth Lo-dB
Trim Type
0. Undefined
7. Mod. Linear
7A. Reduced Area
7B. Full Area
7C. High Capacity
Single Step
0. Undefined
3. Unpacking
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
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.
ŸThe 77000 Series valve must always be
installed with the flowtending to open the
valve plug(side inlet). For applications
where insulation of the valve body is
required, do not insulate the valve bonnet
when possible.
3
throughout the complete throttling process
giving it two advantages :
1. Reduction of the noise produced by the
fluid velocity to humanly acceptable
levels.
2. Considerable decrease of the erosion of
the plug and seat.
The bottom flange is larger than the inlet flange
to retain the low velocity at the outlet and to
eliminate the need for pipe reducers between
the valve and the larger downstream piping.
The plug (3) and seat ring (2) incorporate a
hard-faced(stellite) seating surface at the first
restriction to maintain tight shutoff. The rest of
the steps do not touch.
ŸIt is recommended to install the 77000 Series
valves in the vertical position with the
actuator extended up whenever possible.
This orientation eliminates the need for
additional pipe support, reduces the side
load friction on
Ÿthe actuator, and provides ease of removal of
the trim during maintenance for weld-end
construction designs.
ŸWhen lifting the valve for installation it is
important to never lift the valve by the
actuator, lever or other assembled
components. It is recommended to use lifting

straps around the body or flange connection
whenever picking the valve for installation
or removal from the piping system.
5. Air Piping
Air piping shall be as per the specification of air filter.
6. Maintenance
If it becomes necessary to disassemble the valve
for maintenance, follow the procedure outlined
below. Do not alter the position of the actuator
spring adjusting screw unless the actuator is to
be disassembled.
6.1 Valve Disassembly
1. Bypass the valve and make sure that there
is no pressure in the body. If the actuator
is type 37 (direct), apply sufficient air
pressure to take the plug off the seat.
2. Remove actuator from the valve :
Ÿ when valve is fitted with coupling type
1, (see Fig. 5):
Remove snap rings (31) and (32)
and the two links (29). Drive out
pins (26) and (27) and disengage
lever (33).
Ÿ when valve fitted with coupling type 2,
(see Fig. 6):
Remove snap rings (31), drive out
pins (26) and disengage lever (33).
3. Shut off the air supply pressure and
disconnect the air tubing from the
actuator.
4. Put valve out of the piping and unscrew
drive nut (5) (or cap screws (34) if No 24
actuator) to separate the actuator from
the body S/A.
5. Unlock the nut (24), remove the anti-
rotation screw (23) then unscrew the
clevis (30) from the plug stem. Loosen
the packing box nuts (9) to reduce the
friction of the packing (10) to the plug
stem.
6. Remove bottom flange (4), plug (3), seat
ring (2) and the two Hélicoflex ® gaskets
(2A) from valve body.
7. Clean all parts, particularly the seating
surfaces on the seat ring (2), plug (3),
and body (1). If necessary to lap the plug
to seat ring.
6.2 Valve Reassembly
Plug and seat ring reassembly is the
reverse of the assembly sequence.
Special care must be taken when
reassembling to prevent damage to the
plug, seat ring surfaces or the guiding
surface of the plug stem.
1. Fit the first Hélicoflex® (2A) gasket in
body housing and fit seat ring (2) then
second Hélicoflex® gasket. Fit in plug (3)
in body after light coating the two
guiding parts with MolikoteG® (or its
equivalent).
Caution : When doing this, ensure not to
damage the seat ring or the plug ring.
When fitting plug in body, position the
groove of the plug stem towards the
actuator bracket.
2. Fit bottom flange (4) and ensure the
guide bushing is exactly in plug axis.
Screw and tighten evenly stud nuts (13)
as indicated in table with torque
tightening instructions.
The spacing between the body flange and
bottom flange should be checked by
means of feeler gauges.
Valve Size Torque Tightening of Bottom Flange
mm inches daN.m Ft.lbs
50 x 80 2 x 3
50 x 100 2 x 4
80 x 100 3 x 4
80 x 150 3 x 6
100 x 150 4 x 6
100 x 200 4 x 8
150 x 200 6 x 8
90 to 100 664 to 737
150 to 160 1106 to1180
360 to 380 2655 to 2802
380 to 400 2802 to 2950
Note : The above torque values are only
available for carbon steel bolting. In case
of stainless steel bolts, consult KSB MIL.
4
ŸThe valve must be installed so that the
process fluid will flow through the valve in
the direction indicated by the flow arrow
located on the body.

Caution : The spacing measured around
the periphery after final tightening of
the body nuts must be consistent with
± 0,05 mm. This is required for a good
alignment of the bushing (98) with the
plug. Check this alignment by moving
the plug in the valve body by hand
making sure that it makes its full
stroke.
3. Coat the pipe plug (25) with PTFE tape before
tightening. Install actuator and connect it
to the lever (33).
6.3 Plug Stroke Adjustment
The plug stroke adjustment is an operation
normally performed with the actuator removed
from the valve. The plug stroke is established by
the position of the clevis (30) on the plug stem.
Valve
mm inches
50 x 80 2 x 3
50 x 100 2 x 4
80 x 100 3 x 4
80 x 150 3 x 6
100 x 150 4 x 6
100 x 200 4 x 8
150 x 200 6 x 8
Size Plug Stroke
mm inches Type
Actuator
Stroke
inches
mm
61/4
10 3/8
13 1/2
13.7 35-64
18
18 L
24
24 HPI
Direct
38.1
63.5
88.9
88.9
1 1/2
2 1/2
3 1/2
3 1/2
2A
1
2
3
4
5
6
7
8
9
10
11
12
13
142
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31 32
31
33
Figure 1
The plug reaches its wide open position when
the lever contacts the yoke adapter (21). When
the lever is raised and the plug contacts the seat,
the plug travel should be that value shown in
table below, increased about 0,5 to 1 mm, and
the actuator (end of the lever) should have
traveled its rated stroke.
5

1 Valve Body
2 Seat Ring
2A Hélicoflex®
3 Valve Plug
4 Bottom Flange
5 Drive Nut
6 Packing Follower
7 Packing Flange
8 Packing Flange Stud
9 Stud Nut
10 Packing
11 Lantern Ring
12 Body Stud
13 Stud Nut
14 Upper Guide Bushing
* 15 Serial Plate
* 16 Drive Screw
17 Lower Guide Bushing
18 Actuator Bracket
19 Bracket Stud
20 Stud Nut
21 Yoke Adapter
22 Stem Adapter
23 Anti-rotation Screw
24 Locknut
25 Pipe Plug
26 Pin (Valve End)
27 Pin (Actuator)
28 Link (Valve End)
29 Link(Actuator End)
30 Clevis
31 Snap Ring
32 Snap Ring
33 Lever
* 34 Cap Screw (No. 24 Actuator
Only)
Ref. No.
Part Name Part Name
Parts List
* Not Shown
Ref. No.
1. Screw the clevis (30) all the way onto
the plug stem.
Note: It is important that the adjustment
start with the clevis screwed as far as
possible down the stem. If the
adjustment starts with the clevis further
up on the stem, the plug may hit the
bottom flange (4) before the lever
contacts the yoke adapter (21), a
situation to be avoided.
2. Replace lever (33) with links (28) and
pins (26). Check the stroke of plug and
end of the lever. If the stroke is less
than that indicated in table above,
increased about 0,5 to 1 mm, take off
clevis pin (26), set aside the lever and
unscrew the clevis 1/2 turn.
3. Replace the lever and pin (26), recheck
the stroke and repeat step 2 if
necessary.
4. Lock clevis on stem by means of anti-
rotation screw (23) and nut (24). Make
sure screw goes into the milled slot and
does not damage the thread.
6.4 Mounting and Adjustment of Actuator
6.4.1 No 37 Direct Actuator (air to open)
Valves fitted with coupling device type 1,
(Figure 5)
1. Insert one of the pins (27) through one
link (29) and the lever (33), then mount
the actuator on the bracket (18) and
secure with drive nut (5).
2. Admit air pressure to actuator until the
stem extends by 4 mm. Mark position of
actuator stem in relation to spring
adjustor (49).
3. When actuator in position : screw stem
adapter (22) into clamp (58) and fit plug
(3) in bearing position on its seat using
lever (33). Fit link (29) towards stem
adapter (22) and ensure that plate hole
(29) lines up with hole of the stem
adapter. If not, turn stem adapter (22) to
achieve the position for coupling.
4. Screw stem adapter (22) by 6 to 12 mm
more into clamp (58).
5. Apply air pressure to diaphragm until the
6

stem adapter and link line up. Insert the
second pin (27), link (29) and snap rings
(32). Fit snap rings (31) and tight nut (60)
of the stem clamp (58).
6. Remove air pressure from diaphragm and
ensure that the marking on actuator stem
returns to its position.
Caution : If marking comes in spring
adjustor (49) : Start again step 4 and
screw stem adapter (22) more in stem
clamp (58).
If marking not in correct position : Start
again step 4 and screw stem adapter (22)
less in stem clamp (58).
Note : When marking in position it
ensures the entire spring force is used
to tighten plug onto its seat.
7. With the help of comparator, check the
plug performs its complete travel
starting from the closed position,
when the air pressure passes from the
minimum value to the maximum value
which is given on the serial plate (15).
Adjust travel indicator scale such that
the travel indicator (61) indicates
“OPEN”. Retighten packing box nuts
(9). Install the valve in the line,
connect air pressure tubing and put in
service.
Valve fitted with coupling device type 2,
(Figure 6)
1. Screw stem adapter (22) into clamp
(58) and fit actuator on its bracket
using drive nut (5) or screws (34) and
ensure to fit lower part of stem adapter
(22) into vertical slot at lever end (33).
2. Admit air pressure to actuator until the
stem extends by 4 mm. Mark position
of actuator stem in relation to spring
adjuster (49).
3. Seat the plug firmly by lifting the lever
toward the stem adapter (22). The hole
of the stem adapter should line up with
the horizontal slot in the lever. If not,
remove clevis pin (26), move the lever
toward the back of the valve and
adjust the position of the stem adapter.
4. After achieving alignment, move again
the lever toward the back of the valve.
Then screw stem adapter (22) by 6 to
12 mm more into clamp.
5. Apply air pressure to the diaphragm to
move the stem adapter down. Insert
pin (27) into the hole of the stem
adapter and slide lever onto the pin.
Replace clevis pin (26) and snap rings
(31) then screw stem clamp (58).
6. Remove air pressure from diaphragm
and ensure that the marking on
actuator stem returns to its position.
Caution : If marking comes in spring
adjustor (49) : Start again step 4 and
screw stem adapter (22) more in stem
clamp (58).
If marking not in correct position : Start
again step 4 and screw stem adapter (22)
less in stem clamp (58).
Note: When marking in position, it
ensures the entire spring force is used
to tighten plug onto its seat.
7. With the help of a comparator, check the
plug performs its complete travel starting
from the closed position, when the air
pressure passes from the minimum value
to the maximum value which is given on
the serial plate (15). Adjust travel
indicator scale such that the travel
indicator (61) indicates “OPEN”.
Retighten packing box nuts (9). Install the
valve in the line, connect air pressure
tubing and put in service.
6.4.2 No 38 Reverse Actuator (air to close)
Mounting and adjustment of the No 38 reverse
actuator is done in much the same way as with
the No 37 actuator.
Connection of stem adapter and lever is made
with the valve closed. Air pressure is applied to
the actuator to the maximum value of the spring
range and the connection is
7

Ref. No. Ref. No.
Part Name Part Name
Parts List
5 Drive Nut
21 Yoke Adapter
22 Stem Adapter
23 Anti-rotation Screw
24 Locknut
26 Pin (Valve End)
27 Pin (Actuator)
28 Link (Valve End)
29 Link(Actuator End)
30 Clevis
31 Snap Ring
32 Snap Ring
33 Lever
35 Gasket ( Packing Box)
36 Yoke
37 Cap Screw(L.Case to Yoke)
38 Gasket (L. Case to Yoke)
39 Packing Nut
40 Snap Ring
41 Actuator spring
41A Actuator Spring
42 Actuator Stem
43 Nut (Actuator Stem)
44 Packing Box
45 Packing
46 Spring Seat (Upper)
47 Spring Seat (Lower)
48 Pipe Plug
49 Spring Adjustor
50 Bushing(Spring Adjustor)
51 Diaphragm
52 Diaphragm Plate
53 Diaphragm Washer
54 Upper Diaphragm Case
55 Lower Diaphragm Case
56 Cap Screw (Diaph. Case)
57 Nut (Diaph. Case)
58 Stem Clamp
59 Clamp Screw
60 Clamp Nut
61 Travel Pointer
62 Travel Pointer Screw
63 Ball and Retainer
64 Spring Barrel
65 Spring Barrel Cap
66 Ball Bearing Race
67 Cap Screw
28 26 31 33 30 24 23 22
29
5
60
63
41A
41
37
55
57
51 54 43 53 46 52 56
48
42
36
47
49
50
58
59
62
61
32
27
21
28 26 31 33 30 24 23
22
61
58
60
42
59
62
49
63
41A
67
43
57
51
38
37
53
36
35
45 60
22
29
32
5
Figure 2
No. 37 Direct Actuator
(Increasing air extends stem)
Figure 3
No. 38 Reverse Actuator
(Increasing air retracts stem)
Figure 4
Split Stem Clamp
21
27
61
62
59
58
39
44
40
42
47
52
55
56
54
64
41
46
66
65
8

made. An additional 6 to 12 mm adjustment
(step 4) of the stem adapter is unnecessary. With
the reverse actuator, seating force is provided by
air pressure above the maximum value of the
spring range, so marking of the actuator stem is
also unnecessary.
6.4.3 67 and 68 - Piston Cylinder Double
Acting Actuator
Mounting and adjustment of the 67 and 68
actuator is done in the same way as with the No
38 actuator.
Air pressure is applied to the actuator to the
required stroke of the valve and the connections
are made. An additional 6- 12 mm adjustment
of the stem adapter is unnecessary. With the DA
piston cylinder actuator, seating force is
provided by the air supply pressure, so making
of the actuator stem is also unnecessary.
6.5 Standard Packing
Packing box maintenance is one of the principle
choose of routine servicing. Tightness of the
packing is maintained by packing compression.
Compression is achieved by evenly tightening
the packing flange nuts (9) against the packing
flange (7). Care must be taken not to
overtighten as this could prevent smooth
operation of the valve. If all compression is used
up and the valve leaks, new packing is required.
Caution : Valve must be isolated and the
pressure vented before performing
packing box maintenance.
Proceed as follows :
A. Loosen and remove packing flange nuts
(9).
B. Raise packing flange (7) and packing
follower (6) up the valve stem.
Note : They may be taped in place to
keep them out of the way before
proceeding.
C. Remove old packing (10) and lantern ring
(11).
D. Replace three new packing (10), lantern
ring (11) and enough new packing (10) to
fill the packing box.
Note : The skive cut of each packing
ring must be placed about 180
degrees apart.
E. Replace packing follower (6) and
packing flange (7).
F. Replace and tighten packing stud nuts
(9).
Caution : Do not overtighten.
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. It must be replaced with the
correct packing as soon as possible.
6.6 Grinding Plug (3) to Seat Ring (2)
If the valve leakage becomes excessive, a hand
operation called lapping is necessary. In order
to facilitate this operation, the plug and seat
ring seating surfaces should be free of large
scratches or dents. If there is a fair amount of
damage, a remachining of the seating surfaces
up to a depth of 0,4 mm is possible before
lapping.
1. To perform the lapping operation, turn
the body over and loosen the packing
box nuts (9) so that when the plug is
inserted it will rest against the seat ring
by its own weight.
2. Using a good grade of fine grinding
compound, apply to several spots
equally spaced on the seating surface on
the seat ring. After placing the seat ring
into the body, insert the plug carefully
until it is seated.
3. Install the bottom flange. Secure bottom
flange, using good installation practice,
alternating bolt torquing sequence for a
four bolt pattern. The spacing between
flanges around the periphery should be
consistent within ±0,05mm.
4. Remove the pipe plug (25) from the
bottom flange. Insert through this hole a
threaded rod which will be screwed and
jammed into the tapped hole in the
upper portion of the plug. This rod
having a T handle on the opposite end,
9

will be used to lap the plug to the seat.
The T handle may be made by drilling a
hole through a small piece of flat stock
and fastening to the threaded rod by two
locknuts.
5. Lapping is accomplished rotating the
plug in short oscillating strokes. After 8
to 10 strokes, the plug should be lifted
and turned 90° before repeating the
operation. This intermittent lifting is
important to keep the plug and seat ring
concentric during lapping. It is advisable
to mix a small quantity of lubricant such
as graphite with the grinding compound.
This will slow the cutting rate and avoid
tearing the seating surface. The amount
of lapping required depends on the
22
Coupling of Lever (33)
on Actuator
32
29
33
27
29
32
33 22 27
Coupling Device “Type 1”
Figure 5
Coupling Device “Type 2”
Figure 6
Grinding Plug to Seat Ring
Figure 7
Seat
materials of construction, condition of
the 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 or
small ridges on the plug or seat ring. The only
remedy is replacement of one or both parts.
When lapping new plug and ring, begin with
coarse compound and finish with fine. Old
(used) parts should only be lapped with a fine
grade of compound.
Disassemble and clean the seating surfaces of
the plug and seat ring.
10

INS/77000/REV-A/02-2018/ © 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.