metso automation IMO-R8 Operating and maintenance manual

1GENERAL
This instruction manual contains important information
regarding the installation, operation and troubleshooting
of the Jamesbury 2” (DN 50) 5RRU AND 5RRR Tank Car
Fire-Tite Top-Loading and Unloading Valves. Please read
these instructions carefully and save them for future reference.
2INSTALLATION
Flow through this Jamesbury valve can be in either direction.
In the case of a tongue and groove connection, however,
the tongue is installed against the tank car. Follow the
recommended practices of the gasket manufacturer when
tightening flange bolts.
IMO - R8 Issue Date: 5/03
INSTALLATION, MAINTENANCE, AND
OPERATING INSTRUCTIONS
2” (DN 50) 5RRU AND 5RRR
TANK-CAR FIRE-TITE®
TOP-LOADING AND
UNLOADING VALVES
Read entire instructions carefully before installation or servicing
1.1 WARNING
FOR YOUR SAFETY, IT IS IMPORTANT THAT THE FOLLOWING PRECAU-
TIONS BE TAKEN PRIOR TO REMOVAL OF THE VALVE FROM THE TANK
CAR OR BEFORE ANY DISASSEMBLY.
1. EXERCISE NORMAL SAFETY PRECAUTIONS TO PROTECT YOURSELF
AGAINST BOTH THE FLUID AND POSSIBLE UNRELIEVED PRESSURES
IN THE VALVE ITSELF.
2. CYCLE THE VALVE FROM FULLY CLOSED TO FULLY OPEN AND
BACK AGAIN TWO TIMES TO RELIEVE ANY RESIDUAL PRESSURE.
3. AFTER REMOVAL AND BEFORE DISSSEMBLY, CYCLE THE VALVE
AGAIN SEVERAL TIMES (AS IN NO. 2).
If there is weepage past the stem seals upon installation, it
means the valve may have been subject to wide temperature
variations in shipment. Leaktight performance will be
restored by a simple packing adjustment described in the
MAINTENANCE Section.
3MAINTENANCE
Routine maintenance consists of tightening the lower
stem nut (16) to the torque shown in (Table 1) (stem nut
torque) periodically to compensate for the wear caused by
the stem turning against the stem seals. More frequent
observation is recommended under extreme operating
conditions.The upper stem nut (16) should be retightened.
Overhaul maintenance consists of replacing seats and
seals. A standard service kit consisting of these parts may
be obtained from your Metso Automation distributor (see
Table 2).
TABLE 1
2” (DN 50) 5RRU & 5RRR
Insert Torque 170 – 200 FT•LBS (231 – 271 N•m)
Stem Nut Torque 160 – 170 IN•LBS (18 – 19 N•m)
TABLE 2
Service Kits for 2” (DN 50) 5RRU & 5RRR Valves
Seat Material Kit No.
Filled PTFE RKR-48MT
PTFE RKR-48TT

9. Carefully remove the bottom seat (5) out of the body
taking caution that the body seat face is not scratched
while doing so.
3.2 Assembly
Apply a good lubricant compatible with the flow medium
lightly to seats, seals, ball, and stem to facilitate assembly
and for ease of initial operation.
1. Slide one valve seat (5) sidewise into the body cavity
(1) to just below the stem hole and tilt it into place so
that the proper face will come in contact with the ball
(3) (see Figure 3). Do not scratch or cut the seat face.
2. From inside of the body cavity, insert one stem bearing
(24), then one stem seal (7), then the second stem
bearing (24) up into the lower stem counterbore.
3. From the outside of the body, insert the two upper
stem seals (8) into the upper stem counterbore.
4. Insert the stem (4) into the body cavity (threaded end
first) and press it gently up into the stem bore until
resistance is felt from the lower stem bearing. Be careful
not to scratch the seals.
5. Holding the stem in place from inside the body, drop
the compression ring (21) over the threaded end of
the stem protruding out of the body stem bore. Follow
the same procedure with the slotted stem washer (50)
and then screw on one stem nut (16).
6. Tighten down the nut until stem is snugly into place.
Rotate the stem gently to assure proper seating.
Tighten the nut until the stem seals are fully seated,
then tighten the nut to the torque specified in (Table 1)
(Stem Nut Torque).
7. Using a spanner wrench, screw the insert (2) into the
body until it is fully seated. Mark the position as shown
in (Figure 4). Counting the number of turns, remove
the insert.
8. Insert the ball (3) rotating it onto the stem (4) in the
closed position. If necessary, turn the stem blade to
align with the ball slot.
2
3.1 Disassembly
1. Read the instructions in the WARNING Section.
2. Place the valve in the open position.
3. Remove the stem nut (16), lock washer (19), handle
(17), the second stem nut (16), stem washer (50), and
compression ring (21).
4. Place the valve in a vertical position with the insert
end up.
5. Unscrew and remove the insert (2) and body seal (6).
6. Place the ball into the closed position and remove the
top seat (5) and the ball (3).If these parts do not lift out
easily, take a piece of wood or some other soft material
object and gently tap the ball from the end opposite
the insert.This will unseat these parts without damaging
them.
7. Press the stem (4) into the valve body cavity. It may be
necessary to tap it with a piece of wood or some other
soft material.
8. Remove the stem, then pry out and discard the old
stem seals (8), the stem bearings (24), and secondary
stem seal (7).
Figure 3
Figure 1
Figure 2
2" (DN 50) 5RRU
2" (DN 50) 5RRR

Figure 4
Mark
Body
Insert
12. Place the handle (17), a lock washer (19), and nut (16)
on the valve stem and tighten securely. Cycle the valve
slowly with a gentle back and forth motion to build
gradually to the full quarter turn. A fast turning motion
at this point may cut the seats before they have a
chance to form the proper seal.
4REPAIR KITS/SPARE PARTS
For further information on spare parts and service or
assistance visit our web-site at www.jamesbury.com.
3
Figure 5
1/2” ± 1/8” (12.7 ± 3.175 mm)
9. Insert the second seat (5) so that the sealing surface of
the seat is towards the ball (See Figure 3).
10. Insert the body seal (6) and gently press it into the
groove in the body.
11. Using a thread lubricant compatible with the media,
screw the insert (2) into the body and tighten with the
required torque shown in (Table 1). If a torque wrench
is not available, tighten the insert the same number of
turns as in Step 5 until the marks match the dimension
(shown in Figure 5).
Mark
Body
Insert

4
16
Figure 6
PARTS LIST
ITEM PART NAME QTY
1Body 1
2 Insert 1
3 Ball 1
4Stem 1
5Seat 2
6 Body Seal 1
7 Secondary Stem Seal 1
8 Upper Stem Seal 2
16 Stem Nut 2
17 Handle 1
19 Lockwasher 1
21 Compression Ring 1
22 Identification Tag 1
23 Drive Screw 3
24 Stem Bearing 2
25 Stop Screw 2
50 Stem Washer 1
21
8
50
16
17
19
5
4
24
7
25
1
22
23
2
6
5
3
24
Metso Automation, Field Systems Division
Europe, Levytie 6, P.O.Box 310, 00811 Helsinki, Finland. Tel. int. [phone]. Fax int. [phone]
Europe (UK), 2 Lindenwood, Crockford Lane, Chineham Business Park, Basingstoke, RG24 8QY UK.Tel. int. [phone]. Fax int. [phone]
North America, 44 Bowditch Drive, P.O.Box 8044, Shrewsbury, Massachusetts, 01545-8044 USA. Tel. int. [phone]. Fax int. [phone]
Latin America, Av. Central, 181- Cháracas Reunidas, 12238-430, São Jose dos Campos. SP BRAZIL. Tel. int. [phone]. Fax int. [phone]
Asia Pacific, 501 Orchard Road, #05-09 Wheelock Place, 238880 Singapore. Tel. int. [phone]. Fax int. [phone]
www.jamesbury.com
IMO-R8-5/03 © 2003 Metso Automation Printed in U.S.A.-M-J