Metso Jamesbury 5000 series Operating and maintenance manual

IMO-059 EN • 3/2018
3” & 4” (DN 80 & 100)
SERIES 5000
FLANGED BALL VALVES
Installation, Maintenance and
Operating Instructions

TABLE OF CONTENTS
1. GENERAL................................................................... 3
1.1 Warning............................................................................. 3
2. INSTALLATION.......................................................... 3
3. MAINTENANCE......................................................... 3
3.1 Disassembly..................................................................... 3
3.2 Assembly .......................................................................... 4
4. ACTUATOR MOUNTING............................................ 5
5. REPAIR KITS/SPARE PARTS ...................................... 5
IMO 3/18
2 IMO-059 EN
READ THESE INSTRUCTIONS FIRST!
These instructions provide information about safe handling and operation of the valve.
If you require additional assistance, please contact the manufacturer or manufacturer’s representative.
Addresses and phone numbers are printed on the back cover.
See also www.metso.com/valves for the latest documentation.
SAVE THESE INSTRUCTIONS!

1. GENERAL
This instruction manual contains important information
regarding the installation, operation and trouble shooting
of the Jamesbury® 3” & 4”(DN 80 & 100) Series 5000 Flanged
Ball Valves. Please read these instructions carefully and save
them for further reference.
1.1 WARNING
FOR YOUR SAFETY AND PROTECTION, IT IS IMPORTANT THAT THE
FOLLOWING PRECAUTIONS BE TAKEN PRIOR TO REMOVING THE
VALVE FROM SERVICE OR BEFORE ANY DISASSEMBLY OF THE VALVE.
1. AT ALL TIMES DURING THIS ENTIRE PROCEDURE, KEEP HANDS
OUT OF THE VALVE,A REMOTELY ACTUATED VALVE COULD
CLOSE AT ANY TIME AND RESULT IN SERIOUS INJURY.
2. KNOW WHAT MEDIA IS IN THE LINE. IF THERE IS ANY DOUBT,
CHECK WITH THE PROPER AUTHORITY.
3. WEAR ANY PROTECTIVE CLOTHING OR EQUIPMENT NORMALLY
REQUIRED WHEN WORKING WITH THE MEDIA INVOLVED.
4. DEPRESSURIZE THE LINE AND VALVE AS FOLLOWS:
A. OPEN THE VALVE AND DRAIN THE LINE.
B. CLOSE AND OPEN THE VALVE TO RELIEVE ANY RESIDUAL
PRESSURE THAT MAY BE IN THE VALVE PRIOR TO REMOVING
THE VALVE FROM SERVICE. LEAVE THE VALVE IN THE OPEN
POSITION.
C. AFTER REMOVAL AND PRIOR TO ANY DISASSEMBLY, DRAIN
ANY REMAINING MEDIA BY PLACING THE VALVE IN THE
VERTICAL POSITION AND CAREFULLY OPEN AND CLOSE
THE VALVE SEVERAL TIMES.
5. SEAT AND BODY RATINGS  THE PRACTICAL AND SAFE USE OF
THIS PRODUCT IS DETERMINED BY BOTH THE SEAT AND BODY
RATINGS. READ THE NAME TAG AND CHECK BOTH RATINGS.
THIS PRODUCT IS AVAILABLE WITH A VARIETY OF SEAT
MATERIALS. SOME OF THE SEAT MATERIALS HAVE PRESSURE
RATINGS THAT ARE LESS THAN THE BODY RATINGS. ALL OF
THE BODY AND SEAT RATINGS ARE DEPENDENT ON VALVE
TYPE AND SIZE, SEAT MATERIAL, BOLTING MATERIAL, AND
TEMPERATURE. DO NOT EXCEED THESE RATINGS.
2. INSTALLATION
1. Place the valve in the open position.
2. Flow through a Jamesbury valve can be in either
direction. However, it is recommended that the valve
be installed with the insert facing upstream. For dead
ended service 3” and 4” (DN 80 & 100) Series 5000
valves must be installed with the insert upstream.
3. Flow through this Jamesbury valve can be in either
direction. It is recommended, however, that the valve
be installed with the insert facing upstream.
IMPORTANT: The valve should be tightened between anges
using appropriate gaskets and fasteners for the service, in
compliance with applicable piping codes and standards.
4. If there is seepage past the packing upon installation,
the valve may have been subjected to wide
temperature variations in shipment. “Leak-tight”
performance will be restored by a packing adjustment
described in the MAINTENANCE Section.
3. MAINTENANCE
Although Metso’s Jamesbury valves are designed to work
under severe conditions, proper preventative maintenance
can signicantly help to prevent unplanned downtime and
in real terms reduce the total cost of ownership. Metso
recommends inspecting valves at least every ve (5) years.
The inspection and maintenance frequency depends on
the actual application and process condition.
1. Routine maintenance consists of tightening the
packing nut (15) periodically to compensate for stem
seal wear. This may be done as follows:
A. Manual Valves - Loosen the handle screw (18) and
tighten the packing nut (15) until snug, then tighten
an additional 1/4 turn. retighten the handle screw.
B. Actuated Valves - When the valve is connected to an
actuator by a no-play (clamped) type coupling, loosen
the coupling before tightening the packing nut.
2. Overhaul Maintenance consists of replacing seats
and seals. A standard repair kit consisting of these
parts may be obtained through your Metso Distributor
(See Table 1). Refer to the Disassembly and Assembly
sections below for details on installing the repair kits.
TABLE 1
Repair Kits
Valve Size 3” (DN 80)
5150, 530S, 5300
4” (DN 100)
5150
4” (DN 100)
530S, 5300
PTFE Seats RKN75TT RKN76TT RKN77TT
Filled PTFE Seats RKN75MT RKN76MT RKN77MT
PEEK® Seats RKN75LT RKN76LT RKN77LT
UHMW Seats RKN75UU RKN76UU RKN77UU
PFA Seats RKN75BT RKN76BT RKN77BT
PFA Seats &
Seals RKN75BP RKN76BP RKN77BP
Repair Kits contain one pair of seats, a body seal, upper stem seals, a lower stem
seal and maintenance instructions.
NOTE: Repair kits contain two #8 seals and one #24 seal set. Depending on valve
model, one #8 or one #24 will not be used. See note under parts list on page 4
3.1 Disassembly
Tools needed to disassemble Jamesbury valves, such as
the “breechlock eld wrench” mentioned in Step 5, may be
ordered as service parts from your local Metso Distributor.
NOTE: Replacement of seats and seals is recommended if
any disassembly becomes necessary.
1. Read the WARNING Section before performing any
work on the valve.
2. Open the valve.
3. Remove the cap screw (18) holding the handle to the stem.
4. Remove the handle (17).
5. The “breechlock” design requires that the insert be
compressed and rotated approximately 60 degrees
before removal. Use one of the following methods:
IMO 3/18
IMO-059 EN 3

A. Using the breechlock eld wrench - assemble the
eld wrench as follows. (Refer to Figure 1).
1. Thread a hex nut (6A) onto the rod (3) as shown
in (Figure 1). the second plate (2) over the rod
engaging the dowel pins with the wrenching
grooves.
2. Slide the lockwasher (7) and base (4) down the
rod and securely fasten with another hex nut (6B).
3. Slide a gasket over the rod and push the rod
through the open ball from the end opposite
the breechlock insert.
4. Place the other gasket on the insert and slide
the second plate (2) over the rod engaging the
dowel pins with the wrenching grooves.
5. Fit the handle (1) over the dowel pins of the plate.
6. Fit the washer (5) over the rod and tighten the
entire assembly with the remaining hex nut (6C).
7. Tighten the nut (6C) to preload the insert
enough to ease rotation. The face of the insert
should be ush with the mating sur- face of the
ange. Proceed to Step 6.
B. If a breechlock eld wrench is not available, follow
these steps:
1. Create a bar tool that ts into the two wrench
grooves in the insert and protrudes above the
insert raised face.
2. Place the bar tool into the insert wrench
grooves.
3. Place the valve in the arbor press and posi-
tion the ram over a at washer on the bar tool
approximately at the center of the insert.
4. Load the insert with the press until the raised
face is ush with the body face. Proceed to
Step 6.
5. Rotate the insert with a counterclockwise turning
motion until th notch on the insert is aligned with the
OPEN mark on the valve ange.
NOTE: Failure to properly align the notch before insert
removal may result in damage to the breechlock tabs.
6. Remove the tool and pull out the insert. If the insert
does not come out easily, close the ball, and with a
piece of wood or some other soft material gently tap
the ball from the end opposite the insert. This should
unseat the insert.
7. Place the valve in the vertical position with insert end up.
8. Lift out the body seal (6), seat (5), and ball (3). Rotate the
stem so that the ball is in the closed position for removal.
9. Remove the second seat (5).
10. Remove the stem nut (15), lockwasher (33), and
indicator stop (12). Retain. Discard spring washers if
valve is so equipped.
11. Remove the compression ring (21).
12. Press the stem (4) from the top into the valve body and
remove it.
13. Using a pointed instrument, pry out from the inside and
discard the old bottom stem seal (8) and the secondary
stem seal (7). BEING CAREFUL NOT TO SCRATCH ANY
SEALING SURFACES IN THE BODY. NOTE: Secondary
stem seal (7) is not used in non-re tested valves.
14. Remove the top stem seal (8) or (24).
3.2 Assembly
A lubricant compatible with the ow media should be
applied seats, seals, ball and stem to facilitate assembly
and ease of initial operation. It is advisable to replace seats
and seals if any disassembly and reassembly becomes
necessary. Refer to the Repair Kit chart (See Table 1).
1. Standing the body (1) carefully on end,drop in one seat
(5) with the at surface on the bottom (see Figure 2).
2. From the inside insert the secondary stem seal (7), and
then the lower stem seal (8) into the stem bore.
NOTE: Item (7), the secondary stem seal, is omitted on the
non-re tested valves.
3. Insert the stem (4) through the insert end of the body
(1), being careful not to scratch the seals. Press it gently
up into the stem bore until resistance is felt from the
lower seal. Holding the stem in place from the bottom,
insert the upper stem seal (8) or (24), drop on the
compression ring (21) as shown in the diagram, and the
indicator stop (12) (making sure that the side marked
“BOTTOM” is down). Add lockwasher (33), and screw
on the stem nut (15) with the side marked “TOP” in the
up position.
NOTE: Refer to the footnotes under the parts list.
4. Tighten down the nut until the stem seal is fully seated,
then tighten the nut an additional 1/8 to 1/4 turn.
5. 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. Make certain that the stem
blade is in the middle of the ball slot, i.e., equal distance
from ends of slot. Rotate the ball if necessary.
6. Place the second seat (5) into the insert (2) with the
proper surface adjacent to the ball. Insert the body seal
(6) into the body (1). Turn the ball to the open position.
7. Apply a liberal amount of lubricant on the body seal,
locking grooves and tabs of the body and insert (2).
8. Place the insert subassembly into the body, and align the
notch on the insert with the OPEN mark on the valve body
so that the breechlock tabs engage without interference.
IMO 3/18
4 IMO-059 EN

This alignment should be checked with the proper OPEN
position permanently marked on the ange before
further assembly takes place.Use caution to insure that
the body seal is not dislodged from its shoulder.
9. Follow the instructions as described in Step 5 in
DISASSEMBLY Section, and then proceed to Step 10
below.
10. Rotate the insert with a clockwise turning motion
until the notch on the insert is aligned with the
LOCK mark on the valve ange. If rotation is dicult,
further compression of the insert will improve the
engagement between the insert and body.
11. Place the handle on the valve stem and tighten the
cap screw securely. Cycle the valve slowly with a gentle
back and forth motion to build gradually to the full
quarter turn. By cycling slowly, the seat lips will assume
a permanent seal shape against the ball. A fast turning
motion at this point may cut the seats before they have
a chance to form the proper seal.
4. ACTUATOR MOUNTING
IMPORTANT: When these valves are equipped with an
actuator and the actuator is removed to service the valve,
PROPER ALIGNMENT OF THE ACTUATOR DRIVER AND
VALVE STEM IS ESSENTIAL WHEN THE ACTUATOR
IS REMOUNTED. In the case of valves and actuators
connected with a split no-play (clamped) coupling, tighten
the coupling bolts before nal tightening of the valve
bracket bolts.
5. REPAIR KITS/SPARE PARTS
We recommend that valves be directed to our service
centers for maintenance. The service centers are equipped
to provide rapid turn-around at a reasonable cost and oer
new valve warranty with all reconditioned valves.
NOTE: When sending goods to the service center for
repair, do not disassemble them. Clean the valve carefully
and ush the valve internals. Include the material safety
datasheet(s) (MSDS) for all media owing through the
valve. Valves sent to the service center without MSDS
datasheet(s) will not be accepted.
For further information on spare parts and service or
assistance visit our web-site at www.metso.com/valves.
NOTE: When ordering spare parts, always include the
following information:
a. Valve catalog code from identication plate,
b. If the valve is serialized – the serial number (from
identication plate)
c. From Figure 2, the ballooned part number, part
name and quantity required.
3
7
Gasket
Gasket
Valve
6A
6B
6C
5
1
2
Figure 1
BREECHLOCK FIELD WRENCH
IMO 3/18
IMO-059 EN 5

PARTS LIST
ITEM PART NAME QTY
1 Body 1
2 Insert 1
3 Ball 1
4Stem 1
5Seat 2
6 Body Seal 1
7 Secondary Stem Seal 1
8 Stem Seal 2*
12 Indicator Stop 1
14 Socket Head Cap Screw 1
15 Stem Nut 1
17 Handle 1
18 Cap Screw 1
21 Compression Ring 1
22 Identication Tag 1
23 Drive Screw 3
24 Upper Stem Seal Set*
33** Lockwasher 1
* Valves with the designation MODEL B on
the identication tag use one #8 and one
set of #24 for stem sealing. Original MODEL
A valves use two of #8 for stem sealing.
Repair Kits shown on page 2 contain
sucient seals for both congurations.
** Item (33) used when stem nut (15) is stainless
or Monel®.
Figure 2
18
17
15
33
12
21
14
8
22
7
8
3
5
1
24
4
23
5
6
2
or
Stem must be centered in ball slot
as shown at assembly
Seats must be in
this position at assembly
Outside of valve
Orientation of chevron seals (24)
IMO 3/18
6 IMO-059 EN

IMO 3/18
IMO-059 EN 7

Subject to change without prior notice.
Metso Flow Control Inc.
Europe, Vanha Porvoontie 229, P. O. Box 304, FI-01301 Vantaa, Finland. Tel. [phone]. Fax [phone]
North America, 44 Bowditch Drive, P. O. Box 8044, Shrewsbury, M A 01545, USA. Tel. [phone]. Fax [phone]
South America, Av. Independéncia, 2500-Iporanga, 18087-101, Sorocaba-São Paulo, Brazil. Tel. [phone]. Fax [phone]
Asia Pacic, 238B Thomson Road, #17-01 Novena Square Tower B, Singapore 307685. Tel. [phone]. Fax [phone]
China, 11/F, China Youth Plaza, No.19 North Rd of East 3rd Ring Rd, Chaoyang District, Beijing 100020, China. Tel. [phone]. Fax [phone]
Middle East, Roundabout 8, Unit AB-07, P. O. Box 17175, Jebel Ali Freezone, Dubai, United Arab Emirates. Tel. [phone]. Fax [phone]
www.metso.com/valves
8 IMO-059 EN