Spirax Sarco K Series User manual

IM-S24-15 CH Issue 4 1
K and L Series
Two-port Control Valves
Installation and Maintenance Instructions
1. Safety information
2. General product
information
3. Installation and
commissioning
4. Maintenance
5. Spare parts
Printed in the UK © Copyright 2005
IM-S24-15
CH Issue 4
3010052/4

IM-S24-15 CH Issue 4
2
1.1 Intended use
1. Safety information
Safe operation of these products can only be guaranteed if they are properly
installed, commissioned, used and maintained by qualified personnel (see
Section 1.11) in compliance with the operating instructions. General installation and
safety instructions for pipeline and plant construction, as well as the proper use of
tools and safety equipment must also be complied with.
Safety note - Handling precautions
PTFE
Within its working temperature range PTFE is a completely inert material, but when
heated to its sintering temperature it gives rise to gaseous decomposition products
or fumes which can produce unpleasant effects if inhaled. The inhalation of these
fumes is easily prevented by applying local exhaust ventilation to atmosphere as
near to their source as possible.
Smoking should be prohibited in workshops where PTFE is handled because
tobacco contaminated with PTFE will during burning give rise to polymer fumes. It
is therefore important to avoid contamination of clothing, especially the pockets,
with PTFE and to maintain a reasonable standard or personal cleanliness by washing
hands and removing any PTFE particles lodged under the fingernails.
LAMINATED GASKETS
The metal foil sheet used to reinforce gaskets is very thin and sharp. Care should
be taken when handling to avoid the possibility of cuts or lacerations to fingers
or hands.
Referring to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended use / application.
The products listed on pages 3, 4 and 5 comply with the requirements of the European
Pressure Equipment Directive 97/23/EC, carry the mark when so required and fall
within the Pressure Equipment Directive categories stated.
i) The products have been specifically designed for use on steam, air or condensate
which are in Group 2 of the above mentioned Pressure Equipment Directive. It
can also be used on propane or methane gases which are in Group 1 of the above
mentioned Pressure Equipment Directive. The products’ use on other fluids may
be possible but, if this is contemplated, Spirax Sarco should be contacted to
confirm the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than those
of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers from all connections before installation.

IM-S24-15 CH Issue 4 3
KE valves
Group 1 Group 2 Group 1 Group 2
Product Gases Gases Liquids Liquids
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
KE43 PN40 DN40 - DN50 2 1 SEP SEP
DN65 - DN100 2 1 2 SEP
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
KE43B1 PN40 DN40 - DN50 2 1 SEP SEP
DN65 - DN100 2 1 2 SEP
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
KE43B4 PN40 DN40 - DN50 2 1 SEP SEP
DN65 - DN100 2 1 2 SEP
KE61 PN40 DN15 - DN25 SEP SEP SEP SEP
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
KE63 PN40 DN40 - DN50 2 1 SEP SEP
DN65 - DN100 2 1 2 SEP
DN15 - DN25 SEP SEP SEP SEP
KE71 PN25 DN32 - DN40 1 SEP SEP SEP
DN50 2 1 SEP SEP
DN15 - DN25 SEP SEP SEP SEP
KE71B1 PN25 DN32 - DN40 1 SEP SEP SEP
DN50 2 1 SEP SEP
DN15 - DN25 SEP SEP SEP SEP
KE71B4 PN25 DN32 - DN40 1 SEP SEP SEP
DN50 2 1 SEP SEP
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN40 1 SEP SEP SEP
KE73 PN25 DN50 - DN80 2 1 SEP SEP
DN100 2 1 2 SEP
DN15 - DN25 SEP SEP SEP SEP
DN32 - DN40 1 SEP SEP SEP
KE73B1 PN25 DN50 - DN80 2 1 SEP SEP
DN100 2 1 2 SEP
DN15 - DN25 SEP SEP SEP SEP
KE73B4 PN25 DN32 - DN40 1 SEP SEP SEP
DN50 - DN80 2 1 SEP SEP
DN100 2 1 2 SEP

IM-S24-15 CH Issue 4
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KEA valves
Group 1 Group 2 Group 1 Group 2
Product Gases Gases Liquids Liquids
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
KEA41 ANSI 300 DN40 2 1 SEP SEP
DN50 2 1 2 SEP
DN15 - DN25 SEP SEP SEP SEP
DN40 - DN50 1 SEP SEP SEP
ANSI 150 DN65 - DN100 2 1 SEP SEP
DN150 2 1 2 SEP
DN200 3 2 2 SEP
KEA43 DN15 - DN25 SEP SEP SEP SEP
DN40 2 1 SEP SEP
ANSI 300 DN50 - DN100 2 1 2 SEP
DN150 - DN200 3 2 2 SEP
DN15 - DN25 SEP SEP SEP SEP
DN32 2 SEP SEP SEP
KEA61 ANSI 300 DN40 2 1 SEP SEP
DN50 2 1 2 SEP
DN15 - DN25 SEP SEP SEP SEP
DN40 - DN50 1 SEP SEP SEP
ANSI 150 DN65 - DN100 2 1 SEP SEP
DN150 2 1 2 SEP
DN200 3 2 2 SEP
KEA63 DN15 - DN25 SEP SEP SEP SEP
DN40 2 1 SEP SEP
ANSI 300 DN50 - DN100 2 1 2 SEP
DN150 - DN200 3 2 2 SEP
DN15 - DN25 SEP SEP SEP SEP
KEA71 ANSI 250 DN32 - DN50 2 2 2 SEP
DN15 - DN25 SEP SEP SEP SEP
DN40 - DN65 1 SEP SEP SEP
ANSI 125 DN80 - DN100 2 1 SEP SEP
DN150 - DN200 2 1 2 SEP
KEA73 DN15 - DN25 SEP SEP SEP SEP
DN40 - DN50 2 1 SEP SEP
ANSI 250 DN65 - DN100 2 1 2 SEP
DN150 - DN200 3 2 2 SEP

IM-S24-15 CH Issue 4 5
LE valves
Group 1 Group 2 Group 1 Group 2
Product Gases Gases Liquids Liquids
LE31 PN16 DN15 - DN50 - SEP - SEP
LE31B1 PN16 DN15 - DN50 - SEP - SEP
LE33 PN16 DN15 - DN50 - SEP - SEP
DN65 - DN100 - 1 - SEP
LE33B1 PN16 DN15 - DN50 - SEP - SEP
DN65 - DN100 - 1 - SEP
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
Group 1 Group 2 Group 1 Group 2
Product Gases Gases Liquids Liquids
LEA31 ANSI 125 DN15 - DN50 - SEP - SEP
LEA33 ANSI 125 DN25 - DN65 - SEP - SEP
DN80 - DN100 - 1 - SEP
LEA valves

IM-S24-15 CH Issue 4
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1.8 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns and
consider whether protective clothing (including safety glasses) is required.
PTFE SEALS
If seals made from PTFE have been subjected to a temperature approaching 260°C (500°F)
or higher, they will give off toxic fumes, which if inhaled are likely to cause temporary
discomfort. It is essential for a no smoking rule to be enforced in all areas where PTFE is
stored, handled or processed as persons inhaling the fumes from burning tabacco
contaminated with PTFE particles can develop ‘polymer fume fever’.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables available.
Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and /or others in the vicinity require any protective clothing to
protect against the hazards of, for example, chemicals, high / low temperature, radiation,
noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal ‘permit to work’ system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety. Post ‘warning notices’ if necessary.
1.12 Handling
Manual handling of large and /or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of some products
may reach temperatures of 350°C (662°F).
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation (refer to ‘Maintenance instructions’).
1.14 Freezing
Provision must be made to protect products which are not self-draining against
frost damage in environments where they may be exposed to temperatures below
freezing point.

IM-S24-15 CH Issue 4 7
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this
product is recyclable and no ecological hazard is anticipated with its disposal
providing due care is taken. However, if the valve is fitted with a Viton or PTFE seat,
special care must be taken to avoid potential health hazards associated with
decomposition / burning of these seats.
PTFE:
- Can only be disposed of by approved methods, not incineration.
- Keep PTFE waste in a separate container, do not mix it with other rubbish, and
consign it to a landfill site.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and
Environment Law, when returning products to Spirax Sarco they must provide
information on any hazards and the precautions to be taken due to contamination
residues or mechanical damage which may present a health, safety or
environmental risk. This information must be provided in writing including
Health and Safety data sheets relating to any substances identified as hazardous
or potentially hazardous.

IM-S24-15 CH Issue 4
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2. General product information
The K and L series control valve range consists of; two-port single seat globe valves with
cage-retained seats conforming to either EN 1092 or ANSI/ASTM specification. These valves
are available in three body materials: SG iron, cast steel or stainless steel (with the exception
of the L series, which is available in cast iron only) in sizes DN15 to DN100 (½" to 4").
2.1 Pressure / temperature limits - KE and LE valves
KE43, KE61 and KE63 PN40
Body design KE71 and KE73 PN25
conditions KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 PN16
LE31, LE31B1, LE33 and LE33B1 PN16
KE43 40 bar g @ 120°C
Maximum design KE61 and KE63 40 bar g @ 50°C
pressure KE71 and KE73 25 bar g @ 110°C
KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 16 bar g @ 110°C
LE31, LE31B1, LE33 and LE33B1 16 bar g @ 110°C
KE43, KE61 and KE63 400°C
Maximum design KE71 and KE73 350°C
temperature KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 300°C
LE31, LE31B1, LE33 and LE33B1 300°C
Minimum design KE43B1, KE61B1, KE63B1, KE71B1 and KE73B1 -10°C
temperature KE61 and KE63 -10°C
LE31, LE31B1, LE33 and LE33B1 -10°C
Standard packing PTFE chevron 250°C
PTFE soft seat (G) 200°C
High temperature packing (H) LE Valves 300°C
Maximum operating High temperature packing (H) 400°C
temperature Extended bonnet (E) with PTFE chevron 250°C
Extended bonnet (E) with graphite packing 300°C
Bellows (B1) 300°C
Designed for a KE43 60 bar g
maximum cold KE61 and KE63 60 bar g
hydraulic test KE71 and KE73 38 bar g
pressure of: LE31 and LE33 24 bar g
Warning for valves fitted with bellows - Remove bellows before hydraulic testing is done
Maximum differential pressures: See relevant actuator Technical Information sheet
Key to charts on page 9:
The product must not be used in this region.
High temperature packing is required for use in this region.
High temperature bolting and packing is required for use in this region.
A - A Note: Valves fitted with PN16 bellows (B1) are limited to the maximum bellows rating
of 16 bar.

IM-S24-15 CH Issue 4 9
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Pressure bar g
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Pressure bar g
Temperature °C
Temperature °CTemperature °C Temperature °C
Temperature °C
KE43, KE43B1
and KE43B4
(cast steel)
KE71 and KE71B1,
KE73 and KE73B1
(SG iron)
KE61 and KE63
(stainless steel)
LE31B1 and LE33B1
( cast iron)
LE31 and LE33
(cast iron)
A
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Steam
saturation
curve
Steam
saturation
curve
Steam
saturation
curve
Steam
saturation
curve
Steam
saturation
curve

IM-S24-15 CH Issue 4
10
2.2 Pressure / temperature limits - ANSI KEA and LEA valves
KEA41 and KEA43 ANSI 150 or ANSI 300
Body design KEA61 and KEA63 ANSI 150 or ANSI 300
conditions KEA71 and KEA73 ANSI 125 or ANSI 250
LEA31 and LEA33 ANSI 125
KEA41 and KEA43 740 psi g @ 100°F
Maximum design KEA61 and KEA63 720 psi g @ 100°F
pressure KEA71 and KEA73 450 psi g @ 200°F
LEA31 and LEA33 200 psi g @ 150°F
Maximum design KEA41, KEA43, KEA61 and KEA63 800°F
temperature KEA71 and KEA73 450°F
LEA31 and LEA33 450°F
Minimum design KEA41, KEA43, KEA71 and KEA73 14°F
temperature KEA61 and KEA63 -20°F
LEA31 and LEA33 14°F
Standard packing PTFE chevron 482°F
PTFE soft seat (G) 400°F
Maximum operating KEA41, KEA43,
temperature KEA61 and KEA63 High temperature packing (H) 800°F
KEA71 and KEA73
LEA31 and LEA33 High temperature packing (H) 450°F
KEA41 and KEA43 ANSI 150 450 psi g
ANSI 300 1 125 psi g
Maximum cold ANSI 150 425 psi g
hydraulic test KEA61 and KEA63 ANSI 300 1 100 psi g
pressure: KEA71 and KEA73 ANSI 125 300 psi g
ANSI 250 750 psi g
LEA31 and LEA33 ANSI 125 300 psi g
Warning for valves fitted with bellows - Remove bellows before hydraulic testing is done
Maximum differential pressures: See relevant actuator Technical Information sheet
Key to charts on page 11:
The product must not be used in this region.
Graphite stem sealing is required for use in this region. Note: As standard the KEA,
KFA, KLA series two-port control valves are supplied with the PTFE stem sealing
option.
The product should not be used in this region or beyond its operating range as
damage to the internals may occur.
A - B Flanged ANSI 300 and screwed NPT (KEA41 and KEA61).
A - D Flanged ANSI 150.
A - C Flanged ANSI 250 and screwed NPT (KEA71).
A - E Flanged ANSI 125.

IM-S24-15 CH Issue 4 11
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Temperature °F
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Temperature °FTemperature °F
Steam
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curve
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curve
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saturation
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Temperature °F
Steam
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A
EC
KEA71 and KEA73
(ductile iron)
KEA41 and KEA43
(cast steel)
KEA61 and KEA63
(stainless steel)
LEA31 and LEA33
(ductile iron)

IM-S24-15 CH Issue 4
12
Note: Before actioning any installation, observe the ‘Safety information’ in Section 1.
Referring to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended installation:
3.1 Check materials, pressure and temperature and their maximum values. Do not exceed
the performance rating of the valve. If the maximum operating limit of the product
is lower than that of the system in which it is being fitted, ensure that a safety device
is included in the system to prevent overpressurisation.
3.2 Remove protective covers from all connections.
3.3 Determine the correct installation situation and the direction of fluid flow. The valve
should preferably be installed along a horizontal pipeline with the valve mounted above
the pipe. When mounting an actuator to the valve body, the actuator Installation and
Maintenance Instructions must be followed.
3.4 Bypass arrangements - It is recommended that isolating valves be fitted upstream
and downstream of the control valve, together with a manual bypass control valve.
This enables the process to be controlled manually using the bypass valve while the
pneumatic valve is isolated for maintenance.
3.5 Support pipework should be used to prevent stresses being exerted on the valve
body.
3.6 Ensure adequate space is provided for the removal of the actuator from the valve body
for maintenance purposes:
3.7 Isolate connecting pipework. Ensure it is clean from dirt, scale etc. Any debris entering
the valve may damage the PTFE head seal preventing a tight shut-off.
3.8 Open isolation valves slowly, until normal operating conditions are achieved.
3.9 Check for leaks and correct operation.
3. Installation and commissioning
Isolating
valve
Strainer
Bypass
Control
valve Isolating
valve
Bypass valve
(piped horizontally)
AVV*
* Anti-vacuum valve recommended for steam installations.
Fig. 1

IM-S24-15 CH Issue 4 13
4. Maintenance
4.1 Periodic maintenance
After 24 hours of operation
After 24 hours of operation check the flange bolts for tightness.
On valves with graphite stem seal packing compress the gland seal packing by tightening
the gland nut by ¼ of a turn. Care should be taken not to overtighten as this may cause the
spindle to lock-up.
Every 3 months of operation
Every 3 months of normal operation check the stem gland seal for leakage. In the case of
leakage proceed as follows:
- For valves with a PTFE gland seal renew the gland seal by following the procedure in
Section 4.2.
- For valves with a graphite stem seal packing compress the gland seal packing by tightening
the gland nut by ¼ of a turn. If leakage cannot be eliminated, renew the graphite gland seal
by following the procedure in Section 4.3.
Annually
Inspect the valve to check for wear or scale deposits. Worn or damaged parts, like the plug
or seat may need to be replaced, as well as the gland seal packing.
The graphite packing is normally subject to wear. Therefore it is recommended to renew the
packing rings annually.
Table 1 Recommended tightening torques N m (lbf ft)
Size Seat (4) Bonnet nuts (15) Gland nut
(chevron seals) (9)
DN15 (½") 40 ±5 (30 ±4) 30 ±1.5 (22 ±1) 25 - 30 (19 - 22)
DN20 (¾") 53 ±3 (39 ±2) 30 ±1.5 (22 ±1) 25 - 30 (19 - 22)
DN25 (1") 80 ±5 (59 ±4) 40 ±2 (29 ±1.5) 25 - 30 (19 - 22)
DN32 (1¼") 130 ±5 (96 ±4) 45 ±2 (33 ±1.5) 25 - 30 (19 - 22)
DN40 (1½") 220 ±5 (160 ±4) 45 ±2 (33 ±1.5) 25 - 30 (19 - 22)
DN50 (2") 150 ±5 (110 ±4) 65 ±3 (48 ±2.5) 25 - 30 (19 - 22)
DN65 (2½") 300 ±12 (220 ±9) 65 ±3 (48 ±2.8) 32 - 38 (24 - 28)
DN80 (3") 400 ±16 (295 ±12) 60 ±3 (44 ±2) 32 - 38 (24 - 28)
DN100 (4") 600 ±24 (442 ±18) 60 ±3 (44 ±2) 32 - 38 (24 - 28)
DN150 (6") 678 (500) 488 (360) 81 (60)
DN200 (8") 678 (500) 488 (360) 81 (60)
KEA61 and KEA63 Warning
The 316 type stainless steel used in the construction of this product particularly for
screwed or close fitting parts, is very susceptible to galling or cold welding. This is an
inherent characterisitic of this type of material and great care should therefore be taken
when dismantling or reassembling.
If the application permits, it is recommended that a lighter smear of a PTFE based grease
is applied to any mating parts before reassembly.

IM-S24-15 CH Issue 4
14
4.2 Procedure for renewing PTFE chevron gland seals
- Isolate the valve on both sides.
- Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions
covering Spirax Sarco actuators.
Caution: Care should be taken in removing the bonnet since fluid under pressure may be
trapped between the isolating valves.
- Remove the lock-nut (7).
- Unscrew the bonnet nuts securing the bonnet to the body and remove the bonnet (2)
complete with the plug / stem assembly.
- Unscrew the gland nut (8), withdraw the plug / stem assembly, remove and discard the gland
seal set (10 + 11 + 15) and gland nut gasket (6).
- Examine the parts for signs of damage or deterioration and renew as necessary. Note that
score marks or scaly deposits on the valve stem (5) will lead to early failure of the seals.
- Clean the parts taking care to avoid scratching the stem or bore of the gland nut. Refit the
plug assembly into the valve body.
- Using a new bonnet gasket refit the bonnet (2) onto the valve body, leaving the stem
protruding. Replace the bonnet nuts and tighten to the recommended torque (see Table 1,
page 13), ensuring that the valve plug is centrally located in the seat whilst tightening.
- To replace the new gland seal assembly (10, 11, 15), firstly fit the gland spring (11) over
the valve stem (5). New chevron gland seals should be firmly inserted into the gland
nut (8), as shown in Figure 2. Being careful to avoid damage to the sealing edges, replace
the gland nut gasket (6). Refit the gland nut (8) over the valve stem (5), screwing down to
ensure the gasket is bedded down onto the bonnet (2).
- Ensure that the stem (5) moves freely.
- Refit the valve lock-nut (7).
- Refit the actuator, clamping nut (9) and connect the actuator to the valve stem.
- Bring the valve back into service.
- Check for any leakage at the gland.
Spring (11)
Gasket (6)
Gland nut (8)
'O' ring
Do not assemble dry as this
will damage the 'O' rings.
Upper
bearing
(10) Chevrons
(15) Lower
bearing
Seal
assembly
Fig. 2
Clamp nut (9)
Stem (5)
(2) Bonnet
(7) Lock-nut

IM-S24-15 CH Issue 4 15
4.3 Procedure for renewing graphite gland seals
- Isolate the valve on both sides.
- Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions
covering Spirax Sarco actuators.
Caution: Care should be taken in removing the bonnet since fluid under pressure may be
trapped between the isolating valves.
- Remove the lock-nut (7).
- Unscrew the bonnet nuts securing the bonnet to the body and remove the bonnet (2)
complete with the plug /stem assembly.
- Unscrew the gland nut (8). Withdraw the plug / stem assembly, remove and discard the
gland seal set (10 + 15), and gasket from the bonnet.
- Examine the parts for signs of damage or deterioration. Note that score marks or scaly
deposits on the valve stem (5) will lead to early failure of the seals.
- Clean the parts taking care to avoid scratching the stem or bore of the gland nut.
- The replacement graphite gland seal should now be fitted. Note that the gland seal set
contains a top and bottom support ring and a graphite pack. The order of the graphite pack
should be maintained as supplied during the fitting procedure. Place the bottom support
ring into the bonnet. One by one add the graphite rings and each time use the gland nut (8)
to drive the ring down into the bonnet. Ensuring the junction of the ring ends are rotated by
90°. Leave the gland nut loosely assembled so that the seals are not compressed.
7
5
8
10
15
2
Ring 1 Ring 2 Ring 3 Ring 4 Ring 5
Fig. 3

IM-S24-15 CH Issue 4
16
- Refit the valve plug /stem assembly by carefully sliding the valve stem in order to pass
through the seals.
- Using a new bonnet gasket refit the bonnet (2) onto the valve body, ensuring the plug is
on the valve seat, and replace the nuts and tighten to the recommended torque (see Table 1,
page 13), ensuring that the valve plug is centrally located in the seat whilst tightening.
- Screw down the gland nut until it just starts to compress the packing. Compress the gland
seal packing by tightening the gland nut (8) by 1½ turns. Raise and lower the valve stem
after each tightening of the gland nut to encourage the seals to bed down correctly.
- Ensure that the valve spindle is able to travel fully open and fully closed a minimum of
5 times to ensure a smooth operation.
- Tighten the gland nut (8) by approximately ½ turn to ensure seats are under load and
re-stroke the valve.
- Commission the actuator according to the appropriate Installation and Maintenance
Instructions.
- Bring the valve back into service.
- Should there be a small amount of seepage from the valve stem, this may be stopped by
carefully tightening the gland nut. Care should be taken not to overtighten as this may cause
the spindle to lock-up.
Fig. 4
7
5
8
10
15
2

IM-S24-15 CH Issue 4 17
4.4 Procedure for renewing the valve plug and seat
- Isolate the valve on both sides.
- Remove the actuator from the valve. Refer to the Installation and Maintenance Instructions
covering Spirax Sarco actuators.
Caution: Care should be taken in removing the bonnet since fluid under pressure may be
trapped between the isolating valves.
- Remove the lock-nut (7).
- Unscrew the four bonnet nuts (13) securing the bonnet to the body and remove the
bonnet (2) complete with the stem and plug (3 + 5).
- Unscrew the gland nut (8), withdraw the stem and plug (3 + 5) and remove and discard the
gland seal set (10 + 11 + 15) along with the gasket (6), taking care not to damage the bore
of the gland nut (8). Clean the bonnet and then replace new stem and plug.
- Unscrew and remove the valve seat (4). Remove the seat gasket (16) and replace with a
new seat gasket.
- Lightly smear the threads of the new seat (4) with silicon grease and screw it into the body.
Tighten to the recommended torque (see Table 1, page 13) ensuring the valve plug is on its
seat.
- Using a new bonnet gasket (12) refit the bonnet (2) onto the valve body. Replace the four
bonnet nuts (13) and tighten to the recommended torque (see Table 1, page 13).
- Fit new gland seal and gasket as described in Section 4.2. If graphite seals are used refer
to Section 4.3. Ensure the valve stem (5) moves freely after assembly.
- Bring the valve back into service.
- Check for any leakage at the gland.
9
7
8
4
3
16
13
15
6
11
2
5
10
12
Fig. 5 LE33 DN15 to DN65 shown

IM-S24-15 CH Issue 4
18
4.5 Replacing a PTFE soft seal (DN150 and DN200 valves)
When replacing a soft seal plug / assembly, proceed as follows:
- Taking care not to damage the stem, post or head remove the 6 bolts which attach the
retaining cover (A) to the valve head (B) and remove the old PTFE seal.
- Clean all mating surfaces and fit the new PTFE seal (C). Refit the retaining cover (A), by
assembling the 6 bolts (D) and tightening to a torque of 40 N m (30 lbf ft). The threaded
holes in the valve head have locking wire thread inserts which provide a locking function
for the bolts.
- Reassemble the plug / stem assembly, then reassemble the valve using a new bonnet
gasket.
- Bring the valve back into service.
- Check for any leakage at the gland.
D
A
C
B
Fig. 5

IM-S24-15 CH Issue 4 19
4.6 Procedure for renewing stem seals on bellows sealed valves
Note: These valves are fitted with a bellows stem seal as the primary seal together with a
supplementary graphite stem seal. Any leakage from the stem will indicate a failure of the
bellows seal. In normal service the supplementary graphite seal should be left finger tight
and only tightened to provide a temporary stem seal if the bellows stem seal is leaking.
- Isolate the valve on both sides.
- Remove the actuator from the valve. Note: take care not to rotate the valve stem when
removing the actuator from the valve, since this will destroy the bellows. Refer to the
Installation and Maintenance Instructions covering Spirax Sarco actuators.
Caution: Care should be taken in removing the stem seal if the bellows has failed, since
fluid under pressure may be trapped between the isolating valves.
- Remove the lock-nut (7).
- Unscrew the gland nut (8), remove the gland nut gasket (6), remove and discard the stem
seal set (10 + 15).
- Examine the parts for signs of damage or deterioration and renew as necessary. Note the
stem seal set on this valve is intended for emergency use in the event of bellows failure.
Score marks of scaly deposits on the valve stem (5) will impair sealing efficiency.
- Clean the parts taking care to avoid scratching the stem or bore of the bellows assembly
top end.
- New graphite stem seal set (10 + 15), should be fitted into the bellows assembly top end,
care being taken to avoid damage (see Section 4.3).
- Refit the gland nut gasket (6) and finger tighten the gland nut (8) over the valve stem.
- Ensure the valve stem (5) moves freely.
- Refit the lock-nut (7).
7
8
5
10 and 15
6
Fig. 6

IM-S24-15 CH Issue 4
20
Valve size Seat (4) Bellows housing Bellows lock-nut
KE LE nuts (13) (8)
DN15 ½" 205 (150) 40 (55) 16 (25) 25 (35)
DN20 ¾" 205 (150) 53 (72) 20 (30) 25 (35)
DN25 1" 180 (245) 90 (122) 25 (35) 25 (35)
DN32 1¼" 180 (245) 130 (176) 40 (55) 25 (35)
DN40 1½" 180 (245) 220 (300) 40 (55) 25 (35)
DN50 2" 180 (245) 180 (244) 60 (80) 25 (35)
DN65 2½" 220 (300) 300 (405) 47 (65) 40 (55)
DN80 3" 220 (300) 400 (545) 55 (75) 40 (55)
DN100 4" 220 (300) 600 (815) 45 (60) 40 (55)
DN150 6" 500 (678) - - -
DN200 8" 500 (678) - - -
Table 2 Recommended tightening torques N m (lbf ft)
4.7 Procedure for renewing the valve plug, seat and bellows
assembly (Figure 7)
Note: Due to the delicate nature of the bellows assembly, it is highly recommended that for
renewal of the stem / bellows assembly, valve plug and /or seats, the complete valve is returned
to Spirax Sarco service department.
- Isolate and remove the valve from the pipeline.
Caution: Care should be taken in removing the valve since fluid under pressure may be
trapped between the isolating valves.
- Remove the actuator from the valve.
Note: take care not to rotate the valve stem when removing the actuator from the valve,
since this will destroy the bellows. Refer to the Installation and Maintenance Instructions
covering Spirax Sarco actuators.
- Remove the lock-nut (7).
- Unscrew the nuts (13) securing the bonnet.
- Withdraw the bonnet (2) together with the plug stem / bellows assembly (5). Remove the
gland nut (8), gland nut gasket (6) and the stem seal set (10 + 15) see Figure 7. Unscrew
the plug / stem / bellows assembly lock-nut (25) and anti-rotation screw (22) withdraw the
assembly from the bonnet.
- Unscrew and remove the valve seat (4).
Note: To remove and replace seat (4) a special tool is required which can be obtained
from Spirax Sarco by quoting the valve size and type.
- Replace seat gasket (16) and insert the new seat (4) into the body. Tighten to the
recommended torque (see Table 2, below).
- Insert the new stem / bellows assembly into the bore of the new plug and secure with the
cross pin (24). The pin should be centralised within the plug and should be retained by
deforming the metal around the pin hole by peening. Care should be taken to ensure that no
metal is raised on the surface of the plug diameter - any raised metal should be removed.
- Insert the replacement plug / stem / bellows assembly (5) with new bellows flange
gasket (21) and bonnet gasket (12) into the bonnet (2) taking care not to damage the bellows.
Replace the bellows assembly anti-rotation washer (20) and lock-nut (25) and tighten to
the recommended torque (see Table 2, below).