Swagelok VB03 Series User manual

Seal retainer
Stem seal Fire seal Gland bushing
Carefully read entire instruction before servicing valve.
Kit Contents (contents may vary by kit)
VB03 Series Process Interface Valve
Maintenance Instructions
Wave spring
(25 mm and 38 mm)
Disc spring (2)
Slip ring
Gland bolt (2) Stem Seat (2) Body seal Ball
Hex head screw
Washer Spring (50 mm) (2) Handle sleeve Handle
(type may vary)
Symbols
Discard

2
Bore Kit Number
25 mm
K‐VB25/38‐STMSL‐TOOL‐KIT
K‐VB25/38‐ID‐GUIDE‐TOOL
K‐VB25/38‐OD‐GUIDE‐TOOL
K‐VB25/38‐PUSHER‐TOOL
38 mm
K‐VB25/38‐STMSL‐TOOL‐KIT
K‐VB25/38‐ID‐GUIDE‐TOOL
K‐VB25/38‐OD‐GUIDE‐TOOL
K‐VB25/38‐PUSHER‐TOOL
50 mm
K‐VB50‐STMSL‐TOOL‐KIT
K‐VB50‐ID‐GUIDE‐TOOL
K‐VB50‐OD‐GUIDE‐TOOL
K‐VB50‐PUSHER‐TOOL
Tool Size Component
Vise
—Valve body
Open-ended wrench/socket
Hex head screw, gland bolts, and flange bolts
Bore Size Hex head screw Gland Bolts Flange Bolts
25 mm 13 mm 6 mm hex 14 mm hex
38 mm 13 mm 6 mm hex 14 mm hex
50 mm 17 mm 8 mm hex 17 mm hex
Torque wrench
Capable of 1200 in·lb (135 N·m) Hex head screw, gland bolts, and flange bolts
Plastic pick
—Body seal, seat, ball, fire seal, seal retainer,
and stem seal
Lubricants/fluids P-80®(or equivalent)
Molykote®1000
Permanent thread-locking fluid
Molykote 111
Molykote G-Rapid Plus
Seat and handle sleeve
Flange bolt
Gland bolt and hex head screw
Stem, body, ID surface, and OD surface
Stem, seal retainer, and ID surface
Stem seal assembly tools
Stem seal and stem
Rubber mallet,
Permanent marker —If applicable
Tools Required

Exploded View
Available Kits:
Handle Kit:handle sleeve, hex
head screw, washer and handle
Seat Kit: ball, body seal, seats, and
springs (50 mm only)
Stem Kit: disc springs, wave spring
(25 mm and 38 mm only), gland
bushing, fire seal, seal retainer,
stem seal, gland bolts, slip ring,
stem, ball, body seal, seats, and
springs (50 mm only)
Available Flanges:
Cam
(locking cam version)
Washer
Hex head screw
Handle
Bolted gland
(Locking handle version will have tab)
Wave spring
Gland bushing
Flange
bolts
Flange
Body
seal Ball
Spring
SeatSeat
Stem
Slip ring
Body
Threaded ange
Probe ange
Spring
Disc springs
Fire seal
Seal retainer
Stem seal
Handle sleeve
Gland
bolts
Handle
stop pins
*Bold indicates kit component.
3
Standard ange

Critical Sealing Surfaces
The surfaces highlighted in red are the critical sealing surfaces. These surfaces must be free of scratches, dents, disfigurement,
and debris to ensure successful maintenance and leak-free performance.
4
Body
Flange
Stem seal
Stem

Taller handle
will feed
through gap in
cam.
Image shown without handles for clarity.
6. Remove both disc springs, the wave spring (25 mm and 38
mm bore only), the gland bushing, and both gland bolts.
7. Remove the bolted gland.
8. Remove the ange bolts.
9. Remove the ange with the seat. Tap with a rubber mallet if it
is difcult to remove. Remove the body seal and seat with a
plastic pic.
10. Remove the ball and second seat with a plastic pic.
11. Remove both of the springs (50 mm bore only).
12. Push the stem down through the stem seal.
13. Remove the re seal and seal retainer with a plastic pic.
NOTICE
Be careful not to scratch the critical sealing surfaces.
Leakage could result.
14. Remove the stem through the body bore.
15. Remove the slip ring from the stem.
16. Remove the stem seal from the body with a plastic pic.
•WARNING
Before removing valve from system, to avoid
personal injury, you must
• Depressurize the valve
• Cycle the valve
• Purge the valve to remove any residual system
media left in the valve
Disassembly
1. Clamp the valve body vertically in a vise.
NOTICE
Be careful not to scratch the critical sealing surfaces.
Leakage could result.
2. Close the valve against the handle stop.
3. Document on the body the handle orientation relative to
the body, using a marker, for proper reassembly.
4. Remove the hex head screw and the washer.
5. Remove the handle and cam (locking cam version only).
Refer to Step 44 of Reassembly when replacing handle
only.
NOTICE
Note the location and orientation of each cam for
proper reassembly. They will lock into each other when
reassembled. The handle will not function properly if
assembled incorrectly.
5
Slip ring
Washer
Hex head
screw
Disc spring
Wave spring
Gland bushing Gland bolts
Ball
Seat
Seat
Body seal
Handle
Flange

Reassembly
1. Clean the valve, components, and all critical sealing
surfaces.
NOTICE
Do not use abrasive cleaners on critical sealing
surfaces. Leakage could result.
2. Secure the valve body vertically in a vise.
3. Apply a light coat of P-80 to the back of the seat. Assemble
the seat into body, concave face up.
4. Assemble the slip ring onto the stem with the spiral groove
facing up.
5. Apply a heavy coat of Molykote G-Rapid Plus on the lower
stem neck above the slip ring.
6. Assemble the stem through the body into the stem bore.
7. Assemble the spring into the bottom of the stem
(50 mm bore only).
8. Assemble the spring into bottom of the ball
(50 mm bore only).
9. Orient the ball slot with the stem tab.
10. Push the lower spring into the ball while pivoting the ball to
engage the stem spring (50 mm bore only).
11. Assemble the ball into body and engage with the stem.
NOTICE
Ensure the ball does not fall into the body or the ball
could be scratched. Leakage could result.
12. Ensure both springs are seated in the spring pockets
(50 mm bore only).
13. Apply a light coat of P-80 on back of the seat.
14. Assemble the seat into the ange, concave face up.
15. Assemble the body seal into the body.
16. Clamp the valve body in a vise.
17. Assemble the ange into the body.
NOTICE
Take care not to pinch the body seal. Leakage could
result from the graphite seal. Ensure the seat remains
seated in the ange before torquing to prevent
damage to the seat.
18. Apply a heavy coat of Molykote 1000 to the rst half of the
ange bolt threads.
19. Assemble the ange bolts and nger-tighten.
20. Set the ball to a fully open position using the unassembled
handle.
21. Remove the unassembled handle.
22. Torque the ange bolts to 1200 in∙lb (135 N∙m) in an
alternating pattern of 200 in∙lb (22.6 N∙m) increments.
15
4
3
2
Lube
65
4
3
2
1
or
6
Seat
Slip ring
Lube
Ball
Stem tab
Seat
Flange bolt
Stem
Concave up
Concave up

31. Apply a light coat of Molykote G-Rapid Plus to the ID of the
seal retainer.
32. Assemble the seal retainer over the stem with the
shoulder facing down.
33. Assemble the re seal onto the stem.
34. Orient the stem to the closed position using the
unassembled handle.
35. Remove the unassembled handle.
36. Assemble the bolted gland.
37. Apply a heavy coat of permanent thread-locking uid to
rst half of the threads on the gland bolts.
38. Assemble the gland bolts into the bolted gland.
39. Torque the gland bolts 60 to 120 in∙lb (6.8 to 13.6 N∙m) in
alternating 1/4 turns. Ensure the bolted gland sits level on
the valve.
NOTICE
Gap between bolted gland and valve must be even.
Distance of the bolted gland corners must not vary
more than 0.04 inch from each other. Failure to
maintain the correct distance could result in increased
torque.
40. Apply a light coat of Molykote G-Rapid Plus to the ID of the
bolted gland.
41. Assemble the gland bushing over the stem.
42. Assemble the wave spring over the stem
(25 mm and 38 mm bore only).
23. Apply a heavy coat of Molykote 111 in the gap between the
stem and body.
24. Assemble the stem seals using the stem seal assembly
tools.
a. Thread the ID guide onto the stem and finger-tighten.
b. Insert the OD guide over the ID guide into the stem
pocket.
c. Apply a light coat of Molykote 111 to the OD and ID of
the stem seal.
d. Assemble the stem seal onto the ID guide spring side
(metal side) down.
e. While pressing the OD guide down, press the stem seal
completely into place with the pusher.
f. Remove the stem insertion tools.
7
Seal retainer
Thread-locking uid
Lube
Seal retainer
Gland bolt
Handle
*Pusher
Stem seal
*ID guide
Stem
*OD guide
*Stem seal insertion tools
Body
Stem

43. Assemble the disc springs one concave up and then one
concave down.
44. Assemble the handle sleeve on the handle. Apply P-80 if
difcult to assemble.
45. Assemble the proper cam (from Disassembly step #5)
and handle onto the stem oriented with the mark (from
Disassembly step #3).
NOTICE
Ensure the valve is in the closed position.
Leakage could result.
46. Ensure the cam is in the correct location and orientation
(from Disassembly Step #5) ‐ locking cam version only.
47. Assemble the washer.
48. Apply a heavy coat of permanent thread-locking uid to the
rst half of the hex head screw.
49. Assemble the hex head screw.
50. Torque the hex head screw to 120 to 180 in∙lb
(13.6 to 20.3 N∙m).
51. Open and close the valve several times to inspect for
smooth actuation.
52. Test each valve for proper operation and leak-tight integrity.
NOTICE
Allow thread-locking uid 24 hours to cure before
installing the valve. Failure to do so could result in
leakage.
Taller handle will
feed through gap
in cam.
Image shown without handles for clarity.
Permanent thread-locking uid
For additional information, see www.swagelok.com.
Swagelok — TM Swagelok Company
Molykote — TM Dow Corning Corporation
Molykote is a registered trademark of Dow Corning Corporation,
a wholly owned subsidiary of the Dow Chemical Company.
P-80 — TM International Product Corporation
© 2019 Swagelok Company
MS-CRD-0255, Rev-, August 2019
8
Disc springs
Hex head screw
Concave up
Concave down