Read Series 2200/2220 Control Valve text version

Series 2200/2220 Control Valve Operation and Maintenance

SCOPE OF MANUAL

This instruction manual includes installation and maintenance information for the 1.00" and 2.00" Series 2200/2220 Control Valves. Refer to separate manuals for instruction covering controllers, positioners, etc.

MAINTENANCE

CAUTION Before attempting any repairs, isolate the control valve from the system and make sure that all pressure is released from the valve body. A. VALVE DISASSEMBLY INSTRUCTION 1. When the actuator is to remain connected: 1.1. For reverse (Spring Closing) actuators, remove all spring compression by unscrewing adjusting screw (item 20). 1.2. Disconnect air supply line from actuator. 1.3. Unscrew hammer nut (item 5) from body (item 1). 1.4. Lift entire topworks (actuator assembly with valve stem (item 11) and plug attached) from valve body (item 1) and place on a flat work surface.

DESCRIPTION

The Series 2200/2220 valve design has a close coupled or yoke mounted pneumatic diaphragm actuator, hammer nut closure, and unbalanced valve plug.

VALVE INSTALLATION

1. Before installing the valve, inspect for shipping damage and for any foreign material that may have c ollected during crating and shipping. Remove plastic plugs for flange protectors from body. Blow out pipelines to remove pipe scale, chips, welding slag, and other foreign materials. Install valve in pipeline, with direction of flow through body determined as follows: 3.a. Directed over the seat ( )for quick opening trim, 3.b. Directed under the seat ( ) for modified percent trim. Install valve using good piping practice, with actuator vertical above body. Flanged bodies will require a suitable gasket between the body and pipeline flanges. Working pressure of valve body is not necessarily the shut-off pressure of the valve actuator. Consult the shut-off tables or factory. The series 2200/2220 bodies are rated for ANSI classes 150, 300, 600, 900, and 1500. Do not install the valve in a system where the working pressures exceed those specified in the standards. Connect instrument air to actuator. Actuators with adjustable spring can be adjusted to increase or decrease shut-off capability. Turn clockwise to increase pre-load, turn counterclockwise to decrease pre-load.

2. 3.

CAUTION Be careful with plug and extended stem, protecting the stem from being bent. 1.5. Remove plug (item 2) using 1/8 inch drift pin or punch, drive roll pin (item 15) from plug (item 2). CAUTION Protect stem from bending by using a solid block as back-up while hammering the roll pin from plug. 1.6. Pull seat/cage (item 3) from body (item 1). (It may be necessary to use a hook, hooked in the cage flow openings. 1.7. Replace seat/cage and reassemble valve by reversing the procedure of steps 1 through 6. 2. When actuator is to be disconnected and taken off the body: 2.1. See "Actuator Disassembly" 2.2. Unscrew hammer nut (item 5) and lift off over bonnet (item 10). 2.3. Remove bonnet (item 10) from body (item 1) along with valve plug (item 2) and stem (item 11). 2.4. Remove valve plug (item 2) from stem (item 11).Using 1/8 inch drift pin or punch, drive roll pin (item 15) from plug (item 2).

Doc. Name: OpMain2200.doc Date: 15-Apr-03

4.

5.

6.

7. 8.

Maintained by: Sales Department Approved by: Quality Department

Page 1 of 7 Rev.: C

Series 2200/2220 Control Valve Operation and Maintenance

housing (item 18) by sliding it upward over the stem (item 20). 2.6. Remove cotter pin (item 31 or 34) and unscrew upper stem (item 20) from lower stem (item 11 or 25). 2.7. Remove bearing washer (item 26 or 29), diaphragm (item 17) and diaphragm plate (item 21). 2.8. Unscrew lower housing (item 16) from yoke (item 24) or bonnet (item 10). 2.9. Loosen jam nut (item 38) that secures valve stem to actuator stem (item 25) and unscrew the stem. 2.10. Unscrew and remove yoke (item 24) from bonnet (item 10). C. ACTUATOR ASSEMBLY 1. Reverse Actuator 1.1. Reverse the procedure of "Actuator Disassembly" - Reverse Actuator. Direct Actuator 2.1. Reverse the procedure of Disassembly", - Direct Actuator. "Actuator

CAUTION Protect stem from bending by using a solid block as back-up while hammering the roll pin from plug. 2.5. Remove packing washer (item 7) and spring (item 8), and pull valve stem (item 11) out of bonnet (item 10). 2.6. Remove packing (item 9A2) assembly by inserting drift pin or punch in top of bonnet (item 10) and tapping on upper retainer (item 9A1) until packing (item 9A2) comes out the bottom. 2.7. After any necessary replacement of parts, reassembly is accomplished by reversing the procedure of steps 1 though 6. B. ACTUATOR DISASSEMBLY 1. Reverse Actuator (Spring Closing) close coupled or Yoke mounted. 1.1. For reverse actuators, remove spring compression by unscrewing adjusting screw (item 20). 1.2. Disconnect air supply line from actuator. 1.3. Remove cap screw (item 29) from diaphragm housing (item 18), and remove upper housing (item 18) and actuator spring (item 23). 1.4. Remove hex nuts (item 31) from top of stem (item 11). 1.5. Remove lock washer (item 32), spring retainer (item 24), bearing washer (item 26), diaphragm plate (item 21) and diaphragm (item 17). 1.6. Unscrew lower housing (item 16) from yoke (item 25) or bonnet (item 10). 1.7. Loosen jam nut (item 38) that secures valve stem (item 11) to actuator stem (item 26) and unscrew the stems. 1.8. Remove yoke (item 25) by unscrewing from bonnet (item 10). 2. Direct Actuator (Spring Opening) close coupled or Yoke mounted. 2.1. Disconnect air supply line from actuator. 2.2. Loosen set screw (item 34 or 37) at base of spring cover (item 19) and remove cover, thus exposing spring (item 23). 2.3. Unscrew and remove spring adjusting nut (item 30 or 32) at top of actuator stem (item 20). 2.4. Remove upper spring retainer (item 22), and spring (item 23). 2.5. Remove cap screws (item 32 or 35) around diaphragm housing (item 18) and remove upper

Maintained by: Sales Department Approved by: Quality Department Page 2 of 7 Rev.: C

2.

D. PREVENTIVE MAINTENANCE 1. Seat 1.1. Check every six (6) months if in normal service, i.e., no sand or abrasives and low pressure drop. If in severe service, i.e. high pressure drop and sanding condition, check every sixty (60) days.

2.

Inner Valve 2.1. Same as above. 3. Bonnet 3.1. Check packing every year. 4. Actuator 4.1. Check diaphragm and o-rings once a year. 5. General Maintenance 5.1. When disassembling any portion of valve, always check o-rings for damage or wear before re assembly. 6. Body 6.1. Under normal conditions, body should last years. However, under severe conditions, i.e. corrosion, sand and high pressure drop, valve life could be numbered in days only. Inspect body every time actuator is removed.

Doc. Name: OpMain2200.doc Date: 15-Apr-03

Series 2200/2220 Control Valve Operation and Maintenance

TROUBLE DIAGNOSIS

WARNING SIGNAL Valve leaks when in the closed position. IMMEDIATE CAUSE Something under plug or valve plug and seat are worn. CORRECTIVE ACTION Remove spring tension from valve if a spring closing valve. Remove valve top from body by turning hammer nut. By visual inspection you can see whether plug and seat are worn. Plug is usually the first to be replaced. Remove pressure form diaphragm housing and disassemble top. Replace diaphragm and o-ring. If nuts that hold diaphragm plates are loose, retighten. If spring is compressed all the way, then the actuator is too small or pressure drop across valve plug is too high. Check valve pressure drop table for limits on pressure drop and/or consult your Norriseal representative. Reduce spring tension. If this will not let valve open, then the actuator is too small or pressure drop across valve plug is too high. Consult pressure drop table and/or your Norriseal representative.

Diaphragm housing leaks air from breather plug.

Worn out diaphragm or diaphragm plates have worked loose and need tightening. Pressure drop across valve too great.

Valve leaks. Flow under plug. Valve normally closed. Seat and plug O.K., nothing under plug. Valve will not open. Flow over plug. Normally closed valve.

Pressure drop across valve seat too great.

CAUTION Valve globe body has this symbol ( ( ) cast on one side. Flowing ( ) indicates flow under plug. Flowing

) indicates flow over plug. Flow under seat is for throttle service. Flow over plug can be used for on-off

service. Flow under seat requires adjustment of the spring to be sufficient to keep plug on seat for tight shut off. Flow over seat requires sufficient air supply to raise plug from seat to open valve. CAUTION When flowing over plug and high pressure service is involved, slapping of plug on seat (Bath tub stopper theory) can occur and this will shorten the plug, seat/cage life.

Reverse - normally closed valve: After applying spring compression to the actuator spring apply air to actuator and stroke valve to make sure of valve's travel. Direct - normally open valve: Air supply to actuator must be sufficient to hold plug on seat when flow is under plug. Flow over seat requires enough pre-load on spring to offset pressure over plug to pull plug off seat. Again you must have sufficient air pressure to force the plug into the seat. The 1" and 2" globe body has one inlet and one outlet port. The 1" "T" body has three ports, one inlet and one outlet with a pipe plug in the third port. Valve can be used for globe or angle flow by moving pipe plug to suit user. If customer moves pipe plug to another port after receiving from factory, customer should re-test valve body.

Maintained by: Sales Department Approved by: Quality Department

Page 3 of 7 Rev.: C

Doc. Name: OpMain2200.doc Date: 15-Apr-03

Series 2200/2220 Control Valve Operation and Maintenance

SERIES 1" ­ 2" 2200 CONTROL VALVE

Maintained by: Sales Department Approved by: Quality Department

Page 4 of 7 Rev.: C

Doc. Name: OpMain2200.doc Date: 15-Apr-03

Series 2200/2220 Control Valve Operation and Maintenance

SERIES 1" ­ 2" 2200 CONTROL VALVE

Maintained by: Sales Department Approved by: Quality Department

Page 5 of 7 Rev.: C

Doc. Name: OpMain2200.doc Date: 15-Apr-03

Series 2200/2220 Control Valve Operation and Maintenance

SERIES 1" ­ 2" 2220 CONTROL VALVE

Maintained by: Sales Department Approved by: Quality Department

Page 6 of 7 Rev.: C

Doc. Name: OpMain2200.doc Date: 15-Apr-03

Series 2200/2220 Control Valve Operation and Maintenance

SERIES 1" ­ 2" 2220 CONTROL VALVE

Maintained by: Sales Department Approved by: Quality Department

Page 7 of 7 Rev.: C

Doc. Name: OpMain2200.doc Date: 15-Apr-03

Information

Series 2200/2220 Control Valve

7 pages

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