THE LEADER IN CHOKE TECHNOL OG TECHNOLOG OGYY Our extensive engineering and production facilities make us a global leader in choke valve technology Master Flo Valve is committed to giving total satisfaction in service, quality, and value to our customers.
Master Flo Valve Inc. Edmonton, Alberta, Canada
Master Flo Valve Co. (UK) Ltd. Aberdeen, Scotland
TABLE OF CONTENTS ISO 9001
REG. FIRM/94-74
6A-0138 17D-0008
Accredited by the Dutch Council for Certification
Company Overview ...................... 3 Valve Sizes .................................. 3 Flow Characteristics ................... 4 Valve Features ............................ 5 Valve Options .............................. 7 Testing FFacilities acilities ....................... 11 Valve Specifics .......................... 12 Actuation ................................... 17 Subsea Chokes ........................... 22 Valve Dimensions ...................... 24 Material Specifications ............ 26 THE LEADER IN CHOKE TECHNOLOGY
COMPANY OVERVIEW Master Flo Valve Inc. is an industry leader in choke valve, specialty control valve, and pig ball valve technology. Since our inception in 1979, we have manufactured high quality products supported by engineering, quality control, and service. Our leadership has been achieved through our commitment to continual development of trim and valve designs to ensure our products meet the requirements of high-pressure drops, severe erosion and corrosion conditions, as well as serviceability. Engineering capabilities are supported with three-dimensional CAD and FEA programs, and a fully equipped Research and Development Department. Master Flo’s extensive investment in research and development ensures that we stay on the Leading Edge of Technology. Testing facilities include Cv testing, slurry testing, API Appendix F testing, cycle testing, and hyperbaric testing. This ensures our customer receives a product that meets the demands of the application and stringent certification requirements of today’s oil and gas industry. Our commitment is demonstrated by the performance of the surface and subsea choke valve product lines, which are complemented by our actuation and metal-tometal seal technology. Master Flo Valve Inc. maintains an accredited quality program in accordance to ISO 9001-94 and API Q1 while also manufacturing products under license to API 6A and API 17D. Master Flo Valve (UK) is accredited to ISO 9002. Our staff pride themselves in their ability to respond to specific customer requirements, whether it be erosion, high temperature, or highpressure service, or water depths of 18,000 feet. We work with our customers to provide a product that meets their service requirements.
VALVE SIZES VALVE MODEL
STANDARD END CONNECTION SIZES
EDMONTON Alberta, Canada
CALGARY Alberta, Canada
HOUSTON Texas, U.S.A.
NEW ORLEANS Louisiana, U.S.A.
ABU DHABI United Arab Emirates
STANDARD TRIM
P05 P1 P2
1", 2" 1", 2" 2", 3"
Cv 2.5 10 20
P25
2", 2½", 3"
33
93
P3
3", 4"
50
116
P35
4", 6"
100
160
P4
4", 6"
160
198
P5
5", 6", 8"
250
240
P6 P8
6", 8" 8", 10"
335 650
280 392
BEAN SIZE
24 48 72
MAXIMUM PRESSURE RATING PSI kPa 10,000 69 000 6,000 41 000 10,000 69 000 5,000 34 000 15,000 103 000 20,000 138 000 6,000 41 000 10,000 69 000 15,000 103 000 6,000 41 000 15,000 103 000 6,000 41 000 10,000 69 000 6,000 41 000 10,000 69 000 6,000 41 000 6,000 41 000
MAXIMUM TURNING TORQUE AT 3000 PSI
TURNS Close to Open
ft-lb
Nm
10 35 60 60 70 70 45 45 70
15 46 83 83 92 92 62 62 92
6 6 11 12 9 9 17 17 13
68
92
16
96
130
20
81
110
22½
81 96
110 130
27 33½
ABERDEEN Scotland
LONDON England
PAU France
JAKARTA Indonesia
KUALA LUMPUR Malaysia
FLOW CHARACTERISTICS DESIGN BENEFITS The Master Flo Production Choke features several unique characteristics that minimize wear and maximize durability. The cage with external sleeve trim design creates impinging flow in the cage center, thus dissipating the fluid energy onto itself. The external sleeve also diverts the flow upward into the flow trim (away from the outlet), containing turbulence and wear within the flow trim. The valve body outlet is isolated from wear because turbulence is dissipated before flow enters the outlet, thus eliminating the typical problems of wear in the valve outlet. Another feature is the retaining sleeve which isolates the body bore from the incoming flow thus eliminating body wear. Containment and control of wear makes the Master Flo valve ideal for high-pressure, large-pressure drop, and severe service applications for both liquids and gases.
FLOW TRIM Master Flo’s Flow Trim* consists of a cage with an external sliding sleeve. Our trim provides accurate, long life control by using two pairs of ports in the cage. The lower pair are small ports that provide the initial 15% control range while the upper pair are large ports that provide the overall capacity. This trim configuration produces an equal-percentage flow characteristic which offers maximum control throughout the operating range. Our cage port configuration incorporates an exceptionally high turndown ratio providing a wide control range and excellent versatility. This characteristic reduces the required number of trim sizes to one per body size. The top entry trim system, with the seat being mechanically retained in place by the bonnet, provides for ease of servicing of the flow trim. The Master Flo Flow Trim system is universal between the control valve and production choke product lines. 4
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SEATING Master Flo’s Flow Trim* is designed to eliminate seat wear and problems associated with screw-in seat assemblies. Our seating is comprised of an isolated sealing element upstream of the throttling components, which protects the seat from throttling wear. Exceptional seating is provided by the self-aligned, isolated, tapered metal seal. The collar incorporates a flow deflection lip that isolates the seat face from the incoming flow. This maintains sealing integrity throughout the trim’s service life. Master Flo provides ANSI Class VI (bubble tight) or Class V shutoff per ANSI B16.104 1976 (FCI 70-2).
*patented
VALVE FEATURES
THE LEADER IN CHOKE TECHNOLOGY
MASTER FLO CHOKE VALVES
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CV CURVE The Cv Curve for each valve model is virtually identical at lower settings, illustrating the versatility of our equal percentage trim and verifying the requirement for only one trim size per body size.
PRESSURE RECOVERY The high-pressure recovery factor (F L)throughout the control range of the Master Flo Choke minimizes noise levels, flow velocities, cavitation and valve trim wear.
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MASTER FLO CHOKE VALVES MICROMETER CALIBRATION HEAD Master Flo Chokes are supplied* with a micrometer calibration head to provide valve position indication to increments of 1/10 of a turn for manual operation. This provides exceptional repeatability of valve positioning throughout the valve stem travel. The calibration head is square with a different scale on each of its four faces. This ensures that the valve position can be monitored in the desired units, including C v, bean size, millimeters or number of turns (i.e. micrometer scale). For P2 and larger chokes, the calibration head incorporates a grease fitting to allow for lubrication of the stem threads. * optional on P6 and larger Micrometer Calibration Head
OPTIONS STEM LOCK ASSEMBLY Master Flo’s optional Stem Lock for manually operated chokes allows the stem nut to be locked in 1/10 of a turn increments. This provides a large number of fixed valve positions between the closed and full-open position. Valve Model
Locking Positions
P2 P25 P3 P35 P4
110 120 170 160 200
Stem Lock Assembly
REMOVAL OF INTERNAL ASSEMBLY Servicing of our choke is exceptionally simple, with all internals being removable as a unit from the valve body, without the requirement of special tools. This provides for easy inspection and servicing of our product.
Servicing our valves requires no special tools
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OPTIONS CONTINUED
FLOW TRIM MATERIALS The flow trim is available in a wide range of materials to accommodate all service conditions and applications. Standard trim materials are listed along with service recommendations. Many special materials are available to accommodate specific service condition requirements.
MATERIAL
SERVICE RECOMMENDATION
UNS 17400
A hardened stainless steel used for low or medium pressure drop applications with NACE MR-01-75 compliance.
Stellite
A cobalt alloy used for resisting cavitation and for sour service.
Tungsten Carbide
The premium flow trim material for all service conditions. Very high wear resistance makes this material suitable for high velocity or erosive applications.
Flow Trim
HIGH CAPACITY FLOW TRIM Master Flo has available high Cv flow trim for low-pressure drop applications providing a higher flow capacity. This trim is available in most valve sizes. For further details please contact our local office in your area.
MULTI-STAGE TRIM Master Flo has available multi-stage flow trims for highpressure drop liquid-flow applications. This trim design provides control of high-pressure drops while maintaining metal-to-metal seating.
BODY BLEED Two types of bleed ports are available on selected models as an option on the Master Flo chokes: • An API 6A bleed port, which utilizes a metal-to-metal seal, is designed for test and gauge connectors for 15,000 PSI working pressure. • A ½” NPT port allows for a pressure relief fitting.
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Multi-stage Trim
MASTER FLO CHOKE VALVES
METAL-TO-METAL STEM SEALS Master Flo’s metal stem seal is a mechanical and pressure energized sliding metal-to-metal seal requiring no elastomers for the sealing function. This seal system is generally available for 2” and larger valves.
METAL-TO-METAL BONNET SEALS The static metal bonnet seal provides for sealing from a vacuum to over 20,000 PSIG. The seal is mechanically energized during installation and is pressure-energized by the fluid. The seal utilizes a single sealing lip, which reduces the required sealing areas in the valve. This seal is available on select valves.
Metal-to-Metal Stem Seal
Metal-to-Metal Bonnet Seal
High Temperature Chokes
Utility Steam Application
HIGH TEMPERATURE CHOKES Master Flo manufactures a high temperature model of the Production Choke. The temperature rating of –20 to 850°F with pressures to 6,000 PSI ensures suitability for steam and high temperature applications. This valve style is available on P1 through P2 valve models with either manual or automated operation.
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TESTING FACILITIES Master Flo Valve Inc. takes pride in our experience and the extensive facilities we have to support our product and customers. This overview of our assembly equipment and Research and Development facilities illustrates how we maintain our position as a leader in the field of Choke Valves. ASSEMBLY FACILITIES Master Flo’s production facilities utilize work areas that incorporate independent cleaning and assembly stations. Custom designed fixtures are utilized to provide high efficiency and accuracy in the assembly and testing of our products.
Assembly Facilities HYDROSTATIC TESTING FACILITIES Master Flo’s multi-station hydrostatic testing facilities are capable of testing to 30,000 PSI. Master Flo utilizes a high accuracy hydrotest system allowing full pressure and leakage monitoring combined with an environmentally conscious system for recycling the test fluid. Additional test facilities include high-pressure gas testing capabilities up to 30,000 PSI and low-pressure seat leakage testing.
Hydrostatic Testing Facilities Cv TESTING
Master Flo’s Cv Test Facility features high versatility, accuracy and computerized data-acquisition software operated entirely from a central control panel. Two centrifugal pumps, in parallel, supply in excess of 1,000 GPM. Pressure drop and flow rates are remotely controlled through the central control system. High precision instruments monitor flow rate, pressure differential, valve position, as well as upstream pressure and temperature. Three different flow meters provide wide rangeability and resolution. Real-time data is displayed graphically on a computer screen with data being stored for later retrieval.
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Cv Testing Facility
MASTER FLO CHOKE VALVES
CLEAN ROOM FACILITY
Master Flo Valve Inc. maintains an in-house clean room facility. This facility maintains hydraulic system cleanliness through the use of two flushing systems and a HIAC particle counter.
Clean Room Facility COLD ROOM ENVIRONMENTAL CHAMBER TEST FACILITY Master Flo Valve Inc. has a temperature test facility inhouse to perform testing to API 6A Appendix F PR2 and API 17D specifications. The equipment includes: • an environmental chamber with cooling and heating facilities capable of maintaining low temperature extremes of -60° F and high temperatures in excess of 650° F . • full pressure range test capabilities for valves and actuators when subject to temperature classification extremes. • computer-based data acquisition monitoring equipment to continuously monitor and record temperatures and pressures as well as equipment operating characteristics throughout testing procedures.
Cold Room Test Facility
SLURRY TESTING Product improvement is very important to Master Flo to maintain our capability as a critical-service valve supplier. To accomplish this goal, we have a customdesigned erosion test facility. This test loop allows continuous sand slurry testing at pressures up to 5,000 psi and flow rates up to 168 gpm. Abrasive media concentration, flow rates, and pressures are all variable, and data is collected using data acquisition software. This test facility is assisting Master Flo in maintaining our position as a leader in the supply of high-performance, wear-resistant valves. Slurry Test Facility
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VALVE SPECIFICS P05 The P05 Choke Valve provides for applications with end connections up to 2”. The valve utilizes a threaded bonnet nut to retain the bonnet and flow trim in the valve body.
P05
PARTS LIST 1. Body Assembly 2.* Seal: Seat - Body 3. Seat 4. Nozzle 5. Flow Ring 6. Retaining Sleeve 7. Lock Washer 8.* Groove Pin 9. Stem 10.* Groove Pin 11.* Stem Bearing 12. Bonnet 13.* Thrust Washer 14. Bonnet Nut 15.* Wiper 16. Handle 17. Stem Nut 18. Stem Washer 19. Calibration Head Assembly 20.* Seal: Bonnet - Body 21. Key 22.* Retaining Ring 23.* Seal: Stem - Bonnet 24.* B.U. Ring: Stem - Bonnet 25. Grease Nipple 26. Handle Ring * Parts included in seal kit.
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MASTER FLO CHOKE VALVES
P1 The P1 Choke Valve utilizes a bolted-bonnet flange to retain the bonnet and flow trim. This valve style is available with 1” and 2” end connections. Flanged, threaded, and special connections are available upon request. The P1 is available in inline or 90° valve body configuration. P1
PARTS LIST 1. Body Assembly 2.* Seal: Nozzle - Body 3.* Seal: Seat - Body 4. Seat 5. Nozzle 6. Flow Ring 7. Retaining Sleeve 8. Lock Washer 9.* Groove Pin 10.* Retaining Ring 11.* Seal: Bonnet - Body 12. Bonnet 13. Stem 14.* Groove Pin 15. Stem Nut 16. Grease Nipple 17. Bonnet Flange 18. Cap Screw 19. Handle Ring 20. Calibration Head Assembly 21.* Stem Bearing 22.* Seal: Stem - Bonnet 23.* B.U. Ring: Stem - Bonnet 24. Key 25.* Thrust Washer 26. Thumb Screw 27. Handle 28. Stem Washer * Parts included in seal kit.
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VALVE SPECIFICS CONTINUED
P2 The P2 Choke Valve utilizes a threaded bonnet nut to retain the bonnet and flow trim in the valve body. A bolted-bonnet option is available upon request. Standard end connection sizes range from 2” to 3”. The P2 is available in inline or 90° valve body configuration. P2
PARTS LIST 1. Body Assembly 2.* Seal: Nozzle - Body 3.* Seal: Seat - Body 4. Seat 5. Nozzle 6. Flow Ring 7. Retaining Sleeve 8. Stud 9. Lock Washer 10. Stem 11.* Groove Pin 12.* Seal: Bonnet - Body 13.* B.U. Ring: Bonnet - Body 14. Bonnet Nut 15. Key 16. Stem Nut 17.* Wiper 18. Handwheel 19. Cap Screw 20. Calibration Head Assembly 21.* Retaining Ring 22.* Stem Bearing 23.* Seal: Stem - Bonnet 24.* B.U. Ring: Stem - Bonnet 25. Bonnet 26. Grease Nipple 27.* Thrust Bearing 28.* Thrust Washer 29. Key * Parts included in seal kit.
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MASTER FLO CHOKE VALVES
P25 The P25 Choke Valve provides high capacity flow in a 2” line. The bonnet seal is metal to metal with only three elastomer seals in the valve. A threaded bonnet nut retains the bonnet and flow trim. A bolted-bonnet option is available upon request. Standard end connection sizes range from 2” to 3”. The P25 is available in inline or 90° valve body configuration. P25
PARTS LIST 1. Body Assembly 2.* Seal: Nozzle - Body 3.* Seal: Seat - Body 4. Seat 5. Nozzle 6. Flow Ring 7. Retaining Sleeve 8. Stud 9. Lockwasher 10. Stem 11.* Groove Pin 12.* Seal: Bonnet - Body 13. Bonnet 14. Bonnet Nut 15.* Groove Pin 16. Key 17. Stem Nut 18.* Wiper 19. Handwheel 20. Capscrew 21. Calibration Head Assembly 22.* Retaining Ring 23.* Stem Bearing 24.* Seal: Stem - Bonnet 25.* B.U. Ring: Stem - Bonnet 26. Grease Nipple 27.* Thrust Bearing 28.* Thrust Washer 29. Key * Parts included in seal kit.
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VALVE SPECIFICS CONTINUED
P3 AND LARGER The P3 and larger Choke Valves utilize bolted-bonnet construction with the valve bonnet retaining the flow trim. The flow trim is pressure balanced to minimize stem load and provide low operating torques. Flanged or special end connections are available.
P3
PARTS LIST
1. Body Assembly 2.* Seal: Seat - Body 3.* B.U. Ring: Seat - Nozzle 4.* Seal: Seat - Nozzle 5. Seat 6. Nozzle 7. Flow Ring 8. Retaining Sleeve 9.* Groove Pin 10.* Seal: Balance Sleeve - Body 11.* B.U. Ring: Balance Sleeve - Body 12. Balance Sleeve 13.* Seal: Bonnet - Balance Sleeve 14.* Groove Pin 15.* Spring Pin 16. Bonnet 17. Stem 18. Key 19. Stem Nut 20. Cover Plate 21. Grease Nipple 22. Capscrew 23. Handwheel 24. Key 25. Calibration Head Assembly 26.* Seal: Flow Ring - Balance Sleeve 27.* B.U. Ring: Flow Ring - Balance Sleeve 28.* Wiper 29. Stud 30. Lockwasher 31.* Retaining Ring 32.* Stem Bearing 33.* Seal: Stem - Bonnet 34.* B.U. Ring: Stem - Bonnet 35. Capscrew 36.* Thrust Bearing 37.* Thrust Washer 38.* Wiper 39. Capscrew * Parts included in seal kit.
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MASTER FLO CHOKE VALVES
ACTUATION
Single Acting Pneumatic Piston Actuator
SINGLE ACTING PNEUMATIC PISTON ACTUATOR The Master Flo Piston Actuator is a fail closed, integrally mounted piston actuator. The actuator utilizes 100 PSI supply pressure with springs to provide the fail close function. This actuator has been developed specifically for the Master Flo product line to provide a compact and efficient package.
SINGLE ACTING PNEUMATIC PISTON ACTUATOR DIMENSIONS ACTUATOR SIZE VALVE MODEL P05 P1 P2 P25 P3 P35
PISTON 25 ‘D’ inch mm 6.75 171 6.75 171 6.75 171 -
‘L’ inch 17.69 20.81 21.12 -
mm 449 529 537 -
WEIGHT* lbs. kg 26 12 26 12 30 14 -
‘L’ inch 23.12 23.41 23.47 26.66 28.88
mm 587 595 596 677 733
PISTON 50 ‘D’ inch mm 9.00 229 9.00 229 9.00 229 9.00 229 9.00 229
WEIGHT* lbs. kg 50 23 54 25 54 25 54 25 54 25
*Weights are in addition to Base Weights on Pages 24-25.
DOUBLE ACTING PNEUMATIC PISTON ACTUATOR The Double Acting Piston Actuator design utilizes the air supply to open and close the valve with a spring assist for fail close operation. This actuator style provides high output thrust making it suitable for large valves and high pressure applications. Manual override is available in a top mounted configuration.
Double-Acting Pneumatic Piston Actuator
DOUBLE ACTING PNEUMATIC PISTON ACTUATOR DIMENSIONS ACTUATOR SIZE VALVE MODEL P1 P2 P25 P3 P35 P4 P5 P6
‘L’ inch 26.91 27.22 27.28 30.44 32.69 -
mm 683 691 693 773 830 -
PISTON 50 ‘D’ inch mm 9.00 229 9.00 229 9.00 229 9.00 229 9.00 229 -
WEIGHT* lbs. kg 69 31 69 31 69 31 69 31 69 31 -
‘L’ inch 31.47 31.53 34.72 36.97 39.94 41.16 44.91
mm 799 801 882 939 1014 1045 1141
PISTON ‘D’ inch 12.62 12.62 12.62 12.62 12.62 12.62 12.62
100 mm 321 321 321 321 321 321 321
WEIGHT* lbs. kg 220 100 220 100 220 100 220 100 220 100 220 100 220 100
*Weights are in addition to Base Weights on Pages 24-25.
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ACTUATION CONTINUED
HYDRAULIC ACTUATOR Master Flo’s Hydraulic Actuator is a double-acting unit integrally mounted to the valve bonnet. Our integral actuator mounting provides a compact assembly with no exposed linkages. This Hydraulic Actuator provides fail in position, fail close operation, or fail open operation. The valve position feedback is generated electrically by a 4-20 mA transmitter. Limit switches for open or closed position indication are available.
Hydraulic Actuator
HYDRAULIC ACTUATOR DIMENSIONS VALVE MODEL P05 P1 P2 P25 P3 P35 P4 P5 P6 P8
‘L’ inch 15.16 18.28 24.31 24.38 27.78 37.25 40.25 41.44 45.19 52.06
mm 385 464 618 619 706 946 1022 1053 1148 1322
WEIGHT* lbs. kg 40 18 40 18 78 35 78 35 90 41 120 54 110 49 110 49 110 49 147 67
*Weights are in addition to Base Weights on Pages 24-25.
PNEUMATIC DIAPHRAGM ACTUATOR The Diaphragm Actuators provide fail close or fail open operation and are available with all standard Fisher accessories. Fisher mounting hardware is utilized to mount the actuator. Manual overrides are available in side or top mounted configurations.
Pneumatic Diaphragm Actuator
PNEUMATIC DIAPHRAGM ACTUATOR DIMENSIONS ACTUATOR SIZE 40
45
'L' inch (mm) 29.94 (760) 31.38 (797) 31.44 (799)
'D' inch (mm) 13.12 (333) 13.12 (333) 13.12 (333)
W* lbs. (kg) 50 (23) 50 (23) 50 (23)
P3
-
-
-
P35
-
-
-
VALVE MODEL P1 P2 P25
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'D' inch (mm) 16.00 (406) 16.00 (406) 16.00 (406) 16.00 (406)
W* lbs. (kg) 90 (41) 90 (41) 90 (41) 90 (41)
'L' inch (mm) 36.81 (935) 38.25 (972) 38.31 (973) 42.25 (1073)
'D' inch (mm) 18.62 (473) 18.62 (473) 18.62 (473) 18.62 (473)
W* lbs. (kg) 121 (55) 121 (55) 121 (55) 121 (55)
-
-
-
-
-
-
*Weights are in addition to Base Valve Weights on Pages 24-25.
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'L' inch (mm) 36.81 (935) 38.25 (972) 38.31 (973) 42.25 (1073)
'L' inch (mm)
'D' inch (mm)
W* lbs. (kg)
-
-
-
43.12 (1095) 43.19 (1097) 47.94 (1218) 49.56 (1259)
21.12 (536) 21.12 (536) 21.12 (536) 21.12 (536)
254 (115) 254 (115) 254 (115) 254 (115)
ACTUATION CONTINUED
STEPPING ACTUATOR Master Flo’s Stepping Actuator is available to operate our bolted bonnet 2” and larger valves. The actuator mounts directly on the valve cover plate to drive the valve stem nut. This feature provides for easy field conversion from manual to automated operation without requiring disassembly of the valve. Supply to the actuator can be either hydraulic or pneumatic. The Master Flo Stepping Actuator is designed for remote operation of our Choke Valve. This actuator steps in 36° increments in both the clockwise and counter-clockwise direction, providing high precision operation.
MASTER FLO CHOKE VALVES
Stepping Actuator
OPERATING PRINCIPLE The precise, durable stepping action is accomplished by a ratchet pawl, that engages a drive shaft, to directly operate the choke stem nut. Contact between the ratchet pawl and drive shaft is designed to maintain full face contact during an operating cycle. The back face on the pawl is tapered to ensure that during the return cycle no loads are transmitted to the drive shaft. The pawl is spring loaded to engage the drive shaft by dual torsion springs and is mechanically disengaged at the rest position to allow for reverse direction operation or manual operation. The Master Flo actuator utilizes pneumatic or hydraulic spring-return cylinders. The operating cylinder incorporates a self-lubricating shaft bushing and non-metallic piston wear ring. These features ensure the cylinder will have minimal operating friction, withstand the operating loads and provide a long service life. The vent side of the cylinder is internal to the actuator housing to eliminate contamination or corrosion of the cylinder
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ACTUATION CONTINUED
PERFORMANCE The actuator output torque is regulated by the supply pressure to the actuator. The actuator was developed to work continuously at maximum torque loads. The actuator housing package is of ductile iron construction. This weatherproof housing protects the actuator from the external environment.
POSITION FEEDBACK SYSTEM The actuator incorporates a 4-20 mA transmitter to provide remote monitoring of the choke position. Two limit switches are included to show full open, full closed or an intermediate setting. The position transmitter and switch assembly are available with various certification options. Typical certifications include explosion proof to UL and CSA Class 1, Division 1, Groups C & D, or to CENELEC EEx d IIC T6 IP66; or intrinsically safe to EEx d IIC T6 IP66; or intrinsically safe to EEx ia IIC T4 IP66. The transmitter housing is available in anodized aluminum, bronze or stainless steel.
AVAILABLE OPTIONS
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JUNCTION BOX
POSITION INDICATION
SOLENOID VALVES
A wiring junction box is available to provide one electrical connection point for the actuator.
The local position indicator is marked in % open as a standard but is available with markings of Cv, bean size or millimetres.
The actuator may be supplied complete with solenoid valves piped into the operating cylinders.
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MASTER FLO CHOKE VALVES
ACTUATION CONTINUED
STEPPING ACTUATOR DIMENSIONS VALVE MODEL P2 P25 P25-15k P25-20k P3 P3-10k P3-15k P35 P35-15k P4 P4-10k P5 P5-10k P6 P8
‘L’ inch 17.72 16.72 20.41 22.66 20.31 21.31 21.91 23.78 24.53 27.03 27.03 28.50 28.50 32.28 37.50
mm 450 425 518 576 516 541 557 604 623 686 686 724 724 820 953
WEIGHT* lbs. kg 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75 165 75
STEPS Open to Close 107 119 89 89 169 169 127 159 159 201 201 226 226 270 370
*Weights are in addition to Base Valve Weights on Pages 24-25.
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SUBSEA CHOKES Master Flo Valve Inc. is a leader in the design and manufacture of Subsea Choke Valves and Actuators. A commitment to continuous improvement through extensive research and development ensures the latest proven technology is incorporated in our designs. A brief overview of our subsea product line follows. If you have questions, please contact our local office for further details.
SL SUBSEA STEPPING ACTUATOR Subsea Choke Valves require lightweight, compact, powerful actuators that are capable of providing the reliability, precision, and durability expected in a subsea environment. These requirements are met with Master Flo’s SL Subsea Stepping Actuator. This actuator operates on the same principle as the surface stepping actuator. In addition, it incorporates a pressure compensation system and an internal LVDT position transmitter. The manual override is available in a top-drive configuration or in a side-drive configuration that is positionable in 90° increments. The override interface is also available for diver or R.O.V. operation.
TECHNICAL SPECIFICATIONS Actuator Weight 150 lbs Hydraulic Pressure Rating 3300 PSIG Operating Temperature Range 0 to 150°F Maximum Working Depth 18,000 feet Rated Output Torque 320 ft-lbs @ 3000 PSIG supply Output Rotation per Step 36 degrees Typical Operating Cycle Speed .25 seconds per complete step (dependent on control system) Hydraulic Oil Consumption 1.28 in.3/step Position Transmitter LVDT
NON-RETRIEVABLE CHOKE The Non-Retrievable Bolted-Bonnet Choke is ideal for modular retrieval systems or applications where valve maintenance is not required. Right angle, inline or custom piping configurations are available to meet our customer’s needs. This product is available in a full range of sizes and pressures up to 15,000 PSIG. Manual operation by diver or R.O.V. is available as well as remote operation with Master Flo’s SL Subsea Stepping Actuator. The SL actuator also provides a diver or R.O.V. override interface for manual operation. Non-Retrievable Choke
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MASTER FLO CHOKE VALVES
DIVER-ASSISTED INSERT RETRIEVABLE CHOKE This choke features a diver operated clamp style bonnet. Retrieval of the compact insert is achieved with diver assistance. The visual indication has been designed to ensure good visibility allowing a diver to easily verify the valve position. As with the non-retrievable choke above, manual and remote operation is available. TOOL INSERT RETRIEVABLE CHOKE Master Flo’s third-generation Tool Insert Retrievable Choke utilizes a cable-deployed tool for insert installation and retrieval. The tool is designed to provide positional and rotational alignment of the insert. R.O.V. assistance allows the tool to be purely mechanical with no hydraulic or electrical requirements. This eliminates the need for increased tool complexity. The insert-retaining bonnet clamp is R.O.V. operated and is available with vertical or horizontal access. Master Flo’s metal-to-metal seal technology is utilized throughout the valve. The Tool Insert Retrievable choke incorporates the SL Subsea Stepping Actuator with a top-drive R.O.V. override. Actuator hydraulic connections are accommodated through the body and bonnet with a subsea mateable electrical connection system. This product has been qualified to API-6A Appendix F and API-17D and qualified to water depths of 18,000 feet. Valves are available up to 15,000 PSIG pressure ratings.
Diver Assisted Insert Retrievable
Insert Retrievable
TEST AND TRANSPORT SKID Master Flo’s Test andTransport Skid is designed to secure and protect the choke insert module during transport and storage and to facilitate testing of the insert before deployment.
Test and Transport Skid
HYPERBARIC TESTING Master Flo’s dedication to be a leader in the subsea choke market is demonstrated by our extensive investment in specialized equipment. An example of this includes an in-house hyperbaric test chamber for performance verification at simulated depths. The test chamber utilizes a data acquisition system for monitoring environmental parameters and choke position while facilitating both manual and actuated operation.
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23
VALVE DIMENSIONS
ENVELOPE DIMENSIONS (inches) Choke 'A' 'B' P05 6.12 8.25 P1 8.56 13.00 P2 13.00 18.00 P25 13.19 18.00 P3 17.50 18.00 P35 21.75 18.00 P4 26.00 18.00 P5 28.50 18.00 P6 33.50 28.00 P8 34.00 28.00 Note: 'C' is the Disassembly Clearance
'C' 8.75 14.38 19.00 19.25 25.00 30.50 37.62 40.75 48.00 49.12
Note: ‘I’ and ‘O’ dimensions depend on the type of end connection. When inlet and outlet end connections are the same, ‘I’ and ‘O’ are equal. Standard dimensions and weights are tabulated below for valves with threaded, butt welded, ANSI flanged, and API flanged end connections. Other end connections and special dimensions are available upon request. P25
P05 CONNECTION TYPE Threaded 150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API Butt Weld
1” CONNECTIONS inch 2.38 4.56 4.81 5.06 5.06 5.50 5.50 5.50 6.12 x x x 2.38
mm 60 116 122 129 129 140 140 140 156 x x x 60
lbs. 16 21 24 24 24 33 33 33 42 16
2” CONNECTIONS kg
inch
7 10 11 11 11 15 15 15 19 7
x 4.88 5.12 5.50 5.56 6.62 6.69 6.69 7.69 5.56 6.69 6.69 x
mm x 124 130 140 141 168 170 170 195 141 170 170 x
lbs. 28 32 36 36 64 64 64 100 36 64 64 -
kg
mm
lbs.
kg
inch
mm
lbs.
kg
Threaded 150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API Butt Weld
4.50 7.00 7.25 7.62 7.69 8.75 8.81 8.81 9.81 7.69 8.81 8.81 4.50
114 178 184 194 195 222 224 224 249 195 224 224 114
82 92 96 100 100 128 128 128 164 100 128 128 82
37 42 44 45 45 58 58 58 74 45 58 58 37
4.50 7.25 7.62 8.00 8.06 8.75 8.81 9.44 11.50 8.06 8.81 9.44 4.50
114 184 194 203 205 222 224 240 292 205 224 240 114
82 103 114 116 116 138 138 176 268 116 138 177 82
37 47 52 53 53 63 63 80 122 53 63 80 37
P25 - RATED FOR 15,000 PSI 1” CONNECTIONS
2” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
Threaded 150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API Butt Weld
4.50 6.69 6.94 7.19 7.19 7.62 7.62 7.62 8.25 x x x 4.50
114 170 176 183 183 194 194 194 210 x x x 114
39 41 44 44 44 53 53 53 62 39
18 19 20 20 20 24 24 24 28 18
4.50 7.00 7.25 7.62 7.69 8.75 8.81 8.81 9.81 7.69 8.81 8.81 4.50
114 178 184 194 195 222 224 224 249 195 224 224 114
39 48 52 56 56 84 84 84 120 56 84 84 39
18 22 24 25 25 38 38 38 54 25 38 38 18
2” CONNECTIONS
3” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
2 000 API 3 000 API 5 000 API 10 000 API 15 000 API Butt Weld
8.44 9.56 9.56 9.56 10.06 5.25
214 243 243 243 256 133
206 218 218 218 229 165
94 99 99 99 104 75
8.81 9.56 10.19 10.75 11.25 5.25
224 243 259 273 286 133
258 269 289 293 318 165
117 122 131 133 144 75
P3
P2
24
3” CONNECTIONS
inch
13 15 16 16 29 29 29 45 16 29 29 -
P1
2” CONNECTIONS
CONNECTION TYPE
2” CONNECTIONS
3” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
Threaded 150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API 10 000 API Butt Weld
4.50 7.00 7.25 7.62 7.69 8.75 8.81 8.81 9.81 7.69 8.81 8.81 8.81 4.50
114 178 184 194 195 222 224 224 249 195 224 224 224 114
82 92 96 100 100 128 128 128 164 100 128 128 124 82
37 42 44 45 45 58 58 58 74 45 58 58 56 37
4.50 7.25 7.62 8.00 8.06 8.75 8.81 9.44 11.50 8.06 8.81 9.44 11.38 4.50
114 184 194 203 205 222 224 240 292 205 224 240 289 114
82 103 114 116 116 138 138 176 268 116 138 177 195 82
37 47 52 53 53 63 63 80 122 53 63 80 89 37
www.masterflo.com •
[email protected]
3” CONNECTIONS
4” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
Threaded 150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API Butt Weld
5.25 8.00 8.38 8.75 8.81 9.50 9.56 10.19 12.25 8.81 9.56 10.19 5.25
133 203 213 222 224 241 243 259 311 224 243 259 133
154 177 190 190 190 212 212 250 342 190 212 250 154
70 80 86 86 86 96 96 114 155 86 96 114 70
5.25 8.25 8.62 9.50 9.56 10.00 10.06 10.44 13.19 9.56 10.06 10.44 5.25
133 210 219 241 243 254 256 265 335 243 256 265 133
154 187 207 228 228 256 256 292 446 228 256 292 154
70 85 94 104 104 116 116 133 202 104 116 133 70
MASTER FLO CHOKE VALVES
P3 - RATED FOR 10,000 PSI CONNECTION TYPE 2 000 API 3 000 API 5 000 API 10 000 API Butt Weld
P4 - RATED FOR 10,000 PSI
3” CONNECTIONS inch 10.06 10.81 11.44 12.00 6.50
mm 256 275 291 305 165
lbs. 407 418 438 441 338
4” CONNECTIONS kg 185 190 199 200 153
inch 10.81 11.31 11.69 13.00 6.50
mm 275 287 297 330 165
lbs. 476 490 509 541 338
kg
6” CONNECTIONS
inch
mm
lbs.
kg
inch
mm
lbs.
kg
2000 API 3000 API 5000 API 10000 API Butt Weld
11.81 12.31 12.69 14.00 7.50
300 313 322 356 191
623 637 655 688 485
283 289 297 313 220
12.44 13.31 14.62 16.65 7.50
316 338 371 423 191
864 901 955 1097 485
392 409 434 498 220
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API Butt Weld
11.00 11.38 12.25 12.31 12.75 12.81 13.94 17.00 12.31 12.81 13.94 7.50
279 289 311 313 324 325 354 432 313 325 354 191
516 554 575 575 625 625 697 988 575 625 697 464
234 252 261 261 284 284 316 449 261 284 316 211
11.00 11.38 12.38 12.44 13.25 13.31 14.62 18.75 12.44 13.31 14.62 7.50
279 289 314 316 337 338 371 476 316 338 371 191
516 554 610 610 684 684 792 1220 610 684 792 464
234 252 277 277 311 311 360 554 277 311 360 211
216 222 231 246 153
P3 - RATED FOR 15,000 PSI
4” CONNECTIONS
CONNECTION TYPE
P5
3” CONNECTIONS
4” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
2000 API 3000 API 5000 API 10000 API 15000 API Butt Weld
10.06 10.81 11.44 12.00 12.50 6.50
256 275 291 305 318 165
467 478 497 501 526 373
212 217 226 227 239 169
10.81 11.31 11.69 13.00 13.56 6.50
275 287 297 330 344 165
561 575 593 626 676 373
255 261 269 284 307 169
P35 4” CONNECTIONS
5” CONNECTIONS
6” CONNECTIONS
6” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API Butt Weld
9.50 9.88 10.75 10.81 11.25 11.31 11.69 14.44 10.81 11.31 11.69 6.50
241 251 273 275 286 287 297 367 275 287 297 165
410 430 451 451 479 479 515 669 451 479 515 377
186 195 205 205 217 217 234 304 205 217 234 171
10.00 10.38 11.38 11.44 12.25 12.31 13.62 17.75 11.44 12.31 13.62 6.50
254 264 289 291 311 313 346 451 291 313 346 165
429 467 523 523 597 597 705 1133 523 597 705 377
195 212 237 237 271 271 320 514 237 271 320 171
P5 - RATED FOR 10,000 PSI CONNECTION TYPE 2,000 API 3,000 API 5,000 API 10,000 API Butt Weld
5” CONNECTIONS 'I' & 'O' Weights inch mm lbs. kg 14.31 363 894 406 14.81 376 944 429 15.94 405 1016 461 16.81 427 1051 477 9.50 241 783 355
6” CONNECTIONS 'I' & 'O' Weights inch mm lbs. kg 14.44 367 929 422 15.31 389 1003 455 16.62 422 1111 504 18.65 474 1395 633 9.50 241 783 355
6” CONNECTIONS 'I' & 'O' Weights inch mm lbs. kg 13.00 330 835 379 13.38 340 873 396 14.38 365 929 422 14.44 368 929 422 15.25 387 1003 455 15.31 389 1003 455 16.62 422 1111 504 20.75 527 1539 699 14.44 367 929 422 15.31 389 1003 455 16.62 422 1111 504 9.50 241 783 355
8” CONNECTIONS 'I' & 'O' Weights inch mm lbs. kg 13.50 343 867 394 13.88 352 921 418 15.00 381 1007 457 15.06 383 1007 457 16.12 410 1157 525 16.12 410 1157 525 18.31 465 1329 603 22.56 573 1935 878 15.06 383 1007 457 16.19 411 1157 525 18.31 465 1329 603 9.50 241 783 355
8” CONNECTIONS 'I' & 'O' Weights inch mm lbs. kg 15.25 387 1365 620 15.62 397 1420 645 16.75 425 1505 685 16.81 427 1505 685 17.88 454 1655 750 17.94 456 1655 750 20.06 510 1825 830 24.31 618 2430 1105 16.81 427 1505 685 17.94 456 1655 750 20.06 510 1825 830 11.25 286 1280 580
10” CONNECTIONS 'I' & 'O' Weights inch mm lbs. kg 15.25 387 1405 640 15.88 403 1490 675 17.50 445 1690 768 17.56 446 1690 768 18.75 476 1835 835 18.81 478 1835 835 21.69 551 2300 1045 28.44 722 3295 1495 17.56 446 1675 760 18.81 478 1860 845 21.69 551 2310 1050 11.25 286 1280 580
P6 CONNECTION TYPE
P35 - RATED FOR 15,000 PSI 4” CONNECTIONS
150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2,000 API 3,000 API 5,000 API Butt Weld
6” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
2 000 API 3 000 API 5 000 API 10 000 API 15 000 API Butt Weld
11.81 12.31 12.69 14.00 14.56 7.50
300 275 287 356 370 191
623 637 655 688 753 485
283 289 297 313 342 220
12.44 13.31 14.62 16.65 17.50 7.50
316 338 371 423 445 191
864 901 955 1097 1279 485
392 409 434 498 581 220
P8
P4 4” CONNECTIONS
6” CONNECTIONS
CONNECTION TYPE
inch
mm
lbs.
kg
inch
mm
lbs.
kg
150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2000 API 3000 API 5000 API Butt Weld
9.50 9.88 10.75 10.81 11.25 11.31 11.69 14.44 10.81 11.31 11.69 6.50
241 251 273 275 286 287 297 367 275 287 297 165
410 430 451 451 479 479 515 669 451 479 515 377
186 195 205 205 217 217 234 304 205 217 234 171
10.00 10.38 11.38 11.44 12.25 12.31 13.62 17.75 11.44 12.31 13.62 6.50
254 264 289 291 311 313 346 451 291 313 346 165
429 467 523 523 597 597 705 1133 523 597 705 377
195 212 237 237 271 271 320 514 237 271 320 171
THE LEADER IN CHOKE TECHNOLOGY
CONNECTION TYPE 150 RF 300 RF 600 RF 600 RTJ 900 RF 900 RTJ 1500 RTJ 2500 RTJ 2,000 API 3,000 API 5,000 API Butt Weld
25
MATERIAL SPECIFICATIONS SERVICE APPLICATION
26
SIZE
VALVE PART
STANDARD
P05
Temp. Range Body I & O Flanges Stem Retaining Sleeve Bolting O-Ring BU Ring
-20°F to 250°F ASTM A105 ASTM A105 AISI 4140 AISI 1020 ASTM A193 B7 Nitrile Nitrile
SIZE
VALVE PART
STANDARD
P1
Temp. Range Body I & O Flanges Stem Retaining Sleeve Bolting O-Ring BU Ring
-20°F to 250°F AISI 1020 ASTM A105 AISI 17-4 PH AISI 1020 ASTM A193 B7 Nitrile Nitrile
SIZE
VALVE PART
STANDARD
P2 P25
Temp. Range Body I & O Flanges Stem Retaining Sleeve Bolting O-Ring BU Ring
-20°F to 250°F AISI 8620 ASTM A105 AISI 17-4 PH AISI 1020 ASTM A193 B7 Nitrile Nitrile
SIZE
VALVE PART
STANDARD
P3 P35 P4 P5 P6 P8
Temp. Range Body I & O Flanges Stem Retaining Sleeve Bolting O-Ring BU Ring
-20°F to 250°F AISI 8620 ASTM A105 AISI 17-4 PH AISI 1020 ASTM A193 B7 Nitrile Nitrile
www.masterflo.com •
[email protected]
SOUR -20°F to 400°F ASTM A105 ASTM A105 AISI 17-4 PH AISI 1020 ASTM A193 B7M Viton Teflon
SOUR -20°F to 400°F AISI 1020 ASTM A105 AISI 17-4 PH AISI 1020 ASTM A193 B7M Viton Teflon
SOUR -20°F to 400°F AISI 8620 ASTM A105 AISI 17-4 PH AISI 1020 ASTM A193 B7M Viton Teflon
SOUR -20°F to 400°F AISI 8620 ASTM A105 AISI 17-4 PH AISI 1020 ASTM A193 B7M Viton Teflon
SOUR LOW TEMP -50°F to 400°F AISI 4130 ASTM A350 LF2 AISI 17-4 PH AISI 1020 ASTM A320 L7M Viton Teflon
SOUR LOW TEMP -50°F to 400°F AISI 8620 ASTM A350 LF2 AISI 17-4 PH AISI 1020 ASTM A320 L7M Viton Teflon
SOUR LOW TEMP -50°F to 400°F AISI 8620 ASTM A350 LF2 AISI 17-4 PH AISI 1020 ASTM A320 L7M Viton Teflon
SOUR LOW TEMP -50°F to 400°F AISI 8620 ASTM A350 LF2 AISI 17-4 PH AISI 1020 ASTM A320 L7M Viton Teflon
STAINLESS STEEL -50°F to 400°F ASTM A182 F316 ASTM A182 F316 AISI 17-4 PH AISI 316 ASTM A320 L7M Viton Teflon
STAINLESS STEEL -50°F to 400°F ASTM A182 F316 ASTM A182 F316 AISI 17-4 PH AISI 316 ASTM A320 L7M Viton Teflon
STAINLESS STEEL -50°F to 400°F ASTM A182 F316 ASTM A182 F316 AISI 17-4 PH AISI 316 ASTM A320 L7M Viton Teflon
STAINLESS STEEL -50°F to 400°F ASTM A182 F316 ASTM A182 F316 AISI 17-4 PH AISI 316 ASTM A320 L7M Viton Teflon
HIGH TEMP -20°F to 850°F AISI 8620 ASTM A105 AISI 4140 AISI 1020 ASTM A193 B7 SS/GRAPHOIL n/a
HIGH TEMP -20°F to 850°F AISI 8620 ASTM A105 AISI 4140 AISI 1020 ASTM A193 B7 SS/GRAPHOIL n/a
*Materials subject to change or substitution as determined by Master Flo.
MASTER FLO CHOKE VALVES
OTHER PRODUCTS MANUFACTURED BY MASTER FLO SUB SEA CONTROL VAL VES SUBSEA VALVES
• Manually operated, non-retrievable bolted bonnet • Actuated, non-retrievable bolted bonnet • Diver-assist insert retrievable complete with clamp bonnet • Tool Insert retrievable
CONTROL VALVES • • • •
Manual Pneumatic Hydraulic Electric
PIG BALL VALVES • Bypass Style • Shut off Style
Master Flo’s latest valve and actuator sizing is available on CDROM. This Windows™ based software allows our customers to easily and accurately select Master Flo products to meet their application needs.
www.masterflo.com •
[email protected]
THE LEADER IN CHOKE TECHNOLOGY
27
World-Wide LLocations ocations NORTH AMERIC A AMERICA CANADA
4611 - 74 Avenue EDMONTON, Alberta Canada, T6B 2H5 Tel.: (780) 468-4433 Fax: (780) 469-9853
#540, 333 - 5th Avenue SW CALGARY, Alberta Canada, T2P 3B6 Tel.: (403) 237-5557 Fax: (403) 266-3307
UNITED STATES
Suite #160, 8901 Jameel Street HOUSTON, Texas, U.S.A., 77040 Tel.: (713) 690-2789 Fax: (713) 690-3838 NEW ORLEANS, Louisiana Tel.: (504) 528-9411 Fax: (504) 528-9544
EUROPE SCOTLAND
MASTER FLO VALVE CO. (UK) LTD. The Master Flo Building Blackness Road, Altens Industrial Estate ABERDEEN, Scotland, United Kingdom, AB12 3LH Tel.: (01224) 878999 Fax: (01224) 878989
ENGLAND
MASTER FLO VALVE (UK) LONDON, England Tel.: (01206) 385822 Fax: (01206) 383822
FRANCE
Regional Representative Rue du Souvenir Français 64230 Lescar, France Tel.: (0 559) 81 28 54 Fax: (0 559) 81 29 50
MIDDLE EAST
Canadian Stock Points ALBERTA 191 Industrial Road E. BROOKS, Alberta Canada, T1R 1C3 Tel.: (403) 362-7600 Fax: (403) 362-8329 9560 - 115 Street GRANDE PRAIRIE, Alberta Canada, T8V 5W2 Tel.: (780) 532-1433 Fax: (780) 532-4191 #207, 39015 Hwy. 2A RED DEER, Alberta Canada, T4S 2A3 Tel.: (403) 346-2550 Fax: (403) 347-2022 P.O. Box # 1610 916 - 6th Street, NW SLAVE LAKE, Alberta Canada, T0G 2A0 Tel.: (780) 849-6100 Fax: (780) 849-2264
BRITISH COLUMBIA 10403 Beaver Road FORT ST. JOHN, B.C. Canada, V1J 6H2 Tel.: (250) 785-9500 Fax: (250) 785-8139
SASKATCHEWAN 217 - 3rd Street ESTEVAN, Saskatchewan Canada, S4A 0N6 Tel.: (306) 634-4719 Fax: (306) 634-3287
UNITED ARAB EMIRATES MASTER FLO VALVE INC 8th Floor, A.M.F. Building Corniche Road, P.O. Box # 4118 ABU DHABI, United Arab Emirates Tel.: (02) 329150 Fax: (02) 321276
SOUTHEAST ASIA INDONESIA
5th Floor, Multika Building Jalan Mampang Prapatan Raya No. 71-73 JAKARTA, Indonesia - 12790 Tel.: (021) 797-5168/5177/5178 Fax: (021) 797-5179/5147
MALAYSIA
3rd Floor, UMS Building No. 2 Jalan Segambut Pusat Segambut, P.O. Box 10136 Kuala Lumpur 50704 Malaysia Tel.: (03) 6250 0415 Fax: (03) 6250 0416
www.masterflo.com
[email protected] Printed in Canada
ACTUATORS
V5064A Double Seated Valve
The V5064A is a double seated two-way valve with a cast iron body and flanged end connections. It is used in combination with an electric or pneumatic actuator for control of non-combustible water flow. Pressure balanced trim construction provides higher pressure differential ratings than the single-seated valve, making it suitable for high-pressure applications.
Specifications Materials
Selection Guide
Body: Cast iron
Model No.
Valve size x Port size
Pipe size
Flow capacity
Weight
(in.)
(in.)
(Cv)
(kg)
1 1/4
20
11
Plug, seat: Stainless steel Stem: Stainless steel
V5064A6002
1 1/2 x 1 1/4
Packaging: Asbestos
V5064A6010
1 1/2 x 1 1/2
Fluid temperature
0 to 200°C
V5064A6028
2x2
2
50
15.8
Rated pressure
980kPa
V5064A6036
2 1/2 x 2 1/2
2 1/2
78
21.2
Connection type
980kPa Flat faced flange
V5064A6044
3x3
3
112
29.8
Rated lift
1 1/2 - 3 (B): 19mm
V5064A6051
4x4
4
200
44
4-6 (B): 38mm
V5064A6069
5x5
5
260
61
V5064A6077
6x6
6
380
89.4
Flow characteristics Equal percentage
28
Plug shape: Pressure balanced contoured Available actuators
Modutrol motors - M604, M904, M945, M945B + R7000A, M6284, M9185A, M6285A, MY7114, etc. Actionator motors - M640B, M940B Pneumatic actuator - MP912, MP953
(At full close)
(unit:mm)
ØF
E
Stem (ØG dia)
Model No.
ØD
ACTUATORS
Dimensions
t A
N - Øh
5-12
External dimensions A
E
φD
t
φh
N
φF
V5064A6002
89.4
222
103
140
20
19
4
34.8
φG 8
V5064A6010
89.4
222
103
140
20
19
4
34.8
10
V5064A6028
89.4
254
126
155
20
19
4
34.8
10
V5064A6036
89.4
276
176
175
22
19
4
34.8
10
V5064A6044
89.4
298
180
185
22
19
8
34.8
10
V5064A6051
133.9
352
183
210
24
19
8
47.6
10
V5064A6069
133.9
403
195
250
24
23
8
47.6
13
V5064A6077
133.9
451
220
280
26
23
8
47.6
13
K
5%
10%
20%
50%
90%
CY CMY 25%
CMY 50%
CMY 75%
K 75%
5%
10%
20%
50%
90%
95%
100%
C
95%
MY
Page 1
100%
CM
13:32
5%
10%
20%
50%
90%
95%
100%
Y
3.5.2004
95%
Gas safety valves
90%
100%
OMB kohouty lic
M
Kohouty OMB katalog GB
5%
10%
20%
50%
5%
10%
20%
K 75%
C
50%
Page 2
90%
13:32
95%
3.5.2004
100%
Kohouty OMB katalog GB
Technical details
Gas safety CMY 75%
valves
CMY 50%
Gas safety valves are determined for the connection of the household appliances to the gas distribution system. The valves are according to the norm DIN EN 331.
Operating pressure: MOP: MIP: Variations: Terminations:
8–37 mbar 0,2 bar 5 bar straight valve angular valve Rp – internal conical thread R – external conical thread G – external cylindrical thread
CMY 25%
VAIT
CY
Complete security gas valve with integrated thermal, excess flow and „Push & Turn“ safety fuses.
MY
Thermal safety fuse
CM
By reaching the activating temperature 95 °C (±5 °C) the thermal safety fuse blocks the gas flow. This device will withstand the temperature 650 °C minimally during 30 minutes. During this time the danger of gas escape or of potential explosion is minimized. Once the safety fuse is activated, the complete valve has to be substituted.
VAT Security gas valve with integrated thermal and „Push & Turn“ safety fuses.
Excess flow fuse Excess flow fuse closes automatically the gas input in case of over ranging the limit of the flow rate 2,2 m3/h*. This situation can occur for instance, when the hose is broken or accidentally disconnected from the appliance. When the defect is removed, you can deactivate the fuse by closing and subsequent opening of the valve. * value obtained experimentally (closing flow rate according to the norm is 1,0 aÏ 2,5 m3/h)
VAI Security gas valve with integrated excess flow and „Push & Turn“ safety fuses. 5%
Push & turn safety
10%
Push & turn safety blocks the valve in a closed position and thus it prevents from accidental openings (for example by children). To open the ball valve, it is necessary to push down and turn the hand wheel. To close, just turn the hand wheel.
OMB kohouty rub
20% 50% 90% 95% 100%
5%
10%
20%
50%
90%
95%
K
100%
5%
10%
20%
50%
90%
95%
Y
100%
M
AZ-Pokorny s.r.o., âermákovice 20, 671 73 Tule‰ice, Czech republic tel.: +420 515 300 111, fax: +420 515 300 110 e-mail:
[email protected], www.az-pokorny.cz
BOAR-W
Type leaflet 7111.1/11-10
Maintenance-free soft-seat shut-off globe valves
flanged
PN 6, DN 15-200 PN 16, DN 10-200 Application
Standard variants
· Heating systems up to 120°C to DIN 4751. · Not suitable for fluids containing mineral oil, steam or fluids liable to attack EPDM and cast iron.
· Variant unit (position indicator, locking device and lift stop) · Cap lead-sealable (against unauthorized closing)
Operating data · Temperature range: --10 up to +120°C. · Pressure range: up to Dp = 6 or 16 bar.
Materials
· Body: Cast iron with flake graphite EN-GJL-250 formerly: GG-25 · For further details, see table of materials
Design Straight-way pattern with horizontal seat Compact body cover Maintenance-free stem seal with EPDM profile joint Rotating stem Rising handwheel Cone with tapered seal face and EPDM coating as soft main and back seat · Free from asbestos, CFC and PCB · Exterior finish: blue similar to RAL 5002 · · · · · ·
The valves meet the safety requirements of the Pressure Equipment Directive 97/23/EC (PED) of annex I for fluids of the group 2.
DIN ISO 9001
PED 97/23/EC
Remarks · For temperatures above 120°C and low-pressure steam plants to DIN 4750 we recommend maintenance-free shutoff· globe valves BOAR-H according to type sheet 7150.1 · For water supply systems, cooling circuits and fluids containing mineral oil we recommend BOA-CompactR with electrostatic plastic coating (EKB), acc. to type sheet 7112.11 · Flow characteristics 7111.4 · Operating instructions 0570.8 · Approved by the German Federal Office for Civil Defence for installation in shelters. Shock resistance RK 0,63/6,3 safety factor A · Type-tested in accordance with the Regulations of the ”Germanischer Lloyd”
On all enquiries/orders please specify Shut-off globe valve 1. BOAR-W type leaflet 7111.1 2. PN 6 or 16 3. DN 10-200 (DN 10 only with PN 16) 4. Standard variants
BOAR-W Working pressures Nominal pressure PN
Nominal bore
DN 6 15-200 16 10-200 1) DIN 3230-BQ (ISO 5208) 2) DIN 3230-BN/leak rate 1 (ISO 5208/rate A) 3) up to 120 °C medium temperature
Body pressure bar 1) 9 24
Seat tightness test with water bar 2) 6 16
Materials Part no. 100 161 200 350 410 412 506 544 901 961
2
Name of parts Body Body cover Stem Cone Profile gasket O-ring Retaining ring Threaded bush Hexagon head bolt Handwheel
Material EN-GJL-250 (previously: GG-25) EN-GJL-250 (previously: GG-25) Stainless steel X 20 Cr 13 (1.4021) Cast iron GG-25/elastomer EPDM Elastomer EPDM Elastomer EPDM Thermoplastic Noryl GF 30 Thermoplastic Noryl GF 30 5.6 EN DC 04 (previously: ST 1404)
Working pressure bar 3) 6 16
BOAR-W
With leadsealable cap
With variant unit (position indicator, locking device and lift stop)
a and d2 insulation dimensions
PN 6
16
Dimensions (mm) DN I h1 15 130 155 20 150 160 25 160 165 32 180 180 40 200 195 50 230 205 65 290 240 80 310 305 100 350 340 125 400 380 150 480 435 200 600 545 10 130 155 15 130 155 20 150 160 25 160 165 32 180 180 40 200 195 50 230 205 65 290 240 80 310 305 100 350 340 125 400 395 150 480 465 200 600 545
h2 215 220 245 260 270 280 320 390 435 510 595 745 215 215 220 245 260 270 280 320 390 435 520 600 745
h3 200 205 205 220 230 240 265 340 365 435 480 550 200 200 205 205 220 230 240 265 340 365 455 490 650
d1 100 100 100 100 125 125 125 160 160 160 200 250 100 100 100 100 100 125 125 125 160 160 200 315 315
d2 38 38 38 38 38 38 38 43 43 43 50 56 38 38 38 38 38 38 38 38 43 43 50 56 56
d3 166 166 166 166 166 166 166 206 206 206 256 390 166 166 166 166 166 166 166 166 206 206 256 390 390
d4 130 130 130 130 130 130 130 170 170 170 220 340 130 130 130 130 130 130 130 130 170 170 220 340 340
a 90 95 95 95 120 130 155 185 210 235 275 345 90 90 95 95 110 120 130 155 185 210 250 290 345
D 80 90 100 120 130 140 160 190 210 240 265 320 90 95 105 115 140 150 165 185 200 220 250 285 340
k 55 65 75 90 100 110 130 150 170 200 225 280 60 65 75 85 100 110 125 145 160 180 210 240 295
nxd5 4x11,5 4x11.5 4x11.5 4x14 4x14 4x14 4x14 4x18 4x18 8x18 8x18 8x18 4x14 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 12x22
b 12 15 15 16 16 16 16 18 18 20 20 22 14 14 16 16 18 18 20 20 22 24 26 26 30
Weight approx. kg kg1) 2.5 3.2 3.0 3.7 4.0 4.8 5.0 5.6 7.5 8.0 8.5 8.9 12.0 13.6 18.0 19.8 25.0 26.3 32.5 34.5 54.0 58.5 92.0 95.0 2.9 3.3 3.0 3.7 3.5 4.3 5.0 5.5 6.0 6.9 8.5 9.3 10.5 11.3 15.0 16.4 20.0 22.1 27.5 29.7 37.5 40.5 63.0 70.0 99.0 105.0
1) With cap/with variant unit
Installation instructions BOAR-W
Flow through shut-off globe valves should be in the direction of the embossed arrow on the body. Alternating direction of flow is permissible, but with DN 200 only up to a differential pressure of 12 bar. If the differential pressure is higher, BOAR-H-globe valves with relief cone are required (type sheet 7116.1)
Connection dimensions -- Standards Face-to-face dimension: EN 558-1/1 (previously: DIN 3202/F 1) ISO 5752/1 Flanges: DIN 2501 Raised faces: Type C DIN 2526
3
BOAR-W
Rising handwheel Position ”Open - Closed” can be seen from far away Maintenance-free stem seal with large EPDM profile ring, reliable sealing thanks to several sealing lips, even in case of temperature fluctuations
Threaded bush and retaining rings with stripping effect
Compact body cover thanks to internal stem thread. For full insulation in accordance with Heating system regulations. Little thermal losses
Stem with burnished shank Cover seal with EPDM-O-Ring. No readjusting Asbestos-free
Seat area in the body unmachined. Corrosion protection thanks to intact casting skin
Body of favourable hydraulic design
Subject to change without notice
Back seat with bosses as overload protection
7111.1/11-10
01.01.2002
Cone with soft seat, fully EPDM-coated; large radially acting sealing section, therefore little wear and insensitive to dirt, safe from overloading
KSB Armaturen GmbH 67227 Frankenthal (Germany) · Johann-Klein-Str. 9 Tel. +49 (62 33) 86-0 Fax: +49 (62 33) 86 34 76 · e-mail:
[email protected] · www.ksb-valves.com
Instruction Manual Form 5605 May 2001
Type 1077
Type 1077 Manual Handwheel Actuator Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation
.................................. 1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 W8176-1 / IL
................................ 7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Reference
Figure 1. Type 1077 Handwheel Actuator Mounted on a Type V150 Valve
9
............................ 9
actuator additionally has a spur gear reduction drive for increased torque capability.
Introduction
Specifications
Scope of Manual
Type 1077 actuator specifications are given in table 1. Some specifications for a given actuator as it comes from the factory are stamped on a metal nameplate attached to the actuator mounting yoke (key 7, figure 6).
This instruction manual includes installation, adjustment, operation, and maintenance information for the Type 1077 manual handwheel actuator. Instructions for the control valve is included in a separate manual.
Description The Type 1077 manual-only handwheel actuator (figure 1) is used with rotary-shaft valves such as the 9500 butterfly valve, Type 8532 and 8560 ediscR valves, Design V150, V200 and V300 Vee-BallR valves, Design V250 valves, and Design CV500 and V500 eplugtvalves. In the Type 1077 actuator, torque is transmitted from the handwheel through the handwheel input shaft to a worm and drive sleeve gear (sector) with splined bore. The worm and drive sleeve gear multiply the torque and transmit it to a splined valve shaft or splined stub shaft. The size 10-KE:6
Installation The Type 1077 actuator is normally shipped mounted on a control valve body. Follow the procedures in the control valve body instruction manual for valve installation. Then, proceed to the Operation section of this manual. If the actuator has been shipped separately for installation on a valve body, or if the actuator was removed for maintenance, mount the actuator by following the instructions presented in this section before installing the valve body in the pipeline. Individual part key numbers and part descriptions referenced in this procedure are shown in figure 6 and 7 except where otherwise indicated.
D101296X012
Maintenance
Type 1077 Table 1. Specifications
Actuator Sizes See table 2 Acceptable Valve Shaft Diameters See table 2
Maximum Output Rotation 0 to 90 degrees.
Output Torque See table 2
Mounting Positions J Right-hand (actuator on right side of valve body when viewed from the body inlet) or
Wheel-Rim Force See table 2 Handwheel Turns Required for Full Rotation See table 2 Handwheel Rotation Direct Acting Construction: Clockwise handwheel rotation closes the valve (produces clockwise rotation of valve shaft) as shown in figure 2.
CAUTION Rotating the valve disk or ball in the wrong direction will damage seals and other internal parts in some valve bodies. If the drive sleeve gear (key 1A) is not properly positioned, improper disk or ball rotation could result. If there is any doubt as to whether or not the drive sleeve gear is properly positioned, remove the gearbox cover plate. Use the appropriate view in figures 3, 4, and 5 to determine that the drive sleeve gear is at the proper end of its rotation. 1. Rotate the valve disk or ball to the closed position. Refer to the separate valve body instruction manual to determine the closed position. Consult the appropriate valve instruction manual Installation section for valve shaft orientation marks. 2. Rotate the handwheel (key 5) to move the drive sleeve gear to the position that is to correspond to the closed position of the valve disk or ball as follows: For direct acting turn the handwheel so that the drive sleeve gear and travel indicator are rotated fully clockwise.
2
Reverse Acting Construction: Clockwise handwheel rotation closes the valve (produces counterclockwise rotation of valve shaft) as shown in figure 2.
J left-hand (actuator on left side of valve body when viewed from the body inlet). Position 1 as shown in figure 3 is standard; however, the actuator may be mounted in any of the positions shown in figure 3. Refer to figure 2 to determine the correct actuator construction. Approximate Weights See table 3 For reverse acting turn the handwheel so that the drive sleeve gear and travel indicator are rotated fully counterclockwise. 3. Remove the travel indicator pointer by removing the machine screws. For a size 0-KE actuator only, remove the O-ring seal from the hub of the drive sleeve gear. Locate the four index marks on the drive sleeve gear hub. Also locate the index mark on the end of the valve shaft or stub shaft (key 13, figure 7). 4. Proceed as appropriate: a. For valves with splined shafts, refer to figures 3, 4, and 5 and locate the correct view for the valve body and mounting position being used. When the actuator is installed, the valve shaft index mark must be aligned with the proper gear hub index mark. b. For valves with keyed shafts, compare the position of the stub shaft keyway with the position of the connector (key 11, figure 7) keyway. Align the stub shaft index mark with the appropriate drive sleeve gear hub index mark such that the connector keyway will be in line with the valve shaft keyway.
Type 1077 Table 2. Actuator Size Selection WHEEL-RIM FORCE
ACTUATOR SIZE
ACCEPTABLE VALVE SHAFT DIAMETER
MAXIMUM ALLOWABLE TORQUE((1))
HANDWHEEL DIAMETER
To Produce Maximum All bl Allowable Torque
To Produce Torque Lower Than Maximum All bl Sh ft Allowable Shaft Torque
60-Degree Rotation
90-Degree Rotation
4
6
4
6
6-1/2
9-1/2
6-1/2
9-1/2
6-1/2
10
9
13-1/2
10-1/2
16
10-1/2
16
48
72
48
72
48
72
4
6
4
6
6-1/2
9-1/2
6-1/2
9-1/2
Torque Req’d Req d (In.-Lb.) 120.00
6-1/2 6 1/2
10
Torque Req’d (In.-Lb.) 202.50
9
13-1/2
10-1/2
16
10-1/2
16
48
72
48
72
48
72
Metric Units mm
NSm
mm
N
N
12.7 15.9 19.1 22.2 & 25.4
58 138 240 271(2)
152 152 203(4) 203
129 307 396 445(3)
22.2 & 25.4
468
203
485
31.8 38.1
678(2) 678(2)
305 305
467(3) 467(3)
Torque Req’d (NSm) 0.4572 Torque Req’d (NSm) 0.6096 Torque Req’d (NSm) 0.9652 Torque Req’d (NSm) 1.4478
6-KE
31.8 38.1 44.5 50.8
1110 1360 1360(2) 1360(2)
610 610 610 610
365 445 445(3) 445(3)
7-KE
44.5 50.8
2260(2) 2260(2)
762 762
440(3) 440(3)
44.5 50.8
2260 2260
762 762
436 436
63.5
3390(2)
914
463(3)
63.5
6305
431
431
76.2
6780(2)
610
310(3)
88.9
6780(2)
610
310(3)
Inches
Inch-Pounds
Inches
Pounds
Pounds
1/2 5/8 3/4 7/8 & 1
515 1225 2120 2400(2)
6 6 8(4) 8
29 69 89 100(3)
7/8 & 1
4140
8
109
1-1/4 1-1/2
6000(2) 6000(2)
12 12
105(3) 105(3)
Torque Req’d (In.-Lb.) 18.00 Torque Req’d (In.-Lb.) 24.00 Torque Req’d (In.-Lb.) 38.00 Torque Req’d (In.-Lb.) 57.00
1-1/4 1-1/2 1 1/2 1-3/4 2 1-3/4 2
9820 12,000 12,000(2) 12,000(2) 20,000(2) 20,000(2)
24 24 24 24 30 30
82 100 100(3) 100(3) 99(3) 99(3)
1-3/4 2
23,524 23,524
30 30
98 98
2-1/2
30,000(2)
36
104(3)
2-1/2
55,762
16
97
3
60,000(2)
24
69(3)
3-1/2
60,000(2)
24
69(3)
0-KE 0 KE
2 KE 2-KE
9 KE 9-KE
10-KE:6
HANDWHEEL TURNS REQUIRED FOR FULL VALVE DISK OR BALL ROTATION
Torque Req’d (NSm) 3.0480 Torque Req’d (NSm) 5.1435 Torque Req’d (NSm) 6.096 Torque Req’d (NSm) 7.3152 Torque Req’d (NSm) 15.476 Torque Req’d (NSm) 21.848 Torque Req’d (NSm) 21.848
U.S. Units
0 KE 0-KE
2 KE 2-KE
6-KE 6 KE
7-KE
9 KE 9-KE
10-KE:6
Torque Req’d (In.-Lb.) 240.00 Torque Req’d (In.-Lb.) 288.00 Torque Req’d (In.-Lb.) 612.00 Torque Req’d (In.-Lb.) 864 Torque Req’d (In.-Lb.) 864
1. Values shown are the maximum allowable torque of a splined valve shaft except where indicated. Without regard to the shaft, maximum allowable torque output is 271 NSm (2400 inch-pounds) for the size 0-KE actuator, 678 NSm (6000 inch-pounds) for the size 2-KE actuator, 1360 NSm (12,000 inch-pounds) for the size 6-KE actuator, 2260 NSm (20,000 inch-pounds) for the size 7-KE actuator, 3390 NSm (30,000 inch-pounds) for the size 9-KE actuator, and 6780 NSm (60,000 inch-pounds) for the size 10-KE:6 actuator. 2. Limited to this value by the maximum allowable output torque of the actuator. 3. Wheel-rim force required to produce maximum actuator output torque. 4. Handwheel is 152 mm (6-inch) diameter for keyed-shaft constructions.
3
Type 1077 VALVE SERIES OR DESIGN MOUNTING
Right-Hand
Ball/Plug Rotation To Close CCW(2) CCW
VALVE SERIES OR DESIGN
V250
V150 V200 & V300 V150,
CV500 V500
REVERSE
REVERSE
REVERSE
Disk/Ball Rotation To Close CW CW
V250
8532, 8560 & 9500
NA NA
DIRECT
Left-Hand
CCW CCW
NA NA
REVERSE
REVERSE
CW CW
DIRECT
DIRECT
Left-Hand (Optional)(1)
CW(3) CW
NA NA
DIRECT
NA NA
NA NA
NA NA
NA NA
1. A left hand ball will be required for the 3- through 12-inch Series B and the 14- to 20-inch, with or without attenuator. 2. Counterclockwise 3. Clockwise
40B1561–A / DOC
DIRECT ACTING CONSTRUCTION
REVERSE ACTING CONSTRUCTION
Figure 2. Direct and Reverse Acting Actuator Constructions
5. Making certain that index mark alignment is correct, slide the actuator onto the valve shaft in the desired mounting position (figure 4 or 5). Check to be sure the valve shaft index mark is still aligned with the proper gear hub index mark. 6. Check the alignment of the mounting holes in the mounting yoke (key 2) with those in the valve body. If the holes are not aligned, rotate the handwheel to allow repositioning of the yoke. It may be necessary to loosen the hex nuts and back out the travel stop set screws (key 10) to allow this repositioning. 7. When hole alignment is correct, secure the mounting yoke to the valve body with washers (key 4) and the valve body cap screws (key 9).
4
Table 3. Approximate Weights METRIC UNITS
U.S. UNITS
Handwheel Diameter, mm
Weight of Actuator Assembly, Kg
Handwheel Diameter, Inches
152
3.7
6
8
203
4.7
8
10
203
10.3
8
22
305
11.3
12
24
6-KE
610
20.2
24
43
7-KE
762
28.2
30
60
9-KE
914
40.9
36
87
432
62.6
16
133
610
62.6
24
133
ACTUATOR SIZE
0 KE 0-KE 2 KE 2-KE
10 KE:6 10-KE:6
Weight of Actuator Assembly, Pounds
Type 1077 POSITION 1
VALVE BODY
FLOW DIRECTION FOR RIGHT-HAND MOUNTING
FLOW DIRECTION FOR LEFT-HAND MOUNTING
POSITION 4
POSITION 3
DIRECT ACTING ACTUATOR CONSTRUCTION POSITION 1
VALVE BODY
FLOW DIRECTION FOR RIGHT-HAND MOUNTING
FLOW DIRECTION FOR LEFT-HAND MOUNTING
POSITION 4
POSITION 3
30B0668-A B2002-3 / IL
REVERSE ACTING ACTUATOR CONSTRUCTION
Figure 3. Available Mounting Positions
8. If removed for inspection, install the gearbox cover plate. For a size 0-KE actuator only, also install the O-ring onto the hub of the drive sleeve gear. 9. Making certain that the travel indicator pointer is aligned as it was prior to disassembly, install the travel indicator. 10. Before installing the valve body and actuator in the pipeline, perform the procedures presented in the Adjustment section of this manual.
Adjustment Perform the following steps to adjust the travel stops and the travel indicator pointer. Individual part key numbers and part descriptions referenced in this
procedure are shown in figure 6 except where otherwise indicated. Travel stops (key 10) consist of two set screws and two hex nuts. For 90-degree valve disk or ball rotation, both set screws are of equal length. For 60-degree disk or ball rotation, one set screw is longer than the other. To change from 90-degree to 60-degree disk or ball rotation, one set screw must be replaced with a longer one as explained below. Note Sizes 2-KE, 7-KE, 9-KE & 10-KE:6 use the same actuator for both 0–60 degrees and 0–90 degrees, with the replacement of the appropriate set screw. Sizes 0-KE & 6-KE require a different actuator when changing from 90-degree to 60-degree disk or ball rotation.
5
Type 1077 DRIVE SLEEVE GEAR INDEX MARKS (4)
GEARBOX WITH COVER PLATE AND TRAVEL POINTER REMOVED
E0718 / IL
MOUNTING POSITION 1
MOUNTING POSITION 3
MOUNTING POSITION 4
Figure 4. Direct Acting Mounting Positions (Shown in the Closed Position)
DRIVE SLEEVE GEAR INDEX MARKS (4)
GEARBOX WITH COVER PLATE AND TRAVEL POINTER REMOVED
E0719 / IL
MOUNTING POSITION 1
MOUNTING POSITION 3
Figure 5. Reverse Acting Mounting Positions (shown in the closed position)
6
MOUNTING POSITION 4
Type 1077 For Direct acting (except for 0-KE & 6-KE), replace the set screw that limits counterclockwise drive sleeve gear and travel indicator rotation. For Reveres acting (except for 0-KE & 6-KE), replace the set screw that limits clockwise drive sleeve gear and travel indicator rotation. Note A 60-degree set screw used as an opening stop can limit valve ball or disk opening to any angle between 60 and 90 degrees. Alternately, it may be used as a closing stop to limit valve closing to any angle between 0 and 30 degrees. One or two 60-degree set screws may be used to extend the range of the valve opening stop, the valve closing stop, or both
CAUTION To avoid damage to the actuator, the valve shaft splines, and internal valve parts, do not exceed the maximum allowable torques listed in table 2 or any other torque limitation of internal valve parts. Also, do not use wrenches or other devices on the handwheel or handwheel shaft to increase operating force. If the force required to rotate the handwheel will exceed the wheel-rim force listed in table 2, check for the following conditions: D Insufficient lubrication, D Seized actuator parts,
1. If the valve body is in the line, remove it by following the instructions in the separate valve body instruction manual.
D Excessive pressure drop across the valve body, or
2. Loosen the hex nuts and back out both set screws.
D Obstruction to the valve body disk or ball rotation.
3. Rotate the handwheel (key 5) to move the valve disk or ball to the fully closed position. Refer to the separate valve body instruction manual for instructions to determine the fully closed position of the disk or ball. 4. With the valve disk or ball closed, rotate the set screw that is to limit valve closing until this set screw just hits the drive sleeve gear. Lock the set screw with the hex nut. 5. Rotate the handwheel until the disk is at the desired maximum rotation as indicated by the pointer tip on the travel indicator dial. Rotate the remaining travel stop set screw until it just hits the drive sleeve gear. Lock the set screw with the hex nut. 6. Install the valve body and actuator in the pipeline by following the instructions in the separate valve body instruction manual; then proceed to the Operation section.
Instructions are given in the Maintenance section for lubrication of actuator parts. Refer to the separate valve body instruction manual if valve body maintenance is required. If the actuator does not seem to control the process fluid, worm or drive sleeve gear teeth may be broken, the pin (key 6) may be sheared, or internal valve body parts may be broken. Refer to the separate valve body instruction manual if valve body maintenance is required.
Maintenance WARNING
Operation Individual part key numbers and part descriptions referenced in this procedure are shown in figure 6 except where otherwise indicated. After the travel stops (key 10) and travel indicator pointer have been adjusted and the control valve assembly installed, the actuator is ready for operation. The handwheel rotation direction required to open the valve is indicated on the face of the handwheel (key 5).
Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations: D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal injury. D Be sure the actuator cannot suddenly open or close the valve. D Use bypass valves or completely shut off the process to isolate the valve
7
Type 1077 from process pressure. Relieve process pressure from both sides of the valve. Drain the process media from both sides of the valve.
7. Attach the travel indicator pointer so that it indicates the same point of rotation as was noted before the pointer was removed. Secure the pointer with the machine screws.
D Vent the pneumatic actuator loading pressure and relieve any actuator spring precompression.
Disassembly
D Use lock–out procedures to be sure that the above measures stay in effect while you work on the equipment. D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when loosening the packing box pipe plug.
Parts are subject to normal wear and must be inspected periodically. The following procedure describes actuator disassembly for general inspection and replacement of the drive sleeve gear.
Note In order to remove the drive sleeve gear, it is necessary to first remove the actuator input shaft and worm. 1. Remove the pin (key 6) and the handwheel (key 5).
Individual part key numbers and part descriptions referenced in the following procedures are shown in figure 6 except where otherwise indicated.
2. For a size 10-KE:6 actuator only, remove the cap screws which secure the reduction drive (item not shown) and slide the reduction drive off the input shaft. 3. Perform steps 1, 2, and 3 of the lubrication procedure above.
Lubrication The interior parts of a Type 1077 actuator should be lubricated on a regular schedule with a quality gear lubricant. The interior parts should also be lubricated whenever difficulty in handwheel rotation indicates a need for lubrication. To lubricate the Type 1077 actuator, perform the following steps: 1. Note the location of the travel indicator pointer in relation to the indicator dial. When reassembling the actuator, the travel indicator pointer must be returned to its original position. Remove the machine screws and the travel indicator pointer. 2. For a size 0-KE actuator only, remove the O-ring grease seal from the hub of the drive sleeve gear. 3. Remove the cap screws which secure the gearbox cover plate and remove the gearbox cover plate. 4. Coat the worm, the drive sleeve gear teeth, and the bearing surfaces of the gearbox housing and worm with a quality gear lubricant. 5. Install the cover on the gearbox (key 1) and secure it with the cap screws. 6. For a size O-KE only, install the the O-ring grease seal onto the hub of the drive sleeve gear.
8
4. Remove the pin which secures the worm to the input shaft by following the appropriate procedure for the actuator size: For a size 0-KE or 2-KE actuator, drive the pin into the shaft (the pin length is less than the shaft diameter). Remove the input shaft from the actuator housing and drive the pin out of the shaft. For a size 6-KE actuator, rotate the input shaft so that the pin may be driven through the soft plug (item not shown) on the back side of the gearbox housing. For a size 7-KE, 9-KE, or 10-KE:6 actuator, there is sufficient clearance in the gearbox housing to drive the pin through the shaft. Rotate the input shaft so that the pin will emerge on the drive sleeve gear side of the shaft and carefully drive the pin out of the shaft. 5. Remove the input shaft and push the worm away from the drive sleeve gear. 6. Carefully noting the position of the index marks on the drive sleeve gear hub, remove the drive sleeve gear. 7. Remove the worm gear along with any shims or thrust bearings where used. 8. Inspect all parts for excessive wear.
Type 1077 Assembly
Parts Ordering Note
Before or during assembly, coat the following surfaces with a quality gear lubricant: D The teeth of the worm and the drive sleeve gear, and D The bearing surfaces of the gearbox housing, worm and input shaft. 1. Install the worm and any shims and thrust bearings into the gearbox casing. Keep the worm at the maximum possible distance from the installed position of the drive sleeve gear. 2. Install the drive sleeve gear onto the splined valve shaft. Be sure that the index marks are aligned as they were prior to disassembly. 3. Noting the position of the pin holes and the original position of all shims and thrust bearings, install the actuator input shaft into the bore of the worm. 4. Make sure that the pin holes are aligned and install the worm pin. Be certain that the pin does not protrude from either side of the worm and interfere with the teeth on the drive sleeve gear. For a size 6-KE actuator only, install the soft plug on the back side of the gearbox (key 1) housing. 5. Install the gearbox cover plate. 6. For a size 0-KE actuator only, install the O-ring grease seal onto the hub of the drive sleeve gear. 7. Install the travel indicator making certain that the pointer indicates the same degree of rotation as was noted prior to disassembly. 8. For a 10-KE:6 actuator only, install the reduction drive onto the input shaft and secure with capscrews. 9. Install the handwheel (key 5) and pin (key 6). 10. If necessary, adjust the actuator by following the instructions given in the Adjustment procedure.
Whenever corresponding with your Fisher sales office about this equipment, include the serial number and all other information found on the nameplate (key 7, figure 6). When ordering replacement parts, also specify the complete eleven-character part number of each part required as found in the following parts list. If parts other than those listed in the parts list require replacement, contact your Fisher sales office for assistance.
Parts List
Actuator Assembly Key 1 1A 2 3 4 5 6 7 8 9 10 11 12 13
Description Gearbox, cast iron. Drive Sleeve Gear Mounting Yoke Cap Screw, plated steel Washer, plated steel Handwheel Pin, steel Nameplate, stainless steel Drive Screw, stainless steel (4 req’d) Cap Screw (for use with Type 7600 or 9500 valve body) Travel Stop Set Screw, steel Connector, stainless steel Pin, alloy steel Stub shaft, 17-4PH SST
9
Type 1077
TRAVEL INDICATOR POINTER
O-RING WORM
WORM PIN
COVER PLATE
39A8956-B B2001 / IL
Figure 6. Type 1077 Actuator Assembly for Splined Shaft
10
Type 1077
30B1671-A / DOC
Figure 7. Type 1077 Actuator Assembly for Coupled or Keyed Shafts
11
Type 1077
edisc, Fisher, and Fisher-Rosemount are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners. EFisher Controls International, Inc. 1986, 2001; All Rights Reserved
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
For information, contact Fisher: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461 12 Printed in U.S.A.
