CCI_VALVE

INSTALLATION,OPERATION, MAINTENANCE MANUAL

DRAG VELOCITY CONTROL ELEMENT

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REVISION HISTORY Rev. Ltr. NC

Description RELEASED

Compiled Apvd. by by

Release Date


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TABLE OF CONTENTS SECTION 1

1

SAFETY IS GOOD BUSINESS 1 IMPORTANT TECHNICAL ASSEMBLY/DIS-ASSEMBLY INSTRUCTIONS ARE INCLUDED IN THE DRAWINGS, SEE SECTION 8.INTRODUCTION 1 INTRODUCTION 2

SECTION 2

3

HANDLING

3

SECTION 3

13

PNEUMATIC ACTUATOR-YOKE ASSEMBLY

13

SECTION 4

17

TRIM ASSEMBLY

17

SECTION 5

23

ACTUATOR ACTUATOR

23

SECTION 6

27

MAINTENANCE

27

SECTION 7

34

SPECIAL VALVE COMPONENTS

34

SECTION 8

35

VALVE DRAWINGS AND BILLS OF MATERIAL

35


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SECTION 1 SAFETY IS GOOD BUSINESS

DURING THE COURSE OF MAINTENANCE AND INSPECTION ACTIVITIES ON CCI EQUIPMENT, YOU ARE CAUTIONED TO ADHERE TO THE INSTRUCTIONS CONTAINED IN THIS MANUAL AND TO INSIST UPON STRICT ADHERENCE TO YOUR PLANT SAFETY POLICIES IN ORDER TO AVOID POSSIBLE DAMAGE TO EQUIPMENT AND INJURY TO PERSONNEL.

OUR SERVICE DEPARTMENT IS PREPARED TO DISCUSS SOLUTIONS TO ANY PROBLEMS CONCERNING THE MAINTENANCE AND INSPECTION PROCEDURES APPLICABLE TO CCI EQUIPMENT. PLEASE DIRECT ALL INQUIRIES TO: CCI AG IM LINK 11 INDUSTRIEPARK OBERWINTERTHUR

INSTALLATION,OPERATION, MAINTENANCE MANUAL INTRODUCTION 1.1 GENERAL DESCRIPTION CCI Control Valves are designed to provide solutions to control valve problems in a wide range of severe service applications. CCI DRAG Technology provides specified control and shut-off, with longer intervals between maintenance for increased plant production.

1.2 PRINCIPLE OF OPERATION High fluid velocities through the trim are a principal source of severe service control valve problems. CCI’s patented DRAG disk stack controls flowing velocities through the valve trim by forcing the process fluid through a tortuous path of right angle turns. The resistance to flow provided by these turns (or stages) limits the trim exit velocity, regardless of the pressure drop. This reduction in velocity greatly reduces

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SECTION 2 HANDLING 2.1 SCOPE This Section describes recommended procedures for receiving, storing, handling, and installing CCI control valves.

2.2 INTRODUCTION ALL APPLICABLE REGULATIONS AND SPECIFICATIONS SHOULD BE FOLLOWED. GOOD GENERAL PRACTICE SHOULD BE USED FOR ALL INSTALLATION AND MAINTENANCE ACTIVITIES. Every CCI control valve is custom designed for a specific application and a specific set of operating conditions. The control valve drawing in Section 8 provides complete information on valve design conditions, dimensions, weight, and general arrangement. A nameplate

by contract, CCI products are packaged for domestic shipping and indoor storage. After the shipping container is unloaded at the site, the container should be inspected for damage. Joints and seams should be inspected for signs of separation. In order to inspect the valve, the container lid can be safely removed without reducing the structural integrity of the container. If damage to any part is suspected, carefully check the equipment against the packing list. Make a note of any loose, damaged, or missing parts. Notify both the freight company and your CCI contract administrator.

2.4 STORAGE The control valve may have been shipped either disassembled, or with spare par Valve

INSTALLATION,OPERATION, MAINTENANCE MANUAL 2.5 REMOVAL FROM SHIPPING CONTAINER The unit is shipped in a container designed to support both the body assembly and the actuator assembly. To remove the control valve from the shipping container, carefully place appropriate slings around the valve yoke or actuator and lift with a hoist.

WARNING Applicable codes, regulations and industrial practices for handling (hoisting and lifting) loads must be followed. These include but are not limited to the following: A. Slings should be free of kinks and twists. B. Position the lifting hook over the load so that the load does not swing when lifted. C. The crane operator shall see that the load is well secured and balanced. D. The crane operator shall avoid carrying loads over people.

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The flow direction is indicated by an arrow on the body. The valve must be installed in the correct flow direction. The control valve is normally installed in a vertical position, with the valve actuator pointed straight up. If the assembly is to be installed in any other orientation, then adequate supports may be required for the valve actuator assembly. For flanged valves, complete the bolting of the valve in line. For welded-end valves, see Section 2.7 below.

2.7 WELDING OF VALVE BODY TO PIPE AND POST-WELD STRESS RELIEF All welding is to be perfomed in accordance with the appropriate plant procedures. CAUTION The heat of welding and post weld heat treatment can damage valve seals and compromise hardness and wear capabilities.

INSTALLATION,OPERATION, MAINTENANCE MANUAL address this problem is during the construction or major repair phase.

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the atmosphere. A mirror target at the outlet of the pipe is used to check if the pipe is clean.

Damage from Debris The most common debris generated during construction or major repair is weld slag (sharp edged particles) and weld splatter (small hard beads of weld or base material). Unaddressed weld slag and splatter can become trapped between the tightly toleranced modulating parts of a control valve, resulting in gouges and deep sharpedged scratches. Modulating a scratching surface through a seal can cause the seal to fail leading to additional problems such as trim erosion, loss of guiding and vibration. Debris trapped between moving parts with hardened or overlaid surfaces can result is stuck hardware and loss of control. Frequently the damage done by this debris requires the replacement of parts to restore the control valve’s capabilities.

Since this temporary piping usually creates a low back pressure, the steam blowing is performed at a lower pressure than normal system operation. The flow rate of steam used for flushing should be one that results in a slightly higher dynamic pressure than the normal operation of the system. This ensures that all foreign matter that can be transported by the steam, is removed prior to commissioning. Equipment which would be sensitive to damage during flushing, such as tight toleranced control valve trim components, should be removed, blocked or isolated. A list of components to be removed should of be prepared as part of the flushing procedure. Ball valves should be flushed in the full open position. Following the completion of the flushing, all pipe work should be free from debris, dirt,


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INSTALLATION,OPERATION, MAINTENANCE MANUAL Dedicated flushing components for control valves can have two configurations: “blow through” and “blow out.” In a “blow through” configuration, the flushing medium flows through the control valve along the same path and in the same direction the normal operating fluid would. In a “blow out” flushing configuration, the piping downstream of the control valve is blocked and the flushing medium is routed through the control valve bonnet, which is directly connected (by flange or weld) to the temporary flushing piping. CCI Valve Doctors are available to provide expert assistance in reviewing required commissioning and flushing material.

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containing halogens should not be used on austenitic stainless steel surfaces as they will contribute to the potential for stress corrosion cracking. When chemical cleaners that may result in adverse reactions are used, sensitive items that can be damaged by the cleaning medium should be removed or blanked off. Removed or blanked off items shall be cleaned separately prior to reinstallation. The systems to be cleaned shall have high and low point vents and drains. Dead legs shall be avoided. If chemical cleaning occurs more than 3 months prior to start up of commissioning activities, the system should be preserved with nitrogen.

Chemical Cleaning In addition to debris from weld slag and splatter, oils, grease, preservatives, mill scale and corrosion products will need to be removed from the boiler and piping systems prior to plant commissioni To remove

Dedicated Cleaning Tools Occasionally, it is desirable to use the control valve for throttling during the chemical cleaning process. In these cases, adverse reactions between the permanent


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At least 4 inches (100 mm) of high efficiency thermal insulation should be applied to all exterior surfaces of the valve body and bonnet.

CAUTION Insulation should not be applied to the actuator yoke legs. The actuator yoke legs must be kept open to the air for efficient heat removal.

Commissioning of Control Valves Prior to their initial operation, the condition of the valve bodies and trim should be inspected, and the following checks should be performed. • Control Valves should be properly stored

INSTALLATION,OPERATION, MAINTENANCE MANUAL downstream of the valve should have proper drainage. NOTE: Refer to Section 2.8: Line Flushing and Chemical Cleaning If it is necessary to disassemble a Control Valve, the following checks should be performed prior to the re-assembly. • The correct tools for assembly (lifting eyes, torque wrenches) should be available • Torque wrenches should be calibrated. • Adequate quantities of CCI’s recommended lubricant should be available.

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Pneumatic Actuator Commissioning Checklist The following checks should be performed on the air supply line to the CCI Actuator: • The size of the connection from the air supply should be equal to or greater than that which is shown on the CCI Top Assembly Drawing. • The air supply to the CCI actuator should be provided via flexible lines or compression fittings. No welded connections should be present. • Prior to connection to the CCI actuator, all air lines should have been blown out to remove any contamination or moisture.

• Adequate spare parts (soft goods and hard goods) should be available.

• The supply pressure should not exceed the pressure requirements listed on the CCI Top Assembly Drawing. This should be confirmed with a calibrated gage.

• Disassembly and reassembly of the Control Valve must be performed according to the supplied Maintenance Manual.

• Pressure settings for all filter regulators should be checked against the CCI Top Assembly Drawing.

INSTALLATION,OPERATION, MAINTENANCE MANUAL • If required, anti-contamination (or bug screens) should be present and correctly mounted. • The orientation of all accessories should allow for proper drainage and prevent water or contaminant collection. • The electrical signal strength and voltage of any solenoid valves present should be verified. The power supply should be within +/- 10% of required. • The operational mode of all present solenoids (fail open, fail closed, fail in place), should be verified. • If the Control Valve process fluid (natural gas) is used for the actuator air source, ensure component exhaust is vented to a safe location. If the Control Valves operates at extreme temperature services (>425oC or <-29oC), the Control Valve should be sufficiently insulated to protect the positioner and

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• The positioner linkages should be inspected for damage or potential binding problems.

2.11 START-UP AND OPERATION When reassembling the valve, verify that all valve body assembly and actuator bolting is torqued in accordance with the proper assembly technique outlined in this manual. Verify that all required utilities, including pneumatic, hydraulic, and electric supplies and signals, are cleaned and properly sized, connected and adjusted. Refer to the valve drawing in Section 8. Permanent electrical, hydraulic or air supply lines should not be installed where they will interfere with access to the valve body or actuator for maintenance or removal. Flexible lines with reusable couplings should be used to bring utilities to the valve from the permanent supply lines. Verify that all control and accessory

INSTALLATION,OPERATION, MAINTENANCE MANUAL On some pneumatic actuators, a bypass valve assembly is installed. Verify that the bypass valve on the actuator is closed (see Figure 2-2).

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2.13 POSITIONER CALIBRATION See vendor literature in Section 9 for proper setup and calibration of the positioner. Lubrication of the positioner linkage (refer to Table 5-2) will ensure good modulating control. CAUTION The positioner must be properly calibrated in order to have full seating load when the actuator is in the closed position. Premature trim degradation may occur if the calibration is incorrect.

FIGURE 2-2 Actuator Bypass Valve Positions If a manual override is installed, verify that it is in the proper position and is disengaged (refer to section 7). If a Bailey positioner is used, verify that any bypass valves in the positioner are in the AUTOMATIC position.

For positioners that do not auto-calibrate, the following procedures and signal ranges must be used during positioner calibration. 1.

For “Increasing Signal Opens” valves, move the stem in the closing direction until the signal is equal to the high end of the “low” tolerance band shown in Table 2-1. The valve must not be fully closed at this point. Decrease signal to the low end of the

INSTALLATION,OPERATION, MAINTENANCE MANUAL Table 2-1. Positioner Calibration

Full Range

Split Range

SIGNAL RANGE

LOW BAND

HIGH BAND

3 to15 psig

3.1 to 3.6

14.4 to 14.9

3 to 27 psig

3.2 to 4.0

26.0 to 26.8

6 to 30 psig

6.2 to 7.0

29.0 to 29.8

4 to 20 mA

4.2 to 4.8

19.2 to 19.8

-10V to +10V

-9.8 to –9.1

9.1 to 9.8

3 to 9 psig 9 to 15 psig

3.1 to 3.4 8.7 to 9.0

9.0 to 9.3 14.6 to 14.9


3.2 to 3.6 14.6 to 15.0

15.0 to 15.4 26.4 to 26.8


6.6 to 6.2 17.6 to 18.0

18.0 to 18.4 29.4 to 29.8

4 to 12 mA

4.2 to 4.5

12.0 to 12.3

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SECTION 3 PNEUMATIC ACTUATOR-YOKE ASSEMBLY 3.1 SCOPE This section describes the procedures for disassembly and assembly of the actuator-yoke from the valve.

3.2 DISASSEMBLY Refer to the valve drawing in Section 8 for valve actuator information.

CAUTION To avoid personal injury and damage to the process system, isolate the actuator from the system before attempting disassembly. Isolate the control valve from the system pressure.

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INSTALLATION,OPERATION, MAINTENANCE MANUAL Attach the yoke to the bonnet using the yoke clamp and eye bolts, mounting bolts, or spud nut as supplied and torque per Table 3-3. Lubricate the packing flange nuts and the threads of the eyebolts or packing flange studs. See Table 4-1 for recommended lubrication. Install the packing flange and nuts. Torque the nuts per Table 3-2. Slowly relieve air pressure from the lower cap air port. Install an air line, with a manually controlled regulator installed, to the upper cap air port . Slowly apply sufficient air pressure to extend the actuator shaft until it contacts the plug stem. Install the stem clamp to secure the plug stem to the actuator shaft and torque per Table 3-1. Torque the stem clamp bolts evenly in a cross pattern. As the bolts are tightened, keep the gap equal on both sides of the stem (refer to Figure 3-2).

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WARNING The positioner must be properly calibrated in order to have full seating load when the control element is in a closed position. Premature trim degradation may occur if calibration is incorrect. Refer to Section 2 for positioner calibration. Check for leakage.


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Table 3-1. Recommended Stem Clamp Torque STEM SIZE

TORQUE

BOLT SIZE

(in)

(ft-lbs)

(N-m)

(in)

5/8 1 1-1/2 2

5-10 20-25 45-50 90-100

10-15 25-30 60-70 125-135

1/4 3/8 1/2 5/8

Table 3-2. Recommended Packing Nut Torque FOR TEFLON PACKING TORQUE

STEM SIZE

BOLT SIZE

(in)

(in)

(lbf-ft)

(N-m)

5/8

5/8 11

10

15


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SECTION 4 TRIM ASSEMBLY 4.1 SCOPE This Section describes the procedures for disassembly and assembly of the valve trim.

4.2 DISASSEMBLY Disassembly of the actuator-yoke assembly is required. Please refer to Section 3 for instructions. Evenly remove the bonnet nuts and the bonnet flange from the body. Insert a pry bar under the flange of the metal seal. While moving the pry bar around the metal seal, work the seal out of the cavity between the bonnet and the body. Attach a yoke clamp and sling to bonnet, as shown in Figure 4-1.

Remove the bonnet from the body. Be sure that the plug/spindle assembly remains in the body. See Figure 4-1. Remove the metal seal from the bonnet. If the metal seal is stuck to the bonnet by corrosion use a block of wood and d rive toward the top of the bonnet. Move the block around the metal seal while tapping lightly.


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Apply a lubricant (refer to Table 4-1) on the flexitallic gaskets and place them in the grooves of the seat ring. Position the seat ring in the body. Be certain the seating surface of the seat ring is upward (see Figure 4-7). Rotate the seat ring several times to make sure it is fully seated in the body recess. If provided, place the seat ring spacer in the body. Lower the disk stack/cage assembly into the body until it registers on the seat. Make certain the end marked “seat end” is placed o n the seat ring. If lifting holes are provided, attach two eyebolts and a sling. Make certain the disk stack/cage assembly is fully seated on the seat ring by rotating it several times. Apply a thin coat of lubricant (refer to Table 4-1) on the outside diameter of the plug/spindle assembly (do not apply to the seating angle). Using the yoke clamp, stem clamp, and sling,

FIGURE 4-8 Plug seal configuration Apply a thin coat lubricant (refer to Table 4-1) on the plug seal. Place the plug seal into the bonnet or bonnet spacer cavity as shown in Figure 4-8. Apply a light coat of lubricant (refer to Table 41) to the body bonnet bore an d the outside of the bonnet or bonnet spacer (see Figure 4-9)..

INSTALLATION,OPERATION, MAINTENANCE MANUAL Attach a yoke clamp and sling to bonnet, as shown in Figure 4-1. Lower the bonnet onto the disk stack assembly, cage or bonnet spacer using care to prevent damage to the balance seal. Remove the yoke clamp or eye bolts and sling. Install the metal seal over the bonnet. Position the bonnet flange over the bonnet. Reference the valve drawing in Section 8 for the required bonnet bolt torque. Refer to Table 4-2 for recommended bonnet torquing increments based on the required bonnet bolt torque. Be certain that the plug stem is centered in the bonnet cavity while tightening the nuts alternately by the increments shown in Table 4-2 and using the torque pattern in Figure 4-10. The packing follower may be used as a centering device. Wrap friction tape around the top of the packing follower so that it will not fall

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CAUTION Do not use a pointed tool to install the packing as damage to the sealing capability of the packing will result. Place the Teflon v-rings in the stuffing box between the male and the female adapters. See Figure 4-11 for proper orientation.


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INSTALLATION,OPERATION, MAINTENANCE MANUAL Table 4-2. Recommended Bonnet Torque Increments REQUIRED TORQUE (T)

TORQUE INCREMENTS

(lbf-ft)

(N-m)

(lbf-ft)

(N-m)

T < 100

T < 136

25

34

100 < T < 300

136 < T < 407

50

68

300 < T < 800

407 < T < 1085

100

136

T > 800

T > 1085

200

272

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SECTION 5 ACTUATOR 5.1 SCOPE This section provides instructions for the disassembly and assembly of the actuator assembly.

5.2 INTRODUCTION The actuator assembly is pneumatically operated, connected to the body assembly with a yoke, and to the plug stem with an actuator shaft. The actuator assembly extends or retracts the plug assembly within the body assembly by pressure applied to either side of the piston. In the event of air supply failure, the air tank or springs when supplied, will force the piston to move the plug into the specified fail position (see Figure 5-1).

WARNING

When operating the actuator with the actuator shaft disconnected from the valve stem, the following precautions must be observed to avoid the possibility of serious injury or product damage. 1) Do not let any object, including fingers, get between the end of the actuator shaft and the end of the valve stem. 2) When stroking actuators, do not apply more than 20 psig (140 KPa) air pressure to move the piston in either direction. 3) When checking the actuator static o-rings for leaks, apply equal pressure simultaneously to both end caps using a maximum air supply pressure of 100 psig (700KPa). 4) When checking for a torn or “rolled” piston o-ring, do not apply more than 20 psig (140 KPa) to the piston.

INSTALLATION,OPERATION, MAINTENANCE MANUAL 5.3 DISASSEMBLY Refer to section 3 for removal of the actuator from the valve.

WARNING Damage to the equipment and personnel could occur if the pressure has not been relieved from the actuator assembly. Make certain there is no pressure in the actuator. If a manual override is installed, remove it from the actuator. (refer to section 7 for instructions) Remove all nuts and tie rods (screws) from the uper cap. Remove the upper cap. For sizes SC/V 300, 400, and 500, tilt the cylinder at the top to break the sealing tension at the lower cap. Remove the cylinder.

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Apply lubricant (refer to Table 5-2) to all o-rings and install them. Assemble the manual override if applicable (Refer to section 7 for instructions). Secure the actuator shaft by the milled flats. If the shaft does not have milled flats install the stem clamp onto the shaft and clamp the stem clamp in a vise equipped with soft brass jaws. Secure the piston to the actuator shaft. Insert the actuator shaft assembly into the lower cap. Replace the stem guide bushing on the lower cap (cylinder casing) by turning it clockwise. For sizes SC/V 300, 400, and 500, apply a light coat of lubricant (refer to Table 5-2) to the interior surface of the cylinder. Carefully install the cylinder onto the lower cap. Place the upper cap onto the cylinder. Align the air ports in the lower cap and upper cap. Lubricate and install tie rods, nuts, and washers


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Table 5-1. Actuator Stud Torque Actuator Size

Stud Size

Stud Qty

Required Torque

(lbf-ft)

(N-m)

SC/V 200

M8

8

10

14

SC/V 320

M10

12

15

20

SC/V 300

M16

8

38

52

SC/V 400

M16

8

38

52

SC/V 500

M16

8

38

52

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SECTION 6 MAINTENANCE 6.1 SCOPE This Section presents procedures for preventative maintenance, fault finding, inspection, repair, and cleaning of CCI control valves and pneumatic actuators. Instructions for control devices and accessories provided with the valve are provided in Section 9. Detailed instructions for electric and hydraulic actuators are provided in Section 9. Valve and actuator drawings are provided in Section 8.

6.2 PREVENTATIVE MAINTENANCE CCI control valves are designed to provide long service life with proper preventative maintenance. Preventative maintenance is limited to periodic replacement of seals and packing, and periodic inspection and cleaning of the valve trim. Preventative maintenance schedule (see Table 6-1) should be observed. A CCI Factory Recommended Installation and Service Record is attached (see Table 6-4).

NOTE

NOTE

NOTIFY CCI FIELD SERVICE ENGINEERING (949)858-1877, OF ANY PROBLEMS WHICH ARISE DURING MAINTENANCE.

THE REQUIRED MAINTENANCE SCHEDULE MAY VARY DEPENDING UPON APPLICATION AND DUTY CYCLE .


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6.3 FAULT-FINDING AND RECOMMENDED REPAIR Since CCI control valves are designed to provide long service life when properly maintained, the fault-finding and corrective maintenance procedures for CCI control valves are limited. If factory recommended maintenance schedules are observed, then the need for unscheduled maintenance and repair should be infrequent.

Table 6-2 identifies potential problems, possible causes, and recommended repairs. The potential problems and recommended repairs listed are intended primarily for CCI control valves fitted with CCI pneumatic actuators. If an electric or hydraulic actuator is installed on the valve, also see Section 9. Please contact CCI, Field Service Engineering for assistance in resolving any maintenance problems.

TABLE 6-2: FAULT-FINDING AND REPAIR Problem Packing leakage.

Valve leaks

Possible Cause

Item

Incorrect packing flange torque. Packing damaged or incorrectly installed. Valve stem scratched.

1

Problems with actuator

4

2 3

Recommended Repair Torque the packing flange nuts to the limits specified in Table 3-2. Replace the packing following the procedures given in Section 4. Disassemble the valve and inspect the stem. Replace the stem and plug, if necessary. Reassemble the valve with new packing following the procedures given in Section 4. Check the system supply pressure. Compare


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TABLE 6-2: FAULT-FINDING AND REPAIR (continued) Problem

Possible Cause

Item Recommended Repair

Bonnet leakage. (con’t)

Large temperature gradients.

12

Plug / Stem jumps or sticks while in travel.

Problems with actuator supply pressure Positioner calibration is not correct. Control devices misadjusted or malfunctioning.

13

Very large thermal transients in the valve fluid can cause leakage. Check the start-up and operating procedures for the valve. Disassemble the valve and inspect the valve trim for damage. Contact Control Components Inc. for recommendations. See item No. 4.

14

See item No. 5.

15

Check the setting and operation of all control devices, including supply regulators, needle valves, volume boosters, and solenoid valves.

Incorrect packing flange torque. Valve trim is galling.

16

See item No. 1.

17

Disassemble the valve. Check the plug and disk stack / cage for signs of galling or wear. Check the stem and packing box for scratches and damage. Check for foreign material or loose particles caught between moving parts in the


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TABLE 6-2: FAULT-FINDING AND REPAIR (continued) Reduced flow through element. (con’t) Leakage from valve actuator. Stroke time too slow.

Valve doesn’t open fully.

Valve doesn’t close fully

Valve not fully open

28

See item Nos. 34-36.

Debris blocking flow passages Leaking valve actuator seals. Problems with actuator supply pressure. Incorrect packing flange torque. Control devices misadjusted or malfunctioning.

29

See item No. 6.

30

See item No. 23.

31

See item No. 4.

32

See item No. 1.

33

See item No. 24.

Manual override is limiting stroke Improper positioner calibration Major debris in valve

34 35

Re-Position manual override so it does not interfere with the stroke. See item No. 5.

36

See item No. 6.

Improper positioner calibration Major debris in valve

37

See item No. 5.

38

See item No. 6.


6.4 INSPECTION AND REPAIR The following inspection and repair procedures are recommended for the valve and actuator components (Table 6-3). Replace all parts which cannot be repaired by these procedures. If an electric or hydraulic actuator is installed on the valve, also see Section 9. Contact CCI, Field Service Engineering for recommended wear tolerances and maximum allowable surface flaw depths, especially for seat rings, plugs, spindles, stems, and other valve trim components.

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A complete record of all maintenance and repairs should be maintained. A CCI Factory Recommended Installation and Service Record is attached (see Table 6-4). Defects refer to galling, burrs, nicks, scratches or other imperfections resulting in material being raised above the normal surface which, if not removed, would prevent proper mating of parts and sealing surfaces. Minor defects would not affect the mating of parts and sealing surfaces.

TABLE 6-3: INSPECTION AND REPAIR

COMPONENT

L A

Threaded surfaces

INSPECTION CRITERIA

Galling, burrs, nicks

E E L L B B A T A T T P O P E N E C C C C A A

X

RECOMMENDED REPAIR

Chase all threads with

die.

INSTALLATION,OPERATION, MAINTENANCE MANUAL 6.5 CLEANING MATERIALS REQUIRED The following materials should be used to comply with CCI recommended cleaning methods. Materials and methods may be changed to meet local conditions and requirements. • • • • • • • •

crocus cloth, 400 grit cleaning cloths brush, S.S. wire brush, non-metallic solvent methyl alcohol, anhydrous purified ethyl alcohol, anhydrous denatured acetone, technical grade

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Direct compressed air through each disk passage, in the reverse direction of flow. Dry parts with cleaning cloths and/or compressed air

6.7 RECOMMENDED SPARE PARTS When ordering spare parts, please refer to the information listed on the cover sheet of this manual. Flexitallic gaskets Balance seal Stem packing Packing spacer Packing follower Balance seal spacers Metal seal Actuator soft-goods Kit or o-rings and bushing

     

NOTE RE-DISTILLED SOLVENTS MUST BE EQUIVALENT TO NEW SOLVENT.

 

6.8 LONG LEAD TIME ITEMS WARNING SOLVENTS MAY BE TOXIC AND FLAMMABLE. REFER TO THE

When ordering parts, please refer to the information listed on the cover sheet of this manual.


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TABLE 6-4: FACTORY RECOMMENDED INSTALLATION AND SERVICE RECORD Customer: Site: Valve Tag: CCI Serial No.: Description: Installation Record

Date

By

Notes

Valve Assembly & Test I&C Assembly & Test

Schedule Activity 1.5 years

3 years

4.5 years

Inspect packing follower, plug assembly, seat ring, & disk stack/cage for damage. Replace flexitallic gaskets, balance seal, metal seal if damaged, stem packing, & spacer. Check the operation and calibration of all valve instruments, control devices, and the actuator. Rework or replace as required. Inspect packing follower, plug assembly, seat ring, & disk stack / cage for damage. Replace gaskets, balance seal, metal seal if damaged, stem packing, & spacer. Check the operation & calibration of instruments, control devices, & actuator. Rework or replace as required. Replace actuator bushing and o-rings. Inspect packing follower, plug assembly, seat ring, & disk stack / cage for damage. Replace gaskets, balance seal, metal seal if

Date

By

Notes


SECTION 7 SPECIAL VALVE COMPONENTS NOT APPLICABLE

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SECTION 8 VALVE DRAWINGS AND BILLS OF MATERIAL

Top assembly with Parts list and Material

201242-2CH page 1 of 2

For below-mentioned Documents refer to the register 11, “VENDOR LITARATURE”: - Pneumatic diagram - Pneumatic actuator - Sub-contractor’s equipment (in acc. with the pneumatic diagrams parts list)

201242-2CH, page 2 of 2 SC/V ND 320

CCI_VALVE

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