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Flowserve Valtek FlowTop V726 User Instructions
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Flowserve Valtek FlowTop V726 User Instructions

Flowserve Valtek FlowTop V726 User Instructions

High performance control valve
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U S E R IN S T RU C T ION S
Installation
Operation
Maintenance
Valtek FlowTop
High Performance Control Valve
Type V726 and V738, V740
Type D726 and D738, D740
FCD VLEEIMFTOP-03 06/23
This document is the 'Original Instructions'
Experience In Motion

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Summary of Contents for Flowserve Valtek FlowTop V726

  • Page 1 U S E R IN S T RU C T ION S Installation Operation Maintenance Valtek FlowTop High Performance Control Valve Type V726 and V738, V740 Type D726 and D738, D740 FCD VLEEIMFTOP-03 06/23 This document is the ’Original Instructions’ Experience In Motion...

  • Page 2: Table Of Contents

    9001 standards. The following instructions are designed to assist in unpacking, installing and per- forming maintenance as required on Flowserve Valtek FlowTop control valves. This instruction manual does not include specific product design data. Such data can be found on the valve’s serial plate or specification documents; additionally, dimen- sional information can be found in the Valtek FlowTop technical bulletin.

  • Page 3: Scope Of Manual

    (either as unbalanced or mentation including a technical bulletin and user instructions pressure balanced), and bellows seal bonnets. See Figure 1 at www.flowserve.com. It is the user’s responsibility to keep and Figure 2. this and related documentation on file and accessible for the The Valtek FlowTop is designed in compliance with EN Valtek FlowTop product.

  • Page 4: Valtek Flowtop Modification

    Standard packaging includes a cardboard box, with Flowserve is not a transport and lifting company. It is the or without a wooden pallet base as needed. Special packaging responsibility of the persons commissioned on site to carry may include a wooden box.
  • Page 5 • Promptly touch up any damage to the corrosion pro- tection. • Contact your shipper immediately to report any damage. • Call your Flowserve representative if you experience any problems. Limited construction-related working load limit • Do not remove the protective covers from the body...

  • Page 6: Installation

    In the worst case, such a problem can be resolved only by a subsequent expensive pipe change. Flowserve Control Valves GmbH is a manufacturer of valves, not a piping contractor. Our expertise is in the design and manufacture of control valves.
  • Page 7 WW or EU serial plate. Table 1: Basic safety massages for installing the valve After these requirements are confirmed the valve can be installed and connected in the piping. FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...

  • Page 8: Valve Quick-Check

    Valtek FlowTop 1. Remove the protective flange covers and coating from maintenance. the control valve; clean the flange gasket surface. 3. Install and connect the control valve to the pipeline. Locate gaskets in the center of the body flanges and Unsuitable cleaning agents can dam- NOTICE secure nuts and bolts.

  • Page 9: Valve Maintenance

    Dependent upon results of previous maintenance (see numbers 1 to 4 above) or a the valve minimum once every 60 months Operation test No action Perform 3 full strokes if packing and / or bonnet tightening is modi- fied; check for leakage FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 10 Possible malfunction or safety related incident Check the packing follower for proper tightness. Flowserve uses three solutions to preload the packing rings. These are adjustable, outside spring loaded, or inside spring loaded. The variants are described on pages 50 - 53, 61 as well as the correct tightening method and the recommended torques.

  • Page 11: Troubleshooting

    Make sure there are no leaks. • Valve trim worn or stuck • Contact customer service department or contract partner Jerky stem movement • Damaged stem • Contact customer service department or contract partner FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 12 Valtek FlowTop Defect Possible Causes Remedy Jerky stem movement • Actuator not powerful enough • Compare actuator specifications on the serial plate with operation specifications of the facility. If in- compatible, contact customer service department or contract partner Stem travel less than full stroke • Air supply pressure too low • Provide air at the pressure stated on the serial plate (0 to 100 %)

  • Page 13: Disassembly And Reassembly

    Valtek FlowTop control valve. The Valtek FlowTop control valve is al- lowed to be disassembled and reassem- Only Flowserve trained and authorized personnel are allowed bled only by qualified staff - personnel to repair (disassemble and reassemble) the Valtek FlowTop in hazard areas.
  • Page 14 Valtek FlowTop 13.1 Disassembly instruction of the valve actuator. Hand operated Pneumatic operated see page 15 see page 16 Electric operated - PS-Automation Electric operated - Haselhofer see page 17 Electric operated - Linear thrust unit „light“ Electric operated - Linear thrust unit „heavy“ see page 18 see page 19 FCD VLEEIMFTOP-03 (EN/A4) June 2023...
  • Page 15 7. Place the valve body assembly on a table for disas- sembly. Figure 7: Remove the coupling parts 5.10 Figure 8: Remove the manual actuator Item Item Part Part Lower coupling Cap screw Lock nut 5.10 Yoke lock nut Table 9: Coupling parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 16 Valtek FlowTop Disassembly of the pneumatic actuator. 1. Disconnect the air supply from the actuator and / or assembled accessories. O-ring Positioner 2. Disassemble the positioner from the valve as neces- sary (see Figure 9: Remove the positioner). Socket screw 3.
  • Page 17 6. Place the valve body assembly on a table for disas- sembly. Electric Actuator Figure 12: Remove the electric actuator Item Item Part Part Lock nut 5.10 Yoke lock nut Table 11: Coupling parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 18 Valtek FlowTop Disassembly of the electric rotary actuator and linear thrust unit “light”. Electric multi turn Actuator 1. Disconnect the electric lines from the actuator. Observe the relevant local regulations for NOTICE handling electrical power ! 2. Turn the cap screws (5.11) counter clockwise too loosen (see Figure 13: Remove the electric actuator).
  • Page 19 Linear thrust Unit "heavy" 5.10 Figure 16: Remove the linear thrust unit Item Item Part Part Lock nut 5.10 Thrust unit lock nut Indicator disc 5.11 Cap Screw Table 13: Coupling parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 20 Valtek FlowTop 13.2 Disassembly / reassembly instructions of the valve body. 3-Flange - flanged 3-Flange - welded 3-Flange - flanged with heating jacket Angle - flanged Angle - welded see page 21 - 22 4-Flange - flanged 4-Flange - welded 4-Flange - flanged with heating jacket Top guided - see page 22 - 24 Top and bottom guided - see page 24 - 26...
  • Page 21 3. Remove the plug assembly out of the body if these is method up to a nominal diameter of 150 not done. mm or 6”. Above DN 150 or NPS 6, Flowserve recommends attaching the bonnet to the bonnet-thread (suitable Lifting 4. Remove the bonnet gasket (1.2).
  • Page 22 17. Tighten the bonnet nuts (1.4) in four steps - 30%, 60%, 100%, and all around 100% - using a crosswise mm or 6”. Above DN 150 or NPS 6, Flowserve recommends pattern (See Section 14: Torque Requirements). attaching the bonnet to the bonnet-thread (suitable Lifting Tool with M80 x 2) and pulling it out of the body.
  • Page 23 Bonnet Gasket Seat gasket Body studs (3.1) (40) Bonnet There are different versions - for details NOTICE Body nuts Cover see 13.4 trim variant (Page 44). Table 15: Valve parts FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 24 NOTICE method up to a nominal diameter of 150 23. Install the packing box ring (3.2) and the new packing mm or 6”. Above DN 150 or NPS 6, Flowserve recommends (3.3). attaching the bonnet to the bonnet-thread (suitable Lifting...
  • Page 25 Bonnet Gasket Seat gasket Body studs (3.1) (40) Bonnet Body nuts Cover 26. Finish packing follower (3.4) tightening with a wrench (See Page 50). Table 16: Valve parts FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 26 Flowserve recommends attaching the NOTICE bonnet to the bonnet-thread (suitable 16. Install a new gasket (1.2), seat ring (2.20) and the sec- Lifting Tool with M64 x 2 resp.
  • Page 27 Item Part Part Body Plug Bonnet Gasket Seat gasket Body studs 2.20 Seat Ring Body nuts (3.1) (40) Bonnet Screwed seat Connection Piece Table 17: Valve parts Figure 20: Disassemble / Reassemble the valve FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 28 2. Place a Lifting Tool - see 16 Special Tools (Page 62) - if previously reassembled. on the bonnet and pull the bonnet assembly. 19. Lower the plug assembly (2.2) into the body with the Flowserve recommends attaching the NOTICE plug touching the seat ring surface. bonnet to the bonnet-thread (suitable Exercise care with bellows seal bon- Lifting Tool with M64 x 2 resp.
  • Page 29 Body studs 2.32 V-Port Plug Body nuts 2.33 Spring Washer Screwed seat 2.34 Hex Nut Plug (3.1) (40) Bonnet Seat gasket Connection Piece Table 18: Valve parts Figure 21: Disassemble / Reassemble the valve FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 30 Valtek FlowTop 13.3 Disassembly / reassembly instructions of the valve bonnet. Standard Bonnet - VN High Temperature Bonnet - VR Low Temperature Bonnet - VK see page 31 Bellows Seal Bonnet - VB # A Bellows Seal Bonnet - VB # B Insulating Bonnet - VI Insulating Bonnet - VT see page 32 - 33...
  • Page 31 Check for corrosion or any other damage. Damage sealing surfaces is very likely to NOTICE lead to subsequent leaks. 9. Further assembly is carried out as described in the chapter - body. FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 32 Valtek FlowTop Disassembly instructions of the VB # A bon- net design DN 15 - 50, NPS 1/2 - 2. Do a visual inspection and only disassemble NOTICE assemblies where necessary. This does not include full servicing after 7 years at the latest. 1.
  • Page 33 2.15 Gasket 3.15 Head other damage. Bonnet 3.16 Hex Nut Damage sealing surfaces is very likely to Bottom Ring 3.17 Stud Bolt NOTICE Packing lead to subsequent leaks. Table 21: VB Bonnet parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 34 Valtek FlowTop Reassembly instructions of the VB # B bon- Disassembly instructions of the VI bonnet net design DN 65 - 400, NPS 3 - 16. design. 10. Lower the plug (2.2) into a three jaw-chuck with soft Do a visual inspection and only disassemble NOTICE brackets.
  • Page 35 Washer Stem 3.13 Gasket 2.15 Gasket 3.14 Plug Screw Bonnet 3.15 Head Bottom Ring 3.16 Hex Nut Packing 3.17 Stud Bolt Gland Flange 3.23 Insulating Pipe Stud Bolt Table 22: VI Bonnet parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 36 Valtek FlowTop Disassembly instructions of the VT bonnet. Do a visual inspection and only disassemble NOTICE assemblies where necessary. This does not include full servicing after 7 years at the latest. 1. Remove the lifting tool if it has not already been done. 2.
  • Page 37 Hex Nut 11. Use a standard brass scraper or other suitable tool to 2.23 Circlip Ring Washer clean the sealing surfaces. Check for corrosion or any other damage. Table 24: ON Bonnet parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 38 Valtek FlowTop Disassembly instructions of the OI bonnet Reassembly instructions of the OI bonnet design. design. 13. Lower the plug (2.2) into a three jaw-chuck with soft The expanding force of the lip ring WARNING brackets. clamps the sleeve onto the plug. Both in turn are held in place by frictional forces via the 14.
  • Page 39 Gasket 2.21 Driving Band 3.14 Plug Screw 2.22 Ring 3.15 Head 2.23 Circlip Ring 3.16 Hex Nut 2.24 Sleeve 3.17 Stud Bolt Bonnet 3.23 Insulating Pipe Bottom Ring Table 25: OI Bonnet parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 40 Valtek FlowTop Disassembly instructions of the KR bonnet. other damage. Damage sealing surfaces is very likely to NOTICE The expanding force of the piston WARNING lead to subsequent leaks. rings clamps the sleeve onto the plug. Both in turn are held in place by frictional forces via 13.
  • Page 41 Figure 29: High Temperature Bonnet - balanced KR Item Item Part Part Gasket Bottom Ring Plug Packing Lock Bushing Gland Flange Stem Stud Bolt 2.12 Piston Ring Hex Nut 2.24 Sleeve Washer Bonnet Table 26: KR Bonnet parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 42 Valtek FlowTop Disassembly instructions of the SN bonnet. Do a visual inspection and only disassemble NOTICE assemblies where necessary. This does not include full servicing after 7 years at the latest. 1. Remove the lifting tool if it has not already been done. 2.
  • Page 43 7. Check the bonnet bolting after first pressurization in a de- pressurized and cooled state and retighten if necessary. Gasket settling, the phenomenon intensi- NOTICE 20 screws, 18 ° angular distance fies under increased temperatures! FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 44 Valtek FlowTop 13.4 Disassembly / reassembly instructions of the valve trim. Contoured Plug PO Multi Hole Plug LO Piston Plug SO see page 45 see page 45 see page 45 Silent Pack PK Multi Stream PC, PE, PG, PD, PF, PH Multi Stream PI, PQ, PW see page 45 see page 46...
  • Page 45 Figure 32: SilentPack PK Item Item Part Part Screwed Seat 2.28 Spring Plug 2.29 Internal Ring 2.26 Perforated Cage 2.30 Spacer Bush 2.27 Wire Netting Table 29: PK Trim parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 46 Valtek FlowTop Disassembly instructions of the Contoured Plug and MultiStream PC, PE, PG, PD, PF, PH. 1. As already described elsewhere. 2. After the removing of the plug, remove the spring 2.28 (2.28) and the MultiStream assembly. Make a visual inspection and only in- NOTICE 2.29 stall parts that are technically flawless.
  • Page 47 Make a visual inspection and only in- NOTICE stall parts that are technically flawless. Figure 36: Radial Multi-Step System BO, DO Item Item Part Part Screwed Seat Cover Plug Table 33: BO, DO Trim parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 48 Valtek FlowTop Plug / stem screw connection • Spring pin design for stem diameter 20 to 50 - The actuating forces are transmitted via the stem screw con- screw the stem into the plug using a suitable stud nection. The plug is located exactly in the flow-critical area of driver and torque wrench.
  • Page 49 Balanced plug / stem screw connection with dowel pin (2.3) ø Stem thread diameter Tightening torque ø drilling diameter Dowel pin Concentrity tolerance (mm) (Nm) (mm) (mm) (mm) (mm) centrically in the gap 6 x 40 0,05 FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 50 Valtek FlowTop 13.5 Disassembly / reassembly instructions of the valve packing. Packing # A Packing # H Packing # B Packing # Y Packing A Packing H Packing B Packing Y see page 49 see page 49 see page 49 see page 49 Packing # N Packing # Q...
  • Page 51 Always tighten the packing ring nuts alternately in the same steps. If this is unsuccessful, the packing must be exchanged. Use only genuine Flowserve stuffing box packings. The stuffing box space and the remaining construction elemenets are care- fully coordinated. These were then extensively checked and meet the requirements.
  • Page 52 Valtek FlowTop Outside Life Loaded Packing Box Design gland follower (3.4). N, Q, J, O, W, F, G 2. Use a Packing Driver Tool to remove the bottom ring (3.2) and packing (3.3) by knocking out from below. Spring-loaded design, the long-term function depends on the maintenance interval and the diligence of the maintenance 3.
  • Page 53 2. Use a hook to pull the packing ring, washer and spring out of the packing chamber. 3. Carefully clean the packing chamber of all deposits us- ing a suitable tool. Do not damage high-quality surfaces ! NOTICE FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 54 Valtek FlowTop 13.7 Reassembly instruction of the valve actuator. Hand operated Pneumatic operated see page 53 see page 54 Electric operated - PS-Automation Electric operated - Haselhofer see page 55 Electric operated - Linear thrust unit „light“ Electric operated - Linear thrust unit „heavy“ see page 56 see page 57 FCD VLEEIMFTOP-03 (EN/A4) June 2023...
  • Page 55 9. Run through a valve lift and check the function and all settings. Figure 41: Remove the coupling parts Item Item Part Part Lower coupling Cap screw Lock nut 5.10 Yoke lock nut Table 38: Coupling parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 56 Valtek FlowTop Reassemble the actuator and positioner: 1. Mount the pneumatic diaphragm actuator onto the bonnet and tighten the yoke lock nut (5.10) clockwise (see Section 14: Required Torques). Position the actuator with the vent NOTICE plug positioned at the rear. 2.
  • Page 57 9. Run through a valve lift and check the function and all settings. Figure 45: Adjust the coupling parts Item Item Part Part Lock nut 5.10 Yoke lock nut Table 41: Coupling parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 58 Valtek FlowTop Reassembly of the electric rotary actuator and linear thrust unit “light”. 1. Screw in the lock nut (5.2). The thread protrusion should be as a NOTICE minimum 1 x thread diameter. 2. Press the stem-plug-unit into the seat by hand. Linear thrust Unit "light"...
  • Page 59 11. Adjust the travel indicator on the yoke road. Figure 49: Remove the linear thrust unit Item Item Part Part Lock nut 5.10 Thrust unit lock nut Indicator disc 5.11 Cap Screw Table 43: Coupling parts identification FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...

  • Page 60: 14 Torque Requirements

    Valtek FlowTop 14 Torque Requirements 14.1 Torque Requirements for SCREWED SEATs (2.1) screw connection in Nm per nominal diameter Pressure Class 1/2“ 3/4“ 1“ 1 1/2“ 2“ 3“ 4“ 6“ 8“ 10“ 12“ 16“ PN 10 - 40 1 046 Class 150 40 Nm 1 653...

  • Page 61: Lubricants

    HEL 46-450 Initial [785 (FG)] Bellows anti-twist device (2.4) lubrication Actuator: O-ring‘s (6.17, 6.50, 6.10, 6.51) and guide Klüber Klüberalfa on sliding Klüberalfa (6.8.2) Unisilikon YV 93-1202 surfaces YV 93-1202 L250L [Gleitmo 599] FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...

  • Page 62: Special Tools

    Valtek FlowTop 16 Special Tools Special Tool Seat Change Tool Recommended tool for disassembling and reassembling. Torque wrench cannot afford such needed hight torques. Use therefore an mechanical force multiplier - for example JUWEL Type 01 RS or Type 03L or equivalent. Part N°...

  • Page 63: Disposal

    Since the implementation would go beyond any scope, refer- ence is made here to the order documentation. The materials used can be found in the BOM (bill of material) and the SEC (sectional drawing). FCD VLEEIMFTOP-03 (EN/A4) June 2023 flowserve.com...
  • Page 64 Flowserve products. The purchaser/user should read and understand the Installation Instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection Telephone: +43 (0) 4242 41 181 - 0 with the specific application.

This manual is also suitable for:

Valtek flowtop v738Valtek flowtop v740Valtek flowtop d726Valtek flowtop d738Valtek flowtop d740