Worcester Controls

Worcester Controls
12630-B
Worcester Controls
Tube Bore Clean Valves
1
/2" – 2" WK70 and 1/2" – 2" WK74
Installation, Operation and Maintenance Instructions
CAUTION: Flowserve recommends that this product be stored
indoors prior to installation, in an environment suitable for human
occupancy. Avoid areas where exposure to relative humidity above
85%, acid or alkali fumes, radiation above normal background,
ultraviolet light, or temperatures above 1200°F/below 400°F may
occur. Do not store within 50 feet of any source of ozone.
A. INSTALLATION
2. These valves will provide bubble-tight shut-off when used in
accordance with Worcester’s published pressure/temperature
chart.
3. It is not good practice to leave a ball valve partly open (throttling
operation) without knowledge of the pressure drop and flow at
that position.
4. Media that can solidify, crystallize or polymerize should not be
allowed to stand inside ball valve cavities.
1. WK70/WK74 valves may be installed for flow or vacuum in either
direction. Use care to exclude pipe sealants from the valve cavity.
Valves with upstream relief hole in ball (V3 option) are directional
(one-way) valves.
5. Torque Requirements - Operating torque requirements will vary
depending on the length of time between cycles, line pressure,
type of valve seats, or the media in the piping system. For a
detailed analysis of valve torque requirements, refer to the
Worcester Actuator Sizing Manual.
2. Weld End Valves:
Prior to welding or brazing, ENSURE ALL JOINT SURFACES ARE
CLEAN, to prevent contamination. Valves with XBO pipe ends can
be welded in the line without disassembly of the valve.
C. MAINTENANCE
Tighten the retaining nut if leakage is visible in the stem area.
3. CAUTION:
a. With the exception of valve seats, no fluoropolymer parts are
reusable.
CAUTION: Over-tightening stem nuts results in high operating
torque and shorter stem seal life. Follow proper stem adjustment
procedure below.
b. Special care should be taken to avoid scratching the
fluoropolymer seals during installation. Light lubrication of
these seals can help to prevent damage.
For Manual Valves (with two stem nuts):
c. WK70/WK74 valves and repair kits have been assembled,
cleaned, and packaged for ultra-high purity systems. Caution
should be used to maintain the cleanliness of the valve parts.
1. Tighten retaining nut (lower nut) clockwise until Belleville washers
are “bottomed-out” flat.
2. Back off the retaining nut 1/6 of a turn.
3. Tighten handle nut securely to lock retaining nut in place.
d. WK70/WK74 valves are factory assembled with NO
lubrication.
For Automated Valves (with one self-locking stem nut):
B. OPERATION
1. Valve operation consists of turning the handle a quarter-turn
clockwise to close and a quarter-turn counter-clockwise to open.
The valve is open when the handle and/or stem flats are in line
with the pipeline. WK70/WK74 valves may be automated (used
with actuators).
1. Tighten self-locking stem nut until Belleville washers are “bottomout” flat.
2. Back off nut 1/3 of a turn. NOTE: The self-locking nut requires a
good amount of effort to tighten. Ensure that Belleville washers
are fully compressed flat before backing off.
Flow Control Division
Worcester Controls
D. REBUILDING
a WARNING: BALL VALVES CAN TRAP PRESSURIZED FLUIDS
INSIDE THE BALL CAVITY WHEN CLOSED.
If the valve has been subjected to hazardous media, it must be
decontaminated before disassembly. Follow the steps below for safe
removal and disassembly procedure.
• All personnel involved in the removal and disassembly of the valve
should be equipped with proper protective gear such as face shield,
gloves, apron, etc.
• Relieve the line pressure and cycle the valve back and forth a few
times prior to removal.
• Position valve half-open and flush the line to remove any residual
hazardous media.
1. A standard repair kit is available for these valves. Use repair kit
designation WKRK70 for both WK70 and WK74 valves. The kit
consists of seats, body seals, four Belleville washers, stem seals
and thrust bearings. Specify the material of the seats and body
seals, size, Series and R number (revision no.) of valve or for
non-standard valve, the “P”, “T”, “C”, or similar number, as found
on the handle, the valve nameplate or the actuator bracket
nameplate.
To Order: Valve Size/Series/RK 70/Material/Revison Number, or
P,T,C, or similar number
Example: 1" WK RK 70 RT T1510
d. Using handle or a wrench to prevent stem from turning,
remove retaining or self-locking stem nut, Belleville washers,
and follower from the stem. Remove stem through body
cavity.
e. Remove thrust bearings from body or stem, stem seals and
seal protector from the recess in the top of the body.
f.
NOTE: The ball and the surfaces against which the seats and seals are
installed should be undamaged, clean, and free of pit marks and
scratches. Light marring from the action of the ball against the seats
is normal and will not affect the operation of the valve. Flaws that can
be seen but barely detected with fingertips are acceptable. The stem
and body surfaces that the thrust bearing and stem seals contact
must be undamaged, clean, and free from pit marks and scratches.
g. For stem area rebuilding, refer to exploded view and stem
build illustrations on the next page.
Order of Assembly:
Place new thrust bearings on stem and insert assembly
through body cavity. Place new stem seals, stem seal
protector, and the follower in position. PEEK thrust bearing
and stem seal protectors are placed outside of seals and
bearings. The seals/bearings must contact the body.
Stem seals, stem seal protectors and thrust bearings that are
the same size and color are generally interchangeable.
h. Place two new Belleville washers in position with their larger
diameter faces touching each other.
CAUTION: If the replacement seat and seal material differs
from those being removed, the valve nameplate or stop MUST
be replaced or altered to indicate the new material /new rating
or valve tagged to so indicate.
For those valves with single self-locking stem nut, place four
new Belleville washers in position (two pairs of washers with
larger diameter faces touching).
i.
Thread retaining or self-locking stem nut onto stem and using
handle or a wrench to prevent rotation, tighten the nut snugly.
Follow Section C-Maintenance for proper stem adjustment.
j.
Replace one-piece handle and stop (if manual valve),
lockwasher and handle nut onto stem. (This step is not
applicable to valves with self-locking stem nut).
2. To replace seats and seals:
a. Place valve in open position. Remove three body nuts and
bolts and LOOSEN the fourth, swing out the valve center
section from between the pipe ends.
b. Now, with valve in closed position, remove old seats, body
seals and ball.
c. Remove handle nut, lockwasher, and handle (if manual
valve). This step is not applicable to valves with single selflocking stem nut.
2
Clean/remove all foreign matter from the sealing surfaces of
the valve and the ball.
k. With valve in closed position (stem flats oriented across the
pipeline) replace ball (see note on page 4) and new seats.
With valve in open position, carefully insert new body seals
and place center section between the pipe ends.
Tube Bore Clean Valves: 1/2" – 2" WK70 and 1/2" – 2" WK74 Installation, Operation and Maintenance
12630-B
Flow Control Division
Worcester Controls
/2" – 2" WK70/WK74 VALVES
1
MANUAL
AUTOMATED
STEM
STEM
LOCKWASHER
FREE RUNNING
RETAINING NUTS–2
HANDLE
SELF–LOCKING NUT
BELLEVILLE WASHERS–4
FOLLOWER
SEAL PROTECTOR
(.030 PEEK)
STEM SEAL
(.050 POLYFIL)
THRUST BEARING
(.030 POLYFILL)
FOLLOWER
BELLEVILLE WASHERS–2
SEAL PROTECTOR
(.030 PEEK)
STEM SEAL
(.050 POLYFIL)
THRUST BEARING
(.030 POLYFILL)
STEM SEAL
(.030 POLYFIL)
STEM SEAL
(.030 POLYFIL)
THRUST BEARING
(.030 PEEK)
THRUST BEARING
(.030 PEEK)
TO CONVERT A MANUAL VALVE STEM BUILD TO AUTOMATED:
REMOVE THE TOP RETAINING (HANDLE) NUT, LOCKWASHER,
HANDLE, LOWER RETAINING NUT, TWO BELLEVILLES AND STOP PIN(S).
ADD FOUR BELLEVILLE WASHERS AND THE SELF-LOCKING NUT.
SEE THIS I.O.M. FOR ADDITIONAL INSTRUCTIONS AND CAUTIONS.
COLOR CHART FOR VARIOUS STEM
COMPONENT MATERIALS
MATERIAL
COLOR
BLACK
POLYFILL
PEEK
TAN
HANDLE NUT
LOCKWASHER
HANDLE
RETAINING NUT
FOLLOWER
BELLEVILLE WASHERS
SEAL PROTECTOR
STEM SEAL (.050)
STOP PIN
STEM SEAL (.030)
BOLTS (4)
BODY
PIPE END
BODY SEAL
BALL
SEAT
SEAT
1 1/2"–2" BODY
BODY SEAL
PIPE END
THRUST BEARINGS
STEM
NUTS (4)
12630-B
1/2"–1" BODY
VALVE ASSEMBLY
Tube Bore Clean Valves: 1/2" – 2" WK70 and 1/2" – 2" WK74 Installation, Operation and Maintenance
3
Flow Control Division
Worcester Controls
NOTE: Valves with a pressure relief hole in the ball (V3 option) must
be assembled and installed with the hole upstream, when the valve is
closed, to ensure that cavity relief will occur upstream. Any valve with
a relief hole will have a directional arrow pointing downstream. Arrow
is either stamped on the body or on a metal tag welded to the valve
body.
Replace and tighten body bolts and nuts per torque figures found
in table to the right.
2. Valve Size, Style and five-character code, known as a “P”, “T”,
“C”, or similar number, (the designation for a non-standard
product). Example, 3/4" WK7066RT TC T0726 Ball.
The terminology shown in the exploded view parts listing on the
previous page is standard.
Tighten/torque all body bolts evenly and diagonally opposite each
other, alternating in a crisscross pattern. Use torque figures below:
CAUTION: Use care not to scratch the body seals when replacing the
valve body back into the line.
STAINLESS STEEL STUDS
Bolt Diameter
in-lb
ft-lb
/4"
72-96
6-8
/16"
120-144
10-12
3
/8"
192-216
16-18
/16"
336-384
28-32
1
When ordering parts, please provide the part name and the following
information as found on the valve handle, valve nameplate, or
mounting bracket nameplate:
1. Valve Size, Style and Revision Number, Example /2" WK70 66RT
XBO R0 Stem.
5
1
7
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function
safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial
service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore
assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation
Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.
While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of
satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve
is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning
these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.
For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.
FLOWSERVE CORPORATION
FLOW CONTROL DIVISION
1978 Foreman Drive
Cookeville, Tennessee 38501 USA
Phone: 931 432 4021
Facsimile: 931 432 3105
www.flowserve.com
© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation.
12630-B 7/03 Printed in USA
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