valve repair machines vm6000 vm7000 vm8000

valve repair machines vm6000 vm7000 vm8000
VA LV E R E PA I R M A C H I N E S
FEATURES • SETUP & OPERATION
COMPONENTS & ACCESSORIES • TECHNIC AL DATA
VM6000
VM7000
Repair in-line valves with 2.5 - 13
inch (63.5 - 330.2 mm) diameter
pressure seal bores
Repair a safety valve in
about the same time it
would take to remove the
damaged valve.
The Model VM6000 Portable Valve Repair
Machine makes on-site repair of a wide
range of valves practical. The Model
VM6000 is a “generic”
valve repair machine
that mounts on and
bores the
throat area of
any valve the
mounting
fixtures can
attach to.
Remove
the valve
bonnet
assembly to
allow access
to the valve
throat,
machine
a weld
prep groove, apply a weld
buildup as necessary in the eroded area,
and bore out the valve throat to its original
dimensions.
The Model VM7000 is designed to
mount directly on safety valves and
rework nozzles up to 4 inches (101.6
mm) in diameter. The VM7000 will
mount on Dresser Consolidated
Maxi-Flow valves, orifice sizes 1
through 6, and on many
Crosby Safety Valves.
By eliminating downtime and
spare valve inventory costs,
you can probably pay for the
Model VM7000 by repairing just a
few valves in-line.
VM8000
Repair corroded seal areas on-site
with the valve in-line.
The VM8000 is designed for on-site
remachining of seats and seal areas of
Fisher and Dresser Masoneilan (or any
other, similar type) control valves. The
machine mounts directly on the valve
and bores throat areas from 2.5 - 10
inches (63.5 - 254 mm) in diameter.
With the Model VM8000 Valve Repair
Machine, the repair operation consists of
removing the valve bonnet and stem
assembly,
applying a stainless
weld buildup in the valve seat and seal
areas and remachining to the
manufacturer’s original specifications.
The original in-line welds are not disturbed
and need no recertification.
B r i n g i n g
t h e
s o l u t i o n
t o
y o u .
V M 6 0 0 0 Va l v e R e p a i r M a c h i n e
Repair n-Line Valves With 2.5 - 13 inch
(63.5 - 330.2 mm) Diameter Pressure Seal Bores
Features
The VM6000’s power head long ago
proved its rugged dependability in our
Model FF12 portable flange facing
machine. The 1.2 hp (0.90 kW) pneumatic
motor and gear reduction provide
plenty of torque for remachining valves.
The mounting fixtures, which form a
sturdy base, mount directly on the valve
to align and center the unit. Two
different tool heads provide access to
any inside and outside diameter within
the standard 2.5 - 13 inch (63.5 - 330.2
mm) range.
Valves are often damaged in the throat
area by corrosion or steam cavitation.
Now you can eliminate remove/replace
downtime and expense by repairing the
worn valve while you leave it in-line.
The Model VM6000 Portable Valve
Repair Machine makes on-site repair of
a wide range of valves practical. With
the VM6000, you remove the valve
bonnet assembly to allow access to the
valve throat, machine a weld prep
groove, apply a weld build-up as
necessary in the eroded area. in the
eroded area, and bore out the valve
throat to original dimensions.
Capabilities
The Model VM6000 is a “generic” valve
repair machine that mounts on and bores
the throat area of any valve the mounting
fixtures can attach to. Using three mounting ring sizes, the VM6000 mounts directly
on valves with outside flange diameters
from 3.5 - 17 inches (88.9 - 431.8 mm). It
machines inside diameters from 2.5 - 13
inches (63.5 - 330.2 mm). The VM6000 is
capable of boring inside diameters, turning
outside diameters, undercutting, and
cutting recesses and grooves.
page 2
Axial feed is via automatic power feed
(optional digital readout available). The
power feed unit can be quickly removed
if you want manual feed for tool
positioning. Automatic radial feed is
incorporated in both tool heads and
allows cutting of recesses and grooves.
The small tool head feeds the tool
radially at 0.0025 or 0.005 inches
(0.0635 or 0.1270 mm) per revolution.
Automatic tool stop allows cutting to a
preset diameter.
Setup and operation
To set up the VM6000, attach, center
and align the proper mounting fixture
components. Insert and center the
power head/spindle and align it in the
valve. Once the VM6000 has been
aligned it can be removed and replaced
without disturbing the alignment.
6
2
3
4
1
5
1. Valve clamping ring
2. Power head alignment
plate
3. Support leg
4. Automatic boring head
5. Clamping jaw
6. Power head
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
V M 6 0 0 0 Va l v e R e p a i r M a c h i n e
For cutting weld prep grooves, remove
the machine from the mounting fixture
and adjust the tool head using the
bench gauge/fixture.
the boring depth is controlled manually.
Depth of the bore is determined by
visual inspection or optional digital
readout.
Once the cutting diameter and preset
stop are set on the tool head, insert it
in the power head spindle and replace
the VM6000 in the valve. The machine
is now ready to machine a weld prep
groove to a preset depth. When boring,
the radial feed is disengaged, the boring
diameter is set using a micrometer and
After corroded material and old
weldments are removed, take out the
VM6000 and apply weld buildup as
needed. Finally, reattach the VM6000
and remachine the valve to manufacturer's
original specifications. There is one tool
holder for each of the three standard
machining operations.
Digital readout option
The VM 6000 Valve Repair Machine is
available with or without a digital
readout control unit. The digital readout
control unit allows precise boring to a
predetermined depth without visual
inspection.
VM6000 Components
NO.
DESCRIPTION
17151 VM6000 Valve Repair Machine
Standard machine complete with valve fixturing
assembly for mounting to the valve, 8 inch
stroke power unit assembly, 1.2 hp (0.90 kW) air
motor, pneumatic conditioning unit, small and
large tool holders, small [7 inch (177.8 mm)
maximum OD valves], medium [10 inch (254
mm) maximum OD valves], and large [17 inch
(431.8 mm) maximum OD valves], mounting
rings, tool bits, tool fixture for presetting tool
stops, electric power feed unit, tool kit,
instruction manual, and wooden storage crate.
30487 VM 6000 Valve Repair Machine
with Digital Readout Control
Contains all the features of the
standard VM 6000 (above), plus a
Digital Readout Control unit for precise
boring to a predetermined depth
without visual inspection.
Drawings may not represent actual product.
page 3
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
VM6000 Specifications and Operational Dimensions
VM6000 Specifications
Valve ID min.:
2.5 inches
(63.5 mm)
Valve ID max.:
13 inches
(330 mm)
Valve OD min.:
3.5 inches
(88.9 mm)
Valve OD max.:
17 inches
(431.8 mm)
Air motor:
1.2 hp
(0.90 kW)
Stroke (slide travel) max.:
8 inches
(203.2 mm)
Air pressure requirements:
(at rated hp):
(at max rpm):
inches (mm)
26.50
(673)
90 psi @ 40 ft3/min.
6.2 bar @ 1.13 m3/min.
90 psi @ 50 ft3/min.
6.2 bar @ 1.42 m3/min.
Maximum rpm:
80 rpm
Spindle rpm (at rated hp):
54 rpm
Electric feed:
115V
Net weight:
845 lbs
(348 kg)
Shipping weight:
920 lbs
(418 kg)
Cutter:
0.25 inch square HSS tool
bit
14.63 (371) max.
10.63 (270) min.
1.5
(38.1)
dia.
Radial feed (small tool holder):
automatic, 0.002 inches (0.05 mm) per
revolution.
1.75
(44)
8.0 (203)
max. travel
3.5 (89) min.
17 (431) max.
21.1 (536) min.
34.6 (878.8) max.
Radial feed (large tool holder):
automatic, 0.002, 0.004, 0.006, or 0.008 inch (0.05, 0.10, 0.15,
0.20 mm) per revolution.
Axial feed:
manual or automatic. Automatic feed is infinitely variable 0.04 1.4 inches (1.0 - 35.5 mm) per minute.
page 4
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
V M 7 0 0 0 Va l v e R e p a i r M a c h i n e
Now you can repair a safety valve in about
the same time it would take to remove the
damaged valve.
If the valve was welded in-line, eliminate
rewelding and recertification by
remachining in place. By eliminating
downtime and spare valve inventory
costs, you can probably pay for the
Model VM7000 by repairing just a few
valves in-line.
The tooling assembly consists of the tool
head, the tool set fixture, the boring and
facing heads, and the tool bits. A draw
bolt holds the tool head to the spindle.
The tooling assembly does three basic
valve remachining operations: boring,
turning and facing.
Capabilities
The Model VM7000 is designed to
mount directly on safety valves and
rework nozzles up to 4 inches (101.6
mm) in diameter. The VM7000 will
mount on Dresser Consolidated
Maxi-Flow valves, orifice sizes 1 through
6, and on many Crosby Safety Valves.
The VM7000 mounts on the valve with
a fixturing assembly that consists of
mounting fixtures, adapter rings and
clamp bars. The adapter ring, machined
to fit standard valve bore sizes, centers
and aligns the machine in the valve
opening. The adapter ring raises the
machine slightly above the flange
surface to ensure alignment with the
valve axis, even if the valve face is
uneven due to corrosion. The valve
mounting fixture uses existing valve
flange studs.
Any safety valve with a similar
configuration can be repaired with the
VM7000 (optional modified mounting
fixtures may be needed). Combine the
various tool bits and tool holders to
remachine valve bushing seats to the
manufacturer's original specifications.
Machine outside diameter, inside
diameter, and bushing seat faces to
close tolerances.
1
5
3
2
4
Features
The VM7000 consists of a compact
pneumatic power head and spindle, a
set of mounting fixtures, and tool heads
for a range of machining operations.
The power head features a 1.2 hp (0.90
kW) pneumatic motor that drives a
worm gear reduction, for plenty of
torque at the tool head. The spindle
turns in ball bearings to ensure smooth
operation.
1.
2.
3.
4.
5.
Boring
Turning
Facing
Rotational drive box
Quill
Valve mounting fixture
Removable tool head
Axial feed control
Three tool configurations and
machining operations for the VM7000
page 5
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
V M 7 0 0 0 Va l v e R e p a i r M a c h i n e
Setup and operation
To set up the VM7000, pick the proper
adapter ring and put it in the valve's
counterbore. The upper surface of the
ring will be slightly above the surface of
the valve face.
Next, choose the proper mounting
fixture and put it on the valve. The
adapter ring will automatically center the
mounting fixture. Rotate the mounting
fixture to fit the slots to the valve studs.
Once the mounting fixture is set up, the
power head with attached tool head
goes into the mounting fixture bore and
is bolted in place. With the proper head
and tool bit in place, you can do facing,
boring and turning operations. Vertical
feed is controlled manually. The vertical
adjustment dial is calibrated in 0.001
inch increments.
To start a cut, turn the vertical feed
crank clockwise until the tool just begins
to cut and the vertical adjusting dial is
zeroed. Then cut to the valve
manufacturer's specified depth. A tool
set fixture is provided with the machine
to give a reference point for determining
the cut diameter.
Optional tool gage set
To ensure a perfect tool setup, Climax
offers gage block sets that allow exact
tool positioning every time. The gage
blocks are precision machined to match
the valve nozzle manufacturer's original
specifications.
Tool holder
Tool head
Gage
block
Tool set fixture
Bit
R
VM7000 Components
NO.
DESCRIPTION
16777 VM7000 Valve Repair Machine
Standard machine complete with mounting
fixtures and adapter rings for mounting
to the valve, 5 inch (127 mm) stroke, 80
rpm power unit assembly, 1.2 hp (0.90
kW) air motor, pneumatic conditioning
unit, #40 taper spindle, tool heads, tool
kit, instruction manual and wooden
storage crate.
15220 Tool Gage Set (optional)
Gage blocks precision machined to
original specifications allow exact tool
positioning. Contact your Climax
representative for more information.
page 6
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
VM7000 Specifications and Operational Dimensions
VM7000 Specifications
inches (mm)
Valve nozzle dia. min.:
1.5 inches
(38 mm)
Valve nozzle dia. max.:
6 inches
(152 mm)
Air motor:
1.2 hp
(0.90 kW)
Stroke (slide travel) max.:
5 inches
(127 mm)
Gear reduction:
15:1
Air pressure requirements:
(at rated hp)
(at max rpm)
20 (508)
approx.
overall
height
90 psi @ 32 ft3/min.
(6.2 bar @ 0.91 m3/min.)
90 psi @ 40 ft3/min.
(6.2 bar @ 1.13 m3/min.)
5 (127)
max.
stroke
3.63 (93)
min. bonnet
pilot diameter
Max rpm:
80 rpm
Spindle rpm (at rated hp):
54 rpm
Spindle torque (at rated hp):
90 ft-lbs (122.4N•m)
Net weight:
154 lbs (70 kg)
Shipping weight:
176 lbs (80 kg)
Axial feed:
manual, adjustable in
0.001 inch (0.025 mm)
increments.
Note: fixtures will accommodate 4, 6, and
8-hole bolt patterns that are 5 to 10 inches
(127 - 254 mm) in diameter.
page 7
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
V M 8 0 0 0 Va l v e R e p a i r M a c h i n e
Repair corroded seal areas on-site with
the valve in-line.
With the Model VM8000 Valve Repair
machine, the repair operation consists of
removing the valve bonnet and stem
assembly, applying a weld build-up as
necessary in the corroded valve seat and
seal areas and remachining to the
manufacturer's original specifications.
The original in-line welds are not disturbed and need no recertification.
Capabilities
Sometimes it's economical to replace
smaller valves, but it's usually more costeffective to repair the larger sizes.
Maintaining an inventory of replacement
valves to keep your system operating
would be prohibitive. Using portable
machine tools to repair valves in-line,
you save all the expense of replacement
valve inventory, weld reinspection, recertification, and the downtime necessary
to complete the job.
The VM8000 is designed for on-site
remachining of seats and seal areas of
Fisher and Dresser Masoneilan (or any
other, similar type) control valves. The
machine mounts directly on the valve
and bores throat areas from 2.5 - 10
inches (63.5 - 254 mm) in diameter. Also
reface seats up to 0.75 inches (19.05
mm) wide without tool bit adjustment.
The machine can reach 16 inches
(406.4mm) from the top to the valve
body and has a boring stroke of 10
inches (254mm).
The machine cuts nearly any kind of
finish from fine to 40-pitch scroll for
gasket seals.
Features
Components of the VM8000 include a
main body, rotational drive unit, turning
bar, mounting fixtures and tool holder
set. Machining torque is delivered
through the rotational drive unit, which
may be either hydraulically or pneumatically driven. The axial feed system is
manually controlled. Calibrated in 0.001
inch (0.0254 mm) increments, the feed
dial can be zeroed to cut precise depths
specified by the manufacturer. Boring
diameter is set with the manual hand
wheel on top of the bar. Make multiple
boring passes without removing the
machine for tool adjustments.
Pin locators in the mounting plates allow
accurate repositioning of the machine's
main body during multiple setups.
Because the turning bar rotates in closetolerance needle bearings, the machine
is capable of high precision machining.
During boring operations, total indicated
runout (TIR) will not exceed 0.002 inches
(0.0508 mm) over the entire stroke.
With the long turning bar, deep valve
machining is possible. The rack-actuated
tool head radial feed is automatic at 0.003
inches (0.076 mm) per revolution, or
manual at 0.025 inches (0.635 mm) per
revolution.
Precision machining is achieved with the
calibrated radial feed dial located on top
of the turning bar.
Setup and Operation
Locator
pin
Base
plate
Valve
page 8
Remove the valve's bonnet and stem
and mount the Model VM8000 base
plate. Attach, center and level the
intermediate plate and main body
assembly. Cut the necessary weld preps,
making sure old weldments and all
corrosion is removed. Remove the
VM6000 and apply weld buildup as
needed. Using the pin locator system,
the machine is reattached to the
intermediate plate in perfect alignment
for finish machining all seat and seal
areas. The tool bit remains visible during
machining operations so the operator
has excellent control of all precision
boring and facing operations.
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
V M 8 0 0 0 Va l v e R e p a i r M a c h i n e
Threading option
With the optional threading attachment,
the machine can cut threads that meet
the original manufacturer's specifications.
The machine can cut any pitch between
8 and 16 threads per inch in 1/4-pitch
increments and pitches 16 to 21 in
1-pitch increments. Any six pitches (user
specified) are provided with the machine.
Thread pitch is changed by replacing the
pitch gear in the optional threading
attachment gear box... a five minute
operation.
Model 8000 Components
NO.
DESCRIPTION
17794 Model 8000 Valve Repair Machine
Standard machine includes rotational drive
assembly with 1.1 hp air motor and 1.5 hp
hydraulic motor, main body assembly with cone
locators, turning bar assembly with three tool
holders, pneumatic conditioning unit, tool kit,
and instruction manual.
17788 Model 8000 Valve Repair Machine with
Threading Attachment
As above with threading attachment described
below.
16208 Threading Attachment
Threading attachment allows the Model
VM8000 to cut new or recut existing threads in
Fisher-style control valves. Cut from 8 to 20
threads/inch by changing the threading gears.
Attachment includes gear box which mounts to
the rotational drive assembly, threading gears for
8, 10, 12, 16, 18, and 20 threads/inch, slow
speed 1.1 hp pneumatic motor (20 rpm max
spindle speed), and instructions.
Drawings may not represent actual product.
page 9
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
VM8000 Specifications and Operational Dimensions
VM8000 Specifications
inches (mm)
inches (mm)
Height:
39 inches
(991 mm)
Valve ID min.:
3 inches
(76.2 mm)
Valve ID max.:
10 inches
(254 mm)
Vertical stroke:
(slide travel) max.
10 inches
(254 mm)
Air motor:
1.1 hp
(0.83 kW)
Air pressure requirements:
(at rated hp)
(at max rpm)
14.7 dia.
(374)
90 psi @ 32 ft3/min.
(6.2 bar @ 1.1 m3/min.)
90 psi @ 40 ft3/min.
(6.2 bar @ 1.13m3/min.)
Max. spindle rpm:
75 rpm
Metal removal rate:
(in C1018 steel with a sharp tool)
0.8 in3/min. (13.1 cm3/min.)
Shipping weight:
248 lbs.
39.0
(991)
10 (254)
max. travel
22.3
(566)
(113 kg)
Cutter:
0.5 inch square HSS tool bit or carbide inserts
Radial feed:
Automatic, 0.003 inches (0.076 mm) per revolution with handcrank
Manual, up to 0.025 inches (up to 0.63 mm) per revolution.
Axial feed:
Standard machine feed is manual. Optional threading attachment is
adjustable in 0.001 inch (0.025 mm) increments.
page 10
18 (457.2)
max. reach
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
O t h e r Va l v e R e p a i r O p t i o n s F r o m C l i m a x
Portable valve grinding
and lapping
Stationary valve repair
machines
Models VM/GT and VM/GA
Portable Valve Grinding and
Lapping Machines, For Flat and
Conical Seats.
Return globe and gate valve seats to
operational condition for less than 1/3
the cost of a replacement valve with
these portable valve grinding and
lapping machines. Valve grinding and
lapping machines are available in
pneumatic or electric versions. Six
models for gate valves from 1.26 - 19.68
inches (32 - 500 mm) diameter. Six
models for globe valves from 0.39 -27.56
inches (32 - 500 mm).
Model VM5800 Series
Work stations for grinding and lapping
seal surfaces up to 13.78 inches (350
mm) and face turning seal surfaces up to
9.8 inches (250 mm) for offline/offsite
valve repairs. Tilt table accommodates
valves up to 660 lbs (300 kg). Optional
rotary table accommodates valves up to
550 lbs (250 kg).
VM1000 Series For Gate Valves
VM2000 Series For Globe Valves
Model VM9000
A portable valve machining system that
quickly and safely repairs nuclear plant
MSIV and other globe valve assemblies.
The Climax Model VM9000 is a portable
valve repair system designed to repair
MSIV and other globe valves from 14 30 inches (356 mm – 762 mm) in
diameter. It will machine and grind
pressure-seal bores, guide ribs and seats.
page 11
Grinding and lapping
tables
Models VM5600 & VM5900
For repair operations on gate wedges,
valve plugs. Features variable table
speed, safety rail, optional foot switch.
Grinding and lapping
adapter units
Models VM3000 & VM4000
Turn your radial drilling machine into a
grinding and lapping machine with our
adapter-tool set-tilt table package.
Abrasives, cleaning
technology, and
accessories
Water-resistant, self-adhesive abrasive
rings and segments, all common sizes
and grains in stock. Abrasive rings and
segments are delivered in screw-top jars
for protection against dust and humidity.
CBN-grinding discs, used with planet
wheels for high material removal and
durability.
Self-centering chuck for quick alignment
of globe valve grinding machine.
Professional cleaning set with
ergonomically designed 1000W
professional power brush, assorted
brush heads, safety goggles, and dust
mask.
Valve test benches
These small, portable test benches fit on
any normal workbench. Clamps and
pressure-tests DIN and ASA flanges with
either water or air.
For help contact: Climax Portable Machine Tools, P.O. Box 1210, Newberg, OR 97132 USA
Worldwide Phone: 503.538.2185
USA/Canada Toll-Free: 800.333.8311
Website: www.cpmt.com
Fax: 503.538.7600
Email: [email protected]
Climax Portable Machine Tools Worldwide
Manufacturing, Sales & Rental Facilities
Chicago
Edmonton
Toronto
Philadelphia
Cologne
Portland
World Headquarters
Los Angeles
Houston
Singapore
Rental Depot
Manufacturing / Sales Facility
International Distributor
VRM-1M0604
Corporate Headquarters
Climax Portable Machine Tools, Inc.
2712 E. Second Street, P.O. Box 1210
Newberg, Oregon 97132 USA
Worldwide Telephone: 503.538.2185
USA Toll-Free: 800.333.8311
Fax: 503.538.7600
Email: [email protected]
European Headquarters
Climax GmbH
Willi - Bleicher - Strasse 11
52353 Düren, Germany
Telephone: (+49) (0) 2421.9177.0
Fax: (+49) (0) 2421.9177.29
Email: [email protected]
Houston Sales Office
Climax Portable Machine Tools, Inc.
16823 Highway 35
Pearland, TX 77581 USA
Telephone: 281.469.0429
www.cpmt.com
www.cpmt.com
Copyright © 2004 Climax Portable Machine Tools, Inc. All Rights Reserved.
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