Emerson Spence K3 Manuale utente

▲ WARNING

Failure to follow these instructions or

to properly install and maintain this

equipment could result in an explosion,

re and/or chemical contamination

causing property damage and personal

injury or death.

Emerson Control Valve must be

installed, operated and maintained

in accordance with federal, state and

local codes, rules and regulations

and Emerson Process Management

Regulator Technologies, Inc.

(Emerson) instructions.

If the control valve vents gas or a

leak develops in the system, service

to the unit may be required. Failure

to correct trouble could result in a

hazardous condition.

Installation, operation and maintenance

procedures performed by unqualied

personnel may result in improper

adjustment and unsafe operation. Either

condition may result in equipment

damage or personal injury. Only a

qualied person shall install or service

the Type K3 control valve.

Introduction

Scope of the Manual

This manual provides instructions for the installation,

start-up, setting, maintenance, troubleshooting and

parts ordering for Type K3 control valve.

Spence Type K3 Control Valve

Figure 1. Type K3 Control Valve

Product Description

Type K3 control valve is designed for economical

control of steam, water, gas and process applications

in typical institutional, commercial and industrial

processes. Type K3 is a three-way valve available with

either a direct or reverse acting actuator that meets

most mixing or diverting application requirements.

Type K3

Instruction Manual

VCIMD-14940

November 2021

www.SpenceValve.com

Figure 2. Type K3 Pressure and Temperature Chart

Table 1. Approximate Weight

Specications

This section lists the specications for the Type K3. Factory specication are stamped on the nameplate fastened

on the control valve at the factory.

Control Valve Type

Type K3: Three-way valve with union ends and

pneumatic actuator

Control Valve Sizes

NPS 1/2, 3/4, 1, 1-1/4, 1-1/2 and 2 /

DN 15, 20, 25, 32, 40 and 50

Pressure and Temperature Chart(1)/

See Figure 2

Control Pressure Capabilities(1)

3 to 15 psi / 0.21 to 1.03 bar

End Connection Style

CL250

Flow Coe󰀩cient, Cv

NPS 1/2 / DN 15: 5.6

NPS 3/4 / DN 20: 7.1

NPS 1 / DN 25: 9.2

NPS 1-1/4 / DN 32: 22

NPS 1-1/2 / DN 40: 28

NPS 2 / DN 50: 35

Construction Materials

Body: Bronze

Seat: Stainless steel

Plug, Stem and Stem Assembly: Stainless steel

Stem Guide: Stainless steel, Monel or Brass

Actuator Casing: Steel

Actuator Spring: Steel Wire

Diaphragm: Nitrile (NBR)/Polyester

Yoke: Ductile Iron

Options

36 or 60 sq. in. / 0.02 or 0.04 sqm actuators

Electric Actuator

Applicable Codes

Meets or exceeds ANSI B16.15 Class 250

ANSI/FCI 70-2 Class IV Seat Leakage

Article 3, Section 3 of the

Pressure Equipment Directive.

Approximate Weight

See Table 1

VALVE SIZE 36 in. sq /

0.02 sqm

60 in. sq /

0.04 sqm

NPS DN lbs kg lbs kg

1/2 15 28 12.7 41 18.6

3/4 20 28 12.7 41 18.6

1 25 27 12.3 40 18.2

1-1/4 32 35 15.9 48 21.8

1-1/2 40 37 16.8 50 22.7

2 50 42 19.1 55 25

1. The pressure/temperature limits in this Instruction Manual and any applicable standard or code limitation should not be exceeded.

ANSI/ASME B16.15 CLASS 250

SATURATED STEAM

TEMPERATURE, °F

PRESSURE, psi

PRESSURE/TEMPERATURE CHART

Type K3

Principle of Operation

Type K3 valve is a three-way, universal construction,

globe style, pneumatic diaphragm control valve. The

pneumatic actuator can be arranged as direct or

reverse acting.

When selecting a direct acting actuator, upper port

is failed closed on air loss. When selecting a reverse

acting actuator, the lower port is failed closed on air

loss. When used for mixing, the forces developed by

the two inlet flows oppose each other and create a

balanced environment. Thus, the actuator can control

the flow efficiently without power lost to over come

dynamic unbalance. When using the valve for diverting

service, simply reverse the valve installation.

Installation

▲ WARNING

Personal injury or system damage may

result if this control valve is installed,

without appropriate overpressure

protection, where service conditions

Figure 3. Fluid Flow Direction for Mixing and Diverting Service

could exceed the limits given in the

Specications section and/or control

valve nameplate.

Additionally, physical damage to the

control valve may result in personal

injury or property damage due to

escaping of accumulated gas. To avoid

such injury and damage, install the

control valve in a safe location.

All pressure equipment should be

installed in a non-seismic area;

should not be exposed to re; and

should be protected from thunderbolt

(lightning) strikes.

△ CAUTION

The piping system must be

adequately designed and supported

to prevent extraordinary loads to the

pressure equipment.

AB AB

DIVERTINGDIVERTINGMIXING

Type K3

Planning

• Locate the valve in a straight run of horizontal

pipe as shown in Figure 4. Mount the valve with

the actuator in the upright position. Allow room for

removal of the actuator.

• Prevent pipeline hammering in compressible fluid

service by providing proper drainage before and

after the valve.

• Avoid damaging effects of scale and dirt in pipelines

by using a strainer.

• A three-valve by-pass to facilitate inspection

and maintenance without interrupting service

is recommended.

• To eliminate excessive noise with steam and other

compressible uids, enlarge the delivery pipe size

to allow a reasonable ow velocity at the reduced

pressure. A concentric transition is recommended.

• If possible, avoid sharp turns close to the valve.

• Install upstream and downstream pressure gauges

to indicate performance.

• If the rating of the delivery system or connected

equipment is less than the initial pressure, provide

a safety relief valve.

• Use Uniflex Pipe Coupling for ease of maintenance.

The spiral wound gasket provides a high

performance seal similar to that of a flanged

connection, yet retains the convenience of a ground

joint union.

Start-up and Setting

▲ WARNING

The valve may be handling hazardous

fluids. Only qualified personnel, who are

familiar with the installation, should be

permitted to install, readjust, inspect or

maintain the valve.

△ CAUTION

Insulation, may be applied to the valve

body only. Do not insulate the bonnet.

1. Flush the piping system thoroughly to clear it of

welding beads, scale, sand, etc.

2. Install the valve with the arrow on the side of the

valve body pointing in the direction of fluid flow.

Figure 4. Type K3 Control Valve Recommended Installation for Steam Application

K3 DIVERTING

VALVE

K3 MIXING

VALVE

UNIFLEX UNION

SPENCE

STEAM TRAP

COOL WATER

HEAT

EXCHANGER

TEMPERED

WATER

RETURN

STEAM

Type K3

3. Install controller and accessories in accordance

with instructions furnished by the manufacturer of

these items.

4. Connect necessary air lines and/or electrical

connections to the diaphragm chamber and valve

mounted accessories. Use 1/4 in. / 6.35 mm

outside diameter tubing for all air lines. If the

length of the air line exceeds 25 ft / 7.62 m, use

3/8 in. / 9.53 mm outside diameter tubing.

Maintenance

▲ WARNING

To avoid personal injury, property damage

or equipment damage caused by sudden

release of pressure or explosion of

accumulated gas, do not attempt any

maintenance or disassembly without

rst isolating the control valve from

system pressure and relieving all internal

pressure from the control valve.

Control valves that have been

disassembled for repair must be tested

for proper operation before being returned

to service. Only parts manufactured by

Emerson should be used for repairing this

control valve.

Due to normal wear or damage that may

occur from external sources, this control

valve should be inspected and maintained

periodically. The frequency of inspection

and replacement of parts depends upon

the severity of service conditions or the

requirement of local, state and federal

rules and regulations.

Removal of the Actuator from the Valve

Body Assembly (Refer to Figures 5 to 6)

1. Close inlet and outlet stop valves.

2. Be sure valve body is not under pressure.

3. Remove all accessories from the control valve.

Reverse Acting Actuator

1. Loosen stem nuts (key 24) and move to

approximately 1/3 down valve stem.

2. Retighten the stem nuts (key 31), being careful not

to move valve stem.

3. Energize actuator with air to lift plug off seat.

4. Disengage lock nut (26) from bonnet (key 25).

5. De-energize actuator.

6. Move the actuator and yoke away from bonnet.

7. Lift actuator and yoke assembly along with plug

(key 39) off the seat.

8. With an adjustable wrench, unthread valve stem

from the actuator stem (key 16) until valve stem is

dise ngaged from actuator stem.

9. Remove stem nuts, indicator and lock nut.

Direct Acting Pneumatic Actuator

1. Energize actuator with air slightly (in case of

back seating).

2. Loosen stem nuts (key 24) and re-tighten

approximately 1/8 in. / 3.18 mm away from

actuator stem (key 16).

3. Disengage lock nut (key 26) from bonnet (key 25).

With an adjustable wrench, unscrew valve stem

from actuator stem.

4. When valve stem reaches seat, lift actuator (to

prevent galling the seat and plug).

5. Remove stem nuts, indicator and lock nut.

Disassembly of the Valve Body

1. Remove stem nuts (key 24), indicator (key 32) and

lock nut (key 26).

2. Lift yoke off bonnet (key 25).

3. To complete body disassembly, unscrew bonnet

for Type K3. Turn stem and plug assembly out of

bonnet through packing.

4. Replace packing if necessary.

5. Inspect all parts for wear and clean thoroughly

before re-assembling valve body.

Type K3

Disassembly of the Actuator

1. Remove actuator from the valve.

2. Remove regular casing bolts (key 4) and casing

nuts (key 5).

3. Gradually loosen nuts on the remaining long

casing bolts (key 14) to allow pre-compression of

actuator springs.

4. Remove upper casing (key 2).

5. Pull actuator stem (key 16), along with diaphragm

(key 15), springs (key 3) and piston (key 13), out

through bushing (key 7).

6. Place a wrench on machined flats of the actuator

stem and remove stem nut (key 10), seal washer

(key 12) and stem washer (key 11).

7. Remove o-ring (key 8) from the bushing

and replace if necessary. Lubricate o-ring

after installing.

Reassembly of the Actuator

1. Refer to Figures 5 and 6 for correct orientation

of casings, diaphragm (key 15), piston (key 13),

stem (key 16) and springs (key 3) for direct or

reverse action.

2. Be sure that piston spring recesses line up

between casing ribs as shown in Figure 7.

3. Lubricate bushing o-ring (key 8) and insert

actuator stem through the bushing.

4. Reattach upper casing (key 2) with long bolts

(key 14) and nuts (key 5), tightening alternately.

5. Install remaining casing nuts and bolts.

6. Apply air to diaphragm case and check for

leakage, full travel and dead band less than

0.2 psi./ 0.14 bar

Lapping Plug into the Seat

△ CAUTION

Seats and plugs should never require

more than the lightest touch up with very

fine (400 grit) grinding compound. Heavy

lapping will produce galling, a wider

seating surface and a groove in the plug,

all of which tend to cause leakage.

1. Reface a damaged surface before attempting to

grind it in. Lap sparingly.

2. Replace stem and plug assembly (key 39) in

bonnet (key 25) through packing .

3. Apply lapping compound to the plug.

4. Place bonnet on the body.

5. After lapping, disassemble and clean all

parts thoroughly.

Packing Replacement

1. Check stem for gouges if packing leaks.

2. Install replacement packing cartridges.

Reassembly of Valve Body

1. Insert plug and then tighten bonnet (key 25) to

body. Note that “R” on body must be up for sizes

NPS 1/2 to 1 / DN and the “D” up for sizes NPS

1-1/4 to 2 / DN.

2. Install Inlet (key 42).

3. Replace yoke (key 9), lock nut (key 26), stem nuts

(key 24) and travel indicator (key 32) over stem

(key 34).

Type K3

Replacing the Actuator on the Valve

Body - Pneumatic

1. Put actuator assembly over the valve stem.

2. Place lock nut (key 26) and stem nuts (key 24)

with travel indicator (key 32) on valve stem.

3. Rest actuator stem (key 16) on valve stem.

4. Tighten stem nuts approximately 2/3 down

valve stem.

5. Lift actuator assembly and engage valve stem

with actuator stem (be careful not to gall the plug

and seat).

Reverse Acting

1. When sufficient engagement is met, actuator can

be energized with air to place yoke on the bonnet

(key 25) and lift plug off the seat.

2. Tighten lock nut and packing nut.

Direct Acting

1. Engage valve stem with actuator stem so no

contact is made between plug and seat when the

bottom of the yoke is rested on the bonnet.

2. Tighten lock nut.

Actuator Adjustment - Pneumatic

1. Close inlet and outlet stop valves. Be sure valve

body is not under pressure.

2. Place wrench on machined flats of actuator

stem (key 16). Counter two stem nuts ( key 24)

approximately halfway down the threads of the

stem (key 34).

Reverse Acting

1. Apply sufficient air pressure to diaphragm case to

start moving the valve through its rated travel. This

is shown by the travel indicator (key 32).

2. Engage lower stem nut (key 24) and turn body

stem (key 34) into actuator stem (key 16) until

pre-compression of actuator springs (key 3)

is relieved.

Note

Plug should not be seating on seat ring

when air pressure is removed from

actuator case.

3. Apply prescribed setting pressure to actuator. This

is determined by specific operating conditions.

4. Turn body out of actuator stem until plug seats on

seat ring (key 28). To prevent galling, do not turn

bidy stem after plug has contacted seat ring. Turn

stem nuts up plug and stem assembly and tighten

to lock it in position.

5. Reduce air signal to 0 psi/bar and calibrate

indicator scale (key 20). Check that full travel is

achieved with a 15 psi signal, except for 22 to

30 psi / 1.52 to 2.07 bar springs.

Direct Acting

1. Engage lower stem nut (key 24) and turn body

stem (key 34) into actuator stem (key 16) until plug

and stem assembly stops at upper limit of travel

and/or a slight downward movement of actuator

stem is detected.

2. Turn stem nut up the body stem and tighten to lock

in position.

3. Calibrate indicator scale (key 20). Check that full

travel is achieved at a 3 psi signal.

Type K3

Troubleshooting

▲ WARNING

To avoid personal injury, property damage

or equipment damage caused by sudden

release of pressure or explosion of

accumulated gas, do not attempt any

troubleshooting or disassembly without

rst isolating the control valve from

system pressure and relieving all internal

pressure from the control valve.

Control valves that have been

disassembled for repair must be tested

for proper operation before being returned

to service. Only parts manufactured by

Emerson should be used for repairing this

control valve.

To troubleshoot the valve and actuator, check for the

following: change in operating conditions; pneumatic

signal failure; diaphragm failure; foreign matter lodged

between seat ring and plug; actuator vent plug may

be: plugged, missing, replaced with a solid plug;

packing leakage.

Parts Ordering

When corresponding with your local Sales O󰀩ce about

this equipment, always reference the equipment valve

size, service and serial number.

When ordering replacement parts, reference the key

number of each needed part as found in the following

parts list and indicate the part number. Separate kits

containing all recommended spare parts are available.

Parts List

Valve Body Assembly (See Table 2,

Figure 5)

Actuator Parts (Figure 6)

Key Description Part Number

Repair Part Kit

36 sq. in. / 0.02 sqm WAL51447

60 sq. in. / 0.04 sqm WAL51448

Actuators and Spring Kit See Table 3

Actuator Connector Kits See Table 4

1 Vent Plug, High-density polyethylene

2 Upper Casing, Steel/powder

3 Springs, Steel

4 Casing Bolt, Standard, 10/14 required, 304 Stainless steel

5 Casing Nut, 12/16 required, 316 Stainless steel

6 Lower Casing, Steel/powder

7 Bushing, Bronze

8* Oring, Nitrile WAL05-04017-00

9 Yoke, Cast Iron/Powder

10' Stem Nut, Steel WAL05-13374-00

11* Stem Washer, 1/3 required, 316 Stainless steel WAL05-12963-00

12* Seal Washer, Steel WAL05-13203-00

13 Piston, 316 Stainless steel

14* Casing Bolt, Long, 2 required,

304 Stainless steel WAL05-04889-00

15* Diaphragm, Nitrile

36 sq. in. / 0.02 sqm WAL0@-12968-00

60 sq. in. / 0.04 sqm WAL0@-12986-00

16 Actuator Stem, 303 Stainless steel

17 Machine Screw, 3 required, Steel

18 Casing Gasket, Nitrile WAL05-12566-00

19 Machine Screw, 2 required, Steel

20* Indicator Scale, Aluminum WAL05-17470-00

21* Specification Plate, Aluminum WAL05-13199-00

*These parts furnished in Actuator Repair Kit.

Type K3

ITEM PART NAME QUANTITY MATERIAL NPS 1/2 / DN 15 NPS 3/4 / N 20 NPS 1 /

DN 25

NPS 1-1/4 /

DN 32

NPS 1-1/2 /

DN 40

NPS 2 /

DN 50

23A(1) Stem Bolt - Short 1 Brass WAL4-17277-0 WAL4-17277-0 WAL4-17277-0 WAL4-17277-0 WAL4-17277-0 WAL4-17277-0

23B(2) Stem Bolt - Long 1 Brass WAL4-17281-00 WAL4-17281-00 WAL4-17281-00 WAL4-17281-00 WAL4-17281-00 WAL4-17281-00

24 Stem Nut 2 Brass WAL05-17342-00 WAL05-17342-00 WAL05-17342-00 WAL05-17342-00 WAL05-17342-00 WAL05-17342-00

25 Bonnet 1 Brass WAL558B107-02 WAL558B107-02 WAL558B107-02 WAL558B110-02 WAL558B110-02 WAL558B110-02

26 Lock Nut 1 Stainless steel WAL05-17330-00 WAL05-17330-00 WAL05-17330-00 WAL05-17330-00 WAL05-17330-00 WAL05-17330-00

27 Wave Washer 1 Stainless steel WAL122A155-01 WAL122A155-01 WAL122A155-01 WAL122A155-01 WAL122A155-01 WAL122A155-01

28 Seat 1 Stainless steel WAL562A114-01 WAL562A114-01 WAL562A114-01 WAL562A114-03 WAL562A114-04 WAL562A114-05

29 Union Tailpiece 3 Galvanized Iron WALSZ227 WALSAA227 WALSMP463 WALSBB227 WALSMP465 WALSMP593

30 Body 1 Bronze WALSAM1167B WALSAM1167B WALSAM1167B WALSAN1167B WALSAN1167B WAL564B116-01

31 Adapter 1 Stainless Steel WAL141A166 WAL141A166 WAL141A166 WAL141A166 WAL141A166 WAL141A166

32 Travel Indicator 1 Aluminum WAL05-12962-00 WAL05-12962-00 WAL05-12962-00 WAL05-12962-00 WAL05-12962-00 WAL05-12962-00

33 V-ring Packing Set 1TFE/Stainless steel/Viton WAL204A104-01 WAL204A104-01 WAL204A104-01 WAL204A104-01 WAL204A104-01 WAL204A104-01

34 Stem 1 Stainless steel WAL552A110-03 WAL552A110-03 WAL552A110-03 WAL552A14-03 WAL552A14-03 WAL552A14-03

35 Yoke Bushing 1 Brass WAL04-17278-00 WAL04-17278-00 WAL04-17278-00 WAL04-17278-00 WAL04-17278-00 WAL04-17278-00

36 Spacer 1 Brass WAL04-17280-00 WAL04-17280-00 WAL04-17280-00 WAL04-17280-00 WAL04-17280-00 WAL04-17280-00

37 Bonnet Guide 1 Brass WAL556A113-01 WAL556A113-01 WAL556A113-01 WAL556A113-01 WAL556A113-01 WAL556A113-01

38 Guide 1 Stainless steel WAL556A111-01 WAL556A111-01 WAL556A111-01 WAL556A111-02 WAL556A111-02 WAL556A111-02

39 Plug 1 Stainless steel WAL554A151-01 WAL554A151-01 WAL554A151-02 WAL554A151-03 WAL554A151-04 WAL554A151-05

40 Union Unit 3 Galvanized Iron WALSMP468 WALSMP468 WALSMP468 WALSMP470 WALSMP470 WALSMP592

41 Guide 1 Brass WALSK832 WALSK832 WALSK832 WALSL832 WALSL832 WALSM832

42 Inlet 1 Bronze WAL562B105-01 WAL562B105-01 WAL562B105-02 WAL562B106-01 WAL562B106-02 WAL562B106-03

1. Not included in body assembly; order K-KIT separately.

2. Not included in body assembly: order separately.

PART

NUMBER NOTES

REVERSE - LOWER PORT

NORMALLY CLOSED

DIRECT(1) - UPPER PORT

NORMALLY CLOSED SPRING KIT INCLUDES:

7/32 In. Travel 1/2 In. Travel 7/32 In. Travel 1/2 In. Travel Spring

Other

Code Range Code Range Code Range Code Range Quantity Color Part Number

WAL36KIT098 2 - - - - - - - - - - - - - - - - 36DM 4.5 to 13.5 - - - - - - - - 6 Silver WAL05-05007-00 - - - -

WAL36KIT100 2 36RA 5.5 to 12.5 - - - - - - - - 36DA 6 to 12 - - - - - - - - 6 Yellow WAL05-12991-00 - - - -

WAL36KIT102 2 36RB 6.5 to 11.5 - - - - - - - - - - - - - - - - - - - - - - - - 6 Yellow WAL05-12992-00 - - - -

WAL36KIT104 3 36RC 8 to 11 36RC 5.5 to 12.5 - - - - - - - - 36DC 6 to 12 6 Red WAL05-13090-01 - - - -

WAL36KIT106 2 - - - - - - - - - - - - - - - - - - - - - - - - 36DD 7 to 11 4 Red WAL05-13090-01 - - - -

WAL36KIT108 3 - - - - - - - - 36RE 7.5 to 10.5 - - - - - - - - - - - - - - - - 6 Green WAL05-13085-00 05-04889-00

(2) Bolts

WAL60KIT100 4 - - - - - - - - 60RG 7.5 to 12 - - - - - - - - 60DG 7 to 11 6 Brown WAL05-13093-01 - - - -

WAL60KIT102 3 - - - - - - - - 60RH 8 to 11 - - - - - - - - - - - - - - - - 4 Brown WAL05-13093-01 - - - -

1. For Direct Shutoff - Invert Springs, Piston and Diaphragm from Reverse Shutoff Actuator.

2. Mounts using KKIT-1

3. Mounts using KKIT-2

4. Mounts using KKIT-4

Table 3. Type K3 Actuator Spring Kit

Table 2. Type K3 Valve Body Assembly Parts List

Type K3

Figure 5. Type K3 Control Valve Assembly Drawing

Table 4. Type K3 Actuator Connector Kits

DIVERTING

COMMON

PORT

LOWER

PORT

UPPER

PORT

MIXING

PART NUMBER SIZE

K-KIT INCLUDES

Stem Bolt Bushing Spacer

WALKKIT-1 NPS 1/2 to 2 / DN 15 to 50 WAL04-17277-00 WAL04-17278-00 - - - - - - - - - - -

WALKKIT-2 NPS 1/2 to 2 / DN 15 to 50 WAL04-17281-00 WAL04-17278-00 - - - - - - - - - - -

WALKKIT-4 NPS 1/2 to 2 / DN 15 to 50 WAL04-17277-00 WAL04-17278-00 WAL04-17280-00

Type K3

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