MASCOT VFlo Guida

CAUTION :

1. Use pressure relief valves for high pressure

piping.

2. Use explosion proof valves/accessories for

dangerous media piping.

3. Use ﬁre safe valves for piping where chances of

ﬁre by external means.

4. Use seismic proof valves where chances of

earthquake are frequent.

5. Check whether locaon of the valve mounng is

of the same service/applicaon as speciﬁed on

the marking plate.

Installation, Operation,

Maintenance Instructions

VFlo

Control Valves

VFlo Control Valves

GENERAL INFORMATION

The instructions presented below are for helping in un-packing,

installing and performing maintenance as and when needed on

Mascot VFlo ball valves. The manual should be thoroughly

reviewed by Product users and maintenance personnel before

performing any operation on the valve. Separate maintenance

instructions cover additional features (such as actuators, special

accessories, fail-safe systems, etc.).

For information on Mascot positioners, refer to the appropriate

Mascot Installation, Operation and Maintenance instructions.

Please follow the procedures laid down to avoid possible injury

to personnel or damage to valve parts. Any modification in this

product, or using non-factory or inferior parts, employing

maintenance procedures other than prescribed can affect

performance adversely; moreover, it can be dangerous to

personnel and equipment, and also void existing warranties.

WARNING : It is mandatory to follow standard industry safety

practices. Personal protective and lifting devices must be used

as specified.

Note : The onus of choosing the proper fastener material lies on

the customer. The supplier cannot know what the valve service

conditions or environment might exist. The standard body bolting

material for Mascot's is B7/2H. For applications above 800° F

and with stainless steel or alloy body valves B8 (stainless steel) is

optional. It is up to the customer therefore to consider the

material's resistance to general corrosion and stress corrosion

cracking. Every mechanical equipment needs periodic inspection

and maintenance. The details on fastener materials can be

obtained from your local Mascot representative or factory.

Unpacking

First step is to check packing list against the materials

received during the unpacking of the valve. Each shipping

container has lists describing the valve and accessories.

For lifting the valve from the shipping container, lifting straps

need to be positioned to avoid damage to tubing and

mounted accessories. Where valves are provided with a lifting

ring, please use the same for lifting. Valves up through 8-inch

may be lifted by the actuator lifting ring. Larger valves can be

lifted using lifting straps or hook through the yoke legs and

outer end of the body.

WARNING : During lifting of a valve with lifting straps

through the yoke legs, one must have in mind that the

center of gravity may be above the lifting point and

support must be given to prevent the valve from rotating.

Serious injury to personnel or damage to nearby

equipment can take place if proper attention is not paid to

this factor.

On observation of damage in transit, shipper should be

contacted immediately.

The Mascot representative is always at your service whenever

needed.

Quick-Check

Before beginning, check the control valve as per the steps

mentioned below:

By making the appropriate instrument signal change, verify

for full stroke. The position indicator plate is mounted on the

actuator transfer case for observation. Position of the

indicator plate should change in a smooth, rotary fashion.

CAUTION : The full torque load of the actuator cannot be

taken by the VFlo valve shaft. The shaft could twist and/or

shear if the ball were to seize and full torque continued.

There should be no leaks in the air connections. Any leaky

lines should be repaired by tightening or replacement.

Tighten of the packing nuts is to be done to slightly over

finger-tight and evenly.

CAUTION : Over tightening of packing nuts can cause

excessive packing wear and high shaft friction and shaft

rotation will be adversely affacted. Every short time valve

has been in operation, check the packing nuts to ensure

they are torqued properly. Do correction if necessary. Any

leaking in the packing box should be corrected by

tightening the packing nuts. The tightening should be only

enough to stop leakage.

In case of air failure, for observing the valve failure mode,

position the valve to mid-stroke and shut off the air supply to

the actuator or disconnect the instrument signal to the

positioner. The actuator indicator plate should move to either

fail/open or closed position. If not, the "Reversing the

Actuator Action" section in the actuator maintenance

instructions needs to be referred.

*Torque values are recommended for low and intermediate

strength bolting per ANSI B16.5 5.3.2. Higher torques may be

used with high strength bolting (ANSI B16.5 5.3.1). For all

cases the user must verify the selected bolting's ability to seat

the joint under expected operating condition. Higher strength

bolting and torque values are needed for long thrubolted

joints than shorter flanged bolting - depending on operating

conditions. **Lengths are based on ANSI B16.5 stud bolts and

raised face ends.

Table 1 : Flange Bolting Specificatiions

Valve ANSI Bolt** Torque* (ft. Lbs.)

Size Class Length Low Intermediate

(Inches) Rating (Inches) Strength Strength

 150 2.5 23 61

1 300 3.0 46 122

 600 3.5 46 122

 150 2.75 23 61

11/2 300 3.5 82 218

 600 4.25 82 218

 150 3.25 46 122

2 300 3.5 46 122

 600 4.25 46 122

 150 3.5 46 122

3 300 4.25 82 218

 600 5.0 82 218

 150 3.5 46 122

4 300 4.5 82 218

 600 5.75 132 353

 150 4.0 82 218

6 300 5.5 132 353

 600 6.75 199 531

 150 4.25 82 218

8 300 6.25 199 531

 600 7.5 296 789

 150 4.5 132 353

10 300 6.25 199 531

 600 8.5 420 1119

 150 4.75 132 353

12 300 6.75 296 789

 600 8.75 420 1119

VFlo Control Valves

PREVENTIVE MAINTENANCE

Twice yearly, operation should be checked for trouble free

performance. For the preventive maintenance, follow the steps

that are presented below:

These steps can be very well performed while the valve is in line

and, in some cases, without interrupting service. Refer to the

"Disassembly" and "Reassembly" section if an internal problem is

suspected with the valve.

Tighten flange bolting if signs of gasket leakage through the

body and line flanges are observed (See Table I for

specifications.)

Observe whether any corrosive fumes or process drippings

are damaging the valve.

Valve should be cleaned and areas of severe oxidation

painted.

Packing nuts should be tightened as necessary to prevent

Gland leakage.

CAUTION : Over tightening of packing can cause

excessive packing wear and high shaft friction, which may

retard shaft rotation.

Where the valve is supplied with a lubricator, lubricant supply

and level needs attention. Ensure proper supply and level of

the lubricant.

Where possible, stroke valve and observe for smooth, full-

stroke operation by looking at the position indicator plate

mounted on the transfer case. An internal valve problem is

indicated by unsteady movement of the plate.

In case of a positioner being present, its calibration needs to

be checked by observing the actuator position indicator plate

and gauges. The positioner needs calibration to the correct

range.

In case an actuator is attached, the appropriate maintenance

instructions for preventive maintenance need to be referred.

Where possible, remove the air supply to observe the

actuator stroke plate for correct fail-safe action.

Ensure fastening of all valve accessories, brackets and

bolting.

The exposed portion of the valve shaft must be free from dirt

or foreign material.

I case an air filter is present, the cartridge needs to be

checked and if necessary, replacement needs to be done.

Removing Valve From Line

To remove the valve from the line, in cases where an internal

problem is suspected proceed as mentioned below:

WARNING : Line must be depressurized to atmospheric pres-sure.

All process fluids should be drained. If caustic or hazardous materials

are present, decontaminate the valve. This is very important as it will

prevent any possible injury.

10.

11.

Figure 1: 3", 12" and 16" VFlo Body Assembly with Rotating Post Design

Note : Item numbers correspond to bill of material of Valve. Please refer to it for specific part numbers.

StationaryPostDesign

Packing

(Item No. 88)

PackingStud

(Item No. 109)

Gland Flange

(Item No. 80)

Packing Nut

(ItemNo. 117)

Shaft

(ItemNo. 51)

RetainerRetainerO-rings

(ItemNo.30)(ItemNo.59)

(ItemNo.56)

Seals*

ShaftBearing

(ItemNo.83)

PostBearing

(ItemNo.84)

ShaftO-ring

(ItemNo.62)

(optional)

O-ring

(Item No.61)

Post

(ItemNo.123)

Post O-ring

(Item No. 64)

(optional)

Plug

(Item No. 122)

BodyShaft PinBall

(ItemNo. 1)(ItemNo.52)(ItemNo.50)

Post Pin

(Item No. 121)

Packing Follower

(ItemNo. 87)

PackingSpacer

(Item No. 93)

ThrustBearing

(Item No. 53)

(*See Figure 4 for seal configurations and item numbers.)

VFlo Control Valves

Support the valve with a hoist or some means.

Line bolting should be removed. Do not push or pull on the

valve or actuator to pry line flanges apart.

Valve needs to be slided from the line, carefully. Do not twist

the valve or it will cause damage to the gasket surfaces.

Slowly relieve air pressure from the actuator on complete

removal of valve from the line.

Removing Actuator From Body

The design of the 3 to 12-inch VFlo valves permits disassembly

without removing the Mascot actuator. However, it is advisable

to remove the actuator. Follow the proper actuator installation,

operation, maintenance instructions, and proceed as follows:

Before disconnecting it from the body assembly, support the

actuator assembly.

The spring compression is to be released by loosening the

actuator adjusting screw.

Remove the actuator transfer case cover bolts, carefully pry or

slide the cover plate from the transfer case, then loosen the

linkage bolt - On Mascot actuators.

The bolts connecting the yoke to the body subassembly need

to be removed.

The entire actuator assembly should be slided off the shaft. To

loosen it from the shaft splines, it may be required to wedge

the splined lever arm apart.

DISASSEMBLY AND REASSEMBLY

Disassembling the Body

Although not necessary, it is advisable to remove the actuator

from the body assembly to disassemble 3 to 12-inch bodies. It is

necessary to loosen the valve shaft (On valves) from the actuator

prior to body disassem-bly. Figures 1, 2 and 5 should be

referred to and below mentioned procedure must be followed :

Seal retainer and seals removal

Screw-in style - Loosening the retainer by turning it

counterclockwise and removing it from the body. (A special

cross-wrench tool is available with the factory and can be

ordered. Refer Table IV.) Remove the metal seals. The soft seal

needs to be removed, if applicable.

Lock-ring style - certain valve designs have a retaining ring

held in with set screws. For removing it, the set screws in the

lock ring need removal, then the re-taining ring is to be

removed, lock ring and seal retainer finally. The retaining ring

can be forced out using a flat-headed screwdriver and pliers -

if the lock ring set screws do not loosen. Remove the seals.

By removing both packing nuts, remove the gland flange.

Removing the studs is not necessary.

On rotating post designs, both the shaft and post pins need

to be driven into the center of the shaft and posted until the

outward end of the pin clears the ball. Care should be

exercised not to damage the post or shaft. Pins must be then

punched out of the shaft and posted when they are removed

from the valve. Remove the shaft plug, O-ring and finally the

rotating post. For removing the post, insert a bolt in the jack

screw hole, tapped in the post.

On stationary post designs, drive the shaft pin into the

center of the shaft until the outward end of the pin clears the

ball splines. Care should be taken, not to damage the shaft.

After the shaft is removed, the pin can then be punched out

of the shaft. The anti-rotation clamp must be removed. The

post and the post O-rings should be removed.

From 3 through 12-inch designs, for removal, the shaft needs

to be pulled through the outboard end of the body. On 1

through 2-inch designs, removal of the shaft is by pulling it

out through the inboard end of the body

CAUTION : Care must be taken during disassembly so

that the splined end of valve shaft does not get damaged.

Packing

(Item No. 88)

Packing Stud

(Item No.109)

Gland Flange

(ItemNo.80)

Packing Nut

(ItemNo.117)

Shaft

(ItemNo.51)

Packing Follower

(ItemNo.87)

Packing Spacer

(ItemNo.93)

Post

(ItemNo.123)

PostO-ring

(ItemNo.64)

(optional)

Inboard End

Shaft Bearing

(ItemNo.83)Retainer O-rings

(ItemNo.59)

(ItemNo.56)

Retainer

(ItemNo.30)

Plug

(Item

No. 122)

O-ring

(ItemNo.61)

PinBallPost Bearing

(ItemNo.52)(ItemNo. 50)(Item No. 84)

Thrust Bearing

(Item No. 53)

Body

(Item No. 1)

Seals*

Figure 2: 1" & 2" VFlo Body Assembly

(*See Figure 4 for seal configurations and item numbers.)

Note : Item numbers correspond to bill of material of Valve. Please refer to it for specific part numbers.

VFlo Control Valves

Rotate the ball inside the body in a way so that the non-

splined end of the ball is toward the back port of the valve.

Remove the ball straight out of the body. If needed, on

stationary post designs remove the post bear-ing from the ball

by pushing it out with a press.

CAUTION : The sealing surface of the ball should not be

galled or scratched when re-moving it from body. Scratches

lead to excessive leakage and wearing of the seal.

Employing a bronze dowel with the appropriate diameter,

push the packing and bearings out of the body. The packing

must be pushed out of the body from the center of the valve.

(Refer Table IV for optional shaft/post bearing tool.)

Reassembling the Body

For the reassembling of the body subassembly, refer to Figures 1

or 2, 3, 4, and 5 and proceed as mentioned below :

All parts must be cleaned and all O-rings and soft seals must

be replaced.

The ball sealing surface must be smooth and free of scratches

and scoring.

CAUTION : Keep the seal surfaces clean and free of

damage. Damaged or dirty surfaces cause excessive seat

wear and high torque re-quirements.Prompt replacement of

damaged balls should be done.

The shaft and post are to be inspected for galled surfaces or

scratches. To achieve optimum performance, VFlo shafts and

posts are given a very smooth finish. Replace the shaft or

contact the factory representative if damage exists.

NOTE : Replacing the ball does not require replacing the shaft as

ball and shaft are interchangeable.

We recommended the use of a press to install new bear-ings

in the body and/or ball. (If needed, an optional post/

bear-ing tool is available from the factory. Refer Table IV.) The

ends of the body bear-ings should be flush with the inside of

the body - an indication of correct installation.

The ball is to be position in the body by lowering it, splined

hole first, into the back of the body. Rotate the ball surface

toward the front of the body so that the splined hole is

towards the packing box

CAUTION : Whilst, Replacing it in body be extremely

careful not to scratch or gall the sealing surface of the ball.

Scratches may cause excessive leakage and wearing of

seal

For 3 through 12-inch designs, the shaft is to be inserted

through the outboard end of the body and through the

splined inch designs, insert the shaft through the inboard end

of body and through the packing box into the splined hole of

the ball. (For 1 -inch body designs, before installing the shaft,

the thrust bearing, packing spacer, packing, and packing

follower must be inserted.)

The positioning of the shaft is to be such that the pin hole in

the shaft and ball are in alignment. (Certain shafts have a

half circle mark and line on the end. Align the line mark with

the pin and the half circle symbol with the ball.) The shaft pin

needs to be installed and driven firmly into place so that half

in the shaft and half is in the ball.

On rotating post designs, the post is to be inserted through

the outboard end of the body and into the hole of the ball.

(For 1 through 2-inch valves sizes, before installing post,

insert thrust bearing.) The post must be positioned so that the

pin hole in the post and ball are aligned. (For 6 through 12-

inch valve sizes, make certain that the ball pin hole is aligned

with the smallest diameter pin hole in the post. Some posts

have a half circle mark on the end. This half circle mark

needs to be aligned with the ball.) The post pin is to be

installed and driven firmly into place so that half is in the post

and half is in the ball. To torque the plug, refer Table Il.

Figure 3 : VFlo Packing Configurations

Standard

Single "V"

Standard

Twin Square

Twin "V"

Twin Square

with Lubricator

Twin "V"

with Lubricator

SafeGuard / SureGuard

Fire-safe Option

SafeGuard Live-loading

SureGuard

(packing studs

rotated 45 degrees) (live-loading omitted)

On stationary post designs, make sure that the lubrication of

the post and post threads is proper and done with a high

tem-perature bearing grease (or as required by the

application) before installation. The post O-ring needs to be

replaced and then reinstall the post. To torque the post, refer

Table Il. The anti-rotation clamp kit should be installed.

Over the splined end of the shaft and into the body, slide the

thrust bearing, packing spacer, Packing, and packing

follower. Most packing configurations are presented in Figure

3. (1-inch designs refer to Step 6.)

NOTE : New packing is to be used whenever rebuilding the

packing box.

CAUTION : The sealing on V-ring packing takes place at

the feather edge, so it is necessary to avoid damage to

that edge.

The gland flange is and packing nuts are to be reinstalled

and left loose.

CAUTION : Over tightening the packing can cause

excessive packing wear and shaft friction, which may

impede shaft rotation.

The valve needs to be placed on a flat surface with the

threaded (retainer) port facing up and the shaft is to be pulled

toward the actuator until it is fully against the thrust bearing.

For 3 through 12-inch designs, the ball surface must facing

up and position the ball as close as possible in the center of

the body's inside diameter. (The pinned connection between

the ball and shaft is not a tight connection; the design

includes a consid-erable amount of axial play between the

ball and shaft.)

For 1 through 2-inch designs, make sure the ball surface is

facing up and pull on the shaft until the post is fully against

the thrust bearing. (The ball does not self center. There will be

no axial play between the ball and shaft.)

Replace the soft and/or metal seal rings, as applica-ble to the

application. (Refer to Figure 4.)

In case of soft seal applications, insert the soft seal ring,

followed by the two metal seal rings into the body.

In case of metal seal applications, insert the two metal seal

rings into the body. (There is only one seal ring for 1"

designs.)

For screwed-in retainer designs, replace the O-rings in the

retainer (except on high temperature valves, which do not use

O-rings). Figure 1 or 2 should be referred. The retainer

threads and rings are to be lubricated and reinstall the

retainer in the front of the body. Torque the seal retainer

according to Table III.

For some 10 and 12-inch valves where the retainer is held in

place with set screws, reinsert the lock ring into the body. The

words "Ball Side" facing toward the ball. The lock ring has

"Ball Side" and "Port Side" marked on it. Insert the retaining

ring into the inner groove of the body. Make sure it is fully

seated. The lock ring set screws need to be evenly tightened

to a torque of 225 inch-pounds.

Once the seal retainer is in tight, the packing nuts need to be

tightened just over finger-tight. Packing nuts should be

tightened sufficiently to prevent stem leakage.

CAUTION : Over tightening of packing causes excessive

packing wear and high shaft friction, which may retard

shaft rotation.

Remounting the Actuator

Prior to initiation of the mounting of a Mascot actuator on the

valve body, verify that the ball rotation matches the actuator

rotation and complies with the air failure requirements. Method

for mounting the actuator is presented below :

10.

11.

12.

13.

14.

15.

16.

Valve Stationery Rotating

Size Designs Designs

(Inches) Post Shaft Plug

1, 11/2,N/A 50

2 175 85

3, 4 300 150

6, 8 500 250

10, 12 600 300

Table II : Post/Shaft Plug Torques (Ft.-Lbs)

Valve Torque Valves Torque

Size Value Size Value

(Inches) (ft.-Lbs.) (Inches) (ft.-Lbs)

1, 11/2, 2 150-175 8, 10 650-700

3 250-300 12 900-950

4, 6 550-600 - -

Table III : Screwed-in-Retaineer Torques

Figure 4: Seat Configurations

* Two metal seals required for shaft upstream

Soft lateM*lauD

Retainer/

Flow Ring

(Item No. 30)

Ball

(Item No. 50)

Ball

(Item No. 50)

Body

(Item No. 1)

Body

(Item No. 1)

Metal Seal

(Item No. 20)

Retainer

(Item No. 30)

Soft Seal

(Item No. 21)

Soft Seal

(Item No. 21)

Ball

(Item No. 50)

Retainer

(Item No. 30)

Body

(Item No. 1)

Metal Seal

(Item No. 20)

Ball

Metal Seal

(Item No. 20)

Body

(Item No. 1)

Retainer

(Item No. 30)

Ball

(Item No. 50)

Bi-directional Metal

VFlo Control Valves

Entire actuator assembly is to be slided onto the shaft.

The yoke needs to be bolted to the valve body.

The actuator lever arm should be positioned on the shaft so

the actuator stem is centered in the transfer case.

The linkage bolt should be firmly tightened. Bolt the transfer

case cover plate into place.

Alignment of the stroke indicator plate to be done on the end

of spline lever so that it accurately indicates position of ball.

CAUTION : Without the cover plate installed; never apply

air to the actuator otherwise, the unsupported shaft is likely

to sustain damage.

The valve is to be installed in the line as outlined in the

"Installation" section.

Table IV: Optional VFlo Tools

Valve Retainer Shaft/Post

 Size Tool Bearing Tool

 1 87377 76891

 11/2 87530 76509

 2 76112 76509

 3 62295 75970

 4 62294 75970

 6 62296 81978 / 81974

 8 62336 81978 / 81974

 10 81775 76550 / 76551

 12 81034 76550 / 76551

Gland Flange Stud (Item No. 109)

Gland Flange Nut

(Item No. 117)

Half Ring

(Item No. 11)

Body

(Item No. 1)

Shaft (Item No. 51)

End Plug (Item No. 122)

End Plug O-ring (Item No. 61)

Post (Item No. 123)

Half Ring

(Item No. 11)

End Flange

(Item No. 10)

Post Pin

(Item No. 121)

Post Bearing

(Item No. 84)

Shaft Pin

(Item No. 52)

Ball

(Item No. 50)

Shaft Bearing

(Item No. 83)

Yoke Bolt (Item No. 107)

Packing

(Item No. 88)

End Flange

(Item No. 10)

Seal Rings

(Item No. 20)

Soft Seal Insert (Item No. 21)

Retainer O-ring (Item No. 56)

Retainer O-ring (Item No. 59)

Seal Retainer (Item No. 30)

Packing Spacer (Item No. 93)

Thrust Bearing (Item No. 53)

Packing Follower (Item No. 87)

Gland Flange (Item No. 80)

Figure 5: Exploded Body Subassembly, 3", 12" and 16" VFlo

Note : Item numbers correspond to bill of material of Valve. Please refer to it for specific part numbers.

Failure Probable Cause Corrective Action

Valve moves to failure position, excessive air  1. Failure of actuator O-ring 1.Replace actuator stem O-ring

bleeding from transfer case 2. Failure of sliding seal assembly 2.Repair or replace stem adapter / linkage assembly

Jerky shaft rotation 1. Overtightened packing 1.Retighten packing box nuts to slightly over finger-tight

 2. Improper adjustment of lever arm on shaft causing arm  2. Readjust lever arm (see step 1 in the

  to contact transfer case thus failing to convert torque.  “Remounting Actuator” section)

 3. Cylinder wall not lubricated 3.Lubricate cylinder wall with silicone lubricant

 4. Worn piston O-ring allowing piston to gall on cylinder wall 4. Replace O-ring; if galling has occurred replace all damaged parts

 5. Worn actuator stem O-ring causing ctuator stem to gall on stem collar  5. Replace O-ring; if actuator stem is galled replace it

 6. Worn (or damaged) shaft bearings, shaft bearings or packing followers  6. Disassemble and inspect parts; replace any worn or damaged parts

Excessive leakage through seal 1. Improper adjustment of external stroke stops  1. See “Adjusting External Stroke Stops” section

 2. Worn or damaged seat  2. Replace seat

 3. Damaged ball seating surface  3. Replace disc and shaft

 4. Improper handwheel adjustment acting as limitstop  4. Adjust handwheel until disc seats properly

 5. Ball not centered in body I.D.  5. Center ball; replace damaged seals.

Leakage through line flanges 1. Dirty line gasket surfaces  1. Clean gasket surfaces and reinstall valve

 2. Improper torque on line flanges  2. Tighten line flanges evenly and completely (see Table 1 for proper torque)

 3. Flange or pipe misalignment  3.Realign flanged ends with piping.

 4. Warn Gaskets  4.Replace Gaskets

Leakage through packing box  1. Loose packing box nuts  1. Tighten packing box nuts to slightly over finger-tight

 2. Worn or damaged packing  2. Replace packing

 3. Dirty or corroded packing  3. Clean body bore and stem, replace packing

Valve slams, won’t open, or  1. Improper valve installation  1. See step 2 in “Installation” section and

causes severe water hammer     correct flow direction

Shaft rotates, ball remains open or closed 1. Broken shaft 1.Replace shaft

Actuator operates, shaft does not rotate  1. Broken internal actuator parts  1. Refer to appropriate actuator Maintenance Instructions

Troubleshooting VFlo Valve

MASCOT VALVES PVT. LTD.

166 / 167, G I D C, Naroda, Ahmedabad : 382330.India

Phone : +91 79 22821619/22823369, Fax : +91 79 22822430

Email : info@mascotvalves.com / web : www.mascotvalves.com

Indice

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