Watson McDaniel HB Series Manuale utente

Series HB

Control Valve

Installation

Operations &

Maintenance

Manual

428 Jones Boulevard

Limerick Airport Business Center

Pottstown, PA 19464

Phone: (610)495-5131

Fax: (610)495-5134

www.watsonmcdaniel.com

2533800 Watson McDaniel Company HB Valve Manual Rev 0

HB Specifications

Figure 1: HB Control Valve

Item

Description

Actuator Assembly

Main Valve Assembly

Shut-off Pressures (psi)

Size

3-15psig

Signal

Positioner

1/2

300

3/4

300

1-1/2

170

225

135

HB Valve Pressure-Temperature

Ratings

NPT

300psi @ 450°F

150# Flanges

150psi @ 450°F

300# Flanges

300psi @ 450°F

Actuator effective diaphragm area is

approximately 47in2

Size

A (Face to Face)

Orifice

Diameter

Weight

(lb)

NPT/SW

150PSI

300PSI

1/2

4 1/2

7 1/4

7 3/4

1 3/4

0.88

3/4

4 1/2

7 1/4

7 3/4

1 3/4

6.5

0.88

4 1/2

7 1/4

7 3/4

1 3/4

0.88

21.9

1-1/2

8 3/4

9 1/4

2 3/16

1.25

10 1/2

2 5/16

1.75

26.5

Note: All dimensions in inches unless otherwise noted.

Each Watson McDaniel Company Product is warranted against defects in material and workmanship for one year from date of shipment. This warranty extends to the

first retail purchaser only. All defective material must be returned to the person from whom you purchased the Product, transportation prepaid, free of any liens or

encumbrances, and if found to be defective will be repaired free of charge or replaced, at the warrantor’s or seller’s option. If the material is replaced, any replacement

will be invoiced in the usual manner and after inspection of alleged defective material an adjustment will be made for depreciation caused by purchaser’s use. In no

event will Watson McDaniel Company be liable to do more than refund the original contract price. Incidental and consequential damages are excluded, whether under

this warranty or otherwise. All implied warranties, including warranties of merchantability and fitness for a particular purpose, are disclaimed and excluded

2533800 Watson McDaniel Company HB Valve Manual Rev 0

INTRODUCTION

The HB Series is a high performance, general service control valve designed using CFD

technology for high control accuracy and longevity. Stainless steel body material is standard

making it compatible with many fluids and environments. The standard valve has an equal

percentage flow characteristic with metal seating and a live loaded, Teflon V-ring stem packing.

The spring and diaphragm configuration allows the actuator to be used across the ½” to 2”

valve size range with varying differential pressures. Easy field reversibility allows the actuator

to be installed as either an ATO (air-to-open) or ATC (air-to-close) option. The use of a multi-

spring setup permits the units to be compact and lightweight. This valve series can be used to

automate control valves in both throttling and on/off control of liquids or gases. The HB Series

is also available with electric actuation.

NOTE: This manual is intended to provide detailed information about the

installation, operation, and maintenance of the HB series Actuator. Please refer

to the factory for any clarifications about the instructions provided within or

replacement parts required.

The information should be thoroughly reviewed prior to any installation or maintenance

performed on the equipment. All personnel should be properly trained and aware of the

instructions shipped with the valve/actuator assembly.

UNPACKING AND INSPECTING:

After receiving valve, unpack and inspect to ensure it was not damaged. Verify that the valve

stem is true and was not bent during shipping.

When servicing or installing this valve in systems, all steam and /or

water pressure must be turned off and any fluids should be drained

completely. Lines must be free of pressure.

While air is applied to the actuator to retract the spindle, there is an

extreme finger trapping danger if this air pressure is lost or reduced or

if there is loss of air pressure due to diaphragm failure for example.

Loss of air pressure can lead to rapid extension of the actuator spindle

under high force.

Never clamp or use a tool to hold the valve on the sides of the body.

Damage can occur. Clamp the valve end to end and use the hexes at

the ends of the body for tightening.

PTFE under normal working temperatures is a safe product. Care

should be taken avoid heating PTFE to its sintering temperatures which

could give way to gaseous fumes that would require proper ventilation.

CAUTION

2533800 Watson McDaniel Company HB Valve Manual Rev 0

INSTALLATION:

1. The valve should be installed in horizontal piping with the actuator vertically positioned

above the valve.

2. Be sure to clean and remove any scale or debris in piping prior to installation of valve.

3. Locate the Flow Arrow on the side of the valve body and verify the fluid flow will match

the flow arrow orientation.

4. A strainer is recommended upstream of the valve to prevent any debris from potentially

interfering with operation.

5. To ease maintenance procedures, it is recommended to have isolation valves installed

with unions or flange connections before and after the valve.

6. An optional bypass line can be installed parallel to the control valve.

7. Thread sealant should be applied to connections.

8. Pipe insulation should only be installed on the body and not the actuator.

9. Install the control signal to the actuator via an air or current signal that may use an I/P

or Positioner.

Figure 2: Recommended Valve Installation

Control Signal

2533800 Watson McDaniel Company HB Valve Manual Rev 0

START UP

1. All valves in the installation need to be

closed.

2. Check to verify that the control signal

properly connected to the valve and

that the actuator responds to the

signal.

3. Open the valve ahead of the steam trap

or other drain valve to remove all

condensate from the inlet piping.

Follow the same procedure for a steam

trap on the outlet piping. Note: Serious

damage to the piping system and

control valve could occur from the

effects of water hammer.

4. Verify that the bypass valve is closed.

5. After the condensate has been

removed from the system, slowly open

the outlet gate valve.

6. Slowly open the inlet gate valve to the

HB valve and verify there are no

indications of water hammer.

7. Blow down the main inlet strainer.

8. Slowly adjust the control signal, via a

controller or other device, so that the

control valve begins to actuate.

9. Allow time for the system to adapt to

the change due to the piping system

volume.

10. After the system has stabilized check

the control condition and readjust as

required.

11. Inspect the piping system and valve for

any leaks and tighten as required.

Never thread the valve stem into the

actuator spindle while the valve plug

is seated or close to seated. Damage

to the seat and plug could occur.

REMOVING ACTUATOR:

1. Place the valve body securely in a vise

so that the end connection points are

being clamped and not the sides of

the body.

Improper positioning in a vise could

cause the valve body to distort and

permanently damage.

2. Loosen the two jam nuts on the valve

stem that lock to the actuator spindle.

Take care not to rotate the valve stem

3. Apply air pressure to the actuator so

that the valve stem moves and is

positioned at about the midpoint of

the stroke. Take care to apply air only

to the non-spring side of the

diaphragm.

a. For air-to-open (fail closed) valves

this will be to the connection at the

top of the actuator diaphragm

case, Figure 3.

b. For air-to-close (fail open) valves

this will be to the connection on

the side of the actuator yoke,

Figure 4.

4. Unthread the valve stem from the

actuator spindle. Be careful not to

twist the actuator spindle which could

damage the diaphragm.

5. Loosen the large actuator mounting

nut that retains the actuator yoke to

the valve body.

6. After the valve stem has been

completely disconnected from the

spindle, lift the actuator from valve.

7. Release the air pressure to the

actuator.

CAUTION

2533800 Watson McDaniel Company HB Valve Manual Rev 0

INSTALLING ACTUATOR:

1. Place the valve body securely in a vise

so that the end connection points are

being clamped and not the sides of

the body. Note: Improper positioning

in a vise could cause the valve body to

distort causing permanent damage.

Figure 3: ATO Assembly

2. Apply air pressure to the non-spring

actuator connection to position the

actuator spindle in the approximate

midpoint of travel. Take care not to

exceed the maximum air pressure

marked on the actuator nameplate.

a. For air-to-open (fail closed) valves

this will be to the connection at the

top of the actuator diaphragm

case.

b. For air-to-close (fail open) valves

this will be to the connection on

the side of the actuator yoke.

2533800 Watson McDaniel Company HB Valve Manual Rev 0

3. Push down on the valve stem to

ensure that the valve is in the open

position.

4. Lower the actuator over the valve

body and into place.

5. Fit the large actuator clamping nut to

the valve body and tighten it. Do not

over tighten

6. Actuator positioning:

a. For air-to-open: Adjust the air

pressure in the actuator so that the

actuator spindle extends 1/3 to 1/2

of travel.

b. For air-to-close: Adjust the air

pressure in the actuator so that the

actuator spindle extends 1/2 to 2/3

of travel.

7. Thread the valve stem into the

actuator spindle approximately 3/4 of

an inch.

a. For air-to-open (fail closed) slowly

remove air pressure from the

actuator.

b. For air-to-close (fail open) slowly

apply air pressure to the actuator

until it fully strokes.

8. Check the gap between the actuator

spindle and the upper guide bushing.

The gap should be between 0.02” &

0.06”. A thickness gauge will verify

the gap.

9. Repeat steps 6 through 8 until the gap

is properly set.

10.Thread the 2 stem jam nuts up to the

actuator spindle and tighten the

screws until secure.

11.Verification by applying air pressure to

the valve inlet:

a. For air-to-open: Reduce the

actuator air pressure to 0psig.

b. For air-to-close: Increase the

actuator air pressure until the valve

closes, over 18psig will be enough.

12. Apply approximately 40psig air

pressure to valve inlet and check for

leaks at valve outlet.

13. Re-adjust the stem coupling position if

necessary.

SPRING RANGE VERIFICATION:

Notes: To prevent any damage to the

control valve, it is best to remove the

actuator from the valve prior to testing.

Actuators will have this test performed

at the factory and this will not be

required for new installations.

If the actuator has not been removed from

the valve, read the section below for proper

disassembly instructions. See Figure 3 & 4

for location of ATO and ATC ports. The spring

range will be labeled on the tag mounted on

the side of the actuator yoke. The lower

pressure value will indicate approximately

when the stem will begin to actuate while the

upper pressure value will indicate the

diaphragm pressure at approximately full

stroke.

1. Install a pressure gauge and regulator

with an accurate range to the proper

¼” NPT inlet port

2. Slowly open the regulator until the

stem begins to move

3. Compare the value with the lower

spring range pressure

4. Continue to open the regulator until

the stem reaches its max travel and

observe the pressure reading

5. If the pressure reading does not

match the range listed on the name

tag then the wrong springs may be

2533800 Watson McDaniel Company HB Valve Manual Rev 0

installed or internal components may

not be functioning properly. Parts

should be checked for wear or

damage. Consult the factory with

questions.

VALVE DISASSEMBLY /

MAINTENANCE

NOTE: A spare parts kit is strongly

recommended when disassembling the

valve.

1. Make sure fluid supply is safely shut

off.

2. Allow sufficient time for valve to cool if

required.

3. Remove the actuator assembly from

the valve. See the Removing Actuator

section for instructions.

4. Remove the body plug from the

bottom of the valve body

5. Loosen and remove the packing gland

nut located at the top of the body.

6. Push down on the valve stem to

remove from body.

7. Remove the packing and spring out of

the packing chamber. Reinserting the

valve stem back through the packing

may help to push packing out of

chamber.

8. From the bottom, use a 9/16” socket

to remove the lower seal bushing.

The packing washer and o-ring should

drop out with the bushing.

9. Inspect the guide bushings in the

packing gland nut and lower seal

bushing. Replace as required.

10.Replace the packing O-ring as

required. Be sure to lubricate prior to

install.

11.Clean all surfaces of the stuffing box,

seat, stem, and plug. If the stem or

plug is corroded, worn or marred, it

must be replaced.

LAPPING THE SEAT AND PLUG

1. Follow the disassembly instructions

above for the valve.

2. Loosely reinstall the gland nut and

lower seal packing into the body.

3. Apply a thin amount of lapping

compound around the plug at the

taper near the bottom.

4. Slide the stem through the packing

until the plug rests on the seat.

5. Apply a very light pressure to the plug

on the seat and rotate back and forth.

Rotation should not exceed 90

degrees.

6. Lift the plug away from the seat and

rotate 90 degrees.

7. Repeat steps 5 and 6 several times to

ensure a proper seat. Then remove

the stem & plug and clean the lapping

compound off of the parts.

VALVE ASSEMBLY

1. Install the packing washer, O-ring, and

lower seal bushing from the bottom

opening of the valve body. Be sure to

lubricate the O-ring prior to install.

Packing must be clean and free of

dirt or debris.

2. Install spring from the top of the valve

body.

3. Slide the stem up through the packing

area.

V rings must be carefully installed

over the stem threads and into the

stuffing bore to avoid snagging of

the lips on threads or on the bore. A

sharp edge on the lips is imperative

for sealing.

CAUTION

2533800 Watson McDaniel Company HB Valve Manual Rev 0

4. Install new packing onto the stem and

lower into the packing cavity. The V-

ring packing should be installed so

that the point of the V is aimed up

toward the actuator.

5. Install and tighten the packing gland

nut onto the valve body.

6. Verify that the stem slides through the

packing without any binding or

extreme sticking. Disassemble and

check trueness and cleanliness of

parts if issue occurs.

7. Install the bottom plug with gasket

into the bottom of the valve body.

8. A leak test may be performed to verify

all components have been properly

installed and tightened prior to service

install.

ACTUATOR ASSEMBLY /

REVERSABILITY

NOTE: The actuator does not need to be

completely removed from the valve

body to reverse the actuation.

Figure 4: ATC Assembly

1. Remove air pressure from the actuator

and shut off upstream and

downstream isolation valves.

2. Disconnect the valve stem from the

actuator spindle. See the Removing

Actuator section for details.

3. Remove the thread protectors from

the long screws on the actuator case.

The actuator springs are compressed

when installed and care should be

taken when relieving compression as

to not cause injury or damage.

4. Slowly loosen the screws around the

actuator case. Be sure to loosen the

screws in a star pattern.

a. For air-to-open (fail closed) the

actuator case does not hold

compression on the springs.

b. For air-to-close (fail open) the

actuator case does maintain

compression on the springs. The

long case screws must be used to

slowly decompress the springs

during removal.

5. Remove the upper case. For air-to-

close (fail open) the springs should be

removed at this time as well.

6. Now the actuator spindle needs to be

separated from the upper actuator

stem. Use the diaphragm nut or

upper stem to hold the diaphragm and

upper stem in place while unthreading

the spindle.

For air-to-open (fail closed) this will

relieve the compression from the

springs. The spindle must be rotated

so the springs don’t move out of

position which could cause injury or

damage.

CAUTION

ATC Air Signal

port location on

back of yoke

2533800 Watson McDaniel Company HB Valve Manual Rev 0

7. The diaphragm nut is then removed

from the upper stem to free the

diaphragm, diaphragm plate, and

washer.

8. Inspect the diaphragm and stem O-ring

for wear. Replace as required.

9. To reassemble the diaphragm,

diaphragm plate, and washer will fit on

the end of the upper stem and

tightened with the diaphragm nut. See

figures 3& 4for proper orientation of

the ATO or ATC actuation.

10. Lubricate the stem O-ring and slide

down onto the step of the spindle.

11. Assemble the upper stem to the

spindle by sliding the spindle in from

the bottom of the guide bushing and

the upper stem from the top. Keep the

outer diaphragm holes lined up with

the lower case holes.

a. If this is for air-to-open, 6 springs

must sit between the lower case

and the diaphragm plate. Make

sure to line the springs up with the

depressions on the diaphragm

plate and only rotate the spindle so

that the springs remain seated

while tightening. See Figure 3.

b. For air-to close place 3 springs on

top of the diaphragm plate.

12.Add the top case.

13.For air-to-close use the long bolts,

equally spaced around the case, to

compress the springs.

14.insert the small bolts around the

perimeter of the cases and tighten in a

star pattern.

15.Check that the air fitting is in the

proper location, if not reposition.

a. Air-to-open is on the top case.

b. Air-to-close is located on the side

of the yoke.

NOTE: The spring count will differ for

ATO (6 springs) and ATC (3 springs).

TROUBLESHOOTING

PROBLEM

POSSIBLE

CAUSE CORRECTION

1. Cannot set valve to

give high enough

downstream set

conditions

a) Valve undersized

a) Check capacity of valve against load

b) Downstream piping undersize

b) Check velocity of steam in piping

system

c)Inlet or outlet gate valve partially closed

c) Open valves

d) Upstream pipeline strainer blocked

d) Clean strainer screen

e) Inlet pressure too low causing reduced

capacity thru valve

e) Check with gage and correct as

required

e)Actuator diaphragm failed

e) Replace diaphragm

2. Downstream

condition over rides

set condition under

load conditions

a) Valve is extremely oversized

a) Check catalog for rated capacities

b) Bypass valve open

b) Close valve

c) Control Loop issue

c) Readjust/check control loop

f) Foreign object lodged between valve plug

and seat

f) Check valve plug and seat. Check

stem guide bushing for binding

h) Main valve packing leaking

h) Check packing and area for erosion

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