GESTRA Steam Solutions

GESTRA PN40
DN 15 - 50mm

FCD GSEDS0043-02 Issued 07/14

B4
Replaces CD.4.4.10 Issued 01/98

Intermittent Blowdown Valves Type PB24C

(Key Handle) and MPB24C (Actuated)
General
Time Controlled Bottom Blowdown of Steam Boilers Automatic program controlled
intermittent blowdown valve
type MPB and manual
intermittent blowdown valve
type PB for the desludging of
steam boilers from the bottom
blowdown connection.

The programmable timer

CT841 ensures that the
blowdown is carried out
precisely and regularly by
controlling the frequency and
duration of blowdown.
This also helps to maintain
the desired TDS level when
no other specific TDS control
equipment is fitted and also
assists in the automation of
the boiler towards BG01
typical arrangement 3.

The valve is actuated by air

pressure and closed by a
spring.

For complete drainage of the

boiler, a bypass valve may
be necessary.
SECTION OF STEAM BOILER
The MPB24C may also be
used for feed line 'slam shut'
purposes for protection
Sludge and precipitated solids against high boiler water
levels.
Blowdown controller LRR1-52 can be
used in lieu of the CT841 when the
intermittent blowdown function is
combined with an automatic TDS control
system
Compressed BLOWDOWN

air to solenoid
TIMER CT31

Day Time Auto Off Manual

7 8 9 Output

valve 4 5 6 Enter Set

Time

1 2 3 Run

Verify
0 Cancel Set
Program

MPB24CC Blowdown Timer CT841

To blowdown receiver
Design
The MPB24C is a ball valve
suitable for boiler pressures
of up to 17.2 barg (200
psig).
Actuation Equipment: DIMENSIONS
All dimensions in mm
Air Supply: Dry or lubricated
air at between 4 and 7 barg MPB24C
(60 to 102 psig).

It is available as a one piece Mounting: Actuator to valve

body design in sizes DN15
to 50mm.
Flanges: Integral to the body
and fully machined to DIN
2543/4/5, PN16/25/40.
is ISO standard. Solenoid to
actuator is NAMUR
standard.
Angle of rotation: 90o +/- 1.5o
travel adjustment.

Face to face lengths are to Protection Rating: IP65

DIN3202
Ball: 316 stainless steel,
perfectly spherical, polished
finish, cylindrical bore,
floating in the closed
position, perfect sealing.
Stem: Stainless steel, highly
resistant to torsion, with a
smooth finish perfectly
adjusted to the ball and
handle.
Sealing seat: High
temperature Fluorofill
construction. Water-tight
seal on both sides. Low
torque, long working life.
Lower stem seal: Reinforced
PTFE, highly pressure
resistant, low torque and
perfect seal.
Mounting Bolts: Allows
removal and change to any
of four positions (90o)
making valve installation and
operation easier.
Tee Handle: Construction
from stainless steel.
Removeable from valve
when in closed position only.
Solenoid Valve
With 5/2 configuration for
easy installation avoiding PB24C
pipes and fittings.
Pressure range: 3 to 10 barg
(43.5 to 145 psig).
Temperature Range: -30oC
to +50oC
VOLTAGE OPTIONS
DCC AC

Upper stem seal: Graphite 6v 12v 50/60 Hz

material acts as a second
(safety) seal providing 12v 24v 50/60 Hz
greater reliability to the shaft
assembly. 24v 48v 50/60 Hz

48v 110v 50/60 Hz

110v 230v 50/60 Hz

FLUOROFILL TEMPERATURE LIMITATIONS DIMENSIONS

DN A B C D Weight, kg

15 130 275 206 216 5.5

20 150 275 208 218 6.5

25 160 275 216 226 7.1

40 200 275 227 242 10.4

50 230 275 232 247 12.5

2
 Actuation Equipment

Rack and pinion actuator mechanism

Plan view: Spring return arrangement

PORT 'A' PORT 'A'

PORT 'B' PORT 'B'

Air supplied to port 'A' forces the pistons apart and toward Air or electric failure allows springs to force pistons toward
end position, compressing springs. Exhaust air exits from the centre position with exhaust air exiting from port
port 'B' (anti-clockwise rotation is obtained). 'A' (clockwise rotation is obtained).

Blowdown Discharge Blowdown Timer
Rates CT841
The rate at which the boiler Seven day digital timer
water is discharged when may be programmed to
the intermittent blowdown blowdown the boiler at any
valve opens depends time of the day and on any
mainly on the length and days of the week. Ideal for
size of the pipework single boiler installations.
downstream of the valve.
Up to 200 'events' may be
The chart shown below entered per week
gives and indication of the Blowdown duration is
flow rate to be expected adjustable from 1 to 15
when discharging through seconds.
a pipe of 7.5m (25 ft) Key operation plus auto/
equivalent straight length. off/man override.
Battery reserve protects
settings for up to 3
months.
Supply voltage: 115VAC
or 230VAC.
lb/s kg/s
20
40
")
Blowdown Timer LRR1-52 control unit is DIN
LRR1-52/URB50 rail mounted.
TDS controller with timer for
The LRR1-52/URB50
control of frequency and
controller can be used in
duration of MPB valve is
lieu of the CT841 timer
enabled by a dipswitch
when the automatic bottom
setting and programming.
blowdown system is
combined with an automatic
For multiple boiler
total dissolved solids (TDS)
installations, a password
control system.
protection feature may be
used to comply with PM60.
URB50 HMI unit is panel
mounted. Protusion from
Multi-pulse blowdown
panel face: 4mm.
feature.
Depth of unit from panel
face: 52mm.
H x W x D: 74 x 100 x 120
Panel cut-out: 136mm x
(mm).
96mm. Supply voltage: 24VDC
Supply voltage: 24VDC.
Protection rating:
Protection rating: IP65.
IP40 (housing)
IP20 (terminal strip)
Blowdown Timer CT841
BLOWDOWN
TIMER CT841

(2 Day Time Auto Off Manual

30
mm 7 8 9
50
Output

112
) 4 5 6 Enter Set

.5"
10 Time

20 (1 1 2 3 Run

mm
40 0 Set
7 Verify Cancel
Program

5
10 226
4
") Controller LRR1-52/URB50
(1 ")
Discharge rate

7 3
mm 5
25 0.7
&
5 .5"
2 (0
4 mm
20
&
3 15 75
1
4 5 7 10 20 30 40 barg

70 100 200 300 400 500 psig

Boiler pressure 145

3
 B4
Flowserve – Gestra, Euro House, Abex Road,
GESTRA Newbury, Berkshire, RG14 5EY. UK.
Tel: +44 (0)1635 46999 Fax: +44 (0)1635 36034
Email: gestrasalesuk@flowserve.com
Web: www.gestra.com

GESTRA Steam Solutions FCD GSEDS0043-02 Issued 07/14 Replaces CD.4.4.10 Issued 01/98

Think Gestra for your Steam & Process Fluid Control products

Steam Traps
Manifolds
Trap Monitoring Systems
Non-Return Valves
Control Valves, Actuators & Controllers
Pressure Reducers
Separators
Strainers
Safety Valves
Pressure & Temperature Gauges
Sight Glasses
Ball Valves
Stop Valves
Feedwater Tanks & Systems
Boiler Controls & Systems
Deaerators
Flowmeters
Contamination Detection
Condensate Pumps & Recovery Systems
Tank Car Valves
Plant Data Acquisition, Monitoring & Control Systems
Leaders In Systems Engineering for Steam
and Process Fluid Control

4 Technical Modifications Reserved. E&OE

 1 STORAGE AND PRESERVATION 3 HEALTH AND SAFETY 4 PREPARATION FOR INSTALLATION
User Instructions When despatched, all actuators are prepared for storage. All protective packaging, end cap port plugs, When installing or maintaining actuators: The working area should be clean and clear of any debris that would contaminate the actuator.
pinion covers etc. should remain in position until the actuator is due to be installed.
a) Conduct a risk assessment and eliminate or reduce hazards to an acceptable level. When despatched, actuators contain a mineral oil grease, this will lubricate the actuator for life.
Norbro Pneumatic Actuators Installation Actuators should be stored in a clean, dry environment.
b) Work in accordance with Safe Systems of Work. Special variants may contain other lubricants. An air lubricator may be used if desired.

39R/40R Series Sizes 05, 10, 15, 20, 25, 30, 33, 35, 40 & 42
39/40 Series Sizes 45 & 50
Operation 2 ACTUATOR MARKINGS c) Observe all site Health and Safety Rules in particular Permit to Work and Hot Work procedures. Make sure air supply is clean and filtered before installation, to ANSI/ISA S7.0.01-1996 and does not
exceed 8.3 bar.
d) Wear all necessary Personal Protective Equipment.
Maintenance Each actuator has the following identification information on the product label attached to the side of the NOTE: For size 45 and 50 actuators with limit stops, supply pressure not to exceed 6 bar, actuators to be
body: e) Never remove or maintain an actuator or joint unless the supply has been fully de-pressurised, drained spring return only.
and where necessary, purged of toxic / explosive / flammable media. Always operate the actuator to
NBEIM0002-02 ensure that no trapped pressure exists.
PRODUCT SERIES
f) Never handle actuators that have been used on harmful substances unless they have been completely
ATEX DIRECTIVE decontaminated and certified safe to handle.
g) Never use an actuator on a duty, which exceeds its prescribed operating parameters. Refer to Flowserve
EXPLOSION PROTECTION SYMBOL, Flow Control Technical Sales for further information.
94/9/EC
CE MARK PNEUMATIC ACTUATOR II2GDcX EQUIPMENT GROUP & CATEGORY,
IMPORTANT: Dismantle only in accordance with Installation, ZONE SUITABILITY AND PROTECTION TYPE h) Never modify or alter actuators unless the manufacturer has been consulted and/or
Operation & Maintenance notes. Refer to notes to ensure proper
use of actuator. Maximum Working Pressure 8.3 bar. MAXIMUM WORKING PRESSURE recommends such changes.
PRODUCT CODE YEAR WORKS ORDER
i) Due to the large physical size and weight of some sizes of this product, always use correct lifting meth
FLOWSERVE FLOW WORKS ORDER NUMBER
CONTROL (UK) Ltd ods and equipment when installing, removing and maintaining the product, and that it is correctly
PRODUCT CODE Flowserve Flow Control (UK) Ltd. YEAR OF MANUFACTURE supported in its final operating location.
Tel: +44(0)1444 314400 Fax: +44(0)1444 314401
Website: www.worcestercontrols.co.uk UK & Foreign Patents
j) Due to the variety of duties on which this product can be employed, it is the end users responsibility to
ensure the compatibility of the product with the specific application (i.e. air supply, torque, corrosion,
which may effect it's suitability).
ATEX Directive: If the product label carries the ATEX Directive number '94/9/EC' followed by the Explosion
Protection Symbol and codes identifying the equipment group and category, the zone suitability and k) Before equipment is installed in areas which may be subject to seismic activity or extreme climatic condi
protection type beside the CE mark, the product complies with the ATEX Directive and The Equipment and tions consult Flowserve Flow Control Technical Sales.
Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 1996.
l) If the processes or environments that the products are used in are likely to cause temperatures (high or
Definition of product label marking above: low) that may cause injury to personnel if touched, then adequate insulation/protection must be fitted.
'II' = Equipment Group; '2' = Equipment Category; 'G' = Gas Zone suitability (Zones 1 & 2);
m) If the equipment is to be used on unstable gas duty, ensure that the operational parameters as indicated
'D' = Dust Zone suitability (Zones 21 & 22); 'c' = type of protection i.e. constructional safety
on the product label cannot be exceeded.
(prEN 13463-5).
n) This equipment should be protected by other devices to prevent over-pressurisation. (i.e. caused by
'X' = Special temperature reference (Surface Temperature: As per BS EN 13463-1 paragraph 9.3f,
external fire etc).
the temperature class or maximum surface temperature cannot be marked on the product as it is
dependent on the operating conditions). o) This equipment must be installed in a system that is designed to prevent excessive forces acting on the
mounting kit, switch box/ positioner, connections etc.
The operational temperature range is as follows:
p) Care must be taken when removing the actuator or accessing the valve that the actuator does not unex
(S) Standard -20°C to +100°C.
pectedly operate due to the stored failsafe spring torque, causing personal injury.
(L) Low Temperature variant -40°C to +85°C.
q) This equipment is not a safety device and must be controlled / guarded by other devices.
(H) High Temperature variant -20°C to +150°C.
r) Do not rub actuator with a dry cloth as this can cause a build up of static charge. Only clean with a damp
NOTE: Under constant use the surface temperature of exposed parts may rise by a maximum 20ºC above cloth.
the operating media temperature.

5 INSTALLATION INSTRUCTIONS 5 INSTALLATION INSTRUCTIONS (Cont.) 5 INSTALLATION INSTRUCTIONS (Cont.)

5.1 GENERAL 5.5 SOLENOID CONTROL VALVE 5.8 INDICATOR FITTING INSTRUCTIONS - SIZES 10, 15, 20
Actuators may be installed in-line or cross-line (i.e. 90 degrees to the valve flow). They may be installed Ensure solenoid control valve is correctly configured for a double acting (5/2) or spring return (3/2)
in any orientation, but the bracketry should be of sufficient strength to not distort. The actuator may be actuator. Before fitting the solenoid valve, remove the plastic vent plug from the left hand port of the White Plugs Red Plugs White Plugs Red Plugs
operated by a solenoid control valve directly mounted to the Namur interface on the actuator. Alternatively Namur interface on the end cap (or from the bottom port of the Namur manifold on the 05). Fit solenoid
it may be piped from a remote control system. control valve to the Namur interface ensuring port 2 of the solenoid valve relates to the right hand port of
the actuator. Fit foolproofing stud to ensure solenoid control valve is not fitted inverted if maintenance is
5.2 MOUNTING ACTUATOR TO VALVE carried out at a later stage. Exhaust ports should be fitted with an appropriate bug trap / silencer.

Actuators are usually fitted with ISO5211 spigot and hole pattern. It is suggested that these are used in 5.6 DIRECT AIR CONNECTION
preference to any other mounting arrangement. The actuator can be mounted to the valve in either fail
open or closed mode, by rotating the actuator or drive adaptor by 90° in relation to the valve. Before If the actuator is not controlled by a direct mounting air supply, connect the opening air supply to the
fitting the actuator ensure that both are orientated to achieve the correct operation. Loosely attach the right hand Namur port, labelled port 2 (bottom port on the 05). If the actuator is double acting a
actuator to the valve mounting kit with all the retaining bolts finger tight. Operate the actuator to allow the connection to the closing air supply Namur port is also required, labelled port 5. Spring return actuators
valve and actuator to align correctly. If the alignment of the valve ball or plug is critical for flow, before are supplied with a vent plug already installed in the exhaust port.
fully tightening the retaining bolts rotate actuator body until optimum alignment is achieved. Tighten all
retaining bolts fully. 5.7 HAZARDOUS OR CORROSIVE ENVIRONMENTS FIG.1 As supplied by Worcester Controls FIG. 2 Alternative Indicating Position

5.3 ADJUSTING THE STROKE (WHERE LIMIT STOPS FITTED)
All actuators leave the factory with the travel stops set 0º and 90º. Fine tune the actuator travel to suit the
valve using the travel stops in the end cap. The right hand stop adjusts the closed position of the actuator
and the left hand stop adjusts the open position. Adjust the stroke by loosening the stop nut, turning the
stop using an Allen key until the correct stop position is reached, then retighten the nut. NOTE: Over
tightening will damage the seal! Turning the stop clockwise will reduce the stroke, turning anticlockwise
will increase the stroke.
If a spring return actuator is to be used in a corrosive atmosphere or an atmosphere which may ignite in NOTE: Indicator is set up to show pistons together on actuator, i.e. valve closed when in-line
compression, it is highly recommended to fit some form of device to prevent ingress of the atmosphere mounting - See Fig. 1.
in to the spring chamber of the actuator. In the case of direct mounting, self-breathing Namur solenoid
i) Check which visual indication is required.
control valves are highly recommended.
ii) Check that indicator when located on pinion will show correct indication.
In the case of direct air connection in a hazardous environment, the exhaust should be vented to a safe area.
iii) To change indication, push out red and white buttons and reassemble in alternative
For further information please contact Flowserve Flow Control.
iv) Locate indicator on pinion flats. Press firmly until location nibs fit into recess on pinion.

5.4 MOUNTING POSITIONER, SWITCHBOX ETC. TO ACTUATOR

The Namur (VDI/VDE 3845) hole pattern on the top of the actuator can be used to mount a positioner or INDICATOR FITTING INSTRUCTIONS - SIZES 25, 30, 33, 35, 40, 42, 45, 50
switchbox to the actuator using the applicable bracketry. Loosely attach the positioner or switchbox, with
bracketry, to the actuator with all the retaining bolts finger tight. Operate the actuator to allow the White Plugs
positioner or switchbox and actuator to align correctly. Tighten all retaining bolts fully. Due to space
restrictions the 05 actuator uses the ISO F03 hole pattern with M5 tappings for top mounting, and an M4
Published and Printed by tapping in the top of the pinion.
Flowserve Flow Control
Flowserve Flow Control i) Check which visual indication is
A Division of Flowserve GB Ltd.
required.
Information given in this leaflet is Burrell Road,
made in good faith and based Haywards Heath, ii) Locate indicator on pinion flats.
upon specific testing but does not, West Sussex Press firmly until location nibs fit
however constitute a guarantee. into recess on pinion.
RH16 1TL
England
© Copyright Flowserve Flow Control
Telephone: +44 (0)1444 314400
NBEIM0002-02 Telefax: +44(0)1444 314401
6 OPERATION 6 OPERATION (Cont.) 7 MAINTENANCE 8 REFURBISHMENT INSTRUCTIONS
6.1 GENERAL OPERATIONAL SEQUENCE 05 7.1 GENERAL Repair kits are available for all Norbro actuators. The kits contain replacements for all parts subject to
wear.
Viewed from the top, actuators rotate in anti-clockwise direction when the supply port centre chamber is Spring Return Norbro actuators are designed to have long, trouble free lives and maintenance is seldom needed.
pressurised. Pistons Together Pistons Apart If other parts are required, it is usually recommended that the complete actuator be replaced (although
The following checks will help extend life further and reduce plant problems: piece parts are available).
All sizes have an overall rotational range of 90° with average 1° overtravel anti-clockwise and average 1°
overtravel clockwise. Routine checks / maintenance: Only Norbro authorised spare parts should be used. This includes basic components such as fastenings.
i) Every 25000 cycles or 3 months: Check for any signs of leakage (see 7.2) and that all retaining If the actuator is altered in any way without the consent of Flowserve Flow Control, then Flowserve Flow
fasteners are secure.The maximum permissible leakage rate for a new actuator is a one inch Control will accept no responsibility.
OPERATIONAL SEQUENCE 10 - 50 diameter soap bubble in five seconds (1.7ml per second) when pressurised at 5.5 bar (80 psi). Prior to commencing any work on the actuator or removing it from line:
However leakage in excess of this may not affect performance.
Double Acting VENT VENT VENT SUPPLY
a) Refer to the 'Health & Safety' Instructions.
ii) Infrequent operation: The actuator should not be left standing without operation for more than 1
Pistons Together Pistons Apart month. After this period the actuator should be operated through three full cycles. b) For full refurbishment and lubrication instructions please refer to the instructions contained in the
repair kits available from Flowserve Flow Control.
Where actuators are used in hazardous areas (ATEX Directive) we recommend that the springs in
SUPPLY VENT Double Acting spring return actuators be replaced after one million operations. c) Never remove or maintain an actuator unless the supply air has been disconnected and the actuator
Pistons Together Pistons Apart
cycled to release residual air contained in the actuator. This will stop the actuator from unexpectedly
NOTE: Do not rub actuator with a dry cloth as this can cause a build up of static charge. Only clean with a
perating.
damp cloth
VENT SUPPLY d) Note the orientation of the valve, mounting kit, actuator and positioner / switchbox in order to guar
7.2 LEAK TESTING antee correct operation on reassembly.

Spring Return i) With only one air-line attached to the inlet port, check the leak rate at the opposite port when air is
Pistons Together Pistons Apart applied.
ii) Check for leakage on the top and bottom of the pinion by brushing a soap solution on the joint
SUPPLY VENT VENT SUPPLY
VENT VENT areas with air applied to the centre chamber (air-line connected to right hand port of actuator).

6.2 AIR SUPPLY NOTE: The following tests are only required for double acting actuators.

All standard actuators operate satisfactorily with an air line pressure of up to 8.3bar (120 psi). iii) Reverse the air connections and check for leakage in the opposite direction.
VENT SUPPLY
The actuator will however, have been sized with regard to the torque required to open or close the valve at iv) Check there is no leakage between the end cap and the body by brushing a soap solution on the
a particular pressure. Care must be taken to ensure that actual operating pressure is that which is joint areas with air applied to the outside chambers (air-line connected to the left hand port of actuator).
specified. Supply air must be to the ANSI/ISA S7.0.01-1996 instrument air quality standard.
All actuators are supplied with sufficient lubrication for a normal working life. For extreme life cycle
applications, the use of lubricated air supply is recommended.
NOTE: For ATEX compliance, when used in explosive atmospheres Non Corrosive and/or Non Explosive
gases or liquids MUST be used as an operating medium.

9 REVERSE ACTING MODIFICATION 9 REVERSE ACTING MODIFICATION (Cont.)

Reverse acting is only necessary when anti-clockwise Actuator Angle Reverse Acting 05
"failure stroke" is essential. Size #
When actuator is assembled for "reverse acting" NOTE: 05 0°
10 10° 40º
i) The pinion slot will lie "in line" with the actuator 15 2°
centre line. 20 2°
25 2°
ii) The final rest position may be offset according 30 2°
to the table (right). 33 2°
35 2°
iii) Alternative reverse acting pinions are available to correct 40 13° Pinion engagement position
any offset. for insertion of pistons
42 0°
45 0°
50 12°

Reverse Acting 10-42

Position of pinion
flats and groove Blank support rod
(60º approx.) (without cross hole)
Pistons together
(fully Anti-Clockwise)

Inlet support rod

(with cross hole) Label
Foolproof pin
location holes

Bores containing
bearings only

Inlet
# Switch
End Cap End Cap

Inlet port
Foolproof pin Bores containing Foolproof pin
bearings and
0-rings
Label

Worcester Reduced Bore 53/54 Series
WCEIM0010-01
Published and Printed by
Flowserve Flow Control
Information given in this leaflet is
made in good faith and based
upon specific testing but does not,
however constitute a guarantee.
© Copyright Flowserve Flow Control
WCEIM0010-01 Replaces PB 53/54 IOM Iss. 5/04
1 STORAGE AND PRESERVATION
User Instructions All valves are despatched in the open position and it is recommended that they are left in this position during
storage. All protective packaging should remain in position until the valve is to be installed. Valves should be stored
in a clean, dry environment. Carbon steel valves are manganese phosphated and coated with a de-watering oil. This
Installation coating is non-toxic and is quite safe on edible or potable products.
Operation
Maintenance 2 VALVE MARKINGS
Each valve has the following identification information plate attached to the side of the body:
2.1 Pressure Equipment Directive: If the identity plate carries the Pressure Equipment Directive number '97/23/EC' and
the Notified Body identity number '0086' beside the 'CE' mark, the product complies with the Pressure Equipment
Directive 97/23/EC and the Pressure Equipment Regulations 1999 (SI 1999/2001). Without these numbers, the
product is classified as 'SEP' (Sound Engineering Practice) and may only be used within the limitations defined in
tables 6, 7, 8 & 9 of Schedule 3 of the Pressure Equipment Regulations.
2.2 ATEX Directive: If the identity plate carries the ATEX Directive number '94/9/EC' followed by the Explosion
Protection Symbol and codes identifying the equipment group and category, the zone suitability and protection type
beside the CE mark, the product complies with the ATEX Directive and The Equipment and Protective Systems for
Use in Potentially Explosive Atmospheres Regulations 1996.
Definition of identity plate marking above:
'II' = Equipment Group; '2' = Equipment Category; 'G' = Gas Zone suitability (Zones 1 & 2);
'D' = Dust Zone suitability (Zones 21 & 22); 'c' = type of protection i.e. constructional safety
(BS EN 13463-5).
'X' = Special temperature reference (Surface Temperature: As per BS EN 13463-1:2001 paragraph 14.2g, the tem
perature class or maximum surface temperature cannot be marked on the product as it is dependant on the
operating conditions. However, the maximum/minimum allowable operating temperatures for the product are
marked on the identification plate.
2.3 Should the valve soft trim materials be changed during the course of its operational life it is necessary for this
change to be reflected on the identification plate i.e. material change may impact pressure and temperature
limitations.Refer to Flowserve Flow Control Technical Sales for details.
2.4 Material traceability markings are hard marked on the valve body and connector.
5 INSTALLATION INSTRUCTIONS
a) Standard valves may be installed in either direction. Valves with a upstream relief hole (Q190) are
unidirectional and must be fitted with the flow arrow pointing downstream.
b) Installation of flanged valves should follow prevailing site standards. Where such standards do not exist the
following should be used as a guideline.
i) Flanged joints require compressive loading onto the gasket material as the normal line pressure forces
tend to separate the joint. There should be no misalignment between the valve and mating faces.
ii) Pipework should have the correct gap to allow for the valve face to face length plus assembled gasket
material thickness.
iii) Ensure the pipeline and flange faces are clean and free of any debris which may be detrimental to flange
sealing.
iv) Bolting should be of the correct size, length and material for the duty.
v) Locate the valve between the pipe ends and slide in the gaskets. It may be necessary to lever the mating
flanges gently apart to allow for easy fitting of the gasket. Care should be taken to prevent damage to the
sealing surfaces. Correct lifting equipment must be used when handling valves for operator safety.
vi) Assemble all bolts and loosely tighten. Diametrically and evenly tighten the bolts to the correct torque
required for the specific gasket material.
c) It is recommended that the valves are left in the open position during fitting.
Flowserve Flow Control
A Division of Flowserve GB Ltd.
Burrell Road,
Haywards Heath,
West Sussex
RH16 1TL
England
Telephone: +44 (0)1444 314400
Telefax: +44(0)1444 314401
3 HEALTH AND SAFETY
When installing or maintaining valves:
a) Conduct a risk assessment and eliminate or reduce hazards to an acceptable level.
b) Work in accordance with Safe Systems of Work.
c) Observe all site Health and Safety Rules in particular Permit to Work and Hot Work procedures.
d) Wear all necessary Personal Protective Equipment.
e) Never remove or maintain a valve or joint unless the line has been fully de-pressurised, drained and where
necessary, purged of toxic / explosive / flammable media. Always operate the valve to the open position to
ensure that no trapped pressure exists within the cavity.
f) Never handle valves that have been used on harmful substances unless they have been completely
decontaminated and certified safe to handle.
g) Never use a valve on a duty which exceeds its prescribed operating parameters. Refer to Flowserve Flow
Control Technical Sales for performance curves or further information.
h) Never modify or alter valves unless the manufacturer has been consulted or recommends such changes.
i) The valves wrenches are only designed for use in operating the valves and must not be used to carry
them by. Failure to observe this warning may result in operator injury.
j) Due to the large physical size and weight of some sizes of this product, always use correct lifting methods
and equipment when installing, removing and maintaining the product, and that it is correctly supported in its
final operating location.
k) Due to the variety of duties on which this product can be employed, it is the end users responsibility to
ensure the compatibility of the media with the materials of construction of the product for each specific
application (i.e.corrosion and erosion which may affect the integrity of the pressure-containing envelope).
l) Before equipment is installed in areas which may be subject to seismic activity or extreme climatic conditions
consult Flowserve Flow Control Technical Sales.
m) End Flanges: The end flange design of this product has been verified by either 2001(2003 addenda) ASME
Boiler and Pressure Vessel Code Section VIII Division 1 calculation method, by Finite Element Analysis in
accordance 2001(2003 addenda) ASME Boiler and Pressure Vessel Code Section VIII Division 2 - Alternative
Rules, or by experimental testing as defined in BS EN 12516-3 Valves Design Strength - Part 3 Experimental
Method.
Gaskets: The gaskets used in all methods are Spiral Wound to BS4865 for PN rated flanges, and ASME B16.20 for
Class rated flanges. These have Gasket Factors and Design Stresses of 2.5 and 10000psi respectively for Carbon
Steel gaskets, and 3.0 and 10000psi for Stainless Steel gaskets as defined in the 2001(2003 addenda) ASME
Boiler and Pressure Vessel Code Section VIII Division 1.
If gaskets are used with higher Gasket Factors and Design Stresses than those stated above, please consult
Flowserve Flow Control Technical Sales.
6 OPERATION
6.1 USE
Worcester ball valves provide bubble tight shut off when used in accordance with the published pressure/
temperature chart.
It is not good practice to leave a standard ball valve in the partially (throttled) position as this may cause damage
and seat life may be reduced. Flow control ball valves which contain seats designed for this purpose are available
from Flowserve Flow Control.
Any media which may solidify, crystallise or polymerise should not be allowed to stand in the ball cavity since this
is detrimental to valve performance and life.
6.2 MANUAL OPERATION
The basic type of wrench which is fitted to 15-50mm (½”-2”) valves is of sheet steel with integral stop. The larger
sizes of valves have a cast wrench head and tubular handle secured to the stem by a wrench bolt.
Worcester valves have ¼ turn operation, closing in a clockwise direction. It is possible to see when the valve is
open or closed by the position of the wrench: When the wrench is in line with the pipeline, the valve is open; when
the wrench is across the pipeline, the valve is closed. Similarly, if the wrench is removed the flats of the stem will
also indicate valve position.
When operating the valve the use of excessive side loading on the wrench should be avoided.
6.3 REMOTE OPERATION
Where automation of valves is required, Flowserve Flow Control (UK) Ltd. can supply pneumatic and electric
actuators to cover a wide range of operating torques.
Operation will be in accordance with installation, operation and maintenance instructions for the relevant actuator.
3 HEALTH AND SAFETY (cont.)
Bolting: End flanges have been verified by the methods stated above, using bolt design stress values
based on those for ASTM A193 B8 Cl.2 (i.e. 25000/20000psi - dependant on the bolt size) for
Stainless Steel valves, and ASTM A320 L7 (25000psi) for Carbon Steel valves as defined in 2001(2003
addenda) ASME Boiler and Pressure Vessel Code Section II - Materials - Part D - Properties.
n) Lethal Service. In accordance with the design verification code (2001 (2003 addenda) ASME Boiler
and Pressure Vessel Code Section VIII Division 1) a casting quality factor of 1.0 is allowable for
all products. Those intended for 'lethal service' must have had non-destructive examination carried out
in accordance with Appendix 7 of the code. Refer to Flowserve Flow Control Technical Sales.
o) If the processes or environments that the products are used in are likely to cause temperatures
(high or low) that may cause injury to personnel if touched, then adequate insulation/protection must
be fitted.
p) If the equipment is to be used on unstable gas duty, ensure that the operational parameters as
indicated on the product identification plate cannot be exceeded.
q) This equipment should be protected by other devices to prevent over-pressurisation.
(i.e. caused by external fire etc).
r) This equipment must be installed in a system that is designed to prevent excessive forces acting on
the flanges, connections, etc.
4 PREPARATION FOR INSTALLATION
When dispatched, valves contain a mineral oil which aids the bedding in of the valve. This may
be removed if found unsuitable. Special variants may contain other lubricants or be dry built.
Some valves contain a Silica gel bag inside the ball cavity to absorb humidity during storage.
These must be removed before installation, as must all other protective packaging.
For valves up to and including 65mm it is important to ensure that the gland nut locking clip is
retained at all times. If, during installation, it is noted that the locking clip is not in place, the gland nut
must be adjusted to the correct torque and a new locking clip fitted.
Significant problems can arise with any valve installed in an unclean pipleline.
Ensure that the pipeline has been flushed free of dirt, weld spatter, etc. before installation.
The working area should be clean and clear of any debris which could contaminate the valve.
7 MAINTENANCE
7.1 GENERAL
With self wipe ball / seats and patented pressure equalising slots, Worcester valves have long, trouble free lives
and maintenance is seldom needed. The following checks will help extend life further and reduce plant problems:
Routine checks / maintenance:
i) Every 25000 cycles or 3 months: Check for any signs of leakage (see 7.2, 7.3 & 7.4 below) and that all fasten
ers (including the gland nut) and joints are tightened to their correct torque value (see Section 10).
ii) Infrequent operation: The valve should not be left standing without operation for more than 1 month. After
this period the valve should be operated through three full cycles.
7.2 IN-LINE LEAKAGE
Check that the valve is fully closed. If it is, then any leakage will be due to damage to the body, connector, insert,
seat or ball sealing surfaces and it will be necessary to dismantle the valve to repair it (see Section 9 & 10).
7.3 STEM LEAKAGE
Remove the wrench assembly as detailed in section 9 or the actuator as detailed in the relevant actuator I.O.M.,
followed by the gland nut locking clip (valves up to and including 65mm), and retighten to the recommended
torque. If the leakage persists then it will be necessary to dismantle the valve to establish the cause and/or replace
gland packings and thrust seals (see Section 9 & 10).
7.4 BODY/INSERT/CONNECTOR JOINT LEAKAGE
BODY/CONNECTOR:
Check the interface bolting is tightened to the recommended torque values and tighten if necessary. If leakage still
occurs it will be necessary to remove the valve from line and split the valve at the interface joint to replace the body
seal and to establish whether the seal faces of the body and connector have been damaged (see Section 9 & 10).
BODY/INSERT:
If leakage occurs here, it will be necessary to remove the valve from line. Remove the insert and establish whether
the body and insert seal faces have been damaged. Replace the body seal, refit and tighten the insert to to the
recommended torque value (see Section 9 & 10).
8 REPAIR KITS
Repair kits are available for all Worcester valves. Details of their contents are found in the Instruction sheet
supplied with the kit.
If other parts are required, it is usually recommended that the complete valve is replaced, although piece parts are
available. Parts from different sized / rated valves must not be interchanged.
Only Worcester authorised spare parts should be used. This includes basic components such as fastenings.
Flowserve Flow Control will accept no responsibility if the valve is altered in any way without the consent
of Flowserve Flow Control.
9 REFURBISHMENT INSTRUCTIONS 9 REFURBISHMENT INSTRUCTIONS (cont.) 9 REFURBISHMENT INSTRUCTIONS (cont.) 9 REFURBISHMENT INSTRUCTIONS (cont.)
Prior to commencing any work on the valve or removing it from line, refer to the 'Health & Safety' Instructions. 9.1.2 REBUILDING 9.2 SIZE 65mm - 250mm (2½" - 10") 9.2.2 REBUILDING
NEVER remove or maintain a valve or joint unless the line has been fully de-pressurised, drained and where
necessary, purged of toxic / explosive / flammable media. a) Before rebuilding, ensure the repair kit and/or components used are suitable for the valve requirement. When 9.2.1 DISMANTLING a) Before rebuilding, ensure the repair kit and/or components used are suitable for the valve requirement.
rebuilding, cleanliness is essential for long valve life. The seats may be lightly lubricated with a light oil to aid bed When rebuilding, cleanliness is essential for long life. The seats may be lightly lubricated with a light oil
9.1 SIZE 15mm - 50mm (½" - 2") ONE PIECE VALVES ding in. Ensure that the lubricant is compatible with the pipeline media. a) Ensuring that it is correctly supported, remove the valve from the pipeline by extracting the flange bolting from to aid bedding in. Ensure that the lubricant is compatible with the pipeline media.
each end. Large pipelines have a tendency to spring the flanges together making removal difficult. If necessary,
9.1.1 DISMANTLING b) Fit a new thrust seal on to the stem shoulder and insert the stem through the valve body from inside the valve cavi remove or loosen elbows, couplings or pipe supports to get extra b) Fit a new thrust seal onto the stem shoulder and insert the stem through the valve body from inside
ty. (On 15mm (½") valves, tweezers will make the job easier). manoeuvrability. the valve cavity.
a) Ensuring that it is correctly supported, remove the valve from the pipeline by extracting the flange bolting from
each end. c) Fit the new gland packings into the body recess and the gland and new disc springs (with their outer edges touch b) With the valve securely clamped and in the open position, undo the fastenings retaining the two body parts. c) Place the location ring into the bottom of the gland housing, followed by the gland packing, gland and
ing) on to the stem. stop plate followed by the gland nut. With self locking gland nuts, Rocol 'Copperslip' or a similar
b) With the valve securely clamped and in the open position, undo the insert using the appropriate drive adaptor. It c) Tap one of the flanges sharply with a mallet to break the joint and separate. anti-scuffing agent should be applied to the stem thread.
will be necessary to use a heavy mallet on the tommy bar of the insert tool to break the metal to metal seal. d) Fit the gland nut and preventing the stem from turning, tighten it down to the recommended torque (see Section 10).
d) With the valve in the closed position remove the ball. If there is a large build up of solid scale or media in the cavity d) Tighten the gland nut until the specified stem assembly torque or gland nut tightening torque has been
c) Remove the insert to allow access to the cavity. e) Operate the stem several times and re-adjust the gland nut to the specified figure. The locking clip must then be fit it may be necessary to tap it out using a soft drift. achieved (see Section 10). Over tightening of the gland nut will only reduce the life of the stem
ted correctly, either across the corners or on the flats of the nut. The gland nut can be tightened to the next posi assembly and can seriously increase torque. For 65mm valves a locking clip should be fitted following
d) Remove the body seal and discard. Close the valve and using a soft drift through the body port, tap out the ball and tion to correctly locate the clip (see below). Over-tightening the gland nut will only reduce the life of the stem assembly. e) Using a suitable hook to get under the seat face, remove the seats from the body and the body connector. Care the procedure 9.1.2 Section (e).
insert seat. must be taken to avoid damaging the seal faces.
e) Ensure the valve is in the closed position.
e) Turn the stem back to the open position and, using a suitable hook, pull out the body seat being careful not to f) Remove the body seals from the interface housing.
damage the seat sealing face of the valve body. f) Secure the valve in the vertical position, and place the seat in the body housing.
g) To dismantle the stem assembly remove:
f) To dismantle the stem assembly remove: T-Bar Wrench g) Locate the body seals into the interface housing.
Wrench Nut Locking Clip (65mm only)
Wrench Nut Spring/Star Washer If fitted Gland Nut h) Slide the ball into the body, locating the stem drive tang, and operate to the valve open position.

}
Wrench Correct Correct Stop Plate
Gland Nut Locking Clip Gland i) Locate the connector seat in its housing.
Gland Nut
Disc Springs h) Tap the stem down into the valve cavity and withdraw. The valve gland packing, location washer and thrust seal can j) Fit the body connector to the body, being careful not to damage the body seals.
Gland now be removed. Ensure the connector flange is correctly orientated to the body flange. Lower the connector down
squarely and tap it fully home with a soft mallet.
g) Withdraw the stem from inside the body (N.B. with 15mm (½") valves the gland packing must be removed and the i) All components not replaced by items in the repair kit should be thoroughly cleaned and stored in a clean secure
wrench flats of the stem must be aligned across the valve to allow withdrawal of the stem). The gland packing and Incorrect Incorrect area. All sealing faces on the body, insert and ball must be checked for corrosion, erosion and scratches. If damage k) Replace interface fastenings and tighten evenly to the torque recommended in Section 10.
thrust seal can now be removed from their recesses, being careful not to damage the seal faces. is found or there is any doubt, replace the component. Rocol 'Copperslip' or an alternative should be applied to the threads.

h) All components not replaced by items in the repair kit should be thoroughly cleaned and stored in a clean secure j) Cleaning the valve parts should be carried out using a suitable degreasing agent. Hard deposits can be removed l) If practical, leak tightness and operating torque should be checked prior to refitting in line.
area. All sealing faces on the body, insert and ball must be checked for corrosion, erosion and scratches. If damage f) Fit the wrench, spring washer and wrench nut to the stem (if required) and operate the stem to the valve open using stainless steel wire wool. Care should be taken on all seal faces to avoid damaging them.
is found or there is any doubt, replace the component. position.

i) Cleaning the valve parts should be carried out using a suitable degreasing agent. Hard deposits can be removed g) Fit the body seat into the valve cavity past the stem drive tang,and position it into the seat housing.
using stainless steel wire wool. Care should be taken on all seal faces to avoid damaging them.
h) Turn the stem to the valve closed position and slide the ball into the body, locating on the stem drive tang.

i) Locate the insert end seat into the cavity and the body seal into its housing.

j) Open the valve, and tighten the insert into the valve body to the torque specified in Section 10 using the correct
drive adaptor. It is important that on stainless steel valves an anti-scuffing compound such as Rocol 'Copperslip' is
used on the insert threads. It is advisable, though not mandatory to use it on carbon steel valves as well.

k) If practical, leak tightness and operating torque should be checked prior to refitting the valve in line.

15 - 50mm (½" - 2) VALVES 65 - 250mm (2½" - 10") VALVES 10 VALVE ASSEMBLY TORQUES
DEFINITIONS

Insert Torque - The torque required to fully tighten the insert of one piece valves.

Stem Assembly Torques - The torque required to operate the assembled stem before the ball and seats
are fitted to the valve.
Wrench Sleeve
Gland Nut Torques - The tightening torques to be applied to the gland nuts to achieve the above figures.
Wrench Tube
Wrench Fixing Bolt Note: these figures can only be used with valves fitted with locking clips and must not be used for
tightening self-locking gland nuts.
Wrench Wrench Nut
Wrench Head
Spring Washer INTERFACE FAS- GLAND NUT TORQUES STEM
INSERT (Nm)
TENING ASSEMBLY
Gland Nut NOMINAL SIZE TORQUES
TORQUES GRAPHITE PTFE TORQUES
(Nm)
Gland Nut Locking Clip Indicator Stop (Nm) BUILD BUILD (Nm)
Stop Pin
Gland Nut Gland 15mm (½") 65 - 75 5-7 6-9 3-5

Disc Springs 20mm (¾") 65 - 75 5-7 6-9 3-5

Gland Packings
25mm (1") 70 - 80 6 - 10 8 - 12 4-6
Gland Stem Location Ring
32mm (1¼") 70 - 80 6 - 10 8 - 12 4-6
Gland Packing Stop Pin
40mm (1½") 80 - 90 8 - 12 13 - 18 6-8
Seat 50mm (2") 90 - 100 8 - 12 13 - 18 6-8
Ball Body
Seat 65mm (2½") 85 - 95 21 - 26 19 - 24 8 - 11
Seat Body Seal Primary 80mm (3") 55 - 65 18 - 22
Ball Body Seal Secondary
Seat 100mm (4") 55 - 65 18 - 22
Body Seal Body 150mm (6") 85 - 95 23 - 28
Stem Thrust Seal
Insert 200mm (8") 210 - 220 23 - 28

Stem Thrust Seal Stem 250mm (10") 300 - 310 35 - 40

Stem
Plunger Springs
Body Connector
Anti-static Plungers
Anti-static Spring
Body
Anti-static Plunger Connector Screws