Ge Globe Control Valves Mn 28000 Series Technical Specifications
Ge-Globe-Control-Valves-Mn-28000-Series-Technical-Specifications-656504 ge-globe-control-valves-mn-28000-series-technical-specifications-656504
2015-03-11
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GE Oil & Gas 28000 Series Masoneilan* VariPak* Adjustable-Cv Control Valves Instruction Manual THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECTSPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED. THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE. THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE. THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS. THESE INSTRUCTIONS CONTAIN PROPRIETARY INFORMATION OF GE, AND ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART NOR SHALL ITS CONTENTS BE DISCLOSED TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE. 2 | GE Oil & Gas Contents 1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 After Sales Department . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.3 Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Precise Adjustment of the Varipak 28002 Adjustable-Cv Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 Flow Coefficient of Varipak 28001 Single-Lever and 28002 Adjustable-Cv Valves. . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.4 Handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.5 Reversing the Valve Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 Preliminary Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2 Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3 Pneumatic and Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.4 Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4. Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 4.1 Piston Rod Clevis Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.2 Plug Stem Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.3 Limit Stop Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.4 Varipak 28002 Cv Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4.5 Positioner Start-Up Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.1 Actuator Diaphragm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5.2 Adding Packing Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 5.3 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.4 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5.5 Packing Quick Change Method (Only For Valves With Max. Cv Of 0.6 To 3.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.6 7700P or 7700E Positioner Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.7 Maintenance Operations Specific to the 7700E Positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.8 Converting a 7700P Positioner (Pneumatic) into a 7700E Positioner (Electro-Pneumatic). . . . . . . . . . . . . . . . . . 20 Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 3 1. General These installation, operation, and maintenance instructions apply to Masoneilan VariPak* 28000 series control valves. They also include a parts reference list with recommended spare parts (see page 21). IMPORTANT REMARKS Before installing, operating, or performing maintenance on this equipment, you should read these instructions carefully and make sure you have understood them. Work on this equipment should only be carried out by qualified personnel. Failure to follow the instructions and precautions given in this document could lead to a malfunction and seriously damage the equipment. 1.1 SPARE PARTS 1.3 TRAINING For maintenance purposes, always use original Masoneilan spare parts obtained through your local GE representative or Spare Parts Department. When ordering, always give the references of the original order for the equipment concerned and, in particular, the number indicated on the serial plate. (135). GE organizes regular training courses in the operation, maintenance, and application of its Masoneilan control valves and instruments for customer service and instrumentation personnel at its Condé-surNoireau plant. For further details, contact your local GE representative or the Training Department at the Condé-sur-Noireau plant, in France. 1.2 AFTER SALES DEPARTMENT GE has a highly skilled After Sales Department to assist customers with start-up, maintenance, and repair of valves and instruments. Contact your nearest GE Sales Office or Representative, or the After Sales Department at the Condé-sur-Noireau plant, in France. Based on general field failure data and product design analysis, a useful life period of 25 years or longer can be expected for the Masoneilan 28000 Series Varipak valves. To maximize the useful life of the product it is essential to conduct annual inspections, routine maintenance and ensure proper installation to avoid any unintended stresses on the product. The specific operating conditions will also impact the useful life of the product. Consult the factory for guidance on specific applications if required prior to installation. 4 | GE Oil & Gas 2. Operation The Masoneilan VariPak microflow control valve features a very wide range of rated flow coefficients (Cv), from 0.004 to 3.8. 2.2 FLOW COEFFICIENT OF VARIPAK 28001 SINGLE-LEVER AND 28002 ADJUSTABLE-Cv VALVES Two types of actuators are available: - The VariPak 28001 with a single lever, designed for just one rated Cv. This version is used when enough is known about the operating conditions when sizing the valve. Eight plugs and five seat rings are used to make up the ten available plug and seat ring combinations, identified by codes from 0 to 9 (see figure 2). The shape of each plug and the port diameter of the seat ring can be used to match parts with the table in figure 2. - The VariPak 28002 with an adjustable rated Cv. This valve uses a patented lever system to adjust the rated Cv on site to suit the actual operating conditions, thereby avoiding any oversizing in flow capacity. Each plug and seat ring combination can be adjusted without changing the control signal. 2.2.1 Plug/seat ring combinations (trim) The difference between the four plugs in trim Nos. 6 to 9 lies in the angle of the flat machined on the tip. The same seat ring (3e) and the same spacer (3f) are used in all four cases (see figure 2). Use the table in figure 1 to select the plug and seat ring combination to obtain the Cv value or range of Cv values you require. 2.1 PRECISE ADJUSTMENT OF THE VARIPAK 28002 ADJUSTABLE-Cv VALVE The valve is adjusted using a simple, but robust, crossed-lever system with an adjustable fulcrum. This can be done easily by hand, either before installation or during operation. For example, an application requiring a theoretical Cv of 0.006 could be handled using a VariPak 28002 with a maximum Cv of 0.010, that can subsequently be calibrated on site between 0.004 and 0.010. FLOW COEFFICIENT Cv Trim No. VARIPAK 28002 VARIPAK 28001 MIN. 0.0040 0.0016 0.0020 0.0024 0.0028 0.0032 0.0036 8 0.010 0.004 0.005 0.006 0.007 0.008 0.009 0.010 7 0.025 0.010 0.013 0.016 0.019 0.021 0.023 0.025 6 0.050 0.020 0.025 0.030 0.035 0.040 0.045 0.050 5 0.10 0.04 0.05 0.06 0.07 0.08 0.09 0.10 4 0.25 0.10 0.13 0.16 0.19 0.21 3 0.6 0.25 0.30 0.35 0.4 0.45 0.5 0.55 0.6 2 1.2 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1 2.3 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3 0 3.8 1.5 1.9 2.3 2.6 2.9 3.2 3.5 3.8 9 RISK FREE MAX. 0.0040 0.23 0.25 Figure 1 Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 5 Plug and seat ring No. 9 Plug and seat ring No. 8 Plug and seat ring No. 7 Plug and seat ring No. 6 Plug and seat ring No. 5 Plug and seat ring No. 4 Plug and seat ring No. 3 Plug and seat ring No. 2 Plug and seat ring No. 1 Plug and seat ring No. 0 VariPak 28001 Cv 0.004 Cv 0.010 Cv 0.010 Cv 0.050 Cv 0.10 Cv 0.25 Cv 0.60 Cv 0.2 Cv 2.3 Cv 3.8 VariPak 28002 Cv 0.004 to 0.0016 Cv 0.010 to 0.004 Cv 0.010 to 0.004 Cv 0.050 to 0.010 Cv 0.10 to 0.04 Cv 0.25 to 0.10 Cv 0.60 to 0.25 Cv 1.2 to 0.9 Cv 2.3 to 0.9 Cv 3.8 to 1.5 3f 3d 3c Orifice Dia. 2 mm 3e Orifice Dia. 1.6 mm 2.2.2 Changing the plug and seat ring combination 3a 3b Orifice Dia. 4.5 mm Orifice Dia. Orifice Dia. 14.3 mm 9.5 mm - T he Cv adjustment plate (25) in the case of the VariPak 28002 adjustable-Cv valve. The plug and seat ring combination can be changed very easily for trim Nos. 1 to 9 inclusive. Simply replace the following parts: - If necessary, the actuator spring (134) (see figure 3 to check the spring range corresponding to the new Cv. - The plug and seat ring (see figures 1 and 2 to select the combination required for the new Cv). Max. Pressure Supply Plug/Seat No. Spring Range (134) Flow Coefficient Cv m.bar 0 3.8 to 1.5 1 2.3 to 0.9 2 1.2 to 0.5 3 0.6 to 0.25 4 0.25 to 1.10 5 0.10 to 0.04 6 0.050 to 0.020 7 0.025 to 0.010 8 0.010 to 0.004 9 0.004 to 0.0016 Adjustable Cv CI. IV CI. V CI. IV CI. V bar (Psi) bar (Psi) bar (Psi) ATO Psi Color Code 6-24 Red 2.1 (30) 2.1 (30) 2.1 (30) 3-15 Green 1.4 (20) 1.4 (20) 1.4 (20) 414 1660 207 1035 Figure 3 - Actuator spring ranges and supply pressures 6 | GE Oil & Gas Single Lever ATC 2.8 (40) 1.7 (25) Follow the procedure described in the "Disassembly/ Reassembly" section of the "Maintenance" chapter on pages 14 to 18. - Loosen adjustment knob (24) and slide it along the lever to the required value. Tighten the adjustment knob again firmly. - Also change the serial plate (135) or correct the information on the existing plate. Note: - This operation entails moving lever No. 2, either pneumatically (by allowing air into the actuator), or manually (by pressing piston clevis (140b) with a screwdriver or similar tool) so that the slides of the two levers are perfectly parallel. Caution: If the valve in question includes a 1/2" or 3/4" NPT threaded end, the maximum capacity of the body is respectively limited to trim Nos. 9 to 3 inclusive or 9 to 2 inclusive. A trim No. 9 cannot be installed in a VariPak valve body designed for a trim No. 0. Likewise, a trim No. 0 cannot be installed in valve bodies designed for other trim numbers. - It may be necessary to reset the zero to calibrate the closure point after changing the Cv. 2.3 ACTUATOR A single actuator allows VariPak valves to act in direct Air-to-Close (ATC), or reverse Air-to-Open (ATO). Valve action can be changed with no additional part by simply shifting: 2.2.3 Adjusting the Cv of a Varipak 28002 valve for each plug and seat ring combination - the pivot pin and the attachment hole of the positioner balance spring clamp for the singlelever VariPak 28001 valve, This is done by moving adjustment knob (24) along adjustment plate (25) fastened to the top of lever No. 1 (21). - the two pivot pins for the adjustable-Cv VariPak 28002 valve, then calibrating as required. The adjustment plate (25) gives the range of Cv values offered by the selected plug and seat ring combination. Carry out this adjustment operation as follows: Follow the instructions given under "Reversing the valve action" on page 8. 2.4 HANDWHEEL(Figure 5) The handwheel is an optional feature located on top of the cover and fitted with a locking lever. Access can be gained to it directly without removing any other parts. It consists of a threaded rod, equipped with a handwheel (120) and a lever arm stop (122). The threaded rod rests freely on the actuator bracket (108) and is guided through the cover (110) by handwheel bushing (119). The stop consists of a block screwed onto the threaded rod. The block is guided by the actuator bracket (108). Figure 4 - Adjusting the Cv of VariPak 28002 valve for each plug/seat ring combination Figure 5 Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 7 When the handwheel (120) is turned clockwise, the stop (122) moves up the threaded rod, compressing the spring (134) and raising lever No. 2 (22) (VariPak 28002) or (113) (VariPak 28001). This closes the valve if the valve is equipped with a direct-action actuator (Air-to-Close) and opens the valve if it is equipped with a reverseaction actuator (Air-to- Open). The valve can be returned to automatic mode (neutral position), by turning the handwheel counterclockwise until the stop (122) comes into contact with the bracket (108). Note: During this operation, the compression is released when the stop (122) moves away from the lever (22) (VariPak 28002) or (113) (VariPak 28001). Continue the operation until a slight tension reappears, then tighten the handwheel lock (121). VariPak actuators are equipped with a limit stop. This consists of parts (180) and (181), and is designed to prevent damage to the plug and seat ring assembly and/or the plug stem in the event of handwheel or actuator overstroke. Note: The limit stop is not used with air-to-open valves fitted with a handwheel, and must be screwed down at the bottom of the piston. 2.5 REVERSING THE VALVE ACTION (Figures 5, 6, 26, 27 and 29) Caution: The valve must be isolated and pressure vented before disassembly. A. L oosen and remove cover (110). On valves equipped with a handwheel, loosen cover screw (109), back off handwheel lock (121), and turn handwheel (120) counter-clockwise to release cover (110). B. A djust the signal so that the valve closes. Change the signal slightly so that the plug just moves off the seat ring. On the VariPak 28002 adjustable-Cv valve, set the adjustment knob (24) to the minimum Cv setting. C. Loosen locknut (103) and, using a screwdriver, turn the plug stem one and three-quarter turns counter-clockwise. Shut off the signal and the supply pressure. Slightly tighten locknut (103) against the clevis. D. U nlock nut (117) and completely loosen screw (116). Unhook spring (114) from spring clamp (115). 8 | GE Oil & Gas 2.5.1 VariPak 28001 single-lever valve E. Remove retainer clips (112b) from pin (18), and remove the pin from lever (113) and plug clevis (104a). Note: This operation will be simplified by relieving the load exerted on the plug clevis by the conical compression spring (106). To do this push against the plug stem end with a screwdriver while driving out the pins. F. Remove the two retainer clips (112a) from the pin (105) and disengage it to uncouple the lever (113) from the bracket (108). G. Refit the levers (113) making sure that the pin (105) is fitted into the correct holes in the lever and bracket for the new action of the actuator (see figure 6). Fit the spring clamp (115) into the corresponding lever hole. Note: Ensure that the clevis is correctly positioned before fitting the lever on the bracket. H. Couple the plug stem clevis (104a) to the lever (113) following the normal reassembly procedure (step I. in the "Reassembly" section on page 17). Then follow the same procedure as for the VariPak 28002 adjustable-Cv valve as from step L. 2.5.2 VariPak 28002 adjustable-Cv valve (2 levers) E. Remove retainer clips (112b) from each of the two pins (184) and remove pins from lever (113) and plug clevis (104a). Note: This operation will be simplified by relieving the load exerted on the plug clevis by the conical compression spring (106). To do this push against the plug stem end with a screwdriver while driving out the pins. F. Remove the two retainer clips (112a) from pin No. 1 (105) and disengage it to uncouple lever No. 1 from bracket (108). Loosen adjustment knob (24) and slide it to the maximum Cv setting. Disengage the smooth end of the adjustment pin (23) from the groove in lever No. 2 while removing lever No. 1. G. Drive out pin No. 3 (18) and remove lever No. 2 (22) from the bracket. H. Remove the two screws (26) and refit Cv adjustment plate (25) after turning it round to comply with the new action. I. R efit levers No. 1 and 2 in sequence, making sure that pins (105) and (108) are fitted into the correct holes in the levers and bracket for the new action of the actuator (see figure 6). Note: Ensure that the clevis is correctly positioned before fitting the lever No. 1 on the bracket (108). N. Put the valve back into service. J. R eset adjustment knob (24) to the minimum Cv position. - When replacing an Air-to-Close actuator with an Air-toOpen actuator, do not forget to neutralize the limit stop by screwing it down at the bottom of the piston. K. C ouple plug stem clevis (104a) to lever No. 1 following the normal reassembly procedure (step L. in the "Reassembly" section on page 17). L. H ook spring (114) in the appropriate hole in spring clamp (115) (see figure 6). Note: - When replacing an Air-to-Open actuator with an Air-to-Close actuator, set the limit stop to the opening position. M. Admit supply and signal pressures and complete calibration. Refit cover (110) using the two screws (109). If the valve is equipped with a handwheel, refit the cover and turn the handwheel clockwise so that it engages in lever arm stop (122). Tighten cover screws (109). AIR-TO-CLOSE ACTUATOR AIR-TO-OPEN ACTUATOR VariPak 28001 with single lever VariPak 28002 with adjustable Cv (2 levers) *Only with type 7700 positioner Figure 6 - Identification of lever pivot pin holes Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 9 3. Installation 3.1 Preliminary Steps A. B efore installing the valve in the line, remove all traces of foreign material from the piping such as welding chips, scale, oil, grease, etc. B. Note down all the data given on the serial plate. C. For valve inspection without interrupting process operation, a hand-operated stop valve will be required on either side of the VariPak, together with a hand-operated throttling valve mounted on a bypass line. 3.2 Valve Installation (Figures 7, 8 and 9) Connections: The body of the ANSI Class 1500* rated VariPak valve can be: - Bolted between 25 mm (1") pipe flanges machined to standards ISO-PN 10 to PN 250 (ANSI 150 - 300 - 600 900 and 1500 lb). Use ASTM A 193 Gr B 7 (or equivalent) carbon steel bolting for temperatures between -29° and +350 °C. For corrosive or cryogenic service, use ASTM A 193 Gr B8 strain-hardened stainless steel. All the line bolting required for installation can be supplied by GE on request. Figure 8 - VariPak flanged body The VariPak valve body can be supplied on request with 1/2", 3/4", or 1" NPT threaded ends. Apply PTFE tape or a sealing compound compatible with the process to the threaded pipe ends. Figure 9 - VariPak screwed connection (option) Alignment: This valve is small and light, making it easy to install on the piping. Support the valve body when fitting studs. Suitably shaped bosses are provided to center the valve in the line and prevent rotation before the studs are finally tightened. Figure 7 - VariPak flanged connection - Connected by 25 mm flanges machined to standards ISO-PN 20, 50 and 100 (ANSI 150, 300 and 600 lb). Fit gaskets compatible with service conditions between the valve body and the pipe flanges. 10 | GE Oil & Gas The valve must always be installed with "flow tending to open". The flow arrow on the valve body must be pointing in the direction of flow. Fit the bolts and tighten in criss-cross fashion. Insulation: If the valve is to be insulated, ensure that the insulation does not exceed the shaded area shown in figure 10 below. Figure 12 - Connections with 7700E positioner Figure 10 - Insulation limit for a VariPak valve 3.3 Pneumatic and Electrical Circuit (Figures 3, 11 and 12) - On-off valve: connect the air supply line directly to the 1/8" NPT threaded connection in diaphragm cover (137). - Control valve with 7700P positioner (air signal): connect the supply and instrument signal lines to the appropriate connections on the manifold block (144) (figure 11). Use 4 x 6 mm (1/4" O.D.) tubing. - Control valve with 7700E positioner (electrical signal): connect the manifold block (144) air supply line and make the electrical connection for the I/P module (20) (figure 12). Use 4 x 6 mm (1/4" O.D.) tubing for the air line. 3.4 Limit Switches (Figure 13) In some cases, limit switches can be provided for the VariPak valve, on request. These are wired and adjusted in the factory to customer order. The black wire is connected to either the normally open or normally closed terminal of the upper limit switch. The black and white wire is connected to the common terminal of this switch. The red wire is connected to either the normally open or normally closed terminal of the lower limit switch. The red and white wire is connected to the common terminal of this switch. To adjust limit switches, loosen their fasteners and move the valve to the required position. Adjust the position of the switch until it trips. Tighten fasteners (160 - 161 - 162). Note: Check that the supply pressure is that indicated on the serial plate. 7700P or 7700E positioners can be installed on both VariPak 28001 single-lever and VariPak 28002 adjustable-Cv valves. Figure 13 - Limit switch installation Figure 11 - Connections with 7700P positioner Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 11 4. Calibration VariPak valves are factory-calibrated according to the components specified in the customer order. If for any reason this calibration has been disturbed (e.g. after changing from direct to reverse valve action, or replacing the plug and seat ring), all or some of the adjustments below must be carried out in the following order: - Piston rod clevis (104b) adjustment. - Plug stem adjustment. - Limit stop adjustment. - Cv adjustment. - Positioner start-up pressure adjustment. 4.1 PISTON ROD CLEVIS ADJUSTMENT 4.1.1 Adjusting the piston rod clevis on the VariPak 28001 single-lever valve (Figures 14 and 26) This adjustment is only required if the piston (131) has been removed. In this case, it should be carried out during reassembly, before coupling the lever (113) to the clevises (chap. MAINTENANCE - Reassembly. step H., page 17). With the piston resting against diaphragm cover (137), turn clevis (104b) so that the top of actuator bracket (108) is 0.5 mm to 1 mm from the bottom of indicator (126). A shim will simplify this operation. Admit enough air pressure to disengage locknut (125) and tighten it against indicator. Check that indicator (126) is correctly positioned. Release air pressure. VariPak 28002 adjustable-Cv valve (Figures 14 and 27) This adjustment is only required if the piston (131) has been removed. In this case, it should be carried out during reassembly, before coupling the levers (21) and (22) to the clevises (chap. MAINTENANCE - Reassembly. step K., page 17). With the piston resting against diaphragm cover (137), turn clevis (104b) so that the top of the actuator bracket (108) is 0.5 mm to 1 mm from the bottom of indicator (126). A shim will simplify this operation. Couple lever No. 2 (22) in this clevis position. Admit enough air pressure to disengage locknut (125) and tighten it against the indicator. Check that indicator (126) is correctly positioned. Release air pressure. 4.2 PLUG STEM ADJUSTMENT 4.2.1 Adjusting the plug stem on the VariPak 28001 single-lever valve (Figures 15, 16 and 26) This adjustment should be carried out during reassembly, before coupling the lever (113) to the clevises. A. Loosen nut (103) and turn the plug stem using a screwdriver while blocking clevis (104a) until the clevis is in the position shown in figure 15. Lock nut (103). 4.1.2 Adjusting the piston rod clevis on the Figure 15 - Presetting the plug stem position Figure 14 - Piston rod clevis (104b) adjustment 12 | GE Oil & Gas B. F it lever (113) with spring clamp (115) positioning hole facing upwards, fit pin (105) into hole A, then fit pin (18) into clevis (104a). Note: All pins should be greased slightly before fitting. C. Press the lever on the actuator side to check for plug/ seat ring leaks at ΔP 3.5 barg (50 psig). If the valve is equipped with a handwheel, lever (113) should not touch lever arm stop (122). If the valve leaks, release the pressure at the inlet and remove pin (18) of clevis (104a), then loosen nut (103). Loosen the plug stem in order to move the clevis up (104a). A complete turn moves the position up by 1 mm. Then tighten the locknut (103) again. D. C heck that the distance between clevis (104b) pin and the hole in lever (113) is approximately 2 mm. If necessary, adjust the position of clevis (104a) to obtain this distance, see figure 16. This value provides the initial compression of actuator spring (134). At this closing point where the plug is not tightened onto the seating, the slides of levers No. 1 and 2 should be perfectly parallel. This characteristic makes it possible to change the adjustment knob (24) position later to obtain the required real Cv value. B. L oosen adjustment knob (24) and slide it along lever No. 1 to the maximum Cv position on adjustment plate (25). Fully tighten adjustment knob (24). C. Loosen locknut (103) and, using a screwdriver, turn the plug stem until the plug is just touching the seat ring. If the valve has been removed from the pipe, a bubble test can be performed on the calibration bench to obtain a very accurate adjustment. Using the screwdriver to hold the plug stem in position, tighten locknut (103) against clevis (104a). D. A dmit air pressure again to remove the shim, then release the pressure. Note: On an Air-to-Open actuator, shim thickness may be increased or decreased by one or two-tenths of a millimeter to ensure that levers No. 1 and 2 are perfectly parallel and to obtain the required tightness on closing, especially for very low Cv values (Cv < 0.10). Figure 16 - Adjusting the lever (113) E. Admit enough air pressure to the actuator to drive piston clevis (104b) upwards. Couple the clevis to lever (113) using pin (124). F. Release the actuator pressure and repeat the plug/ seat ring leak test at ΔP 3.5 barg (50 psig). Dimension A should be the same as in figure 16 . Release the valve pressure once this step is completed. 4.2.2 Adjusting the plug stem on the VariPak 28002 adjustable-Cv valve (Figures 27, 28 and 29) Once all the coupling operations are completed, proceed as follows: A. A dmit enough pressure to the actuator to drive out the piston rod far enough to place a shim under the indicator (126). Use a 1.5 mm shim for an Air-toOpen actuator, and a 25 mm shim for an Air-to-Close actuator. Release the air pressure after inserting the shim. 4.3 LIMIT STOP ADJUSTMENT (Figure 5) VariPak valves include a limit stop to prevent damage to the plug and seat ring and/or plug stem in the event of actuator or handwheel overstroke. This device consists of a nut (180) acting as a stop, screwed onto the piston rod inside the spring chamber, and a locknut (181). If necessary, this device should be adjusted immediately after plug stem adustment (see section 4.2). A. R emove the shim (for VariPak 28002 adjustable- Cv valve only) and admit sufficient supply pressure to close the valve. Turn locknut (181) on the piston rod until it touches locknut (125). Turn limit stop (180) until it just touches the inside of actuator bracket (108). B. H old the limit stop with a 12 mm wrench and tighten locknut (181). Release the air pressure. Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 13 4.4 VARIPAK 28002 Cv ADJUSTMENT This adjustment is carried out by moving adjustment knob (24) along adjustment plate (25) fastened to the top of lever No. 1 (21). See section “Adjusting the Cv of a Varipak 28002 valve for each plug and seat ring combination”, page 7. 4.5 POSITIONER START-UP PRESSURE ADJUSTMENT (Figures 7, 25, 26 and 27) A. C onnect the air supply and signal lines to the 7700P or 7700E (with electrical signal) positioner. B. S et the supply pressure according to the valve Cv value (see the table in figure 3). C. Set the signal to the minimum value for an Air-toOpen actuator, and to the maximum value for an Airto-Close actuator. Turn take-up screw (116) until the piston rod just begins to move. Tighten locknut (117). 5. Maintenance Figure 17 - Diaphragm replacement 5.2 ADDING PACKING RING (Figures 18, 26 and 27) A. B efore adding packing ring, the valve must be isolated and all pressure released. Remove packing flange nuts (8b), lift the packing flange and follower, and insert a new packing ring. Tighten nuts (8b) finger tight and then tighten one full turn with the wrench. Caution: Always ensure that there is no pressure in the valve, actuator, or positioner before maintenance or disassembly. 5.1 ACTUATOR DIAPHRAGM REMOVAL (Figures 17, 24, 25, 26 and 27) A. U nscrew the two pressure connection nuts (138a) and pull tubing (140) out. Remove the four cap screws (139) and diaphragm cover (137). Remove the worn diaphragm. Form new diaphragm (136) and fit it on the piston as shown in figure 17. Fit the diaphragm roll into the bracket groove. Take care not to twist or bend the diaphragm during replacement. Refit diaphragm cover (137) with the four screws (139) and reconnect the tubing with the two pressure connection nuts (138a). Check that all connections are leaktight. 14 | GE Oil & Gas Figure 18 - Adding a packing ring 5.3 DISASSEMBLY (Figures 5, 24, 25, 26, 27, 28 and 29) remove balance spring (114) from the positioner. In some cases, it may be necessary to disassemble the VariPak valve, for example, to replace the plug/seat ring assembly (fitting new parts or changing the maximum Cv value) or to change the packing rings when the maximum Cv is less than 0.6. E. R emove the retainer clip (112b) from each of the two pins (184) and disengage the pins from lever No. 1 and clevis (104a). Note: If the maximum Cv ≥ 0.6, a quick change method can be used to avoid disassembling the valve (see page 18). Note: This operation will be simplified by relieving the load exerted on the plug clevis by the conical compression spring (106). To do this push against the plug stem end with a screwdriver while driving out the pins. Caution: The valve must be isolated and pressure vented before disassembly. F. Remove the two retainer clips (112c) from pivot pin No. 4 (124) and disengage the pin to uncouple piston clevis (104b) from lever No. 2 (22). A. L oosen cover screws (109) and remove cover (110). If the valve is equipped with a handwheel, loosen cover screws (109) and handwheel lock (121), then turn handwheel (120) counterclockwise to release cover (110). Disassembly procedure for the VariPak 28001 singlelever valve: B. U nlock nut (117) and completely loosen screw (116). Remove spring clamp (115) from lever (113) and remove spring (114) from the positioner. C. Remove the two retainer clips (112c) from pin (124) and disengage the pin to uncouple piston clevis (104b) from lever (113). Note: To simplify this operation, admit air pressure to the actuator to drive the piston clevis (104b) upwards, then release the air pressure. D. R emove retainer clips (112b) from pin (18) and disengage the pin from lever (113) and plug clevis (104a). E. Remove two retainer clips (112a) from pin (105) and disengage the pin to uncouple lever (113) from actuator bracket (108). Now proceed in the same way as for the VariPak 28002 adjustable- Cv valve, as from step I. Disassembly procedure for the VariPak 28002 adjustable-Cv valve: B. A djust the signal to close the valve. Change the signal slightly so that the plug just moves off the seat ring. Set adjustment knob (24) to the minimum Cv position. C. Loosen locknut (103) and, using a screwdriver, turn the plug stem one and three-quarter turns counterclockwise. Shut off signal and supply pressure. Slightly tighten locknut (103) against the clevis. D. C ompletely loosen locknut (117) and screw (116). Remove spring clamp (115) from lever No. 2 and G. Remove the two retainer clips (112a) from pivot pin No. 1 (105) and disengage the pin to uncouple lever No. 1 from the actuator bracket (108). Disengage the smooth end of adjustment pin (23) from the groove in lever No. 2 and remove adjustment knob (24) and adjustment pin (23) from lever No. 1. H. Drive out pivot pin No. 3 (18) and remove lever No. 2 (22). I. H old the plug stem in place using a screwdriver and unlock nut (103). Loosen clevis (104a) and locknut (103). Remove spring button (102), spring (106), and grommet plate (101). J. R emove the two packing flange nuts (8b), packing flange (10) and packing follower (9). Remove the two bracket mounting nuts (8a) as well as the bracket (108). K. U sing a packing hook, remove as many packing rings (6) as possible from the packing box. Remove safety pin (11) and pull the plug stem to remove the packing spacer (5), the plug and its stem and, if necessary, the rest of the packing. L. U sing a 9/16" or 14 mm piece of hex stock and a wrench, unlock and pull out the seat-ring retainer (4). M. Remove seat ring (3) and gasket (2) using a hook made from steel wire, approx. diameter 3 mm. Carefully fettle the hook end. Note: - The seat-ring of VariPak valves with Cv max.< 0.10 consists of two parts: the seat ring proper (3e), and a spacer (3f). These parts have a small orifice and so cannot be removed using a hook. It is therefore necessary to remove the body from the pipe and turn it over and, if necessary, hit the bottom with a wooden mallet. If the seat ring (3a) is jammed in its housing, it can be removed by inserting a screwdriver through the outlet orifice. Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 15 - VariPak valves with Cv max. 3.8 do not have seatring gaskets (2). 5.4 REASSEMBLY (Figures 5, 15, 19, 20, 24, 25, 26, 27, 28 and 29) Before reassembly, thoroughly clean the inside of the valve body and parts, paying particular attention to gasket seating surfaces and contact surfaces. Make sure to use a new seat-ring gasket (2) and new packing (6) during reassembly. A. Insert a new seat-ring gasket (2) into valve body (13), then fit seat ring (3), making sure that the gasket is correctly centered on the seat-ring shoulder. Turn it so that one of its ports is lined up with the valve body outlet orifice. Note: If the maximum Cv is less than 0.10, first fit the seat ring (3e) on the new gasket (2), taking the same precautions as above. Then fit the spacer (3f), turning it so that one of its ports is turned towards the body outlet orifice. VariPak valves with a maximum Cv of 3.8 do not include a seat-ring gasket (2). B. C arefully apply Never Seez grease or equivalent to the threads and bottom of the seat-ring retainer (4). Using a 9/16" or 14 mm piece of hex stock and a wrench, torque the retainer to 59 ftlb or 8 daN.m for stainless-steel reinforced graphite gaskets or 40 ft-lb or 5.5 daN.m for glass-filled PTFE gaskets (see figure 19). Note: Torque the retainer to 30 ft-lb or 4 daN.m for valves with a maximum Cv of 3.8. C. Insert the plug and stem assembly into the seat ring. For valves with a maximum Cv < 0.10, check that there are no friction points in the plug stroke. If a friction point is detected, loosen retainer (4) and reposition seat ring (3e) until the stem slides smoothly. Fit spacer (5), turning it so that one of its holes is aligned with safety pin (11) hole in the valve body. Note: For valves with a maximum Cv less than 0.10, check that the retaining ring (182) is fitted on the plug before fitting the plug in the spacer (3f). If the retaining ring is worn or damaged, replace it. Figure 19 - Tightening the seat-ring retainer (4) D. W ind two layers of PTFE tape around the safety pin (11). Screw the pin into the bonnet five and a half to six turns as from the thread engagement point. Note: To determine the thread engagement point: - Screw the safety pin about one turn. - Pull the safety pin out while unscrewing it. E. Fit the packing, making sure that the skive cut of each packing ring is located 120° away from the that of the adjacent ring. Push the rings down slightly using a 1/2" sch., size 160 tube. Fit the packing follower (9) onto the plug stem. F. Fit actuator bracket (108) and secure it with two nuts (8a). Slip packing flange (10) onto plug stem. Handtighten the two packing flange nuts and add one full turn with the wrench. G. Fit, in the following order, grommet plate (101), conical compression spring (106) and its spring button (102) (see position in figure 26 and 27). Screw nut (103) and clevis (104a) on the plug stem. Adjust the nut and clevis without locking them together until the clevis holes are positioned approximately: - 2.3 mm below the alignment of the pin holes in the actuator bracket (108) for the VariPak 28001 single-lever valve (see figure 15). - 1.5 mm above the alignment of the pin holes in the actuator bracket (108) for the VariPak 28002 adjustable-Cv valve (see figure 20). Note: Measuring this distance can be simplified by fitting pins (105), (184) and (18) into their holes. 16 | GE Oil & Gas Reassembly procedure for the VariPak 28002 adjustable-Cv valve (continued): H. Couple lever No. 2 (22) to the actuator bracket (108) using pin (18). Ensure that the hole in lever No. 2 where spring clamp (115) is fitted is located above and in line with balance spring (114). Figure 20 - Plug stem pre-adjustment for VariPak 28002 adjustable-Cv Reassembly procedure for the VariPak 28001 singlelever valve (continued): H. Couple lever (113) to actuator bracket (108) using pin (105) and the 2 retainer clips (112a). Ensure that the holes in lever (113) where spring clamp (115) is fitted is located above. Note: Check that the clevis (104a) is correctly positioned before fitting the lever (113) on the actuator support (108). To identify the position of the lever connecting holes and the spring clamp (115) attachment hole, with respect to the required action, see figure 6. I. C ouple clevis (104a) to lever (113). To do this, press the end of the plug stem with a screwdriver until the holes in the clevis and lever are aligned. Couple using the pin (18) and retainer clips (112b). Note: Slightly grease all pins before fitting. Perform the adjustment operation described in "Calibration", section 4.2.1, page 12. J. If piston rod clevis (104b) has not been disturbed during disassembly, couple it to the end of lever (113) by admitting air pressure to the actuator to drive clevis (104b) upwards. Couple the clevis to lever (113) using pin (124) and two retainer clips (112c). I. F it adjustment pin (23) in the slide of lever No. 1 and screw adjustment knob (24) on its threaded end. Insert the smooth end of pin (23) into the groove in lever No. 2 and place lever No. 1 on support bracket (108). Couple lever No. 1 to actuator bracket (108) using pin (105) and two retainer clips (112a). Note: Check that the clevis (104a) is correctly positioned before fitting lever No. 1 on the actuator support (108) To identify the position of the connecting holes of levers No. 1 and 2 with respect to the required action, see figure 6. J. S et adjustment knob (24) to the minimum Cv position. K. If piston rod clevis (104b) has not been disturbed during disassembly, couple it to the end of lever No. 2 using pin (124) and two retainer clips (112c). Note: This operation will be simplified by applying air pressure to the diaphragm (136) to set the piston rod to an intermediate position, and by setting the adjustment knob to a position where lever No. 2 is most accessible. If the clevis (104b) has been disturbed, proceed with adjustment and coupling as described in "Calibration", section 4.1.1, page 12. L. C ouple clevis (104a) to lever No. 1. To do this, press the end of the plug stem with a screwdriver until the holes in the clevis and lever No. 1 are aligned. Couple using the two pins (184) and retainer clips (112b). Note: The clips are inserted on the pins between the sides of the clevis and lever No. 1. Note: If the clevis (104b) has been disturbed, proceed with adjustment and coupling as described in "Calibration", section 4.1.1, page 12. M. Fully unscrew take-up screw (116) from spring clamp (115), then fit clamp, after hooking balance spring (114) first to the positioner spring bracket of the diaphragm S/A (152), and then to spring clamp (115). K. R elease the pressure from the actuator and check tightness again (see "Calibration", section 4.2.1, page 12). Then continue from step M. of the VariPak 28002 procedure. Note: The spring clamp (115) has two holes. If an Air-toOpen actuator is used, the spring must be hooked to the top hole. If an Air-to-Close actuator is used, the spring must be hooked to the bottom hole (see figure 6). Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 17 spacer (5). The function of the safety pin and spacer is to prevent the plug from being pushed out if the actuator is accidentally removed while the valve is still pressurized. The internal parts of the valve cannot be removed unless the safety pin is removed first. Remove the two packing flange nuts (8b) and back off the two actuator bracket mounting nuts (8a) as far as possible. N. A dmit the signal and supply pressure and complete calibration. Refit cover (110) using the two screws (109). If the valve is equipped with a handwheel, refit the cover, then turn the handwheel clockwise until it is engaged in lever arm stop (122). Tighten cover screws (109). O. If the valve body has been removed, reinstall it taking the precautions given under "Valve Installation" on page 10. Put the valve back into service. 5.5 PACKING QUICK CHANGE METHOD (ONLY FOR VALVES WITH MAX. Cv OF 0.6 TO 3.8) (Figures 21, 26 and 27) The quickest and easiest way to replace packing is to remove the entire actuator from the valve body, taking care not to modify the actuator setting. This method is not recommended, however, for valves with a maximum Cv less than 0.6 because of their extremely fine plugs. For these valves, disassemble the valve to replace the packing (see "DISASSEMBLY", page 15). C. Remove the actuator-plug assembly from the valve body, tapping it off with a block of wood and mallet if necessary. Clean the packing box in the valve body. Remove the worn packing, then clean the plug stem thoroughly. Carefully fit new packing rings around the stem, positioning the skive cut of each ring 120° from that of the adjacent ring. D. R efit the actuator-plug assembly on the valve body, taking care to: - align hole in packing spacer (5) with safety pin (11) hole, - and refit the two mounting nuts (8a). - T ake extra care when guiding each packing ring into the packing box. E. W ind two layers of PTFE tape around the safety pin. Screw the pin into the bonnet five and a half to six turns as from the thread engagement point. Note: To determine the thread engagement point: - Screw the safety pin about one turn, - Pull the safety pin out while unscrewing it. F. Refit the packing follower, packing flange, and flange nuts (8b). Tighten the packing assembly correctly. If the valve is equipped with an Air-to- Open actuator, release the air pressure or turn the handwheel to bring the plug back into contact with the seat ring. Put back into service. 5.6 7700P OR 7700E POSITIONER MAINTENANCE (Figures 22, 23, 24, 25, 26 and 27) Figure 21 - Packing replacement (for Cv maxi ≥ 0.6) Vent the valve pressure and proceed as follows: A. C heck that the plug is not resting on the seat ring. For valves equipped with an Air-to-Open actuator, admit air pressure under the diaphragm and turn the handwheel to move the plug off its seat ring. BR emove safety pin (11) from the valve body. The safety pin stub engages with the hole in packing 18 | GE Oil & Gas Caution: Shut off the signal and supply pressure. Isolate and depressurize the valve body. A. D isconnect the two pressure connection nuts (138a) and pull tubing (140) out. B. L oosen the two cap screws (141a) and remove manifold block (144), spring (158), gasket (146) and its three O-rings, pilot valve assembly (155 to 157), shims (145), and O-ring (153). Caution: Handle the shims carefully (145). C. Loosen locknut (117) and take-up screw (116), unhook the spring clamp from lever (22) or (113). D. Unscrew cap screws (141b) from positioner block (147) and remove the positioner block from the actuator bracket. Note: The ports in gasket (146) must be aligned with those in the positioner block (147). To ensure correct positioner performance, check that all gaskets are perfectly leaktight. I. H ook spring clamp (115) to lever (22) or (113). In the case of VariPack 28001 valve, see figure 6 to position the spring clamp (115) according to the actuator required action. Admit the supply pressure and the signal. Set the start-up pressure following the instructions given in the "Calibration" chapter. Put back into service. Spring color code 114 Yellow 154 Red 3-9 114 154 White Blue 9-15 114 154 White Green 4-20 mA 114 154 Yellow Red Signal (Psi) 7700P 3-15 or 6-30 or 3-27 Remove screws (148) to separate positioner diaphragm assembly (152) and spring (154) from the positioner block. Examine all the parts and replace if worn or damaged. E. Refit positioner diaphragm assembly (152) and spring (154) to positioner block and tighten screws (148). Check that the small signal port Oring is in its recess in the diaphragm assembly. Spring ref. No. Positioner F. Reinstall the block assembly on the actuator bracket. Note: When installing the positioner block (147), turn it so that when the manifold block (144) is installed, the gauge(s) is(are) facing in the right direction (figure 22). 7700E Figure 23 - Color code for positioner springs (114 and 154) 5.7 MAINTENANCE OPERATIONS SPECIFIC TO THE 7700E POSITIONER REFER TO ATEX INSTRUCTION MANUAL No. 185977 FOR ALL MAINTENANCE ON THE ELECTRICAL PARTS OF THE 7700E POSITIONER. A. Loosen screws (27) and remove I/P module (20). Note: If damaged, the I/P module must be replaced. B. C heck that O-rings (28, 29 and 30) and their seats are not worn or damaged. Figure 22 - Positioner assembly Note how the positioner (147) and gasket (146) are oriented G. Check that gasket (146), three O-rings, and seats are not worn or damaged and replace if necessary. H. Fit O-ring (153), shims (145), pilot valve assembly, gasket (146) and its three O-rings, spring (158) and manifold block (144). Tighten the screws (141a), refit tubing (140) and tighten pressure connection nuts (138a). Note: All worn or damaged parts must be replaced. C. Fit O-rings (28, 29 and 30) in their recesses on the I/P module (20). Refit I/P module (20) on manifold block (144). Tighten screws (27). Note: To ensure correct positioner performance, check that all gaskets are perfectly leaktight. Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 19 5.8 CONVERTING A 7700P POSITIONER (PNEUMATIC) INTO A 7700E POSITIONER (ELECTROPNEUMATIC) C. If the parts mentioned above have been removed, proceed as follows: A kit comprising the manifold block (144) and the I/P module (20) is available from your local Masoneilan representative or the Spare Parts Department. Fit the O-ring (153), shims (145), pilot valve assembly (155 to 157), gasket (146) and the three O-rings, the spring (158) and manifold block (144) - I/P module (20). Tighten screws (141a), refit tubing (140) and tighten pressure connection nuts (138a). REFER TO ATEX INSTRUCTION MANUAL No. 185977 FOR ALL MAINTENANCE ON THE ELECTRICAL PARTS OF THE 7700E POSITIONER. Shut off the signal and supply pressure. Isolate and depressurize the valve body. A. D isconnect the two pressure connection nuts (138a) and pull the tubing (140) out. B. L oosen the two cap screws (141a) and remove manifold block (144). The spring (158), gasket (146) and the three O-rings, the pilot valve assembly (155 to 157), shims (145), and O-ring (153) do not need to be removed unless you have new parts. Otherwise, simply check that parts are in perfect condition before refitting. Caution: Handle the shims carefully (145). 20 | GE Oil & Gas Note: The ports in gasket (146) must be aligned with those in positioner block (147). To ensure correct positioner performance, check that all gaskets are perfectly leaktight. D. H ook spring clamp (115) to lever (22) (VariPak 28002) or (113) (VariPak 28001). In the case of VariPack 28001 valve, see figure 6 to position the spring clamp (115) according to the actuator required action. Admit the supply pressure and enable the electrical signal. Adjust the start-up pressure following the instructions under "Calibration". Put back into service. Figure 24 - Cross-section of the VariPak 28002 adjustable-Cv actuator and the 7700P positioner PARTS LIST Ref. Δ ☐ 1 Ο 2 a b c 3 ☐ ☐ 3 4 5 Ο 6 7 8 8 9 10 11 12 13 13 18 20 21 22 23 24 25 26 27 28 29 30 Ο Ο Ο d e f a b a b c d a b Qty 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 Part Name 1/4" NPT pipe plug Seat-ring gasket Seat ring Cv max. 3.8 Seat ring Cv max. 2.3 and 1.2 Seat ring Cv max. 0.25 and 0.60 Seat ring Cv max. 0.10 Seat ring Cv max. < 0.10 Spacer Cv max. < 0.10 Seat-ring retainer Packing spacer Packing ring Packing flange stud Mounting nut Packing flange nut Packing follower Packing flange Safety pin Plug/stem Cv max. 3.8 Plug/stem Cv max. 2.3 Plug/stem Cv max. 1.2 & 0.6 Plug/stemCv max. 0.25 & 0.10 Body Cv max. < 3.8 Body Cv max. 3.8 Pivot pin No. 3 (22/108) I/P module Lever No. 1 Lever No. 2 Adjustment pin Cv adjustment knob Cv adjustment plate Adjustment plate screw Screw O-ring O-ring O-ring Ο Recommended spare parts Ref. 101 102 103 104 Qty 1 1 1 2 Part Name Grommet support plate Spring button Locknut Clevis Ref. 140 141 (a, b) 142 143 105 1 Pivot pin No. 1 144 106 Ο 107 108 109 110 112 (a, b, c) 114 115 116 117 118 119 120 121 122 123 124 125 126 127 129 130 131 133 134 135 Ο 136 137 138 139 1 1 1 2 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 1 1 145 146 147 148 152 153 154 155 156 157 158 Conical compression spring Grommet Actuator bracket Cover screw Cover Retainer clip Balance spring Spring clamp Take-up screw Locknut Handwheel locknut Handwheel bushing Handwheel Handwheel lock Lever arm stop Cover plug Pivot pin No. 4 Locknut Indicator Indicator plate Indicator plate screw Speed nut Piston S/A Serial plate screw Actuator spring Serial plate Diaphragm Diaphragm cover Union elbow t(incl. 138a) Cover cap screw See table in figure 23. ☐ Complete subassembly includes: plug and stem (183), Only for handwheel (optional) (fig. 5). retaining ring (182), seat ring (3e) and spacer (3f) (see ΟC omplete subassembly includes Ref. Nos. (155, 156 figure 2). and157). Only for pneumatic positioner. ■ Not shown. See Figure 2. Ο Ο Ο ♥ Ο Ο Ο Δ 159 Δ 160 Δ 161 Δ 162 Δ 163 Δ 164 ■ 165 168 170 ■ 171 ■ 172 173 ▼ 180 ▼ 181 182 183 184 Qty 1 4 1 1 Part Name Tubing Screw Output gauge Instrument gauge 1 Manifold block 1 to 5 1 1 2 1 1 1 1 1 1 1 2 4 4 4 4 1 2 1 2 1 1 1 1 1 1 1 2 Shim Gasket (includes 171 & 172) Positioner block Slotted flat. c screw Positioner diaphragm S/A O-ring Spring Sleeve Spool Spring Spring Switch Screw Washer Nut Wire Terminal Logo Cover washer Signal decal O-ring O-ring Cover plug Limit stop Locknut Retaining ring (Cv max. <0.10) Plug (Cv max. <0.10) Pivot pin No. 2 ▲ Only for cast bodies. ▼O nly on actuator with handwheel and/or Model 8013 E.P. positioner (fig. 5). Δ Only for optional limit-switch adaptation: quantity given for two limit switches (see fig. 13). Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 21 Figure 25 - C ross-section of the VariPak 28001 single-lever actuator and the 7700E positioner 181 180 Figure 26 - Partial cross-section of VariPak 28001 single-lever, air-to-open valve 22 | GE Oil & Gas Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 23 181 180 Figure 27 - Partial cross-section of VariPak 28002 adjustable-Cv, air-to-open valve Figure 29 - Coupling detail of levers No. 1 and 2 Figure 28 - Partial top view 24 | GE Oil & Gas DIRECT SALES OFFICE LOCATIONS AUSTRALIA Brisbane: Phone: +61-7-3001-4319 Fax: +61-7-3001-4399 Perth: Phone: +61-8-6595-7018 Fax: +61 8 6595-7299 Melbourne: Phone: +61-3-8807-6002 Fax : +61-3-8807-6577 BELGIUM Phone: +32-2-344-0970 Fax: +32-2-344-1123 BRAZIL Phone: +55-11-2146-3600 Fax: +55-11-2146-3610 CHINA Phone: +86-10-8486-4515 Fax: +86-10-8486-5305 FRANCE Courbevoie Phone: +33-1-4904-9000 Fax: +33-1-4904-9010 GERMANY Ratingen Phone: +49-2102-108-0 Fax: +49-2102-108-111 INDIA Mumbai Phone: +91-22-8354790 Fax: +91-22-8354791 New Delhi Phone: +91-11-2-6164175 Fax: +91-11-5-1659635 ITALY Phone: +39-081-7892-111 Fax: +39-081-7892-208 SOUTH AFRICA Phone: +27-11-452-1550 Fax: +27-11-452-6542 JAPAN Chiba Phone: +81-43-297-9222 Fax: +81-43-299-1115 SOUTH & CENTRAL AMERICA AND THE CARIBBEAN Phone: +55-12-2134-1201 Fax: +55-12-2134-1238 KOREA Phone: +82-2-2274-0748 Fax: +82-2-2274-0794 SPAIN Phone: +34-93-652-6430 Fax: +34-93-652-6444 MALAYSIA Phone: +60-3-2161-0322 Fax: +60-3-2163-6312 UNITED ARAB EMIRATES Phone: +971-4-8991-777 Fax: +971-4-8991-778 MEXICO Phone: Fax: UNITED KINGDOM Wooburn Green Phone: +44-1628-536300 Fax: +44-1628-536319 +52-5-310-9863 +52-5-310-5584 THE NETHERLANDS Phone: +0031-15-3808666 Fax: +0031-18-1641438 RUSSIA Veliky Novgorod Phone: +7-8162-55-7898 Fax: +7-8162-55-7921 Moscow Phone: Fax: UNITED STATES Massachusetts Phone: +1-508-586-4600 Fax: +1-508-427-8971 Corpus Christi, Texas Phone: +1-361-881-8182 Fax: +1-361-881-8246 +7 495-585-1276 +7 495-585-1279 Deer Park, Texas Phone: +1-281-884-1000 Fax: +1-281-884-1010 SAUDI ARABIA Phone: +966-3-341-0278 Fax: +966-3-341-7624 Houston, Texas Phone: +1-281-671-1640 Fax: +1-281-671-1735 SINGAPORE Phone: +65-6861-6100 Fax: +65-6861-7172 * Masoneilan and VariPak are registered trademarks of the General Electric Company. Other company names and product names used in this document are the registered trademarks or trademarks of their respective owners. © 2014 General Electric Company. All rights reserved. GEA30857 03/2014
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