IMO-19

Issue Date 10/93

BUTTERFLY VALVES
SERIES 8000 and 8200
Read these entire instructions carefully
before installation or servicing.
DESCRIPTION MAlNTENANCE
WARNING ROUTINE MAINTENANCE
VALVE INSTALLATION VALVE REMOVAL- BENCH MAINTENANCE
VALVE DISASSEMBLY ACTUATOR MOUNTING
VALVE ASSEMBLY ACTUATOR/VALVE ADJUSTMENTS
SERIES 8000
NOTE REGARDING FLANGE
BOLT HOLE THREAD
In order to accommodate
normal alloy steel bolt-
ing, flange bolt holes
larger than 1" are being
standardized with a UN-8
thread. Inspect the
valve body to determine
whether it has previous
UNC-I or new UN-8 tapped
holes.
Figure 1
SERIES 8200
Figure 2
DESCRIPTION
The Jamesbury Wafer-Sphere valve is a high per-
formance butterfly valve with a one-piece body
and a resilient, positive-sealing seat. In
24" - 48" sizes , it is available in two stan-
dard series:
8000 Series - Wafer design for ANSI Class 150
piping systems.
8200 Series - Single flange (lugged) design for
ANSI Class 150 piping systems.
Important Note: Maximum shut-off pressure rating
depends on the materials chose. Refer to the tag
attached to each valve for this rating.
Offset Shaft Design
One of the design features of the Wafer-Sphere
valve that is responsible for its superior perfor-
mance is the valve's eccentric shaft design. The
shaft is offset in two planes: (1) away from the
valve disc centerline; and (2) behind the disc
sealing plane (See Fig. 5). Offset shaft design
makes the rotating disc cam back and away from the
seat, eliminating the usual wear points at the top
and bottom of the seat. Because the disc rotates
off the seat in an eccentric arc, it operates in
one quadrant only (See Fig. 5)
Positive Stop Feature
TO prevent seat damage from over-travel of the
disc beyond the closed position (primarily during
field mounting of an actuator), a "positive stop"
feature has been designed into the Wafer-Sphere
butterfly valve. The "positive stop" feature
also makes it possible to adjust the actuator
stops in-line. The location of the feature on
the body is shown in the drawing, Figure 4.
WARNING
SAFETY FIRST: FOR YOUR SAFETY, TAKE THE FOLLOWING PRE-
CAUTIONS BEFORE REMOVING THE VALVE FROM THE LINE, OR
BEFORE ANY DISASSEMBLY:
1. WHAT'S IN THE LINE?
BE SURE YOU KNOW WHAT FLUID IS IN THE LINE. IF
THERE IS ANY DOUBT, DOUBLE-CHECK WITH THE PROPER
SUPERVISOR.
2. ARE YOU PROTECTED?
WEAR ANY PROTECTIVE CLOTHING AND EQUIPMENT NOR-
MALLY REQUIRED TO AVOID INJURY FROM THE PARTICU-
LAR FLUID IN THE LINE.
3. IS THE LINE DEPRESSURIZED?
DEPRESSURIZE THE LINE AND DRAIN THE SYSTEM FLUID.
THE WAFER-SPHERE'S OFFSET SHAFT CREATES GREATER
DISC AREA ON ONE SIDE OF THE SHAFT. THIS MEANS
THAT A WAFER-SPHERE VALVE TENDS TO OPEN WHEN
_ _ - - -
PRESSURIZED ON THE INSERT SIDE WITHOUT AN ACTUA-
- - - -
TOR ON THE VALVE.
NOTE: DO NOT PRESSURIZE THE VALVE WITHOUT AN
ACTUATOR MOUNTED ON IT. DO NOT REMOVE AN ACTUATOR
FROM A VALVE UNDER PRESSURE.
4. IS THE VALVE CLOSED?
BEFORE YOU INSTALL A WAFER-SPHERE VALVE IN, OR
REMOVE IT FROM THE LINE, CYCLE THE VALVE FULLY
CLOSED. THE WAFER-SPHERE VALVE MUST BE REMOVED
FROM THE LINE IN THE CLOSED POSITION OR DAMAGE
TO THE WAFER WILL RESULT.
WARNING: AT ALL TIMES KEEP HANDS OUT OF THE WATERWAY
OF THE VALVE. A VALVE WITH ACTUATOR COULD CLOSE UN-
EXPECTEDLY AT ANY TIME AND RESULT IN SERIOUS INJURY.
INSTALLATION
I. FULL PRESSURE RATING - POLYMERIC-SEATED
WAFER-SPHERE VALVES (Refer to the catalog for
allowable pressures and temperatures.)
In general, for full pressure rating, all
polymeric-seated Wafer-Sphere butterfly valves
should be installed with the disc face toward
the higher pressure (shaft downstream.)
II. METAL-SEATED WAFER-SPHERE VALVES
Metal-seated Wafer-Sphere butterfly valves are
single-directional. They must be installed ONLY
with the disc face toward the higher pressure
(shaft downstream).
2
III. GENERAL INFORMATION
1. Read the GENERAL WARNING Section
carefully.
2. IMPORTANT: ONLY actuator stop set screws
should be used to stop the disc in
position. DO NOT use the "positive stop"
feature by itself to limit actuator travel.
3. Before installing the closed valve in the
line, be sure that the actuator is attached
so that a counterclockwise rotation, viewed
from above, opens the valve (See Fig. 5).
Again, fully close the valve before instal-
ling it in the line.
4. The valve should be installed with l/16"
thick asbestos or equivalent gasket material.
NOTE: DO NOT use thick rubber or other gaskets
of a "spongy" consistency.
5. For optimum performance, compress the gasket
uniformly. Tighten the flange bolts in the se-
quence shown in Fig. 9. Recommended torque
values for bolting are listed in Fig. 3.
6. If there is weepage past the stem seals upon
installation, it means the valve may have been
subject to wide temperature variations in ship-
ment. Leaktight performance will be restored
by a simple packing adjustment described in the
MAINTENANCE Section.
2 .
3 .
4 .
5 .
6 .
7. Cycle the valve closed.
8 . Place the new seat in the valve. Make sure
the angle on the inside diameter of the seat
corresponds to the angle of the outer edqe
of the disc.
9.
9a.
Remove the insert screws (21) and the insert
(2). If the insert does not lift out easily,
tap it out from the shaft side using a wooden
or plastic rod and hammer. Do not strike the
valve directly with the hammer.
Remove the seat, and discard it.
Clean the valve.
Carefully clean and polish the disc sealing
surface. It should be free of all grooves
and scratches.
If the disc is slightly damaged it may be
possible to smooth the sealing surface with
crocus cloth, a fine stone, or the equiva-
lent. If deep scratches are present replace
the disc or return the valve to the factory
for service.
The insert should be installed per Figure 4.
9b Seat compression is accomplished when the
Install the socket head cap screws (21) and
tighten as shown in the sequential diagram
(Fig. 10) and torque chart (Table II).
valve is installed between flanges and the
flange bolts are tightened.
CAUTION: Unless the valve is in the fully
closed position, compressing the seat may
damage it.
NOTE: After installation of a new seat, torque
will be higher for a few cycles. Whenever a
seat is replaced or an actuator is removed
and reinstalled on a valve, the actuator
travel stops will in all likelihood have to
be readjusted. See ACTUATOR/VALVE ADJUSTMENTS
for instructions.
V. Upper Shaft Seal Replacement
1.
2.
3.
4.
5.
6.
Remove the actuator.
Remove the indicator (29). Take off the
compression plate (10) by removing the
stud nuts (15) and lockwashers (16). The
studs (14) do not have to be removed.
Remove the compression ring (9).
Remove the old shaft seals (8) with a
packing tool.
Do not remove the spacer (7), unless com-
plete disassembly is necessary.
Replace the old seals with new seals.
NOTE: If the seals are of the chevron
type, keep the seal rings stacked in the
same order as removed from the kit, and
install them in the direction shown in
Fig. 4.
Reinstall the compression ring (91, the
compression plate (l0), the lock washers
(16) and nuts (15). Replace the indicator
(29). Be sure that the hardware has been
installed so that the indicator plate is
under the pointer.
Close the valve (the seat and insert should
be installed in the valve at this point).
Tighten the nuts (15) evenly until the packing
is adequately compressed to prevent leakage.
This should require tightening the nuts approxi-
mately l-l/2 to 2 full turns past the
'finger-tight" position.
VI. Lower Shaft Seal Replacement (SEE STUD NOTE FIG.4)
3
1. Remove the two locknuts (30) on the wafer
shaft.
GASKET DIMENSIONS
VALVE 1
Figure 3
MAINTENANCE
Routine maintenance consists of tightening down the
compression plate periodically to compensate for seal
wear. The valve should be closed during tightening.
The compression plate, however, should not be tightened
down too severely, since this will shorten the
life of the seals. More extensive maintenance
such as seat, seal and bearing replacement is
described in the following sections. Numbers in
( ) refer to items shown in Fig. 4.
VALVE REMOVAL AND SHOP MAINTENANCE
I.
II.
III
IV.
Read the WARNING Section carefully.
Valve must be fully closed before sliding
it out of the pipeline.
CAUTION: Valves equipped with fail-open Spring
return actuators must have sufficient air pres-
sure applied to the actuator to close the valve.
After valve removal, slowly relieve the pressure
in the actuator. Take care to protect the ex-
posed sealing edge of the disc.
Seat Replacement (Refer to Fig. 4)
1. After removing the valve from the line, cycle
the valve open. Take care not to damage the
edge of the disc while it is open.
4
2.
3.
4.
5.
6.
7.
8.
Remove the two outer stud nuts (15) and
lockwashers (16). The studs do not have to
be removed. Do not adjust the stud nuts be-
tween the body and the compression plate.
Remove the compression plate washers (34 and
35) and the compression plate (33).
Remove the bottom compression ring (32).
Remove the old shaft seals (8) with a packing
tool.
Replace the old seals with new seals.
NOTE: If the seals are of the chevron type,
keep the seal rings stacked in the same order
as removed from the kit, and install them in
the direction shown in Fig. 4.
Do not remove the spacer (7), unless com-
plete disassembly is necessary.
Reassemble according to assembly instructions
#6 through #12.
VALVE DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Place the valve on a bench or other suitable
working space.
If the seat is to be replaced, follow steps
2, 3, and 4 in the SEAT REPLACEMENT Section.
NOTE: It is a good idea to replace the
seat any time a valve is rebuilt.
Remove the shaft packing compression hard-
ware as detailed in Steps 2-5 in the Upper
Shaft Seal Replacement section. The packing
material itself can be more easily removed
after the shaft has been removed from the
valve.
Remove the disc pins by grinding or machin-
ing off the welds. Drive out the pins in the
direction shown in diagram (Fig 4.).
Disassemble the lower seal assembly as de-
tailed in Steps 2-7 in the Lower Shaft Seal
Replacement section.
Support the disc so that it will not drop
upon removal of shaft. Remove the shaft
through the top of the valve. Use a
hammer or press to drive the shaft. Pro-
tect the threads and the bearing surface at
the end of the shaft from damage during
this operation. Do not hammer on the end
of the threaded center stud.
NOTE: In removing the shaft and freeing the
disc, be careful not to scratch the sealing
surface of the disc.
Remove the top bearing (6) by pushing it up from
the bottom (waterway).
Remove the bottom bearing (6) by pushing it down
from the top (waterway).
NOTE: To keep bearings in place, the valve body
is staked on the I.D. DO NOT try to remove the
bearing by pushing them toward the center
of the valve.
VALVE ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Clean all valve components.
Inspect all components for damage before
starting to assemble the valve. Look espe-
cially for damage to sealing areas on the
disc, shaft and body and for wear in the
bearing areas of the shaft and body.
Carefully clean and polish the disc sealing
surface. It should be free of all grooves
and scratches.
If the disc is slightly damaged it may be
possible to smooth the sealing surface with
crocus cloth, a fine stone, or the equivalent.
If deep scratches are present replace the disc
or return the valve to the factory for service.
Place the body (1) on a flat surface with the
insert facing the assembler. Remove the seat
(5) if not already removed.
Insert the bearings (6), lubricating the inside
diameter with silicone grease or other lubricant
compatible with the fluid to be handled. Using
a center punch, stake the inboard end of the
bearing bores to prevent movement during assembly
and service. On 24" - 48" valves, stake the out-
board end of the lower bearing bores.
NOTE: This staking will not be required if the
original factory staking has not been damaged.
Position the disc (3) in the body and slide
the shaft (4) through the body and disc. Use
caution to prevent damage to the bearings.
An arrow on the disc indicates which end
of the disc should be located on the bonnet
side.
Insert the pins (13) and drive them into
place according to sequence in Fig. 8. The
sequence and direction is very important to
avoid alignment error between shaft and
disc and assure that all the pins can be in-
stalled. Weld both ends of the pins, small
end first. After the disc cools, clean the
welds with a wire brush. Welding may be left
for the last operation if desired.
9.
10.
11.
12.
13.
Slide the spacer (7), shaft seals (8), and
compression ring (9) over the shaft (4) at
the top of the valve. Slide the compression
plate (10) over the shaft and studs (14),
then place the two lockwashers (16) and nuts
(15) on the studs (14). DO not tighten these
nuts down onto the compression plate at this
time.
Slide the spacer (7). shaft seals (8), and
compression ring (32) onto the shaft (4) at
the bottom of the valve.
Slide one thrust washer (34) onto the threaded
stud at the bottom of the shaft. Slide
the compression plate (33) over this shaft
stud and the two studs (14), making sure
that there are two nuts (15) on each stud
between the compression plate and the valve
body, one with lockwasher (16) to secure
the stud to the body, and the other for ad-
justing the compression plate. Back the seat
screws (25) out far enough to prevent them
from contacting the compression ring (32).
Place the second thrust washer (35) and the
two nuts (30) on the shaft stud, tightening
the first nut only enough to take up all
slack. Tighten the second (jam) nut securely
against the first. The compression plate
should be free to rotate but must not have
any axial freedom on the shaft stud. Check
for this.
Place the two lockwashers (16) and nuts (15)
on the studs (14). Use these two nuts with
the two nuts on the other side of the compres-
sion plate to adjust the disc upward or down-
ward so that it is centrally spaced in the
waterway. Measurements taken from the disc
to the valve body at the top and bottom must
be identical with one another within .015".
Make sure all four nuts are tight. 5
14.
15.
16.
Cycle the valve and recheck this measurement.
Install the seat according to maintenance
instructions IV-7 through 10.
Tighten the set screws (25) at the bottom of
the valve and nuts (15) at the top of the
valve adequately to prevent shaft seal leak-
age. They should not be tightened too severely,
since this will shorten the life of the seals.
ACTUATOR MOUNTING
1. Install the actuator on the valve in accordance
with the applicable Actuator Mounting Instruc-
tions (AMI). If no AMI is available, install
the actuator in accordance with the following
general procedure.
2. Reinstall the actuator bracket on the valve,
holding the two together with four bolts. The
actuator should be securely bolted to the
bracket at this point. Note that the bracket/
valve bolt pattern is not symmetrical with
respect to the valve shaft. Check to be cer-
tain that the actuator/bracket/valve orienta-
tion is such that the actuator is correctly
oriented on the valve and that the actuator
drive shaft and valve shaft are exactly
aligned. The bolts between the valve and
bracket should be snug but not too tight.
(excessive tightening will prevent proper
alignment of the actuator drive shaft and
valve stem. Failure to tighten snugly will
cause the shaft and disc to be driven down-
ward away from optimum seat contact when
final tightening is accomplished).
3. Match the actuator position to the valve
position, i.e. valve open/actuator open and
vice versa. Install the coupling and tighten
the coupling bolts. Be sure the actuator
drive shaft and valve stem are properly
aligned and the coupling bolts are tight.
4. Now fully tighten the four bolts holding
the bracket to the valve.
Setting Stops (Valve in the Line)
It is preferable to adjust the stops on the
actuator before the valve is installed in the
line because of the ability to check disc posi-
tion visually. If this is not possible, and the
valve is installed in the line, use the proce-
dures which follow, ignoring any reference to
measured clearance to the disc. CAUTION: There
must be no pressure across the valve while the
stops are being set. Following adjustments, check
all linkage and coupling bolts for tightness. Re-
commended torque valves for fasteners are shown
in Table II.
Setting Stops (Valve out of the Line)
The following steps rely upon the insert (2) being
clamped in the position it will take when installed
in the line. The insert must be flush with the face
of the body (1) within l/64" maximum. The installed
seat tends to lift the insert unless it is completely
clamped or screwed in place. It may be most conveni-
ent to adjust the stops with the seat removed from
the valve. Following the setting of the stops, the
seat and insert must be reinstalled as described in
the SEAT REPLACEMENT Section.
Following adjustments, check all linkage and coupling
bolts for tightness. Recommended torque valves for
fasteners are shown in Table II.
Setting Stops on ST and ST-MS Pneumatic Actuators
1.
(Fig.6)
Disc travel on a Wafer-Sphere valve with 2 type
ST or ST-MS pneumatic actuator is controlled with
a closed ("shut") travel stop set screw (19A) and
by an open travel stop set screw (19B) in the
actuator.
2.
3.
4.
Remove the acorn nuts (19) protecting the stop
set screws. NOTE: Be sure the O-rings remain in
the acorn nuts.
Adjust the closed ("shut") stop set screws (19A)
until the disc just touches the insert when the
actuator is at the end of its stroke. Air pres-
sure may have to be applied to ST-MS actuators to
relieve the load on the closed ("shut") stop set
screw during the adjustment. CAUTION: If pressure
is supplied to the actuator while the valve is
exposed, keep hands and tools away from the disc.
From the position which allows the disc to just
touch the insert, turn the stop set screw in
about l/8 turn to get the disc l/64" off the insert.
5.
6.
7.
8.
9.
Cycle the actuator open and back to closed several
times and verify that the disc returns to the same
position each time. Keep hands and tools away from
the disc and do not allow the disc to drag across
surfaces which can scratch the sealing edge.
Cycle the valve to the open position. If necessary,
adjust the open stop set screw (19B) until the poin-
ter (24) is approximately 90 from the closed
("shut") position. This is full open.
With the valve in the full open position,
and with air applied so that load is applied
to the open stop set screw to prevent it from
moving, cover the open stop set screw with an
acorn nut. Tighten the open stop set screw acorn
nut.
Now close the valve. With the valve in the closed
position, an air (or spring) load applied to the
stop set screw, tighten the closed ("shut") stop
set acorn nut.
Cycle the valve open and closed, with full air
pressure, three times. The disc must return to
the same position each time. Visually check to
see that the disc is within l/64" of the insert
stop but is not lifting the insert from its proper
position.
6
Setting Stops on Quadra-Powr Actuators
Follow the instructions for adjustment of ST-MS actua-
tors with the following exceptions:
a. The Quadra-Powr has no acorn nuts on
the stop screws.
b. Because the stop screws can be held in
position with a screwdriver while tightening
the jam nuts, there is not need to apply a
load to the ends of the screws during this
operation.
Setting Stops on MA Manual Gear Actuator (Fig.7)
1. Loosen the jam nuts (32) locking the stop
set screws (19). Back out the closed (shut)
stop set screw (19A) far enough to allow
the actuator to move the disc until it just
touches the positive stop.
2. Screw in the closed (shut) stop set screw
until it stops against the gear face inside
the actuator.
3. Taking care not to move the set screw, use
the handwheel to open the disc slightly.
Turn the closed (shut) stop set screw in
about l/8 turn. Check to see that the disc
is l/64" off the positive stop.
4. Lock the stop set screw with the jam nut at
this point. The screw must be kept from moving
while the nut is being tightened. This may be
done either by holding the screw with a wrench,
or by using the handwheel to drive the gear
firmly against the end of the screw.
5. Open the valve so that the pointer is approxi-
mately 90 from the closed (shut) position using
the handwheel. Adjust the open stop set screw
(19B) to stop the gear at this position. Hold
the stop set screw and tighten the j am nut.
Setting Stops on Electric Actuators
Electric actuator stops are controlled by adjustable
cams and switches. Follow basically the same proce-
dure for these actuators as for ST actuators.
The closed (shut) switch should stop the disc
within the l/64" of the insert. Do not set the stop
so that the disc touches the insert before the
switch turns the actuator off.
TOP VIEW
NOTES :
1. INSERT LOCATING PIN "A" (ALWAYS 2ND FROM
BOTTOM) DRIVE IN SECURELY.
2. INSERT CANTED PINS "B". DRIVE IN
ALTERNATELY AND SECURELY.
3. INSERT REMAINING PINS "C" AND DRIVE IN
SECURELY.
4. PINS TO BE INSERTED IN DIRECTION OF
ARROW CAST ON DISC HUB.
AFTER FINAL ASSEMBLY OF SHAFT & DISC INTO
BODY. TACK WELD ON BOTH SIDES OF PINS. NO
PLAY MUST EXIST BETWEEN SHAFT AND WAFER
PRIOR TO WELDING.
Figure 8
7
Jamesbury Inc. l 640 Lincoln Street l Box 15004
Worcester, Massachusetts 01615-0004 USA
Tel: 508-852-0200 l Fax: 508-852-8172 l Internet: www.Jamesbury.com
Neles Controls Group l A member of Rauma Corporation