Metso AS series User manual

Control Valves

Angle Steam Conditioning,

Combination Type

Series AS

with Desuperheater for Globe type,

Series GS

Installation, Maintenance and

Operating Instructions

4 GV 76 en • 6/2016

24 GV 76 en

READ THESE INSTRUCTIONS FIRST!

These instructions provide information about safe handling and operation of the valve.

If you require additional assistance, please contact the manufacturer or manufacturer's representative.

Addresses and phone numbers are printed on the back cover.

SAVE THESE INSTRUCTIONS!

Subject to change without notice.

All trademarks are property of their respective owners.

Table of Contents

1 GENERAL...............................................................3

1.1 Scope of the manual ............................................3

1.2 Valve construction ................................................3

1.3 Valve markings .......................................................3

1.4 Technical specifications ......................................3

1.5 Valve seat leakage class .....................................3

1.6 Recycling and disposal ........................................3

1.7 Safety precautions ................................................4

2 TRANSPORTATION, RECEPTION AND

STORAGE...............................................................4

3 VALVE INSTALLATION ........................................4

3.1 General ......................................................................4

3.2 Installation into the pipeline .............................4

3.3 Control valve assembly .......................................5

3.4 Valve insulation......................................................5

4 MAINTENANCE .....................................................5

4.1 General ......................................................................5

4.2 Gland packing adjustment.................................5

4.3 Replacing the gland packing ............................6

4.4 Replacing the trim and body reassembly.....6

4.5 Pilot Plug...................................................................7

4.6 Spray Nozzle............................................................7

4.7 ‘GS’ Desuperheater ..............................................8

5 TESTING THE VALVE ............................................9

6 REMOVAL & MOUNTING THE ACTUATOR ........10

7 TOOLS .................................................................12

8 ORDERING SPARE PARTS...................................12

9 EXPLODED VIEW AND PARTS LIST....................13

10 DIMENSIONS AND WEIGHTS ............................15

10.1 Actuators VD, VC................................................. 15

11 INSTALLATION GUIDELINES..............................18

11.1 Pipeline cleaning ................................................ 18

11.2 Installation and orientation of the valve.... 18

11.3 Hydrostatic testing and Line flushing......... 18

11.4 Piping upstream ................................................. 18

11.5 Downstream piping........................................... 19

11.6 Spray water pipe................................................. 20

11.7 Drains...................................................................... 20

11.8 Pre-Heating........................................................... 21

11.9 Temperature sensor ......................................... 21

12 TYPE CODE..........................................................22

4 GV 76 en 3

1 GENERAL

1.1 Scope of the manual

This manual provides essential information on series AS:

Angle Steam Conditioning, Combination type valve

installed sliding stem valves. Also, this manual explaining

the GS: Desuperheater for Globe type.

Actuators and positioners are only discussed briefly. Refer

to the individual manuals for further information on their

installation, operation and maintenance.

1.2 Valve construction

Series AS, Angle Steam Conditioning, Combination type

valves are flanged (weld end available) single seated sliding

stem control valves.

The valve seat ring and cage and plug with stem is a mod-

ule accessible through the bonnet opening (top entry) of

the body.

Our standard design provides a cage guide with a piston

type plug with a quick change seat ring. The two split cages

and inserted plug seal ring makes strong support to ensure

valve alignment.

This series is available with series of reduced Cv trims and

the standard seat tightness is class III~IV, optional trims can

meet to class V, ANSI/FCI 70-2.

The detailed structure is revealed by the type code shown

on the valve identification plate. The type code is explained

in Section 11.

Fig. 1 Construction of the Neles Angle Steam Conditioning

Valve, Series AS

1.3 Valve markings

The body markings are: manufacturer's trademark, nominal

size, pressure rating and material of the body. The valve has

an identification plate attached to it, see Fig. 2.

Fig. 2 Identification (name) plate example

Markings on the identification plate:

1. Type designation (Valve code)

2. Size, Rating

3. Cv

4. Body material

5. Plug, Stem material

6. Seat material

7. Temp. min./max.

8. Maximum (shut-off) pressure

9. Valve manufacturing date

10. Tag No.

11. Serial No.

1.4 Technical specifications

Face-to-face length: customized dimensions depending on

the customer spec.

Body rating: Class 150 to Class 900

Max. pressure differential:

acc. to pressure class

Temperature range: amb. to +593 °C (depending on the

body materials and bonnet type)

Flow direction: indicated by an arrow on the body

(normally flow to close)

Actuator mounting: threaded bonnet with yoke nut or

bolted yoke

Stem connection: clamp with bolts/nuts

Dimensions: see Section 10

Weights: see Section 10

Note that the max. shut-off pressure is based on the mechan-

ical maximum differential pressure at ambient temperature.

You must always observe the fluid temperature when decid-

ing on applicable pressure values. When selecting a valve

you must also check the noise level, cavitation intensity, flow

velocity, actuator load factor, etc. using Nelprof.

1.5 Valve seat leakage classification

The valve follows the seat leakage classifications of ANSI/

FCI 70-2 requirement.

1.6 Recycling and disposal

Most valve parts can be recycled if sorted according to

material. Most parts have a material marking. A material list

is supplied with the valve. In addition, separate recycling

and disposal instructions are available from the manufac-

turer. A valve can also be returned to the manufacturer for

recycling and disposal for a fee.

NOTE:

Selection and use of the valve in a specific application

requires close consideration of detailed aspects. Due to

the nature of the product, this manual cannot cover all the

individual situations that may occur when the valve is

used.

If you are uncertain about use of the valve or its suitability

for your intended purpose, please contact Metso.

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44 GV 76 en

1.7 Safety precautions 2 TRANSPORTATION, RECEPTION AND

STORAGE

Check the valve and the accompanying devices for any

damage that may have occurred during transport.

Store the valve carefully before installation, preferably

indoors in a dry place.

Fig. 3 Lifting the valve

Do not remove the flow port protectors until immediately

before installation of the valve into the pipeline.

The valve is delivered in the closed position. A valve

equipped with a spring-return actuator is delivered in the

position determined by the spring.

3 VALVE INSTALLATION

3.1 General

Remove the flow port protectors and check that the valve is

clean inside.

3.2 Installation into the pipeline

3.2.1 Pipeline cleaning

Make sure no foreign particles, such as sand or pieces of

welding electrode, are in the pipeline, they may damage

the sealing surfaces.

CAUTION:

Do not exceed the valve performance limitations!

Exceeding the limitations marked on the valve may cause

damage and lead to uncontrolled pressure release.

Damage or personal injury may result

CAUTION:

Do not dismantle the valve or remove it from the pipe-

line while the valve is pressurised!

Dismantling or removing a pressurised valve will result in

uncontrolled pressure release. Always isolate the relevant

part of the pipeline, release the pressure from the valve

and remove the medium before dismantling the valve.

Be aware of the type of medium involved. Protect yourself

and the environment from any harmful or poisonous sub-

stances. Make sure that no medium can enter the pipeline

during valve maintenance.

Failure to do this may result in damage or personal injury.

CAUTION:

Beware of the plug movement!

Keep fingers, other parts of the body, tools and other

objects out of the open flow port. Leave no foreign

objects inside the pipeline. When the valve is actuated,

the plug functions as a cutting device. Close and detach

the actuator pressure supply pipeline for valve mainte-

nance. Failure to do this may result in damage or personal

injury.

CAUTION:

Protect yourself from noise!

The valve may produce noise in the pipeline. The noise

level depends on the application. It can be measured or

calculated using the Metso Nelprof software. Observe the

relevant working environment regulations in terms of

noise emission.

CAUTION:

Beware of a very cold or hot valve!

The valve body may be very cold or very hot during use.

Protect yourself against cold injuries or burns.

CAUTION:

When handling the valve or the control valve assem-

bly, take its weight into account!

Never lift the valve or control valve assembly by the positi-

oner, the limit switch or their piping.

Place the lifting ropes securely around the valve body (see

Fig. 3). Damage or personal injury may result from falling

parts.

NOTE :

*. Only acceptable case-3, when lift and move the valves;

1)up to outlet 6"- 300# body with VD (Diaphragm type)

actuators

2) up to outlet 10"- 300# body with VC (Cylinder type)

actuators

In the above two cases the lifting is limited to max. height

of 1.0 m and max. moving distance of 70 m.

CAUTION:

When handling the valve or the control valve assem-

bly, take its weight into account!

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4 GV 76 en 5

3.2.2 Installation valve

The valve has an arrow indicating the flow direction. Install

the valve in the pipeline so that the flow direction of the

valve corresponds to the flow direction marked on the pipe.

The mounting orientation of the valve should be vertical

position as it shown on Fig.4.

Choose flange gaskets according to the operating conditions.

Fig. 4 Installing the control valve into pipeline using supports

Do not attempt to correct a pipeline misalignment by

means of flange bolting.

Loads on the valve body from pipeline vibrations can be

reduced by supporting the pipeline properly. Reduced

vibration also increases the lifetime of the positioner.

Where necessary, you can support the valve by the body, using

regular pipe clamps and supports. Do not fasten supports to

the valve or flange bolting or to the actuator, see Fig. 4.

3.2.3 Hydrostatic testing and Line flushing

When the line is hydrostatic test and flushing, the control valve

should not used as an isolating valve. Make sure the control

valve always be opened position before start this process.

Otherwise valve and trim damage or failure of the seals could

result.

Flushing and hydrostatic test kit can be purchased from Metso.

3.3 Control valve assembly

Check all joints, piping and cables.

Check that the actuator stop screws, positioner and limit

switches are calibrated. Refer to their installation, mainte-

nance and operating manuals.

3.4 Valve insulation

If necessary, the valve may be insulated. Insulation must not

continue above the upper level of the valve body, see Fig. 5.

Fig. 5 Insulation of the valve

4 MAINTENANCE

4.1 General

The Neles series AS, Angle Steam Conditioning valve

require regular maintenance. Check the gland packing for

leakage. This section outlines the maintenance that can be

carried out by the user.

The numbers in parentheses refer to the parts lists and the

exploded views of the valve in Section 9.

4.2 Gland packing adjustment

In the event of a packing leakage tighten the gland nuts

(18) in ¼ turn steps each until the leakage is stopped. Do

not tighten more than necessary.

CAUTION:

Flushing trim kit should be installed in the valve (espe-

cially 'Tendril & Omega trim' application) to protect the

original trim and the flow passages while the valve

installation and line flushing. Unless this caution could

result in clogging trim, low flow rates, unstable control,

valve leakage and exessive noise and other trouble.

CAUTION:

Observe the safety precautions listed in Section 1.7

before starting work!

CAUTION:

When handling the valve or the control valve assem-

bly, take its weight into account!

NOTE:

If you send the valve to the manufacturer for repair, do not

dismantle it. Clean the valve carefully, including the inside.

For safety reasons, inform the manufacturer of the nature

of the medium when you send the valve.

NOTE:

Always use original spare parts to make sure the valve

functions as intended.

Insulation limit

64 GV 76 en

4.3 Replacing the gland packing

Fig. 6 Gland packing

Make sure the valve is not pressurised.

Remove the actuator from the valve stem according

to the instructions given in the actuator manual.

Loosen and remove the hexagon nuts (18).

Remove the gland flange (9b), and gland (9a) up to

the valve stem.

Remove the old packing rings (69) using a pointed

tool, avoid damaging the seal surfaces and valve stem.

Clean the packing ring counterbore.

Mount the new packing rings one by one into the

packing gland box using the gland as a tool and

mount the gland with hand-tightened nuts.

Fasten the gland with the hexagon nuts (18) and

tighten them.

Check leakage when the valve is pressurised.

Fig. 7 Tightening sequence of the bonnet nuts

4.4 Replacing the trim and body

reassembly

Make sure the valve is not pressurised.

Remove the actuator from the valve stem according

to the instructions given in the actuator manual and

next Section 6.

Remove the hexagon nuts (18) slightly.

Remove the hexagon nuts (17).

Remove the bonnet (8)

Remove the cage guide (16), cage (15) and the seal

ring (64). Avoid from damaging the seal ring

between the cage and cage guide.

Remove the body gasket (65 & 65a), one piece of

seat ring (7) and diffuser (81), seat gasket (63).

Remove the hexagon nuts (18), gland flange (9b)

and gland (9a).

Remove the old packing rings (69).

CAUTION:

Do not dismantle the valve or remove it from the pipe-

line while the valve is pressurised!

NOTE:

The trim set consists of the seat ring, valve plug and stem,

retainer and gaskets(for seat ring and bonnet).

Standard construction

Low Emission with

Live Load Spring

Table 1 Required torques for bonnet nuts

Valve Size Rating

(ANSI)

Bonnet Stud Bolts Required Torques

(± 5 % allowable)

mm in Size Q`ty

Carbon Steel

Bolts St. Steel Bolts

Nm lbf ft Nm lbf ft

50 2

150-300 1/2"-13UNC 8 101 74 80 59

600 1/2"-13UNC 8 158 116 123 90

900 7/8"-9UNC 8 199 146 199 146

1500 7/8"-9UNC 8 286 210

80 3

150-300 3/4"-10UNC 8 176 129

136 100

600 3/4"-10UNC 8 211 155

900 1-1/8"-8UNC 8 558 409

1500 1-1/8"-8UNC 8 792 581

100 4

150-300 7/8"-9UNC 8 222 163

160 118

600 7/8"-9UNC 8 327 240

900 1-1/4"-8UNC 8 867 633

1500 1-1/4"-8UNC 8 1339 982

150 6

150-300 1"-8UNC 8 316 232 291 214

600 1"-8UNC 12 327 240

900 1-1/2"-8UNC 12 1192 874 942 691

1500 1-1/2"-8UNC 12 1456 1068

200 8

150-300 1-1/4"-8UNC 8 478 351 478 351

600 1-1/4"-8UNC 12 653 479 653 479

900 1-5/8"-8UNC 12 1676 1229 1140 836

1500 1-5/8"-8UNC 12 1870 1372

250 10

150-300 1-1/4"-8UNC 12 486 356 486 356

600 1-1/4"-8UNC 16 909 667 716 525

900 1-3/4"-8UNC 12 2059 1510

300 12

150-300 1-1/2"-8UNC 12 729 535

729 535600 1-1/2"-8UNC 12 1317 966

900 1-1/2"-8UNC 16 1408 1032

350 14

150-300 1-1/2"-8UNC 12 875 642

875 642600 1-1/2"-8UNC 12 1581 1160

900 1-1/2"-8UNC 16 1689 1238

400 16 150-300 1-1/2"-8UNC 12 1529 1121 980 719

600 1-1/2"-8UNC 16 1426 1046

500 20 150-300 1-3/4"-8UNC 20 1816 1332 1725 1265

600 1-3/4"-8UNC 24 2107 1545 2001 1468

600 24 150-300 1-3/4"-8UNC 20 1923 1410 2491 1827

600 1-3/4"-8UNC 24 2216 1625 2105 1544

NOTE:

The standard is ‘quick change seat type’, other design has

a ‘weld seat type’ according to weld seat ring on the body

side.

NOTE:

The standard is one piece with seat ring (7) and the

diffuser (81) by welded, other design has a separated type

according to weld diffuser on the body side.

NOTE:

If the valve have excess leakage, the plug and seating

surface need lapping and cleaning.

NOTE:

‘Omega’ Disk Stack Cage Cleaning

The welded ‘Omega’ disk stack cage is not available

disassembling, make sure the ultrasonic cleaning in the

frequency range of 250 ~ 400 kHz and Min. duration

60 min.

4 GV 76 en 7

Clean the body gasket surface.

Insert a new seat gasket (63) and the seat ring (7) &

diffuser (81) kit into the body.

Install the cage (15), seal ring (64), cage guide (16)

and plug stem assembly (3, 5, 6) very carefully.

Insert the body gasket (65 & 65a).

Mount the bonnet on the body carefully maintaining

alignment with the plug and the stem and with the

retainer (or cage) in the closed position, so that the

bonnet position in relation to the body is the same

as the original position.

Insert the hexagon nuts (17) into stud (13) and

slightly fasten the nuts.

Insert the packing rings (69) according to above 4.3

Tighten hexagon nuts (17) until plug and seat con-

tact is obtained with proper bolt torque.

Fig. 8 Omega quick change, Standard balanced trim

Fig. 9 Pilot Omega-balanced trim

4.5 Pilot Plug

Disassembly & Assembly

Mount the plug and stem assembly on the chuck to

setting.

Remove the pilot wire (76).

Remove the pilot bolts (75).

Remove the pilot cover (74).

Remove the pilot plug (73) and pilot stem (72) from

pilot main plug (71).

Remove the pilot spring (77) carefully.

Remove the pilot plug (73) and the pilot seat as well

as the surface inside of the pilot main plug (71). If

there is damage, scratches or grooves, it should be

replaced or repaired.

Insert the cleaned pilot spring (77) into the upper

side of main plug.

Install the pilot plug (73) & pilot stem (72) on the

spring (77).

Install the pilot cover (74) and fasten the pilot bolts

(75) keep in balance.

Install wire (76) for connecting the all pilot bolts due

to prevent loose on operation.

4.6 Spray Nozzle

Disassembly & Assembly

Remove the (Spray to Spray) hexagon nuts (87a).

Remove the spray cover (84).

Remove the spray gasket (86).

CAUTION:

Do not reuse the spiral wound gaskets (63 & 65 & 65a),

this is need to be replace each time the valve is disas-

sembled.

CAUTION:

Do not strongly tighten stud nuts at this time

CAUTION:

The all related parts (seat ring, retainer, cage, plug &

stem, bonnet) must be properly aligned in the body.

CAUTION:

Make sure to balance when loose the pilot bolts, and

be careful the spring tension to bounced off the pilot

plug and stem.

84 GV 76 en

Remove the old packing rings (85) using a pointed

tool, avoid damaging the seal surfaces and spray

retainer.

Remove the spray retainer (88) sub-assembly using

by the one of stud (87) carefully.

Grind welded point between the spray nozzle sub-

assembly (detail ‘a’, 89a~d) and the spray retainer (88).

Remove the spray nozzle sub-assembly (detail ‘a’,

89a~d) from the spray retainer (88) and replace them

by new one.

Re-weld one point the spray nozzle sub-assembly

(detail ‘a’, 89a~d) and the spray retainer (88).

Clean the body gasket surface.

Install the new or repaired spray retainer (88) sub-

assembly using by the one of stud (87) carefully.

Mount the new packing rings (85) one by one into

the packing gland box using the gland as a tool.

Insert a new spray gasket (86) into the spray retainer

(88).

Install the spray cover (84).

Tighten hexagon nuts (87a).

Fig. 10 Integral Spring loaded injection type spray nozzle

4.7 ‘GS’ Desuperheater

Disassembly & Assembly

Remove the (housing) hexagon nuts (96a).

Remove the housing bonnet (95) sub-assembly care-

fully.

Remove the flange gasket (97).

Grind welded point between the spray nozzle sub-

assembly (detail ‘a’, 89a~d) and the spray nozzle (89).

Remove the spray nozzle sub-assembly (detail ‘a’,

89a~d) from the spray nozzle (89) and replace them

by new one.

Fig. 11 Globe PCV + Desuperheater type

CAUTION:

Do not reuse the spray nozzle sub-assembly (detail ‘a’,

89a~d), this is need to be replace each time the valve is

disassembled.

CAUTION:

Do not reuse the spiral wound gasket (86), this is need

to be replace each time the valve is disassembled.

4 GV 76 en 9

Fig. 12 Different trim designs

Re-weld one point the spray nozzle sub-assembly

(detail ‘a’, 89a~d) and the spray nozzle (89).

Clean the flange gasket surface.

Insert the spray gasket (86).

Install the new or repaired spray nozzle (89) sub-

assembly carefully.

Tighten hexagon nuts (96a).

5 TESTING THE VALVE

We recommend that the valve body is pressure-tested after

the valve has been assembled.

The pressure test should be carried out in accordance with

an applicable standard for the pressure rating. The valve

must be in the open position during the test.

Omega quick change, Standard balanced trim Omega quick change, Pilot balanced trim

Tendril multi-stage Tendril multi-stage Pilot balanced trim

CAUTION:

Do not reuse the spray nozzle sub-assembly (detail ‘a’,

89a~d), this is need to be replace each time the valve is

disassembled.

CAUTION:

Do not reuse the spiral wound gasket (86), this is need

to be replace each time the valve is disassembled.

CAUTION:

Make sure same direction to be cooperate the lines

with the flange of desuperheater housing (80) and

housing bonnet (95) for avoid miss arrangement of

spray nozzle direction (see Detail ‘b’ of fig. 11).

CAUTION:

Pressure testing should be carried out using equip-

ment conforming to the correct pressure class!

10 4 GV 76 en

6 REMOVAL & MOUNTING THE

ACTUATOR

The actuator is attached to the valve according to the manual

for actuator with body assembly and plug stem adjustment.

Several types of Metso actuators can be used with suitable

clamps. Refer to the model VD spring-diaphragm and VC

double acting cylinder actuator manuals for further informa-

tion on their installation, maintenance and operation.

A. Actuator removal for VD Reverse<air to open, stem

retract> actuator (Fig. 13)

Lift up to the valve plug 100% from the seat ring,

using by specified air pressure.

Loosen the stem lock nut (5**) and socket head

screws (1a**) and hexagon nuts (1b**).

Remove the clamp (1**).

Shut off and disconnect air supply line.

Support actuator with the suitable lifting device.

Remove the yoke nut (3**).

Remove the actuator from the valve body assembly.

B. Actuator replacement (mounting) for VD Reverse<air

to open, stem retract> actuator (Fig. 13)

Mount the new or repaired actuator on top of the

bonnet, using a suitable lifting device.

Insert the yoke nut and tightly fasten the yoke by

turning the yoke nut clockwise using tightening

tools.

Connect air line and accessories.

Lift the top stem (18), using by specified air pressure.

Adjustment stem length after clamping the

clamp (1**) according to rated travel(stroke) as

‘open’ and ‘close’ position as per pressurizing and

depressurizing the lower diaphragm chamber.

Tighten stem socket head screws (1a**) and hexa-

gon nuts (1b**) with stem lock nut (5**).

C. Actuator removal for VD Direct<air to close, stem

extend> actuator (Fig. 13)

Shut off and disconnect the air supply lines and

accessories.

Loosen stem lock nut (5**) and stem socket head

screws (1a**) and hexagon nuts (1b**).

Remove the clamp (1**).

Support actuator with the suitable lifting device.

Remove the yoke nut (3**).

Remove the actuator from the valve body assembly.

Fig. 13 VD Actuator

CAUTION:

Beware of the plug movement!

Do not use air pressure higher than what specified on the

identification plate.

Direct Action actuator

(Air to Close, stem extend)

Reverse Action actuator

(Air to Open, stem retract)

VD Actuator part

1. YOKE 10. LOWER CASE 18 TOP STEM 20. UPPER CASE

21. LIFTING EYE NUT 22. WASHER 23. HEXAGON SCREW 24. HEXAGON SCREW

25. HEXAGON NUT 30. IDENTIFICATION PLATE 32. INDICATOR 32a. ROUND HEAD SCRREW

34. VENT CAP 99. AIR SUPPLY PORT

V-A (Valve-Actuator) Mounting Part (**)

1** CLAMP 1a**SOCKET HEAD SCREW

1b** HEXAGON NUT 3**YOKE NUT (see above VD g.)

5** STEM LOCK NUT 6** LOCK WASHER

This manual suits for next models

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