USER INSTRUCTIONS

Valtek ShearStream SB Control Valves

V Installation
Segmented V-port Ball Valves Operation
FCD VLENIM4152-01 07.09 Maintenance

Experience In Motion
 ShearStream SB FCD VLENIM4152-01 07.09

Contents

General 1
Lifting 2
Receiving inspection 3
Installation 4
Flange gaskets 5
Starting up 6
List of materials and spare parts 7
Ordering of spare parts 8
Maintenance 9
To remove the valve from the pipework 9.1
To inspect the ball sector and seat ring 9.2
To inspect and replace the upper shaft
seal of Safeguard type 9.3
To inspect and replace the upper shaft
seal of ZebraCL™ type 9.4
To change the gasket at the lower stem 9.5
Fitting the actuator to the valve 10

1. General 3. Receiving Inspection

The instructions and list of spare parts are applicable to All valves leaving our plant are inspected and tested in
ShearStream SB ball sector valves in accordance with accordance with the relevant requirements or in accor-
catalogue sheet FCD NFEETB4152-01. dance with the requirements specified by the purchaser.
Valves equipped with actuators are subject to functional
testing and are adjusted in such a manner that every unit
2. Lifting is completely ready for direct installation in the pipework.
All lifting must be carried out on the valve itself and not However, in view of damage that may have occurred
on the actuator. The joint between the valve and the actua- during transport, it is advisable that receiving inspection
tor is designed for carrying the operating torque and the is performed.
weight of the actuator - see Fig. 1. We would suggest the following inspection procedure:

- Check that the valve delivered is correct in

terms of type, size, equipment, etc.

- Examine the valve, actuator and valve positioner

regarding possible damages.

Fig.1 Lifting of the valve

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 ShearStream SB FCD VLENIM4152-01 07.09

4. Installation
Before installing the valve, ensure that the pipework is
free from impurities, that the pipe ends between which
the valve is to be installed are parallel and are correctly
aligned, and that the distance between the pipe ends
corresponds to the valve length, including gaskets. The
valve could not be used for forcing together or aligning
incorrectly pipes as this will cause loads on the valve
and pipe which may lead to difficult damages during
operation. See Fig. 3.

Wrong installation Correct installation

Fig. 3. Ensure that the pipe ends align and have the correct distance

ShearStream SB valves can be installed in any position.

However, we recommend the direction of flow which
is shown by an arrow on the valve body. The sealing
performance of the valve is limited if the flow is in the
opposite direction.

We also recommend that the valve is mounted with

the stem pointing vertically upwards when the valve is
installed in a horizontal run of pipe.

The pipes should be supported on each side of the

valve, in order to relieve the valve of loads and avoid
vibrations.

Locate the valve so that it will be easily accessible for

inspection and service, particularly if the valve is equipped
with a pneumatic actuator and valve positioner.

5. Flange Gaskets
Gaskets with sizes according to ANSI B16.5, Table E1
Figure E2, SS 359 or DIN 2690 are recommended.

6. Starting up
Before starting up, flush the pipework - with all valves
in the open position - so that any impurities that may
damage the sealing surfaces of the valve and impede its
operation will be flushed away.

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 ShearStream SB FCD VLENIM4152-01 07.09

Seat ring
7. List of Materials and Spare Parts
Item Qty Part Material Metal Soft
1 1 Body EN1.4408/CF8M 12 12
1 1 Body EN1.0619/WCB 10 10
2 1 Ball sector EN1.4408/CF8M HCP
11 29
2 1 Ball sector EN1.4408/CF8M
2 2
3 1 Stem, upper EN1.4460
4 1 Stem, lower EN1.4460
Stem sealing
5 1 Gland cover EN1.4408/CF8M
6 1 Bottom cover EN1.4408/CF8M 14
7 1 Gasket Graphite
8 1 Locking segment EN1.4436
9 1 Bearing seat EN1.4460
10 1 Wave spring EN1.4436
11 1 Seat ring Alloy 6
12 1 Seat seal PTFE
13 1 O-ring FPM 13
14 1 Backing ring PTFE
117 22 117 22
17 2 Screw A4
18 2 Nut A4 118 118
21
19A 1 Boxpacking Safeguard V-ring PTFE liveloaded
13 13
19B 1 Boxpacking Zebra-CL V-ring PTFE
20 4 Bolt A4
5 5
21 1 Cap spring EN1.4310
22 1 Key Steel
119B
B 19A
23 1 Indicating pin SS
8
26 1 Washer A4 8

27 1 Thread insert Stainless 9 9

28 1 Bolt A4
29 1 Seat ring/Back-up ring PTFE/SS
30 1 Stem bearing Metaloplast
Zebra-CL Safeguard
31 1 Stem bearing Metaloplast
32 1 Washer A4 22

33 1 Cylindrical pin EN1.4460 3

32
34 1 Washer Metaloplast 23
30

27
2
26
28

33

31
1
34

4 6 7 20

4 Fig. 4. ShearStream SB - spare parts, types of stem sealings and seat rings
 ShearStream SB FCD VLENIM4152-01 07.09

8. Product code for important spare parts and spare parts sets
Set or detail
Stem sealing set Seat ring set Other spare parts
Type Zebra CL ™ Safeguard Alloy 6 PTFE
Item No 19A 19B 11, 12 12, 29 7 10
DN
25 349 08 050 349 25 540 349 08 080 349 17 460 348 88 295 333 98 460
0040 349 08 050 349 25 540 349 08 081 349 17 461 348 88 295 333 98 461
0050 349 08 050 349 25 540 349 08 082 349 17 462 348 88 295 333 98 462
0065 349 08 050 349 25 540 349 06 089 349 17 469 348 88 295 333 98 469
0080 349 08 050 349 25 540 349 08 083 349 17 463 348 88 294 333 98 463
0100 349 08 050 349 25 540 349 08 084 349 17 464 348 88 294 333 98 464
0150 349 08 051 349 25 500 349 08 085 349 17 465 348 88 290 333 98 465
0200 349 08 052 349 25 720 349 08 086 349 17 466 348 88 291 333 98 466
0250 349 08 053 349 25 760 349 08 087 349 17 467 348 88 292 333 98 467
0300 349 08 054 349 25 140 349 08 088 349 17 468 348 88 293 333 98 468
0350 - 349 25 180 349 17 430 349 20 030 349 15 260 333 00 430
0400 - 349 25 180 349 17 431 349 20 031 349 15 260 333 00 431
0500 - 349 25 180 349 17 432 349 20 032 349 15 261 333 00 432

* Three rings are requested per valve for DN 25 - 100, four rings per valve for DN 150 - 300

8.1 Ordering of Spare Parts 9.1 To remove the valve from the pipework
When placing orders for spare parts, specify: The procedure for inspection and maintenance, for
1. Product code of the valve - incl. DN, see part No. which no special tools are necessary, is as follows:
specified on the identification plate of the valve. 1. Ensure that the recommended spare parts and
2. Description of the part, its item No. or spare also the gaskets - important - for the pipe
parts set number, and the quantity required. flanges are available.
2. Close the valve.
Ordering example 3. Shut off all compressed air connections
For ShearStream SB 8782EB-0200-AAAABA, and isolate all electrical connections to the
Part. No. 1234567 actuator.
1 - Stem upper, item 3 4. Disconnect all compressed air lines and electric
or cables connected to the actuator.
For ShearStream SB 8782EB-0200-AAAABA, 5. Release the flanged joint between the valve
Part. No. 1234567 and the pipework. Then lift out the valve. Don’t
1 - Stem sealing set, product code 349 08 052 use the actuator for lifting. Apply all lifting
forces to the valve itself and not to the actuator
- see fig. 1.
Note the direction of flow which is shown by an
9. Maintenance arrow on the valve body.
If the ball segment or seat ring has sustained damage due
to impurities in the pipework or for some other reason, or 9.2 To inspect the ball sector and seat ring
if the seat ring and stem seals need replacing after a long 1. If an actuator is fitted to the valve, remove it. See
period of service, the valve must be overhauled. section 9.3, items 1 and 2.
2. Remove the indicating pin (23 - fig. 4).
Many valves are installed in such locations that their 3. Turn the ball sector through more than 90°, until
performance is of decisive importance to the entire it is no longer in contact with the seat ring.
process. Such valves should be inspected regularly and 4. Push the seat ring out of its seat at the valve
any faults should immediately be corrected. body inlet. Withdraw it past the ball sector -
between the ball sector and the inside
of the valve body - towards the outlet, and
remove it from the body.
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 ShearStream SB FCD VLENIM4152-01 07.09

5. Remove the compression spring (10) in the 4. Clean the surfaces of the stem, gland (5) and
same way. packing area in the valve body.
6. Carefully wash all parts with warm water and 5. Carefully examine the surface of the stem which
then, if necessary, with a suitable solvent. Never must be completely free from marks and
scrape the sealing surfaces with hard tools. scratches.
7. Examine the surface of the ball sector (2). 6. Grease the stem with a suitable grease, such as
Remove any deposits and clean the ball sector Silicone grease.
as described in item 6 above. 7. Mount new packing (19). Then mount the gland
(5) and the nuts (18).
N.B. Take care not to scratch the sealing 8. Tighten the nuts (18) sufficiently to ensure that
surface of the ball sector. the packing is correctly seated.
Note: Check the tightness of the packing after the
8. Inspect the seat ring (11) and clean it as valve has been taken into service, retighten the
described in item 6 above. nuts (18), if necessary.
9. Inspect the sealing ring (12) - it need not be
removed from its groove in the body. Fit a new 9.4 To inspect and replace the upper shaft seal of
sealing ring if the original one is damaged. Zebra CL™ type
10. Lubricate the ball segment with a suitable The stuffing box usually requires inspection and adjust-
lubricant, such as Molykote Paste U, Gleitmo ment after the valve has been taken into service.
700 or similar. After a certain period of time in service, it may some-
11. Lubricate the surface of the sealing ring (12) times also be necessary to replace the packing.
with a silicone-base grease, such as Silicone
grease DC 111, Silicone grease TKM 1011 or 1. Remove the actuator as described in section 9.3,
similar. tems 1. Remove the keys (22) and the indicator
12. Fit the compression spring (10) and seat ring (11). pin (23).
Turn the ball sector (2) until it is in contact with 2. Remove the nuts (18), spring cups and gland (5).
seat ring (11). Use a soft object to press the Then remove the packing (19).
seat ring towards the compression spring (10) 3. Clean the surfaces of the stem, gland (5) and
to enable the ball sector to move into its proper packing area in the valve body.
position. Continue turning the sector to the 4. Carefully examine the surface of the stem which
closed position. must be completely free from marks and
13. Fit the indicating pin (23). scratches.
5. Grease the stem with a suitable grease, such as
N.B. An additional function of the indicating Silicone grease.
pin is to restrict the travel of the ball segment 6. Mount new packing (19) when mounting the
to 95 - 100°, so that it will always remain in gland (5) and the spring cups and then the
contact with the seat ring. nuts (18).
7. Tighten the nuts (18) sufficiently according to the
torque table in catalogue sheet FCD NFEETB4152-01
9.3 To inspect and replace the upper shaft seal of to ensure that the packing is correctly seated.
Safeguard type Note: Check the tightness of the packing after the
The stuffing box usually requires inspection and adjust- valve has been taken into service.
ment after the valve has been taken into service.
After a certain period of time in service, it may some- 9.5 To change the gasket at the lower stem
times also be necessary to replace the packing. 1. The gasket (7) should be replaced in conjunction
with the inspection of the seat ring (11).
Make sure that the valve is not under pressure. 2. Remove the bolts (20) and the cover (6).
1. If an actuator is fitted to the valve, remove it. 3. Withdraw the stem (4) and remove the gasket (7).
Begin by removing the valve positioner. This 4. Carefully clean the inside of the cover (6) and the
can easily be done after the plastic cover of the stem (4).
valve positioner has been removed. Remove the 5. Fit a new gasket (7) and lubricate the small end
four bolts securing the valve positioner to the of the stem with a suitable lubricant, such as
actuator. Then remove the nuts securing the Molykote Paste U or Gleitmo 700.
actuator to the valve mounting plate and dismantle 6. Fit the stem (4) with the gasket (7).
the actuator. 7. Spray the bolt threads with locking compound,
2. Remove the key. such as Loctite 641.
3. Remove the nuts (18). Remove the gland (5). 8. Fit the cover (6) and tighten the bolts (20).
6 Then remove the packing (19).
 ShearStream SB FCD VLENIM4152-01 07.09

10. Fitting the Actuator to the Valve

1. The actuator can be mounted directly on the
valve. The mounting flange and the valve stem
follow the NAF standard for securing the
actuator. 11 2
2. Turn the valve to the closed position. The key
should face towards the inlet.
3. Fit the actuator. 3
4. Connect the compressed air supply to the
actuator - applies to pneumatic actuators. If the
end position stop is correctly set, the ball
segment will not move when compressed air
pressure is applied.
5. If moving - adjust the end position stop until the
actuator has turned the ball segment to the
closed position.
Fig. 5. Locating of the ball sector sphere when
6. General adjusting the actuator
The actuator may be fitted either in line with the
connected pipes or transversely to them. An
intermediate plate is necessary for mounting the
actuator in line with the pipework.

N.B. The direction of closure must always be

clockwise, as viewed from the actuator.

Before fitting the actuator, it is important to ensure that

the actuator fits the stem. First try without key to check
that the drive slips onto the shaft. Also check that the
key fits and matches the keyways in the shaft. Grease the
actuator shaft entry. Push the actuator onto the stem.

The travel of the ball sector should be restricted to 90°,

which is the travel necessary between fully open and
fully closed. If the sector is turned beyond this range,
the sealing surfaces of the sector and seat ring may
be damaged when an attempt is made to turn the
ball sector back to the correct position and the sector
may jam against the seat ring.
In practice, this is prevented by the indicating pin which
will come into contact with the bolts retaining the top
cover if an attempt is made to turn the ball sector outside
the range between fully open and fully closed. When
adjusting the actuator, make sure that, in the closed posi-
tion, the sphere of the ball sector (2) is located opposite
the seat ring (11), i.e. that the sphere projects beyond the
seat ring by equal amounts on each side of the seat as
shown in Fig. 5.

7
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