18
MegaStream
Control Valves
GENERAL INSTRUCTIONS
The following instructions are designed to assist in the placed in-line before the valve to catch debris prior to
disassembly, reassembly and troubleshooting of it reaching the MegaStream valve.
MegaStreamTM attenuators in Valtek® valves. Product WARNING: Improper installation will result in ex-
users and maintenance personnel should thoroughly cessive noise, causing possible damage to valve
review this bulletin in conjunction with Installation, parts or injury to personnel.
Operation, Maintenance Instructions 1 (Mark One and
Two Control Valves) before installing, operating or DISASSEMBLY AND REASSEMBLY
performing any maintenance on the valve.
Disassembling Unbalanced MegaStream
This publication does not contain information on install-
ing, maintaining, troubleshooting, calibrating, and oper- Refer to Figure 1 and proceed as follows:
ating Valtek positioners. Refer to the appropriate Main- WARNING: Depressurize line to atmospheric pres-
tenance Instructions when this information is required. sure and drain all fluids before working on the
valve. Failure to do so can cause serious injury.
To avoid possible injury to personnel or damage to
valve parts, WARNING and CAUTION notes must 1. Fully retract plug until stem clamp is pointing to the
be strictly adhered to. Modifying this product, open position on the actuator stroke plate.
substituting nonfactory parts, or inferior parts, or 2. Remove bonnet flange bolting and lift actuator, bon-
using maintenance procedures other than outlined net and plug assembly out of the valve body. Re-
could drastically affect performance and be move the bonnet gasket.
hazardous to personnel and equipment. WARNING: A hoist may be necessary for larger
MegaStream attenuators are designed to reduce gase- actuators (size 50 and larger). Care must be
ous noise in automatic control valves through staged taken to lift the actuator and plug straight out of
pressure reduction and turbulence control. Mega- the valve body. Any scraping of parts while
Stream valves have two basic designs: A one- or two- removing the actuator may damage valve parts.
stage attenuator for low to moderate pressure drop When the actuator is not equipped with a lifting
services and a multi-stage attenuator for high pressure ring, do not attach one; instead, lift the actuator
drop applications. Pressure-balance designs are avail- by using lifting straps through the yoke legs. In
able in both types. this case, the center of gravity may be above the
lifting point. Therefore, support must be given to
Installation prevent the actuator from rotating; otherwise,
Standard unpacking and installation instructions are out- serious injury may result.
lined in Installation, Operation, Maintenance Instructions 3. With the actuator, bonnet and plug removed, the
1. Regardless of the air-action, it is imperative that valves attenuator can be lifted out of the valve body. In larger
equipped with MegaStream attenuators be installed in sizes, the attenuator may be too heavy to lift without a
the line with the flow direction under the plug. It is also hoist; in this case, tapped holes are machined into the
strongly suggested that during start-up, a strainer be top of the attenuator for installation of lifting rings.
Rev. 6/89 Valtek Part No. 10076401 1
Bonnet Bonnet Flange Bolting
(Item No. 40) (Item No. 108/114)
Bonnet Gasket Bonnet Flange
(Item No. 58) (Item No. 70)
Body Attenuator
(Item No. 1) (Item No. 30)
Seat Ring Plug
(Item No. 20) (Item No. 50)
Seat Ring Gasket
(Item No. 55)
Figure One: Unblanced MegaStream Assembly
NOTE: Item numbers correspond directly to valve's bill of material. Refer to it for specific part numbers.
4. Remove the seat ring and seat ring gasket. CAUTION: The bonnet aligns closely to the
body. Damage could result from misalignment
5. The attenuator may now be cleaned according to
of the plug and attenuator; therefore, extreme
established industry methods. If uncertain as to
caution should be exercised in this operation to
which methods to use with a particular attenuator
make sure it is installed squarely.
and application, contact factory.
5. Once the actuator is resting on the body, tighten the
bonnet flange bolting fingertight.
Reassembling Unbalanced MegaStream
Refer to Figure 1 and proceed as follows: 6. Seat the plug two or three times to center the seat
ring. This can be done by applying air to the actuator.
1. Install a new seat ring gasket and reinstall seat ring.
7. Leaving the plug in the extended (or closed) position,
NOTE: Bonnet and seat ring gaskets should be begin tightening the bonnet flange bolting in a criss-
replaced each time the valve is disassembled. cross pattern that will keep the bonnet square with
2. Install the cleaned attenuator, making sure the hole the body. Tighten the first bolt 1/6 turn, then tighten
pattern closest to the edge is situated at the bottom the bolt directly opposite 1/6 turn.
(by the seat ring). 8. Continue tightening all bolts until the bonnet is firmly
3. Replace bonnet gasket. seated, metal-to-metal, in the body. This can be
4. Fully retract the plug (stem clamp indicator pointing easily felt through the wrench.
to the open position) and lower the actuator, bonnet 9. Slowly stroke the plug up and down to check the
and plug squarely into the body and attenuator. alignment of the plug with the attenuator.
2
Bonnet
(Item No. 40)
Bonnet Flange Bolting
Sleeve Gasket (Item No. 108/114)
(Item No. 56)
Bonnet Flange
Bonnet Gasket (Item No. 70)
(Item No. 58)
Sleeve
Body (Item No. 31)
(Item No. 1)
Attenuator
Seat Ring (Item No. 30)
(Item No. 20)
Plug Seals
(Item No. 65)
Plug
(Item No. 50)
Seat Ring Gasket
(Item No. 55)
Figure Two: Pressure-balanced MegaStream Assembly
NOTE: Item numbers correspond directly to valve's bill of material. Refer to it for specific part numbers.
Disassembling Pressure-balanced this case, the center of gravity may be above the
lifting point. Therefore, support must be given to
MegaStream
prevent the actuator from rotating; otherwise,
Refer to Figure 2 and proceed as follows: serious injury may result.
WARNING: Depressurize line to atmospheric pres- WARNING: Danger exists in removing the actua-
sure and drain all fluids before working on the tor, bonnet and plug–especially if Teflon pres-
valve. Failure to do so can cause serious injury. sure-balanced seals are used. The attenuator
1. Fully retract plug until indicator is pointing to the sleeve may stick to the plug and fall during
open position. disassembly, causing possible serious injury
2. Remove bonnet flange bolting and lift the actuator, and/or damage to the valve or nearby equipment.
bonnet and plug out of the valve body. A hoist may Steps 3 thru 6 must be followed before attempt-
be necessary for larger valves. ing to remove the plug from the sleeve.
WARNING: A hoist may be necessary for larger 3. If the sleeve is observed sticking to the plug during
actuators (size 50 and larger). Care must be removal, do not attempt to lift the plug and sleeve out
taken to lift the actuator and plug straight out of of the body.
the valve body. Any scraping of parts while 4. Fully extend the plug, allowing the bonnet to raise
removing the actuator may damage valve parts. above the body.
When the actuator is not equipped with a lifting 5. Place wooden blocking of equal thickness in at least
ring, do not attach one; instead, lift the actuator three places between the sleeve and bonnet. Re-
by using lifting straps through the yoke legs. In tract the plug until it is freed from the sleeve.
3
6. Lift the actuator bonnet and plug assembly from inches to allow the use of a ring compressor on the
body, taking care not to damage the sleeve bore or metal rings. A suitable sized screw-type hose clamp
plug head. will also serve to compress the rings for reassembly.
7. Remove the sleeve attenuator, seat ring and gaskets Care should be taken to avoid damaging the sealing
from the body. surfaces while fitting the plug into the sleeve bore.
8. The attenuator may now be cleaned according to 4. Once the bonnet is resting on the body, reinstall and
established industry methods. If uncertain as to tighten the bonnet flange bolting fingertight.
which methods to use with a particular attentuator 5. Using the actuator, seat the plug two or three times
and application, refer to factory. to center the seat ring.
6. Leaving the plug in the extended (or closed) posi-
Reassembling Pressure-balanced tion, begin tightening the bonnet flange bolting in a
MegaStream crisscross pattern that will keep the bonnet square
Refer to Figure 2 and proceed as follows: with the valve. Tighten the first bolt 1/6 turn, then
1. Install new seat gasket and reinstall seat ring. tighten the bolt directly opposite 1/6 turn.
NOTE: All gaskets should be replaced whenever 7. Continue tightening all bolting until the bonnet is
the valve is disassembled. firmly seated, metal to metal, in the body. This can
2. Install attenuator and sleeve. Replace bonnet and be easily felt through the wrench.
sleeve gaskets, and plug seals. 8. Slowly stroke the plug up and down to check the
3. Lower the actuator, bonnet and plug assembly alignment of the plug with the attenuator. If binding,
squarely into the sleeve bore. If Teflon seals are sticking or scraping noises are heard, stop stroking
used, the plug may remain retracted. With metal valve immediately. Disassemble the valve to deter-
piston ring seals, the plug must be extended a few mine noise and to detect possible damage.
Troubleshooting MegaStream Control Valves
Problem Probable Cause Corrective Action
Jerky 1. Galling or scoring between 1. Superficial scoring or galling may be removed with a light application
stem travel plug and pressure-balanced of emery cloth; if more serious damage exists, contact factory
sleeve CAUTION: Trim parts are machined to close tolerances which are essential
for correct functioning of the valve; attempting to remove deep scratches
could result in high leakage rates or improper functioning of valve.
2. Overtightened packing 2. Adjust the packing box nuts to slightly over finger-tight (over-tightening
will cause excessive packing wear and high stem friction)
3. Service temperature exceeds 3. Reconfirm service conditions and contact factory
operating parameter of trim design
4. Inadequate air supply 4. Check for leaks in air supply or instrument signal system; tighten any
loose connections and replace any leaky lines
5. Malfunctioning positioner 5. Refer to positioner maintenance instructions
Excessive 1. Insufficiently tightened 1. Refer to “Reassembly” section for correct tightening procedure
leakage bonnet flange bolting
2. Worn or damaged seat ring 2. Disassemble and replace or repair seat ring (for correct procedure on
remachining seat, see Maintenance Instructions 1)
3. Worn or damaged plug seals 3. Disassemble and replace plug seals
4. Worn or damaged gaskets 4. Disassemble and replace gaskets
5. Inadequate actuator thrust 5. Check for adequate air supply to the actuator; if supply is okay, reconfirm
service conditions and contact factory.
6. Incorrectly adjusted plug 6. Refer to Maintenance Instructions 1 for correct plug adjustment
Restricted 1. Dirty attenuator 1. Disassemble and clean attenuator, using established industry
flow cleaning methods
2. Incorrectly adjusted limit- 2. Check stroke limiting device and correct, if necessary
stop or handwheel
Excessive 1. Improper flow direction 1. Check installation for flow direction under the seat; reinstall, if necessary
noise 2. Excessive pressure drop 2. Check design service conditions
3. Jerky or improper stemtravel 3. See corrective action under “Jerky stem travel”
4. Throttling too close to the seat 4. Recommended throttling should be 5 percent or more open
5. Loose parts 5. Check all external bolts and nuts for tightness; if noise is internal,
disassemble, check for damaged, scored parts or missing seat gasket
