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Azbil ACN Series, User Manual

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7.  Maintenance and inspection

Adhere to the following items of Warning and Caution while conducting maintenance or 
inspection.

CAUTION

When leakage from a valve is found, do not come close to the valve 
until safety is assured of. A serious accident or physical injury may occur 
depending on the type of fluid.

WARNING

•   Check gland daily and ensure that there is no leakage from it. Check valve 

operation daily, and confirm that it is not hunting.

•   Make sure that there is no abnormal vibration or noise during operation,
•   When the valve is repaired or disassembled, old parts should be properly 

disposed of as industrial waste. Otherwise, they may contaminate the 
environment.

Check scale

Check for hunting

Inspect gland (leakage)

Inspect gland

connection (leakage)

Check for abnormal

noise or vibration

Fig. S-4.

Summary of Contents for ACN Series

Page 1: ...CM2 ACP100 2001 Control Valves Model ACP_ _ _ ACN_ _ _ User s Manual ...

Page 2: ...ss for a particular purpose and makes no express warranty except as may be stated in its written agreement with and for its customer In no event shall Azbil Corporation be liable to anyone for any indirect special or consequential damages This information and specifications in this document are subject to change without notice 2001 2018 Azbil Corporation All Rights Reserved ...

Page 3: ...ies and words in this guide please read the following explanations before using the device Diaphragm Yoke Bonnet Valve body Flange Actuator Fig S 1 Nomenclature of globe valve Body Valve body Vane or disk Link Actuator Fig S 2 Nomenclature of butterfly valve i ...

Page 4: ...t Handle it with care to avoid damaging it When unpacking check for the following items in the crate Main valve body actuator and accessories as ordered Additional equipment as ordered Installation Options 3 2 Verification of specifications Please check and see if that the process flow fluid conditions and valve Tag No agree with the purchasing specifications The nameplate of each product are foun...

Page 5: ...the crate verify specifications and cover with polyethylene protecting sheet When storing a used valve follow the procedures as described below 1 Flush out the process fluid from inside the valve body and dry 2 When there is a possibility of the valve body rusting preservation treatment should be given 3 To prevent water from getting in the instrument cover pneumatic tubing connection and electric...

Page 6: ...pipe runs Provide a cover or protective fence around valve installation when a valve is installed facing a path or if physical contact with valve is expected Do not install a valve where it may be submerged water or snow or where freezing may take place Provide a wall for protection against heat radiation Provide measures to protect valve against salt spray or corrosive atmospheres To stop operati...

Page 7: ... that the flanges on pipe have been chamfered Remove dust sand welding spatter or any other foreign matter from pipe and clean out pipe Any foreign matter will damage the valve seat and reduces shutoff characteristics Ensure that upstream and downstream pipe supports are sufficiently strong Otherwise the valve s weight may cause leakage from flange connections WARNING Operation of valve over and b...

Page 8: ...ak Always use new gaskets for pipe flanges that will meet process fluid specifications temperature and pressure conditions Otherwise process fluid leakage may occur When flushing pipes keep valve in the fully open position and do not stroke valve Welding spatter or foreign matters may damage valve Weight limit Suspending 1 2 3 4 Tighten diagonally WARNING When installing a valve on a pipe keep han...

Page 9: ...is may block air passage and cause malfunction of valve When using liquid packing seize lock on pneumatic tubing care should be exercised so as not to leak the liquid into tubing It may block the air passage resulting in valve malfunction Avoid electrical work in rainy weather or time of high humidity Any intrusion of water into connector or terminal will cause rusting and electric leakage Covers ...

Page 10: ...m the body ensure that the proper type of specialized tool is used Refer to the instruction manual for proper tools Otherwise the trim may be damaged WARNING Before disassembling the valve ensure that the pressure within piping has been reduced to atmospheric pressure Flow out of process fluid may cause physical injury When disassembling the valve flush out interior of the valve or replace fluid i...

Page 11: ...s use new gaskets Old or reused gasket may cause leakage When assembling trim inner valve ensure that specialized tools are available and use only those which meet specifications WARNING When assembling the valve tighten bolts and nuts at a torque as specified in instruction manual Any damage or corrosion on the bolts or nuts may cause destruction of control valve which will lead to physical injur...

Page 12: ...e of fluid WARNING Check gland daily and ensure that there is no leakage from it Check valve operation daily and confirm that it is not hunting Make sure that there is no abnormal vibration or noise during operation When the valve is repaired or disassembled old parts should be properly disposed of as industrial waste Otherwise they may contaminate the environment Check scale Check for hunting Ins...

Page 13: ...assembly procedure 4 2 4 2 1 2 Inspection 4 2 4 2 1 3 Assembly procedure 4 3 4 2 2 Disassembly and assembly of extension1 bonnet type 230 t 400 C valve body 4 6 4 2 2 1 Disassembly procedure 4 6 4 2 2 2 Inspection 4 8 4 2 2 3 Assembly procedure 4 9 4 3 Disassembly and assembly of actuator 4 11 4 3 1 Disassembly and assembly of model HA2 HA3 or HA4 actuator 4 12 4 3 1 1 Disassembly procedure 4 12 4...

Page 14: ...sassembly and assembly 10 3 Chapter 11 Azbil Low Emission standard compliant gland packing 11 1 11 1 Overview 11 1 11 2 Structure 11 1 11 3 Installation into the gland 11 2 11 3 1 Preparation for installation 11 2 11 3 2 Start of installation 11 3 11 3 3 Retightening 11 6 11 4 Parts List 11 7 Chapter 12 Certified ISO 15848 1 compliant low emission gland packing 12 1 12 1 Overview 12 1 12 2 Structu...

Page 15: ...0100 Model HEP10 11 CM2 HEP100 2001 Model AVP300 301 302 200 201 202 CM2 AVP300 2001 Model AVP701 702 CM2 AVP302 2001 Model AVP703 CM2 AVP303 2001 1 2 Main components of control valves Each control valve is comprised of two main components namely a valve body and an actuator Various combinations of valve body and actuator are available to meet various types of uses with different valve sizes press...

Page 16: ...luid or to let the valve body make up a pressure vessel The valve plug is supported by the guide ring and cage and driven by the actuator The actuator has multiple springs and a diaphragm and converts the pneumatic control signal into a mechanical positional control signal with which to position the valve plug Fig 1 1 Pressure balanced cage type control valve model ACP Fig 1 2 Low noise cage type ...

Page 17: ...alve make sure that the specifications indicated on the nameplate conform to the conditions of use The nameplate also indicates the product number PROD NO of the control valve Please mention this number also when consulting your Azbil Corporation agent for parts replacement or any other modification of the control valve TRIM PLUG BODY RATING SIZE MODEL mm VALVE TAG NO LIFT PACKING AIR TO SUPPLY PR...

Page 18: ...1 4 ...

Page 19: ...orce is applied to the actuator or the valve body 2 2 Installing valve on process pipe 1 Before installing the valve on the process pipe remove foreign substances such as scales and welding chips from both upstream and downstream sides of the process pipe 2 Confirm that the direction of process fluid flow conforms with that of the arrow provided on the valve body 3 Pay attention so that the pipe c...

Page 20: ... 80 20 32 320 18 180 10 100 25 28 280 15 150 30 66 660 36 360 20 200 Note The tightening torques mentioned in the above are only to given as reference values Note that tightening torques may vary depending on the type of packing Table 2 3 Tightening Torques of packing Flange Nuts for PTFE yarn Certified ISO 15848 1 compliant low emission gland packing Model Actuator model Stem size Tightening torq...

Page 21: ...Packing Lubricator Fig 2 1 Gland section 4 If the valve is provided with a lubricator as shown in Fig 2 2 check whether the bonnet section has been lubricated or not To do this loosen the lubricator handwheel and turn the squeeze screw If the squeeze screw turns easily then apply grease following the lubricating procedure mentioned below If the squeeze screw turns stiffly this means that grease ha...

Page 22: ...wheel 5 When pressuring the valve check that there is no leak from the gasket sections between the valve body and process pipe If leakage is found tighten the nuts Especially when the process fluid temperature is 400 C or higher tighten the nuts again after raising temperature of the valve so that it may be in serve for a longer period without requiring immediate maintenance service Standard tight...

Page 23: ...tening procedure is as given in Chapter 2 3 3 on page 2 2 Lubricating the gland Lubricate the gland about once every 6 months The lubricating procedure is as given in Chapter 2 3 4 on page 2 2 Check for hunting of valve position Refer to Chapter 13 Troubleshooting on page 12 1 Check for abnormal noise and vibration Refer to Chapter 13 Troubleshooting on page 12 1 ...

Page 24: ...3 2 ...

Page 25: ...ator stem from the valve stem 3 Remove the clamping nut of the yoke 4 Raise the actuator to detach it from the valve body Precautions To detach the actuator from the valve body which is kept installed in the process pipe be sure to shut down the process fluid and release the process pressure before detaching the actuator 4 2 Disassembly and assembly of valve body To disassemble or assemble the eac...

Page 26: ...plug and then pull out the cage from the valve body 4 2 1 2 Inspection Inspect the disassembled parts for damage If any damages is found replace the parts When ordering parts mention also the Prod No of the valve which is indicated on the nameplate 1 Do not re use the removed gland packing Use fresh packing when reassembling the valve 2 Check and ensure that there is no scar on sliding portions of...

Page 27: ...lug s tip passes through seal ring apply even load on the plug to push it in until the tip of the plug touches and sits against the seat on the cage lower 6 Insert gasket upper into cage upper Apply Never seize on all gaskets except those for degreased valve for oxygen application 7 Put the bonnet on the valve body and check that the bonnet is correctly mated with the indented section of the valve...

Page 28: ...4 4 Table 4 1 Tightening torque of bonnet stud bolts Bolt Torque N m kgf cm M12 60 600 M16 100 1 000 M20 150 1 500 M22 200 2 500 M24 250 2 500 M27 350 3 500 M30 500 5 000 M33 660 6 600 ...

Page 29: ... Stud bolt Gland packing Packing follower Valve plug Valve stem Scraper ring Gasket upper Bonnet Cage upper Cage lower Spiral gasket Gasket lower Seal ring Stud bolt Valve body Fig 4 1 Model ACP ACN control valves ...

Page 30: ...ge nut of the packing Flange 2 Remove the hex nuts of the bonnet extension 1 bonnet using wrench 1 Packign flange nut 2 Packing flange 3 Packing follower 4 Stud blot 5 Bonnet extension 6 Hex nut 1 7 Valve stem 8 Valve plug 9 Carbon ring 10 Gasket upper 11 Cage upper 12 Gasket lower 13 Cage lower 14 Stud bolt 15 Valve body Fig 4 2 Extension 1 230 t 400 С ...

Page 31: ...are extracted together turn the plug and cage upper to remove them from the bonnet exercising care not to damage the stem 7 Please take care not to drop the plug and cage upper Pull out the plug from the bonnet Eyebolt Fig 4 3 4 Pull out the carbon ring 9 from the plug refer to Fig 4 4 Since this breaks easily be careful of handling Carbon ring Fig 4 4 5 Pull out the cage lower 12 using the specia...

Page 32: ... nameplate 1 Check and ensure that there is no scar on gland packing box 2 Check and ensure that there is no scar on sliding portions of plug cage upper cage lower seat face and stem 3 Check and ensure that there is no scar on carbon ring For a guideline on parts replacement refer to Chapter 14 Recommended spare parts 4 Check and ensure that there is no scar on body bonnet and gasket faces ...

Page 33: ...to push it in until the tip of the plug touches and sits against the seat the cage lower Special tool for insert plug Fig 4 6 6 Insert the gasket 10 into cage upper 7 Attach carefully not to throw bonnet at a stem Put the bonnet on the valve body and check that the bonnet is correctly mated with the intended section of the valve body Tighten the nuts uniformly paying attention so that they are not...

Page 34: ...4 10 Table 4 2 Tightening torque of cage lower Nominal size inches Torque N m 1 3 4 255 to 314 2 382 to 461 2 3 4 510 to 617 3 637 to 764 4 784 to 980 5 784 to 980 6 1176 to 1470 8 1470 to 1862 ...

Page 35: ...when installing it on a valve body when modifying its specifications or when replacing damaged parts The disassembly and assembly procedure of the actuator for such purposes are covered in Chapter 4 3 1 Disassembly and assembly of model HA2 HA3 or HA4 actuator on page 4 12 Hex bolt Stem connector Lock nut Pointer Yoke clamping nut Fig 4 7 ...

Page 36: ...uator employs powerful compressed springs and if you remove the bolts and nuts carelessly the springs may leap out causing hazards When removing the bolts and nuts be sure to observe the instructions given for the disassembly and assembly procedures of the actuator and top handwheel 4 3 1 Disassembly and assembly of model HA2 HA3 or HA4 actuator 4 3 1 1 Disassembly procedure a Direct action type S...

Page 37: ...2Dor HA3D Fig 4 9 Actuator Model HA4D Eye bolt Hex bolt Eye bolt Diaphragm case top Hex nut Lock nut Hex nut Lock nut Hex bolt Diaphragm case bottom Pointer Pointer Yoke Diaphragm case top Stem connector Stem connector Diaphragm case bottom Actuator rod Actuator rod ...

Page 38: ...r of eyebolts The initial setting of the springs is done by these eyebolts 5 Remove the diaphragm case Remove the springs 6 Pull the actuator rod upward together with the diaphragm Fig 4 10 Actuator Model HA2R or HA3R Fig 4 11 Actuator Model HA4R Eye bolt Hex bolt Eye bolt Diaphragm case top Hex nut Lock nut Lock nut Hex nut Hex bolt Diaphragm case bottom Pointer Pointer Yoke Yoke Spring Spring St...

Page 39: ...kgf cm Total 16 springs with double springs 3 Insert the actuator rod to which the diaphragm is connected into the bushing exercising care not to damage the bushing inside surface or dust seal with the threaded section of the rod For example cover the threaded section with adhesive tape to prevent damaging the bushing Set the stopper in parallel with the yoke 4 Place the top diaphragm case and fix...

Page 40: ...tape to prevent damaging the bushing 3 Make the stopper in the diaphragm plate in parallel with the yoke by turning the rod 4 Install the springs on the spring plate The quantities of springs are as follows Model HA2 4 springs Model HA3 HA4 8 springs Except particular models as follows Model HA2 38 mm stroke 80 240 kPa 0 8 2 4 kgf cm Total 8 springs with double springs Model HA3 50 mm stroke 80 24...

Page 41: ...the bottom diaphragm case 10 After the assembly is complete as above check the following 1 Applying an air pressure of 490 kPa 5 kgf cm via the air piping connection port of the bottom diaphragm case check the diaphragm periphery for air leak by using soapsuds 2 Check that the actuator smoothly operates at its full stroke unit Note Check this operation by operating the actuator as an independent ...

Page 42: ...m kgf cm No Material For Model HA2 For Model HA3 For Model HA4 1 SK5 S45C M10 37 370 M14 100 1 050 M20 310 3 170 2 S30C M12 42 420 M16 100 1 050 M24 360 3 600 3 S20C M14 69 690 M18 145 1 450 M30 700 7 160 4 S20C M8 16 160 M8 16 160 M12 42 420 5 SUS304 M8 18 185 M8 18 185 M12 63 630 6 S30C M10 37 375 M10 37 375 M12 42 420 56 560 56 560 63 630 ...

Page 43: ... 5 Hex nut SUS304 21 Hex bolt S30C 6 Diaphragm case bottom SAPH370 22 Ssal Washer NBR SPCC 7 Bushing SPCC PTFE 23 Rod packing NBR 8 Bearing S20C 24 Rod SUS304 9 Dust seal NBR 25 Lock nut SUS304 10 Pointer S25C 26 Trus screw spring washer or speed nut SUS304 SUS304 SK5 11 Yoke SCPH2 27 Scale plate SUS304 12 Stem connector S25C 28 Screw SUS304 13 Stem connector Bolt SUS304 S30C 29 Nameplate SUS304 1...

Page 44: ...4 20 ...

Page 45: ...pe 4 Apply to the actuator the maximum air pressure corresponding to the spring range indicated on the nameplate 5 Increase the air pressure once Then increase it again to the maximum value corresponding to the spring range in the increasing direction 6 In the above state align the actuator stem and valve stem in a straight line adjust so that the thread of the stem connector mates with those of a...

Page 46: ...5 2 Actuator stem Yoke Yoke clamping nut Set at maximum or minimum value of spring range for direct or reverse action by moving actuator stem in this direction Valve stem Fig 5 1 ...

Page 47: ...tely the direct type and reverse type of actuators and not to convert actuators into different types However when it has become unavoidable to convert actuators into other types conversions may be done by using the parts mentioned below Table 6 1 on page 6 2 and Table 6 2 on page 6 3 The parts marked are the ones which are newly needed and those marked are ones which are not used ...

Page 48: ...For stroke 38 mm Seal washers 2 82521069 102 82521069 102 82521069 102 Rod packing 1 82521067 102 82521067 102 82521067 102 Rod unit 1 82521431 201 82521063 103 25 mm 82521063 104 38 mm 82521431 204 Rain cap 1 82553334 101 82553334 101 82553334 101 Rod 1 82521428 101 82521428 102 25 mm 82521428 103 38 mm 82521428 104 Model HA4D Model HA4R Part name Qty For stroke 25 mm For stroke 38 mm 50 mm 75 mm...

Page 49: ...For stroke 38 mm Seal washers 2 82521069 102 82521069 102 82521069 102 Rod packing 1 82521067 102 82521067 102 82521067 102 Rod unit 1 82521428 101 82521428 102 25 mm 82521428 103 38 mm 82521428 104 Rain unit 1 82521431 201 82521431 202 25 mm 82521431 203 38 mm 82521431 204 Rain cap 1 82553334 101 82553334 101 82553334 101 Model HA4D Model HA4R Part name Qty For stroke 25 mm For stroke 38 mm 50 mm...

Page 50: ...ifications can be done by using the parts mentioned below Of models HA2 and HA3 there are two different diameters of bonnet connecting sections For these models note the following Of model HA modification for change between read stroke of 14 3 or 25 mm and that of 38mm cannot be done Of model HA3 modification for change between rated stroke of 25or 38 mm and that of 50mm cannot be done ...

Page 51: ...0 0 8 2 4 8 82521206 102 82521209 101 Rod unit R reverse action 1 82521431 202 82821431 203 D Direct action 1 82521428 102 82521428 103 Actuator Model HA4D Model HA4R Part name Qty Stroke 25 mm Stroke 38 mm Stroke 50 mm Stroke 75 mm Scale plate 1 80225037 164 80225039 164 80225041 164 80224425 164 Spring 20 98 0 2 0 1 8 82521244 104 82521207 101 82521207 102 82521210 103 80 240 0 8 2 4 8 82521244 ...

Page 52: ...0 0 8 2 4 Blue 69 8 Blue 90 7 Red and green 103 6 25 20 98 0 2 1 0 Green 68 7 Yellow 89 8 Red 100 3 Yellow and green 148 1 80 240 0 8 2 4 Purple 78 8 Brown 98 3 Blue 108 1 Red and green 155 3 38 20 98 0 2 1 0 Green 93 9 Yellow 103 9 Red 151 8 80 240 0 8 2 4 Purple 107 Brown 115 9 Blue 162 7 50 20 98 0 2 1 0 Green 107 5 Yellow 155 3 80 240 0 8 2 4 Purple 123 2 Brown 169 6 75 20 98 0 2 1 0 Green 162...

Page 53: ...el bears the SHUT mark to indicate that the valve is closed as the handwheel is turned clockwise and the OPEN mark to indicate that the valve is open as the handwheel is turned counterclockwise For automatic operation of the actuator fully raise the handwheel if the actuator is of the direct action type or fully lower the handwheel if the actuator is of the reverse action type and then tighten the...

Page 54: ...w shaft 18 Yoke 32 Compressed coil spring 46 Connection 5 Lock nut 19 Stem connector 33 Spring plate 47 Bearing washer 6 O ring 20 Stem connector bolt 34 Hex bolt 48 Cotter pin 7 Cotter 21 Housing 35 Spring washer 49 Castle nut 8 Nut 22 Bearing 36 Rod 50 Seal washer 9 Diaphragm case top 23 Spring retainer 37 Lock nut 51 Setscrew 10 Eye bolt 24 O ring 38 Truss screw spring washer or speed nut 52 Se...

Page 55: ...8 Lock nut 32 Hex bolt 45 Keybolt 5 Lock nut 19 Yoke 33 Hex nut 46 Setscrew 6 Bearing 20 Stem connector 34 Stopper 47 Setscrew 7 Bearing case 21 Stem connector bolt 35 Hex bolt 48 Spring washer 8 Cotter 22 Housing 36 Spring plate 49 Diaphragm retainer 9 Connection 23 Piston plate 37 Washer 50 Cap 10 Eye bolt 24 O ring 38 Dust seal 51 Washer 11 Hex nut 25 Hex bolt 39 Truss screw spring washer or sp...

Page 56: ...crew shaft from the housing 5 Remove the O ring To assemble the top handwheel follow the disassembly procedure in the reverse order b Reverse action type Step Procedure 1 Disconnect the air piping 2 Set the handwheel shaft to the automatic operation position fully lower the handwheel shaft 3 Remove the handwheel and the lock nut Insert the shaft into the housing by uniformly and alternately after ...

Page 57: ... handwheel turns smoothly within its full stroke 2 For the direct action type of actuator check by means of soapsuds that there is no air leak from the connecting sections of the housing and top diaphragm case Direct action type Reverse action type Fig 7 5 Fig 7 6 ...

Page 58: ...7 6 ...

Page 59: ...a manual operation kit a side handwheel set and its mounting accessories 2 To install the handwheel no machining or other physical processing on the actuator is necessary 3 By turning the handwheel set the pointer of the operation nut to the AUTO position 4 Loosen the bolt item number 6 as shown in Fig 8 1 and widen the distance between levers 5 Install the handwheel on the mounting pad at the bac...

Page 60: ...orces larger than the below mentioned limits Model HA2 190 N 19 kgf Model HA3 290 N 29 kgf Model HA4 460 N 46 kgf at the outmost periphery of the handwheel 8 3 Disassembly and assembly of side handwheel Refer to Fig 8 1 Before starting disassembly check that the pointer is set to the AUTO position Step Procedure 1 Loosen the bolt 6 which connects the levers 2 and then disengage the levers from the...

Page 61: ...or 17 Handle lock 25 Washer 2 Lever 10 Hex bolt 18 Hex nut 26 Hex bolt 3 Shaft 11 Hex bolt 19 Washer 27 Washer 4 Bushing 12 Bushing 20 Bushing 28 Hex bolt 5 Bearing 13 Spring washer 21 Bearing holder 29 Color 6 Nut 14 Wheel 22 Bearing 30 Spring washer 7 Screw 15 Washer 23 Bush 31 Pin 8 Pointer 16 Hex nut 24 Hex nut 32 Spring washer ...

Page 62: ...8 4 ...

Page 63: ... whirl stop Please don t hit the maximum stopper and the whirl stop to the shaft stopper when tightening them 6 Lock the whirl stop 9 2 Adjustment for Maximum Flow Stopper 1 Loosen the whirl stop to remove the adjust cover for maximum flow stopper from the housing 2 Loosen the hex nuts for minimum flow stopper to remove them from the shaft stopper Valve can move in full stroke because the flow sto...

Page 64: ...oosening the hex nuts for minimum flow stopper please don t apply the excessive torque to the shaft stopper Reverse action type Direct action type Fig 9 1 Cut view of actuator with mechanical flow stopper No Parts name 1 Adjust cover for maximum flow stopper 2 Whirl stop 3 Hex nut for minimum flow stopper 4 Shaft stopper 5 Housing ...

Page 65: ...his Chapter covers primarily the particular items related to bellows sealed type of control valves Note The bellows seal assembly should be replaced periodically The frequency of replacements depends on the conditions of use When handling a mechanism which as a bellows seal assembly exercise care so that the mechanism is not twisted Note that the bellows is not highly resistant against torsion ...

Page 66: ...alve body Stud bolt Hex nut Hex nut Gasket Seal ring Backup ring Stem Gasket upper Scraper ring Extension Cage upper Cage lower Gasket lower Seal ring Spiral gasket Gasket Stud bolt Hex nut Bellows seat Bellows assembly Packing follower Stud bolt Gland packing Bonnet Fig 10 1 Model ACP ACN Control Valve ...

Page 67: ...seat stationary so that no unreasonably large torsion is applied to the bellows which is not highly resistant against torsion 6 Remove the bellows flange and gasket Note The bellows seat can be readily detached by lightly tapping its top The most effective method is to tap it by passing a pipe onto the stem 7 Remove the hex nut which fixes the extension with a wrench Detach the extension from the ...

Page 68: ...10 4 ...

Page 69: ...ing box 1 2 3 4 5 6 7 8 9 10 11 12 Key Part name Fig 11 1 Structural drawing of Azbil low emission gland packing 11 2 Structure The gland packing P4519 for use in Azbil low emission gland packing is woven PTFE yarn with carbon fiber core This gland packing provides asbestos free properties in addition to low sliding friction and adaptability to heat cycles and is adaptable to a wide range of fluid...

Page 70: ...e specified value because of fluid leakage from the periphery of a flaw Stuffing box Both ends of the spacer Packing follower Packing contact surface O ring groove Packing flange Gland nut contact surface The amount of gland leakage may exceed the specified value because of insufficient tightening Packing flange Entire surface Gland stud Gland nut No flaws rust or defects Damage to the control val...

Page 71: ...of installation 1 Coating with lubricating grease Step 1 Apply a thin film not more than 0 3 mm thick of the grease indicated in Table 11 3 G40M made by Shin Etsu Chemical Co Ltd to the entire surface of all the gland packing Step 2 Apply the grease indicated in Table 11 3 Plastilube No 3 made by Sulflo Inc in the U S to each of the two backup O rings on the inner diameter side and the outer diame...

Page 72: ... ring side is the packing side Install it while being careful not to damage the surface of the stem Step 5 With reference to Fig 11 1 install the Belleville springs while being careful not to damage the surface of the stem Step 6 With reference to Fig 11 4 install the spring case in such a manner that two opposed side grooves are guided with the gland studs Two pairs of opposed side grooves are th...

Page 73: ...ion of the Belleville springs through the front window of the spring case When the Belleville springs are set properly the lower edge of the outer diameter of the lowest Belleville spring almost coincides with the lower scale mark of the spring case In some cases it does not exactly coincide because of the dimensional tolerance of the Belleville springs Front appearance of the spring case Scale ma...

Page 74: ... 11 4 Tightening torque of the gland nuts Actuator model Stem size Tightening torque PSA1 HA2 φ 10 mm 8 to 10 N m HA2 HA3 φ 13 mm 13 to 16 N m HA3 φ 16 mm 22 to 26 N m HA4 φ 20 mm 29 to 35 N m 11 3 3 Retightening In the following cases retighten the gland nuts with the specified torque a At the time of an inspection before the installation of the control valve b At the time of a test operation or ...

Page 75: ...71711 101 1 Packing follower for O ring use SUS304 82571715 101 1 Spacer SUS304 82555645 066 1 Spacer for O ring use SUS304 82555645 566 1 Main packing HA2 φ13 mm P4519 80255385 111 5 Belleville spring SUS304 82559308 101 4 O ring small Viton 82592221 497 1 O ring large Viton 82592222 297 1 Stem connector S20C S25C 82520978 206 1 Gland stud SUS304 82571706 011 2 Gland nut SUS304 82592448 173 2 Spr...

Page 76: ...01 1 Packing follower for O ring use SUS304 82571717 101 1 Spacer SUS304 82555645 766 1 Spacer for O ring use SUS304 82555645 101 1 Main packing HA4 φ20 mm P4519 80255387 111 5 Belleville spring SUS304 82571710 201 4 O ring small Viton 82592221 997 1 O ring large Viton 82592223 397 1 Stem connector S20C S25C 82551348 202 1 Gland stud SUS304 82571707 011 2 Gland nut SUS304 82592448 023 2 Spring cas...

Page 77: ...eville spring 5 Packing follower 6 Carbon ring P6210C2FS 7 Adapter packing P6720 8 Main packing P4519 9 Spacer 10 Stem 11 O ring for inner side of packing follower optional 12 O ring for outer side of packing follower optional 13 Stuffing box Fig 12 1 Structure of Certified ISO 15848 1 low emission gland packing for PTFE yarn No Name 1 10 11 12 13 2 3 4 5 6 7 8 9 1 Gland stud 2 Gland nut 3 Packing...

Page 78: ...packing system which is composed of Belleville springs and other parts With other systems in the course of valve operation seal performance deteriorates due to loosening of the gland packing The force of the Belleville springs reduces the release of tension to maintain the seal The load on the Belleville springs can be observed from the position of the packing flange and packing follower 12 3 Star...

Page 79: ...tire surface is even No burrs Clean surface with no adhering coating material powder or dirt If necessary take necessary measures such as cleaning with alcohol If the problems stated on the left remain fluid leaks from flawed areas may cause the total amount of leakage from the gland to exceed the specified value Stuffing box Both ends of the spacer Packing follower Packing contact surface O ring ...

Page 80: ...fied value in a short period of time because of insufficient tightening 3 Lubricating grease and anti seizing agent Have an appropriate amount of the following lubricating grease and anti seizing agent or equivalent on hand Table 12 3 Lubricating grease and anti seizing agent Product name Applied area Gland for PTFE yarn Gland for expanded graphite Krytox GPL207 fluoropolymer grease made by DuPont...

Page 81: ...sides of the packing follower apply grease Plastilube No 3 made by Sulflo Inc indicated in Table 12 3 to both rings 2 Assembling 1 3 Step Procedure 1 Check the correct direction of the gland studs in Fig 12 3 Apply Never Seez anti seizing agent made by Bostik Inc indicated in Table 12 3 to the threads on the stuffing box end of the studs and screw them into the stuffing box Gland nut side Stuffing...

Page 82: ...main packing rings Certified ISO 15848 1 low emission gland packing for expanded graphite Insert one adapter packing ring without opening the gap all the way to the bottom with a pipe etc and push it lightly Insert one of the main packing rings without opening the gap with the marking facing upward all the way to the bottom with a pipe etc and push it lightly Insert the remaining two main packing ...

Page 83: ... if the tightening torque is insufficient the amount of leakage may exceed the specified value On the other hand tightening the gland nuts with excessive torque increases the friction on the stem and causes the gland packing to wear out faster which may lead to an amount of leakage exceeding the specified value in a short period of time Table 12 4 Gland nut tightening torque for PTFE yarn Model Ac...

Page 84: ...does not comply with the torque specified in Table 12 4 and Table 12 5 the level of the top of the packing flange and packing follower will not be the same see Fig 12 7 Check if the direction of washers of the Belleville springs and the tightening torque are correct Gap No gap Before tightening Tightened to the specified torque Fig 12 6 Load on Belleville springs correctly assembled There is a gap...

Page 85: ...101 1 Packing follower SUS304 82573463 101 1 Packing follower for O ring use SUS304 82573464 101 1 Spacer SUS304 82573476 110 1 Main packing HA3 except 6B P4519 80255385 111 3 Adapter packing P6720 82573475 102 2 Carbon ring P6210C2FS 82573484 002 2 Belleville spring SUS304 82573462 102 6 O ring small Viton 82592221 497 1 O ring large Viton 82592222 297 1 Gland stud A193 GrB8CL2 82571706 012 2 Gla...

Page 86: ...on ring P6210C2FS 82573484 004 2 Belleville spring SUS304 82573462 104 6 O ring small Viton 82592221 997 1 O ring large Viton 82592223 397 1 Gland stud A193 GrB8CL2 82571707 012 2 Gland nut SUS304 82592448 023 2 Packing flange SCS13 82573459 101 1 Packing follower SUS304 82573469 101 1 Packing follower for O ring use SUS304 82573470 101 1 Spacer SUS304 82573476 113 1 Main packing PSA6R P4519 82571...

Page 87: ...1 Packing follower SUS304 82573463 201 1 Packing follower for O ring use SUS304 82573464 201 1 Spacer SUS304 82573476 114 1 Main packing HA3 except 6B P6617CL 82573489 002 3 Adapter packing P6720 82573475 102 2 Carbon ring P6210 82573488 002 2 Belleville spring SUS304 82573462 107 6 O ring small Viton 82592221 497 1 O ring large Viton 82592222 297 1 Gland stud A193 GrB8CL2 82571706 012 2 Gland nut...

Page 88: ... 2 Carbon ring P6210 82573488 004 2 Belleville spring SUS304 82573462 108 6 O ring small Viton 82592221 997 1 O ring large Viton 82592223 397 1 Gland stud A193 GrB8CL2 82571707 012 2 Gland nut SUS304 82592448 023 2 Packing flange SCS13 82573459 101 1 Packing follower SUS304 82573469 201 1 Packing follower for O ring use SUS304 82573470 201 1 Spacer SUS304 82573476 117 1 Main packing PSA6R P6617CL ...

Page 89: ...low emission gland packing with the current actuator In addition if it is used with the actuator the shutoff differential pressure will decrease If supply air pressure to the actuator is increased in order to meet the required shutoff differential pressure check that the specifications for the pressure gauge of the positioner and pressure reducing valve are satisfied and that there is no effect on...

Page 90: ...12 14 ...

Page 91: ...piping capacity and restriction capacity are appropriate Supply air pressure regulator is inadequate or not operating properly Controller is not properly tuned Property tune the controller properly set the proportional band and other parameters Check that the controller output does not change abnormally Hunting of output of positioner itself Check and repair or replace the positioner Being affecte...

Page 92: ... packing flange Check for insufficient grease Check for damaged valve shaft Liquid leak from gasket section Check for loose nuts of bonnet Check for defective gasket deformed or damaged Even when valve plug is in closed position large flow leaks to downstream side Air leak at actuator section For trial apply the air supply pressure or atmospheric pressure to the actuator Check the air supply sourc...

Page 93: ...flow fluid fluid temperature or pressure As a general rule replace them once every totalized stroke of 2 5 km or once every three years Actuator Replace the following parts at every 5 years or thereabouts Diaphragm Bushing Seal washer Be sure to replace these parts whenever the actuator is dissembled Dust seal Rod seal Of the bellows sealed type of control valves the bellows seal assembly must be ...

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Page 96: ...nsibility taking the following matters into consideration 1 Regulations and standards or laws that your Equipment is to comply with 2 Examples of application described in any documents provided by Azbil Corporation are for your reference purpose only and you are required to check the functions and safety of your Equipment prior to your use 3 Measures to be taken to secure the required level of the...

Page 97: ...nt you are required to renew any Azbil Corporation s products every 5 to 10 years unless otherwise specified in specifications or instruction manuals System products field instruments sensors such as pressure flow level sensors regulating valves etc will reach the end of their life due to aged deterioration of parts For those parts that will reach the end of their life due to aged deterioration re...

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Page 99: ...nt Name Control Valves Model ACP_ _ _ ACN_ _ _ User s Manual Date 1st Edition Jun 2015 7th Edition Nov 2018 Issued Edited by Advanced Automation Company Address 1 12 2 Kawana Fujisawa kanagawa 251 8522 Japan URL https www azbil com global ...

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