Unicon v100 Globe Valves
Unicon v100 Globe Valves
Unicon v100 Globe Valves
01
Manual No. M-01
6
Installation & Instruction Manual
Table of Contents
1. Introduction
1-1 General
1-2 Personnel qualification
2. Product description
2-1 Conformity
2-2 Valve identification
3. Safety Instruction
3-1 Use of a medium unsuitable for the valve
3-2 Exceeding the permissible pressure with risk of bursting
3-3 Leakage of dangerous substances
3-4 Emergency information
5. Maintenance
7. Storage
8. Packaging
9. Transport
11. Specification
7
Installation & Instruction Manual
Safety Information
Important – Please Read Before Installation
UNICON Globe Control Valve instructions contain Danger, Warning and Caution labels,
where necessary, to alert you to safety related or other important information. Read the
instructions carefully before installing and maintaining your control valve. Danger and
Warning hazards are related to personal injury. Caution hazards involve equipment or
property damage. Operation of damaged equipment can, under certain operational
conditions, result in degraded process system performance that can read to injury or
death. Total compliance with all Danger, Warning and Caution notices is required for
safe operation.
The safety terms Danger, Warning, Caution and Note have used in these instructions to
highlight particular dangers and/or to provide additional information on aspects that may
not be readily apparent.
Danger : indicates that death , severe personal injury and/or substantial property damage
will occur if proper precaution is not taken.
Warning : indicates that death, severe personal injury and/or substantial property damage
can occur if proper precaution is not taken.
Caution : indicates that minor personal injury and/or property damage can occur if proper
precaution is not taken.
Note : indicates and provides additional technical information which may not be obvious,
even to qualified personnel.
1. Introduction
1-1 General
This instruction manual included installation, operation and maintenance information for
UNICON Globe Control Valves. Please refer to separate manuals for instructions covering
controllers and positioners.
This operating manual covers the areas of installation, commissioning, maintenance,
storage, packaging and transport. The operation manual was compiled in accordance with
the regulations of guideline 97/23/EC concerning pressure devices.
Warning
In order to ensure successful and safe operation of our valves the entire operation manual
must have been read through and understood prior to installation and commissioning.
Under certain operating conditions, the use of damaged equipment could cause a
degradation of the performance of the system which may lead to personal injury or death.
If you have any questions about problems arise, contact UNICON office.
8
Installation & Instruction Manual
2. Product description
UNICON valve is designed for general and severe purpose use in liquid and gas control
application calling for either modulating or on/off service. Plug control trim is used with the
fluid flowing up the characterized valve plug. The fluid pressure drop occurs in the flow area
between plug and seat.
Balance cage control trim is used with the fluid flowing either down or up through the
characterized ports in the cage. The fluid pressure drop occurs in the flow area of the cage's
port with the port's contour characterizing flow as a linear or equal percent.
UNICON valves are equipped standard with spring diaphragm pneumatic actuators, either
reverse acting or direct acting type. Both actuator types are available in a range of sizes and
with a selection of springs to suit the operating conditions.
The valves are intended for installation in pipelines in accordance with the EC guideline
97/23/EC concerning pressure devices. The type of medium (chemical, abrasion and corrosive
effect) agreed with the order and the limit values of medium pressure and temperature
according to the data sheet must be adhered to.
2-1 Conformity
UNICON valves have been built according to the state of the art and in accordance with the
guideline 97/23/EC concerning pressure devices.
3. Safety Instruction
Product safety
The valves comply with the state of the art and the recognized rules of technical safety, but
dangers can still arise. Operate the valves only in perfect condition taking into account the
entire operating manual.
Warning
Use of material-incompatible media, exceeding the limit values of medium pressure and
temperature and mechanical additional loads such as caused by connected pipelines can
result in failure of the valve material and bursting of the valve.
Danger
When using unintended media, the materials included in the valve may be attacked or could
even be combusted explosively with fatal consequences. For the reason, only use media for
which the valve has been approved. Keep valves for oxygen free of oil and grease. For
ammonia, use valves free of non-ferrous metals.
Warning
Maximum allowable pressures for the valve body and actuator and the maximum allowable
pressure at the maximum temperature of the valve are shown on the nameplate mounted on
the actuator. If pressure to the valves or other over-pressure protection devices in the
pressure lines.
10
Installation & Instruction Manual
Warning
Collect and dispose of dangerous media (for instance leakages from relief bores or traces of
the medium remaining during the disassembly of the valve) so that persons and the
environment are not endangered. Observe the legal regulations.
Caution
When ordered, the valve configuration and construction materials were selected to meet
particular pressure, temperature, pressure drop, and fluid conditions. Since some body/trim
material combinations are limited in their pressure drop and temperature ranges, do not
apply any other conditions to the valve without first contacting the UNICON office or your
sales representatives.
Danger
Before disassembly or maintenance, all pressures in this device must be relieved. Failure to
relieve pressures may result in personal injury or device damage.
① Before installing the valve, inspect it for any shipping damage and for any foreign material
that may have collected during crating and shipment. Remove flange protectors from the
body end connections.
② Blow out all pipelines to remove pipe scale, chips, welding slag, and other foreign materials.
Gasket surfaces should also be free of any foreign materials.
③ Install the valve so that flow in the direction indicated by the flow direction arrow on the
tag plate pinned to the body.
④ Install valve using good piping practice. For flanged bodies, use a suitable gasket between
the body and pipeline flanges.
⑤ Where piping is insulated, do not insulate the valve above the valve bonnet flange.
⑥ Connect instrument air to actuator or positioner connection. Refer to the nameplate for the
maximum instrument air pressure.
11
Installation & Instruction Manual
5. Maintenance
Valve parts are subject to normal wear and must be inspected and replaced as necessary,
with the frequency of inspection and maintenance depending upon the severity of service
conditions. All maintenance operations may be performed while the valve body remains in
line as long as the line is not in service and/or is isolated from active process by block valves.
Caution
Use care to avoid damaging gasket sealing surfaces. The surface finish of the valve stem is
critical for making a good packing seal. The seating surfaces of the valve plug and seat ring
are critical for tight shutoff. Assume all of these parts are in good condition when
disassembling the valve and protect them accordingly.
① Supply the instrument air to the actuator for lifting up the 25% position of the valve open
to avoid injury or damaging valve parts from disassembly of actuator from bonnet.
② Loosen the lock bolts on the actuator clamp and remove it from valve stem.
③ Loosen the lock bolts on the yoke clamp and remove them from actuator yoke.
④ Lift up the actuator from bonnet by using slings or chins around the actuator or the
lifting eye.
⑦ Lift the plug-stem, balance cylinder, cage and seat ring out of the body in sequence.
Always replace the packing if the stem is removed from the valve bonnet.
Caution
Place the “Body” on a flat surface when you repair the bottom of the body.
12
Installation & Instruction Manual
Caution
If the packing is to be reused and was not removed from the bonnet, use care when
installing the stem in the bonnet to avoid damaging the packing with the valve stem threads.
① Clean all gasket surfaces, including the body, bonnet, and guide.
② A light coat of lubricant, such as light oil/ silicone grease, may be used on the soft seals to
aid ease of assembly.
③ Install the new seat gasket into the seat cavity in the body.
⑥ Insert the balance seal into the balance cylinder's bottom groove. If flow to open condition,
the balance seal's groove upward and backup ring installed on top of the cage. If reverse
condition, insert the backup ring and the balance seal, which groove downward into the
balance cylinder in sequence.
⑦ Install the plug-stem through the balance cylinder and cage until it faces to seat ring.
⑧ Install the new bonnet gasket into the top valve body and the cage gasket in the groove
on top of balance cylinder.
⑪ Mount the actuator on the bonnet and connect actuator stem to the valve stem.
13
Installation & Instruction Manual
④ Diaphragm Actuator
① Stem Clamp
② Packing Flange
Body
Disassembly Order
①→②→③→④
1. disassemble the Stem Clamp 2. disassemble the Packing Flange 3. disassemble the Yoke Clamp
Note!
For more information, refer to the actuator manual(M-04, M-05).
14
Installation & Instruction Manual
② Bonnet
⑤ Stem
④ Plug
⑨ Bonnet Gasket
⑧ Seat Gasket
⑩ Balance Cylinder
⑪ Balance Seal
⑥ Cage
⑫ Back-Up Ring
⑧ Seat Gasket
③ Seat
① Body
Arrow Of Assembly
Direction!!
“ “
15
Installation & Instruction Manual
① Supply the instrument air to the actuator for lifting up the 25% position of valve open to
avoid injury or damaging valve parts from disassembly of actuator from bonnet.
② Loosen the lock bolts on the actuator clamp and remove it from the valve stem.
③ Loosen the lock bolts on the yoke clamp and remove them from actuator yoke.
④ Lift up the actuator from bonnet by using slings or chins around the actuator or the
lifting eye.
⑥ Lift the bonnet off the body along with cage, plug-stem being carefully to lift straight up
to avoid scoring or damaging the valve internals.
⑧ Lift the seat ring and gasket out of the body. Always replace the packing if the stem is
removed from the valve bonnet.
① Clean all gasket surfaces, including the body, bonnet, and guide.
② A light coat of lubricant, such as light oil/ silicone grease, may be used on the soft seals
to aid ease of assembly.
③ Install the new seat gasket into the seat cavity in the body.
⑤ Insert the plug-stem through the cage and install the assembly on top of the seat ring
carefully.
⑥ Install the new bonnet gasket into the top valve body
⑧ Mount the actuator on the bonnet and connect actuator stem to the valve stem.
16
Installation & Instruction Manual
⑬ Packing Set
⑨ Bonnet Gasket
⑥ Cage
⑤ Stem
③ Seat
⑧ Seat Gasket
④ Plug
① Body
Arrow Of Assembly
Direction!!
“ “
17
Installation & Instruction Manual
≫ Visually inspect the valve plug and seat for signs of erosion, pitting, scratched and damage
from corrosion.
≫ Fit the plug and the seat together. While looking into the bottom of the seat, hold the trim
set against a bright light. If any light can be seen between the plug and seat contact surfaces,
this is an indication of poor seat condition.
≫ Determine the magnitude of any wear or corrosion damage. Many times the plug and seat
contact surfaces can be fully restored by relapping. Replace any parts that cannot be fully
restored by relapping. After the restoration of trims, wash plug and seat in solvent to remove
all lapping compounds and wipe the parts dry.
≫ If the stem has been removed, examine the stem for pitting, scratches, or other damage in
the packing box area. If any damage cannot be removed by polishing the stem, replace the
stem.
Packing box maintenance is one of the principle chores of routine servicing. Tightness of the
packing is maintained by packing compression. Compression is achieved by evenly tightening
the packing flange nuts against the packing flange. Care must be taken not to over tighten as
this could prevent smooth operation of the valve.
If all compression is used up and the valve leaks, new packing is required.
≫ Remove the two nuts retaining the packing flange and lift the packing flange and packing
gland from bonnet. Pull out the old packing with a hook or packing removal tool.
Note!
be careful to avoid scratching the packing box wall or stem. If the stem has been removed, the
packing may be pushed out using a rod inserted through the hole in the bottom of the bonnet.
≫ Insert the new packing and associated parts in the following sequence :
18
Installation & Instruction Manual
4 5
4
3
3
2
2
1 1
Caution
Materials and assembly methods must be various according to product specification.
1 1 8
1
3 6 4
5
3 4
3 6
5 4
2 2 7 2
150~600 84 115 197 113 146 200 320 490 710 1000 1000 1223 1542
Note!
Tables are based on the use of bolts with a yield strength of 100,000 psi.
7. Storage
During storage, protect the valves from external effects and dirt. Avoid the formation of
condensate through ventilation, desiccant or heating. Protect the connection openings to
prevent entry of dirt.
The storage room should be dry, dust-free and moderately ventilated. Storage temperature
frost-free up to +25℃.
19
Installation & Instruction Manual
8. Packaging
Warning
Valves that have come in contact with health-threatening media at the customer must be
decontaminated prior to packaging.
Pack the valves so that any coatings or accessories such as plug-in devices, controllers and
sensors cannot be damaged through subsequent transport. Protect connection openings to
prevent the entry of dirt. Use the packing material in accordance with the applicable
regulations and observe country specific regulations.
9. Transport
Valves that can be no longer be moved by hand must be transported with lifting equipment
suitable for the weight to be moved.
Transport the valves by using Eyebolts if available. Do not hook up lifting equipment to
accessories such as hand wheels, control lines, pressure gages or flange bores. When using
suspension belts, these must be placed around the valve body, providing edge protection
and ensuring even weight distribution.
20
Installation & Instruction Manual
21
Installation & Instruction Manual
SYMPTOM POSSIBLE
TROUBLE CORRECTIVE ACTION
CAUSE
1. Replace stem.
2. Remove upper diaphragm housing.
1. Broken valve stem.
Inspect the diaphragm and replace if
Valve will not cycle when 2. Diaphragm ruptured or torn.
necessary.
instrument air is applied to the 3. Diaphragm plate connection at top
3. Remove upper diaphragm housing.
actuator. may be loose.
Inspect the plate-to-stem connection
4. Actuator vent plugged
and tighten if loose.
4. Clean out vent fitting.
Instrument air leaks from outer 1. Hex bolts securing upper and lower
1. Inspect hex bolts, tighten as necessary.
edge of diaphragm cases. cases may be loose.
Valve stem movement is sticky 1. Valve stem or actuator stem may be 1. Disassemble valve and/or actuator to inspect
or jerky. bent or misaligned. stem. Replace if bent or otherwise damaged.
22
Installation & Instruction Manual
11. Specification
FCI-70.2
Standard : ANSI Class IV
Seat Leakage Option : ANSI Class V
ANSI Class VI(Soft Seat)
MSS-SP61(On-Off)
23
Installation & Instruction Manual
Up to 4000psi (g)
Operating Pressure Range
Up to 280 Kg/cm² (g)
-58˚F to +1,050˚F
Operating Temperature
-50˚C to +565˚C
Range
Option : -320˚F to +1,562˚F, -192˚C to +850˚C
Pneumatic Diaphragm
Pneumatic Cylinder
Actuator
Electric Motorized
Electric Hydraulic
24