IMO-19 Issue Date 10/93

Installation, Maintenance& Operating Instructions

24"- 48" WAFER-SPHERE®

BUTTERFLY VALVESSERIES 8000 and 8200Read these entire instructions carefullybefore installation or servicing.

DESCRIPTION MAlNTENANCE

WARNING ROUTINE MAINTENANCE

VALVE INSTALLATION VALVE REMOVAL- BENCH MAINTENANCE

VALVE DISASSEMBLY ACTUATOR MOUNTING

VALVE ASSEMBLY ACTUATOR/VALVE ADJUSTMENTS

SERIES 8000

NOTE REGARDING FLANGEBOLT HOLE THREAD

In order to accommodatenormal alloy steel bolt-ing, flange bolt holeslarger than 1" are beingstandardized with a UN-8thread. Inspect thevalve body to determinewhether it has previousUNC-I or new UN-8 tappedholes.

Figure 1

SERIES 8200

Figure 2

DESCRIPTIONThe Jamesbury Wafer-Sphere valve is a high per-formance butterfly valve with a one-piece bodyand a resilient, positive-sealing seat. In24" - 48" sizes , it is available in two stan-dard series:

8000 Series - Wafer design for ANSI Class 150piping systems.

8200 Series - Single flange (lugged) design forANSI Class 150 piping systems.

Important Note: Maximum shut-off pressure ratingdepends on the materials chose. Refer to the tagattached to each valve for this rating.

Offset Shaft Design

One of the design features of the Wafer-Spherevalve that is responsible for its superior perfor-mance is the valve's eccentric shaft design. Theshaft is offset in two planes: (1) away from thevalve disc centerline; and (2) behind the discsealing plane (See Fig. 5). Offset shaft designmakes the rotating disc cam back and away from theseat, eliminating the usual wear points at the topand bottom of the seat. Because the disc rotatesoff the seat in an eccentric arc, it operates inone quadrant only (See Fig. 5)

Positive Stop Feature

TO prevent seat damage from over-travel of thedisc beyond the closed position (primarily duringfield mounting of an actuator), a "positive stop"feature has been designed into the Wafer-Spherebutterfly valve. The "positive stop" featurealso makes it possible to adjust the actuatorstops in-line. The location of the feature onthe body is shown in the drawing, Figure 4.

WARNINGSAFETY FIRST: FOR YOUR SAFETY, TAKE THE FOLLOWING PRE-CAUTIONS BEFORE REMOVING THE VALVE FROM THE LINE, ORBEFORE ANY DISASSEMBLY:

1. WHAT'S IN THE LINE?

BE SURE YOU KNOW WHAT FLUID IS IN THE LINE. IFTHERE IS ANY DOUBT, DOUBLE-CHECK WITH THE PROPERSUPERVISOR.

2. ARE YOU PROTECTED?

WEAR ANY PROTECTIVE CLOTHING AND EQUIPMENT NOR-MALLY REQUIRED TO AVOID INJURY FROM THE PARTICU-LAR FLUID IN THE LINE.

3. IS THE LINE DEPRESSURIZED?

DEPRESSURIZE THE LINE AND DRAIN THE SYSTEM FLUID.THE WAFER-SPHERE'S OFFSET SHAFT CREATES GREATERDISC AREA ON ONE SIDE OF THE SHAFT. THIS MEANSTHAT A WAFER-SPHERE VALVE TENDS TO OPEN WHEN_ _ - - -PRESSURIZED ON THE INSERT SIDE WITHOUT AN ACTUA-- - - -TOR ON THE VALVE.

NOTE: DO NOT PRESSURIZE THE VALVE WITHOUT ANACTUATOR MOUNTED ON IT. DO NOT REMOVE AN ACTUATORFROM A VALVE UNDER PRESSURE.

4. IS THE VALVE CLOSED?

BEFORE YOU INSTALL A WAFER-SPHERE VALVE IN, ORREMOVE IT FROM THE LINE, CYCLE THE VALVE FULLYCLOSED. THE WAFER-SPHERE VALVE MUST BE REMOVEDFROM THE LINE IN THE CLOSED POSITION OR DAMAGETO THE WAFER WILL RESULT.

WARNING: AT ALL TIMES KEEP HANDS OUT OF THE WATERWAYOF THE VALVE. A VALVE WITH ACTUATOR COULD CLOSE UN-EXPECTEDLY AT ANY TIME AND RESULT IN SERIOUS INJURY.

INSTALLATIONI. FULL PRESSURE RATING - POLYMERIC-SEATED

WAFER-SPHERE VALVES (Refer to the catalog forallowable pressures and temperatures.)In general, for full pressure rating, allpolymeric-seated Wafer-Sphere butterfly valvesshould be installed with the disc face towardthe higher pressure (shaft downstream.)

II. METAL-SEATED WAFER-SPHERE VALVESMetal-seated Wafer-Sphere butterfly valves aresingle-directional. They must be installed ONLYwith the disc face toward the higher pressure(shaft downstream).

2

III. GENERAL INFORMATION1. Read the GENERAL WARNING Section

carefully.

2. IMPORTANT: ONLY actuator stop set screwsshould be used to stop the disc inposition. DO NOT use the "positive stop"feature by itself to limit actuator travel.

3. Before installing the closed valve in theline, be sure that the actuator is attachedso that a counterclockwise rotation, viewedfrom above, opens the valve (See Fig. 5).Again, fully close the valve before instal-ling it in the line.

4. The valve should be installed with l/16"thick asbestos or equivalent gasket material.NOTE: DO NOT use thick rubber or other gasketsof a "spongy" consistency.

5. For optimum performance, compress the gasketuniformly. Tighten the flange bolts in the se-quence shown in Fig. 9. Recommended torquevalues for bolting are listed in Fig. 3.

6. If there is weepage past the stem seals uponinstallation, it means the valve may have beensubject to wide temperature variations in ship-ment. Leaktight performance will be restoredby a simple packing adjustment described in theMAINTENANCE Section.

2 .

3 .

4 .

5 .

6 .

7. Cycle the valve closed.

8 . Place the new seat in the valve. Make surethe angle on the inside diameter of the seatcorresponds to the angle of the outer edqeof the disc.

9.

9a.

Remove the insert screws (21) and the insert(2). If the insert does not lift out easily,tap it out from the shaft side using a woodenor plastic rod and hammer. Do not strike thevalve directly with the hammer.

Remove the seat, and discard it.

Clean the valve.

Carefully clean and polish the disc sealingsurface. It should be free of all groovesand scratches.

If the disc is slightly damaged it may bepossible to smooth the sealing surface withcrocus cloth, a fine stone, or the equiva-lent. If deep scratches are present replacethe disc or return the valve to the factoryfor service.

The insert should be installed per Figure 4.

9b Seat compression is accomplished when the

Install the socket head cap screws (21) andtighten as shown in the sequential diagram(Fig. 10) and torque chart (Table II).

valve is installed between flanges and theflange bolts are tightened.

CAUTION: Unless the valve is in the fullyclosed position, compressing the seat maydamage it.

NOTE: After installation of a new seat, torquewill be higher for a few cycles. Whenever aseat is replaced or an actuator is removedand reinstalled on a valve, the actuatortravel stops will in all likelihood have tobe readjusted. See ACTUATOR/VALVE ADJUSTMENTSfor instructions.

V. Upper Shaft Seal Replacement

1.

2.

3.

4.

5.

6.

Remove the actuator.

Remove the indicator (29). Take off thecompression plate (10) by removing thestud nuts (15) and lockwashers (16). Thestuds (14) do not have to be removed.

Remove the compression ring (9).

Remove the old shaft seals (8) with apacking tool.

Do not remove the spacer (7), unless com-plete disassembly is necessary.

Replace the old seals with new seals.NOTE: If the seals are of the chevrontype, keep the seal rings stacked in thesame order as removed from the kit, andinstall them in the direction shown inFig. 4.

Reinstall the compression ring (91, thecompression plate (l0), the lock washers(16) and nuts (15). Replace the indicator(29). Be sure that the hardware has beeninstalled so that the indicator plate isunder the pointer.

Close the valve (the seat and insert shouldbe installed in the valve at this point).

Tighten the nuts (15) evenly until the packingis adequately compressed to prevent leakage.This should require tightening the nuts approxi-mately l-l/2 to 2 full turns past the'finger-tight" position.

VI. Lower Shaft Seal Replacement (SEE STUD NOTE FIG.4)

31. Remove the two locknuts (30) on the wafer

shaft.

GASKET DIMENSIONS

VALVE 1

Figure 3

MAINTENANCERoutine maintenance consists of tightening down thecompression plate periodically to compensate for sealwear. The valve should be closed during tightening.The compression plate, however, should not be tighteneddown too severely, since this will shorten thelife of the seals. More extensive maintenancesuch as seat, seal and bearing replacement isdescribed in the following sections. Numbers in( ) refer to items shown in Fig. 4.

VALVE REMOVAL AND SHOP MAINTENANCE

I.

II.

III

IV.

Read the WARNING Section carefully.

Valve must be fully closed before slidingit out of the pipeline.

CAUTION: Valves equipped with fail-open Springreturn actuators must have sufficient air pres-sure applied to the actuator to close the valve.After valve removal, slowly relieve the pressurein the actuator. Take care to protect the ex-posed sealing edge of the disc.

Seat Replacement (Refer to Fig. 4)

1. After removing the valve from the line, cyclethe valve open. Take care not to damage theedge of the disc while it is open.

4

2.

3.

4.

5.

6.

7.

8.

Remove the two outer stud nuts (15) andlockwashers (16). The studs do not have tobe removed. Do not adjust the stud nuts be-tween the body and the compression plate.

Remove the compression plate washers (34 and35) and the compression plate (33).

Remove the bottom compression ring (32).

Remove the old shaft seals (8) with a packingtool.

Replace the old seals with new seals.NOTE: If the seals are of the chevron type,keep the seal rings stacked in the same orderas removed from the kit, and install them inthe direction shown in Fig. 4.

Do not remove the spacer (7), unless com-plete disassembly is necessary.

Reassemble according to assembly instructions#6 through #12.

VALVE DISASSEMBLY1.

2.

3.

4.

5.

6.

7.

8.

Place the valve on a bench or other suitableworking space.

If the seat is to be replaced, follow steps2, 3, and 4 in the SEAT REPLACEMENT Section.NOTE: It is a good idea to replace theseat any time a valve is rebuilt.

Remove the shaft packing compression hard-ware as detailed in Steps 2-5 in the UpperShaft Seal Replacement section. The packingmaterial itself can be more easily removedafter the shaft has been removed from thevalve.

Remove the disc pins by grinding or machin-ing off the welds. Drive out the pins in thedirection shown in diagram (Fig 4.).

Disassemble the lower seal assembly as de-tailed in Steps 2-7 in the Lower Shaft SealReplacement section.

Support the disc so that it will not dropupon removal of shaft. Remove the shaftthrough the top of the valve. Use ahammer or press to drive the shaft. Pro-tect the threads and the bearing surface atthe end of the shaft from damage duringthis operation. Do not hammer on the endof the threaded center stud.NOTE: In removing the shaft and freeing thedisc, be careful not to scratch the sealingsurface of the disc.

Remove the top bearing (6) by pushing it up fromthe bottom (waterway).

Remove the bottom bearing (6) by pushing it downfrom the top (waterway).NOTE: To keep bearings in place, the valve bodyis staked on the I.D. DO NOT try to remove thebearing by pushing them toward the centerof the valve.

VALVE ASSEMBLY1.

2.

3.

4.

5.

6.

7.

8.

Clean all valve components.

Inspect all components for damage beforestarting to assemble the valve. Look espe-cially for damage to sealing areas on thedisc, shaft and body and for wear in thebearing areas of the shaft and body.

Carefully clean and polish the disc sealingsurface. It should be free of all groovesand scratches.

If the disc is slightly damaged it may bepossible to smooth the sealing surface withcrocus cloth, a fine stone, or the equivalent.If deep scratches are present replace the discor return the valve to the factory for service.

Place the body (1) on a flat surface with theinsert facing the assembler. Remove the seat(5) if not already removed.

Insert the bearings (6), lubricating the insidediameter with silicone grease or other lubricantcompatible with the fluid to be handled. Usinga center punch, stake the inboard end of thebearing bores to prevent movement during assemblyand service. On 24" - 48" valves, stake the out-board end of the lower bearing bores.NOTE: This staking will not be required if theoriginal factory staking has not been damaged.

Position the disc (3) in the body and slidethe shaft (4) through the body and disc. Usecaution to prevent damage to the bearings.An arrow on the disc indicates which endof the disc should be located on the bonnetside.

Insert the pins (13) and drive them intoplace according to sequence in Fig. 8. Thesequence and direction is very important toavoid alignment error between shaft anddisc and assure that all the pins can be in-stalled. Weld both ends of the pins, smallend first. After the disc cools, clean thewelds with a wire brush. Welding may be leftfor the last operation if desired.

9.

10.

11.

12.

13.

Slide the spacer (7), shaft seals (8), andcompression ring (9) over the shaft (4) atthe top of the valve. Slide the compressionplate (10) over the shaft and studs (14),then place the two lockwashers (16) and nuts(15) on the studs (14). DO not tighten thesenuts down onto the compression plate at thistime.

Slide the spacer (7). shaft seals (8), andcompression ring (32) onto the shaft (4) atthe bottom of the valve.

Slide one thrust washer (34) onto the threadedstud at the bottom of the shaft. Slidethe compression plate (33) over this shaftstud and the two studs (14), making surethat there are two nuts (15) on each studbetween the compression plate and the valvebody, one with lockwasher (16) to securethe stud to the body, and the other for ad-justing the compression plate. Back the seatscrews (25) out far enough to prevent themfrom contacting the compression ring (32).

Place the second thrust washer (35) and thetwo nuts (30) on the shaft stud, tighteningthe first nut only enough to take up allslack. Tighten the second (jam) nut securelyagainst the first. The compression plateshould be free to rotate but must not haveany axial freedom on the shaft stud. Checkfor this.

Place the two lockwashers (16) and nuts (15)on the studs (14). Use these two nuts withthe two nuts on the other side of the compres-sion plate to adjust the disc upward or down-ward so that it is centrally spaced in thewaterway. Measurements taken from the discto the valve body at the top and bottom mustbe identical with one another within .015".Make sure all four nuts are tight.5

14.

15.

16.

Cycle the valve and recheck this measurement.

Install the seat according to maintenanceinstructions IV-7 through 10.

Tighten the set screws (25) at the bottom ofthe valve and nuts (15) at the top of thevalve adequately to prevent shaft seal leak-age. They should not be tightened too severely,since this will shorten the life of the seals.

ACTUATOR MOUNTING1. Install the actuator on the valve in accordance

with the applicable Actuator Mounting Instruc-tions (AMI). If no AMI is available, installthe actuator in accordance with the followinggeneral procedure.

2. Reinstall the actuator bracket on the valve,holding the two together with four bolts. Theactuator should be securely bolted to thebracket at this point. Note that the bracket/valve bolt pattern is not symmetrical withrespect to the valve shaft. Check to be cer-tain that the actuator/bracket/valve orienta-tion is such that the actuator is correctlyoriented on the valve and that the actuatordrive shaft and valve shaft are exactlyaligned. The bolts between the valve andbracket should be snug but not too tight.(excessive tightening will prevent properalignment of the actuator drive shaft andvalve stem. Failure to tighten snugly willcause the shaft and disc to be driven down-ward away from optimum seat contact whenfinal tightening is accomplished).

3. Match the actuator position to the valveposition, i.e. valve open/actuator open andvice versa. Install the coupling and tightenthe coupling bolts. Be sure the actuatordrive shaft and valve stem are properlyaligned and the coupling bolts are tight.

4. Now fully tighten the four bolts holdingthe bracket to the valve.

Setting Stops (Valve in the Line)

It is preferable to adjust the stops on theactuator before the valve is installed in theline because of the ability to check disc posi-tion visually. If this is not possible, and thevalve is installed in the line, use the proce-dures which follow, ignoring any reference tomeasured clearance to the disc. CAUTION: Theremust be no pressure across the valve while thestops are being set. Following adjustments, checkall linkage and coupling bolts for tightness. Re-commended torque valves for fasteners are shownin Table II.

Setting Stops (Valve out of the Line)

The following steps rely upon the insert (2) beingclamped in the position it will take when installedin the line. The insert must be flush with the faceof the body (1) within l/64" maximum. The installedseat tends to lift the insert unless it is completelyclamped or screwed in place. It may be most conveni-ent to adjust the stops with the seat removed fromthe valve. Following the setting of the stops, theseat and insert must be reinstalled as described inthe SEAT REPLACEMENT Section.Following adjustments, check all linkage and couplingbolts for tightness. Recommended torque valves forfasteners are shown in Table II.

Setting Stops on ST and ST-MS Pneumatic Actuators

1.

(Fig.6)

Disc travel on a Wafer-Sphere valve with 2 typeST or ST-MS pneumatic actuator is controlled witha closed ("shut") travel stop set screw (19A) andby an open travel stop set screw (19B) in theactuator.

2.

3.

4.

Remove the acorn nuts (19) protecting the stopset screws. NOTE: Be sure the O-rings remain inthe acorn nuts.

Adjust the closed ("shut") stop set screws (19A)until the disc just touches the insert when theactuator is at the end of its stroke. Air pres-sure may have to be applied to ST-MS actuators torelieve the load on the closed ("shut") stop setscrew during the adjustment. CAUTION: If pressureis supplied to the actuator while the valve isexposed, keep hands and tools away from the disc.

From the position which allows the disc to justtouch the insert, turn the stop set screw inabout l/8 turn to get the disc l/64" off the insert.

5.

6.

7.

8.

9.

Cycle the actuator open and back to closed severaltimes and verify that the disc returns to the sameposition each time. Keep hands and tools away fromthe disc and do not allow the disc to drag acrosssurfaces which can scratch the sealing edge.

Cycle the valve to the open position. If necessary,adjust the open stop set screw (19B) until the poin-ter (24) is approximately 90° from the closed("shut") position. This is full open.

With the valve in the full open position,and with air applied so that load is appliedto the open stop set screw to prevent it frommoving, cover the open stop set screw with anacorn nut. Tighten the open stop set screw acornnut.

Now close the valve. With the valve in the closedposition, an air (or spring) load applied to thestop set screw, tighten the closed ("shut") stopset acorn nut.

Cycle the valve open and closed, with full airpressure, three times. The disc must return tothe same position each time. Visually check tosee that the disc is within l/64" of the insertstop but is not lifting the insert from its properposition.

6

Setting Stops on Quadra-Powr Actuators

Follow the instructions for adjustment of ST-MS actua-tors with the following exceptions:

a. The Quadra-Powr has no acorn nuts onthe stop screws.

b. Because the stop screws can be held inposition with a screwdriver while tighteningthe jam nuts, there is not need to apply aload to the ends of the screws during thisoperation.

Setting Stops on MA Manual Gear Actuator (Fig.7)

1. Loosen the jam nuts (32) locking the stopset screws (19). Back out the closed (shut)stop set screw (19A) far enough to allowthe actuator to move the disc until it justtouches the positive stop.

2. Screw in the closed (shut) stop set screwuntil it stops against the gear face insidethe actuator.

3. Taking care not to move the set screw, usethe handwheel to open the disc slightly.Turn the closed (shut) stop set screw inabout l/8 turn. Check to see that the discis l/64" off the positive stop.

4. Lock the stop set screw with the jam nut atthis point. The screw must be kept from movingwhile the nut is being tightened. This may bedone either by holding the screw with a wrench,or by using the handwheel to drive the gearfirmly against the end of the screw.

5. Open the valve so that the pointer is approxi-mately 90° from the closed (shut) position usingthe handwheel. Adjust the open stop set screw(19B) to stop the gear at this position. Holdthe stop set screw and tighten the jam nut.

Setting Stops on Electric Actuators

Electric actuator stops are controlled by adjustablecams and switches. Follow basically the same proce-dure for these actuators as for ST actuators.The closed (shut) switch should stop the discwithin the l/64" of the insert. Do not set the stopso that the disc touches the insert before theswitch turns the actuator off.

TOP VIEW

NOTES :

1. INSERT LOCATING PIN "A" (ALWAYS 2ND FROMBOTTOM) DRIVE IN SECURELY.

2. INSERT CANTED PINS "B". DRIVE INALTERNATELY AND SECURELY.

3. INSERT REMAINING PINS "C" AND DRIVE INSECURELY.

4. PINS TO BE INSERTED IN DIRECTION OFARROW CAST ON DISC HUB.

AFTER FINAL ASSEMBLY OF SHAFT & DISC INTOBODY. TACK WELD ON BOTH SIDES OF PINS. NOPLAY MUST EXIST BETWEEN SHAFT AND WAFERPRIOR TO WELDING.

Figure 8

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Jamesbury Inc. l 640 Lincoln Street l Box 15004Worcester, Massachusetts 01615-0004 USA

Tel: 508-852-0200 l Fax: 508-852-8172 l Internet: www.Jamesbury.comNeles Controls Group l A member of Rauma Corporation