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Cashco — RANGER QCT ROTARY CONTROL VALVE BODY ASSEMBLY FLANGED OR FLANGELESS DESIGN

RANGER QCT
ROTARY CONTROL VALVE BODY ASSEMBLY
FLANGED OR FLANGELESS DESIGN


SECTION I

I. DESCRIPTION AND SCOPE
This manual covers the body assembly of the Cashco
Ranger QCT. Available sizes include 1", 1-1/2", 2",
3", 4", 6" and 8" (DN25, 40, 50, 80, 100, 150, 200).
Flangeless DI bodies fi t 150 and 300 lb. RF fl anges.
Flangeless CS and SST bodies, all sizes, fi t 150, 300
and 600 lb. RF fl anges. Integral fl anged CS and SST
bodies, sizes 1" through 3", mate with 150, 300 and
600 lb. RF fl anges. Integral fl anged CS and SST bodies,
sizes 4", 6" and 8", mate with 150 and 300 lb. RF
Flanges. All sizes of fl angeless construction may be
installed between PN40 fl ang es. Quick Change Trim
(QCT) is furnished as a stan dard feature and allows
use of several seal re tain ers and inserts to vary orifi ce
size, help control cav i ta tion and reduce noise. All trims
use 90° plug rotation. Dis as sem bly, in spec tion and
reassembly of the trim can be accomplished easily
without disturbing the packing, linkage or po si tion er
calibration. Trim parts are self-centering.
Either of Cashco's pneumatically actuated actuators,
Model 48 and Model 148, can be mounted to the
Ranger QCT body.

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SECTION II


II. REFERENCES
Refer to Technical Bulletin Ranger-TB for complete
tech ni cal specifi cations coupled with either Cashco
Actuator Model 48 or 148.
www.cashco.com/techbulletins/ranger.pdf
Refer to following Installation, Operation & Mainte
nance Manuals (IOM’s) for either actuator and/or
devices that maybe mounted to a Model Range body:
Actuators: www.cashco.com/IOM/48.pdf
www.cashco.com/IOM/148.pdf
Positioners:
P/P: www.cashco.com/techbulletins/73.pdf
P/P: www.cashco.com/techbulletins/9540r.pdf
I/P: www.cashco.com/techbulletins/srd991.pdf
I/P: www.cashco.com/iom/PS2iom.pdf
ABBREVIATIONS
ATC-FO – Air-to-Close, Fail Open
ATO-FC – Air-to-Open, Fail Close
CCW – Counter-Clockwise Rotation
CS – Cast Carbon Steel
CW – Clockwise Rotation
CWP – Cold Working Pressure
DIR – Direct Acting
DI – Ductile Iron
IAS – Instrument Air Supply
IOM – Installation, Operation and Maintenance
Manual
LOAD – Positioner Output Air Pressure
REV – Reverse Acting
RF – Raised Face
SIG – Output Signal from Instrument
SST – Cast or Wrought 316 Stainless Steel
V – Vent

SECTION III


III. INSTALLATION
A. Orientation:
1. Preferred orientation when valve is installed
in either a horizontal or vertical pipeline is
with the valve stem horizontal. Valves may
be installed with the stem any where between
horizontal or vertical for all sizes.
2. Ranger QCT valve with actuator is not recom
mend ed for installation with the actuator
ori ent ed down wards.
3. In no case is additional weight to be applied
to the actuator subassembly when installed
in any orientation.

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B. Piping System:
1. It is recommended that the control valve unit
be installed with a double-block and bypass
as indicated in Figure 1. This arrangement is
necessary when main te nance is to be done
on the valve body. Valve must be removed
from the pipeline to gain access to unit’s
internal trim parts.

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2. If the pipe reducers, elbows, noise at ten u a tion
de vic es, etc., are located before and/or after
the valve body, keep these pieces as close
as practical to the valve body.
NOTES: 1. For fl angeless design, allow suffi
cient clear ance up stream from valve body for
line bolt in ser tion and removal. See Figure 2
and Ta ble 1.
2. Undue piping stress/strain or bendingtorques
may not be transmitted through the
control valve body. One pipe (inlet or outlet)
should be anchored rigidly for piping that is
“hot” or “cold’” with respect to ambient temper
a ture; the remaining pipe (inlet or outlet)
should be supported and guided to ensure
uni di rec tion al expansion/con trac tion. Prop er ly
align prior to installing valve with required
fl ange bolting.

3. Clean the piping of all foreign debris, including
chips, weld scale, weld splatter, oil, grease,
sand or dirt, prior to installing the control valve.
THIS IS AN AB SO LUTE RE QUIRE MENT!
4. Field hydrostatic testing the completed piping
system, including the Ranger QCT valve,
to the max allowable CWP indicated on the
valve’s name plate is acceptable. If hydro test
pres sure is to exceed this limit, the Rang er
QCT must be removed before such test ing.
Be fore pres sur iza tion, the valve plug must be
rotated out of the seat if of reverse, ATO-FC
action.

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TABLE 1 – LINE BOLTING REMOVAL CLEARANCEimage.png

C. Plug Position for Installation:

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NOTE: All ATC-FO valves are shipped from the
factory in the closed position to ensure align ment
of body trim internals. After installing valve body
in piping system, rotate valve plug to full open
po si tion.
1. All indicated Item Numbers that are with respect
to IOM-48 or IOM148 will be in pa renthe
sis and underscored; i.e. (20); the same is
true for the positioner parts. All Item Numbers
that are with respect to this IOM-Ranger are
not underscored; i.e. (6).

2. For ATC-FO Direct Action Valves with Handwheel
Assembly:
a. After installation in piping, loosen locking
le ver (59) and turn handwheel (58) CCW
to fully open the plug (6).
b. Check travel indicator (16) to confi rm
valves full open plug po si tion.
c. Tighten locking lever (59).
3. For ATC-FO Direct Action Valves without
Handwheel Assembly:
NOTE: For shipping and installation purposes
these valves use a mechanical device to temporarilyhold the plug in the closed po si tion. A
slotted “C” washer is positioned on the push
rod (10) between the lower case (2) and the
upper jam nut (43). See Figure 23.
a. After installation of valve in piping, connect
a temporary air supply with an in-line
adjustable airset reg u la tor with gauge to
the actuator top works.


b. Pressurize the actuator to a level 2-3 psig
(0.1–0.2 Barg) above the upper pressure
lev el of the bench setting as stated on the
name plate (21); i.e. 5–15 psig (.34–1.03
Barg) range, set pressure at 17–18 psig
(1.17–1.24 Barg).
c. Remove machine screws (36) and cov er
plate (20).
d. Locate “C” washer and remove. Re tight en
upper jam nut (43) to lower jam nut (43).
Re place cov er plate (20) and ma chine
screws (36).
e. De pres sur ize the actuator and check
trav el indicator (16) for full plug travel.
Disconnect temporary air supply.
NOTE: Save slotted “C” washer for reuse
when reinstalling the valve back into the
pip ing.

WARNING
Do not adjust temporary air supply pressure after cover plate (20) has been removed. Valve contains parts which could move during maintenance exposing hand and/or fingers to a hazardous condition.

D. Body Installation:
The Ranger QCT body can be installed be tween
ANSI Class 150, 300 or 600 lb. RF or FF fl anges
or their ISO equivalent of PN20, 50 or 100. Socket
weld, weld neck or slip on companion fl anges
can be used. Face-to-face di men sions are per
ISA 75.08.02.
1. Install valve so the fl ow direction matches the
arrow on the valve body.
2. For fl angeless design alignment, special
boss es cast on the valve body contact the
line bolting and help center the valve in the
pipe line. See Table 2 for Line Bolting Di mensions.

CAUTION
DO NOT USE THE RANGER BODY ASSEMBLY AND LINE BOLTING TO PULL FLANGE PIPE ENDS INTO ALIGNMENT. Seal retainer may shift, dam ag ing the seal retainer gasket allowing leakage between body and seal retainer. Movement of seal retainer may compromise the valve's ability to meet stated shut-off leakage rates. Could also allow leak age between body and fl ange pipe ends.

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3. Line Bolting Material must comply with ANSI B16.34
and be compatible with the in tend ed service.


CAUTION
Do not allow the body to “cock” between the fl anges.
Valve must be centered on the fl anges.



4. Tighten the line bolting evenly and in small in crements
to avoid uneven load ing of the seal retainer
(3) and seal retainer gas ket (9). See Ta ble 3 for
minimum and max i mum line bolt ing torques.

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CAUTION
Do not torque line bolting beyond the limitations of
Table 3. Ref er ence the “Ranger-TB” for tem per a ture
range of Opt-7A alloy steel and Opt-7C SST line
bolting.


E. Packing Check:
1. Ensure that packing fl ange nuts (22) have not
worked loose during shipment.
2. For non-live loaded construction, hand tight en
the nuts (22) enough to stop any leakage. Do
not over tighten.
3. For live loaded construction, if spacer ring
(29) is loose, tighten both nuts (22) equally
until spacer ring (29) no longer “spins freely”
using two fi ngers. Rotate both nuts (22) addi
tion al 1/2 revolution for correct packing
load. See Figure 9 for correct orientation of
live-loaded packing design.
F. Insulation:
1. Insulate the valve body only. Do not insulate
the integral extension bonnet as this could
result in premature packing failure in low or
high temperature services. See Fig ure 3.

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FIGURE 3:Insulated Body Flangeless Design

SECTION IV


IV. MAINTENANCE
A. General:
1. Maintenance procedures hereinafter are based
upon removal of the valve/actuator unit from
the piping where installed.
2. Owner should refer to owner’s procedures for
re mov al, handling and cleaning of non re us able
parts; i.e. gaskets, suitable solvents, etc.
3. Valves supplied from the factory do not use
any aid to assist in gasket sealing such as oil,
sealant or pipe dope.
4. Valves originally supplied per Opt-55 require
spe cial cleaning procedures. Refer to Cashco
Specifi cation No. S-1134 for details. When in
compliance with/to Spec. No. S-1134, the
valve is suitable for oxygen service. This proce
dure is limited to bodies of SST material
B. Trim Removal:
Access to the cage assembly with internal trim
pieces may be accomplished without removing
the actuator assembly (AA). Thus, it is not nec essary to remove the pack ing set (13) or the stem
subassembly (7) to change internal trims. NOTE:
Plug (6) must be in the closed position to remove
the trim.


  1. Position valve on a fl at work sur face with the
    actuator assembly (AA) oriented vertical.
    NOTE: If actuator assembly (AA) has been
    re moved, rotate stem (7) to close plug (6), and
    proceed with Steps 4 through 8.
    2. If the valve actuator includes a handwheel/adjusting
    screw (58) assembly, use handwheel/
    ad just ing screw (58) to remove the closing
    torque; i.e. “stem windup”.
    a. For ATO-FC valves: Loosen locking le ver/
    nut (59) with CCW rotation when viewed
    from above and rotate handwheel/ad justing
    screw (58) CW just enough to relieve
    the closing torque, but not enough to start
    opening the plug (approximately 1/2-1
    handwheel rev o lu tion).
    b. For ATC-FO valves: Loosen locking lever
    (59) with CCW rotation when viewed
    from above and turn handwheel (58) CW
    to fully close the plug (6) and then back
    off enough to relieve the closing torque
    by reversing the handwheel/adjusting
    screw (58) CCW (approximately 1/2-1
    handwheel revolution).
    c. Remove machine screws (36) and cover
    plate (20). Through opening in arm housing
    (4), insert a tool similar to a screw driv er
    and apply force to either side at the lower
    rod end (9). Rod end (9) will move easily
    from side to side when all clos ing torque
    has been relieved.


3. If the valve actuator does not include handwheel
(58) assembly, connect a tem po rary
air supply with an in-line ad just able airset
reg u la tor with gauge to the ac tu a tor top works.
Remove machine screws (36) and cover plate
(20).

WARNING
Do not insert hands/fi ngers into body (1) or actuato rarm housing (4) openings while actuator is pressurized.

a. For ATC-FO Valves: Pressurize ac tu a tor
to a level 2-3 psig (0.1-0.2 Barg) under the
upper pressure lev el of the bench setting
as stated on the name plate (21); i.e. 5-15
psig (.34–1.03 Barg) range, set pressure
at 12-13 psig (.83-.90 Barg). Refer to 2.c.
previous to confi rm relief of all closing
torque. Ad just ac tu a tor pres sure slow ly
±1 to 2 psig (±.07–0.2 Barg) to con fi rm
great est/eas i est move ment of lower rod
end (9). Install slotted “C” wash er on push

rod (10) be tween the lower case (2) and
the upper jam nut (43) to help se cure plug
in the closed position.
4. Remove the seal retainer screws (18) and
washers (23) and (47)
5. Remove the seal retainer (3) (full or i fi ce, reduced,anti-cavitation, lo-noise), seal re tain er
gas ket (9), soft seal (10) (if supplied) and metal
seal (11).
6. Through backside of body (1), place a wood en
hammer handle on the vane on the back side of
the plug (6), or the LN2–LN4 lo-noise insert (25),
and tap lightly to remove cage as sem bly.
7. Remove bearings (4)( 5) from the cage (2).
(If necessary, pry or tap the bear ings loose.)
Rotate plug (6) 135° to 180° from the closed
position and lift plug (6) from the cage (2).
8. Remove abrasion sleeve (26) or LN2–LN4
lo-noise insert, if installed.
9. Depressurize actuator for ATC-FO valves.

C. Trim Reassembly:
Inspect and clean all parts. If any parts are worn,
replace with new parts. If the stem assembly (7) has been removed, reassemble per Section IV, Sub section
F., then proceed to reassemble the trim.
For sizes 1" - 3", Reorient unit so that the back-end
of the body (1) is directed downwards, and the
front-end is up wards and in a horizontal plane. In
this position gravity will assist in proper alignment of internals. For 4" - 8" sizes orient body on its side.
NOTES: A. The seal retainer gasket (9) and soft
seal (10) should always be replaced after every
dis as sem bly. Use only original factory re placement
parts.
B. For ATC-FO Valves without handwheel
(58) assembly: Pressurize ac tu a tor to levels in dicated per previous Sub sec tion 3.a. to prop er ly aligngroove in stem sub as sem bly (7) to mate with the tongue on the plug (6).

1. Install LN2/4 “lo-noise” insert (25) or “abra sion
sleeve” insert (26) into the body (1) cavity before
inserting the cage/plug subassembly (2)(4)(5)
(6). Ensure that the insert (25)(26) is properly
located within the groove located in the backend
of the body (1)
NOTE: For proper orientation of LN2, LN3 or LN4
trims, see Figure 6.

2. If at the body assembly (BA) level, ensure
that the stem sub as sem bly (7) is pulled back
into the bonnet of the body (1) so that the
stem (7) is in contact with the retainer sleeve
sub as sem bly (8).
3. Place plug (6) into cage (2). The ori en ta tion
must be such that the short stub shaft of the
plug (6) with the ma chined tongue extends
through the fl at side of the cage (2) toward
the stem (7). The plug (6) must be rotated
135° to 180° open before the plug (6) stub
shafts will slip into the cage's (2) bearing (4)
(5) slots. See fi gures 4 and 5.

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FIGURE 4: Quick Change Trim Parts

4. Slip bearings (4)(5) onto the plug (6) stub
shafts.
NOTE: Bearings (4) (5) are not the same length.
The shorter bear ing (5) fi ts the plug (6) stub shaft
that has the tongue end. See Figure 5.
5. Rotate plug (6) to the closed position. Ensure
that the plug (6) is fully pulled into the mechan
i cal stop (5) on the cage (2). See Figure
7. Ensure that the closing torque is nil; i.e.
actuator assembly (AA) linkage is “loose” or
“slack”.
6. Insert the cage/plug subassembly (2)(4)(5)(6)
into the body (1). On 1-1/2" and 2" sizes with
lo-noise inserts or abra sion sleeve, make sure
these pieces and the cage (2) slip together
on the back of the cage (2). Make sure the
tongue on the plug (6) stub shaft and the
groove in the stem sub as sem bly (7) mate
to geth er. Check by look ing in through the
back-end of the body (1) or by ad just ing the
supply pres sure to the ac tu a tor within limits
of bench range as spec i fi ed on name plate
(21), watch ing for plug (6) move ment as stem
sub as sem bly (7) ro tates.

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                                       FIGURE 5
Back-end view of Cage/Plug Subassembly

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                                  FIGURE 6
Lo-Noise Trim – LN2 through LN4

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                                  FIGURE 7

Mechanical Travel Stops - Plug in Closed Position
Front-End View

NOTE: All Sizes - Reorient unit so that the backend
of the body (1) is directed downwards, and
the front-end is up wards and in a horizontal plane
so seals properly align on plug.
7. With plug (6) in the closed position, install the
metal seal (11) with cham fered edge of I.D.
to ward the plug (6); a note is “etched” on the
side of the metal seal (11) stating “TO WARD
PLUG”. Place seal re tain er gas ket (9) against
body (1) face and metal seal (11). Place soft
seal (10) against plug (6) face. See Figure 8
for as sem bly details.
NOTE: The soft seal (10) is not used with anticavitation trim (3) or with some trim des ig na tions.
In reverse fl ow di rec tion, the soft seal (10) is
ineffective.
8. Carefully set seal retainer (3) into position.
Vi su al ly check to see if the soft seal (10) is
centered over the metal seal (11), and that
the plug (6) is closed.

NOTE: The soft seal (10) is not used with anticavitation trim (3) or with some trim des ig na tions.
In reverse fl ow di rec tion, the soft seal (10) is
ineffective.
8. Carefully set seal retainer (3) into position.
Vi su al ly check to see if the soft seal (10) is
centered over the metal seal (11), and that
the plug (6) is closed.
NOTE: To center the seals on the plug (6) face,
hold the seal retainer (3) against the as sem bled
trim parts with light hand pressure and rotate the
seal retainer (3) back and forth 90°, 3-4 times.
Spin 360° 3-4 revolutions.

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FIGURE 8:
Typical Seal Assembly

9. Install washers (23), belleville washers (47) (convexsideup)
andcapscrews(18) andhandtighten.
Reduced port seal re tain ers (3) have recess
es ma chined-in to receive the washers
(23, 47). See Figure 17. These ensure that
the elon gat ed port (slot) is prop er ly aligned.
Wrench-tighten the cap screws (18) in 1/2
revolution in cre ments, in an alternating pattern,
until tight.
NOTE: The seal retainer gasket (9) and the soft
seal (10) are not “set” until the valve is placed in
the line and compressed between fl anges. If the
seals are “set” by clamping the valve between the
fl ang es during a seat leak age test, retighten the
cap screws (18) to hold the seal retainer (3) and
seals (9, 10 and 11) fi rmly in place. Once a soft
seal (10) is “set” by clamping the valve be tween
fl anges, it cannot be re moved, re in stalled and then
prop er ly centered to pro vide Class VI shutoff.
10. On ATO-FC and ATC-FO Valves with out
handwheel (58), replace cover plate (20)
and machine screws (36). De pres sur ize the
ac tu a tor for ATC-FO valves and dis con nect
tem po rary air sup ply.
11. Return to Section III.A. through F. for in stalla
tion instructions.

D. Stem Removal:

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  1. Remove the actuator as sem bly (AA) from the
    valve body as sem bly (BA). Refer to Ac tu a tor
    main te nance manuals IOM-48 or 148.
    2. Secure body (1) in a vise with the stem (7)
    hor i zon tal to the fl oor. Place matchmarks
    be tween yoke (12) and body (1) to assist in
    fi nal orientation when re-assembled.
    3. For live-loaded construction:
    a. Loosen both packing fl ange nuts (22) until
    clearance exists between the bot tom of
    the nut (22) and the retainer (28).
    b. Spacer ring (29) should “spin freely”. If
    stacked mech a nism (27)(28)(29) is not
    loose due to corrosion, debris, packed
    dirt, etc., tap the spacer ring (29) lightly
    while at tempt ing to pry up the spacer ring
    (29) bottom with a thin fl at tool.
    c. Remove both packing fl ange nuts (22)
    only after the live-loaded mechanism (27)
    (28)(29) is “free” and loose.
    d. Pry up both live-loaded mechanisms (27)
    (28)(29) one side at a time. Carefully lift the
    mechanism (27)(28)(29) over the pack ing
    stud (21) ensuring that the Belleville spring
    washers (27) are not dropped in removal,
    preventing a de ter mi na tion of washers'
    (27) orientation one-to-the-oth er. Set
    the two mech a nisms (27)(28)(29) down
    together, side by side.

  2. e. Inspect the retainers (28) for ori en ta tion.
    Both of the retainers (28) should have
    the same orientation. Improper/differing
    ori en ta tions will cause un bal anced loading
    of the packing rings (13). See Figure
    9 for proper ori en ta tion.
    f. Inspect both spring washer (27) stacks
    for proper orientation by carefully lifting
    off the spacer ring (29) and retainer (28),
    exposing the spring washer (27) stack.
    Each stack of spring washers (27) should
    be oriented the same. Improper/differing
    orientation will cause unbalanced load ing
    of the packing rings (13). See Figure 9
    for proper orientation.
    g. Replace all Belleville spring wash ers (27)
    if there are any signs of corrosion. It is
    recommended that spring washers be
    replaced in full sets. The spacer rings (29),
    retainers (28), as well as the packing studs
    (21) should be re placed if corroded.
    h. Remove yoke (12) bolting by removing
    two cap screws (19) on 1", 1-1/2" and 2"
    sizes, or two nuts (22) on the 3", 4", 6"
    and 8" sizes.

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                         FIGURE 9
Ranger Live-Loaded Packing Design
Initial Setting
Position - TYP
Maximum Wear Position
-Adjustment Required - TYP
Max Wear 0.050"-0.060"
- TYP Max Wear 1" & 1-1/2" RANGERS ONLY
8 Spring Washers - Inverted Retainer
i. Pull yoke (12), packing fl ange (14), pack ing
follower (15) and follower bushing strip
(16) off over end of stem (7). Re place packing
follower (15) if sig nifi cant ly cor rod ed.
Always replace fol low er bushing strip (16)
when of standard construction. (NOTE:
When Opt-38HT high tem per a ture packing
is sup plied, the packing fol low er (15.1)
con tains a pressed-in car bon bush ing
(15.2) that is not fi eld re place able and
must be sup plied as a packing follower
(15) sub as sem bly.)
j. Loosen stem retainer screw (17) by ro tating
CCW (viewed from above screw head)
2-3 rev o lu tions to check for trapped fl uid.
After all fl uid is vented, remove screw
(17).
k. Rotate stem (7) CW when viewed from
actuator end of stem (7) to close plug
(6).
l. Withdraw stem subassembly (7), retainer
sleeve subassembly (8) and packing set
(13) out of body (1).
NOTE: If diffi culty is encountered in re mov ing
the stem subassembly (7), use a puller assem
bly. See Figure 10. Hold the double nut
with a wrench to prevent rotation of the stem
as this could damage the seals if the trim is
still in the valve body (1). Use the single nut
to jack the stem sub as sem bly (7) out.

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FIGURE 10: Stem Puller

m. Using a suitable solvent acceptable to the owner,
thoroughly clean the valve stem (7) and the
body's (1) stuffi ng box. Inspect surface fi nish of
stem sub as sem bly (7) and internal wall fi nish of
packing box bore at packing (13) area. If deeply
scratched, corroded or pit ted, re place with new
parts.
n. It will be desirable to restore the surface of
the body's (1) stuffi ng box to 16 mi cro-inch Ra
fi nish; metal removal should not exceed 0.001
inch ma te ri al.
o. It will be desirable to restore the sur face of the
stem's (7) critical area to 6–8 micro-inch Ra fi nish
or better, metal re mov al should not exceed
0.001 inch ma te ri al. Minimum stem OD should
not be less than indicated in Table 4.
p. Remove retainer sleeve sub as sem bly (8) from
stem subassembly (7). Ex am ine carbon bushing
insert of re tain er sleeve subassembly (8)
for dam age or signs of wear. Replace re tain er
sleeve sub as sem bly (8) if worn more than 0.005
inch (0.13 mm). See Figure 12 for indicated
di men sion “X”.

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q. Examine packing studs (21) and nuts (22).
Replace if signs of corrosion are present.

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4. For Non-Live-Loaded Packing Con struc tion:
a. Remove two packing flange stud nuts
(22) and two cap screws (19) on the 1",
1-1/2" and 2" sizes, or four nuts (22) on the
3", 4", 6" and 8" sizes.
b. Pull yoke (12), packing fl ange (14), pack ing
follower (15) and follower bushing strip (16) off
over end of stem (7). Re place packing follower
(15) if sig nifi cant ly cor rod ed. Always replace
fol low er bushing strip (16) when of standard
construction.
c. Proceed with previous steps 3.j. through 3.q.
for stem removal.
E. Stem Reassembly – Trim Retained in Body:
1. Slide retainer sleeve subassembly (8) onto
the stem subassembly (7), with the car bon
bushing (8.2) end against the shoul der of the
stem subassembly (7).
NOTE: For Slurry Trim see Subsection H.
2. Insert the stem/retainer sleeve (7)(8) as sembly
into the body (1), aligning the hole in the
retainer sleeve (8) to be directly in line with
the thread ed hole in the body (1) bonnet.
Align the stem sub as sem bly (7) so that the
plug’s (6) tongue and the stem's (7) groove
will engage.


NOTE: A small "fl at" area has been milled on the
stem and for correct engagement this "fl at" must
be on the same side as the face of the plug (6).

image.png

3. Visually confi rm alignment of hole in re tain er
sleeve (8.1) with threaded hole in body (1)
bonnet. Place thread sealant Cotronic Resbond
907, or equal, on stem retainer screw
(17) threads for valves used in non-oxygen
service; thread sealant to be Oc ci den tal
Petroleum Corp. Fluorolube GR-362, or
equal, for valves used in oxygen service.
Insert and tight en stem re tain er screw (17)
20-25 ft# (27-34 N-M) for 1"– 2" sizes,
80-85 ft# (108-115 N-M) for 3"– 8LF" sizes
and 90 ft# (122 N-M) for 8"HF size.
4. Rotate stem (7) to ensure tongue and groove
engagement with plug (6).


5. Proceed to Subsection G. for installation of
pack ing (13).
F. Stem Reassembly – Trim Removed from Body
1. Install retainer sleeve subassembly (8) and
stem subassembly (7) in ac cor dance with
Subsection E, Ar ti cles 1 through 3, pre vi ous.
Rotate stem (7) to plug's (6) closed po sition.
2. Install trim in accordance with Subsection C,
Ar ti cles 1 through 10, previous.
3. Install packing in accordance with Subsection
G.
G. Packing Replacement:
Remove stem as per Subsection D. previous and
pro ceed as follows.
1. Secure body (1) in a vise with stem (7) vertical
to the fl oor. Reassemble stem (7) per
ap pro pri ate Subsection E., F., or H.
2. Never replace packing (13) without re condi
tion ing the stem (7) surface fi nish and the
body (1) stuffi ng box as specifi ed in Sub sec tion
IV.D.

3. For TFE V-Ring Packing. (See Figure 11.)
NOTE: Following text pertains to “stan dard”
pack ing stack (13) orientation. Stack procedures
differ slightly for other packing options. See Figure
11.
a. Remove packing follower bushing strip
(16). Solvent clean packing follower (15).
Insert new packing follower bushing strip
(16). Ensure no overlap of strip (16).
b. Carefully place lower adapter (13.1) of
packing ring set (13) over stem's (7) end,
properly oriented (see Figure 11). Using
the packing follower (15), push the adapt er
(13.1) into the body's (1) stuffi ng box.
c. Carefully install the fi rst individual V-ring
(13.2) over stem's (7) end, properly orient
ed. Push down as far as possible using
fi n gers. Carefully place each ring (13.2)
upon the other until all V-rings (13.2) are
stacked, properly oriented.
d. Place upper adapter ring (13.3) over the
stem's (7) end, properly oriented.
e. Place the packing follower (15) over the
stem (7) end, properly oriented, until
sit ting on the upper adapter ring (13.3).

image.png

FIGURE 11
Packing Stack Orientation
Push down on the packing follower (15)
using fi ngers; all V-rings (13.2) and upper
adapter (13.3) should easily slide into the
body (1) stuffi ng box.
NOTE: It will be necessary to pull up on
the stem (7) as the adapters (13.1, 13.3)
and packing rings (13.2) are “pushed” into
the stuffi ng box.
f. For body sizes 1", 1-1/2" & 2":
f.1. Slide both yoke (12) and packing
fl ange (14) over end of stem (7), proper
ly ori ent ed, and over pack ing studs
(21). Align matchmarks be tween body
(1) and yoke (12).
f.2. Install two cap screws (19) to assem
ble the yoke (12) to the body (1)
securely.
g. For body sizes 3", 4", 6" & 8":
g.1. Slide yoke (12) over end of stem (7),
properly oriented, and over packing
studs (21). Align matchmarks between
body (1) and yoke (12).
g.2. Slide packing fl ange (14) over end of
stem (7), properly oriented, and over
pack ing studs (21).
g.3. Install two nuts (22) on studs (20) to
assemble the yoke (12) to the body
(1) securely.
h. Proceed to Article 6 for Opt-38 Jammed
Pack ing.

With Externally Live-Loaded Construction
pro ceed as follows:
i. Place each spring washer (27) stack over
its packing stud (21) oriented as shown
in Figure 9.
j. Place each spacer ring (29) over its packing
stud (21) and spring washer stack (27)
oriented as shown in Figure 9.
k. Place each retainer (28) over its packing
stud (21) oriented as shown in Figure 9.
Ensure that each retainer (28) is properly
positioned into each spacer ring's (29)
groove, and that the retainer's (28) in version
is correct.
l. Proceed to Article 5. , this Subsection.
4. For Opt-38HT High Temp Packing:
a. Solvent clean the packing follower (15).
b. Carefully place the lower braided ring
(13.4) over the stem's (7) end. Using the
packing follower (15) push the braided
ring (13.4) into the body's (1) stuffi ng box.
NOTE: It will be necessary to pull up on
the stem (7) as the rings (13.2, 13.4) and
lower adapter (13.1) are “pushed” into the
stuffi ng box.

c. Carefully place the lower adapter (13.1)
properly ori ent ed (see Figure 11) over the
stem's (7) end and push into the stuffi ng
box similar to the lower braided ring (13.4)
of Step 4.b.
d. Carefully place a packing ring (13.2)
prop er ly oriented (see Figure 11) over the
stem's (7) end and push into the stuffi ng
box similar to the lower braided ring (13.4)
of Step 4.b. Repeat for each ring (13.2).
e. Carefully place the upper adapter (13.3)
similar to the lower retainer (13.1) of Step
4.b. Leave packing follower (15) in po sition,
properly oriented.
f. Place the packing fl ange (14) over the
stem's (7) end and over the packing studs
(21). Place the retainer (28) over each
stud (21). Install packing nuts (22) and
fi nger-tighten.
g. Wrench-tighten the packing nuts (22) in
1/2 revolution increments until the “upper
groove” identifi ed as “Line A” (see Figure
13) on the packing follower (15) is fl ush
with the top edge of the body's (1) stuffi ng
box.
h. Remove the packing nuts (22), retainers
(28), packing follower (15) and packing
fl ange (14).

i. Carefully place the upper braided ring
(13.5) over the stem's (7) end and push
into the stuffi ng box similar to the lower
braided ring (13.4) of Step 4.b. Leave
packing follower (15) in position.
j. Place the packing fl ange (14) over the
stem's (7) end and over the packing studs
(21). Place the retainers (28) over each
stud (21). Install packing nuts (22) and
fi nger-tighten.
k. Repeat Step 4.g. with the exception that
the packing set (13) is to be compressed
into the stuffi ng box until the “lower groove”
identifi ed as “Line B” (see Figure 13) on
the packing follower (15) is fl ush with the
top edge of the body's (1) stuffi ng box.
l. Remove the packing nuts (22), retainers
(28) and packing fl ange (14).
m. For body sizes 1", 1-1/2" & 2":
m.1. Slide both yoke (12) and packing
fl ange (14) over end of stem (7),
prop er ly ori ent ed, and over packing
studs (21). Align matchmarks
be tween body (1) and yoke (12).
m.2. Install two cap screws (19) to assem
ble the yoke (12) to the body
(1) securely.

n. For body sizes 3", 4", 6" & 8":
n.1. Slide yoke (12) over end of stem (7),
properly oriented, and over packing
studs (21). Align matchmarks
be tween body (1) and yoke (12).
n.2. Slide packing fl ange (14) over end
of stem (7), properly oriented, and
over pack ing studs (21).
n.3. Install two nuts (22) on studs (20) to
assemble the yoke (12) to the body
(1) securely.
o. Place each spring washer (27) stack over
its packing stud (21) oriented as shown
in Figure 9.
p. Place each spacer ring (29) over its packing
stud (21) and spring washer (27) stack
oriented as shown in Figure 9.
q. Place each retainer (28) over its packing
stud (21) oriented as shown in Fig ure 9.
Ensure that each retainer (28) is properly
positioned into each spac er ring's (29)
groove, and that the retainer's (28) in version
is correct.
5. Common For All Live-Loaded Designs:
a. Install packing nuts (22) fi nger-tight down
to each retainer (28).

b. Draw down each packing nut (22) in
al ter nat ing 1/2 revolution increments,
check ing each spacer ring (29) after each
tight en ing. When spacer ring (29) can no
long er be rotated freely by fi ngers, make
an ad di tion al 1/2 revolution – no further
tight en ing should occur to main tain the
“live-loaded” intent of the design. Overtight
en ing of the design as de scribed
caus es the mechanism to func tion as
a “jammed pack ing. This will de feat the
design intent of the mech a nism and will
increase packing (13) wear.
c. Refer to Actuator Maintenance Man u als
IOM-48 or 148 to reconnect ac tu a tor/arm
housing (AA) to yoke (12).
6. Common to Opt-38J Jammed Packing
Only:
NOTE: Packing follower (15) must penetrate into
the stuffi ng box of the body (1).
a. Install nuts (22) on packing studs (21) and
fi nger tighten.
b. Refer to Actuator Maintenance Man u als
IOM-48 or 148 to reconnect ac tu a tor/arm
housing (AA) to yoke (12).
c. Tighten packing nuts (22) to torque levels
indicated in Table 5.

image.png

NOTE: When valve is returned to operation, check
for leakage and tighten the nuts (22) evenly in
alternating 1/4 revolution in cre ments until leak age
stops. DO NOT OVERTIGHTEN.

H. Slurry Trim – Opt-AS:
1. Install the trim in the body (1) per Section IV,
Sub sec tion C, Articles 1 through 10.
2. Slide retainer sleeve subassembly (8) onto
the stem assembly (7) with the stem retainer
carbon bushing (8.2) end against the stem
(7) subassembly shoulder.
3. Apply lubricant (silicon grease or equiv a lent)
to O-ring (30), and slide backup ring (31) and
O-ring (30), re spec tive ly, into groove on stem
(7) groove-end. See Figure 21 for O-ring (30)
orientation.
4. Insert the stem/retainer sleeve (7)(8) as sembly
into the body (1), aligning the hole in the
retainer sleeve (8) to be directly in line with
the thread ed hole in the body (1) bonnet.
Align the stem sub as sem bly (7) so that the
plug’s (6) tongue and the stem's (7) groove
will engage. Insert as sem bly.

image.png

NOTE: A small "fl at" area has been milled on the
stem and for correct engagement this "fl at" must
be on the same side as the face of the plug (6).
5. Visually confi rm alignment of hole in re tain er
sleeve (8.1) with threaded hole in body (1)
bonnet. Insert and tighten stem re tain er screw
(17).
6. Rotate stem (7) to ensure tongue and groove
engagement with plug (6).
7. Proceed to Section IV, Subsection G. for
in stal la tion of packing (13).
J. Pressure Test:
1. Cashco recommends that a pressure integrity
test be performed following reassembly when
the pack ing set (13) has been replaced.

SECTION V

V. STARTUP
A. General:
1. Ensure that the Ranger QCT unit has been
properly adjusted and calibrated, including
the positioner if installed, per actuator mainte
nance manuals IOM-48 or 148.
2. Recommend startup to be in “manual” mode.
This procedure assumes double block (isola
tion) and bypass valves for the “control valve
station”. See Figure 1.
3. Start with one of the two block valves closed,
with the other open. The bypass valve should
be closed. Pressurize system if possible/
prac ti cal.
4. Back out the airset's adjusting screw until
loose.
5. Turn on air supply pressure.
6. Adjust the air supply airset (fi lter-regulator)
to the proper level as indicated on the unit's
nameplate (20), in IOM-48 or IOM-148, or
the tech ni cal bulletin Ranger-TB. DO NOT
STROKE THE CONTROL VALVE WITH
AN AIR SUPPLY PRES SURE SETTING
GREAT ER THAN REC OM MEND ED MAX IMUM PRESSURE!

7. Place loop controller into “manual” mode. Vary
setting from minimum – mid-range — maximum
SIG output. Observe response of control
valve unit to these changes of input SIG. The
valve should fully stroke at the variation from
minimum SIG to maximum SIG; the mid-range
SIG should have the valve stem travel at/near
1/2 open.
8. Confi rm that action of controller and po si tion er
– direct or reverse – are producing the desired
response in the control unit. Confi rm that the
control valve “fail” position is as re quired.

9. Hereafter, the procedure assumes that actual
fl uid fl ow may be established. This may not
be practical/possible in all cases; if so, vary
pro ce dure as required.
Always “heat” or “cool” down the system pip ing
SLOW LY by opening the control valve station
bypass valve in small in cre ments.

image.png


10. With one of the control valve station block
valves still closed, and the loop controller
still in “manual” mode, open bypass valve
and vary fl ow rate manually to observe the
re sponse of the controller and control valve
unit together.
11. Attempt to develop manual control of the loop
by opening/closing the manual bypass as required,
or by manually controlling main stream
fl ow as required.
12. When the control valve is partially open, slow ly
crack open the closed block valve while si mul -
ta neous ly closing the bypass valve; it may be
necessary/desirable to vary the manual out put
SIG from the controller simultaneously also.
Continue this pro ce dure until the bypass is
closed and the block valves are both fully open.
The system is still under “manual” mode control,
but all fl ow is passing through the control
valve.
13. Vary controller “manual” SIG output until
match ing the “automatic” SIG output, then
change the mode of the controller over to
“automatic”, and the loop will experience a
minimum of upset conditions, and will be in
automatic control.


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