Instruction Manual

Globe Single Seated Valve

Series-1100
1Feb 2009

0062 2 G/D T 3/4/5/6

CONTENTS PAGE NO.
1.0 Foreword 2
1.1 Scope of Instruction Manual 2
1.2 Copyright and Modification Rights Reservation 2
2.0 Storage & Preservation 2
3.0 Valve Marking 3
4.0 Health & Safety 4
5.0 Unpacking 5
6.0 Lifting Details 6
7.0 Installation 7
8.0 Maintenance 9
8.1 Removing Actuator from Valve Body 10
Fig.2 Direct & Reverse Acting Actuator 10
Fig.3 Various Gland Packing Arrangements 11
8.2 Packing Maintenance 12
9.0 Replacing Gland packing 12
9.1 V-PTFE Packing 13
9.2 Double V-PTFE Packing 13
9.3 Grafoil Packing 14
9.4 Double Grafoil Packing 14
9.5 V-PTFE Fugitive Emission Packing 15
9.6 Grafoil Low Fugitive Emission Packing 15
Fig.4 Trim Combination 16
10.0 Trim Maintenance. 17
10.1 Disassembly 17
10.2 Assembly 18
Fig.5 Direct & Reverse Acting Actuator 18
10.3 Lapping Procedure 19
11.0 Reassembly of Actuator on valve body 19
11.1 Direct Acting Actuator 19
11.2 Reverse Acting Actuator 20
12.0 Trouble Shooting 20
13.0 Torque for Studs 21
14.0 Recommended Spares 21
15.0 Part Illustrated 22

1
1.0 Foreword

1.1 Scope of Instruction Manual

This Instruction Manual covers Information regarding Installation and Maintenance of Dembla's Globe two
way Valves, Series 1100,Valve Size ½”in.(DN15) to 16”in (DN400) No person may Install, operate or
maintain Dembla valve without 1) being fully trained and qualified in Valve, Actuator and Accessory
Installation, operation and maintenance 2) Carefully reading and understanding the contents of this Manual.

If you have any questions about these Instructions contact your Dembla sales office before proceeding.

1.2 Copyrights And Modification Rights Reservation

Dembla Valves Ltd. retains the Copyright on the contents of this Instruction Manual. The Total content of this
Instruction Manual described here corresponds to the information during preparation of the Instruction Manual. It
is user's responsibility to refer the latest version. All data, specifications and illustrations here are subjected to
Technical Modifications and improvements and hence Modification can be done by us at any time without any
prior notice. No claim to Modification or repair of these valves, which have already been supplied by us, can be
made.

2.0 Storage & Preservation

All Valves are dispatched in the closed/open position as ordered and it is recommended that they are left
in this position during storage. All protective packing should remain in position until the Valve is to be
installed. Valve should be stored in a clean and dry environment, without disturbing company setting.
(E.g. Gland, Seat etc.) Protect it from shock & lifting damage.

! Caution

If hoisting the Valve, use a nylon sling to protect the surface. Carefully position the sling to prevent
damage to Actuator tubing and any Accessory. Also, take care to prevent people from being injured in
case the hoist or rigging slips unexpectedly. For Weight refer Valve Packing Slip.

2
3.0 Valve Marking

1) Valve name plate attached on Valve by riveting carrying all Valve Identification Information.

2) Markings like Valve Size, Rating, Material etc. are as cast on Valve Bodies.

3) Valve Serial no. punched on Valve Body Flange for Valve Traceability.
4) If the product is not CE marked, then Name plate also without CE mark.

Name plate for

Series:-1100 Valves

0062 II 2 G/D T *

INDIA

3
4.0 Health & Safety
! Warning
1) Before attending to Valve Installation / Maintenance, the Instruction Manual must be compulsorily read and
understood properly.

2) Valve must be operated by qualified personnel.

3) Ensure that the operator handling these Valves must follow Safety and Accident Prevention Rules and
Regulations.
4) Follow the Safety Instructions before Installation, Maintenance or removing the Valve.

5) Always wear protective gloves, clothing and eyewear when performing any Installation operations to
avoid personal injury.

6) All Safety Messages such as Cautions, Warnings and Notes are highlighted in this Instruction Manual
which must be strictly followed to avoid any possibility of arising danger / risk of damage to the
equipment / person's life
7) No Liability on Manufacturer for any wrong handling, improper commissioning and wrong
assembly.
8) Line must be fully drained and de-pressurized before Installation or Maintenance of Valve.

9) Never handle Valves that have been used on harmful substances unless they have been completely
decontaminated and certified safe to handle.

10) Due to the large physical size and weight of some size of this product, always use correct lifting methods
and equipment when Installing , removing and Maintaining the product: Use lifting lugs on the body, wherever
provided. Valve without lifting lugs-use chains or slings wrapped around the Body. Do not attempt to lift the Valve
using the sealant fittings, gear unit, handwheel, Actuator, or the Valve Stem.
11) If the processes or environments that the products are used in are likely to cause temperature (high or
low) that may cause injury to person if touched, then adequate insulation /protection must be fitted. It is
recommended that the insulation allows easy access for Maintenance , to the sealant fittings , and to the
Valve operator.
12) Valve must be protected from earthquake loading, traffic & wind.

13) No Modification / Conversions are allowed without written authorization from Dembla Valves Ltd.

4
5.0 Unpacking

For Carton
· Keep Carton in position (Carton ‘up side’ should not be ‘down’).
· Cut plastic strip properly which is tied around Carton & remove it. (White in colour).
· Cut cello tape properly which is stuck on Carton opening.
· Open Carton properly.
· Remove foam properly along with polythene wrapping.
· Lift the valve properly & keep on clean & dry place

For Wooden Box

· Keep Wooden Box in Position (’upside’ of Wooden box should not ‘down’).
· Cut iron strip properly which is tied around Wooden Box & remove it.
· Remove nail properly from top cover with proper equipment.
· Loosen and remove Valve fixing nut (from inside of Box).
· Lift the Valve properly as shown in figure 1

5
6.0 Lifting Details

Valve should be lifted by using chain (Take care that Valve should not damage while handing) or bearer
cables as shown in figure 1.

DEMBLA

Fig. 1

6
7.0 Installation
! Warning
· The Valve configuration & Material of construction were selected to meet particular pressure,
temperature, pressure drop and controlled fluid condition. Since the Body and trim Material
combinations are limited in their pressure drop and temperature ranges, hence do not apply any other
condition to the valve without first contacting, Dembla Valves Sales office or Sales Representative.
· Before installing WELDING END Bodies, having soft seating arrangements, remove the trim to
avoid damage to soft parts from the heat generated by welding.

Before installing any Control Valve please check the following. :-

1) Inspect it for any shipment damage and for any foreign material that might have been collected during
packing & shipment.
2) Blow out all pipe lines to remove pipe scale, chips, welding, slag & other foreign material.
3) Before installing the Valve make sure that pipeline flow is in the same direction as the arrow on the side
of the Valve.

4) Install the Control Valve preferably in a straight run of pipe away from bends or sections of abnormal
velocity.

5) Control Valves can be installed in any orientation but the normal method is with the Actuator Vertical.
Should the need arise to install the Valve in other positions, adequate supports must be given to Yoke.
6) If continuous operation is required during maintenance and inspection, a conventional three-way Valve
by pass should be installed.
7) Install the Valve using accepted piping practices. For Flanged Bodies use a suitable Gasket between the
Body and pipe line Flanges and tighten the bolts evenly to avoid any strain on the Body or cracking of
Flange.
8) An air supply pressure regulator with filter should be installed in the air line ahead of any
instrument on the Valve.

! Warning

· Always wear protective gloves, clothing, and eye ware when performing any installation
operation to avoid personal injury.
Rise in temperature on surface of Valve Body depend on working media. End user must be
maintaining the surface temperature & it should not go beyond marking temperature on Valve
(Name Plate).

· Always wear protective gloves, clothing, and eye ware when performing any installation
operation to avoid personal injury.

7
 ! Warning
· Valve should be used by End-user with same pressure & temperature rating which as given in
valve marking (Name Plate) If there is any change please contact Dembla Sales Office.

· Avoid personal injury or property damage caused by components dropping .With the Valve or
Actuator upside, components may drop during disassembly or Assembly. Be careful not to position
yourself below the valve in the path of falling parts.

· Personal injury could result from Packing Leakage. Valve Packing was tightened prior to shipment,
but should there be any Gland Leakage after Installation, further tightening, just enough to stop
Gland Leak is required. Excessive tightening will disturb Valve Calibration.

· Our Valves can not be used for Defence, Nuclear, Telecommunication, Marine, Railway and
Laboratory & Mines.

· Our Valve is valid for atmospheres having pressure ranging for 0.8 bar to 1.1 bar and
temperatures ranging for -20ºC to +60ºC .

· Earthing facility must be provided by the end user before operating the Valve.

· Equipment should not be used for dead end service.

After the Valve has been Installed, make a final check of the following :-

1) An occasional cleaning of Valve Stem will prevent dirt or grit being carried away into the Packing.

2) Vary air lines and fitting to the Actuator to ascertain actual Travel Scale Indication.

3) Check all air lines and fitting to the Valve Actuator & Accessories for air leaks.

4) Ensure that the combined Action of Controller, Positioner and Valve provide the desired Valve Stem Movement.
Also ensure the required fail safe position of Control Valve.

! Caution

· In case of Leak, presence of high temperature may be dangerous to the person life.
· Equipment to be used as per intended and not misused / improperly use to avoid dangerous effects
such as over Load ,over heating ,stress corrosion cracking, etc.

8
8.0 Maintenance ! Warning

· Avoid personal injury or damage to process system from sudden release of pressure of process
fluid.
· Before starting dis-assembly use by-pass Valve or completely shut off the process to isolate the
Valve from process pressure. Drain fluid from both ends of the Valve.
· Disconnect all operating lines providing air pressure, electric power or a Control Signal to the
Actuator.

· Earthing facility and Valve parts should be checked periodically by the end user.

· Any Gasket once removed should be replaced by a new one upon re-assembly. This is necessary to
ensure a good seal since the used Gasket may not seal properly.

· Equipment should be cleaned regularly.

9
8.1 Removing Actuator From Valve Body

Note

The Valve Plug must be off the Seat while the Stem Connector is being removed.

Refer Fig. 2. below:-

1) Release Spring Compression.

2) Loosen the travel Indicator Lock Nut.

3) Unscrew the Allen Bolts of Stem Connector& take off the two halves of Stem Connector.

4) Unscrew the Yoke Locking Ring (Part Ring) & remove it out of Bonnet.

5) Lift the Actuator Assembly over the Valve Stem, off the Valve, taking care to avoid damaging any Valve part
or accessories attached to it.

10
 VARIOUS GLAND PACKING ARRAGEMENTS

SINGLE V-PTFE DOUBLE V-PTFE DOUBLE V-PTFE

WITH SPRING DOUBLE BRAIDED RINGS
WITH SPRING WITHOUT SPRING

V-PTFE BRAIDED RINGS

WITHOUT SPRING

FIG.3
11
8.2. Packing Maintenance

For Packing Arrangement, please refer to Fig. 3.

If there is undesirable Packing Leakage tight the Gland Flange Nuts just enough to stop Gland Leakage. If
Leakage cannot be stopped in this manner, proceed to Section 9. “Replacing Gland Packing”. Do not tight the
Packing excessively, this may disturb the Calve Calibration.

9.0 Replacing Gland Packing

1) Isolate the Control Valve from line pressure & release the pressure.
2) Remove Actuator from Valve Body as shown in section 8.1 “Removing Actuator from the Valve Body.

3) Remove the Nuts from Body Studs on Bonnet and lift the Bonnet carefully off the Body. If the Valve Plug & Stem
assembly starts to lift along with bonnet, use a brass or Nylon hammer on the end of the Stem & tap it back down.

! Caution
Set the Bonnet on a protective surface to prevent damage to the Bonnet Gasket surface.
4) Remove the Valve Plug & stem assembly from the Body.

Handle the Plug & Stem carefully to avoid the damage at seating surface of & Stem diameter.

5) Unscrew and remove Gland Flange Nut.

6) Remove Gland Flange.
7) Push out Gland Packing from the Bonnets bottom side Gland Packing & Spreader carefully take out by
using a rounded rod or other tool that will not scratch but clean the stuffing box wall.

8) Install Plug & Stem assembly. Then slide the Bonnet over the Stem and on to the Body Studs.

9) Install new Packing Seal & Metal Gland Parts according to the appropriate arrangement.
10) Lubricate the Body Studs and Install the Nuts. Use accepted bolting procedure during tightening so that
the Body to Bonnet joint will with stand test pressures and application service condition, before tightening
nuts make sure that Plug & Stem assembly is properly aligned with Seat Ring.
11) For the Installation of Gland Packing refer following 9.1 to 9.6

12) Mount the Actuator & Connect Stem Connector as specified in the “Reassembly of Actuator on Valve body”
Refer Section 11.0 of this Manual.

12
9.1 V-PTFE Packing

NUT GLAND STUD

GLAND FLANGE
GLAND BUSH PACKING SPREADER (FRONT)

V-PTFE GLAND PACKING

PACKING SPREADER (REAR)

VALVE SHAFT

This Gland Packing consists of 1 Rear Packing Spreader, 1 set of V-PTFE Gland Packing and 1 Front Packing
Spreader.
(1) Place the V-PTFE Gland Packing set in the Body after 1 Rear Packing Spreader followed by Front Packing
Spreader as shown in Fig. 9.1 Lubrication is not required.
! Caution
Push each V-PTFE Packing carefully inside to avoid the Packing lip to bend towards the outer side.
(2) Insert the Gland Bush.
(3) Insert the Gland Flange on Gland Studs and tighten their Nuts to specified torque.

9.2 Double V-PTFE Packing

NUT GLAND STUD

GLAND FLANGE
GLAND BUSH FRONT PACKING SPREADER (of 2 nd set)

V-PTFE GLAND PACKING(of 2 nd set)

REAR PACKING SPREADER (of 2 nd set)
FRONT PACKING SPREADER (of 1st set)
V-PTFE GLAND PACKING (of 1st set)
VALVE SHAFT REAR PACKING SPREADER (of 1st set)

13
 This Gland Packing consists of 1st set of Front and Rear Packing spreader, 1st set of V-PTFE Gland packing, 2nd
set of Front and Rear Packing Spreader & 2nd set of V-PTFE Gland Packing.
1) Place the 1st set of V-PTFE Gland Packing after Rear Packing Spreader of 1st set followed by the Front Packing
Spreader of 1st. set.
2) On the Front Packing Spreader of 1st. set place the 2nd set of V-PTFE Gland Packing after Rear Packing
Spreader of 2nd set followed by the Front Packing Spreader of 2nd set.
3) Insert the Gland Bush.
4) Insert the Gland Flange on Gland Stud and tighten their nuts to specified torque.

9.3 Grafoil Packing

NUT GLAND STUD

GLAND FLANGE
GLAND BUSH

GRAFOIL GLAND PACKING

VALVE SHAFT VALVE BODY

9.4 Double Grafoil Packing

NUT GLAND STUD

GLAND FLANGE
GLAND BUSH

GRAFOIL GLAND PACKING

LANTERN RING

GRAFOIL GLAND PACKING

VALVE SHAFT

14
9.5 V-PTFE Low Fugitive Emission Packing

NUT GLAND STUD

SPRING WASHER WASHER
GLAND FLANGE
GLAND BUSH FRONT PACKING SPREADER

V-PTFE GLAND PACKING

REAR PACKING SPREADER

VALVE SHAFT

9.6 Grafoil Low Fugitive Emission Packing

NUT GLAND STUD

SPRING WASHER
GLAND FLANGE
GLAND BUSH

GRAFOIL GLAND PACKING

VALVE SHAFT

15
TRIM COMBINATION

FIG.4

16
10.0 Trim Maintenance.

10.1Disassembly

1) Isolate the Control Valve from line pressure & release the pressure from the Valve.
2) Remove Actuator from Valve Body as shown in Section 8.1 “Removing Actuator from Valve Body”.

3) Remove the Nuts from Body Studs on Bonnets end and lift the Bonnet carefully from the Body. If the Valve
Plug & Stem assembly starts to lift along with Bonnet, use a brass or Nylon hammer on the end of the Stem
& tap it back down.

For Trim arrangement please refer Fig. No. 4.

! Caution

Avoid damaging Gasket Seating surface. The surface finish of the Valve Stem is critical for making
a good Packing Seal. Handle these parts carefully.

4) If required remove Gland Packing. (Refer. 9.0 to 9.6)

5) Remove Stem with the Plug from Valve.
6) Drive out the Locking Pin and unscrew the Stem from Plug.

7) If required replace Plug / Stem with new one. (From Dembla Valves)

8) Unscrew and remove the seat should it require machining or replacement.

9) Use reverse sequence for Plug and stem assembly.

10) Keep all part on clean and dry space properly.

For Soft Seated Plug Disassembly (Refer fig. 4)

1) Plug below 4” :-

i) Hold Plug- shank than unscrew Plug nose and remove it.
ii) Remove Soft Facing if required.
iii) For assembly use reverse sequence.

2) Plug above 4” :-

i) Hold Plug Shank loosen and remove Plug Nose bolds.

ii) Remove Plug Nose.
iii) Remove Soft Facing it required.

Iv) For assembly use reverse sequence.

17
10.2 Assembly

1) Clear all Gasket surface & use all new Gasket for assembly.
2) Install Seat Ring in the Body.

3) Insert Plug & Stem assembly in the Body so as to gently rest over the Seat. Then slide the Bonnet over the
Stem and tight the nuts on to the Body studs. Before tightening the nuts make sure that Plug and Stem
assembly is properly aligned with Seat Ring.

! Caution

If the Packing is to be re-used and was not removed from the Bonnet, take care when Installing

Bonnet to avoid damaging the Packing with the Valve Stem threads. However the stem threads are
always truncated.

4) Install Gland Packing refer. 9.0 to 9.6

5) Lubricate the Body Studs & Install Nuts. Use accepted bolting procedure during tightening
6) Mount Actuator & Connect Stem Connector as specified in the section 11.0 “Reassembly of Actuator on
Valve Body.”

Fig. 5

18
10.3 Lapping Procedure

a) Produce a simple Lapping tool. This can be made by welding a screwed Stud ( having threading to match
with Plug)to the centre of a Hexagonal bar about one foot long. Screw and lock the tool to the end of the
plug.

b) Apply Lapping compound to the seating surface of the Seat Ring only. Lubricate the Plug Stem where it
enters the Bonnet, with light oil.
c) Lap with short oscillating strokes. The Weight of the Plug, Stem and Lapping tool provide ample pressure for
Lapping. Do not bear down.
d) Raise the Plug occasionally, lower of to another position and resume the oscillation strokes. This ensures an
even lap over the entire seating surface of Plug and Seat.

e) Approximately 5 to10 minutes Lapping time is usually required to obtain a satisfactory fit between a new
Plug and Seat.

f) Clean the Plug and Seat. Holding the Plug on to the seat by hand, apply compressed air to the inlet side of
the Valve to check the tightness of the Lapped parts. Repeat the lapping procedure, if necessary.
g) Disassemble the Valve and clean all parts thoroughly. Remove all traces of Lapping compound.

11.0 Re-Assembly of Actuator on Valve Body

11.1 Direct Acting Actuator

L1) Lower the Actuator over the Valves Stem & Gland Flange to sit squarely on Bonnet shoulder.

2) Rotate the Actuator to the correct position. Keep the travel Indicator plate no front side.

3) Screw the Yoke Lock Ring into the Valve Bonnet threads and tighten it.

4) While the Actuator Stem be connected to the Valves Stem, both the Stem should be at their lowest position
of travel. The Plug should be resting on its seat. Apply air pressure to Actuator diaphragm to bring Actuator
Stem to lower position of travel as indicated on travel scale. Press the two halves of Stem Connector against
the Actuator Stem & Valve Stem. Lock the Stem Connector screws in this position .Tight the Indicator Lock
Nut against the top of Stem Connector.

5) Remove the air supply & check the travel once again on travel Indicator.

19
11.2 Reverse Acting Actuator

1. Mount the Actuator on the Valve Bonnet shoulder accordingly to the steps 1,2 & 3,of Re-assembly of Direct
Acting Actuator.
2. While the Actuator Stem is to be connected to the Valve the Plug should rest, on Seat & the Actuator Stem
should be lifted by approx. 2-3mm upward.
Apply little air pressure to the Diaphragm so that the Actuator Stem lifts to 2-3mm approximately. Push the
Valve Stem downward so that Plug rests on the Seat Ring. Press two halves of Stem Connector against the
Actuator Stem & Valve Stem. Lock the Stem Connector screw in the position. Lock the Indicator lock nut
against the top of the Stem Connector.

3. Apply full air pressure to Diaphragm as indicated in the Tag of the Valve so that the Indicator reads 100%
opening on travel scale. Remove air pressure & once again check the travel.

12.0 Trouble Shooting

No. Condition Possible Cause Remedy

Gland Nut loose Adjust Gland Nut
1 Gland Leakage
Worn Out Packing Replace Gland Packing

Sealing Edge of Seat Damaged Replace Soft Seat

Valve pressurized to high+pressure Reduce line pressure to rated pressure
2 Seat Leakage
Fluid is abrasive and eroding away Replace the worn out component of
the components Valve with material suitable for abrasive Media

Foreign object got stuck up between Open the Valve and clean the line /
Valve does not
3 Plug and Seat Valve to remove Foreign object
Open / Close Fully
Disturbed Calibration Correct Calibration.

Foreign object got stuck up between Open the Calve and clean the line / Valve to
Opening / Closing
4 plug and seat remove Foreign object
thrust excessive
Extra Gland nut tightening Retighten the Gland Nuts.

20
13.0 Torque for Studs

Studs Torque Nm
5/16” 5
3/8” 7
1/2” 30
5/8” 50
3/4” 170

14.0Recommended Spares

Each Body-Bonnet assembly is assigned with a Serial number, which can be found on the Valve Flange O.D.
This same number also appears on Actuator name plate. While ordering spares please do not miss to
indicate Valve Serial No. The Valve Sr. No starts with Prefix V-12345...

It is recommended to stock the following parts as spare for commission and routine service. Parts marked
(*) have generally longer life, hence are left to the choice of customer to include in their spares.

Sr. No. Part Name Recommended Quantity

14 Body Gaskets One No. Per Unit

7 Gland Packing One Set Per Unit

2 *Seat Ring One for Every Five Identical or

One Minimum

3 *Valve Plug One for Every Five Identical or

One Minimum

12 One for Every Five Identical or

*Valve Stem One Minimum

21
15.0 Part Illustrated

VALVE WITH REVERSE ACTING VALVE WITH DIRECT ACTING

DIAPHRAGM ACTUATOR DIAPHRAGM ACTUATOR

10

9
11 8

6
12
13 5

14 4

SR. NO. PART NAME SR. NO. PART NAME

1 VALVE BODY 8 GLAND BUSH

2 SEAT RING 9 GLAND FLANGE
3 VALVE PLUG 10 STEM CONNECTOR
4 GUIDE BUSH 11 PACKING STUDS/NUTS
5 LOCKING PIN 12 VALVE STEM
6 BONNET 13 BODY STUDS/NUTS
7 GLAND PACKING 14 BODY-GASKET

22
 The contents of this publication are presented for informational purposes only, and while every effort has
been made to ensure their accuracy. They are not to be construed as warranties or guarantees, express or implied,
regarding the products or services described herein or their use or applicability. We reserve the right to modify or
improve the designs or specifications of such products at any time without notice.
Dembla does not assume responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use and maintenance of any Dembla product remains solely with the
purchaser and end-user.

SALES (INTERNATIONAL) OFFICE ADDRESS : SALES (DOMESTIC) OFFICE ADDRESS

M/S Dembla Valves Ltd (Unit 2) M/S Dembla Valves Ltd.
C-30, Jai Matadi Compound, Kalher Village 1-Adarsha Industrial Estate Pokhran Road No.1,
Thane-Bhiwandi-Agra Road-421302, Maharashtra, India. Upvan, Thane - 400 606 (Maharashtra), India.
Tel : 912522 275132 / 275184 / 275104 / 241700 Tel (O): 022 - 25858234/25853957/25853899
Fax: 912522 275132 / 275184 / 275104 Fax: 022 - 25853429
E-Mail: [email protected] E-Mail: [email protected]

Dembla
REG. OFFICE & WORKS :
Unit 1 : Purna Village Thane - Bhiwandi - Agra Road,Dist : Thane - 421 302, Maharashtra, India
Unit 2 : C-30, Jai Matadi Compound, Kalher Village, Thane-Bhiwandi-Agra Road - 421302, Maharashtra, India

23