ensamble y mtto

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NOTE: It is imperative that the workstation being used to assemble the valve be clean and

free of anything that could possibly contaminate the grease such as metal shavings, dirt, rust,

old paint, etc. Do not sand or deburr near the workstation.

Check surfaces around the valve bore inside the valve pocket for sharp edges that could cause

cutting of the insert o-rings.step 1 &step 2 Screw the clean adjusting nut (13) all the way into the valve body tomake sure the threads are not damaged. After inspection, remove the adjusting nut (13) and

install adjusting nut o-ring (12).

step 3 Check the roll pins (8) in the valve body by gently sliding a set ofinserts (10) intothe valve. The inserts should move freely up and down the length of the roll pin slots without

interference.

step 4 &step 5 Install the plug seals (7) into the recess in the valve body and adjustingnut with the metal back up towards the recess and facing away from the pressure. Always apply

a film of lubricant before pressing the plug seals into place.

step 6 &step 7 &step 8 Check the plug (11) outside diameter for surface defects such asnicks, dings, scratches, etc. that could possibly affect the sealing area. Pack adjusting nut(13)

plug seal(7) with valve grease. Install the lower end of the plug (11)(opposite thehex/keyway) in the adjusting nut (13) and push down until the plug shoulders on the

adjusting nut.

NOTE: For the 0.38" and 1 valves, insert the plug seal (7) first and then the plug

(11) into the recess of the adjusting-nut (13) but do not push the plug (11) all the

way down. Lightly grease the O.D. of the plug (11) and the I.D. of the inserts (10).

Place the inserts (10) around the plug (11) and align the plug bore with the insert

bore. Push the plug (11) down until it shoulders at the bottom of the recess on the

inserts (10).

step 9 Apply a thin film of grease to the entire O.D. of the plug (11).step 10 &step 11 &step 12 &step 13 Check the surface finish of the inserts (10)making sure it does not have any scratches, dings, nicks, or sharp edges that could also affect


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the sealing area. Inspect the o-rings for any possible non-conformities. Place the inserts (10)

around the plug and insert the o-rings into the grooves and pack with grease to thoroughly

grease the sealing surface.

step 14 Secure the plug to the adjusting nut with a cap screw (1) and two washers (2 &14).

step 15 Lubricate the valve pocket.step 16 Apply thread compound (Never-sez) to the adjusting threads and adjusting nutsealing surfaces.

step 17 &step 18 Install the plug (11), inserts (10) and adjusting nut (13) assemblyinto the valve body. Support the valve so that the plug (11) hex can pass through

unobstructed.

step 19 Screw in the adjusting nut until proper alignment is obtained between the valvebore and the insert and plug. Do not tighten beyond proper alignment as actuating an overtightened valve could damage internal parts. If sight through the bore is not possible, then

screw in the adjusting nut until 1/2 or no threads are visible.

step 20 Install grease fitting (6).step 21 &step 22 &step 23 Place spiral ring on male end connection and place wing nutand nut retainers and secure with spiral ring (for certain end connections only).

step 24 &step 25 &step 26 Install stop bolt (5) and stop collar (4) (if required), andhandle adapter (3) on top of the valve and secure with a cap screw (1) and two washers

(2 & 14).

step 27 &step 28 Remove excess grease from valve bore and inspect plug alignment.Adjust as necessary with adjusting nut (13).

step 29 Open the valve with the handle adapter (3) and pump grease through the greasefitting (6) to approximately 3000 p.s.i. Actuate the valve to release grease pressure.


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step 1

CHECKING ADJUSTING NUT THREADS

step 2

INSTALLING ADJUSTING NUT O-RING


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step 3

CHECKING ROLL PIN AND INSERT CLEARANCE

step 4

INSTALLING PLUG SEAL IN VALVE BODY


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step 5

INSTALLING PLUG SEAL IN ADJUSTING NUT

step 6


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INSPECTING SURFACE OF PLUG

step 7

PACKING ADJUSTING NUT PLUG SEAL WITH GREASE


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step 8

INSERTING THE PLUG INTO THE ADJUSTING NUT

step 9


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APPLY THIN LAYER OF GREASE TO PLUG

step 10

INSPECTING SURFACE OF INSERT


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step 11

INSPECTING INSERT O-RINGS

step 12

ASSEMBLING THE INSERTS


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step 13

PACKING INSERT O-RINGS WITH GREASE

step 14

SCREW CAP WITH WASHERS


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step 15

APPLY LAYER OF LUBRICANT INSIDE VALVE POCKET

step 16


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APPLY THREAD COMPOUND TO ADJUSTING SEAL BORE AND THREADS IN VALVE POCKET

step 17

INSERT THE VALVE INTERNALS INTO THE VALVE


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step 18

SUPPORT VALVE SO THAT PLUG HEX CAN PASS THROUGH BODY

step 19


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TIGHTENING ADJUSTING NUT

step 20

APPLY TEFON TAPE TO GREASE FITTING


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step 21

INSTALLING SPIRAL RING

step 22

INSTALLING WING NUT RETAINERS


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step 23

SECURING WING NUT AND RETAINERS WITH SPIRAL RING

step 24

INSTALLING STOP BOLT


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step 25

INSTALLING HANDLE ADAPTER

step 26


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SECURING HANDLE ADAPTER WITH CAP SCREW AND WASHERS

step 27

REMOVING EXCESS GREASE FROM VALVE BORE


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step 28

CHECK VALVE ALIGNMENT

step 29


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GREASE VALVE THROUGH FITTING

Note: If handle adapter (3) or adjusting nut (13) appears to be stuck or locked,pressure may be trapped in the valve. This is also known as pressure locking. Do

not attempt to disassemble a pressure locked valve. Never attempt to remove the

grease fitting of a pressure locked valve.

Remove the handle adapter (3) and stop collar (4). Turn valve over so that adjusting

nut (13) is facing up. Leaving the bottom cap screw (1) in place, screw out (turning

counter-clockwise) the adjusting nut (13). This will allow the entire internal assembly

(adjusting nut (13), plug (11)& inserts (10)) to be removed from the valve pocket at

once.Remove the cap screw (1) attaching the plug to the adjusting nut.Remove the plug (11) and inserts (10).Remove the insert o-rings (9), adjusting nut o-rings (12) and plug seals (7).Clean all of the old lubricant and debris from the parts and valve body internal profile.

Valves should be greased as part of a regular maintenance program. Regular greasing will

increase the service life of the internal valve parts. Routine disassembly and cleaning as partof a maintenance program can prevent unnecessary damage to the valve body. Dixie Iron

Works, Ltd. recommends that valves be greased after every job or every 5 actuations,

whichever one comes first.Valves should be greased according to the severity of use. Each operating company

should establish guidelines for a greasing and/or disassembly program. These

guidelines should be based on the operating conditions. Special consideration

should be given for conditions in which the following would be involved: Abrasives in the fluid stream High flow rates Caustic or Acidic fluid streams High Temperature


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Fluid Streams that would act as solvents such as condensate High number of valve actuations

Valves should not be greased while under pressure. In addition, valves should not

be disassembled for repair while part of an operating arrangement such as a

manifold. This should not be attempted even though the valve may be isolated fromthe fluid stream by other valves.Never attempt to remove the grease fitting from a valve to relieve a pressure-

locking situation.

When repairing a MSI plug valve, the following basic guidelines can help you ensure a good

hydrostatic test of the reassembled valve.

Disassemble the valve completely and detach the internal parts from the adjusting nut. See Section 2.0DISASSEMBLY PROCEDURESfor detailed instructions on valve disassembly. Remove old grease and

debris from valve pocket with a solvent and inspect for wear or damage such as: In the adjusting nut seal bore of the pocket: Scratches could be caused by previous installation

of a damaged adjusting nut. Dings can also occur during assembly. Pitting is usually caused by

failure to disassemble and clean valves after they are in service. Use your fingers to feel for any

surface defects which may either fail to seal against the o-ring or may even damage the o-ring

during assembly. On the adjusting nut o-ring groove area: Check for scratches, dings, or pitting. Dings and

scratches here are usually caused by careless use of sharp metal objects when trying to remove

old o-rings. Feel for any raised edges that might scratch the internal seal bore of the valve body

and sand or file as necessary. On the adjusting nut threads: Check for damaged threads, especially the lead thread. Use your

fingers to check for any raised edges and carefully sand as needed. Severely damaged threadsmust be repaired at the factory.

On the pocket walls: Scratches, dings, or pitting, especially in the area immediately

surrounding the valve bore. Use your fingers to feel for any surface defects which may either fail

to seal against the o-ring or may even damage the o-ring during assembly. Check for any sharp

edges around the valve bore that can cut the insert o-rings. These can be caused by using a bar

when swabbing excess grease or using a bar to carry the valve. On the internal threads: Check for damaged threads, especially the lead thread. Use your

fingers to check for any raised edges and carefully sand as needed. Severely damaged threads

must be repaired at the factory. On the plug seal area: Check for scratches, dings, or pitting. Dings and scratches here are

usually caused by careless use of sharp metal objects when trying to remove old seals. On the plug outside diameter: Check plug for washout, which will render the part unusable.

Hold part in a well illuminated area and inspect for slight scratches in plug. If scratches are

visible use 600 grit sandpaper to remove.

On the insert inside diameter: Check inserts for washout, which will render the parts unusable.

Hold parts up to a well illuminated area and inspect for slight scratches in outer and inner

diameters of inserts. If scratches are visible use 600 grit sandpaper to remove.



Disassemble the valve completely and detach the internal parts from the adjusting nut. See Section 2.0DISASSEMBLY PROCEDURESfor detailed instructions on valve disassembly. Remove old grease and

debris from valve pocket with a solvent and inspect for wear or damage such as:
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In the adjusting nut seal bore of the pocket: Scratches could be caused by previous installation

of a damaged adjusting nut. Dings can also occur during assembly. Pitting is usually caused by

failure to disassemble and clean valves after they are in service. Use your fingers to feel for any

surface defects which may either fail to seal against the o-ring or may even damage the o-ring

during assembly. On the adjusting nut o-ring groove area: Check for scratches, dings, or pitting. Dings and

scratches here are usually caused by careless use of sharp metal objects when trying to removeold o-rings. Feel for any raised edges that might scratch the internal seal bore of the valve body

and sand or file as necessary. On the adjusting nut threads: Check for damaged threads, especially the lead thread. Use your


must be repaired at the factory. On the pocket walls: Scratches, dings, or pitting, especially in the area immediately

surrounding the valve bore. Use your fingers to feel for any surface defects which may either fail

to seal against the o-ring or may even damage the o-ring during assembly. Check for any sharp

edges around the valve bore that can cut the insert o-rings. These can be caused by using a bar

when swabbing excess grease or using a bar to carry the valve. On the internal threads: Check for damaged threads, especially the lead thread. Use your


must be repaired at the factory. On the plug seal area: Check for scratches, dings, or pitting. Dings and scratches here are

usually caused by careless use of sharp metal objects when trying to remove old seals. On the plug outside diameter: Check plug for washout, which will render the part unusable.

Hold part in a well illuminated area and inspect for slight scratches in plug. If scratches are

visible use 600 grit sandpaper to remove.

On the insert inside diameter: Check inserts for washout, which will render the parts unusable.

Hold parts up to a well illuminated area and inspect for slight scratches in outer and inner

diameters of inserts. If scratches are visible use 600 grit sandpaper to remove.



Sanding is necessary to repair blemishes from the sealing surfaces of parts. Sanding of scratches, dings, and pitting should always be done with 600 grit sanding cloth that

is well lubricated with water or solvent. When sanding sealing surfaces, it is VERY important to

avoid sanding in one spot continuously; sand evenly across the entire sealing surface. Sand

scratches by moving the sandpaper around the plug, not up and down, along the length of the

plug. If scratches cannot be removed utilizing this technique, replace the parts. If raised edges

or dings in non-sealing areas are too large to be sanded effectively, you may use a rotary

flapper-type sanding wheel. It is very important that you do not remove any material other than

the actual raised edge. Do not remove any of the base material or you may permanently damage


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the valve and render it unsafe for use.When repairing a MSI plug valve, the following basic guidelines can help you ensure a good


If you choose to mix old and new parts, you must make absolutely sure that the old part does not have

any defects. Using 600 grit sanding cloth, wet sand any surface blemishes as described in the 5.2

Sanding Practices. See Section 1.0 ASSEMBLY PROCEDURES for detailed instructions.

Disassemble the valve completely and detach the internal parts from the adjusting nut. See Section 2.0

DISASSEMBLY PROCEDURESfor detailed instructions on valve disassembly. Remove old grease and

debris from valve pocket with a solvent and inspect for wear or damage such as: Drain after testing. All equipment should be drained and lubricated after testing and prior to

storage. All components and assemblies should be cleaned of dirt, rust, and other contaminants. Rust Prevention: Equipment should have exposed metallic surfaces protected with a rust

inhibitor which will not become fluid and run at a temperature less than 125 F( 52 C ). Sealing surface protection: Exposed sealing surfaces should be protected from mechanical

damage.

The following is recommended for maximum equipment shelf life:# of Months inStorage Manufacturers Recommendations

0-3 months Nothing required3-6 months Re-grease and operate. Operate by rotating the plug. Check to see that rotation is

smooth without grinding or scraping.6+ months Disassemble, rebuild & retest the valve. Replace all internal seals

Use only MSI recommended greases. Greases intended for gate valves or other

applications may result in failure to achieve a good test and may actually damage

the new parts.MSI Part Number Description Manufacturer's Website

VC0402

Everlast #3 Arctic Grade

Lubchem

VC0429 #700 CO2 / Hi-Temp / Condensate (size J) Val-TexVC0357 #302 CO2 / High Temperature (size K) Val-Tex
http://www.diwmsi.com/support/manuals/ltmanual/1_0.asphttp://www.diwmsi.com/support/manuals/ltmanual/2_0.asphttp://www.diwmsi.com/support/manuals/ltmanual/2_0.asphttp://www.diwmsi.com/support/manuals/ltmanual/2_0.asphttp://www.lubchem.com/http://www.valtex.com/http://www.valtex.com/http://www.diwmsi.com/support/manuals/ltmanual/1_0.asphttp://www.diwmsi.com/support/manuals/ltmanual/2_0.asphttp://www.diwmsi.com/support/manuals/ltmanual/2_0.asphttp://www.lubchem.com/http://www.valtex.com/http://www.valtex.com/


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VC0012 #972 General Service (size K) Val-TexVC0144 Low Temperature (size K) Val-Tex

Use only MSI recommended greases. Greases intended for gate valves or other

applications may result in failure to achieve a good test and may actually damage

the new parts.MSI Part Number Description Manufacturer's WebsiteVC0402 Everlast #3 Arctic Grade LubchemVC0429 #700 CO2 / Hi-Temp / Condensate (size J) Val-TexVC0357 #302 CO2 / High Temperature (size K) Val-TexVC0012 #972 General Service (size K) Val-TexVC0144 Low Temperature (size K) Val-Tex

Valve Size Approximate amount of grease3/8 VALVE 1/3 STICK1 VALVE 1/3 STICK1.3 VALVE STICK1 VALVE STICK2 VALVE STICK2 VALVE 1 STICK3 VALVE 1 STICK4 VALVE 1 STICK
http://www.valtex.com/http://www.valtex.com/http://www.lubchem.com/http://www.valtex.com/http://www.valtex.com/http://www.valtex.com/http://www.valtex.com/http://www.valtex.com/http://www.valtex.com/http://www.lubchem.com/http://www.valtex.com/http://www.valtex.com/http://www.valtex.com/http://www.valtex.com/


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