3.563.5275.

201 IM-P359-01
CH Issue 4 - 2015

Control Valves Series "Q" DN15 - DN100

Installation and Maintenace Instructions

The PED Directive 97/23/EC is repealed and replaced by the new

PED Directive 2014/68/EU with effect from 19 July 2016.

1. Safety Information

2. General
product information

3. Installation and
commissioning

4. Maintenance

5. Spares parts

E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y © Copyright 2004
2 3.563.5275.201
 1. Safety Information
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use/application. The products listed below
comply with the requirements of the European Pressure Equipment Directive 97/23/EC. The products
fall within the following Pressure Equipment Directive categories:

Gas Liquid Gas Liquid

Product: Serie Q Valves DN PS
Group 1 Group 1 Group 2 Group 2
15 - 25 - - SEP SEP
QL33 - Cast Iron 32 - 50 16 bar - - SEP SEP
65 - 100 - - 1 SEP
15 - 25 *SEP *SEP *SEP *SEP
32 - 40 1 *SEP *SEP *SEP
QL73 - Sferoidal Cast Iron 25 bar
50 - 80 2 *SEP 1 *SEP
100 2 1 *SEP
15 - 25 *SEP *SEP *SEP *SEP
QL43 - Carbon Steel 32 2 *SEP *SEP *SEP
40 bar
QL63 - Stainless Steel 40 - 50 2 *SEP 1 *SEP
65 - 100 2 2 1 *SEP
*SEP= not subjected to CE marking as per para 3.3 of Directive 97/23/EC.

I) The products have been specifically designed for use on compressed air or condensate which
are in Group 2 of the above mentioned Pressure Equipment Directive. The products’ use on
other gas within Group 2 may be possible but, if this is contemplated, Spirax Sarco should be
contacted to confirm the suitability of the product for the application being considered.

II) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which
it is being fitted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.

III) Determine the correct installation situation and direction of fluid flow.

IV) Spirax Sarco products are not intended to withstand external stresses that may be induced
by any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.

V) Remove protection covers from all connections before installation.

1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.

3.563.5275.201 3
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel at
risk? Dangers might include isolation of vents or protective devices or the rendering ineffective of
controls or alarms.
Ensure isolation valves are turned on and off in a gradual way to avoid system shocks.

1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that
the system has depressurised even when the pressure gauge indicates zero.

1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and
dangers to eyes and face.

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the product according
to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no such
system, it is recommended that a responsible person should know what work is going on and, where
necessary, arrange to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.

1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling,
carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.

1.13 Residual hazards

In some cases the product is provided with pre-compressed springs. Any operation to open the
spring housing is to be carried on strictly following the correct procedure given in the Instalaltion
and Maintenance Instructions.

4 3.563.5275.201
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.

1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.

1.16 Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment Law, when
returning products to Spirax Sarco they must provide information on any hazards and the precautions
to be taken due to contamination residues or mechanical damage which may present a health, safety
or environmental risk. This information must be provided in writing including Health and Safety data
sheets relating to any substances identified as hazardous or potentially hazardous.

1.17 Working safely with cast iron products on steam

Cast iron products are commonly found on steam and condensate systems. If installed correctly
using good steam engineering practices, it is perfectly safe. However, because of its mechanical
properties, it is less forgiving compared to other materials such as SG iron or carbon steel. The
following are the good engineering practices required to prevent waterhammer and ensure
safe working conditions on a steam system.

Safe Handling
Cast Iron is a brittle material. If the
product is dropped during installation
and there is any risk of damage the
product should not be used unless it
is fully inspected and pressure tested
by the manufacturer.
Please remove label before
commissioning.

Prevention of water hammer

Steam trapping on steam mains:

30÷50 m. intervals
Gradien
t 1:100 Steam
Gradien
t 1:100
Trap set
Steam Trap set
Trap set

Condasate
Condasate
Condasate

3.563.5275.201 5
Steam Mains - Do’s and Dont’s:

Prevention of tensile stressing

Pipe misalignment:

Installing products or re-assembling after maintenance:

Do not over tighten. Flange bolts should be gradually tightened across

Use correct torque figures. diameters to ensure even load and alignment.

6 3.563.5275.201
Thermal expansion:
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.

Guides

Axial movement

Fixing point
Short distance

Axial movement
Guides

Guides

Small
lateral
Limit rods movement Large
lateral
movement

Medium
distance Fixing point

Limit rods Small Large

lateral lateral
Guides movement movement

3.563.5275.201 7
 2. General product information
2.1 Description
The QLM and QLD are three port control valves which have linear characteristics for mixing or
diverting service. They are available in four body materials: cast iron, SG iron, carbon steel or
stainless steel. All valves can be supplied with the standard metal-to-metal seats, stellite facing for
increased resistance to wear or soft seats for tight shut-off. The standard stem sealing is by spring
adjusted PTFE chevrons but high temperature graphite seals or metal bellows with supplementary
safety packing may also be specified.

The QLM and QLD three port control valves can be used with the following actuators:
PN 3000 series
PN 4000 series
PN 5000 series
Pneumatic:
PN 6000 series
PN 7000 series
PN 8000 series
EL 3500 series
Electric:
EL 5600 series

2.2 Sizes and pipe connections

All valve flanges referred to in this document are in accordance with EN 1093.
Type Body material Connection Size range
QL33M Cast iron PN 16 DN15 to DN100

QLM: QL43M* Carbon steel PN 25/40 DN15 to DN100

Mixing service QL63M* Stailess steel PN 25/40 DN15 to DN100
QL73M SG iron PN 25 DN15 to DN100
QL33D Cast iron PN 16 DN25 to DN100

QLD: QL43D* Carbon steel PN 25/40 DN25 to DN100

Diverting service QL63D* Stailess steel PN 25/40 DN25 to DN100
QL73D SG iron PN 25 DN25 to DN100
* Note: QL43M, QL43D, QL63M and QL63D three port control valves are also available with
PN16 flanges by special order.

8 3.563.5275.201
2.3 Technical data
Plug Type "V" Port
Leakage Class Metal to metal seal IEC 534-4 Class IV (0.01% of Kv)
Plug Characteristic Linear
Rangeability 50:1
DN15 - DN50 20 mm
Travel
DN65 - DN100 30 mm

2.4 Product limitations

Bonnet
Connec. Material Body Standard Extended Bellows
PTFE Graphite PTFE Graphite PN16 PN25
Press. (bar) 16 13 16 13 16 13 - - - - 16 13 - -
Cast iron
(PN16)
Temp. (°C) -5/+120 200 -5/+120 200 -5/+120 200 - - - - -5/+120 200 - -

Press. (bar) 25 15 25 18,7 25 18 25 18 25 15 16 11,0 25 15

SG iron
(PN25)
Temp. (°C) -10/+120 300 -10/+120 300 -5/+120 232 -5/+120 250 -10/+120 300 -10/+120 300 -10/+120 300
UNI / DIN
Press. (bar) 40 21 40 33 40 32 40 32 40 21 16 10 25 16
Carbon steel
(PN40)
Temp. (°C) -29/+120 400 -5/+120 232 -5/+120 250 -29/+120 250 -29/+120 400 -10/+120 350 -10/+120 350

Press. (bar) 40 22,1 40 26,8 40 26,2 40 26,2 40 22 16 10 25 16

Stainless steel
(PN40)
Temp. (°C) -29/+120 400 -5/+120 232 -5/+120 250 -29/+120 250 -29/+120 400 -10/+120 350 -10/+120 350

Hydrostatic Test Pressure: 1.5 Times the maximum working pressure

Differential Pressure
To establish maximum differential pressures see Spirax Sarco TIs of pneumatic actuators Series
PN3000 and PN4000 (TI n° 7C.425) , PN5000 and PN6000 (TI n° 7C.435), PN7000 and PN8000
(TI n° 7C.445); and electric actuators Series EL3500 and EL5600 (TI n° 7C.480 and 7C.485).

3.563.5275.201 9
2.5 Materials
2.5.1 Cast Iron, SG Iron and Carbon Steel Valves
Material designation
Type No. Part. Material
ASTM/DIN STD
1 Body Cast iron DIN 1691 GG 25
Cast iron Standard bonnet SG iron DIN 1693 GGG 40.3
2
Extended bonnet Carbon steel DIN 17243 C22.8
1 Body SG iron DIN 1693 GGG 40.3
SG iron Standard bonnet SG iron DIN 1693 GGG 40.3
2
Extended bonnet Carbon steel DIN 17243 C22.8
1 Body DIN 17245 GG C25
Carbon
Standard bonnet Carbon steel DIN 16 MnCr 5
steel 2
Extended bonnet DIN 17243 C22.8
3 Plug (s) Stainless steel BS 970 431 S29
4 Valve seats Stainless steel BS 970 431 S29
Valve stem BS 970 431 S29
5 Stainless steel
Bellows AISI 316 L
6 Spacer Stainless steel AISI 304
7 Stuffing box gasket Graphite
8 Lock-nut Stainless steel AISI 304
9 Stuffing box Stainless steel BS 970 431 S29
10 Mounting nut Stainless steel NFA 35553 XC 18S
SG iron 11 Packing PTFE / graphite
and
12 Spring Stainless steel BS 2056 316 S42
Carbon
steel 13 Bonnet gasket Graphite
14 Stud Carbon steel A193 B7M
15 Nut Carbon steel A194 Gr. 2H
16 Lock-nut Stainless steel AISI 316
17 Guide bush PTFE
18 Stem guide bush Stainless steel Hardened AISI 440B
19 Lock-nut Stainless steel AISI 304
20 Pin Stainless steel AISI 316
21 Gasket Graphite
22 Anti-rotation screw Stainless steel AISI 304

10 3.563.5275.201
 8

7 9
11 10
12
14
15
2 18
13
5

1
A
 4
3
 AB

4 16

Fig. 1 - Mixing valve


B

20 16

A  4

6
3
 AB

3
16

Fig. 2 - Diverting valve


B

3.563.5275.201 11
2.5.2 Stainless Steel Valves
Material designation
Type No. Part. Material
ASTM/DIN STD
1 Body Stainless steel DIN 17445 1.4581
Standard bonnet Stainless steel DIN 17445 1.4581
2
Extended bonnet Stainless steel ASTM A182 F316
3 Valve plug Stainless steel ASTM A351 CF8M
4 Valve seats Stainless steel ASTM A276 316L
Valve stem ASTM A276 316L
5 Stainless steel
Bellows AISI 316 L
6 Spacer Stainless steel AISI 316
7 Stuffing box gasket Stainless steel AISI 304
8 Lock-nut Stainless steel AISI 316
9 Stuffing box Stainless steel AISI 316
10 Mounting nut Zinc plated steel NFA 35553 XC 18S
Stainless
steel 11 Packing PTFE/graphite PTFE/graphite
12 Spring Stainless steel BS 2056 316 S42
13 Bonnet gasket Graphite
14 Stud Stainless steel A193 B8
15 Nut Stainless steel A194 Gr. 304
16 Lock-nut Stainless steel AISI 316
17 Guide bush PTFE
18 Stem guide bush Stainless steel Hard faced AISI 316
19 Lock-nut Stainless steel AISI 316
20 Pin Stainless steel AISI 316
21 Gasket Graphite  
22 Anti-rotation screw Stainless steel AISI 304

Gland Seal: PTFE with bonnet standard t ≤ 232°C

Graphite with bonnet standard t ≤ 250°C
PTFE with bonnet extended 232 < t ≤ 250°C
Graphite with bonnet extended t > 250°C
Bellows seal plus safety graphite gland seal t ≤ 350°C

12 3.563.5275.201
2.6 Dimensions in mm and weights in kg (approximate)
Dimensions Weights
Size Standard Extended
A B C C1*
bonnet bonnet
DN15 130 90 105 166 7,0 166,0
DN20 150 95 105 166 6,9 8,3
DN25 160 100 109 170 8,8 10,2
DN32 180 105 124 185 11,0 12,4
DN40 200 115 137 190 14,5 15,9
DN50 230 125 143 196 18,5 20,0
DN65 290 145 160 357 31,0 33,0
DN80 310 155 165 361 40,8 42,8
DN100 350 175 180 373 48,5 50,5
* C1 dimension is relevant to valves with extended or bellows seal bonnet.

Fig. 3

3.563.5275.201 13
 3. Installation
3.1 General Rules
The valve should be installed in such a position as to allow full access to valve and actuator for
maintenance purposes. Prior to fitting the valve the pipework should be flushed clear to remove
any debris or other particles.
Remove the flange protectors and fit the valve into the pipeline taking notice of direction of flow
arrows on the body.
Care should be taken to prevent any strain being imposed on the valve body due to pipe misalignement.
Care should be taken to ensure that the valve/actuator spindle is not painted or coated with any
other substance.

3.2 By-Pass Arrangements

It is reccomended that isolating valves be fitted upstream and downstream of the control valve. A
bypass can be fitted around the valve with a manual regulating valve allowing the process to be
controlled whilst the control valve isolated for maintenance.

3.3 Commissioning
For commissioning instructions refer to the Operation, Installation and Maintenance Instructions,
covering Spirax Sarco Actuators.

4. Maintenance
4.1 Periodic maintenance
After 24 hours of operation
After 24 hours of operation check flange bolts for tightness.
On valves with graphite stem seal packing compress the the gland seal packing by tightening the gland
nut by ¼ of a turn.Care should be taken not to overtightening as this may cause the spindle lock-up.
Every 3 months of operation
Every 3 months of normal operation check stem gland seal against leakage. In case of leakage
proceed as follows:
- for valves with PTFE gland seal renew gland seal by following the procedure at paragraph 4.1.1.
- for valves with graphite stem seal packing compress the the gland seal packing by tightening
the gland nut by ¼ of a turn. If leakage cannot be eliminated, renew the graphite gland seal by
following the procedure at paragraph 4.1.3.
Every year
Inspect the valve to verify the wear of parts or scale deposit. Worn or damager parts, like plug or
seat may need to be replaced, as well as the gland seal packing.
The graphite packing is normally subject to wear. Therefore it is recommended to renew the graphite.

Safety note - Handling precautions

PTFE
Within its working temperature range PTFE is a completely inert material, but when
heated to its sintering temperature it gives rise to gaseous decomposition products or
fumes which can produce unpleasant effects if inhaled. The inhalation of these fumes
is easily prevented by applying local exhaust ventilation to atmosphere as near to their
source as possible. Smoking should be prohibited in workshops where PTFE is handled
because tobacco contaminated with PTFE will during burning give rise to polymer fumes.
It is therefore important to avoid contamination of clothing, especially the pockets, with
PTFE and to maintain a reasonable standard or personal cleanliness by washing hands
and removing any PTFE particles lodged under the fingernails.
LAMINATED GASKETS
The metal foil sheet used to reinforce gaskets is very thin and sharp. Care should be taken
when handling to avoid the possibility of cuts or lacerations to fingers or hands.

14 3.563.5275.201
4.2 Valves with packing stem seal
4.2.1 Procedure for renewing PTFE chevron gland seal (Fig. 1, 2 and 4)
a) Isolate valve on both sides.
b) Remove actuator from valve. Refer to Installation and Maintenance Instructions covering Spirax
Sarco actuators.
Caution: Care should be taken in removing the gland nut since fluid under pressure may be
trapped between the isolating valves
c) Remove lock nut (8).
d) Unscrew gland nut (9), withdraw spring (12) from the stem; remove and discard lower bush,
gland seal set and upper bush (17a + 11 + 17b), and gland nut gasket (7).
e) Examine parts for signs of damage or deterioration and renew as necessary. Note that score
marks or scaly deposit on valve stem (5) will lead to early failure of the seals. Clean parts taking
care to avoid scratching stem or bore of gland nut. In case valve stem (5) needs to be replaced,
follow instructions from point f) to h) and point k).
f) Unscrew the nuts (15) securing the bonnet to the body and remove the bonnt (2) complete with
stem and plug (3 + 5).
g) Fit the new valve stem and plug.
h) Using new bonnet gasket (13) refit the bonnet (2) on the valve body, leaving the stem protruding.
Replace the nuts (15) and finger tighten.
i) To renew the gland seal set, first fit the spring (12) over valve stem, and replace gland nut gasket
(7). The upper bush (17a) (only for valves DN15-50), the new gland seal set (11) and the lower bush
(17b), must be firmly inserted into the gland seal nut (9), as indicated in Fig. 3, care being taken to
avoid damage to the sealing edges. Refit gland nut (9) over the valve stem, screwing down with care
to ensure the gasket is bedded down onto the bonnet. Tighten to the right torque as given in Table 1.
j) Ensure the stem (5) moves freely.
k) (Only if bonnet has been removed) While pushing the valve plug against the seat, tighten the
nuts (15) to the right torque as given in Table 1.
l) Refit valve lock-nut (8).
m) Refit actuator, clamping nut and connect actuator to valve stem following actuator instructions.
n) Bring valve back into service.
o) Check for leakage at gland.

8
8

5
5
9
9
7
7
17a 11
11

17b 17b

12 12
2
2

DN15-50 DN65-100
Fig. 4

3.563.5275.201 15
4.2.2 Procedure for renewing graphite gland seals (Fig. 1, 2 and 5)
a) Isolate valve on both sides.
b) Remove actuator from valve. Refer to Installation and Maintenance Instructions covering Spirax
Sarco actuators.
Caution: Care should be taken in removing the gland nut since fluid under pressure may be
trapped between the isolating valves
c) Remove lock nut (8).
d) Unscrew gland nut (9b) and stuffing box (9).
e) Remove and gland seal set (17b), and gland nut gasket (7).
f) Examine parts for signs of damage or deterioration and renew as necessary. Note that score
marks or scaly deposit on valve stem (5) will lead to early failure of the seals.
Note: In case valve stem (5) needs to be replaced, follow instructions at point c) and g) of
paragraph 5.2.
g) Clean parts taking care to avoid scratching stem or bore of gland nut.
h) Replace gland nut gasket (7). Refit stuffing box (9) over the valve stem, screwing down with care to
ensure the gasket is bedded down onto the bonnet. Tighten to the right torque as given in Table 1.
i) The replacement graphite gland seal should now be fitted. Note that the gland seal set contains
a top and bottom support ring and a graphite pack. During fitting the order of the graphite pack
should be maintained as supplied. Place the bottom support ring into the stuffing box (9). One by
one add the graphite rings and each time use the gland nut (9b) to drive down into the stuffing
box. Ensuring the junction of the ring ends are rotated by 90°. Leave the gland nut (9b) loosely
assembled so that the seals are not compressed.
Note: if the plug stem has been replaced, and therefore the bonnet has been removed and
refitted, it is necessary now tighten the nuts (15), as described in point i) of paragraph 5.2.
j) Screw down the gland nut until it just starts
to compress the packing. Compress the
the gland seal packing by tightening the
gland nut by ¼ of a turn until 1½ turns.
Rise and lower the valve stem after each 8
tightening of the gland nut to encourage
the seals to bed down correctly.
5
k) Refit actuator, clamping nut and connect
actuator to valve stem.
l) Stroke the valve a minimum of 5 times 9b
to ensure smooth operation.
m) Tighten the gland nut (9b) by ¼ of a turn 9
for DN15 to DN50 valves, and ½ of a turn 7
for DN65 to DN100 valves. 17a
n) Commissioning the actuator according
to the Installation and Maintenance
Instructions. 17b
o) Bring valve back into service.
p) Should there be a small amount of
seepage from the valve stem, this may 17c
be stopped by carefully tightening the
gland nut. Care should be taken not to 2
overtightening as this may cause the
spindle lock-up.

Fig. 5

16 3.563.5275.201
4.2.3 Procedure for renewing stem, valve plug and seats on mixing
valves (Fig. 4, 5 and 6)
a) Isolate and remove valve from the pipeline.
Caution: care should be taken in removing the valve since fluid under pressure may be trapped
between the isolating valves.
b) Remove actuator from valve. Note: take care not to rotate the valve stem when removing
actuator from valve service, this will damage the bellows. Refer to Installation and Maintenance
Instructions covering Spirax Sarco actuators.
c) Remove lock nut (8).
d) Ensure the spindle (5) is held still by locating a spanner onto the machined flat on the spindle (5) and
unscrew the plug lock-nut (16) from the valve stem (5). In case the flat on the spindle is not easily
accessible, fit the nut (8) and a lock nut onto the spindle, tighten firmly and locate the spanner.
e) Unscrew the nuts (15) securing the bonnet (2). Remove the bonnet (2) and withdraw the stem
(5). Remove the packing gland seal according to procedure in paragraph 4.1.1 or 4.1.2.
f) Unscrew and remove the top valve seat (4). Withdraw the valve plug (3), unscrew and remove
the bottom valve seat (4).
Note: To remove and replace seat (4) a special tool is required which can be obtained from
Spirax Sarco by quoting the valve size type.
g) Lightly smear the threads of the new seats with silicon grease. Insert the new bottom seat (4)
into the body. Tighten to the correct torque (see Table 1). Carefully insert the new valve plug and
stem assembly (3 + 5). Insert the new top seat (4) into the body. Tighten to the correct torque
(see Table 1).
g) Insert the new spindle (5) into the plug (3). Ensure the spindle (5) is held still by locating a
spanner on to the machined flat on the spindle. Replace the plug nut and lock-nut (16) and
tighten to the correct torque (see Table 1, page 5)
h) Using a new gasket (13) refit the bonnet (2), taking care not to damage the spindle (5). Replace
and finger tighten the bonnet nuts (15).
i) Fit the packing gland seal according to procedure in paragraph 4.1.1 or 4.1.2, ensuring the valve
stem (5) moves freely after assmbly.
j) Loosen again the bonnet nuts (15) and, while pushing the valve stem so that the valve plug is
on the bottom seat, finally tighten them to the correct torque (see Table 1).
k) Refit actuator and connect actuator to valve stem.
l) Bring valve back into service.
Check for leakage around all gasket joints.
8
7 9
11 10
12
15 14
2 18
13
5

4
3

4 16

Fig. 6
Mixing Valve

3.563.5275.201 17
4.2.4 Procedure for renewing stem, valve plug and seats on diverting
valves (Fig. 4, 5 and 7)
a) Isolate and remove valve from the pipeline.
Caution: care should be taken in removing the valve since fluid under pressure may be trapped
between the isolating valves.
b) Remove actuator from valve. Note: take care not to rotate the valve stem when removing
actuator from valve service, this will damage the bellows. Refer to Installation and Maintenance
Instructions covering Spirax Sarco actuators.
c) Remove lock nut (8).
d) Ensure the spacer (6) is held still by locating a spanner onto the machined flat on the spacer
and unscrew the plug lock-nut (16) of the lower valve plug (3) from the spacer (6). In case the flat
on the spacer is not easily accessible, fit the nut (8) and a lock nut onto the spindle (5), tighten
firmly and locate the spanner. Withdraw the lower valve plug (3).
e) Unscrew the nuts (15) securing the bonnet (2). Remove the bonnet (2) with the stem and upper
valve plug, and withdraw the stem (5). Remove the packing gland seal according to procedure
in paragraph 4.1.
f) Unscrew and remove the top and bottom valve seat (4).
Note: To remove and replace seat (4) a special tool is required which can be obtained from
Spirax Sarco by quoting the valve size type.
g) Lightly smear the threads of the new seats with silicon grease. Insert the new bottom seat (4)
into the body. Tighten to the correct torque (see Table 1). Insert the new top seat (4) into the
body. Tighten to the correct torque (see Table 1).
h) Unscrew the lock nut (16) and remove the bottom plug from the new spindle and plug assembly.
Insert the new top plug (3) into the top seat (4). Insert the new bottom plug (3) into the bottom seat
(4). Ensure the space (6) is held still by locating a spanner on to the machined flat on the spacer.
Replace the plug nut and lock-nut (16) and tighten to the correct torque (see Table 1, page 5)
i) Using a new gasket (13) refit the bonnet (2), taking care not to damage the spindle (5). Replace
and finger tighten the bonnet nuts (15).
j) Fit the packing gland seal according to procedure in paragraph 4.1.1 or 4.1.2, ensuring the valve
stem (5) moves freely after assmbly.
k) Loosen again the bonnet nuts (15) and, while pushing the valve stem so that the valve plug is
on the top seat, finally tighten them to the correct torque (see Table 1).
l) Refit lock nut (8).Refit actuator and connect actuator to valve stem.
m) Bring valve back into service.
Check for leakage around all gasket joints.

8
7 9
11 10
12
15 14
2 18
3
5

4
3

4 6
3
16
Fig. 7
Diverting Valve

18 3.563.5275.201
4.3 Bellows sealed valves 5
4.3.1 P r o c e d u r e f o r r e n e w i n g 8
bellows stem seals (Fig. 8)
a) Isolate valve on three ports.
9 11
b) Remove actuator from valve. Note: take care
17
not to rotate the valve stem when removing
actuator from valve service, this will damage the
bellows. Refer to Installation and Maintenance
Instructions covering Spirax Sarco actuators.
c) Remove lock-nut (1). 16
Caution: Care should be taken in removing
the stem seal if the bellows has failed, since 21
fluid under pressure may be trapped between
the isolating valves.
d) Unscrew gland nut (3), remove the gland bush
(2), remove and discard the stem seal set (4).
e) Examine parts for signs of damage or
deterioration and renew as necessary. Note
the stem seal set on this valve is intended
for emergency use in the event of bellows
failure. Score marks or scaly deposits on the
valve stem (5) will impair sealing efficiency.
f) Clean parts taking care to avoid scratching
the stem or bore of the bellows assembly
top end (6).
g) New graphite stem seals (4) should be
inserted into the bellows assembly top end
(6), care being taken to avoid damage.
h) Refit gland bush (2) and finger tighten the
gland nut (3) over the valve stem (5). Fig. 8
i) Ensure that the stem (5) moves freely.
j) Refit valve lock-nut (1).
k) Bring the valve back into service.

Table 1 Recommended tightening torques (N m)

Bellows Bellows Plug lock-nut
Valve Seat
housing nuts lock-nut Mixing Diverting
size (4)
(15) (19) (16) (16)
DN15 150 - 155 25 - 30 25 - 30 15 - 20 -
DN20 150 - 155 25 - 30 25 - 30 15 - 20 -
DN25 180 - 190 25 - 30 25 - 30 25 - 30 45 - 50
DN32 180 - 190 25 - 30 25 - 30 25 - 30 45 - 50
DN40 180 - 190 36 - 40 25 - 30 25 - 30 45 - 50
DN50 180 - 190 36 - 40 25 - 30 25 - 30 45 - 50
DN65 200 - 220 42 - 48 40 - 45 40 - 45 70 - 80
DN80 200 - 220 60 - 65 40 - 45 40 - 45 70 - 80
DN100 200 - 220 90 - 95 40 - 45 40 - 45 70 - 80

3.563.5275.201 19
4.3.2 Procedure for renewing valve plug, seats and bellows assembly
on mixing valves (Fig. 9)
Note: Due to the delicate nature of the bellows i) Using a new gasket (13) refit the bonnet and
assembly, it is highly recommended that for stem/bellows assembly on the valve body
renewal of the stem/bellows assembly, valve plug ensuring that the spindle fits into the valve
and/or seats, the complete valve is returned to plug bore (3). Replace and finger tighten
Spirax Sarco service department. the bonnet nuts (15). Ensure the spindle (5)
a) Isolate and remove valve from the pipeline. is held still by locating a spanner on to the
Caution: Care should be taken in removing machined flat on the spindle (5). Replace the
the valve since fluid under pressure may be plug nut (16) and lock-nut and tighten to the
trapped between the isolating valves. correct torque (see Table 1). Loosen again
b) Remove actuator from valve. Note: take care the bonnet nuts (15) and, while pushing the
not to rotate the valve stem when removing valve stem so that the valve plug is on the
actuator from valve service, this will damage the bottom seat, finally tighten them to the correct
bellows. Refer to Installation and Maintenance torque (see Table 1).
Instructions covering Spirax Sarco actuators. j) Fit new stem seal assembly (17) as described
c) Remove lock-nut (8). in Paragraph 4.2.1, ensuring valve stem (5)
moves freely after assembly.
d) Ensure the spindle (5) is held still by locating a
spanner onto the machined flat on the spindle k) Refit actuator and connect actuator to valve
(5) and unscrew the plug lock-nut (16) from stem. Note: take care not to rotate the valve
the valve stem (5). In case the flat on the stem when fitting actuator to valve since this
spindle is not easily accessible, fit the nut will destroy the bellows.
(8) and a lock nut onto the spindle, tighten l) Bring valve back into service.
firmly and locate the spanner. Unscrew the m) Check for leakage around all gasket joints.
nuts (15) securing the bonnet (2).
e) Withdraw the bonnet (2) together with
the stem/bellows assembly (5). Remove 8
gland nut (9), gland bush (11), and stem
9 11
seal set (17). Unscrew the stem/bellows 17
assembly lock-nut (19), loosen completely 19
the anti-rotation screw (20) and withdraw the
assembly from the bonnet. 20
f) Unscrew and remove the top valve seat (4). 21
Withdraw the valve plug (3), unscrew and remove
the bottom valve seat (4). Note: To remove and 2
replace top and bottom seat (4) a special
tool is required which can be obtained from
15
Spirax Sarco by quoting the valve size type.
g) Lightly smear the threads of the new seats with 13
silicon grease. Insert the new bottom seat (4)
into the body. Tighten to the correct torque (see
Table 1). Carefully insert the new valve plug
(3). Insert the new top seat (4) into the body.
Tighten to the correct torque (see Table 1). 5
h) Insert replacement stem/bellows assembly 4
(5) with new bellows flange gasket (21) into
the bonnet (2) taking care not to damage the 3
bellows. Replace and finger tighten lock-nut
(19). Rotate the bellows assembly until the
slot onto the top end of the bellows does 4
correspond to the hole of the anti-rotation
screw (20). Replace the anti-rotation screw
(20) until it enters in the slot of the bellows 16
end and finger tighten. Tighten the lock nut
(19) to the correct torque (see table 1); firmly
tighten the anti-rotation screw (20). Fig. 9 - Mixing Valve

20 3.563.5275.201
4.3.3 Procedure for renewing valve plug, seats and bellows
assembly on diverting valves (Fig. 10)
Note: Due to the delicate nature of the bellows i) Using a new gasket (13) refit the bonnet and
assembly it is highly recommended that for stem/bellows assembly on the valve body
renewal of the stem / bellows assembly, valve ensuring that the top valve plug fits into the
plug and / or seats; the complete valve is returned seat (4). Replace and finger tighten the bonnet
to the Spirax Sarco service department. nuts (15). Refit the bottom plug (3) and lock
a) Isolate and remove valve from the pipeline. nuts (16). Ensure the spacer (6) is held still by
Caution: Care should be taken in removing locating a spanner on to the machined flat on
the valve since fluid under pressure may be the spacer and tighten to the correct torque
trapped between the isolating valves. (see Table 1). Loosen again the bonnet nuts
b) Remove actuator from valve. Note: take care (15) and, while pushing the valve stem so that
not to rotate the valve stem when removing the valve plug is on the top seat, finally tighten
actuator from valve service, this will damage the them to the correct torque (see Table 1).
bellows. Refer to Installation and Maintenance k) Fit new stem seal assembly as described
Instructions covering Spirax Sarco actuators. in paragraph 4.2.1, ensuring valve stem (5)
c) Remove lock-nut (8). moves freely after assembly.
d) Ensure the spacer (6) is held still by locating a l) Refit actuator and connect actuator to valve
spanner onto the machined flat on the spacer stem. Note: take care not to rotate the valve
and unscrew the bottom plug lock-nut (16). stem when fitting actuator to valve, since this
In case the flat on the spacer is not easily will destroy the bellows.
accessible, fit the nut (8) and a lock nut onto the m) Bring valve back into service.
spindle, tighten firmly and locate the spanner. n) Check for leakage around all gasket joints.
Withdraw the bottom plug (3). Unscrew the
nuts (15) securing the bonnet (2).
e) Withdraw the bonnet (2) together with
the stem/bellows assembly (5). Remove 8 11
gland nut (9), gland bush (11), and stem 9 17
seal set (17). Unscrew the stem/bellows 19
assembly lock-nut (19), loosen completely
the anti-rotation screw (20) and withdraw the
assembly from the bonnet. 20
21
f) Unscrew and remove the top valve seat (4),
unscrew and remove the bottom valve seat (4).
Note: To remove and replace top and bottom 2
seat (4) a special tool is required which can
15
be obtained from Spirax Sarco by quoting the
valve size type.
g) Lightly smear the threads of the new seats with 13
silicon grease. Insert the new bottom seat (4)
into the body. Tighten to the correct torque (see 5
Table 1). Insert the new top seat (4) into the body. 21
Tighten to the correct torque (see Table 1). 22
h) Remove bottom valve plug (3) from the new
stem/bellows assembly (5). Insert replacement 4
stem/bellows assembly (5) with new bellows 3
flange gasket (21) into the bonnet (2) taking
care not to damage the bellows. Replace and 4
finger tighten lock-nut (19). Rotate the bellows
assembly until the slot onto the top end of the
bellows does correspond to the hole of the 3
anti-rotation screw (20). Replace the anti- 16
rotation screw (20) until it enters in the slot of 16
the bellows end and finger tighten. Tighten the
lock nut (19) to the correct torque (see table Fig. 10 - Diverting Valve
1); firmly tighten the anti-rotation screw (20).

3.563.5275.201 21
 5. Spares parts
5.1 Valves with packing gland seal
The spare parts available are in heavy outline. Parts drawn in broken line are not supplied as
spares. These spares are for the following valves:
QL33M, QL43M, QL63M, QL73M Mixing DN15 to DN100
QL33D, QL43D, QL63D, QL73D Diverting DN25 to DN100

Available spares (Fig. 11)

PTFE Gland seal kit (spring, bushes, packing set) B
Graphite Gland seal kit ( bush, packing set) C
Stem plug gasket D
Seats (2 items) F, G
Bonnet gasket (packet of 3) E

G
C

Diverting

Mixing

Fig. 11

22 3.563.5275.201
5.2 Valves with bellows seal
Available spares (Fig. 12)
Graphite Gland seal kit ( packing set) AS
Bellows gasket (packet of 3) DS
Bonnet gasket (packet of 3) CS
Seats (2 items) BS
Confezione guarnizione cappello (3 pezzi) E
Spindle/bellows and plug assembly, gasket,
ES, CS, DS
for diverting valves
How to order spares
Always order spares by using the description given in the column headed "Available spares" and
stating the size and type of valve.
Example: 1 - Gland seal kit for DN25 QL73DB1 Kvs 10 PN25.

AS

DS

CS

ES / FS
BS

BS

Fig. 12

3.563.5275.201 23
SERVICE
For technical support, please contact our local Sales Engineer or our Head Office directly:

Spirax Sarco S.r.l. - Technical Assistance

Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Italy
Tel.: (+39) 0362 4917 257 - (+39) 0362 4917 211 - Fax: (+39) 0362 4917 315
E-mail: [email protected]

LOSS OF GUARANTEE
Total or partial disregard of above instructions involves loss of any rights to guarantee.

Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17307

3.563.5275.201 CH Issue 4 - 2015.11