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MARC Certified Technician Training
Section III
(21000 Valve, 87/88 Actuator & 4700 Positioner
Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 1

Learning Objectives
 What a 21000 with standard

actuator and instrument is?
 Why it exists?
 How it works.
 How to disassemble, inspect,

repair, assemble, calibrate
and test.

Reciprocating Control Valves
Globe Design
 Post (Shank) Top Guided Packing Follower
 Unbalanced
 Single Seated Packing Ring (S)
 Captured Seat Ring (QC) Stem
 Top Entry Plug Guide

Bushing
 Crane 285K / Grafoil
Bonnet Gasket
Packing
Cage
 General Service
Plug Head
 ¾” thru 6” ASME 150—
2500 Seat Ring
Seat Ring
 Raised Face End Gasket
Connection

Globe Design
 Unbalanced Packing Ring (S)
Bonnet
 Single Seated
 Captured Seat Ring (QC)
Bellows
 Top Entry
 Bellows
Bonnet Extension
 Special Service
 1” thru 6” ASME 150—300
Plug Guide
Bushing
Masoneilan 21000
Plug Head
2” Cv = 46
Cage
Seat Ring

Angle Design
 Post (Shank) Top Guided
 Unbalanced
Packing Follower
 Single Seated Packing Ring (S)
 Captured Seat Ring (QC) Stem
 Top Entry Plug Guide

Bushing
 Wide Trim Selection
Cage
 General Service
 ¾” thru 6” ASME 150—2500 Plug Head
Seat Ring
Lo-db/Anti-Cavitation Trim
Masoneilan 21000
2” Cv = 25

Globe Design
 Single Seated
Bonnet
 Threaded Seat Ring
Bellows
 Top Entry
 Bellows
Bonnet Extension
 Special Service
 1” thru 6” ASME 150—300
Masoneilan 21000 Plug Guide

Bushing
1” Cv = 12 Body
Plug Head
Seat Ring

Globe Design
 Heavy Plug Guided
Packing Follower
 Single Seated Lantern Ring
Plug Stem
 Threaded Seat Ring
Disc Springs
 Top Entry
Plug Shank
 Live-Loaded Seat Bonnet
 Chemical Service Plug Guide

Bushing
 1” thru 2” ASME 300
Soft Seat Insert
Plug Tip
Masoneilan 215X1 Seat Ring
2” Cv = 45 Body

21000A SERIES Top Guided Angle
21000A Series Cast Angle

Follower
 1 -6 ASME 150-2500 Class Lantern Ring
Grafoil Packing
 Carbon Steel & Alloy Ring
 Extended Bonnet Stem
 End Connections - SW,BW,RF,RTJ Extended Bonnet
Plug Bushing
 Reduced Trim
Bonnet Gasket
Plug
 ANSI Class IV & V Shutoff
 Stellite Venturi Outlet Seat Ring
Retainer
 Spring Diaphragm & Piston Actuation

Seat Ring Gasket
Stellite Venturi
Seat
Angle Body
Stellite Venturi Outlet

Disassembly 21000 Series Valve Body SA

Disassembly 21000 Series Valve Body SA
Bonnet Gasket Seat Ring
Packing Rings
Seat Ring Gasket

Cage
Plug Guide Bushing
Plug & Stem
Gland Flange Studs

Packing Follower Bonnet
Gland Flange
Gland Flange Hex Nuts Body Bolting Hex Nuts

Instructor Guided Demo Components

Disassembly
21000 Series Valve Body SA
Instructor Guided Demo

Disassembly - Review

Inspection - Review
 Wall thickness in
wear areas. ASME
Gasket Surface
B16.34
 Flange thickness
Bonnet Locating
ASME B16.5 Register
 Gasket Surfaces
 Guides Gasket Surface
(125/250 RMS
Typical) Wall Thickness

ASME B16.34 and B16.5

Hydrostatic Shell Test Pressures
Per ASME 16.34 & ISA S75.19
ASME Carbon and
Class Chrome-Moly Stainless Unalloyed
Steels Steel Bronze Zirconium 702 Titanium Ductile Iron
150 450 450 340 300 450 400
300 1125 1125 750 600 1050 975
400 1500 1500 775 1400
600 2250 2250 1175 2000
900 3375 3375 1750 3150
1500 5625 5625 2900 5225
2500 9375 9375 4825 8725
4500 16875 16875
ASME
Nickel Alloy Monel Inconel Alloy Hastelloy Hastelloy
Class
Alloy 20Cb 200 Alloy 400 600 Alloy B-2 Alloy C-275
150 400 250 400 450 450 450
300 1025 600 1025 1125 1125 1125
400 1350 825 1350 1500 1500 1500
600 2025 1225 2025 2250 2250 2250
900 3025 1825 3025 3375 3375 3375
1500 5025 3025 5025 5625 5625 5625
2500 8375 5025 8375 9375 9375 9375
4500 15050 9050 15075 16875 16875 16875
Reference Material ES127, CES-1001 & APS-1600

ANSI/FCI 70-2 Leakage Class
 Class I no test procedure
 Class II 0.50 % of rated Cv (air)
 Class III 0.10 % of rated Cv (air)
 Class IV 0.01 % of rated Cv (air)
 Class V 0.0005 ml/min of water per

inch of orifice dia. Per psi
 Class VI ml/min per orifice dia. (air)
Reference Material ES143, CES-1002 & APS-1600

ANSI/FCI 70-2 Leakage Class
 Class II, III, IV Test media :

50 psig air at 50 - 125º F
 Class V Test media :

Water at 50 - 125 º F
Test pressure is maximum differential
 Class VI Test media : Water

50 psig air at 50 - 125 º F

Body Wall Thickness
Reference Table 3-8
ASME B16.34

ASME B16.5
Flange Dimensions
B Y
tf
0.06”
Raised face height

O no greater than
0.06” (1/16”)
 Class 150 and 300

Flange Thickness
X
A
B Y
O
tf
tf
O
Raised Face
Blind Welding Neck Height no greater
than 0.250” (1/4”)
TABLE F16
See tab 8
Inspection - Review
21000 Series Valve Bonnet

 Gasket Surfaces
 Packing Box
Gland Flange
Studs  Stud
– Threads
– Bent
 Bushing
Packing Box
Surface Finish &  Guide Surfaces
Inside Diameter
Gasket Surface
Plug Guide
Bushing

Inspection - Review
21000 Series Valve Trim
 Stem
 Pin
 Plug
 Seat Ring
 Sometimes:
– Cage
– Bushing

Seat Re-Machining 0.015’’ max.
30º
28º
Stellite

Inspection - Review
 Common Types of Damage
− Cavitation
− Flashing
− Wire Drawing
− Erosion
− Chemical Corrosion
− Fretting

Cavitation
 Localized
 Rough pock marked
 Sounds like rocks
 Will attack any material
 Worse with high

pressure

Flashing
 Erosion
 Mechanical solutions
 Material solutions

Wire Drawing
 Erosion
 Seat leakage at
high pressure
 Cavitation secondary

Erosion

Corrosion
 Chemical induces
 All wetted parts

are affected
 Material

Fretting
 Vibration induced
 Hardened materials

Review 21000 Series Valve Body SA
Threaded Trim
Packing Follower
Packing Spacer
 Single Seated Stem
Plug Guide
 Threaded Seat Ring Bushing
Bonnet Gasket
 Top Entry
 Crane 285K / Grafoil
Packing Plug Head
 General Service Seat Ring

(Threaded)
 ¾” thru 6” ASME 150—2500

 Race Face End Connection
Body

Review 21000 Series Valve Body SA
Lo-dB® - Anti-Cavitation Trim

21000 Series Valves
Lo-dB® Noise Attenuation

 Drilled Hole Technology
 Flow-to-Open (FTO)
 Single Stage Trim
– 20 dBA Reduction
 Compressibles only
– Including Steam
 Application Dependent
– Pressure Ratio (P1/P2)

21000 Series Valves
Anti-Cavitation Trim
 Drilled Hole Technology
 Flow-to-Close (FTC)
 Single Stage Trim
– 20 dBA Reduction
 Incompressibles only
– Clean Service
 Application Dependent
– Pressure Ratio (P1/P2)

21000 Series Valves
Anti-Cavitation Single Stage Trim
Fluid enters through the drilled cage.

Bubbles form and collide into each other.
As the bubbles collide they implode
against each other instead of the valve
trim.

21000 Series Valves
Anti-Cavitation Two Stage Trim

Fluid enters through the drilled cage.
Bubbles form and collide into each other.
As the bubbles collide they implode
against each other instead of the valve
Turn
trim. Recombine
Split
Two stage cavitation control

works on the same principle as
the single stage. However a
second stage or cage is added
to take an initial pressure drop.


Assembly Review
Bonnet Gasket
Cage
Packing Rings
Body Bolting Studs Seat Ring
Plug Guide Bushing

Bonnet
Plug & Stem
Gland Flange Studs

Packing Follower
Seat Ring Gasket

Gland Flange
Gland Flange Hex Nuts
Body Bolting Hex Nuts

Torque Procedures
 Reference ASME
– Bulletins
– Instructions

21000 Series Control Valve
Model Number Identification
1st 2nd - 1st 2nd 3rd 4th 5th

Actuator Body Plug Control Seat
Type Series Type Characteristics Type
37 Air-to-Close 21 0 - Undefined 0 - Undefined 0 - Undefined
38 Air-to-Open 1 - Unbalanced 1 - Linear 4 - Quick
47 Air-to-Close contoured 2 - Equal % Change
48 Air-to-Open 7 - LO-DB 5 - Threaded
87 Spring Diaphragm
6 - Soft Seat
Air-to-Close
88 Spring Diaphragm
Air-to-Open

Part Numbers
 Trim Components
 12 Digits
 Non Significant Except Material Code
Base Dash Material Code
xxxxxx - xxx - xxx (Alpha)

Location

Typical Material Call-Outs
Material Code Description ASTM Application
010 Chrome-Moly Alloy Hex Nuts per ASTM A194 Gr 2H Nuts
066 Chrome-Moly Alloy Bolting per ASTM A193 Gr B7 Bolting
030 Carbon Steel Forge per ASTM A105 Body/Bonnet
104 Carbon Steel Cast per ASTM A216 Gr WCC Body/Bonnet
153 304 Stainless Steel Body/Bonnet/Trim
158 Austenitic stainless steel 304 per ASTM A194 Gr 8 Nuts
163 316 Stainless Steel Cast/Forge Body/Bonnet/Trim
177 304 Stainless Steel Bolting per ASTM A193 B8 Bolting
173 316 Stainless Steel Bolting per ASTM A193 B8M Bolting
174 316 Stainless Steel Hex Nuts per ASTM A194 Gr 8M Nuts
193 Martensitic Stainless Steel Cast per ASTM A487 Gr CA6NM Trim
210 17-4ph per ASTM A564 Gr 630 Trim
220 Martensitic SS per ASTM A276 Gr 440C Guide Bushings
244 Chrome-Moly casting per ASTM A217 Gr WC9 CL 3 Body/Bonnet
246 Chrome-Moly Casting per ASTM A217 Gr WC6 Body/Bonnet
250 Stainless Steel any 300 Series General
254 High-Strenght Bolting up to 1000F per A453 Gr 660 Bolting/Nuts
300 Casting Gray Iron Per ASTM A126 Class B General
322 Casting Ferritic Ductile Iron per ASTM A395 General
537 Inconel X-750 Per ASTM B637 GR 688 Trim
567 Stellite 6B Bar Trim
587 Hardface Stellite 6b on 316 SS Trim W/Over-Lay

Actuator Force Calculations
Exercise
Air to Open / Fail Close
Actuator Selected
– #10 Actuator = 100 sq. inch area
• 6 Psi - 30 Psi spring range Air to Open
• 45 psi Supply 1-1/2” Stroke
Air To Retract F = (Ps - Pf ) x Af

 Available thrust to Open Valve = Supply Pressure (Pi) – Spring Final (Pf) x Area of Diaphragm (Ai)
 Available Thrust (Factuator) = 45 Psi – 30 psi x 100 sq. inch
 Available Thrust (Factuator) = 15 x 100= 1500 Pounds
Spring to Extend F = Pi x Ai
 Available thrust to Close Valve = Spring Initial (Pi) x Area of Diaphragm (Ai)
 Available Thrust (Factuator) = 6 psi x 100 sq. inch
 Available Thrust (Factuator) = 6 x 100= 600 Pounds

Actuators Model 87
 Air to Extend
 Rolling elastomer diaphragm for
constant area.
 Multi-spring arrangement allows for
4 standard spring ranges.
– 3 - 15 PSI
– 6 - 30 PSI
– 11 - 23 PSI
– 21 - 45 PSI
 Changes are made by varying the
spring quantity (3 or 6), type and
placement.
 Field reversible with no additional
parts.

Caution and max. supply warnings for 87/88 actuator

Actuators Model 87
 Air Inlet
 Upper Diaphragm Case
 Rolling Diaphragm
 Diaphragm Plate
 Spring (s)
 Stem Bushing with Wiper Seal
 O’ring
 Actuator Stem
 Travel Scale
 Stem Connector (Top & Bottom)
 Short Yoke

Actuators Model 88
 Air to Retract
 Rolling elastomer diaphragm for
constant area.
 Multi-spring arrangement allows
for 4 standard spring ranges.
– 3 - 15 PSI
– 6 - 30 PSI
– 11 - 23 PSI
– 21 - 45 PSI
 Changes are made by varying the
spring quantity (3 or 6), type and
placement.
 Field reversible with no additional
parts.

Actuators Model 88
 Spring (s)
 Upper Diaphragm Case
 Rolling Diaphragm
 Diaphragm Plate
 Stem Bushing with Wiper Seal
 O’ring
 Actuator Stem
 Travel Scale
 Stem Connector (Top & Bottom)
 Short Yoke

87/88 Spring Diaphragm Actuators
Actuator Travel Spring Color Code Spring Range Number of Springs Spring Spacer
.8" Red 3-15 psi 3 No
1.5" Blue 6-30 psi 6 No
2.0" Green 11-23 psi 3 Yes
2.5" Yellow 21-45 psi 6 Yes
Spacers required on size (10) 1-1/2" stroke
Spacers required on size (16 & 23) 1-1/2" thru 2-1/2" stroke
Spring Selection and Location
Lower Pedestal Upper Pedestal

87/88 Actuators
Instructor Guided Demonstration

Disassemble Inspect and Assemble
Model 88
Model 87

88 Actuators Disassembly
Diaphragm Plate
Jam Nut
Washer
Spring (s)
Upper Diaphragm Case
Capscrew Head Hex
Compression Nuts
Diaphragm
Hex Nuts

88 Actuators Assembly
Jam Nut
Washer Diaphragm Plate
Diaphragm
Spacer
Actuator Stem
Diaphragm

87/88 Actuators
Instructor
Guided
Demonstration
Disassemble
Inspect and
Assemble

Type 87/88 Actuators
Handwheels

21000A SERIES
TOP GUIDED ANGLE

 Unbalanced
 Single Seated
 Captured Seat Ring Signal to Close
 Extended Bonnet Fail Open
 Top Entry
 Wide Trim Selection
 General Service
 ¾” thru 6” ASME 150—2500

Bench Set and Test
 Spring Initial
 Spring Final
 Travel
 Operation
 Leakage

Instructor Guided Demo Assemble

4700 Series Positioner
Model Numbering
1st 2nd 3rd 4th 5th

4 E&P
P = Pneumatic
E = Electro/pneumatic

Positioners
 Input  Output
 Pneumatic  Pneumatic

Pneumatic Force Balanced Direct Feedback
Positioner
Actuator
Cam Differential Diaphragm
Pilot Assembly
Instrument Instrument Exhaust Output

Signal Supply

4700E Positioner Pneumatic
 Input  Output
 Pneumatic
 Analog

4700E Positioner
Electro-pneumatic
 Replace gauges
 Replace all O-Rings
 Replace Diaphragm
 Check Pilot Spool !!!!!
– Don’t over tighten

Valve Assembly Testing
Completing the MARC

Class “A” Repair
 Calibration
 Seat Test
 Hydro Test
 Performance Signature
 Tagged

Masoneilan Global Standards
CES 1001 Hydrostatic Testing
CES 1002 Seat Leakage Testing
CES 1003 Minimum Quality Requirements for

Pressure Retaining Parts
CES 1004 General Requirements - Welding
CES 1006 Materials for H2S - Nace Service
CES 1007 Packing Leakage
CES 1008 Performance Testing

Masoneilan Standards
CES 1009 Hysteresis & Deadband
CES 1011 Procedure to Rate Valves Other

than ASME B16.34 Code Material
CES 1013 Part Marking
CES 1014 Product Painting - Refer to ES 407
CES 1015 Product Cleaning - Refer to ES 392
CES 1016 Packaging - Refer to ES 256-1, -2
CES 1017 Stroke Time Test - Refer to ES 345

Masoneilan Standards
CES 1018 Actuator Sizing - Unbalanced Valves
CES 1019 Actuator Sizing - Balanced Valves

CES 1021 Maximum Tightening Torque Table
for Studs & Bolts in Pressure Retaining
Service & Other Product Specific Global
Standards

Compare and Contrast to 21000

 Older Style Version of 21000
 Never Stopped Making For Nuclear Industry
 Equipped With 37/38 Actuator
• Stem Diameter was 3/8” (21000 Min. ½”)

• Body & Bonnets not interchangeable
• Stem projection changes due to 87/88
implementation
• Cage design changed to “Bar-Stock”
• Body Bolt pattern 4-Bolt & 8-Bolt
• Some trim components are
interchangeable

MARC Certified
Technician Training
Section III

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MARC Certified Technician Training

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 1

 What a 21000 with standard

 How to disassemble, inspect,

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 2

 Captured Seat Ring (QC) Stem

 Top Entry Plug Guide

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 3

 Unbalanced Packing Ring (S)

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 4

 Captured Seat Ring (QC) Stem

 Top Entry Plug Guide

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 5

 Unbalanced Packing Ring (S)

Masoneilan 21000 Plug Guide

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 6

 Single Seated Lantern Ring

 Live-Loaded Seat Bonnet

 Chemical Service Plug Guide

Masoneilan 215X1 Seat Ring

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 7

21000A Series Cast Angle

 Extended Bonnet Stem

 End Connections - SW,BW,RF,RTJ Extended Bonnet

 Spring Diaphragm & Piston Actuation

Stellite Venturi Outlet

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 9

Bonnet Gasket Seat Ring

Seat Ring Gasket

Plug Guide Bushing

Plug & Stem

Gland Flange Studs

Gland Flange Hex Nuts Body Bolting Hex Nuts

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 10

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 11

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 12

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 13

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 14

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 15

Reference Material ES127, CES-1001 & APS-1600

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 16

 Class I no test procedure

 Class II 0.50 % of rated Cv (air)

 Class III 0.10 % of rated Cv (air)

 Class IV 0.01 % of rated Cv (air)

 Class V 0.0005 ml/min of water per

 Class VI ml/min per orifice dia. (air)

Reference Material ES143, CES-1002 & APS-1600

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 17

 Class II, III, IV Test media :

 Class V Test media :

 Class VI Test media : Water

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 18

Reference Table 3-8

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 19

Raised face height

 Class 150 and 300

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 20

21000 Series Valve Bonnet

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 22

21000 Series Valve Trim

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 23

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 24

Marc Repair Mechanic Training Section 3 pg 1/70 Company Confidential © 2009 25