1. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVES
INSTRUCTIONS
©
FOR DeZURIK
3-WAY AND 4-WAY
TAPERED PLUG
VALVES
D-10188
December 1993
December 1993
© 1993 DeZURIK, A UNIT OF GENERAL SIGNAL
D-10188

2. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVESThe DeZURlK 2" thru 16" Tapered Plug valves will provide dependable, trouble free
INTRODUCTION
service provided the application is correct and the valve is installed and maintained to
DeZurik specifications. Each DeZurik valve is tested at the factory to some of the most
stringent standards in the industry.
A copy of these instructions should be made available to the personnel responsible for
the installation and maintenance of this equipment. Refer to the applicable sales
bulletin and to the valve data plate regarding materials of construction and product
limitations.
The following instructions are written following a modular concept. Each separate
major assembly in this product will have a separate instruction. Thus the basic valve
will have a separate instruction, as will the actuator and any accessories your unit may
have. The assembly drawings you receive also follow this concept. This concept was
created to make the entire product seem less complicated by breaking it down into
smaller, easier to understand modules.
SAFETY MESSAGES Safety messages in these instructions and on label(s) on the valve are flagged with
one of the words Caution, Warning or Danger. The messages must be carefully read
and followed to avoid personal injury and/or equipment damage.
After installation, if a safety label on the valve becomes difficult to see or read, or if a
label has been removed, please contact DeZURIK for replacement label(s). Include
the 7-digit part number from the data plate on the valve, the quantity of valves, and an
appropriate name and mailing address.
INSPECTION This equipment has been adequately packaged and protected for shipping; however,
due to improper handling, the possibility of damage in transit exists. When the valve
arrives at its final destination, it should be carefully inspected for damage and
equipment malfunction.
STORAGE Because the rubber lined seat and plug in this valve may deteriorate if it is not
protected from dust, freezing water, sunlight or other ultraviolet rays, store the valve in
a clean, dry, cool location with the flange protectors intact. The valve should be stored
with the plug horizontal and partially open.
If it is necessary to store the valve outdoors, it should be wrapped in plastic and stored
high enough off the ground to ensure it will not be immersed in water or buried by
snow. The plastic plugs in the cylinder or positioner (if equipped) must be replaced with
pipe plugs.
REPLACEMENT It is advised that one set of Recommended Spare Parts be inventoried for each valve
PARTS size and type. Recommended Spare Parts are identified on the Assembly Drawing.
When ordering parts, please include the valve size and part number (7-digit) from the
data plate. If possible, also include the Assembly Drawing number, Part Name, Balloon
Number and Quantity of parts as shown on the Assembly Drawing.
D-10188 December 1993

3. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVES
DESCRIPTION The DeZurik 3-Way and 4-Way Tapered Plug valves are available with material,
actuator and accessory options to meet a wide range of application requirements.
Three plug styles are offered to provide flow paths with 90 and 360 degree plug
rotation. Each different flow path arrangement has a unique number called a
Combination Number. See the Product Bulletin for these valves for a complete
description of the Combination Numbers.
WARNING
THIS VALVE IS A PRESSURE VESSEL. PIPELINE PRESSURE
MUST BE COMPLETELY RELEASED BEFORE DISASSEMBLY. USE
EXTREME CAUTION WHEN REMOVING THE BONNET. THE
BONNET WILL BLOW OFF THE VALVE IF THE BOLTS ARE
REMOVED WITH PRESSURE IN THE VALVE.
INSTALLATION This Instruction Manual covers the installation requirements of the valve only. For
actuator or accessory installation information, see the Instruction Manual for that
component.
FLANGE DRILLING Flanges on U.S. Standard valves are drilled to ANSI Class 125/150 specifications. For
flange drillings other than U.S. Standard, see DeZurik Data A-16374.
FLOW DIRECTION It is recommended that the valve be installed so pipeline pressure will push the plug
into the seat(s) of the port(s) being sealed.
TOOLS REQUIRED This valve is assembled using only standard SAE fasteners. To service this valve, you
should have a full set of combination wrenches, a pin punch, and a dead blow
hammer. You may want to machine a shaft to aid you in removing the lower bearing
from the body. See the DISASSEMBLY section for details.
LUBRICATION This valve does not require routine maintenance lubrication. If the valve is
disassembled, the plug journals and packing must be lubricated as follows:
PACKING Packing lubrication requirements are dependent upon the packing material.
PTFE Packing - Requires no lubrication.
All Packing Other Than PTFE - Apply a light coat of Keystone Nevastane HT-2 to the
inside and outside diameters of the packing rings.
PLUG JOURNALS Plug journal lubrication is dependent upon the materials used in construction of the
valve.
Hard Rubber Lined (RS53) Valves - Lubricate the journals on the plug with Dow
Corning #44.
December 1993 Page 1 of 6 D-10188

4. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVES
Cast Iron, Ni-Resist, Bronze and Acid Bronze Valves - Lubricate the journals on the
plug with Keystone Nevastane HT-2.
All Valves except Hard Rubber Lined, Cast Iron, Ni-Resist, Bronze and Acid
Bronze Valves - Spray the journals on the plug with a light coat of Molykote G Rapid
Spray, then lubricate with a mixture of powdered graphite and Standard Oil #140 Gear
Lube.
ADJUSTMENTS All standard DeZurik Tapered Plug valves feature adjustable stem seal packing. If a
stem seal packing leak should occur, tighten the gland nuts evenly just until the
leakage stops. Do Not continue tightening after leakage stops. If packing leakage
cannot be stopped by tightening the gland nuts, the packing must be replaced.
On valves not utilizing a Lift, Turn, Reseat actuator, the seat/plug clearance can be
adjusted by removing the locknut and wrenching square from the top of the valve, then
turning the plug adjusting nut to change the seat/plug clearance. Turning the nut
clockwise will increase the clearance between the seat and plug; turning the nut
counterclockwise will decrease the clearance. Recommended seat plug clearance is
.030" for paper stock and .010" for all other applications.
PACKING When Tapered Plug valves are mounted in a vertical pipeline, or mounted in a
REPLACEMENT horizontal pipeline with the plug stem horizontal, there is a chance that gravity will
cause the plug to swing to a lower position in the valve body when the actuator is
removed. To avoid this hazard, place the plug in the lowest position before removing
the actuator.
Follow these steps to replace the packing:
1. Discontinue pipeline flow and relieve pipeline pressure.
2. Scribe the adaptor and bonnet for alignment when reassembling.
3. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or
electrical power to prevent accidental operation of the actuator.
WARNING
Moving parts from accidental operation of power actuator can
cause personal injury or equipment damage. Disconnect and lock
out power to actuator before servicing.
4. Remove the actuator from the valve as described in the Actuator Instruction
Manual, under the ACTUATOR REMOVAL heading.
5. Remove the six screws fastening the actuator adaptor to the valve, then separate
the adaptor from the valve.
6. Remove the two packing gland nuts, then slide the packing gland off the valve
shaft.
7. Pull the packing out of the bonnet.
D-10188 Page 2 of 6 December 1993

5. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVES
8. Lubricate the new packing, then install it one ring at a time in the sequence shown
in Figure 1.
9. Slide the packing gland down the valve shaft and over the studs.
10. Turn the packing gland nuts onto the studs until they contact the packing gland,
then one additional turn. It will be necessary to adjust the packing gland nuts after
the valve is pressurized.
11. Fasten the adaptor to the valve, lining up the scribe marks made during
disassembly.
12. Install the actuator on the adaptor as described in the Actuator Instruction
Manual, under the ACTUATOR INSTALLATION heading.
13. If the actuator is a powered actuator, reconnect power to the actuator.
14. The valve is now ready to control flow.
DISASSEMBLY When Tapered Plug valves are mounted in a vertical pipeline, or mounted in a
horizontal pipeline with the plug stem horizontal, there is a chance that gravity will
cause the plug to swing to a lower position in the valve body when the actuator is
removed. To avoid this hazard, place the plug in the lowest position before removing
the actuator.
Together, the DISASSEMBLY and REASSEMBLY sections cover the steps required to
replace all the recommended spare parts in this valve.
December 1993 Page 3 of 6 D-10188

6. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVES
WARNING
THIS VALVE IS A PRESSURE VESSEL. PIPELINE PRESSURE
MUST BE COMPLETELY RELEASED BEFORE DISASSEMBLY. USE
EXTREME CAUTION WHEN REMOVING THE BONNET. THE
BONNET WILL BLOW OFF THE VALVE IF THE BOLTS ARE
REMOVED WITH PRESSURE IN THE VALVE.
1. Discontinue pipeline flow and relieve pipeline pressure.
2. Scribe the adaptor, bonnet and valve body for alignment when reassembling.
3. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or
electrical power to prevent accidental operation of the actuator.
WARNING
Moving parts from accidental operation of power actuator can
cause personal injury or equipment damage. Disconnect and lock
out power to actuator before servicing.
4. Remove the actuator from the valve as described in the Actuator Instruction
Manual, under the ACTUATOR REMOVAL heading.
5. Remove the six screws fastening the actuator adaptor to the valve, then separate
the adaptor from the valve.
6. Remove the screws securing the bonnet to the valve body, then separate the
bonnet from the valve.
7. Note the orientation of the plug in relationship to the valve ports, then lift the plug
from the valve body.
8. Remove the two packing gland nuts, then slide packing gland off the valve shaft.
9. Pull the packing out of the bonnet.
10. Reaching in thru the packing chamber in the bonnet, drive the upper bearing out
of the bonnet using a hammer and pin punch.
11. Remove the lower bearing from the valve body. The bearing can be chiseled out;
or, it can be hydraulically forced out by filling the ID of the bearing with water,
then pounding a shaft with the same OD as the lower journal of the valve plug
into the bearing. This will create a hydraulic force under the bearing that will force
it out. See Figure 2.
1. Push a new lower bearing into the valve body.
REASSEMBLY
2. Place the plug in the valve body. Turn it so it is in the position noted during
disassembly.
3. Push a new bearing into the bonnet.
D-10188 Page 4 of 6 December 1993

7. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVES
4. Place the bonnet on the valve, line up the scribe marks, then fasten the bonnet in
place.
5. Lubricate the new packing, then install it one ring at a time in the sequence shown
in Figure 1.
6. Slide the packing gland down the valve shaft and over the studs.
7. Turn the packing gland nuts onto the studs until they contact the packing gland,
then one additional turn. It will be necessary to adjust the packing gland nuts after
the valve is pressurized.
8. Fasten the adaptor to the valve, lining up the scribe marks made during
disassembly.
9. If the actuator is a powered actuator, reconnect power to the actuator.
10. Install the actuator on the adaptor as described in the Actuator Instruction
Manual, under the ACTUATOR INSTALLATION heading.
11. The valve is now ready to control flow.
VALVE REMOVAL To remove the entire valve assembly from the pipeline, follow these steps carefully.
FROM PIPELINE
1. Relieve pipeline pressure and drain the portion of the system where the valve is
located.
2. Close the valve.
3. If the actuator is powered, disconnect and lock out the pneumatic, hydraulic, or
electrical power to prevent accidental operation of the actuator.
December 1993 Page 5 of 6 D-10188

8. DeZURIK® 2" THRU 16"
3-WAY AND 4-WAY
TAPERED PLUG VALVES
WARNING
Moving parts from accidental operation of power actuator can
cause personal injury or equipment damage. Disconnect and lock
out power to actuator before servicing.
4. Support the valve assembly, then remove the flange bolts.
5. Remove the valve from the pipeline.
D-10188 Page 6 of 6 December 1993