Masoneilan Controlled Engineering Specification:

Assembly & Test Specification

10,000 Series Body S/A

CES-303

Revision History
The table below describes the revision history of this document.

Rev. Date Brief Description

A 29 August, 2011 Initial Release
B 24 July, 2013 Update to Global Document Format
C June – 2016 PDR-ECO-0025325

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 1 of 14

GE PROPRIETARY INFORMATION
The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced
without the express written consent of GE. It is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration
changes or to obtain government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document
shall appear in any such reproduction in whole or in part. Copyright © 2012 General Electric Company. All rights reserved.
This document contains controlled technical data. Any export of this technical data from the United States, or the originating country, must be in accordance with U.S .Export Administration Regulations
and/or the originating country’s export regulations. Diversion contrary to such law(s) is prohibited.
 TABLE OF CONTENTS
1  GENERAL ................................................................................................................................................... 3 

2  SCOPE ........................................................................................................................................................ 3 

3  REFERENCED DOCUMENTS ...................................................................................................................... 3 

4  DEFINITIONS .............................................................................................................................................. 3 

5  SAFETY ....................................................................................................................................................... 4 

6  PROCESS FLOW ......................................................................................................................................... 5 

7  PROCEDURE .............................................................................................................................................. 5 

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 2 of 14

GE PROPRIETARY INFORMATION
Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.
1 GENERAL
Provide the information required by an experienced valve technician to properly assemble a 10,000
series body subassembly.

2 SCOPE
Assembly and test of 10,000 series body subassemblies as listed in Figure 1. For 10,000 Series
Product Scope and Construction Rules see CES-302 & CES-304 respectively.

3 REFERENCED DOCUMENTS
 CES-1001 - Hydrostatic Testing

 CES-1002 - Seat Leakage Testing

 CES-1007 - Packing Leakage Testing

 CES-1008 - Performance Testing and Final Product Inspection

 CES-1036 - Paint

 CES-164 - Assembly and Test Procedure for 87/88 Actuator

 Mounting Procedure for 37/38 Actuator

 CAP-107 - Rules for Establishing a Standard Global Serial Number Format

 Drawing 010170001 - Plug Stem Pinning Instructions

 Drawing 400132700 - Valve Assembly and Location Drawing

4 DEFINITIONS
Body Subassembly – A fully tested assembly consisting of all the parts required by this procedure.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 3 of 14

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5 SAFETY
Any organization performing testing under this procedure shall have written safety instructions
detailing how to perform the work safely. The information presented in this procedure is an aid to
creating a safe work environment.

5.3 Hazard
There are no major or unusual hazards associated with valve assembly and performance testing,
however there are possibilities of pinch or crush points and leakage during hydrotest.

5.4 Failures
The credible risks associated with the use of compressed air include; loose airlines, pinching (blunt
trauma) and eye injuries.

5.5 Risk Mitigation

Test Conditions

Provide written instructions.

Personal Protective Equipment

Eye protection is mandatory during test when valves and / or actuators are pressurized. Conform
to local regulation when they are more stringent i.e. eye protection is mandatory all the time.

Equipment

All test equipment should be examined regularly under a preventive maintenance program and
any worn or unsafe equipment must be replaced. When needed use appropriate electrical
connection, correctly insulated.

Open end and adjustable open end wrenches are not to be used for valve assembly or torquing.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 4 of 14

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6 PROCESS FLOW

Figure 1 – Body Subassemblies

7 PROCEDURE
7.1 Operations prior to assembly
7.1.1 Inspect
• Check parts/materials for conformity to bill of material call-out.

• Check pressure containing parts for clear and legible heat numbers.

• Inspect inner surface of body, bonnet, lower flange, seat and plug for cleanliness.
Remove any foreign matter and clean the gasket surfaces.

• Inspect body, bonnet, seat ring, plug, plug stems, and bushings for nicks, scratches,
burrs, sharp corners, etc., on sealing and sliding surfaces. These parts must be protected
prior to assembly. During assembly care must be exercised to prevent damage to these
parts.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 5 of 14

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 7.1.2 Assemble plug to stem and pin per drawing number 010170001.
a) Check that stem, plug and pin meet appropriate drawing dimensional requirements.

b) Screw the stem into plug solidly and fully engaged.

c) Drill and ream plug/stem assembly per drawing

d) Using the appropriate pin; press fit into hole.

e) After pinning check plug/stem run-out is ≤ 0.13mm[.005 in]

7.1.3 Press bushing into bonnet and into lower flange.

7.2 Valve Body Assembly

See specified valve assembly drawing

7.2.1 Body Stud Assembly

With the application of a small amount of Never-Seez or equivalent, install the body studs with a
stud driver. For reference data see figure 2.

STUD d

L H

Stud L H
Valve Size Rating
Dia No +/‐ 1,5 [0,06] +2,5[0,10] / ‐3,0[0,12]
3/4 1/2 57,2 [2,25] 41,2 [1,62] BODY
150 / 600 6
1 1/2 57,2 [2,25] 41,2 [1,62]
1,5 150 / 600 1/2 12 57,2 [2,25] 41,2 [1,62]
2 150 / 600 1/2 16 57,2 [2,25] 41,2 [1,62]
3 150 / 600 5/8 16 69,8 [2,75] 50,8 [2,00]
4 150 / 600 3/4 16 83,0 [3,27] 61,0 [2,40]
6 150 / 600 3/4 24 98,0 [3,86] 76,0 [2,99]
150 / 300 5/8 32 79,0 [3,11] 60,0 [2,36]
8
600 3/4 40 104,6 [4,12] 82,6 [3,25]
150 / 300 3/4 32 93,0 [3,66] 71,0 [2,80]
10
600 1 1/8 32 137,0 [5,39] 105,0 [4,13]
150 / 300 7/8 32 113,0 [4,45] 81,0 [3,19]
12
600 1 1/2 32 170,0 [6,69] 130,0 [5,12]
150 / 300 ‐ ‐ ‐ ‐ ‐ ‐
14
600 ‐ ‐ ‐ ‐ ‐ ‐
150 / 300 1 1/4 32 153,0 [6,02] 110,0 [4,33]
16
600 1 1/2 32 215,0 [8,46] 165,0 [6,50]

Figure 2 – Stud Projection

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 6 of 14

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 7.2.2 Seat Ring Installation, Threaded Trim
Lubricate seat ring threads with Never-Seez (or equivalent). Install upper and lower seat ring into
the body finger tight as shown in figure 3. Tighten seat rings in body to assure metal to metal seat
ring / body contact force to prevent leakage. Use the torques shown in figure 4 as a guide

Item Description
B120 Plug Stem
B201 Packing Flange Nut
B213 Packing Flange
B200 Packing Flange Stud
B017 Drive Nut
B003 Bonnet
B001 Body
B903 Plug Pin
B112 Plug
B102a Lower Flange
B014 Body Stud Nut
B002 Body Stud
B015 Body Gasket
B011 Bushing
B102a Lower Seat Ring
B102 Upper Seat Ring
B206 Packing
B211 Spacer
B212 Packing Follower
Figure 3 – Sectional Drawing 10000

Seat Ring Thread Dia. Torque

Valve Size
(Inches) (ft-lbs) (mdaN)
20-25 [3/4 & 1"] 1.625 70 9
40 [1-1/2"] 2,125 236 32
50 [2"] 2,625 383 52
80 [3"] 3,313 741 100
100 [4"] 4,250 1148 155
150 [6"] 6.125 2287 309
200 [8"] 8,000 4817 650
250 [10''] 9.875 9458 1277
300 [12''] 11.750 17155 2316
350 [14''] - - -
400 [16''] 15.625 33321 4498
Figure 4 – Seat Ring Torque

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 7 of 14

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NOTE: Do not over tighten. Do not strike the seat ring lugs. This could distort the seat ring,
resulting in unwarranted seat leakage.

7.2.3 Trim / Bonnet-Lower Flange / Body Assembly

Place body gasket in position on body, assemble bottom flange and loosely install body stud nuts.

With the plug stem assembly held up in the bonnet, lower the bonnet down onto the body. Prior to
tightening the body/bonnet and body/lower flange bolting, assure that bonnet / lower flange /
trim assembly is centered in the body for best plug to seat ring alignment.

NOTE: Correctly assembled valves with in specification components should pass leakage testing
with no lapping of the plug to seat-ring. In the rare instance that a valve does not shut off, light
lapping of the plug to seat is allowed as a repair.

NOTE: For 10132 option (V-Port Control Characteristics), the plug must be installed so that the
larger of the two V notches in that plug is in line with the inlet of the valve. Placement of a witness
mark on the stem may be helpful.

7.2.4 Body / Bonnet / Lower Flange / Bolting

Lubricate stud threads and bearing surfaces of the body stud nuts with Molykote G, Graphikote
No. 143, or equivalent.

Tighten both bonnet stud nuts and lower flange stud nuts in torque steps (see note below) and
sequence (shown in figure 5), to the limits that are shown in the table below. Torque bonnet down
until metal to metal contact exists between the bonnet and body. Additionally the plug must be
stroked manually while evenly tightening the body stud nuts around both bonnet and bottom
flange to ensure proper alignment and prevent binding between the plug guides and the
bushings. After metal to metal contact between the bonnet and body and lower flange and body
is achieved, torque nuts the additional preload torque value given in the table. DO NOT EXCEED
MAXIMUM TORQUE LEVELS LISTED BELOW.

Example: If a ½-13 stud requires 50 ft-lbs to achieve metal to metal, an additional 5 ft-lbs pre-load
should be added. However if it requires 62 ft-lbs to achieve metal to metal the stated pre-load
torque cannot be used because the total torque of 67 ft-lbs will compromise the maximum allowed
of 66 ft-lbs.

If metal to metal contact is not achieved at maximum torque this is cause for rejection. After each
torquing interval the stem shall be stroked to ensure proper alignment of trim parts. The bonnet /
lower flange must contact the body around the entire 360 degrees of contact area. Also insure
that the minimum torque value listed below is obtained.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 8 of 14

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 Valve Size ANSI Stud Pre Load Torque Maximum Torque
mm in Class Qty Size (in) ft.lbs. m.daN ft.lbs. m.daN
20 ¾ 600 6 1/2 5 0,7 55 7,5
25 1 600 6 1/2 5 0,7 55 7,5
40 1½ 600 6 1/2 5 0,7 55 7,5
50 2 600 8 1/2 5 0,7 55 7,5
80 3 600 8 5/8 10 1,4 89 12
100 4 600 8 3/4 20 2,7 170 23
150 6 600 12 3/4 20 2,7 170 23
300 16 5/8 10 1,4 89 12
200 8
600 20 3/4 20 2,7 170 23
300 16 3/4 20 2,7 170 23
250 10
600 16 1 1/8-8 60 8,1 428 58
300 16 7/8 30 4,1 236 32
300 12
600 16 1 1/2-8 115 15,6 789 107
350 14 - - - - -
300 16 1 1/4-8 100 13,6 332 45
400 16
600 16 1 1/2-8 115 15,6 789 107
Figure 5 – Torque Requirements Body / Bonnet and Body / Lower Flange Bolting

Tighten the bonnet stud nuts using small increments of torque. First tighten nuts to 10 ft-lbs in
sequence shown in Figure 6. Tighten nuts once again to 20 ft-lbs using same sequence stated
above. Repeat tightening of nuts using torque values of 40, 75, 140, 225, 400, and 650 ft-lbs until
the required torque is reached. If more than 650 ft-lbs of torque is required use increments of 250
ft-lbs until required torque is reached.

Verify proper stud and nut installation by visual inspection. Fewer than one stud thread or more
than 2-1/2 threads exposed above the nut after final torquing is cause for rejection.

NOTE: With the correct studs and body machining this inspection assures that proper engagement
between stud and body has been achieved.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 9 of 14

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 Figure 6 – Torque Sequence

7.3 Packing Box

7.3.1 Standard Packing
Visually inspect stem & packing box for cleanliness and proper surface finish. Lubricate the I.D. of
the packing box with Never-Seez or equivalent. Consult Figure 7 for the proper number of packing
rings and their arrangement. Assemble the packing box parts (packing rings, packing
follower/flange, and nuts). The skive cuts should be staggered between consecutive pieces of
packing (approx. 120 degrees). The packing nuts should only be finger tight at this time.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 10 of 14

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 Figure 7 – Standard Packings

7.3.2 Low Emission (LE) Packing

Inspect stem finish in the packing area. The stem finish requirement is 3-7 AARH. Ensure there are
no nicks or scratches on the stem in the packing area. Violation of any of these requirements is
cause for stem rejection.

Note: A properly Electro Chemical etched part number on the stem in the packing area will have no
adverse effect on the performance of the packing. Inspect the packing box for cleanliness. Remove
any foreign matter, parts can be cleaned with a suitable solvent.

Inspect packing box I.D. surface finish. A finish greater than 125 AARH is cause for rejection.

Inspect KALREZ/VESPEL CR-6100 packing set; do not use packing if any nicks or scratches are
observed.

Check packing to assure that the proper arrangement is provided, see Figure 8. KALREZ material
can be identified by the gloss black molded finish. VESPEL CR-6100 material has a dull black
machined finish.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 11 of 14

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 Figure 8 – LE Packing Configuration (Shown in Loaded Position)

PACKING SET Qty FOLLOWER ASSEMBLY Qty

VESPEL CR 6100 Female Adapter 1 Upper Follower 1
KALREZ V-Ring 2 Disc Spring 8
VESPEL CR 6100_ V-Ring 1 Lower Follower 1
VESPAL CR 6100 Male Adapter 1
Lubricate the packing with fluorinated grease. KRYTOX GPL206 or equivalent. Lubricate the
packing as a set (NOT INDIVIDUAL PIECES), this minimizes the possibility of getting lubricant into
the V’s (pressure spaces) of the packing. Ensure all exposed surfaces of the packing set are
covered with grease.

Install KALREZ/VESPEL CR-6100 packing set in the valve by sliding the packing set (NOT
INDIVIDUAL PIECES) down the stem. If the packing separates while on the stem DO NOT REMOVE.
To put the set back together, continue installing the remaining pieces. Gently press the packing
into the packing box, do not tamp (by impact) the packing down.

Install 8 disc springs in the lower follower in alternating directions. The O.D. of the bottom most
spring must contact the lower follower as shown in Figure 6. Install the upper follower into the
lower follower as shown.

Install the spring loaded follower assembly down over the stem on top of the packing set. Install
the packing flange on to the packing follower. Install the packing nuts onto the packing studs with
Anti-Seize Compound. Tighten down on the packing flange evenly until the alignment groove
inscribed on the O.D. of the upper follower is even with top of the lower follower, see Figure 6.

NOTE: This is the optimum loading for this packing, further tightening will result in shorter life
expectancy.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 12 of 14

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 7.3.3 Teflon V-Ring Packing
Inspect stem finish in packing area. The stem finish requirement is 3-7 AARH. Ensure there are no
nicks or scratches on the stem in the packing area. Violation of any of these requirements is cause
for stem rejection.

NOTE: A properly Electro Chemical etched part number on the stem in the packing area will have no
adverse effect on the performance of the packing.

Inspect the packing box for cleanliness. Remove any foreign matter, parts can be cleaned with a
suitable solvent.

Inspect packing box I.D. surface finish. A finish greater than 125 AARH is cause for rejection.

Inspect PTFE-V-RING packing set; do not use packing if nicks or scratches are observed.

Lubricate the packing with fluorinated grease. KRYTOX GPL 206 or equivalent. Lubricate the
packing as a set (NOT INDIVIDUAL PIECES), this minimizes the possibility of getting lubricant into
the V’s (pressure spaces) of the packing. Ensure all exposed surfaces of the packing set are
covered with grease.

Install TEFLON V-RING packing set in the valve by sliding the packing set (NOT INDIVIDUAL PIECES)
down the stem. If the packing separates while on the stem DO NOT REMOVE. To put the set back
together, continue installing the remaining pieces. Gently press the packing into the packing box,
do not tamp (by impact) the packing down.

7.4 Actuator to Valve Assembly

7.4.1 87/88 Actuator:

See CES 164

7.4.2 37/38 Actuator:

Before mounting, check:

 The spring scale.
 The actuator stroke.

Mounting precautions of the actuator on the valve:

 Check that the valve plug is in contact with the seat ring.
 Present the actuator on the valve bonnet, supplied with the yoke nut.
 Orient correctly the actuator.

CAUTION: putting down the actuator, take care of the bonnet threads.

7.4.2.1 Direct actuators: No 18 and 24

 Mount the actuator on the valve

Assembly & Test Specification Revision C
Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 13 of 14

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  Supply the air in the actuator so as the stem makes the indicated stroke.
 Mount the stem connector.
 Check the valve stroke and the closed point.
 Adjust the spring final force to get the specified final air supply pressure when the plug
reaches the seat ring contact.

7.4.2.2 Reverse actuators: No 18 and 24

 Mount the actuator on the valve.

 The plug being in contact on the seat, supply the actuator so as the actuator stem
makes 2 mm stroke.
 Connect the valve plug stem and the actuator stem with the stem clamp.
 Check the stroke and the starting point.
 Adjust the initial force spring to meet the specified initial air pressure value when the
plug reaches the seat ring contact.

7.5 Testing
7.5.1 Hydrostatic Test
Perform valve hydrostatic shell test per CES 1001 unless otherwise specified.

7.5.2 Seat Leakage Test

Perform valve seat leakage test per CES-1002 unless otherwise specified.
 

NOTE: Flow direction is to Flow to Ports; the flow arrives between the two seats and then it flows over 
the upper seat ring and under the lower seat ring. 

7.5.3 Packing Leakage Test

Perform valve packing leakage test per CES-1007.

7.6 Paint
Paint the valve assembly per CES-1036.

7.7 Final Inspection

7.7.1 Final Inspection and Performance
Perform final inspection and operational test per CES-1008.

7.7.2 Dead-Band
For Hysteresis and Deadband testing to be followed according to the CES-1009
Packing tightening to be done as per CES-1007.

Assembly & Test Specification Revision C

Title 10,000 Series Body S/A No. CES-303
Date 08/29/11

Author L. Fico Approved P. Di Gioia Page 14 of 14

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Use or disclosure of data contained on this sheet is subject to the restrictions on the cover or first page.