Instruction Manual Form 5657 October 2000
7000 Series
7000 Series Ultra High Purity Control Valve Contents Introduction
1 1 2 2 2
Installation
2 2 3 3 3
Maintenance
............................... Valve Packing Replacement . . . . . . . . . . . . . . . . . . . Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug Assembly Removal—Quick Method . . . . . . . . Plug Assembly Removal . . . . . . . . . . . . . . . . . . . . . . Plug Assembly Installation . . . . . . . . . . . . . . . . . . . . Plug Assembly Installation—Quick Method . . . . . .
3 4 4 5 5 6 6 7
Inspection of Parts . . . . . . . . . . . . . . . . . . . . . . . .
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Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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............................... Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................. Pre-operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling the Valve . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . .
Introduction W8138 / IL
Scope of Manual Figure 1. 7000 Series Globe Valve
Only persons qualified through training or experience should install, operate, and maintain 7000 Series valves. If you have any question about these instructions, contact your Fisher sales office before proceeding.
D102763X012
The 7000 Series Ultra High Purity (UHP) valves are manufactured by Severn Glocon for Fisher. Instructions in the following paragraphs describe the installation procedures for the 7000 Series UHP control valve. Instructions not included in this manual are to be performed in accordance with standard acceptable practices, which may be required by local codes, specifications and or regulations.
7000 Series Unless specifically specified by the contract, the valve has been packed for domestic shipping and indoor storage at the job site.
Installation WARNING
Storage The valve should be stored in a fire resistant, weather tight and well ventilated building. The valve should be kept at a temperature in the range of –29 to 48_C (–20 to 120_F). The area should be constructed and situated so that it will not be subjected to flooding, the floor paved or similarly level, firm, protected and well drained. Valves should be placed on pallets or shoring to permit air circulation.
Handling Applicable codes, regulations and industrial practices for handling loads must be followed. These apply to, and are not limited to, the following precautions. D Slings to be free of kinks and twists. D Position lifting hooks over the load so that the load does not swing when lifted. D The operator shall see that the load is well secured, balanced with slings installed correctly, not handled without the knowledge of the operator and that loads are not carried over the heads of the personnel.
Cleaning The control valve has been cleaned at the factory and sealed for delivery. The protective covers will guard against entry of foreign matter and no further cleaning should be required. A visual examination of the interior should be made to ensure that the valve is free of contaminates. Prior to startup, determine if the control valve is installed as a collection point for line rubbish such as rust, weld slag and other foreign objects. If so, temporary screens or strainers should be installed immediately upstream. A well-lapped seat can be ruined by one small piece of slag and a plug cage guide clearance can be reduced causing pick up in operation. If the process stream is normally contaminated with scale, dirt or other foreign matter, the use of a permanent strainer or filter should be considered.
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Personal injury, property damage, equipment damage, or leakage due to escaping gas or bursting of pressure containing parts may result if the control valve or its accessories are over pressured or installed where service conditions exceed the limits of the valve. The weight of the control valve can cause serious injury if the valve is not handled correctly. Adequate lifting equipment must be used and properly attached. Damage to the seal surfaces of the flanges may result in leakage. Position the valve in the line with the flow direction as indicated by the flow arrow on the valve body. Be certain that all utilities are available. Take note of any special warning tags or plates attached to the valve and take appropriate actions. The preventive maintenance of a properly specified control valve begins at the time of installation. While the valve body and connections of a control valve are rigid structures, they are not intended to be the means of aligning improperly installed pipe. Care must be taken to ensure that all stresses by improper pipe alignment are relieved elsewhere in the pipe system. Pipeline stresses on a control valve may result in misalignment of the plug stem, guide, packing and seat system. This may cause excessive hysteresis, seat leakage and possible packing leakage. Every effort should be made to install control valves so that the plug stem travels in a vertical plane with the actuator vertically above the valve body. However, it is acknowledged that in certain cases, such as cryogenic cold-box installations, valve stems can be near horizontal. In this case, support braces should be considered to support the actuator casing. An unsupported valve may have plug stem misalignment resulting in unacceptable hysteresis, seat leakage and possible packing leakage. The weight of a control valve should be taken into consideration when mounting in the pipe-work. Pipe supports may be required on either side of the valve and/or under the control valve body.
Pre-Operation Be certain that the correct utilities are connected and that accessory items are connected and correctly adjusted. If the actuator has a handwheel override,
7000 Series check that the unit is in the auto position. Clean the actuator shaft of any foreign material. The positioner must be adjusted correctly, as failure to have the valve seating correctly may cause premature trim degradation. Stroke the valve to check for proper operation and calibration. Inspect all connections for leakage.
Dismantling the Valve To avoid personal injury and damage to the process system, isolate the control valve from the system pressure and release all pressure from the valve body and actuator assembly before attempting disassembly. Note that springs are installed in some actuators. Bleed all of the air from the lines and make sure that there is no pressure left in the system (check both sides of the piston). Disconnect all the utility lines. Attach a sling to the actuator assembly.
Description The 7000 Series UHP control valves were designed specifically for application in the manufacture and distribution of Ultra High Purity gas/liquid for use primarily in the semiconductor industry. Operation can be provided either manually or by a piston actuator in order to meet the required control and standards of shutoff that may be specified. All normal accessories such as solenoid valves, limit switches, boosters, etc. are available installed to the valve and tested to prove the required performance.
Installation Procedure Upon receipt of valve check the assembly for shipment damage. If damage is found, contact your Fisher sales office. It is not recommended that this type of valve be disassembled prior to installation, but if site conditions dictate, the actuator can be removed. Follow
instructions in the sections entitled Actuator Removal and Actuator Assembly.
Maintenance WARNING Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations: D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal injury. D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve. D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure from both sides of the valve. Drain the process media from both sides of the valve. D Vent the pneumatic actuator loading pressure and relieve any actuator spring precompression. D Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when loosening the packing box pipe plug.
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7000 Series Table 1. Bonnet Bolt Torques AMERICAN STANDARD BOLTING Stud Size & Number of Threads Per Inch
APPROXIMATE EQUIVALENT METRIC BOLTING
Nut lbfSft(1)
Torque NSm
Stud Size & Number of Threads Per Inch
Nut lbfSft(1)
Torque NSm
3/8 - 16
9
12
1/2 - 13
24
32
M10X1.5
11
15
M12X1.75
22
5/8 - 11
47
64
M16X2
53
30 72
3/4 - 10
83
113
M20X2.5
102
138
7/8 - 9
135
183
M22X2.5
141
191
1-8
202
274
M25X1.5
234
317
1 1/8 - 8
301
408
M27X2
291
395
1 1/4 - 7
403
546
M30X2
403
546
1 1/4 - 8
419
568
M33X2
539
731
1 3/8 - 6
522
708
1 3/8 - 8
571
774
1 1/2 -6
697
945
1 1/2 - 8
756
1025
1 1/2 -12
818
1109
1 5/8 - 8
976
1323
1 5/8 - 12
1049
1422
1 3/4 - 8
1236
1676
1 3/4 -12
1320
1790
1 7/8 - 8
1537
2083
2-8
1885
2556
2 1/3 - 8
2727
3697
2 1/2 - 8
3791
5140
2 3/4 - 8
5097
6911
3-8
6678
9054
1. Torque tolerance lbfSft is +5%.
Valve Packing Replacement With the valve and actuator in the vertical position and before starting any dismantling sequence, the plug must be located off the seat. For valves with fail open actuators, no further action is necessary. For valves with fail close actuators, the valve plug/actuator stem must be raised to the 100% open position by means of air connected to the underside of the actuator. Remove any accessory components as required. Refer to figure 3 for the following steps. 1. Loosen and remove the packing nuts and packing bolts (keys 15 and 14). 2. Lift and prop the packing flange (key 13) up. 3. Place a screwdriver in the machined grove located on the outside of the packing follower (key 10) and carefully lift up and secure in the up position. 4. Packing (key 8) can now be removed. Be careful not to damage the plug stem or the bonnet wall with the packing removal tool. 5. The new packing can now be installed taking care to stagger the joint rings.
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6. Reinstall the packing follower, packing flange, and packing nuts and bolts. Tighten the packing nuts, but do not over tighten. Remove air from the underside of actuator if applied and the operation is complete.
Actuator Removal With the valve and actuator in the vertical position and before starting any dismantling sequence, the plug must be located off the seat. For valves with fail open actuators, no further action is necessary. For valves with fail close actuators, the valve plug/actuator stem must be raised to the 50% open position by means of air connected to the underside of the actuator. Remove any accessory components as required. Refer to figure 3 for the following steps. 1. Loosen the plug locknut (key 25), remove the packing bolts (keys 14 and 15). As the yoke clamps (key 23) are loosened by keys 21 and 22 and removed, the actuator will move downward. This allows the yoke half rings (key 24) to be removed. 2. The air connection to the underside of the actuator can now be disconnected, allowing the actuator to raise.
7000 Series CAUTION Do not try to turn the valve stem. This will cause damage to the anti-rotation screw (key 12) and the plug assembly (key 20). 3. With the actuator supported on slings to take the weight, it can now be rotated slowly counterclockwise until the actuator piston rod (key 36) is disconnected from the plug assembly (key 20). 4. The actuator is lifted slightly and the plug locknut (key 25) removed along with the packing flange (key 13).
29 13 14 15
5. The actuator can now be moved to a safe position.
20
36 25 24 2122 23
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Actuator Assembly Before starting any assembly procedure, the piston rod must be in the down position. For valves with fail open actuators, it is necessary to apply air to the top of the actuator to extend the piston rod. For valves with fail close actuators, no further action is necessary. Note Great care must be taken when assembling an actuator to an inclined unit. 1. Support the actuator according to figure 2 and carefully lower over valve assembly, installing the packing flange (key 13) and the locknut (key 25). The locknut must be screwed right down the thread on the plug assembly (key 20). 2. During this procedure, great care must be taken when locating the piston rod (key 36) onto the plug assembly (key 25). This is achieved by rotating the actuator clockwise. The yoke (key 29) will engage on the bonnet (key 5). Continue rotating until a slight resistance is felt; stop and unscrew one half turn. 3. Install the half rings (key 24) in the groove in the bonnet (key 5) and turn the actuator counterclockwise until the half rings (key 24) are located in the yoke (key 29). When a slight resistance is felt, stop. 4. For fail open actuators, reduce the air supply pressure, allowing the piston rod (key 36) to move upwards slightly. Turn the actuator counterclockwise a minimum of one half turn and locate at the actuator orientation position. Install the yoke clamp assembly (keys 21, 22, and 23) and secure. Remove the air supply from the top of the actuator. 5. For fail close actuators, connect a controlled air supply to the underside of the actuator and increase
E0526 / IL
Figure 2. Actuator Supported by Slings
slightly. Turn the actuator counterclockwise a minimum of one half turn and locate at the actuator orientation position. Remove the air supply from the underside of the actuator. Install the yoke clamp assembly (keys 21, 22, and 23) and secure. 6. Install packing bolts and packing nuts (keys 14 and 15), but do not over tighten. Secure the locknut (key 25). 7. Replace any accessory components. The unit is ready to go back into service.
Plug Assembly Removal—Quick Method This method can be adopted when the actuator is not required to be removed, and the actuator is orientated vertically or inclined. Before starting any dismantling sequence, the plug must be located off the seat. For valves with fail open actuators, no further action is necessary. For valves with fail close actuators, the valve plug/actuator stem must be raised to the 100% open position by means of air connected to the underside of the actuator. For this procedure the valve must be opened, therefore a clean environment must be prepared i.e. a polythene envelope encompassing the entire work area. Before disassembly takes place, the valve and the surrounding area must be cleaned thoroughly along with tools necessary to complete the procedure. Personel performing this procedure must be familiar with all aspects of ultra clean valves and must be dressed in the correct attire etc. More detailed Information can be obtained from your Fisher sales office.
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7000 Series Remove any accessory components as required. Refer to figure 3 for the following steps. 1. With the actuator supported on slings see figure 2 and the air still connected to the underside of the actuator, loosen the valve body nuts (key 3) diametrically and remove along with the spring washers (key 4). 2. With the actuator in a vertically plane, hoist the assembly slowly with a straight lift. If the actuator is inclined, lift in a slanted manner, being careful to stabilize the bonnet (key 5) when removing the valve body (key 1). For an inclined actuator, move to the vertical and hold position, then remove the gasket (key 6) from the valve body (key 1).
envelope encompassing the entire work area. Before disassembly takes place, the valve and the surrounding area must be cleaned thoroughly, along with the tools necessary to complete the operation. Personel performing this procedure must be familiar with all aspects of ultra clean valves and must be dressed in the correct attire etc. More detailed information can be obtained from your Fisher sales office. Remove any accessory components as required. Refer to figure 3 for the following steps. 1. Loosen the valve body nuts (key 3) diametrically and remove along with the spring washers (key 4).
3. Remove air from the underside of the actuator, the plug assembly (key 20) will move downwards.
2. By hand remove slowly, taking care to stabilize the bonnet (key 5) when removing the valve body (key 1); place down horizontally in a clean area.
4. Loosen the locknut (key 25), remove the packing nuts and bolts (keys 14 and 15).
3. Remove the gasket (key 6) from the valve body (key 1).
5. Remove the pressure plug (key 11) and take out anti-rotation screw (key 12).
4. Remove the pressure plug (key 11) and take out the anti-rotation screw (key 12).
Note
Note
Earlier valves had the Anti Rotation Peg located in the Bonnet Flange.
Earlier valves had the anti-rotation peg located in the Bonnet Flange.
6. The plug assembly (key 20) can now be separated from the bonnet (key 5) by rotating counterclockwise from the piston rod (key 36) at the same time as unscrewing the locknut (key 25). When separated, remove the packing flange (key 13).
5. The plug assembly (key 20) can now be separated from the bonnet (key 5) by holding the plug head and pulling with a twisting motion.
7. To complete the disassembly, ensure there is room to remove the plug assembly (key 20) and pull downward with a twisting motion. Lift off the gasket (key 6). 8. Remove the packing follower (key 10), packing (key 8), and stem guide (key 7) from the bonnet (key 5). 9. The plug assembly (key 20) includes retainer (key 18) and the lower guide (key 9). This is dependant on the plug head size. Disassembly beyond this point is not recommended. Complete assembles can be obtained from Fisher by referring to the serial number of the valve.
Plug Assembly Removal This procedure is performed when the actuator has been removed, see the section entitled Actuator Removal. For this procedure the valve must opened, therefore a clean environment must be provided i.e. a polythene
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6. Remove the gasket (key 6). 7. Remove the packing follower (key 10), packing (key 8), and the stem guide (key 7) from the bonnet (key 5). 8. The plug assembly (key 20) includes a retainer (key 18) and the lower guide (key 9). This assembly is dependent on the plug head size and disassembly beyond this point is not recommended. Complete assembles can be obtained from Fisher by referring to the serial number of the valve.
Plug Assembly Installation For this procedure the actuator should have the piston rod retracted, up to 90%. An air fail close actuator must have air applied to the underside of the motor. For an air fail open actuator, no further action is necessary. Prior to assembly, ensure that all parts are clean and fully degreased. Spare parts purchased from Fisher will be supplied clean to relevant specification and sealed in polyethylene bags. For this procedure a clean environment must be provided i.e. a polythene envelope encompassing the entire work area. Before disassembly takes place, the
7000 Series valve and the surrounding area must be cleaned thoroughly, along with the tools necessary to complete the operation. Personel performing this procedure must be familiar with all aspects of ultra clean valves and must be dressed in the correct attire etc. More detailed information can be obtained from your Fisher sales office. 1. Install a new gasket (key 6) to the top of the bellows flange on the plug assembly (key 20). See figure 5. 2. Insert the plug assembly (key 20) in the bonnet (key 5). As the plug thread emerges from the bonnet at the actuator end, install the stem guide (key 7), new packing (key 8) and the packing follower. 3. Now rotate the piston rod (key 36), checking the position of the slot in the plug assembly (key 20) at the anti-rotation port in the bonnet (key 5). When the slot aligns, install the anti-rotation screw (key 12), taking care not to impede the plug assembly movement. Install the pressure plug (key 11).
Note Earlier valves had the anti-rotation peg located in the bonnet flange. 4. Install the second new gasket (key 6) to the valve body (key 1). 5. Support the bonnet assembly in a relevant position, and carefully stabilize the bonnet as it enters the valve body. 6. Now install the spring washers (key 4) to the studs (key 2) along with the valve body nuts (key 3) and tighten down diametrically in 25 lbfSft increments. Ensure that the gap at the bonnet body is maintained evenly until the correct bolting torque is reached (see table 1). The bonnet should bolt down face to face with the valve body. 7. To complete the operation of installing the actuator and setting the plug to the seat, refer to the section entitled Actuator Assembly.
Plug Assembly Installation (Quick Method) For this operation, the actuator should have the piston rod retracted, up to 90%. An air fail close actuator must have air applied to the underside of the piston. For an air fail open actuator, no further action is necessary.
Prior to assembly ensure that all parts are clean and fully degreased. Spare parts purchased from Fisher will be supplied clean to relevant specification and sealed in polyethylene bags. For this procedure a clean environment must be provided i.e. a polythene envelope encompassing the entire work area. Before disassembly takes place, the valve and the surrounding area must be cleaned thoroughly, along with the tools necessary to complete the operation. Personel performing this procedure must be familiar with all aspects of ultra clean valves and must be dressed in the correct attire etc. More detailed information can be obtained from your Fisher sales office. 1. Install a new gasket (key 6) to the top of the bellows flange on the plug assembly (key 20). See figure 5. 2. Insert the plug assembly (key 20) in the bonnet (key 5). As the plug thread emerges from the bonnet at the actuator end, install the stem guide (key 7), new packing (key 8), packing follower (key 10), packing flange (key 13), and locknut (key 25). 3. Screw the plug assembly (key 20) into the piston rod (key 36), checking the position of the slot in the plug assembly (key 20) at the anti-rotation port in the bonnet (key 5). When the slot aligns, install the anti-rotation screw (key 12) taking care not to impede the plug assembly movement. Then install the pressure plug (key 11). Note Earlier valves had the anti-rotation peg located in the Bonnet Flange. 4. Install the second new gasket (key 6) to the valve body (key 1). 5. Support the actuator in a relevant position and carefully stabilize the bonnet assembly as it enters the valve body. 6. Now install the spring washers (key 4) to the studs (key 2) along with the valve body nuts (key 3) and tighten down diametrically in 25 lbfSft increments. Ensure that the gap at the bonnet body is maintained evenly until the correct bolting torque is reached (see table 1). The bonnet should bolt down face to face with the valve body. 7. Install the packing bolts and packing nuts (keys 14 and 15). 8. Loosen and remove the yoke clamp (keys 21, 22, and 23). 9. To complete the operation of setting the plug to the seat, refer to the section entitled Actuator Assembly.
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7000 Series Note
Inspection of Parts Valve Packing (key 8) - figure 3.
For all actuator adjustments, refer to appropriate instruction manuals.
The reuse of packing is not recommended.
If you have any questions, contact your Fisher sales office with the valve serial number.
Soft Seats The reuse of soft seats is not recommended. Gaskets (key 6) The reuse of gaskets is not recommended. Plug Assembly (key 20) Examine the plug head for signs of damage. Wear on the plug contour will not, unless very severe, prevent the valve from controlling, but it may cause problems in the loop response and shutoff specification. If damage is found on the stem diameter or the bellows is suspect, the complete assembly should be replaced. Integral Seat (key 1) Examine seat area for damage. If damage is found and it is felt this could effect the required seat leakage class, then the seat area should be recut taking care to ensure that no particulate remains in the valve body. If damaged beyond local repair, then the valve body (key 1) must be removed and returned to a Fisher service center for remachining. Stem Guides (keys 7, 9, and 10) Examine for general condition and renew if necessary.
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Parts List Key
Description
7 8 10 11 12 13 14 15 20 21 22 23 24 25 26 27 28 29 36
STEM GUIDE PACKING GLAND FOLLOWER PRESSURE PLUG ANTI ROTATION SCREW GLAND FLANGE GLAND BOLTS GLAND NUT PLUG ASSEMBLY NUT CAPSCREW YOKE CLAMP HALF RINGS LOCKNUT NUT HEX BOLT POSITIONER TAKE OFF ARM YOKE/BASEPLATE PISTON ROD
7000 Series
36 29 26 27 28 25 13 14 15 10 24
8 7
21 22 23
20 11
12
E0527 / IL
Figure 3. Type 7000 Assembly
9
7000 Series
E0528 / IL
Figure 4. Series 7000 Assembly
10
7000 Series
E0529 / IL
Figure 5. Series 7000 Assembly
11
7000 Series
Fisher and Fisher-Rosemount are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners. EFisher Controls International, Inc. 2000; All Rights Reserved
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
For information, contact Fisher: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461 12 Printed in U.S.A.