Instruction Manual Form 5427 February 2001
Design CP—1/2 and 3/4-Inch
Design CP Control Valve—1/2 and 3/4-Inch Contents Introduction
............................... Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
1 1 1 2
................................. 2
Maintenance
............................... Packing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . Replacing Packing . . . . . . . . . . . . . . . . . . . . . . . . . . Trim Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lapping Metal Seats . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 3 3 5 5 5 6
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Parts Kits
.................................. 6
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 W6808b/IL
Introduction
Figure 1. FloVuet Final Control System (Design CP Control Valve / System 9000 Actuator / FIELDVUE R Digital Valve Controller)
This instruction manual includes installation, maintenance, and parts information for the 1/2 and 3/4-inch Design CP control valve. Refer to separate manuals for instructions covering the actuator, positioner, and accessories.
Description
Only persons qualified through training or experience should install, operate, and maintain these valves. If you have any questions about these instructions, contact your Fisher sales office before proceeding.
The 1/2 and 3/4-inch Design CP control valve, shown in figure 1, is a globe-style valve with stem guiding and quick-change trim. The valve has multiple-trim options, including full-capacity and restricted-capacity trims.
D102321X012
Scope of Manual
Design CP—1/2 and 3/4-Inch Table 1. Specifications
End Connections
Shutoff Classification per ANSI/FCI 70.2 and IEC 60534-4
Raised-face integral flanges to mate with Class 150 or 300 flanges
J Class IV or J Class V (optional) Flow Characteristics/Valve Plug Styles
Multiple Face-To-Face Offering Standard: ISA-S75.03 and IEC 60534-3-1 (interchangeable with Design E) Long: ISA-S75.20 (All Design CP control valves have integral flanges, providing replacement for Design CE separable flange and other long face-to-face valves)
Maximum Inlet Pressures and Temperatures(1) CF3M (316L Stainless Steel) Valve Body: Consistent with applicable Class J 150 or J 300 pressure-temperature ratings per ASME B16.34, but do not exceed the pressure, temperature, and pressure drop conditions specified when the valve was ordered. See the Installation section for additional information
Full-Capacity and Restricted-Capacity Trims: J Linear or J equal percentage Flow Direction Flow up only Yoke Boss and Stem Connection Diameters for Actuator Mounting 1/2 and 3/4-inch Sizes: 28.6 mm (1-1/8 inch) yoke boss, 7.9 mm (5/16-inch) stem with 7.9 mm (5/16-inch) stem connection Approximate Weights WEIGHT
VALVE SIZE, INCHES
Class 150
Class 300
Class 150
1/2
4
4
8
9
3/4
4
5
8
11
kg
Pounds Class 300
1. The pressure or temperature limits in this manual and any applicable standard limitations should not be exceeded.
Specifications Specifications for the 1/2 and 3/4-inch Design CP control valves are shown in table 1. Some of the specifications for a given valve assembly appear on the actuator nameplate if the valve is part of a control valve assembly.
Installation WARNING Personal injury or equipment damage caused by sudden release of pressure may result if the valve assembly is installed where service conditions could exceed the limits given in table 1 or on the appropriate nameplates. To avoid such injury or damage, provide a relief valve for overpressure protection as required by accepted industry or local, state, and Federal codes and good engineering practices.
2
CAUTION When ordered, the valve configuration and construction materials were selected to meet particular pressure, temperature, pressure drop, and controlled fluid conditions. Since some body/trim material combinations are limited in their pressure drop and temperature ranges, do not apply any other conditions to the valve without first contacting your Fisher sales office. 1. Before installing the valve, inspect it to be certain that the valve body cavity is free of foreign material. Clean out all pipelines to remove scale, welding slag, and other foreign materials. 2. The control valve assembly may be installed in any orientation unless limited by seismic criteria. However, the normal method is with the actuator vertical above the valve body. With some valves, the actuator may also need to be supported when it is not vertical. For more information, consult your Fisher sales office. Flow through the valve body must be in the direction indicated by the arrow on the valve body.
Design CP—1/2 and 3/4-Inch 3. Use accepted piping practices when installing the valve in the pipeline. Use a suitable gasket between the valve body and pipeline flanges. 4. If continuous operation is required during inspection or maintenance, install a three-valve bypass around the control valve assembly. 5. If the actuator and valve are shipped separately, refer to the appropriate actuator instruction manual for the actuator mounting procedure. Note The 1/2 and 3/4-inch Design CP valves are equipped with ENVIRO-SEALR packing.
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 power 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. Due to the care Fisher takes in meeting all manufacturing requirements (heat treating, dimensional tolerances, etc.), use only replacement parts manufactured or furnished by Fisher. Valve parts are subject to normal wear and must be inspected and replaced as necessary. Inspection and maintenance frequency depends on the severity of service conditions. This section includes instructions for Packing Maintenance, Trim Maintenance, and Lapping Metal Seats. All these maintenance operations may be performed with the valve in the line. Note Whenever a gasket seal is disturbed by removing or shifting gasketed parts, a new gasket should be installed upon reassembly. This is necessary to ensure a good gasket seal, since the used gasket will not seal properly.
Packing Maintenance Key numbers refer to figure 4. If the packing (key 215) is relatively new and tight on the stem, and stem leakage is observed, the valve stem may be worn or nicked so that a seal cannot be made. The surface finish of a new valve stem is 0.1Âľm (4 micro-inches) rms. If the leakage comes from the outside diameter of the packing, the leakage may be caused by nicks or scratches in the packing box wall. While replacing the packing per the numbered steps below, or when performing any of the following procedures, inspect the valve stem and packing box wall for nicks and scratches.
Replacing Packing
WARNING To avoid personal injury or property damage caused by sudden release of pressure from the valve body or bonnet assembly, remove the valve plug stem assembly (key 7) by performing the steps below. Do not remove a stuck bonnet by pulling on it with equipment that can stretch or store energy in any other manner. The sudden release of stored energy can cause uncontrolled movement of the bonnet, resulting in personal injury or property damage.
3
Design CP—1/2 and 3/4-Inch
PACKING NUT
BELLEVILLE SPRINGS
ENVIRO-SEAL PACKING SET
ENVIRO-SEAL PACKING SET
B2525/IL
Figure 2. ENVIRO-SEAL Packing Arrangement
1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. If using a power actuator, also shut off all pressure lines to the power actuator, release all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. 2. Disconnect the stem connector, and then remove the actuator from the valve by unscrewing the yoke locknut (key 18).
Note
The following step provides assurance that fluid pressure in the packing box has been relieved. 3. Loosen, but do not remove, the packing nut (key 220) so that the packing is not tight on the valve stem. Remove any travel indicator parts and stem locknuts from the valve stem threads.
4
Note The following step provides additional assurance that the valve body fluid pressure has been relieved. 4. Hex nuts (key 11) attach the bonnet to the valve body. Loosen these nuts approximately 3 mm (1/8 inch). Then loosen the body-to-bonnet gasketed joint by either rocking the bonnet or prying between the bonnet and valve body. Work the prying tool around the bonnet until the bonnet loosens. If no fluid leaks from the joint, remove the nuts completely and carefully lift the bonnet and valve plug stem assembly (keys 12 and 7) as a unit. If the valve plug stem assembly does not come out of the valve with the bonnet, pull it out of the valve body. Set the bonnet and valve plug assembly on a protective surface to prevent damage to the bonnet gasket surface. 5. Remove the valve plug and stem from the bonnet and carefully set it on a protective surface. 6. Remove the bonnet gasket (key 9). Cover the opening in the valve body to protect the gasket surface and prevent foreign material from getting into the valve body cavity. 7. Remove the packing nut (key 220). Carefully push out all the packing box parts from the bonnet using a
Design CP—1/2 and 3/4-Inch rounded rod or other tool that will not scratch the packing box wall or lower guide bushing. Clean the packing box and the metal packing box parts. 8. Inspect the valve stem threads and packing box surfaces for any sharp edges that might cut the packing. Scratches or burrs could cause packing box leakage or damage to the new packing. If the surface condition cannot be improved by light sanding, replace the damaged parts. 9. Remove the covering protecting the valve body cavity, make sure the gasket seating surfaces are clean, then install a new bonnet gasket (key 9). Note The bolting procedures in step 10 include—but are not limited to—ensuring that bolting threads are clean, and the hex nuts are evenly tightened onto the studs in a crisscross pattern. Tightening one nut may loosen an adjacent nut. Repeat the crisscross tightening pattern several times until each nut is tight and the body-to-bonnet seal is made. When the operating temperature has been reached, perform the torquing procedure once again. 10. Lubricate the stud bolts, nuts, and the surface between nuts and bonnet with a suitable lubricant. Carefully slide the valve plug into the bonnet, slide the bonnet onto the bolts, and secure with the stud bolt nuts (key 11). Using accepted bolting procedures, tighten the body-to-bonnet joint to withstand test pressures and application service conditions. Tighten the body-to-bonnet joint to 15 NSm (14 lbfSft) of torque. 11. Install new packing and the metal packing box parts according to the appropriate arrangement in figures 2 or 4. 12. You will obtain maximum benefit from your ENVIRO-SEAL packing system when you tighten the packing nut and compress the Belleville springs to their “target load”. The target load is the point where the Belleville springs are designed for optimum performance, when they are compressed to 85% of their maximum deflection, or nearly flat. (Maximum deflection is when the springs are 100% compressed, or completely flat.) To obtain the target load of 85% compression of maximum deflection, perform the following: D Tighten the packing nut until the Belleville springs are compressed 100% (or completely flat). D Loosen the packing nut 1/2 turn (180_ of rotation).
The “target load” of 85% compression has now been reached. 13. Mount the actuator onto the valve assembly, and reconnect the actuator and valve stem according to the procedure in the appropriate actuator instruction manual.
Trim Maintenance Key numbers in this section refer to figure 4.
Removal 1. Remove the actuator and the bonnet as described in steps 1 through 4 of the Replacing Packing section. 2. Packing parts can be removed if desired. Replace these parts as described in the Packing Maintenance section. 3. Inspect parts for wear or damage that would prevent proper operation of the valve. The valve plug and stem assembly are marked to show valve size, flow characteristic, and part number. 4. Replace or repair trim parts according to the following Lapping Metal Seats section (for eroded valve seats) or Assembly procedures as appropriate.
Lapping Metal Seats A certain amount of leakage should be expected with metal-to-metal seating in any valve body. If the leakage becomes excessive, however, the condition of the seating surfaces of the valve plug (key 7) and valve body can be improved by lapping. Deep nicks should be machined out rather than lapped out. Using a 400 grit commercial lapping compound, apply the compound to the valve plug and valve body seating surfaces. The valve must be assembled to the extent that the valve plug stem assembly is in place and the bonnet (with packing installed but not tightened) is bolted to the valve body. A simple handle can be made from a piece of strap iron locked to the valve plug stem with nuts. Rotate the handle alternately in each direction with light downward pressure to lap the seats. If there is any indication of insufficient lubrication (e.g., squeaking, vibration, etc.), stop the procedure, and apply more lapping compound before continuing. After lapping, remove the bonnet, and clean the seating surfaces. Completely assemble as described in the Assembly portion of this section, and test the valve for shutoff. Repeat the lapping procedure if leakage is still excessive.
5
Design CP—1/2 and 3/4-Inch 1/2 =% 27B3642X012
B2526/IL
Figure 3. Trim Identification
Assembly 1. Clean all gasketed surfaces, and use new gaskets for assembly.
CAUTION If the packing is to be reused and was not removed from the bonnet, install the valve plug carefully to avoid damaging the packing with the valve stem threads. 2. Install the bonnet gasket, mount the bonnet on the valve, and complete the assembly according to steps 9 through 13 of the Replacing Packing section, omitting
steps 11 and 12 if new packing is not being installed. Be sure to observe the note prior to step 10.
Parts Ordering Each body-bonnet assembly is assigned a serial number, which can be found on the valve body. This same number also appears on the actuator nameplate when the valve is shipped from the factory as part of a control valve assembly. Refer to the serial number when contacting your Fisher sales office for technical assistance. When ordering replacement parts, refer to the serial number and to the 11-character part number from the following Parts List.
Parts Kits Repair Kits (Valve Packing) Valve Size, Inches Stem Diameter, mm (Inches)
1/2 and 3/4 7.9 (5/16)
Double PTFE, (Contains keys 214 and 215)
RCPXPACK212
Parts List Note Except where indicated, sizes shown are valve body sizes. Key 1
7*
6
Description Part Number Valve Body If you need a valve body as a replacement part, order by valve size, serial number, and desired material Valve Plug/Stem, S31603 1/2-Inch Valve Equal Percentage, 3/8-Inch Port, 1/2-Inch Travel Full Capacity 27B3642X012 First Reduction 27B3644X012 Second Reduction 27B3646X012 Linear, 3/8-Inch Port, 1/2-Inch Travel Full Capacity 27B3643X012 First Reduction 27B3645X012 Second Reduction 27B3647X012 3/4-Inch Valve Equal Percentage, 9/16-Inch Port, 1/2-Inch Travel Full Capacity 27B3648X012 First Reduction 27B3650X012 Second Reduction 27B3652X012 Linear, 9/16-Inch Port, 1/2-Inch Travel Full Capacity 27B3649X012 First Reduction 27B3651X012 Second Reduction 27B3653X012
Key 9* 10 11 12 15 17 18 28 --214* 215*
216 220 221
Description Bonnet Gasket Graphite Laminate/S31600 Stud Bolt Hex Nut Bonnet, untapped Nameplate Drive Screw (for nameplate) Yoke Locknut Lead Seal/Wire Lubricant Washer, 4 req’d Packing Set ENVIRO-SEAL PTFE (2 req’d) Carbon PTFE Packing Spacer Packing Nut Belleville Springs
*Recommended spare parts
Part Number 17B3641X012
17B3635X012
17B3636X012
Design CP—1/2 and 3/4-Inch
APPLY LUB 37B3656-A B2527/IL
Figure 4. Design CP Control Valve Assembly (1/2 and 3/4-Inch)
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Design CP—1/2 and 3/4-Inch
This product may be covered by one or more of the following patents: 5,129,625; 5,131,666; 5,056,757; 5,230,498; and 5,299,812 or under pending patents. ENVIRO-SEAL, FIELDVUE, FloVue, 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. 1996, 2001; 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 8 Printed in U.S.A.