Instruction Manual Form 5263 April 1998
HIGH-SEALt Live-Loaded Packing
t Scope of Manual
Description
SPRING
PACKING FOLLOWER PACKING RINGS
HIGH-SEAL live-loaded packing systems are designed to provide a nearly constant packing load over the service life of the graphite packing arrangement. The Belleville springs react, as the graphite packing compresses, causing the packing follower to move in response to the change in packing height. This reduces the need to retighten the packing nuts. The load scales (see figure 2) ensure proper packing load. Your application will have its proper packing load when the spring load indication falls between MIN and MAX on the load scales. If you adjust the packing near the MIN indication on the load scales, the packing friction will be low, but future adjustment may be required. Adjusting the packing near the MAX indication yields higher packing friction, and your packing system will have maximum travel reserve for fewer adjustments.
Selection Guideline For Sliding Stem Valves. However, do not exceed the pressure/temperature limits of the valve. If the piping and valve are insulated, do not allow insulation to extend above the yoke boss surface, covering the HIGH-SEAL packing arrangement. Keep the HIGH-SEAL packing arrangement exposed to ambient air conditions.
HIGH-SEAL packing systems are intended for moresevere applications with pressure limits up to 4200 psig (290 bar), except for 3/8 inch (9.5 mm) stem size, which is restricted to 1600 psig (110 bar). If your application exceeds these limits, consult your Fisher Controls sales office or sales representative. For ratings on packing systems, refer to 59.1:062(A) Packing
The flange, Belleville springs, stud bolts and nuts, packing follower, and packing arrangement are an integral part of the HIGH-SEAL system (see figures 6 and 7). For maximum packing life and to operate within the friction specified in table 1, do not interchange any other packing parts with the parts in the HIGH-SEAL system.
W5784 / IL
Figure 1. HIGH-SEAL Live-Loaded Packing System
D101453X012
This instruction manual includes installation, maintenance, and parts information for HIGH-SEAL liveloaded packing systems (see figure 1). These systems are available for sliding-stem valves with 3/8, 1/2, 3/4, 1, 1-1/4, and 2-inch (9.5, 12.7, 19.1, 25.4, 31.8 and 50.8 mm) stem diameters. Refer to separate manuals for instructions covering valves and actuators. For rotary valve applications, contact your Fisher Controls sales office or sales representative or refer to your rotary valve instruction manual.
HIGH-SEALt Live-Loaded Packing Table 1. Packing Friction VALVE STEM SIZE Inches
Pounds (Force)
PRESSURE RATING, MAXIMUM Psig
3/8 1/2 3/4 1 1-1/4 2 mm
420 1130 2120 3390 4240 6790 Newtons
1600 4200 4200 4200 4200 4200 Bar
9.5 12.7 19.1 25.4 31.8 50.8
1870 5030 9430 15,080 18,860 30,200
110 290 290 290 290 290
PACKING FRICTION
The Belleville springs for HIGH-SEAL systems are rated by stem size (see table 1). Available materials for the Belleville springs are S17700 (17-7 PH stainless steel) and N07718 (Inconel 718). It is important to match the appropriate load scale (see figure 2) to the stem size of the valve. Stem size is stamped on the load scale.
HIGH-SEAL packing systems are designed for quality performance over extended periods. This longevity allows packing maintenance to be performed as it should be, at regularly scheduled plant outages or turn-arounds.
WARNING Avoid personal injury from sudden release of process pressure. Before performing any maintenance operations: 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.
2
A4990-1 / IL
Figure 2. Typical Load Scale
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. If the valve is in service, 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 shutoff all pressure lines to the power actuator and 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. Refer to instructions in the appropriate valve and actuator instruction manuals. If you are installing the HIGH-SEAL packing system in a valve that is still connected to an actuator, it will be necessary to disconnect the valve from the actuator to provide sufficient space to install the packing assembly. Refer to appropriate valve and actuator instruction manuals. Remove old packing parts from the packing box by using the valve instruction manual procedures. The valve stem condition is critical in obtaining a good seal. The finish of a new valve stem is 4 Ra (0.1 Âľm). If the valve stem surface is 8 Ra (0.2 Âľm) or greater, replace the valve stem before installing the HIGH-SEAL packing arrangement. Refer to the appropriate valve instruction manual for instructions on replacing the valve stem. Check the condition of the packing bore after you have removed the packing. An easy method for cleaning debris and minor imperfections from the bore is to use a brake cylinder hone attached to an electric drill. This method will do a good job of cleaning the packing bore without changing the dimension of the bore. When you have completed this exercise, a good guideline to use in checking the condition of the packing bore is the 20/20 rule. If less than 20% of the
HIGH-SEALt Live-Loaded Packing
A4992-2 / IL
A4991-2 / IL
Figure 3. HIGH-SEAL Packing Assembly Showing the Load Properly Adjusted for Decompressed Springs
Figure 4. Load Scale Indicating Minimum Spring Compression
surface area of the bore is pitted and if there are no pits deeper than 0.020 inch, then your packing will work fine. This does not need to be an exact measurement; visual inspection is adequate. If the packing bore does not meet this criteria, however, you should replace the valve or have your Fisher Controls service center repair it.
BELLEVILLE SPRINGS WITH MAXIMUM COMPRESSION
Key number locations are shown in figures 6 and 7. INDICATOR DISK
1. Remove existing packing studs from the valve, and replace them with the longer studs (key 200).
INDICATOR DISK ALIGNED WITH MAXIMUM COMPRESSION LINE ON LOAD SCALE
2. Install the packing arrangement into the valve packing box. Note Be sure to install the packing rings in the sequence shown in figures 6 and 7. Identify parts by color or by the number stamped on the part.
A4993-3 / IL
Figure 5. Load Scale Indicating Maximum Spring Compression
D For valves with 3/8-inch (9.5 mm) valve stems, do not install the packing follower (key 203) at this time. (Note: the yoke boss will not slide over the packing follower. The packing follower must be installed while lowering the actuator yoke onto the valve.) D For valves with larger stem diameters, install the packing follower (key 203). 3. Refer to the appropriate valve and actuator instruction manuals when connecting the valve to the actua-
tor. While lowering the actuator yoke onto the valve, install the packing follower [for a 3/8-inch (9.5 mm) valve stem size], indicator disk, springs, and flange (keys 203, 206, 202, and 201). 4. Place the packing follower against the packing as shown in figures 6 and 7. 5. Place the indicator disk (key 206) and the first Belleville spring (key 202) while guiding them onto the packing follower (key 203). Make certain the cone-
3
HIGH-SEALt Live-Loaded Packing
A6138 / IL
Figure 6. HIGH-SEAL Graphite Packing Assembly
shaped side of the Belleville spring is towards the indicator disk as shown in figure 3. 6. Place the second Belleville spring (key 202) with the coned-shaped side toward the flange (key 201); see figure 3. Position the flange on top of the spring, making sure the second spring fits into its guide in the flange.
CAUTION Keep the packing follower and flange centered on the valve stem. If any metal part makes contact with the stem, it can cause damage to the stem surface. Vertical scratches or nicks on the stem surface can cause excessive leakage from the packing. 7. Lubricate the packing nuts with Nickel-Special Never Seez or equivalent and tighten them hand-tight. 8. The load scale (figure 2) is used to indicate compression on the Belleville springs. Position the load scale (key 205) by slightly loosening the mounting
4
screws (key 204). Align the bottom edge of the load scale with the indicator disk and retighten the screws. Figure 3 illustrates the load scale properly adjusted before the nuts have been tightened and with the Belleville springs not compressed. 9. Tighten the packing nuts while observing the two load scales (key 205) to make sure the flange (key 201) is tightened evenly. Figure 4 indicates minimum spring compression with the indicator disk aligned with the minimum compression line on the load scale. Be sure to keep the follower centered on the stem while tightening the nuts. Tighten the nuts alternately and evenly, keeping the flange parallel with the valve (see figures 4 and 5), until the indicator disk aligns with the maximum compression line on the load scales, as shown in figure 5. 10. The packing is now properly loaded and the packing nuts do not need to be retightened unless the indicator begins to approach the minimum compression line (see figure 4). After the valve has been in service for awhile, visually check the load scale to determine loading. Retighten the packing nuts alternately and evenly as necessary.
HIGH-SEALt Live-Loaded Packing
A6139 / IL
Figure 7. HIGH-SEAL Graphite with PTFE Packing Assembly
5
HIGH-SEALt Live-Loaded Packing
Each valve assembly is assigned a serial number that can be found on the valve. 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 Controls sales representative or sales office for technical assistance. When ordering replacement parts, refer to the serial number and to the 11-character part number for each part required from the following parts list.
Retrofit kits include parts to convert existing Design A, CAV4, E, EH, HP, YD, and YS valves to the HIGHSEAL packing box construction. Spring material is S17700 (17-7 stainless steel). Stems and packing box constructions that do not meet Fisher Controls stem finish specifications, dimensional tolerances, and design specifications may adversely alter the performance of this packing kit.
Design A, CAV4, E, EH, HP, YD, and YS Retrofit Kits Stem Diameter, Inch (mm)
Yoke Boss Diameter, Inch (mm)
Kits
3/8 (9.5)
2-1/8 (54)
11B2179X052
1/2 (12.7)
2-13/16 (71)
11B2182X052
3/4 (19.1)
3-9/16 (90)
11B2184X052
1 (25.4)
5 (127)
11B2187X052
1-1/4 (31.8)
5, 5H (127)
11B2189X052
2 (50.8)
7 (177.8)
12B5870X052
Parts Included in Retrofit Kits QUANTITY KEY NUMBER
6
DESCRIPTION
For 3/8, 1/2, 3/4, 1, & 1-1/4 Inch Stems (9.5, 12.7, 19.2, 25.4, & 31.8 mm Stems)
For 2-Inch Stems (50.8 mm Stems)
200
Packing Stud
2
3
201
Packing Flange
1
1
202
Belleville Spring
2
2
203
Packing Follower
1
1
204
Screw
4
6
205
Load Scale
2
3
206
Indicator Disk
1
1
207
Bushing
2
2
208
Bushing
1
1
209
Packing Ring
3
3
210
Packing Ring
2
2
211
Packing Box Ring
1
1
212
Packing Nut
2
3
214
Packing Washer
5
---
219
Washer (not required on 3/8-inch [9.5 mm] stem)
2
3
HIGH-SEALt Live-Loaded Packing Key
Description
213 Never-Seez Nickel Lubricant, 4 pound (1.8 kg) can (not furnished with unit) (not shown)
Part Number
Note
1M5539X0012
For Keys 200 through 212 refer to the following tables.
For 3/8, 1/2 and 3/4 Inch (9.5, 12.7 and 19.1 mm) Stems PART NUMBER KEY NO.
QTY
200
2
Stud
S31600 (316 SST)
3/8 inch (9.5 mm) Stem, 2-1/8 inch (54 mm) Yoke Boss 11B6951X072
201
1
Flange
S31600
21B2195X012
21B2196X012
21B2197X012
S17700 (17-7PH SST)
11B2179X022
11B2182X022
11B2184X022
N07718 (Inconel 718)
11B2179X032
11B2182X032
11B2184X032
DESCRIPTION
MATERIAL
1/2 inch (12.7 mm) Stem, 2-13/16 Inch (71 mm) Yoke Boss 1K7298X00A2
3/4 Inch (19.1 mm) Stem, 3-9/16 Inch (90 mm) Yoke Boss 1R387335222
202 and 205
2
Spring(1)
2
Load scale
18-8 stainless steel
11B2168X012
11B2171X012
11B2173X012
203
1
Spring guide packing follower
S31600
21B2190X012
21B2191X012
21B2192X012
204
4
Screw
18-8 stainless steel
1B2752X0022
1B2752X0022
1B2752X0022
206
1
Indicator disk
18-8 stainless steel
11B3757X012
11B3787X012
11B3788X012
207*
2
Bushing (black w/white color code)
Carbon
12B5780X012
12B5782X012
12B5784X012
208*
1
Bushing (black)
Carbon
12B5781X012
12B5783X012
12B5785X012
209*
3
Packing ring(2)
Carbon/graphite composite
12B5798X012
12B5799X012
12B5800X012
210*
2
Packing ring (packing ribbon)
Graphite/zinc
1V3160X0022
1V3802X0022
1V2396X0022
211*
1
Packing box ring
S31600
12B5774X012
12B5775X012
12B5776X012
212
2
Nut
S31600
1E944035252
1E944535252
1E944635252
214*
5
Packing washer
PTFE
12B6936X012
12B6937X012
12B6938X012
*Recommended spare part. 1. For additional spring information, refer to the Spring Identification and Dimension table. 2. Part number is stamped on part.
Spring Identification and Dimensions SPRING DIMENSIONS SPRING
Valve Stem Diameter Inches
mm
Inches
mm
Inches
mm
Inches
mm
Inches
mm
Inches
mm
3/8
9.5
1/2
12.7
3/4
19.1
1
25.4
1-1/4
31.8
2
50.8
Inside Dia
1-7/8
47.6
2-3/8
60.3
2-15/16
74.6
3-13/16
96.8
4-1/16
103.2
5-7/16
138
Outside Dia
3-7/8
98.4
4-3/8
111.1
5-3/4
146.1
8-1/8
206.4
8-1/8
206.4
8-7/8
225
Thickness
3/32
2.4
5/32
4.0
13/64
5.2
17/64
6.7
9/32
7.1
21/64
8.3
7
HIGH-SEALt Live-Loaded Packing For 1, 1-1/4 and 2-inch (25.4, 38.1, and 50.8 mm) Stems QTY
PART NUMBER
For 1 & 1-1/4 Inch (25.4 & 38.1 mm) Stems
For 2 Inch (50.8 mm) Stems
200
2
3
Stud
S31600 (316 SST)
1-inch 1-1/4 Inch 2-Inch (25.4 mm) (31.8 mm) (50.8 mm) Stem, Stem, Stem, 5-Inch 5-Inch 7-Inch (127 mm) (127 mm) (178 mm) Yoke Boss Yoke Boss Yoke Boss 12B5844X012 1N471435222 12A3277X032
201
1
1
Flange
S31600
21B2198X012 21B2199X012 22B5808X012
KEY NO.
DESCRIPTION
MATERIAL
2
2
Spring S ring((1))
S17700 (17-7PH SST) N07718 (Inconel 718)
2
3
Load Scale
18-8 stainless steel
11B2176X012 11B2178X012 12B6326X012
203
1
1
Packing follower
S31600
22B5772X012 22B5773X012 32B5806X012
204
4
6
Screw
18-8 stainless steel
1B2752X0022 1B2752X0022 1B2752X0022
206
1
1
Indicator disk
18-8 stainless steel
11B3789X012 11B3811X012 12B5841X012
207*
2
2
Bushing (black w/white color code)
Carbon
12B5786X012 12B5788X012 12B5790X012
208*
1
1
Bushing (black)
Carbon
12B5787X012 12B5789X012 12B5791X012
Carbon/graphite composite
12B5801X012 12B5802X012 12B5803X012
202 and 205
ring(2)
11B2187X022 11B2189X022 12B5870X022 11B2187X032 11B2189X032 12B5870X032
209*
3
3
Packing
210*
2
2
Packing ring (packing ribbon)
Graphite/zinc
1U6768X0022 1V5666X0022 10A4801X022
211*
1
1
Packing box ring
S31600
12B5777X012 12B5778X012 12B5779X012
212
2
3
Nut
S31600
1A343335252 1A368135252 1A440935252
214*
5
---
Packing washer
PTFE
12B6939X012 12B6940X012
---
*Recommended spare part. 1. For additional spring information, refer to the Spring Identification and Dimension table. 2. Part number is stamped on part.
HIGH-SEAL, Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners. D Fisher Controls International, Inc. 1989, 1998; All Rights Reserved
For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461 8 Printed in U.S.A.