3000 Valve Instruction Manual

Instruction Manual Form 5662 January 2001

3000 Series

3000 Series Cryogenic Valve Contents Introduction

1 1 2 2 2

Installation

2 2 3 3 3

...............................

Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................

Pre-operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dismantling the Valve . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Box Installation Procedure . . . . . . . . . . . . . . . .

Section 1

................................... 4 Actuator Removal (Size 25, 50, and 100) . . . . . . . 4 ...................................

Removing the Valve Bonnet . . . . . . . . . . . . . . . . . . .

Removing the Packing and Stem Guides . . . . . . . .

Removing the Plug and Seat . . . . . . . . . . . . . . . . . .

Assembly of Valve Body . . . . . . . . . . . . . . . . . . . . . .

Assembly of Actuator to Valve (Size 25, 50, and 100) . . . . . . . . . . . . . . . . . . . . .

Adjusting Plug to Seat Position . . . . . . . . . . . . . . . .

5 5 5 5 6

Inspection of Parts . . . . . . . . . . . . . . . . . . . . . . . .

7

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Introduction Scope of Manual The 3000 Series cryogenic valves (figure 1) are manufactured by Severn Glocon for Fisher.

Instructions in the following paragraphs describe the installation procedures for the 3000 Series cryogenic 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.

6 6

W8141 / IL

Figure 1. Type 3310 Series Cryogenic Globe Valve with Design DVC6000 FIELDVUE R Digital Valve Controller

Only persons qualified through training or experience should install, operate, and maintain 3000 Series valves. If you have any question about these instructions, contact your Fisher sales office before proceeding.

D102769X012

Section 2

3000 Series WARNING 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.

Unless specifically specified by the contract, the valve has been packed for domestic shipping and indoor storage at the job site.

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.

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.

Installation 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 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

2

Be certain that the correct utilities are connected and that accessory items are connected and correctly adjusted. If the actuator has a handwheel override, 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.

3000 Series Dismantling the Valve

Description

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.

Type 3000 Series cryogenic control valves are specifically designed to control the flow of cryogenic liquids and gases within cold box installations.

For ease of maintenance, construction is based upon a single seat design with a replaceable seat ring.

Servicing can be easily performed from outside the cold box by removing the bonnet, plug and actuator from the valve assembly leaving the valve body undisturbed within the cold box.

WARNING Cold Box Installation Procedure Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations:

Upon receipt of the valve, check the assembly for shipment damage and verify that spare valve body gaskets have been provided (wired to actuator yoke).

D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal injury.

It is common practice to disassemble the valve prior to installation during cold box fabrication. The following steps are given to assist in this procedure.

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.

1. Remove the valve body nuts and washers (keys 12 and 19) figure 3.

2. While supporting the actuator and extension, carefully remove these from the valve body. This will have the effect of permitting the plug (key 13) to withdraw the valve body spacer (key 8).

3. The now exposed internal valve components should be sealed to protect against contamination by enclosing in a heavy duty plastic bag and stored in a safe place to avoid damage.

4. After welding the valve body in the line, reassembly may be completed by reversing the above procedure ensuring the new valve body gasket is used.

5. The correct torque should be applied to the valve body nuts as shown in table 1.

6. Following installation, all valves should be operated to check that they will still function correctly. Inspect all connections for leakage. It is normal practice after installation of pipe work to clean the system with the valves in the fully open position by flushing to remove debris. The valve body cavities may form a natural trap for such debris to settle and adversely affect valve operation. Also, abrasive material carried by high velocity flushing may cause serious damage to seating surfaces.

3

3000 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

1/2 - 13

24

12

M10X1.5

11

15

32

M12X1.75

22

5/8 - 11

30

47

64

M16X2

53

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%.

Section 1 Actuator Removal (Size 25, 50, and 100) WARNING To avoid personal injury or damage when disassembling the valve in the pipeline, ensure that there is no line pressure.

Before starting any disassembly operation, the plug must be located off the seat. For valves assembled with fail open actuators, no further action is necessary.

For valves assembled with fail close actuators, the plug / actuator stem must be raised to the 50% open position by applying air, the plug locknut loosened and the plug screwed up into the actuator stem.

After completing the previous step, the air supply must be turned off and all air bled from the actuator cylinder

4

and positioner if applicable. By disconnecting the air line tubing from all the cylinder ports the pressure can be released. Finally, ensure all pressure gauges indicate zero pressure.

Remove any accessories as required (see figure 2).

1. Support the weight of the actuator.

2. Remove packing bolts, nuts and anti-rotation device if installed.

3. Remove yoke clamp screws and yoke clamps (key 28).

4. Push the actuator downwards toward the valve body to allow removal of the two yoke retaining half rings (key 23) from the groove in the valve bonnet.

5. While ensuring the plug is held in position, rotate the actuator on the valve plug to separate the plug from the actuator piston rod.

6. Remove the plug locknut (key 24) from the valve plug, the travel indicator (key 25), and the packing flange (key 12).

The actuator can now be removed from the valve.

3000 Series 6. During this operation take care not to lose the yoke retaining half rings (key 23, figure 2) and the packing follower (key 17).

27 26

18 25 24

It is possible to remove the bonnet complete with the actuator and plug by following the above steps, but there will be extra weight and lifting equipment may be required on larger valves. If this method is used, all parts must be removed with care and by a straight lift to avoid pick up of the spacer (key 8) and the valve body (key 9).

14,13,12 11 23 19 28,29 7 8 Key 7 8* 11* 12 13 14 18 19* 23 24 25 26 27 28 29

Description Bonnet Extension Collar Upper Stem Guide Packing Follower Packing Flange Packing Bolt Packing Nut Serial Number Plate Packing Yoke Retaining Half Rings Plug Locknut Stem Travel Indicator Yoke Anti-Rotation Clamp Yoke Clamp Yoke Clamp Screws

E0643 / IL

Figure 2. Actuator Removal

Removing the Packing and Stem Guides 1. Remove the bonnet (key 14) as above.

2. Remove the packing flange (key 12, figure 2). A groove is machined outside of the packing follower to allow a screwdriver to be used to pry the item loose if the component is tight. This should be removed next.

3. Remove the packing.

4. Remove the upper stem guide (key 15).

5. Removal of the lower stem guide (key 7) is achieved by lifting out the spacer (key 8). A special tool obtainable from Fisher can be used to help in this operation (figure 5). Care must be taken when removing this spacer as it is a close fit in the valve body and must be lifted out using a straight lift.

If the bonnet is not removed from the valve, a packing extractor tool may be required to dig out the packing (figure 4). Moving the plug up and down may also loosen the packing rings.

Removing the Plug and Seat

Section 2

1. Remove the bonnet (key 14) as previously stated.

Refer to figure 3.

2. Remove the spacer gasket.

3. Remove the plug, lower stem guide, spacer and lower stem guide retainer as one subassembly.

Removing the Valve Bonnet 1. If disassembing in the pipeline, ensure that there is no line pressure.

2. Remove the actuator as described in Section 1.

3. On valve sizes 1/2, 1-, 1-1/2, and 2-inch, remove the actuator clamp ring (key 7, figure 2) from the extension bonnet.

4. Remove the valve body nuts (key 12) and washers (key 19).

5. Lift the bonnet (key 14) off the plug (key 13). If there are any excessive deposits built up on the plug stem above the packing follower, remove this first.

*Recommended spare parts

4. Slide the spacer (key 8) off the plug.

5. Remove the set screws and tab washers, releasing the stem guide retainer. The lower stem guide can now be removed.

6. Remove the body gasket (key 11) from the recess in the valve body.

7. Unscrew the valve seat (key 2) from the valve body using the special seat ring installation tool. Unscrew counterclockwise. (See figure 6.)

8. Remove the seat gasket (key 18) from the seat.

Some valve trims are assembled with soft seated plugs. To replace the seal, unscrew the retainer and install a new seal.

5

3000 Series Note There is a pin installed to the male thread to prevent the collar / nut from unscrewing. This must also be replaced.

See figure 7.

Assembly of Valve Body Prior to assembly, ensure that the parts are clean and fully degreased where necessary.

1. Install a new seat gasket (key 18) to the valve seat (key 2) and screw the seat into the valve body, using an appropriate seat ring installation tool. Take care not to assemble the seat cross threaded.

2. Install a new valve body gasket (key 3) into the recesses provided.

3. Install the lower stem guide (key 7) to the spacer (key 8) and retain with the stem guide retainer (key 6) using screws and tab washers (keys 21 and 22).

4. Install the spacer assembly with its gasket (key 10) over the valve plug stem and insert the plug assembly into the bore of the valve body.

5. Locate the bonnet into valve body studs ensuring the plug is correctly aligned and moves freely up and down within the bonnet.

6. Install the upper stem guide (key 15) into the bonnet bore.

2. Lower the actuator onto the valve body assembly.

During this operation, loosely install the packing flange (key 12), plug locknut (key 24), and stem travel indicator (key 25). Screw the valve plug (key 21) into the actuator piston rod while ensuring that the plug is not in contact with the valve seat during this operation.

3. By screwing the valve plug into the actuator piston rod, it will be possible to allow the yoke to be pushed down and the yoke retaining half rings installed (see figure 5).

4. Install the yoke clamps (key 28) and screws (key 29). By tightening the clamps, the yoke is forced upwards onto the half rings and the yoke is held in place (see figure 5).

5. Adjust the plug to seat position and tighten the plug locknut / or anti-rotation device if installed.

6. Install the packing bolts into the side lugs on the actuator yoke and through the packing flange. Connect the packing nuts onto these bolts.

7. Tighten the packing by pulling down the packing flange nuts (key 14). Continue to evenly tighten down until the packing is firm; do not over tighten. If the correct amount of packing is installed, the packing follower should protrude above the valve bonnet.

Correct any significant deviation from this by adding or removing a packing ring.

Do not tighten the packing until the plug is in position as adjustment will be difficult.

7. Install the packing rings (key 16) into the bonnet bore.

Adjusting Plug to Seat Position

8. Install the packing follower (key 17) into the bonnet.

1. Assemble the valve complete with the actuator.

9. Install the valve body washers (key 19) and the valve body nuts (key 12) and tighten down evenly around the bonnet flange. Before final tightening, move the plug up and down to ensure free movement and that all components are concentric and square.

Fully tighten the valve body nuts alternately using a cross circular pattern in 25 lbfSft steps until the correct bolt torque loading is reached (see table 1). The bonnet should bolt down face-to-face with the valve body. Check that the plug still moves up and down freely and locates correctly in the valve seat.

2. Set the actuator to its lowest position. If this cannot be achieved, the plug will have to be raised by screwing the valve plug into the actuator stem. Ensure that the plug is not in contact with the seat during this operation.

3. Screw the plug down until it just contacts the seat.

Raise the plug and actuator stem with air. Screw the valve plug down a further 1/16 inch. This provides adequate seat / plug loading for shutoff.

Note

Assembly of Actuator to Valve (Size 25, 50, and 100)

On soft seated valves, do not exceed this amount. Excessive load may damage soft seals.

Refer to figure 2.

4. Tighten the plug locknut or anti-rotation device.

1. Install the bonnet extension collar (key 7) when required (valve sizes 1/2, 1-, 1-1/2, and 2-inch).

5. Set the stem travel plate to its correct position indicating closed when the valve is shut.

6

3000 Series Inspection of Parts Valve Packing (key 19) - figure 2.

The reuse of packing is not recommended.

Soft Seats The reuse of soft seats is not recommended.

Gaskets (valve body and seat)

17

The reuse of any gaskets is not recommended.

16 15

Plug / Seat Examine the plug / seat for signs of damage. Wear on the plug contour, unless very severe, will not prevent the valve from controlling, but it may cause problems in the loop response.

14

Minor blemishes can be removed from the plug stem by fine emery paper.

Wear on the seating angles may also be removed by lapping.

13

Stem Guides Examine for general condition and renew if necessary.

20

Note For all actuator adjustments, refer to appropriate instruction manuals.

12

19 11 10

If you have any questions, contact your Fisher sales office with the valve serial number.

9

Parts List

21, 22 8

Refer to figure 3 Key

Description

Key

Description

2 3* 4 5 6 7 8 9 10* 11* 12*

Seat Soft Seal Retainer Stub Stem Guide Retainer Stem Guide Spacer Valve Body Spacer Gasket Valve Body Gasket Valve Body Nuts

13* 14 15* 16* 17* 18 19 20 21 22

Plug Bonnet Upper Stem Guide Packing Packing Follower Seat Gasket Spring Washer Valve Body Stud Set Screw Tab Washer

18 7 6 4 3 2 5

Figure 3. Type 3000 Assembly *Recommended spare parts

7

3000 Series PACKING REMOVAL TOOL PACKING BONNET

PACKING SPACER E0645 / IL

Figure 4. Packing Removal

E0647 / IL

Figure 6. Seat Removal Tool

E0646 / IL

Figure 5. Spacer Removal Tool E0648 / IL

Figure 7. Soft Seat Insert

FIELDVUE, 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. 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.