Instruction Manual Form 5663 January 2001
5000 Cryo Series
5000 Series Cryogenic Valve Contents Introduction
1 1 2 2 2
2 2 3 3 3
............................... Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................. Pre-operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling the Valve . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Box Installation Procedure . . . . . . . . . . . . . . . .
................................... 4 Actuator Removal (Size 25, 50, and 100) . . . . . . . 4
................................... Removing the Valve Extension Bonnet . . . . . . . . . Removing the Packing and Stem Guides . . . . . . . . Removing the Plug / Cage 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 5
Inspection of Parts . . . . . . . . . . . . . . . . . . . . . . . .
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W8142 / IL
Introduction Figure 1. Cutaway View of Type 5413 Globe Valve with Series â€œPâ€? Cylinder Actuator
Scope of Manual
Only persons qualified through training or experience should install, operate, and maintain 5000 Cryo Series valves. If you have any question about these instructions, contact your Fisher sales office before proceeding. D102770X012
The 5000 Cryo Series cryogenic valves (figure 1) are manufactured by Severn Glocon for Fisher. Instructions in the following paragraphs describe the installation procedures for the 5000 Cryo 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.
5000 Cryo 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 â€“29 to 48_C (â€“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.
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 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.
5000 Cryo Series 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.
Type 5000 Cryo Series cryogenic control valves are specifically designed to control the flow of cryogenic liquids and gases within cold box installations. Particular attention has been paid to a clean bore and an easy flow line through the valve.
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.
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. When process conditions dictate, it is sometimes necessary to install a cage trim design.
Cold Box Installation Procedure 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). 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. 1. Remove the valve body nuts and washers (key 6, figure 3). 2. While supporting the actuator and extension, carefully remove these from the valve body. 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.
5000 Cryo Series Table 1. Bonnet Bolt Torques AMERICAN STANDARD BOLTING Stud Size & Number of Threads Per Inch
APPROXIMATE EQUIVALENT METRIC BOLTING
Stud Size & Number of Threads Per Inch
3/8 - 16
1/2 - 13
5/8 - 11
3/4 - 10
7/8 - 9
1 1/8 - 8
1 1/4 - 7
1 1/4 - 8
1 3/8 - 6
1 3/8 - 8
1 1/2 -6
1 1/2 - 8
1 1/2 -12
1 5/8 - 8
1 5/8 - 12
1 3/4 - 8
1 3/4 -12
1 7/8 - 8
2 1/3 - 8
2 1/2 - 8
2 3/4 - 8
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
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 (keys 9 and 10). 4. Push the actuator downwards toward the valve body to allow removal of the two yoke retaining half rings (key 8) 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 25) from the valve plug, the travel indicator (key 23), and the packing flange (key 21). The actuator can now be removed from the valve.
5000 Cryo Series required on larger valves. If this method is used, all parts must be removed with care and by a straight lift to avoid damage to the plug head. 24 23 25
21,22 7 20
1. Remove the bonnet (key 5) as above. 2. Remove the packing flange (key 21, figure 2). A groove is machined outside of the packing follower (key 20) 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 (key 19).
Key 5 7 8 9 10 17 18* 19 20* 21 22 23 24 25
Removing the Packing and Stem Guides
Description Valve Bonnet Actuator Yoke Yoke Retaining Half Rings Yoke Clamp Yoke Clamping Screws Stem Guide Retainer Upper Stem Guide Packing Packing Follower Packing Flange Packing Bolts / Nuts Stem Travel Indicator / Anti-Rotation Clamp Stem Travel Plate Plug Locknut
E0638 / IL
Figure 2. Actuator Removal
Section 2 Refer to figures 2 and 3.
Removing the Valve Extension Bonnet 1. If disassembing in the pipeline, ensure that there is no line pressure. 2. Remove the actuator as described in Section 1. 3. Remove the valve body nuts and washers (key 6). 4. Lift the bonnet (key 5) off the plug (key 15). If there are any excessive deposits built up on the plug stem above the packing follower, remove this first. 5. During this operation take care not to lose the yoke retaining half rings (key 8, figure 2) and the packing follower (key 20). 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
*Recommended spare parts
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 / Cage and Seat 1. Remove the bonnet (key 5) as previously stated. 2. Remove the plug (key 15), cage (key 13), and cage gaskets (key 14). 3. If a screwed-in seat type has been supplied, unscrew the valve seat (key 11) in a counterclockwise direction from the valve body using the appropriate seat removal tool (see figure 5). 4. 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. Note There is a pin installed to the male thread to prevent the collar / nut from unscrewing. This must also be replaced. See figure 6.
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 12) to the valve seat (key 11) 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 new cage gaskets (key 14) and valve body gasket (key 4) into the recesses provided. 3. Insert the plug assembly into the bore of the valve body. 4. Locate the bonnet into valve body studs ensuring the plug is correctly aligned and moves freely up and down within the bonnet.
5000 Cryo Series 5. Install the stem guide (key 16) into the bonnet bore.
Adjusting Plug to Seat Position
6. Install the packing spacer (key 17) into the bonnet bore.
1. Assemble the valve complete with the actuator.
7. Install the packing rings (key 19) into the bonnet bore. 8. Install the packing follower (key 20) into the bonnet bore. 9. Install the valve body washers and nuts (key 6) and semi-tighten down evenly around the bonnet flange. Before final tightening, move the plug up and down several times 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 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. 4. Tighten the plug locknut or anti-rotation device. 5. Set the stem travel plate to its correct position indicating closed when the valve is shut.
Inspection of Parts Valve Packing (key 19) - figure 2.
Assembly of Actuator to Valve (Size 25, 50, and 100) Refer to figure 2. 1. Lower the actuator onto the valve body assembly. During this operation, loosely install the packing flange (key 21), plug locknut (key 25), and stem travel indicator (key 23). Screw the valve plug (key 15) into the actuator piston rod while ensuring that the plug is not in contact with the valve seat during this operation. 2. 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. 3. Install the yoke clamps (key 9) and screws (key 10). By tightening the clamps, the yoke is forced upwards onto the half rings and held in place. 4. Set the plug to seat position and tighten the plug locknut / or anti-rotation device if installed. 5. Install the packing bolts into the side lugs on the actuator yoke and through the packing flange. Connect the packing nuts onto these bolts. 6. Tighten the packing by pulling down the packing flange nuts (key 22). 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.
The reuse of packing is not recommended. Plug Soft Seats The reuse of soft seats is not recommended. Gaskets (valve body / seat and cage) The reuse of any gaskets is not recommended. 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. Minor blemishes can be removed from the plug stem by fine emery paper. Wear on the seating angles may also be removed by lapping. Stem Guides Examine for general condition and renew if necessary. Note For all actuator adjustments, refer to appropriate instruction manuals. If you have any questions, contact your Fisher sales office with the valve serial number.
5000 Cryo Series Parts List Refer to figure 3 Key
1 2 3 4* 5 6 7 8 9 10 11* 12* 13 14* 15* 16* 17 18* 19* 20* 21 22 23 24 25 26
Valve Body Separable Flanges Flange Half Rings Valve Body Gasket Valve Bonnet 26 Studs, Nuts, and Washers 25 Actuator Yoke Yoke Retaining Half Rings Yoke Clamp Yoke Clamping Screws 21,22 Valve Seat Seat Gasket 20 Cage (when installed) 19 Cage Gasket (when installed) Valve Plug Lower Stem Guide 18 Packing Spacer Upper Stem Guide Packing Packing Follower Packing Flange Packing Bolts / Nuts Stem Travel Indicator / Anti-Rotation Clamp Stem Travel Plate Plug Locknut Nameplate
13 15 12
3 2 1
E0639 / IL
Figure 3. Type 5000 Cryo Assembly
*Recommended spare parts
5000 Cryo Series PACKING REMOVAL TOOL PACKING BONNET
E0642 / IL
Figure 6. Soft Seat Insert
E0640 / IL
Figure 4. Packing Removal
E0641 / IL
Figure 5. Seat Removal Tool
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.