Emerson Fisher Control-Disk Instruction Manual
Contents
1. a LK 5 5 PIE 1 WS 9 ZZ Cm EN P 2 0 a yg o y LON EN aAA GN VAR VE 107 STACKING ORDER GRAPHITE PACKING RINGS NS S M 5 34B7524 B GRAPHITE PACKING SYSTEM NOTES 1 gt VALVES WITH SHAFTS LARGER THAN 38 1 mm 1 1 2 INCH USE GRAPHITE RINGS 27 Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 Key 21 Gasket 1 CL150 CL300 36 V148909X022 V148909X012 V148909X032 20 24 30 36 14 20 24 0 o Key 24 Thrust Bearing VALVESIE NPS QUANTITYNEEDED PEEK BRONZEIGRAPHITE PTFE COMPOSITE LM 2 1 3 2 pf ae GE 38 2 pf Gea m 2 pf Ge GHSZMXMI GEO 3 mers visen 3 vimse CL300 amom NN Of amom ano GESTIGSA 1381959 012 visene m ter VH6MBOI winter Recommended spare parts Fisher Control Disk FIELDVUE and ENVIRO SEAL are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publi2. TO FACE C EEE WEIGHT VALVE SIZE NPS ACTUATOR YOKE DIMENSION POUNDS single Flange nm mm mm 1532 17 40 1 Face to face dimensions are in compliance with MSS SP68 and API 609 specifications 2 Minimum I D is the minimum pipe or flange I D required for disk swing clearance 3 Contact your Emerson Process Management sales office for information Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 A Control Disk valve is normally shipped as part of an assembly with an actuator and other accessories such as a valve positioner If the valve and actuator have been purchased separately or if the actuator has been removed for maintenance properly mount the actuator and adjust valve actuator travel before inserting the valve into the line CAUTION Damage to the disk will occur if any pipe flanges or piping connected to the valve interfere with the disk rotation path Be certain to align the valve accurately to avoid contact between the disk key 2 and the flanges Figure 2 Available Seal Configurations BACKUP O RING SEAL RING RETAINING RING NORMAL FLOW DIRECTION PTFE OR UHMWPE SOFT SEAL WITH BACKUP 0 RING GRAPHITE GRAPHITE GASKET GASKET BACKUP O RING METAL RETAINING SEAL RING RING METAL SEAL RESILIENT VALVE DISK CENEL FON NORMAL FLOW DIRECTION D DIRECTION NOVEX METAL SEAL PHOENIX Ili FIRE SAFE SEAL B2313 3 NOTES 1 gt THIS UNIDIRECTIONAL SEAL MUST
3. 36 vesen vneueou voa YHON3X32 VHON3XMD o S 36 2 vir 360x022 visene vioo visene vinnes 07 2 vs visne 01 00 O a vnr 3 vns visa vmsr oz 2 E 1 Not available in UHMWPE Recommended spare parts 25 Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 Key 7 Bearing VALVE SIZE NPS QUANTITY NEEDED 316 NITRIDE BRONZE GRAPHITE PTFE COMPOSITION CL150 V161474X022 V161474X042 V161474X052 V111398X032 V111398X042 V111398X052 V175057X012 39 1 49 f VI69414X032 4 a 8 3 1 49 vies viser visner gt 1 70 012 veon visene 000 49 f 2 VI3699X032 1699 012 1 49 veo VI3TASXOS2 L 5 45 vir 3e 49 gt 1 Upper bearing 2 Lower bearing 3 Both upper and lower bearings 26 Recommended spare parts Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 Figure 10 ENVIRO SEAL Packing Systems f WE sz Ns GE CON NTT 109 EV 19
4. BE INSTALLED SO THAT THE RETAINING RING IS DOWNSTREAM FROM THE HIGH PRESSURE SIDE OF THE VALVE AT SHUTOFF AS SHOWN 2 gt FOR THIS BIDIRECTIONAL SEAL THE PREFERRED VALVE ORIENTATION PLACES THE RETAINING RING DOWNSTREAM FROM THE HIGH PRESSURE SIDE OF THE VALVE AT SHUTOFF Adjusting the Actuator Travel Key number locations are shown in figure 9 unless otherwise noted 1 Adjust the actuator to bring the disk to the fully closed position at the end of the actuator stroke To determine the fully closed disk position measure the distances between the disk face and the seal retainer face at the top and bottom of the valve X1 and X2 as shown in figure 3 Adjust the actuator to rotate the disk slightly until the two measurements are within 0 8 mm 0 032 inch of each other Refer to the appropriate actuator instruction manual for assistance 2 Before installing the valve actuator assembly in the process line cycle the valve several times to be sure the valve disk returns to the proper position Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 Figure 3 Sectional of Typical Valve Body X1 ACTUATOR END OF SHAFT CCW DISK ROTATION TO OPEN POSITION INDICATION MARK INDICATES APPROXIMATE DISK POSITION X2 GE53027 A Installing the Valve The maximum allowable inlet pressures for Control Disk valves are consistent with the applicable ASME pressure temperature ratings except where limited by the material capabil
5. Fisher valve because they may void your warranty might adversely affect the performance of the valve and could cause personal injury and property damage Note Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user 20 Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 Retrofit Kits Retrofit kits include all parts required for installation of the ENVIRO SEAL packing system into existing high performance butterfly valves Retrofit kits are available for single PTFE packing See table 7 for retrofit kit part numbers Retrofit Kit Included Parts Anti blowout follower Jam nut Packing stud Packing nut Packing flange NN Spring pack assembly Packing Set Anti extrusion washer Packing box ring Tag Cable 1 Not included in graphite packing kit 2 Only 1 req d for NPS 18 CL300 NPS 20 CL150 and NPS 24 CL150 Note Key 103 the spring pack assembly is made up of the packing spring stack held in place by an O ring on the packing follower 990722 Repair Kits PTFE Repair kits include a single PTFE packing set and anti extrusion washers Graphite packing sets include graphite packing rings and carbon anti extrusion rings See table 7 for PTFE repair kit part number
6. See figure 2 to identify the specific seal design CAUTION In the following procedure take care not to damage the seal or T slot area of the valve body during removal of the seal 4 Insert a regular screwdriver or other similar tool under the top edge of the seal and gently pry the seal out of the T slot area in the valve body Take care not to damage the seal or T slot area of the valve body After the seal has been removed clean the T slot area retaining ring and if required polish the disk key 2 thoroughly with fine steel wool or other appropriate material To install a new seal O ring key 6 and retaining ring gasket follow the appropriate instructions given below Table 6 Torque Values for Fasteners RETAINING RING SCREWS GASKET RETAINING BOLTS 1356 Note These values are based upon standard materials 566286 N07718 screws and ASTM A193GRB6 bolts For other special fastener materials please contact your Emerson Process Management sales office PTFE Seals 1 Locate the replacement seal ring key 5 and note the shape of the ring The ring is wider across one edge diameter and narrower across the other edge diameter Around the outside circumference is one wide groove Before installing the seal ring into the valve body place the O ring key 6 into the wide outer groove of the seal ring Refer to figure 8 2 Install the seal ring and O ring assembly in the valve body The wider outside diameter of the seal rin
7. between the flanges into the cradle formed by the flange bolts B2263 1 4 Install the remaining flange bolts e For Wafer Style Valves Make sure the gaskets are centered on the gasket sealing surfaces of the flange and body 5 Forall Valves Tighten the flange bolts in an alternating criss cross fashion to a torque value of one fourth of the final bolting torque Repeat this procedure several times increasing the torque value each time by a fourth of the final desired torque After applying the final torque value tighten each flange bolt again to allow for gasket compression Packing Adjustment and Shaft Bonding WARNING Personal injury could result from packing leakage Valve packing was tightened before shipment however the packing might require some readjustment to meet specific service conditions Check with your process or safety engineer for any other hazards that may be present from exposure to process media Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 Figure 6 Optional Shaft to Valve Body Bonding Strap Assembly 37A6528 A A3143 2 CAUTION For non ENVIRO SEAL packing Tighten the packing follower nuts only enough to prevent shaft leakage Excessive tightening will accelerate wear of the packing and could produce higher friction loads on the valve stem For PTFE or graphite packing Tighten standard packing follower nuts only enough to prevent shaft leakage
8. 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 Check with your process or safety engineer for any other hazards that may be present from exposure to process media Removing and Replacing the Actuator Refer to the appropriate actuator instruction manual for actuator removal and replacement procedures Packing Maintenance The Control Disk valve is designed so the packing can be replaced without removing the valve from the process pipeline CAUTION For non ENVIRO SEAL packing Tighten the packing follower nuts only enough to prevent shaft leakage Excessive tightening will accelerate wear of the packing and could produce higher friction loads on the valve stem Usually packing leakage can be eliminated by merely tightening the hex nuts key 15 located above the packing follower key 11 while the valve is in the pipeline However if leakage continues the packing must be replaced For PTFE ENVIRO SEAL packing systems refer to the separate instruction manual ENVIRO SEAL Packing System for Rotary Valves D101643X012 see figure 10 Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 Figure 7 Anti Blowout Design Details PACKING FOLLOWER STUD amp HEX NUT ANTI BLOWOUT FOLLOWER HEX JAM NUT VALVE BODY EXTERNAL
9. to separate instruction manuals for information covering the actuator and accessories Do not install operate or maintain Control Disk valves without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all the contents of this manual including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office before proceeding Unless otherwise noted all NACE references are to NACE MR0175 2002 ae EMERSON www Fisher com Process Management Control Disk NPS 14 36 April 2011 Table 1 Specifications Valve Size and End Connection Styles NPS 14 M 16 18 20 24 30 36 valves in wafer style flangeless or single flange lugged with raised face flanges CL150 or CL300 Maximum Pressure Drop Consistent with CL150 and CL300 pressure temperature ratings per ASME B16 34 Contact your Emerson Process Management sales office for additional information Shutoff Classification Per ANSI FCI 70 2 and IEC 60534 4 Standard Soft Seal Bidirectional shutoff Class VI bubble tight NOVEX Seal Unidirectional shutoff Class V reverse flow direction only Phoenix Seal Bidirectional shutoff Class VI bubble tight Phoenix Seal for Fire Tested Applications
10. 011 Ifthe Control Disk valve is equipped with a fail open actuator cycle the valve into the fully closed position Ensure the valve cannot open during installation by using a manual actuator a constant supply pressure to the pneumatic actuator or other steps as necessary Table 3 Valve Body Data CL150 VALVE SIZE NPS MNCTUATORYOKE DIMENSONO MINMUMID APPROKIMATE WEIGHT KILOGRAMS EE cl cO c RI QUE 1 o 32 4 389 23 1 38 3 1 8 5 1 78 amp 5 8 3 8 1 ns 863 94 WS SHAFT DIAMETER AT FACE TO FACE VALVE SIZE NPS ACTUATOR YOKE DIMENSION MINIMUM 0 2 APRROXIMATE VVRIGHT ROUNDS LM S 1 pm mm mm 3 10 am mm 39 39 3 16 40 9 3 48 x 35 9 87 11 4 56 22 35 O amp 3 88 89 3 8 8 25 38 3x 8 f 7e 3s X 26 00 1 NPS 14 to 24 face to face dimensions are in compliance with MSS SP68 and API 609 specifications 2 Minimum I D is the minimum pipe or flange I D required for disk swing clearance 3 Contact your Emerson Process Management sales office for information Table 4 Valve Body Data CL300 VALVE SIZE NPS ACTUATOR YOKE DIMENSION KILOGRAMS mm war SmgeFange m 1 mm mw me 3 45 1 13 382 28 1 34 38 Si mm s 33 4 m ma mw 4e m 53 2 3 DIAMETER AT
11. 7X022 V124882X022 V124883X022 Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 ENVIRO SEAL Packing System Part Number See figure 1 0 NPS 18 1483541X032 NPS 20 14B3541X082 Key Description Part Number NPS 24 14B3541X042 CL300 10 Anti Blow Flange NPS 14 14B3541X082 17 Hex Jam Nut 4 req d NPS 16 14B3541X052 100 Packing Flange Stud 4 req d NPS 18 14B3541X042 101 Packing Flange Nut 4 req d NPS 20 14B3541X062 102 Packing Flange SST NPS 24 14B3541X072 103 Spring Pack Assembly 106 Anti Extrusion Ring Composition graphite 105 Packing Set filled PEEK 2 req d Use with PTFE packing Single PTFE packing w std packing box CL150 CL150 NPS 14 14B3490X012 NPS 14 14B3489X012 NPS 16 14B3495X012 NPS 16 14B3494X012 NPS 18 13B9155X012 NPS 18 13B9159X012 NPS 20 13B9164X012 NPS 20 13B9168X012 NPS 24 12B7782X012 NPS 24 12B7783X012 CL300 CL300 NPS 14 13B1964X012 NPS 14 13B9168X012 NPS 16 14B3647X012 NPS 16 14B3642X012 NPS 18 12B7782X012 NPS 18 12B7783X012 NPS 20 13B9164X012 NPS 20 13B9168X012 NPS 24 14B5730X012 NPS 24 14B5734X012 Use with Graphite packing 107 Packing Box Ring CL150 111 Tag notshown NPS 14 14B3541X112 112 CableTie not shown NPS 16 14B3541X122 113 Lubricant Key 5 Seal Ring SOFT SEAL PHOENIX SEAL METAL SEAL VALVE SIZE NPS 1 ETFE NOVEX CL150 senn Visser VMISSI mf vima visse 4 V142380X022 VI423
12. 84X032 159146022 3 woo varar gt inearaxor vissoaexo22 3s varmen VMBISDO2 vis 8051x012 T 39 vnr gt 19825008 3 weno vassere gt vasse 1383645012 1 Includes FKM fluorocarbon NBR EPR CR and PTFE 2 Includes FKM NBR EPR and CR Recommended spare parts 23 Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 Figure 9 Fisher Control Disk Wafer Style Valve Assembly PARTS NOT SHOWN 29 32 33 26 111 112 NOTE 12 USEONLY WITH SOFT SEAL AND PHOENIX III SEAL Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 Key 6 Backup Ring vawes e nes AM WR a C o vs visse isse 1 7 vinen vinner visne vesen vinene vinnes ves vni Vm VIA VID voo 2 VHUTSON Wiese O 7 vesen vies vesso 3 vns visa Visse 2 L3 vneene vuewexsz vneueou M vies viner 36 visene visse Vinsnes Winner visene vinnes viso 27 2 11375 032 vises vassos o C o visse visse
13. DETAILS HEX NUT F3 STUD SPLINED SHAFT INC 22 FOLLOWER FOLLOWER EA 1282 ES des HEX BELLEVILLE DN JAM SPRINGS ON WE NUT EN NE ANTI BLOWOUT T N N 2 ANTI FOLLOWER PACKING LUN PA BLOWOUT 207 FOLLOWER AN NES N TJA N VALVE BODY WW 7 CIRCUMFERENTIAL ES ANTI BLOWOUT N SHOULDER fh a GLAND N LA N N TYPICAL PACKING CUTAWAY ENVIRO SEAL CUTAWAY INTERNAL DETAILS vr PACKING ASSEMBLY C0758 1 CAUTION Never use a wrench or pliers on the splined upper shaft key 3 A damaged shaft could cut the packing and allow leakage 1 Before loosening any parts on the valve release the pressure from the pipeline Then remove the hex nuts key 15 and lift off the packing follower key 11 2 Remove the hex jam nuts key 17 and the anti blowout flange key 10 Remove the packing follower key 12 Refer to figure 7 for details of the anti blowout design parts The packing is now accessible 3 Use a packing extractor to remove packing Insert the corkscrew like end of the tool into the first piece of packing and pull firmly to remove the packing Repeat this process until all packing parts have been removed Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 CAUTION Be careful when cleaning the packing box Scratches to the upper shaft key 3 or inside diameter of the packing bore might ca
14. Excessive tightening of packing will accelerate wear and could produce higher rotating friction loads on the valve stem If necessary refer to the Packing Maintenance section 2 The ENVIRO SEAL Packing Systems will not require this initial re adjustment Refer to the separate instruction manual ENVIRO SEAL Packing System for Rotary Valves D101643X012 for repair and adjustment procedures For hazardous atmosphere or oxygen service valves read the following Warning and provide the bonding strap assembly mentioned below if the valve is used in an explosive atmosphere WARNING The valve shaft is not necessarily grounded when installed in a pipeline unless the shaft is electrically bonded to the valve UJ To avoid personal injury or property damage resulting from the effects of a static electricity discharge from valve components in a hazardous atmosphere or where the process fluid is combustible electrically bond the drive shaft key 3 to the valve according to the following step Note Standard PTFE packing is composed of a partially conductive carbon filled PTFE female adaptor with PTFE V ring packing Standard graphite packing is composed of all conductive graphite ribbon packing Alternate shaft to valve body bonding is available for hazardous service areas where the standard packing is not sufficient to bond the shaft to the valve see the following step For oxygen service applications provide alternate shaft to valve body bon
15. Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 Fisher Control Disk NPS 14 36 CL150 300 High Performance Butterfly Valve Contents Figure 1 Fisher Control Disk Valve with 1061 ETT OTT 1 Actuator and FIELDVUE DVC6020 Digital Valve Scope of 1 Controller PEPE 2 Specifications uus eir dr br 2 Installation llle 3 Valve Orientation 4 Before Installing the Valve 4 Adjusting the Actuator Travel 6 Installing the Valve 7 Packing Adjustment and Shaft Bonding 9 Maintenance oe wee dx Pur RE RR zeus RE 11 Removing and Replacing the Actuator 11 Packing Maintenance 11 Removing the Valve 13 Seal Maintenance 13 ES 14 NOVEX Phoenix and or Phoenix Fire Tested Seals 15 Anti Blowout Design Packing Valve Shaft Disk and Bearing Maintenance 16 Installing the Two Piece Shaft 18 Gasket Retainer 20 Parts Ordering EE 20 W9138 1 PO EE cm 22 Introduction Scope of Manual This instruction manual includes installation maintenance and parts ordering information for NPS 14 through 36 CL150 300 Control Disk High Performance Butterfly Valves see figure 1 Refer
16. Seal Ring CL150 Only NBR Backup O Ring RA CR Backup O Ring R EPR Backup O Ring Fluorocarbon Backup O Ring PTFE Backup O Ring Phoenix IIl and or Fire Tested Construction S31600 and PTFE Seal Ring with NBR Backup O Ring CR Backup O Ring EPR Backup O Ring Fluorocarbon Backup O Ring NOVEX 531600 Seall Ring CL150 NOVEX 531600 SealO 6 Ring CL300 Seal Ring NOVEX S21800 Seal Ring CL300 29 to 427 198 to 538 198 to 816 198 to 538 198 to 538 198 to 538 3 to 427 196 to 427 3 to 260 198 to 816 54 to 232 198 to 916 198 to 538 7 to 316 29 to 93 43 to 149 54 to 182 29 to 204 73 to 204 29 to 93 43 to 93 54 to 93 29 to 93 3 to 93 40 to 149 54 to 149 62 to 204 40 to 232 29 to 538 29 to 816 29 to 816 Control Disk NPS 14 36 April 2011 TEMPERATURE RANGE 2225 4 22 400 OE 20 to 800 325 to 1000 325 to 1500 325 to 1000 325 to 1000 325 to 1000 100 to 800 320 to 800 100 to 500 325 to 1500 65 to 450 325 to 1500 325 to 1000 20 to 600 20 to 200 45 to 300 65 to 360 20 to 400 100 to 400 20 to 200 45 to 200 65 to 200 20 to 200 100 to 200 40 to 300 65 to 300 80 to 400 40 to 450 20 to 1000 20 to 1500 20 to 1500 Cryogenic Seal Ring Contact your Emerson Process Management sales office 1 NACE trim constructions are available consult your Emerson Process Management sales office 2 PEEK stands for poly
17. Unidirectional shutoff Class VI reverse flow direction only bubble tight Fire Tested per API 607 Rev 4 For cryogenic seal applications consult your Emerson Process Management sales office Available Seal Configurations Standard Constructions See figure 2 and table 2 Standard Construction Materials See table 2 Flow Characteristic Equal percentage Flow Coefficients Contact your Emerson Process Management sales office Instruction Manual D103545X012 Flow Coefficient Ratio 2 100 to 1 Noise Levels See Catalog 12 for sound pressure level prediction Valve In Line Position Shaft horizontal See figure 4 Valve Actuator Action With diaphragm or piston rotary actuator field reversible between push down to close extending actuator rod closes valve and push down to open extending actuator rod opens valve Valve Body Classification NPS 14 to 24 Face to face dimensions are in compliance with MSS SP68 and API 609 standards Valve bodies are designed for installation between ASME B16 5 CL150 and CL300 raised face flanges NPS 30 to 36 Valve bodies are designed for installation between ASME B16 47 CL150 and CL300 raised face flanges Disk Rotation Clockwise to close when viewing from the drive shaft end through 90 degrees rotation Shaft Diameter and Approximate Weight See tables 3 and 4 ENVIRO SEALT Packing This optional packing system provides improved sealing guiding and transmission
18. are when driving the pins into the disk hub and shaft s Use the right tool Do not use excessive force 12 Install the appropriate tangential pins and disk pins Use 2 tangential pins that will go through the upper shaft and 1 disk pin that will go through the lower shaft 13 Refer to the Anti Blowout Design Packing Valve Shaft Disk and Bearing Maintenance procedures in this manual to re install the packing and anti blowout design Gasket Retainer Valves with a two piece shaft use a gasket retainer and gasket keys 20 and 21 to cover the lower shaft opening in the valve body The gasket is held in place by the gasket retainer and four hex head bolts and lockwashers keys 23 and 22 When re assembling the valve use a new gasket Be sure to center the gasket over the lower shaft bore before retightening bolts Tighten down bolts evenly in a Crossover or star pattern Refer to table 6 for proper torque values Parts Ordering Typical parts are shown in figure 9 When corresponding with your Emerson Process Management sales office about a Control Disk valve identify the valve as a Control Disk and provide the valve serial number For valve actuator combinations assembled at the factory the valve serial number is stamped on the nameplate attached to the actuator WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any
19. arings Use care when removing the valve disk to avoid loss of or damage to the thrust bearings 9 After removing the shaft s remove the disk Do not force the disk past the seal or T slot area Collect the thrust bearings 10 Remove the bearings key 7 Using a suitable punch or puller drive or pull the bearings into the valve body bore from the upper shaft bearing bore Remove the bearing from the lower shaft bearing bore 11 Inspect the valve body bore bearings bearing bores and packing box for damage Note In these instructions the drive shaft with splined end is called the upper shaft key 3 The shaft opposite the upper shaft is called the lower follower shaft key 4 Installing the Two Piece Shaft Key numbers in this procedure are shown in figure 9 unless otherwise indicated WARNING Avoid personal injury or property damage caused by the impact of a falling or tipping of a large valve Support large valves during maintenance 1 Properly secure the valve on a suitable worktable so it cannot slip twist or fall during maintenance Be prepared to support the valve disk Note Replacement disk and shafts are provided as a matched set and both should be replaced at the same time Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 2 Inspect all parts removed from the valve for wear or damage Replace any worn or damaged parts Clean the valve body and all parts to be installed with an appropr
20. bolting lengths shown by 0 25 inch Figure 4 Installation of Wafer Style Valves A5557 1 See figure 4 for recommended valve orientation e For Wafer Style Valves Install the lower flange bolts first to form a cradle for the valve see figure 5 See table 5 for flange bolt specifications e ForSingle Flange Valves Position the valve between the flanges Be sure to leave enough room for the flange gaskets Install the lower flange bolts 2 For all Valves Select the appropriate gaskets for the application Flat sheet spiral wound or other gasket types made to the ASME B16 5 standard or user s standard can be used on Control Disk valves depending on the service conditions of the application Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 Figure 5 Proper Installation Steps VALVE IN CLOSED POSITION DURING INSTALLATION OR REMOVAL TO PREVENT DAMAGE TO DISC SEALING AREA SHAFT HORIZONTAL FLANGE GASKETS BE SURE THESE ARE PIPE FLANGES CENTERED ALONG WITH OPENED ENOUGH TO ALLOW THE VALVE VALVE AND GASKETS TO SLIP EASILY INTO PLACE 1 FLANGE BOLTS FORMING A CRADLE FOR VALVE DURING INSTALLATION 1 BOLTS TIGHTENED EVENLY TO PREVENT GASKET LEAKAGE 3 For Wafer Style Valves Properly orient the valve according to the specific application Place the valve in the line so the flow properly enters the valve as indicated by the flow tag Then install the valve and the gaskets
21. cation 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 quarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore www Fshercom lt lt 4 lt lt Q4Q 000 EMERSON OFisher Controls International LLC 2011 All Rights Reserved
22. ches above the disk when it is screwed into a pin d After screwing the rod into the pin slide the spacer over the rod and pin Thread a nut onto the rod and tighten it As you tighten the nut the nut will drive the spacer against the disk The increasing force will draw the pin from the disk 17 Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 6 The gasket retainer key 20 on the side of the valve opposite the upper shaft must be removed before removing the lower shaft Remove the hex head bolts key 23 and lockwashers key 22 from the gasket retainer and remove the gasket retainer and gasket key 21 to expose the end of the lower shaft 7 Before removing the lower shaft key 4 be sure the valve disk is properly supported Pull the lower shaft from the valve body Use a shaft extractor screwed into the puller hole in the end of the lower shaft 8 Before removing the upper shaft key 3 be sure the valve disk is properly supported Pull out the upper shaft key 3 by hand pulling or by using a shaft extractor screwed into the end of the shaft CAUTION To avoid damage to the disk seal and T slot area do not force the disk past the seal or T slot area Remove the disk from the opposite side of the valve body Note Both the upper shaft and the lower shaft have a thrust bearing key 24 between the disk and the bearings key 7 The thrust bearing is located outside of the bearing bore which holds the be
23. complete refer to the Installation procedures in this manual UJ 4 Seal Maintenance Note For larger valves it is possible to replace the seal key 5 while the actuator is mounted to the valve and can be accomplished by cycling the valve to 90 degrees open Key numbers in this procedure are shown in figure 9 unless otherwise indicated 1 After removing the valve from the pipeline remove the manual or power actuator Manually rotate the upper shaft key 3 counterclockwise until the disk has moved a full 180 degrees away from the closed position WARNING Avoid personal injury or property damage caused by the impact of a falling or tipping of a large valve Support large valves during maintenance 13 Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 2 Lay the valve flat on a work bench in a secure position with the retaining ring key 18 and retaining ring screws key 19 facing up Properly secure the valve on a suitable worktable so it cannot slip twist or fall during maintenance Remove all retaining ring screws 3 Remove the retaining ring by placing a socket head cap screw from the retaining ring in each of the two retaining ring jacking screw holes Slowly turn the screws until the retaining ring has been lifted from the valve body Remove the retaining ring to expose the seal in the T slot area of the valve body Note The Control Disk valve is available with different seal designs and components
24. ding according to the following step 4 Attach the bonding strap assembly key 131 figure 6 to the shaft with the clamp key 130 figure 6 10 Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 5 Connect the other end of the bonding strap assembly to the valve flange cap screws 6 For more information refer to the Packing Maintenance section below Maintenance Valve parts are subject to normal wear and must be inspected and replaced as necessary The frequency of inspection and replacement depends upon the severity of service conditions Key numbers in this procedure are shown in figure 9 unless otherwise indicated WARNING Avoid personal injury from sudden release of process pressure Before performing any maintenance operations e Always wear protective gloves clothing and eyewear when performing any maintenance operations to avoid personal injury e 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 e Use bypass valves or completely shut off the process to isolate the valve from process pressure Relieve process pressure on both sides of the valve Drain the process media from both sides of the valve e Ventthe power actuator loading pressure e Use lockout procedures to be sure that the above measures stay in effect while you work on the equipment The valve packing box may contain
25. e to the gasket 4 Install the retaining ring and align the screw holes in the retaining ring with the holes in the valve body Install the first retaining ring screw through the punched hole in the ring gasket Install the other ring screws by pushing the screws through the graphite gasket and threading them into the valve body 5 Tighten the retaining ring socket head cap screws just enough to eliminate any movement of the retaining ring Do not over tighten the retaining ring screws WARNING Avoid personal injury or property damage caused by the impact of a falling or tipping of a large valve Support large valves during maintenance 6 To complete this step stand the valve up Support the valve securely using methods appropriate for the valve size If a vise or other clamps are being used be sure to not damage the flange gasket sealing area of the valve body 7 Manually rotate the upper shaft key 3 to turn the disk clockwise to meet the seal 8 Adjust the actuator to bring the disk to the fully closed position at the end of the actuator stroke To determine the fully closed disk position measure the distances between the disk face and the seal retainer face at the top and bottom of the valve X1 and X2 as shown in figure 3 Adjust the actuator to rotate the disk slightly until the two measurements are within 0 8 mm 0 032 inch of each other Refer to the appropriate actuator instruction manual for assistance 9 The final sea
26. earing bore so it is flush with the body bore 8 Insert the lower shaft through the bore in the valve body uncovered by removal of the gasket retainer Hold the lower shaft thrust bearing key 24 in the valve body bore against the counterbore of the lower shaft bearing bore Push the lower shaft into the bearing bore just enough to hold the thrust bearing CAUTION To avoid damage to the disk seal and T slot area do not force the disk past the seal or T slot area Install the disk from the opposite side of the valve body 9 Place the flat side of the disk on a flat surface and insert wooden blocks to raise the disk approximately 51 mm 2 inches from the worktable surface Then suspend the valve body over the disk so the seal T slot area is facing up Align the shaft bores through the disk with the upper shaft and lower shaft bores Lower the valve body over the disk using caution not to dislodge or damage the thrust bearings placed on the ends of the shafts 10 With the disk key 2 properly positioned in the valve body key 1 push the upper shaft and lower shaft the rest of the way through the thrust bearings and into the shaft bores in the valve disk 11 Align the holes in the shafts with the holes in the disk Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 CAUTION To avoid damage to the tangential pins disk pins valve disk or shaft s resulting from the application of excessive force use appropriate c
27. ether ether ketone 3 For a complete material description contact your Emerson Process Management sales office 4 UHMWPE stands for ultra high molecular weight polyethylene 5 Cast or wrought plate grades used interchangeably depending upon availability unless specified by customer 6 Seal rated for CL 150 pressures For fully rated CL300 seal rating use 521800 seal ring Installation The valve is normally shipped as part of a control valve assembly with the power actuator mounted on the valve If the valve or actuator has been purchased separately or if the actuator has been removed for maintenance mount the actuator on the valve and adjust actuator travel before installing the valve into the line This is necessary due to the measurements that must be made during the actuator calibration adjustment process Refer to the Actuator Mounting section of this manual and to the separate actuator instruction manual for mounting and adjusting instructions before proceeding WARNING To avoid personal injury or property damage resulting from the sudden release of pressure Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 e Always wear protective gloves clothing and eyewear when performing any maintenance operation e Do not install the valve assembly where service conditions could exceed the limits given in this manual or on the nameplates Use pressure relieving devices as required by governme
28. g goes into the T slot area of the body see figure 5 Start the edge with the wider diameter into the T slot of the valve body using a blunt end screwdriver If you have a maintenance kit use the seal installation tools Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 Figure 8 Typical Seal Installation LARGEST i OUTSIDE DIAMETER KEY 5 A5251 1 3 Carefully tuck the O ring downward into the body T slot until the seal ring is completely entrapped in the body T slot and it completely covers the backup O ring 4 Re install the retaining ring and the socket head cap screws Tighten the cap screws just enough to eliminate any movement of the retaining ring Do not over tighten the retaining ring screws Using a blunt end tool carefully tuck the lip of the seal ring under the retaining ring 5 When the seal is under the lip of the retaining ring continue to tighten the cap screws according to standard procedures Do not fully torque the screws at this time Final tightening of the screws is accomplished in step 7 of this procedure 6 Manually rotate the upper shaft clockwise 180 degrees to return the disk key 2 to its closed position 7 The final seating of the retaining ring cap screws can now be done For the screw torque values refer to table 6 The seal is now fully installed Refer to the Installation procedures in this manual NOVEX Phoenix IIl and or Phoenix Fire Tested Seals 1 Locate the
29. iate solvent or degreaser Note When installing the bearings apply lubricant to the outside diameter of the bearing for ease of installation CAUTION Premature valve failure and loss of process control may result if bearings are improperly installed or are damaged during installation 3 When installing the lower bearings key 4 insert one or more bearings into the lower shaft bearing bore so it is flush with the body bore The number of bearings required changes with valve size and construction Two bearings are required in the upper shaft and two bearings in the lower shaft If using an NPS 14 CL150 valve with metal bearings four bearings in the upper and four in the lower shaft will be required 4 Hold the lower shaft thrust bearing key 24 in the valve body bore against the counterbore of the lower shaft bearing bore Push the lower shaft into the bearing bore just enough to hold the thrust bearing 5 When installing the upper bearing key 7 insert one or more bearings into the upper shaft from the body bore into the bearing bore below the packing box Use caution to prevent damage to the bearing 6 Hold the upper shaft thrust bearing key 24 in the valve body bore against the counterbore of the upper shaft bearing bore Push the upper shaft through the packing box side into the bearing bore just enough to hold the thrust bearing 7 When installing the lower bearing key 4 insert one or more bearings into the lower shaft b
30. ipeline 2 Install a three valve bypass around the control valve assembly if continuous operation is necessary during inspection and maintenance of the valve 3 Inspect the valve to be certain that it is free of foreign material 4 Be certain that adjacent pipelines are free of any foreign material such as pipe scale or welding slag that could damage the valve sealing surfaces CAUTION Damage to the disk will occur if any pipe flanges or piping connected to the valve interfere with the disk rotation path If the piping flange has a smaller inner diameter than specified for schedule 80 piping measure carefully to be certain the disk rotates without interference before placing the valve into operation Minimum inside diameters for flanges or pipe mating with valves are shown in tables 3 and 4 Valve Orientation The valve can be installed in any orientation however it is recommended that the valve drive shaft be horizontal and the actuator vertical as shown in figure 4 Install the valve with the high pressure shutoff side in the direction noted by the flow arrow for proper installation and see figure 4 for more information Before Installing the Valve WARNING The edges of a rotating valve disk key 2 figure 9 close with a shearing cutting motion To avoid personal injury keep hands tools and other objects away from the disk while stroking the valve Instruction Manual Control Disk NPS 14 36 D103545X012 April 2
31. ities as shown in table 2 or figure 2 Refer to table 5 for the quantity and size of line bolting required to install the valve in the pipeline CAUTION To avoid damage to the valve disk during installation the valve must be in the fully closed position If the Control Disk valve is equipped with a fail open actuator remove the actuator before installing the valve actuator assembly or cycle the valve into the fully closed position Then take appropriate steps to be sure that the actuator does not cause the valve to open during installation Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 Table 5 Hex Head Screw Stud Bolt and Cap Screw Data Single Flange Style 1 4 25 35 ae 3 4 H mms 3 35 1088 fee 33 4 Ca 4 4 1088 ms E Wafer Style 1 1 8 8 1 1 4 8 4 4 5 5 KE ose 4 55 35 95 4 5 18 mw gt 8 3 3 mes ee 4 nm ps 3 3 3 mas 1348 45 s 3 amp amp a 28 s 5 1 Thread engagement in accordance with ASME B31 3 Chemical Plant and Petroleum Refinery Piping 2 Bolting lengths are based on installation of valve between standard raised face flanges and utilizing flange gaskets with a final compression thickness of 0 125 inch When gaskets used have a final compression thickness of less than 0 125 inch reduce
32. nt or accepted industry codes and good engineering practices to protect from over pressurizing the system Check with your process or safety engineer for any other hazards that may be present from exposure to process media If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section in this instruction manual CAUTION When ordered the valve configuration and construction materials were selected to meet particular pressure temperature pressure drop and controlled fluid conditions Responsibility for the safety of process media and compatibility of valve materials with process media rests solely with the purchaser and end user 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 Emerson Process Management sales office 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 shut off all pressure lines to the power actuator release pressure from the actuator and disconnect the pressure lines from the actuator Use lock out procedures to be sure that the above measures stay in effect while you are working on the equipment See the WARNING at the beginning of the Maintenance section for more information before removing the valve from the p
33. of loading force to control liquid and gas emissions Contact your Emerson Process Management sales office for availability of ENVIRO SEAL packing 1 The pressure temperature limits in this manual and any applicable code or standard limitation should not be exceeded 2 Ratio of maximum flow coefficient to minimum usable flow coefficient may also be called rangeability Description The valve is available in either a flangeless wafer body or a single flange lugged body design with a variety of seals and internal components The pressure assisted seal provides tight shutoff The upper splined shaft combines with a variety of pneumatic piston or spring and diaphragm actuators Maximum inlet pressure temperature ratings are consistent with CL150 and CL300 Instruction Manual D103545X012 Table 2 Material Temperature Ratings COMPONENT AND MATERIAL OF CONSTRUCTION 1 Body Steel WCC or SA 516 70 6 CF8M 316 SST CL150 CF8M FMS 20B16 0 0425 min carbon CL300 Disk CF8M 316 SST w or w o Hard coating CF8M with CoCr A edge Alloy 6 Shaft S20910 17400 17 4 PH H1025 17400 17 4 PH H1150M Bearings PEEK 2 standard 316000 Packing PTFE Packing and PTFE ENVIRO SEAL Packing Graphite packing Graphite packing with oxidizing media Graphite ENVIRO SEAL packing PTFE Seal Ring NBR Nitrile Backup O Ring CR chloroprene Backup O Ring EPR Backup O Ring Fluorocarbon Backup O Ring PTFE Backup O Ring UHMWPE
34. replacement seal ring key 5 and note the shape of the ring The ring is wider across one edge diameter and narrower across the other edge diameter as shown in figure 8 Around the outside circumference is one wide groove Install the seal ring key 5 in the valve body by first placing the wider outside diameter of the seal ring into the T slot area of the valve body which is shown in figure 2 The backup O ring key 6 for the Phoenix III seal will have to be installed after placement of the seal ring in the valve body using a blunt end screwdriver or the seal installation tool in the maintenance kit Do not use the screwdriver or seal tool directly on the metal seat Use tools on the O ring only Control Disk NPS 14 36 Instruction Manual April 2011 D103545X012 2 With the seal ring inserted all the way around the body T slot now lay the O ring into the opening between the valve body and the seal ring Use the seal tool to apply pressure to the O ring and carefully tuck the O ring down into the T slot between the valve body and the seal ring Note On larger valves it may be more efficient to have someone hold down the seal ring while you push the O ring into the T slot 3 Oncethe seal ring and backup O ring have been fully installed into the body T slot the retaining ring gasket can be installed This gasket is a thin graphite material Punch one initial screw hole through the gasket for alignment being careful not to cause additional damag
35. s Table 7 Retrofit and Repair Kit Part Numbers SHAFT RETROFIT KITS REPAIR KITS VALVE SIZE NPS PRESSURE RATING DIAMETER 1 2 M TEN PTFE PTFE SE 8101 1150 44 5 1 3 4 i CL300 63 5 2 1 2 RRTYXRT0642 RRTYX000222 CL150 50 8 2 RRTYXRT0652 RRTYX000182 24 CL150 63 5 2 1 2 RRTYXRT0662 RRTYX000222 30 36 No kit available 1 Shaft diameter Diameter through the packing box 2 For larger shaft sizes consult your Emerson Process Management sales office 21 Control Disk NPS 14 36 April 2011 Parts List Instruction Manual Key Description Note Part numbers are shown for recommended spares only For part NPS 30 numbers not shown contact your Emerson Process Management sales NPS 36 offica 14 Stud 2 req d 15 Hexnut 2req d 17 Nut 2 req d 18 Retaining Ring Er 19 Retaining Ring Screw Key Description Part Number 20 Gasket Retainer 1 Valve Body 21 Gasket See following table If you need a valve body as a replacement part order the 22 Lockwasher 4 req d valve size Class and desired material Contact your 23 Screw 4 req d Emerson Process Management sales office 24 Thrust Bearing See following table 2 Disk 26 Retaining Ring Gasket 3 Drive Shaft NOVEX and Phoenix III Seal 4 Follower Shaft Standard amp NACE 5 Seal Ring See following table CL150 6 Backup Ring See following table NPS 14 7 Bearing See following table NPS 16 9 Tangential Pin Disk Pin NPS 18 10 An
36. s during maintenance 2 Properly secure the valve on a suitable worktable so it cannot slip twist or fall during maintenance 3 Removing the Anti Blowout Design a For PTFE or Graphite Packing Remove the hex nuts key 15 and pull off the packing follower key 11 Remove the hex jam nuts key 17 and the anti blowout flange key 10 Remove the anti blowout gland key 12 See figure 7 b For ENVIRO SEAL Packing System Remove the hex nuts key 101 the packing follower key 102 jam nuts key 17 anti blowout flange key 10 and the spring pack assembly key 103 See figure 10 4 Remove the packing from around the upper shaft 5 Remove the tangential pins or disk pins Locate the pins key 9 in the upper shaft key 3 and the pin in the lower shaft key 4 if the valve has a two piece shaft a If a maintenance kit is available use the pin extractor to remove the disk pins Select the correct size pin extractor tip with screws of proper thread size to match the thread size in the disk pins If you do not have a kit see steps c and d below b Screw the pin extractor tip into the pin as far as possible With an upward straight sliding motion pull out the pin Repeat the same procedure for the other pins c You can use a threaded rod with an appropriate spacer tube and nut as an extractor tool If you use a threaded rod choose a rod with threads that fit the inside thread of the pins The rod should extend several in
37. ti Blowout Flange NPS 20 11 Packing Flange NPS 24 12 PackingFollower NPS 30 13 Packing Set NPS 36 PTFE V Ring CL300 CL150 NPS 14 NPS 14 V111433X012 NPS 16 NPS 16 V167865X012 NPS 18 NPS 18 V110460X012 NPS 20 NPS 20 V111437X012 NPS 24 NPS 24 V111699X012 NPS 30 NPS 30 V111704X012 NPS 36 NPS 36 V121811X012 Oxygen Service CL300 CL150 NPS 14 V111437X012 NPS 14 NPS 16 V110631X012 NPS 16 NPS 18 V111699X012 NPS 18 NPS 20 V111704X012 NPS 20 NPS 24 V111708X012 NPS 24 NPS 30 V121593X012 NPS 30 NPS 36 V122149X012 NPS 36 Graphite CL300 CL150 NPS 14 NPS 14 V111434X012 NPS 16 NPS 16 V167864X012 NPS 18 NPS 18 V111028X012 NPS 20 NPS 20 V111438X012 NPS 24 NPS 24 V111442X012 NPS 30 NPS 30 V111705X012 NPS 36 NPS 36 V129596X012 27 Screw Actuator 4 req d CL300 28 HexNut Actuator 4 req d NPS 14 V111438X012 29 Nameplate not shown NPS 16 V111696X012 32 Drive Screw 2 req d not shown NPS 18 V111442X012 33 Flow Direction Arrow not shown NPS 20 V111705X012 34 Packing Box Ring NPS 24 V111709X012 35 Disk Shaft Pin Assembly 22 Recommended spare parts D103545X012 Part Number V115138X012 V115155X012 V161467X012 V161468X012 V161469X012 V112062X012 V161471X012 V168292X012 V124869X012 V113741X012 V112064X012 V161469X012 V112062X012 V124867X012 V124882X012 V124883X012 V161467X022 V161468X022 V161469X022 V169962X012 V161471X022 V168292X022 V124869X022 V113741X022 V112064X022 V161469X022 V112062X022 V12468
38. ting of the retaining ring screws can now be done For the screw torque values refer to table 6 Anti Blowout Design Packing Valve Shaft Disk and Bearing Maintenance Note The Control Disk valve has a two piece shaft In these procedures the shaft with the splined end is called the upper shaft key 3 The shaft opposite the upper shaft is called the lower follower shaft key 4 CAUTION When removing the actuator from the valve do not use a hammer or similar tool to drive the lever off the valve shaft Driving the lever or actuator off the valve shaft could damage the valve internal parts Instruction Manual Control Disk NPS 14 36 D103545X012 April 2011 If necessary use a wheel puller to remove the lever or actuator from the valve shaft It is okay to tap the wheel puller screw lightly to loosen the lever or actuator but hitting the screw with excessive force could also damage internal valve parts Key numbers in this procedure are shown in figure 9 unless otherwise indicated 1 Remove the valve from the pipeline Remove the actuator from the valve CAUTION Never use a wrench pliers or similar tool to turn the upper shaft A damaged shaft can cut the packing and allow leakage Note It is not necessary to remove the retaining ring and valve seal when removing the shaft s and disk WARNING Avoid personal injury or property damage caused by the impact of a falling or tipping of a large valve Support large valve
39. use leakage 4 Before installing new packing clean the packing box 5 Install new packing one ring at a time using the packing follower as a driver If using split ring packing stagger the splits in the rings to avoid creating a leak path 6 Reinstall packing parts Refer to figure 9 for sequence of packing parts Removing the Valve 1 Disconnect any operating lines providing air pressure electric power or a control signal to the actuator Be sure the actuator cannot suddenly open the valve Vent the power actuator loading pressure 2 Use bypass valves or completely shut off the process to isolate the valve from process pressure Relieve process pressure on both sides of the valve Drain the process media from either side of the valve CAUTION Damage to the valve disk can occur if the disk is not closed when the valve is being removed from the pipeline If necessary stroke the actuator to place the disk in the closed position while removing the valve from the pipeline Loosen the flange bolting that holds the valve Make sure the valve cannot slip or twist while loosening and removing the bolting Before removing the valve from the pipeline make sure the valve disk is closed Removing the valve with the disk open could cause damage to the disk piping or pipe flanges 5 After removing the valve from the pipeline move the valve to an appropriate work area Always support the valve properly 6 When valve maintenance is
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