Emerson Fisher D3 User manual

www.Fisher.com

Fisher™D3 FloPro Control Valve

Contents

Introduction 1.................................

Scope of Manual 1.............................

Description 1.................................

Specifications 2...............................

Educational Services 3.........................

Installation 3..................................

Setting the Valve FloPro Flow Adjuster 4............

Maintenance 4.................................

Valve Plug and Seat Ring Maintenance 5..........

Packing Maintenance 10........................

Servicing the Actuator 12.......................

Changing Actuator Action 20....................

Parts Ordering 20...............................

Parts Kits 23...................................

Parts List 23...................................

Figure 1. Fisher D3 FloPro Control Valve

NPS 2 RF Flanged End Connection

W9249

Introduction

Scope of Manual

This instruction manual provides installation, maintenance, and parts information for the Fisher D3 FloPro control

valve and actuator.

Do not install, operate, or maintain D3 FloPro 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 sales office or Local Business Partner before

proceeding.

Description

The D3 FloPro control valve (figure 1) is a compact, rugged valve designed for on‐off control of a variety of fluids at

pressures up to 155 bar (2250 psig). This valve is ideal for use as a dump valve on gas separators and scrubbers. It is

also well suited for other high pressure applications in natural gas production, compression, and processing. NPS 1 and

NPS 2 D3 FloPro control valves are available in CL900 NPT end connections and CL600 raised face flanged end

connections.

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

Table 1. Specifications

Valve Body Sizes and End Connection Styles(1)

See table 3

Maximum Inlet Pressures and Temperatures(1)

VALVE BODY SIZE

MAXIMUM INLET

PRESSURE TEMPERATURE RANGE

bar (psig) _C (_F)

NPS 1 and NPS 2 NPT

CL900

155 (2250) -46 to 93 (-50 to 200)

150 (2185) 93 to 149 (200 to 300)

NPS 1 and NPS 2 RF

CL600

103 (1500) -46 to 93 (-50 to 200)

100 (1455) 93 to 149 (200 to 300)

Maximum Shutoff Pressure Drops(1)

See table 2

Shutoff Classification per ANSI/FCI 70‐2

and IEC 60534‐4

Class IV

Flow Characteristic / Valve Plug Style

Equal percentage / Micro‐Form Valve Plug

Port Diameters

See table 3

Maximum Travel

15 mm (0.6 inch)

Material Temperature Capabilities(1)

Valve Body Assembly:

Standard O-Ring: -40 to 135°C (-40 to 275°F)

Actuator Assembly: -34 to 82°C (-30 to 180°F)

Flow Direction

Flow Up or Flow Down

Available Actuator Configurations

Spring‐to‐Open

Spring‐to‐Close

Maximum Actuator Casing Pressure(1)

3.4 bar (50 psig)

Actuator Diaphragm Effective Area

329 cm2(51 square inches)

Actuator Pressure Connections

1/4 NPT internal

1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.

Specifications

Table 1 lists specifications for the D3 FloPro control valve. Some of the specifications for a given control valve as it

originally comes from the factory are stamped on a nameplate located on the upper diaphragm casing.

Table 2. Fisher D3 Maximum Shutoff Pressure Drops

FLOW DIRECTION ACTUATOR

ACTION

INPUT SIGNAL NUMBER OF

SPRINGS

MAXIMUM nP (PSI) PER PORT SIZE (INCH)

psi 0.375 0.75 1.00

Spring‐to‐Close 0‐20 3 2250 544 341

0‐35 6 2250 1504 999

Spring‐to‐Open 0‐20 2 2250 935 608

0‐35 2 2250 2250 2094

Down

Spring‐to‐Close 0‐20 2 1558 1800 950

0‐35 3 2250 2250 2250

Spring‐to‐Open 0‐20 2 2250 1700 939

0‐35 3 2250 2250 1575

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

Table 3. Valve Sizes and Connection Styles

VALVE

SIZE,

NPS

PORT DIAMETER, (INCHES)

THREADED RAISED FACE (RF) FLANGED

CL900 CL600

10.375, 0.75, 1 X X

20.375, 0.75, 1 X X

X = Available construction.

Educational Services

For information on available courses for Fisher D3 valves, as well as a variety of other products, contact:

Emerson Automation Solutions

Educational Services - Registration

Phone: 1-641-754-3771 or 1-800-338-8158

E-mail: [email protected]

emerson.com/fishervalvetraining

Installation

WARNING

Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal

injury.

To avoid personal injury or property damage caused by bursting of pressure‐retaining parts or by uncontrolled process

fluid, be certain the service conditions do not exceed the limits shown on the valve nameplate and in table 1. Use

pressure‐relieving devices required by government or accepted industry codes and good engineering practices.

Check with your process or safety engineer for any additional measures that must be taken to protect against 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 sales office or Local Business Partner.

To avoid product damage, inspect the valve before installation for any damage or any foreign material that may have

collected in the valve body. Also remove any pipe scale, welding slag, or other foreign material from the pipeline.

1. Before installing the control valve assembly, inspect it for any damage and for any foreign material that may have

collected in the valve body.

2. Clean out all pipelines to remove scale, welding slag, and other foreign materials.

3. The control valve assembly may be installed in any orientation, but normally the actuator is vertical above the valve.

Install the valve so the flow direction arrow on the side of the valve indicates the direction of the process flow.

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

4. Install the valve following local and national piping codes when they apply to the application. For screwed

connections, treat the external pipe threads with a good grade pipe compound. For flanged connections, use

suitable gaskets between valve and pipeline flanges.

5. If continuous operation is required during inspection or maintenance, install a three‐valve bypass around the

control valve assembly.

6. Connect loading pressure for the Spring‐to‐Close configuration to the lower casing assembly (key 21) as shown in

figure 7. The Spring‐to‐Open configuration loading pressure connection is in the upper casing assembly (key 32) as

shown in figure 8.

Figure 2. FloPro Adjusts to Vary Flow Capacity (Shown with Valve Plug in Seated Position)

FULL CAPACITY SETTING (FACTORY SET)

15 mm (0.6 INCH) TRAVEL

REDUCED CAPACITY SETTING

10 mm (0.4 INCH) TRAVEL

CLOSED

50%

100%

CLOSED

50%

100%

Setting the Valve FloPro Flow Adjuster

The flow setting may only be adjusted if the 0.375 and 0.75 inch port sizes are installed.

When shipped from the factory, the actuator has the FloPro flow adjuster set at the maximum flow rate position for

the given port size.

Spring‐to‐Close Actuator Action

1. Ensure the valve plug is in the seated position.

2. To change the valve flow rate, loosen the flow adjuster socket head cap screws (key 15), and reposition the flow

adjuster halves (key 13 and 14) to the desired flow rate position. See figure 2 for flow rate settings.

3. Retighten the socket head screws (key 15) to 3 NSm (26 lbfSin).

Spring‐to‐Open Actuator Action

1. Attach a pressure line to the actuator. Pressurize the actuator to a maximum of 2.41 bar (35 psi) to seat the plug in

the seat ring.

2. To change the valve flow rate, loosen the flow adjuster socket head cap screws (key 15), and reposition the flow

adjuster halves (key 13 and 14) to the desired flow rate position. See figure 2 for flow rate settings.

3. Retighten the socket head screws (key 15) to 3 NSm (26 lbfSin).

Maintenance

Refer to figures 7 and 8.

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

Valve parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection

and maintenance depends on the severity of the service conditions.

WARNING

Avoid personal injury from sudden release of process pressure or bursting of parts. Before performing any maintenance

operations:

D Do not remove the actuator from the valve while the valve is still pressurized.

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

on both sides of the valve. Drain the process media from both sides of the valve.

D Vent the power actuator loading pressure.

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.

D Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

Valve Plug and Seat Ring Maintenance

Trim Disassembly

Spring‐to‐Close (Air‐to‐Open)

Key numbers are referenced in figure 7.

1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body (key 1), and drain

the process media from both sides of the valve.

CAUTION

The following steps are intended to prevent damage to the valve plug (key 3) and seat ring (key 2) during the removal of

the bonnet and actuator.

2. Pressurize the actuator to a maximum of 2.41 bar (35 psi) to stroke the valve to mid travel. This will raise the valve

plug (key 3) off its seat and expose all of the serrations on the valve stem (key 16).

3. Loosen the hex socket head cap screws (key 15) and lower the flow adjuster (keys 13 and 14) to its lowest position

on the valve stem.

4. Tighten the hex socket head cap screws to 3 NSm (26 lbfSin).

5. Relieve pressure to the actuator, shut off all pressure lines to the actuator, and disconnect. Use lockout procedures

to ensure the above measures stay in effect while you work on the equipment.

6. Break the bonnet nut (key 5) loose with a hammer. Continue turning the bonnet nut by using a hammer or a large

adjustable wrench, tightened around one ear of the bonnet nut. If the bonnet (key 7) is stuck in the valve, continue

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

to unscrew the bonnet nut. The bonnet nut will contact the spring pins (or pipe plugs) (key 6, figures 7 or 8) and

jack the bonnet out of the valve. Carefully lift the actuator assembly from the valve body.

WARNING

The spring pins/pipe plugs (key 6) must always be in place during valve operation. They provide a safeguard against injury

when the unit is being disassembled.

7. Completely remove the packing retainer (key 8) using a 1‐1/8 inch wrench.

8. Remove the valve plug by driving out the pin (key 43) and unscrewing the valve plug from the stem. Utilize a 1/8

inch drift punch in the holes provided on the stem to keep the stem from turning as the plug is removed. Do not

remove the Belleville springs (key 9) from the stem, in order to retain the Belleville stacking orientation as shown in

figure 3.

9. Use a 1‐3/16 inch socket wrench to loosen and remove the seat ring (key 2).

CAUTION

Inspect the seat ring and valve body interior for wear, erosion, or damage in the following steps.

10. Inspect the seat ring for wear or damage. If the seating surface has been damaged, discard the seat ring.

11. Visually inspect the valve body interior below the seat ring for erosion or damage. Replace the valve body if

necessary.

WARNING

Be careful to avoid damaging the seating surface on the valve plug or seat ring as damage in these areas will allow

excessive leakage at shutoff. Avoid damaging the highly polished valve stem surface. A damaged valve stem could cut the

packing and allow process fluid to leak to the atmosphere.

Cover the opening in the valve body to prevent foreign material from getting into the valve body cavity.

Spring‐to‐Open (Air‐to‐Close)

Key numbers are referenced in figure 8.

1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body (key 1), and drain

the process media from both sides of the valve.

Note

The following steps are intended to ensure the groove pin is fully exposed below the bonnet to allow you to remove the pin before

removing the valve plug.

2. Pressurize the actuator to a maximum of 2.41 bar (35 psi) to stroke the valve fully closed. This will seat the valve

plug (key 3) and expose the top of the serrations on the valve stem (key 16).

3. Loosen the hex socket head cap screws (key 15) and raise the flow adjustor (keys 13 and 14) to its highest position

on the valve stem.

4. Tighten the hex socket head cap screws to 3 NSm (26 lbfSin).

5. Relieve pressure to the actuator and disconnect the air lines. Ensure the flow adjustor is touching the top of the

bonnet window. Use lockout procedures to ensure the above measures stay in effect while you work on the

equipment.

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

6. Break the bonnet nut (key 5) loose with a hammer. Continue turning the bonnet nut by using a hammer or a large

adjustable wrench, tightened around one ear of the bonnet nut. If the bonnet (key 7) is stuck in the valve, continue

to unscrew the bonnet nut. The bonnet nut will contact the spring pins (or pipe plugs) (key 6, figures 7 or 8) and

jack the bonnet out of the valve. Carefully lift the actuator assembly from the valve body.

WARNING

The spring pins/pipe plugs (key 6) must always be in place during valve operation. They provide a safeguard against injury

when the unit is being disassembled.

7. Completely remove the packing retainer (key 8) using a 1‐1/8 inch wrench.

8. Remove the valve plug by driving out the pin (key 43) and unscrewing the valve plug from the stem. Utilize a 1/8

inch drift punch in the holes provided on the stem to keep the stem from turning as the plug is removed. Do not

remove the Belleville springs (key 9) from the stem, in order to retain the Belleville stacking orientation as shown in

figure 3.

9. Use a 1‐3/16 inch socket wrench to loosen and remove the seat ring (key 2).

CAUTION

Inspect the seat ring and valve body interior for wear, erosion, or damage in the following steps.

10. Inspect the seat ring for wear or damage. If the seating surface has been damaged, discard the seat ring.

11. Visually inspect the valve body interior below the seat ring for erosion or damage. Replace the valve body if

necessary.

WARNING

Be careful to avoid damaging the seating surface on the valve plug or seat ring as damage in these areas will allow

excessive leakage at shutoff. Avoid damaging the highly polished valve stem surface. A damaged valve stem could cut the

packing and allow process fluid to leak to the atmosphere.

Cover the opening in the valve body to prevent foreign material from getting into the valve body cavity.

Trim Assembly

Spring‐to‐Close (Air‐to‐Open)

1. Ensure the threads of the valve stem (key 16) and valve plug (key 3) are clean and free of debris.

2. Make sure the Belleville springs (key 9) are properly installed on the valve stem, as shown in figure 3.

3. Install the valve plug on the stem and insert a new pin (key 43).

4. Lubricate the threads of the packing retainer with anti‐seize and install into the bonnet using a 1‐1/8 inch wrench.

Make sure the Belleville springs (key 9) are completely enclosed by the packing retainer as shown in figure 4.

5. Torque the packing retainer to 81 NSm (60 lbfSft). The packing retainer has been installed correctly when a

metal‐to‐metal contact has been made between the packing retainer end and the bonnet (key 7). The packing

retainer threads should be completely enclosed by the bonnet.

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

Figure 3. Packing and Belleville Spring Stacking Order

UPPER PACKING

SPACER (KEY 12)

ANTI‐EXTRUSION

WASHER (KEY 10)

PACKING RING

(KEY 11)

FEMALE PACKING

ADAPTER (KEY 11)

LOWER PACKING

SPACER (KEY 12)

BELLEVILLE

SPRINGS (KEY 9)

PIN (KEY 43)

MALE PACKING

ADAPTER (KEY 11)

ANTI‐EXTRUSION

WASHER (KEY 10)

VALVE

PLUG (KEY 3)

VALVE PLUG INSTALLED WITHOUT PACKING RETAINER

Figure 4. Packing and Belleville Spring Stacking Order

VALVE PLUG, BELLEVILLE SPRINGS, AND PACKING RETAINER

CORRECTLY INSTALLED AND TIGHTENED

BELLEVILLE SPRINGS FULLY ENCLOSED BY

THE PACKING RETAINER

PACKING RETAINER

(KEY 8)

UNTIGHTENED,

NOTE THE GAP

FULLY TIGHTENED,

NO GAP

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

Figure 5. Lubrication Locations on Packing

FEMALE PACKING ADAPTER

MALE PACKING ADAPTER

PACKING RING

LUBRICATE WITH 3mm (1/8 INCH

BEAD) OF SUPPLIED HIGH

PERFORMANCE FLUORINATED

GREASE (KEY 44)

LUBRICATE WITH 3mm (1/8 INCH

BEAD) OF SUPPLIED HIGH

PERFORMANCE FLUORINATED GREASE

6. Thoroughly clean the seat ring (key 2) threads and the mating threads in the valve body (key 1).

7. Apply anti‐seize lubricant to the threads of the seat ring and its mating threads in the valve body.

8. Screw the seat ring into the valve body. Use a 1‐3/16 inch socket wrench to tighten the seat ring to 170 NSm (125

lbfSft). Remove all excess lubricant after tightening.

9. Lubricate the bonnet O‐ring (key 4) with lithium grease and install on the bonnet.

10. Apply anti‐seize lubricant to the threads on the valve body and bonnet nut (key 5) and the contact surfaces of the

bonnet and bonnet nut flange. Install the bonnet and actuator assembly onto the valve body. Tighten the bonnet

nut until the nut stops turning. A few hammer blows will be required to ensure that the assembly is tight.

11. Pressurize the actuator to a maximum of 2.41 bar (35 psi) to stroke the valve to mid travel.

12. Loosen the hex socket head cap screws (key 15) and remove the flow adjuster (keys 13 and 14).

13. Relieve pressure to the actuator to fully close the valve.

14. Make sure the valve is fully seated and install the flow adjustor (keys 13 and 14) and hex socket head cap screws

(key 15).

15. Set the desired flow rate position according to figure 2.

16. Tighten the hex socket head cap screws to 3 NSm (26 lbfSin).

Spring‐to‐Open (Air‐to‐Close)

1. Ensure the threads of the valve stem (key 16) and valve plug (key 3) are clean and free of debris.

2. Make sure the Belleville springs (key 9) are properly installed on the valve stem, as shown in figure 3.

3. Install the valve plug on the stem and insert a new pin (key 43).

4. Lubricate the threads of the packing retainer with anti‐seize and install into the bonnet using a 1‐1/8 inch wrench.

Make sure the Belleville springs (key 9) are completely enclosed by the packing retainer as shown in figure 4.

5. Torque the packing retainer to 81 NSm (60 lbfSft). The packing retainer has been installed correctly when a metal to

metal contact has been made between the packing retainer end and the bonnet (key 7). The packing retainer

threads should be completely enclosed by the bonnet.

6. Thoroughly clean the seat ring (key 2) threads and the mating threads in the valve body (key 1).

7. Apply anti‐seize lubricant to the threads of the seat ring and its mating threads in the valve body.

8. Screw the seat ring into the valve body. Use a 1‐3/16 inch socket wrench to tighten the seat ring to 170 NSm (125

lbfSft). Remove all excess lubricant after tightening.

Instruction Manual

D103221X012

D3 FloPro Valve

June 2017

9. Lubricate the bonnet O‐ring (key 4) with lithium grease and install on the bonnet.

10. Apply anti‐seize lubricant to the threads on the valve body and bonnet nut (key 5) and the contact surfaces of the

bonnet and bonnet nut flange. Install the bonnet and actuator assembly onto the valve body. Tighten the bonnet

nut until the nut stops turning. A few hammer blows will be required to ensure that the assembly is tight.

11. Pressurize the actuator to a maximum of 2.41 bar (35 psi) to stroke the valve fully closed.

12. Loosen the hex socket head cap screws (key 15) and set the desired flow rate position according to figure 2.

13. Tighten the hex socket head cap screws to 3 NSm (26 lbfSin).

14. Relieve pressure to the actuator.

Packing Maintenance

WARNING

Observe the warning at the start of the Maintenance section.

Key numbers are referenced in figure 3.

The valve stem packing can only be serviced by removing the bonnet from the valve body.

Packing Disassembly

Spring‐to‐Close (Air‐to‐Open)

1. Disassemble the valve per steps 1 ‐ 8 in the Spring‐to‐Close Trim Disassembly section of the Valve Plug and Seat

Ring Maintenance section of this manual.

2. Remove the five Belleville springs (key 9), lower packing spacer (key 12), packing set (key 11), and two

anti‐extrusion washers (key 10) from the bonnet (key 7) using a formed wire hook.

3. Clean and inspect the packing box wall to ensure that the packing surfaces are not damaged. If the surface

condition is damaged and cannot be improved by light sanding, replace the bonnet.

4. Inspect the valve stem (key 16) and valve plug (key 3) for scratches or wear and replace if necessary.

Spring‐to‐Open (Air‐to‐Close)

1. Disassemble the valve per steps 1 ‐ 8 in the Spring‐to‐Open Trim Disassembly section of the Valve Plug and Seat

Ring Maintenance section of this manual.

2. Remove the five Belleville springs (key 9), lower packing spacer (key 12), packing set (key 11), and two

anti‐extrusion washers (key 10) from the bonnet (key 7) using a formed wire hook.

3. Clean and inspect the packing box wall to ensure that the packing surfaces are not damaged. If the surface

condition is damaged and cannot be improved by light sanding, replace the bonnet.

4. Inspect the valve stem (key 16) and valve plug (key 3) for scratches or wear and replace if necessary.

Packing Assembly

The following steps define the proper procedure for installing the packing in a D3 FloPro Control Valve. Improper

packing assembly can lead to poor valve performance. The proper packing arrangement is shown in figure 3.

Spring‐to‐Close (Air‐to‐Open)

1. Ensure the upper packing spacer (key 12) is installed.

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