Emerson Fisher DSV1000 User manual

www.Fisher.com

Fisher™DSV1000 Full-Bore Ball Valve

Contents

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

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

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

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

Educational Services 2.........................

Installation 4..................................

Maintenance 5.................................

Packing Maintenance 6.........................

Stopping Leakage 6........................

Replacing Packing 6........................

Seal Ring Maintenance 8.......................

Valve Disassembly 8.......................

Valve Assembly 10.........................

Actuator Mounting 13...........................

Determining Closed Position 13.................

Parts Ordering 13...............................

Parts List 15...................................

Figure 1. Fisher DSV1000 Valve

X1492

Introduction

Scope of Manual

This instruction manual provides installation, operation, maintenance, and parts information for the Fisher DSV1000

Full-Bore Ball valve (see figure 1). Refer to separate manuals for information concerning the actuator, positioner, and

accessories.

Do not install, operate, or maintain a DSV1000 valve 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 before proceeding.

Description

The Fisher DSV1000 is a three piece, trunnion mounted, full-bore ball valve designed with features for isolation

shutoff. The DSV1000 comes standard with dual seal construction allowing unidirectional or bidirectional flow and

double block-and-bleed operation. The full-bore ball design presents little or no restriction to flow at full travel. The

DSV1000 construction meets ANSI / NACE MR0175 / ISO 15156 as standard.

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Table 1. Specifications

Valve Body Size

JNPS 6, J8, J10, J12, J14, J16, J20, and

J24

Body/Shell Pressure Rating(1)

JCL150, JCL300, and JCL600

pressure‐temperature ratings per ASME B16.34

Standard Materials of Construction

See table 2

Valve Temperature Capability

-40 to 82_C (-40 to 180_F)

End Connections

Raised Face per B16.5

Shaft Connection Style

Keyed

Face-to-Face Dimensions

Long Pattern per B16.10

Shutoff Classification

API 598

Flow Direction

Unidirectional or Bidirectional flow

Flow Characteristic

Modified equal percentage

Maximum Ball Rotation

90 degrees

Approximate Weight

See table 3

1. The pressure/temperature limits in this manual and any applicable standard or code limitation for valve should not be exceeded.

Educational Services

For information on available courses contact:

Emerson Automation Solutions

Educational Services - Registration

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

E-mail: [email protected]

emerson.com/fishervalvetraining

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Table 2. Standard Materials of Construction

Part Material

Valve Body LF2 Carbon Steel

Ball LF2 Carbon Steel / ENP

Seal Devlon with S31600 SST Seal Carrier

Drive Shaft S17400 H1150D

Spring N07750

Tailpiece LF2 Carbon Steel

Tailpiece Mounting and Packing Box Bolting L7M Steel

Bearing Plate LF2 Carbon Steel

Trunnion Bushings Carbon Steel, Bronze, PTFE

Thrust Washer Glass filled PTFE

Shaft Bushing N04400 / Comp

Packing Box Housing Carbon Steel

Packing Live-Loaded PTFE

Packing Bolting B7M Steel

Packing Follower, Packing Box Ring S31600 SST

Straight Pins S17400 H1150D

O Ring , Backup Rings Nitrile

Actuator Mounting Bolting Steel Grade 5

Table 3. Face‐to‐Face Dimensions and Approximate Weights

VALVE SIZE, NPS CLASS FACE‐TO‐FACE DIMENSIONS APPROXIMATE WEIGHT

mm Inches kg lbs

150 394 15.50 170 370

300 403 15.88 190 415

600 559 22.00 280 620

150 457 18.00 305 670

300 502 19.75 350 775

600 660 26.00 465 1020

150 533 21.00 430 950

300 568 22.38 495 1095

600 787 31.00 745 1640

150 610 24.00 645 1425

300 648 25.50 770 1695

600 838 33.00 1050 2320

150 686 27.00 1045 2305

300 762 30.00 1065 2350

600 889 35.00 1365 3015

150 762 30.00 1275 2810

300 838 33.00 1455 3210

600 991 39.00 1925 4250

150 914 36.00 2245 4945

300 991 39.00 2580 5685

600 1194 47.00 3450 7610

150 1067 42.00 3380 7450

300 1143 45.00 4280 9435

600 1397 55.00 5775 12740

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Installation

WARNING

DTo avoid personal injury, always wear protective gloves, clothing, and eyewear when performing any installation

operations.

DTo avoid personal injury or property damage resulting from the bursting of pressure retaining parts, be certain the

service conditions do not exceed the limits given in this manual.

DTo avoid personal injury or property damage that can result from the sudden release of process pressure if valve or

mating pipe flange pressure ratings are exceeded, provide a relief valve for over‐pressure protection as required by

government or accepted industry codes and good engineering practices.

DPersonal injury could result from packing leakage. See the Packing Maintenance section for adjustment information.

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

media.

DIf installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this

instruction manual.

DUse proper lifting and rigging practices while moving the valve or valve/actuator assembly.

Key number locations are shown in figures 4, 5, and 6, unless otherwise noted. Throughout this manual, the

component key number will be identified for clarity.

1. Install a three‐valve bypass around the valve assembly if continuous operation will be necessary during inspection

and maintenance of the valve.

2. The valve is normally shipped as part of a valve assembly, with a factory adjusted actuator mounted on the valve. If

the valve or actuator has been purchased separately, or if the actuator has been removed, refer to the Actuator

Mounting section and the appropriate actuator instruction manual for installation and adjustment procedures.

3. The standard valve construction allows uni-directional or bi-directional flow. If possible, install the valve in a

horizontal pipeline with the drive shaft vertical, however, the orientation of the valve does not affect the

performance.

NOTICE

Be certain the valve and adjacent pipelines are free of any foreign material that could damage the valve sealing surfaces.

4. Provide appropriate flange gaskets, and place the valve in the pipeline. Tighten flange bolting in a star pattern to

ensure the flange gaskets are compressed evenly.

Note

Standard Fisher DSV1000 live-loaded PTFE packing is composed of partially conductive packing rings (carbon‐filled PTFE male and

female adaptors) to electrically bond the drive shaft to the valve body. For hazardous area service, an alternate shaft‐to‐body

bonding strap is also available by using the following step (see figure 2).

5. For hazardous area applications where redundant shaft-to-body grounding is preferred, attach the optional

bonding strap assembly (key 45) to the valve drive shaft (key 4) with the clamp (key 44) and connect the other end

of the bonding strap assembly to the valve body with the mounting cap screw as shown in figure 2.

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Figure 2. Optional Shaft‐to‐Body Bonding Strap Assembly

VALVE BODY ACTUATOR

VIEW A-A

A3143-2

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.

WARNING

Avoid personal injury or equipment damage from sudden release of process pressure or uncontrolled movement of parts.

Before performing any maintenance operations:

DDo not remove the actuator from the valve while the valve is still pressurized.

DDo not loosen any pressure retaining bolting while the valve is still pressurized. This includes the body to tailpiece nuts

(key 21), packing box housing screws (key 10), packing nuts (key 36) or pipe plugs (keys 23 and 28).

DAvoid injury by keeping hands, tools, and other objects away from the ball while stroking the valve.

DAlways wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal

injury.

DDisconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Check the

actuator cannot suddenly open or close the valve.

DVent the power actuator loading pressure and relieve any actuator spring precompression.

DUse bypass valves or completely shut off the process to isolate the valve from process pressure, relieve any process

pressure from both sides of the valve body, and drain the process media from both sides of the valve.

DDual‐seal constructions can retain pressure and process fluid even after process pressure has been removed from both

sides of the valve. The ball should be partially opened to relieve this pressure before disassembling or removing the

valve from the line. Take additional care if the process fluid is hot, flammable, caustic, or hazardous.

DA tip over hazard exists for the valve/actuator assembly. Ensure the valve/actuator assembly is properly secured and

always supported to prevent falling or rolling which may cause injury or property damage.

DUse lock-out/tag-out best practices and procedures to be sure that the above measures stay in effect while you work on

the equipment.

DThe valve packing box housing 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.

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

media.

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Packing Maintenance

Refer to figure 3 for details of the standard live-loaded PTFE packing. All maintenance operations in this section may be

performed on an unpressurized valve that is still installed inline.

Note

For additional information on the live-loaded packing system refer to the ENVIRO-SEAL Packing System Instruction Manual

(D101643X012).

Stopping Leakage

Optimum performance of the PTFE live-loaded packing system is obtained when the Belleville springs are compressed

to the required “target load”. The target load is the point where the springs are compressed to 85% of their maximum

deflection.

Under normal conditions, the packing nuts should not require re‐tightening. However, when servicing, if the springs

do not remain at the target load of 85% compression, retighten the packing box nuts per the following:

1. Tighten the packing flange nuts alternately and evenly, keeping the packing flange parallel with the valve flange

(see figure 3), until the Belleville springs are compressed 100% (or completely flat).

a. For PTFE packing, loosen each packing flange nut one half turn (180_of rotation).

2. The target load of 85% compression has now been reached. If leakage continues, replace the packing components

and inspect the packing box housing bore and valve drive shaft for damage as described in the following

procedures.

Replacing Packing

Replacing the packing requires bleeding off the system and removing the actuator from the valve. Valve/actuator

adjustments cannot be made correctly without observing the fully open or closed position of the ball (key 3). It is not

necessary to remove the valve from the pipeline to make adjustments, if care is taken to note the position and

alignment of the shaft and coupler.

Refer to figure 3 which identifies the DSV1000 packing components by key number.

Packing Disassembly

1. Isolate the 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 (or other power source) to

the power actuator, release pressure from the actuator, and disconnect the pressure lines from the actuator. Use

lockout/tagout procedures to be sure that the above measures stay in effect while disassembling the equipment.

WARNING

DSee the WARNING at the beginning of the Maintenance section for more information before removing the valve from

the pipeline.

DUse proper lifting and rigging practices while moving the valve or valve/actuator assembly.

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Figure 3. Packing Arrangement Details

LIVE-LOADED

PACKING ARRANGEMENT

DRIVE SHAFT

(KEY 4)

PACKING FLANGE

(KEY 37)

SPRING PACK AND

FOLLOWER ASSEMBLY

(KEY 38)

ANTI-EXTRUSION

RING (KEY 32)

PACKING BOX

RING (KEY 34)

PACKING STUD AND NUT

(KEYS 35 AND 36)

PTFE V-RING

PACKING SET

(KEY 33)

B2472-1

E1659

2. To assist with future reassembly, note and mark the orientation of the actuator with respect to the valve body and

the coupler orientation with respect to the valve drive shaft.

3. Refer to the appropriate actuator instruction manual for information on removal.

4. Remove the actuator mounting screws, bolts, or nuts while properly supporting the actuator then separate the

actuator and mounting bracket from the valve.

5. If necessary, remove the bonding strap assembly, shown in figure 2, from the valve before removing the packing

parts.

6. Remove the packing follower nuts, packing flange, and spring pack and packing follower (keys 36, 37, and 38).

7. Remove the packing parts:

a. If the packing box housing (key 6) is mounted on the valve: Use a formed wire hook with a sharp end to pierce

the packing rings, and pull the rings out of the packing box housing. Do not scratch the drive shaft or packing

gland bore. Scratching these surfaces could cause leakage. Clean, inspect, and obtain replacement parts as

necessary for reassembly. Examine the drive shaft and packing gland bore for any signs of damage that may

prevent proper sealing.

b. If the packing box housing is separated from the valve (refer to Seal Ring Maintenance section of this manual for

disassembly instructions): Remove the drive shaft (key 4) from the packing box housing. With the drive shaft

removed, remove all internal packing parts. Clean, inspect, and obtain replacement parts as necessary for

reassembly. Examine the drive shaft and packing gland bore for any signs of damage that may prevent proper

sealing.

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

Packing Assembly

For additional information on the live-loaded packing system refer to the ENVIRO-SEAL Packing System Instruction

Manual (D101643X012).

1. If the packing housing box (key 6) is removed from the valve, use the valve assembly steps to reinstall the drive

shaft (key 4) and packing box housing assembly on the valve. (Refer to Seal Ring Maintenance section of this manual

for additional assembly instructions).

2. Place the new packing components over the drive shaft and slide each into the packing box housing until properly

seated at the bottom of the packing gland. Use the parts sequence shown in figure 3 and verify the Belleville springs

are in the correct configuration.

3. Secure the spring pack and packing follower assembly and packing flange with the packing nuts (keys 38, 37,

and 36).

4. Tighten the packing flange nuts alternately and evenly, keeping the packing flange parallel with the valve flange

(see figure 3), until the Belleville springs are compressed 100% (or completely flat).

a. For PTFE packing, loosen each packing flange nut one half turn (180_of rotation).

5. If necessary, install the bonding strap assembly shown in figure 2.

6. Use the steps provided in the Actuator Mounting section to install the actuator on the valve. For actuator travel

adjustments, refer to the appropriate actuator instruction manual.

7. When the valve is in operation, carefully examine the packing follower region for any signs of leakage.

Seal Ring Maintenance

WARNING

DSee the WARNING at the beginning of the Maintenance section for more information before removing the valve from

the pipeline.

DUse proper lifting and rigging practices while moving the valve or valve/actuator assembly.

Valve Disassembly

Refer to figures 4, 5, and 6 to identify the DSV1000 valve components by key number.

Disassemble the valve only to the extent necessary to accomplish the needed inspection and repairs. For some repairs

complete disassembly of the valve is not necessary. Follow the disassembly procedures to the point necessary to

accomplish the repair, then skip to the appropriate assembly steps to complete the reassembly of the valve. Always

clean and protect sealing surfaces from damage.

Mark parts as necessary to allow them to be returned to the same position and orientation as removed. The tailpiece,

for instance, shall be returned to the same end of the valve from which it was removed. The seal assembly shall also be

returned to the same tailpiece and in the same orientation from which it was removed.

1. Isolate the 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 lockout/tagout

procedures to be sure that the above measures stay in effect while working on the equipment.

2. Remove line bolting, remove the valve from the pipeline, and clean all valve surfaces. Place the actuator/valve

assembly on a flat working surface.

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

3. Mark parts as necessary to allow them to be returned to the same position during re‐assembly.

4. Refer to the appropriate actuator instruction manual for information on removal. Loosen the actuator mounting

screws, bolts, or nuts while properly supporting the actuator then separate the actuator and mounting bracket

from the valve. When valve maintenance is complete, refer to the Mounting Actuator procedure in this manual to

reinstall the actuator on the valve.

5. Provide a clean soft working surface to protect the tailpiece‐flange serrated surface. Lift the valve and place it on

either tailpiece flange face. Be sure the valve is in a stable, upright position before releasing the hoist connection.

Note

If the packing is in good condition, it is possible to remove and replace the seal assembly without removing the packing box

assembly. However, the packing box assembly must be removed to remove the ball (key 3) from the valve body.

6. Remove the packing box housing socket head cap screws (key 10).

a. If necessary, two packing box housing cap screws can be used as jack bolts to assist with separating the packing

box housing assembly from the valve.

b. Remove the two plastic plugs (key 39) from the packing box housing and install two packing box housing cap

screws until contact with the body occurs. Alternately and evenly, turn each fastener clockwise until the packing

box housing assembly is adequately separated from the valve body. Remove the packing box housing assembly

from the valve body. The packing box housing assembly includes all packing parts, drive shaft (key 4), O‐ring seal

(key 14), drive shaft bushing (key 8), and thrust washer (key 9). The two straight pins (key 7) may stay attached

to the packing box.

c. If necessary, use a punch and drive each straight pin towards the valve side of the packing box to remove.

7. If it is desired to separate the packing box assembly parts, loosen or remove the packing components and slide the

shaft down and out the valve side of the packing box. Inspect the drive shaft bushing (key 8) and the thrust washer

(key 9). If necessary, replace worn components.

8. Remove the heavy hex nuts (key 21) from the studs, if applicable, remove base brackets (key 25), and lift the upper

tailpiece from the body. If studs (key 19 and 20) are removed from the valve body, mark installed locations of long

studs (key 20) in valve body.

NOTICE

While lifting the tailpiece (key 2) from the valve body, check to see if the seal (key 5) is lifting with the tailpiece. If so, use

caution in case the seal falls out and protect the ball's spherical surface. An additional strap can be employed to ensure the

seal stays in place.

9. Turn the tailpiece assembly over so the seal is facing up, and place it on a clean soft surface to protect the flange

serrated surface. Note the tailpiece O-ring (key 13).

10. Lift the seal out of the tailpiece. Note the seal O-ring and back up ring (keys 15 and 16) and the multitude of springs

(key 18). Ensure all springs and the bearing plate dowel pins (key 22) are accounted for. Clean and protect all sealing

surfaces.

Instruction Manual

D104727X012

DSV1000 Valve

June 2022

WARNING

When lifting the ball, ensure the bearing plates (key 11) are secure on the ball trunnions to prevent parts from falling which

may cause personal injury or property damage.

Note

Refer to figure 6 and note the NPS6 CL150 construction is different than the balance of the DSV1000 product line in that it lacks

bearing plates and the ball design does not have male trunnions. Specific to the NPS6 CL150, ball removal also requires removal of

the follower trunnion (key 42) and fasteners (key 43).

11. Turn the ball (key 3) to the closed position. Use an approved lifting sling through the ball bore to lift the ball out of

the valve body. Lift the ball and set it on a clean soft surface.

12. Remove the two bearing plates (key 11) and thrust washers (key 17) from the ball. Inspect the lined bushing

(key 12) in each bearing plate and the thrust washers. If necessary, replace worn components.

13. Evenly loosen the heavy hex nuts (key 21) from the studs, if applicable, remove base brackets (key 25), and lift the

body (key 1) from the lower tailpiece (key 2).

14. Lift the seal out of the lower tailpiece. Note the seal O-ring and back up ring (keys 15 and 16) and the multitude of

springs (key 18). Ensure all springs and the lower bearing plate dowel pins (key 22) are accounted for. Clean and

protect all sealing surfaces.

Valve Assembly

Be sure to replace valve parts in the same position and orientation from which they were removed. Use the following

steps to reassemble the valve.

Note

Clean and protect all sealing surfaces from damage while installing parts. Lubricate components when necessary as an aid for

installation and to help protect sealing surfaces.

Refer to figures 4, 5, and 6 to identify the DSV1000 valve components by key number.

During assembly, visually inspect component surfaces that interface with an O-ring or seal for any damage that may

prevent proper sealing.

1. Place both tailpieces (key 2), flange end down on a clean soft surface with the seal assembly cavity facing up. Use

caution to protect the flange end serrated surfaces.

2. Lubricate the tailpiece counterbores where the seal will insert and inject lubricant into each of the spring holes.

Install the seal springs (key 18).

3. On both seals (key 5), install the O-ring (key 15) and backup ring (key 16) in the correct orientation (see figure 5

and 6.

4. Lubricate the seal O-rings and insert the seal assembly into the tailpiece counterbores. Maintain axial alignment of

the two components as the seal assembly is pushed into place.

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