Emerson Fisher SS-264 User manual

www.Fisher.com

Fisher™SS-264 Rotary Control Ball Valve

Contents

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

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

Description 2.................................

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

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

Principle of Operation 3.........................

Installation 3

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

Lifting Guidelines 5............................

Maintenance 7

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

Packing Maintenance 8.........................

Replacing Packing 8........................

Packing Load Adjustment 11................

Replacing the Trim Parts 11.....................

Troubleshooting 18.............................

Actuator Mounting 18

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

Actuator Mounting Instructions 24...............

Periodic FlowScanner™Testing 25..................

Parts Ordering 30................................

Parts List 30.....................................

Spare Parts 32.................................

Figure 1. Fisher SS-264 Valve with Bettis™

NG4020-SR3 Actuator and 3610J Positioner

09AA03200

Introduction

Scope of Manual

This instruction manual provides installation, operation, maintenance, and parts information for the Fisher SS-264

rotary control valve (see figure 1). It also outlines the assembly and testing procedures for the CL1725 SS-264 rotary

ball valve designed for use with the Bettis NG4020-SR3 rotary actuator.

The SS-264 valve is the passive residual heat removal valve for use in third generation PWR Nuclear Generating

Stations. The valve body has NPS 14 (AP1000, CAP1000) or NPS 16 (CAP1400) butt weld ends with a cammed ball

operating against a one-piece metal seal.

Features include the following:

D Cammed, segmented ball with hard faced seat band manufactured from forged bar.

D Fisher involute spline connection for ball/shaft and a keyed connection which is used for the Bettis actuator

connection.

D Tight tolerances and heavily loaded ball/seal interface.

Instruction Manual

D103565X012

SS-264 Valve

September 2021

Instruction Manual

D103565X012

SS-264 Valve

September 2021

Table 1. Specifications

Valve Sizes and End Connection Styles

SS-264: NPS 14 and NPS 16 valve with Schedule 160

butt weld ends

Standard Flow Direction

Forward (into the convex face of the ball)

Pressure Drop Limits(1,2)

Flowing: 120 psid

Shutoff: 53 psid

Max Temperature Limit(1)

426°C (800°F)

Maximum Ball Rotation

Standard: Ball rotates clockwise to close when viewed

from the top of the valve

Ball rotation is 90 degrees

Valve/Actuator Action

Clockwise to close on air stroke, counterclockwise to

open on spring stroke. See actuator manual for

details

Actuator Mounting

Counterclockwise to open

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

2. Exceeding pressure drop limits will begin to yield the metal seat ring and can cause deformation which may lead to excessive leakage though the valve seat.

D Emerson Automation Solutions designed liveloaded packing with positive stop screws controlling Belleville spring

deflection.

D The zero positioning of the ball is achieved by torque seating.

Do not install, operate, or maintain an SS-264 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 SS-264 ball valve (figure 1) is used in throttling or on‐off service. The SS-264 valve is an NPS 14 (AP1000, CAP1000)

or NPS 16 (CAP1400) schedule 160 buttweld construction, per customer specified weld end configuration

requirements. The keyed valve shaft of this valve connects to a Bettis spring-return actuator.

Specifications

Specifications for these valves are shown in table 1.

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

D103565X012

SS-264 Valve

September 2021

Principle of Operation

The ball and machined body combine to create smooth transitioning flow geometry which enables efficient flow

through the valve. The drive shaft and follower shaft center the ball in the flow stream to minimize dynamic torque

and permit easy ball rotation.

The ball rotates counterclockwise out of the seal to a standard open rotation of 90 degrees. The ball is cammed into

the seal to create an effective seal. The drive linkage between the ball and shaft has been designed for minimal lost

motion using a “spline connection” on the shaft and ball.

Table 2. Recommended Bolting Torques

Description, Key Number Size Wrench Size N•m lbf•ft

Seat ring to Body - Sckt Hd Cap Screw, 28 1/2-13 3/8 Allen 92 68

Body to Bonnet - Hex Nut, 117 2 1/2-8 3 3/4 10970 8090

Bonnet to Actuator - Hex Hd Cap Screw, 3 3/4-10 1 1/4 271 200

Washer to Drive Shaft - Hex Hd Cap Screw, 31 5/8-11 15/16 163 120

Travel stop hex nut, 1 1/8-8 1 1/2 136 100

Go Switch/Positioner Mounting

Go Switch Bracket to Actuator - Hex Hd Cap Screw 1/2-13 3/4 92 68

Namur Disc to Actuator - Sckt Hd Cap Screw M6 4mm 10.2 90 in•b

Trip Arm Bracket to Namur Disc - Sckt Hd Cap Screw M6 5mm 10.2 90 in•lb

Target Magnet to Trip Arm Bracket - Hex Nut 7/16-20 11/16 47 35

Go Switch to Go Switch Bracket- Hex Nut 5/8-18 15/16 47 35

Standoff - Pan Hd Mach Phillip Screw 6-32 Phillips 1.9 17 in•b

Travel Ind. Scale - Pan Hd Mach Phillip Screw 6-32 Phillips 1.9 17 in•lb

Positioner - Sckt Hd Cap Screws 5/16-18 5/16 23 17

546/67CFSR Mounting

546 Bracket to Actuator - Hex Hd Cap Screw 1/2-13 3/4 92 68

546 to Bracket - Hex Hd Cap Screw 5/16-18 1/2 23 17

67CFSR to Bracket - Hex Hd Cap Screw 5/16-18 1/2 23 17

Solenoid/2625 Booster Mounting

2625 Bracket to Actuator - Hex Hd Cap Screw 1/2-13 3/4 92 68

2625 V-blocks to Bracket - Hex Hd Cap Screw 5/16-18 1/2 23 17

Solenoid to Bracket - Hex Hd Cap Screw 5/16-18 1/2 23 17

Installation

Key numbers in installation procedures are shown in figure 18 unless otherwise indicated.

WARNING

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

injury.

Personal injury or equipment damage caused by sudden release of pressure may result if the valve assembly is installed

where service conditions could exceed either the valve body rating or the mating pipe flange joint rating. To avoid such

injury or damage, provide a relief valve for overpressure protection as 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.

Instruction Manual

D103565X012

SS-264 Valve

September 2021

WARNING

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. To avoid possible personal injury and because

some valve/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.

WARNING

The valve drive shaft is not necessarily grounded to the pipeline when installed. Personal injury or property damage could

result from an explosion caused by a discharge of static electricity from valve components if the process fluid or the

atmosphere around the valve is flammable. If the atmosphere around the valve or the process fluid is flammable,

electrically bond the drive shaft to the valve.

Note

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.

1. If the valve is to be stored before installation, protect the buttweld ends and keep the valve body cavity dry and free

of foreign material.

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

valve and actuator have been purchased separately or if the actuator has been removed, mount the actuator

according to the Actuator Mounting section.

3. Standard flow direction is forward flow, spherical face of the ball is upstream.

4. Install the valve in a horizontal pipeline with the drive shaft in the vertical position.

5. The actuator is counterclockwise to open with the shaft in a vertical orientation as shown in figure 1. If necessary,

refer to the appropriate actuator instruction manual for actuator installation and adjustment procedures.

CAUTION

Ensure the valve and adjacent pipelines are free of foreign material that could damage the valve seating surfaces.

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

surfaces.

7. Be sure the pipelines are in line with each other.

8. Use accepted pipeline piping and welding practices when installing the valve in the pipeline.

9. Connect pressure lines to the actuator.

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

additional measures that must be taken to protect against process media.

10. Verify that gap “A”, in figure 4, is closed before pressurizing the pipeline.

Instruction Manual

D103565X012

SS-264 Valve

September 2021

Lifting Guidelines

X0397

X0420

Figure 2. Lifting Guidelines

X0398

X0399

Instruction Manual

D103565X012

SS-264 Valve

September 2021

Figure 3. Lifting Guidelines (continued)

EYE BOLT

½-13UNC x 1.5

(NOT PROVIDED)

CAPSCREW

⅝-11UNC x 1.5

(NOT PROVIDED)

LIFTING PLATE

3.4

CAUTION

Care must be taken when lifting the valve/actuator assembly to ensure the accessories and tubing are not damaged in the

process. The entire NPS 14 assembly with accessories weighs approximately 3656 kg (8060 lb) and the entire NPS 16

assembly with accessories weighs approximately 3597 kg (7930 lb). Make sure to use appropriate lifting

straps/eyebolts/hoists capable of lifting this weight.

Lifting Valve/Actuator Assembly

To lift the assembly, insert 1-1/4-7 UNC swivel hoist rings into the four lifting hole locations on the outside diameter of

the bonnet flange. The lifting point must be high enough away from the top of the accessory mountings to prevent

damage to accessories or piping. The hbeam illustrated in figure 2 is adjustable axially along the pipe run in order to

lift at the center of gravity (CG) of the assembly. Two adjustable length chains on one side of the valve body ensure the

assembly is lifted vertically. Refer to the appropriate drawing for the CG of your assembly.

Lifting Actuator Only

WARNING

Do NOT attempt to lift the actuator while attached to the bonnet or valve body as this will damage components and could

cause bodily harm.

Instruction Manual

D103565X012

SS-264 Valve

September 2021

To lift the actuator, choke two straps, one around the spring barrel and one around the air cylinder, and connect to an

adjustable chain leveler. The chain leveler ensures the actuator and bonnet mating surfaces are parallel prior to

removal or installation. Proper alignment of the actuator and bonnet is critical to prevent binding of the shaft and

actuator. If accessories are not removed prior to lifting, use care to keep straps or chains away from piping and

accessories.

Alternatively, if the four actuator lifting lugs are accessible, chains can be used to lift the actuator. Similarly, the

actuator and bonnet mating surfaces must remain parallel.

Lifting Bonnet Only

To lift the bonnet, insert 1-1/4-7 UNC swivel hoist rings into the four lifting hole locations on the outside diameter of

the bonnet flange. Use proper length, or adjustable chains to ensure the bonnet and valve body mating surfaces

remain parallel when hoisted.

Lifting Valve Only

To lift the valve, insert two 2-1/2-8 swivel hoist rings, diametrically opposed and on opposite sides of the valve body

run, into the bodytobonnet bolt circle. An alternative to the swivel hoist rings is to use an internal thread lifting ring

which can be threaded onto the existing 2-1/2-8 studs (key 10).

Lifting Ball/Shaft Assembly

To lift the ball/shaft assembly, install the lifting plate (GE48210) and 5/811x1.50 cap screw (not provided) as shown in

figure 3. Align the lifting plate edge with the keyway groove of the shaft; this will position the lifting end of the plate

over the ball. Torque the cap screw to 163 N•m (120 ft•bf). Install a 1/2-13 eye bolt into the lifting end of the plate

and torque to 92 N•m (68 ft•lbf). Lift the ball/shaft assembly vertically out of the body, being careful not to damage

the sealing surface of the ball.

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.

The open and closed travel stops of the actuator do not require adjustment unless the bonnettobody joint is

loosened. If the actuator is removed for packing replacement, simply remount the actuator per the Actuator Mounting

section of this manual. If the bonnettobody joint is loosened for any reason, establish the zero position per the

Determining Closed Position section of this manual.

Key numbers in this procedure are shown in figure 18, unless otherwise noted.

WARNING

The ball closes with a shearing, cutting motion, which could result in personal injury. To avoid injury, keep hands, tools, and

other objects away from the ball while stroking the valve.

Avoid personal injury from sudden release of process pressure. Before performing any maintenance operations:

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

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.

Instruction Manual

D103565X012

SS-264 Valve

September 2021

D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure

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

D Vent the power actuator loading pressure and relieve any actuator spring precompression.

D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.

D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations.

D The valve packing area may contain process fluids that are pressurized. 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.

Packing Maintenance

Key numbers in this procedure are shown in figures 15 and 18 unless otherwise noted. A detailed view of the packing is

also shown in figure 4.

Refer to the Parts List section of this manual for individual parts.

If the packing is relatively new and tight on the drive shaft (key 8), and if tightening the packing nuts (key 16) does not

stop leakage, it is possible that the drive shaft is worn or nicked so that a seal cannot be made. If the leakage comes

from the outside diameter of the packing, it is possible that the leakage is caused by nicks or scratches on the packing

box wall. Inspect the drive shaft and packing box wall for nicks or scratches while performing the following procedure.

Replacing Packing

The open and closed travel stops of the actuator do not require adjustment unless the bonnettobody joint is

loosened. If the actuator is removed for packing replacement, simply remount the actuator per the Actuator Mounting

section of this manual.

Disassembly

WARNING

Observe the steps in the WARNING at the beginning of the Maintenance section.

1. Remove the actuator from the bonnet by removing the eight cap screws (key 18).

2. Remove the yoke key (key 103), coupler (key 102), and square key (key 15) from the drive shaft.

3. Loosen and remove packing nuts (key 16), packing flange (key 5), Belleville springs (key 6A), and the stop flange

(key 6C).

Note

Do not loosen or adjust the stop cap screws (keys 22 or 24) on the packing flange (key 5) or the stop flange (key 6C).

WARNING

Personal injury could result from packing leakage. Do not scratch the drive shaft or packing box wall while removing

packing parts in the following procedure.

Instruction Manual

D103565X012

SS-264 Valve

September 2021

4. Use packing removal tools to pull the packing set (key 11) out of the bonnet (key 7).

5. Carefully clean the drive shaft (key 8) and packing box bore of the bonnet (key 5). Using a flashlight, look into the

packing box bore and ensure all packing and residue are cleaned out.

6. Properly dry out the packing box bore of the bonnet (key 7) before repacking the valve.

WARNING

When the actuator is removed from the valve, the ball/shaft assembly may suddenly rotate with a shearing or cutting

motion, which could result in personal injury. To avoid injury, carefully rotate the ball to a stable position after the actuator

is removed.

Packing Installation

1. Refer to figures 4 and 15 and install the following parts in the packing box bore by aligning each parts ID with the

OD of the drive shaft. First, insert the packing box ring (key 19), then one antiextrusion ring, two graphite ribbon

packing rings, and lastly the other antiextrusion ring.

2. Install the packing follower/bushing assembly (key 25).

Note

If the stop screws and nuts (keys 22, 23 and 24) were adjusted during disassembly, refer to the Packing Adjustment section in this

instruction manual before proceeding.

3. If the stop screws (key 22) were not adjusted during disassembly skip to step 5.

4. Apply Loctite 242 (key 77) to the two 3/824x1.50 hex cap screws (key 22). Install the cap screws with two 3/824

hex nuts (key 23) in the stop flange (key 6C). Final stop screw lock position will be set with gauged clearance to the

packing flange.

5. Install the stop flange (key 6C) assembly against the packing follower/bushing assembly (key 6B).

6. Install three Belleville springs (key 6A) on top of the stop flange (key 6C). Orient the Belleville stack as shown in

figure 3 (top spring with large OD against packing flange (key 5)).

7. If the stop screws (key 24) were not adjusted during disassembly skip to step 9.

8. Apply Loctite 242, (key 77) to two 3/824x2.50 stop cap screws (key 24). Install the two stop cap screws (key 24)

with 3/8-24 hex nuts (key 23) in the packing flange (key 5). Final stop screw lock position will be set with gauged

clearance to the stop flange

9. Install the packing flange assembly on top of the Belleville springs (key 6A).

10. Lubricate the two 3/410x5.75 continuous thread packing box studs (key 20) with Nuclear Grade anti-seize

lubricant (key 36) and install into the bonnet (key 7).

11. Lubricate the threads and seating surface of the two 3/410 hex nuts (key 16) with Nuclear Grade anti-seize

lubricant (key 36) and install onto the packing studs (key 20).

12. Tighten the packing nuts (key 16) without torque until they are snug against the packing flange (key 5).

Note

Use care to keep the packing flange parallel to the stop flange (key 16). Reference figure 4.

Instruction Manual

D103565X012

SS-264 Valve

September 2021

13. If the stop screws (key 22 and 24) were not adjusted during disassembly, then check the Gap A and Gap B clearance

using the gap gage and adjust if necessary following Section Stop Screw Gap Settings steps 3 and 4; if adjustments

are not necessary, then proceed to Section Stop Screw Gap Settings step 5.

Figure 4. Positive Stop Packing Loading Method

GE51823

GAP GAGE

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