Emerson Fisher D3 FloPro Instruction Manual

Instruction Manual

D103221X012

Fisherr D3 FloPro Control Valve

D3 FloPro Valve

February 2014

Contents

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

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

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

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

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

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

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

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

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 Process Management sales office 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.

www.Fisher.com

D3 FloPro Valve

February 2014

Table 1. Specifications

Instruction Manual

D103221X012

Valve Body Sizes and End Connection Styles

(1)

See table 3

Maximum Inlet Pressures and Temperatures

MAXIMUM INLET

VALVE BODY SIZE

NPS 1 and NPS 2 NPT

CL900

NPS 1 and NPS 2 RF

CL600

PRESSURE

bar (psig) _C(_F)

155 (2250) -46 to 93 (-50 t o 200)
150 (2185) 93 to 149 (200 to 300)
103 (1500) -46 to 93 (-50 t o 200)
100 (1455) 93 to 149 (200 to 300)

Maximum Shutoff Pressure Drops

TEMPERATURE RANGE

(1)

(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

1. The pressure or temperature limits in the referencedtables and any applicable ASMEcode limitations should not be exceeded.

Maximum Travel

15 mm (0.6 inch)

Material Temperature Capabilities

Valve Body Assembly:
Standard O-Ring: -40 to 135C(-40to275F)

Actuator Assembly: -34 to 82C(-30to180F)

Flow Direction

Flow Up or Flow Down

Available Actuator Configurations

Spring-to-Open
Spring-to-Close

Maximum Actuator Casing Pressure

3.4 bar (50 psig)

Actuator Diaphragm Effective Area

329 cm

2

(51 square inches)

Actuator Pressure Connections

1/4 NPT internal

(1)

(1)

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

Up

Down

2

ACTUATOR

ACTION

Spring-to-Close

Spring-to-Open

Spring-to-Close

Spring-to-Open

INPUT SIGNAL

psi 0.375 0.75 1.00

0-20 3 2250 544 341
0-35 6 2250 1504 999
0-20 2 2250 935 608
0-35 2 2250 2250 2094
0-20 2 1558 1800 950
0-35 3 2250 2250 2250
0-20 2 2250 1700 939
0-35 3 2250 2250 1575

NUMBER OF

SPRINGS

MAXIMUM nP (PSI) PER PORT SIZE (INCH)

Instruction Manual

D103221X012

Table 3. Valve Sizes and Connection Styles

VALVE

SIZE,

NPS

1 0.375, 0.75, 1 X X

2 0.375, 0.75, 1 X X

X = Available construction.

PORT DIAMETER, (INCHES)

THREADED RAISED FACE (RF) FLANGED

CL900 CL600

Educational Services

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

Emerson Process Management
Educational Services - Registration
P.O. Box 190
Marshalltown, IA 50158-2823
Phone: [phone] or 641-754-3771
FAX: [phone]
e-mail: [e-mail]

D3 FloPro Valve

February 2014

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 Process Management sales office.

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

D3 FloPro Valve

February 2014

Instruction Manual

D103221X012

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

Installthevalvesotheflowdirectionarrowonthesideofthevalveindicatesthedirectionoftheprocessflow.

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
showninfigure8.

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

100%

50%

CLOSED

FULL CAPACITY SETTING (FACTORY SET)

15 mm (0.6 INCH) TRAVEL

REDUCED CAPACITY SETTING

10 mm (0.4 INCH) TRAVEL

100%

50%

CLOSED

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. Ensurethevalveplugisintheseatedposition.

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(26lbfSin).

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.

4

Instruction Manual

D103221X012

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

D3 FloPro Valve

February 2014

Maintenance

Refer to figures 7 and 8.

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. Isolatethecontrolvalvefromthelinepressure,releasepressure 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 t o 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.

5

D3 FloPro Valve

February 2014

Instruction Manual

D103221X012

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

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 t he 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

inchdriftpunchintheholesprovidedonthestemtokeepthestemfromturningastheplugisremoved.Donot
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

Becarefultoavoiddamagingtheseatingsurfaceonthevalveplugorseatringasdamageintheseareaswillallow
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. Isolatethecontrolvalvefromthelinepressure,releasepressure 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. Pressurizetheactuatortoamaximumof2.41bar(35psi)tostrokethevalvefullyclosed.Thiswillseatthevalve

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

6

Instruction Manual

D103221X012

D3 FloPro Valve

February 2014

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(26lbfSin).

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.

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 t he 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

inchdriftpunchintheholesprovidedonthestemtokeepthestemfromturningastheplugisremoved.Donot
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

Becarefultoavoiddamagingtheseatingsurfaceonthevalveplugorseatringasdamageintheseareaswillallow
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(60lbfSft). 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.

7

D3 FloPro Valve

February 2014

Figure 3. Packing and Belleville Spring Stacking Order

Instruction Manual

D103221X012

UPPER PACKING
SPACER (KEY12)

ANTI-EXTRUSION
WASHER (KEY10)

FEMALE PACKING
ADAPTER (KEY 11)

PACKING RING
(KEY 11)

MALE PACKING
ADAPTER (KEY 11)

ANTI-EXTRUSION
WASHER (KEY 10)

LOWER PACKING
SPACER (KEY12)

BELLEVILLE
SPRINGS (KEY 9)

VALVE PLUG INSTALLED WITHOUT PACKING RETAINER

Figure 4. Packing and Belleville Spring Stacking Order

UNTIGHTENED,
NOTE THE GAP

PACKING RETAINER
(KEY 8)

PIN (KEY 43)

VALVE
PLUG (KEY 3)

FULLY TIGHTENED,
NO GAP

BELLEVILLE SPRINGS FULLY ENCLOSED BY

THE PACKING RETAINER

8

VALVE PLUG, BELLEVILLE SPRINGS, AND PACKING RETAINER

CORRECTLY INSTALLED AND TIGHTENED