Emerson Fisher D4 Instruction Manual
Instruction Manual
D103042X012
Fisherr D4 Control Valve Assembly
D4 Valve
November 2013
Contents
Introduction 1.................................
Scope of Manual 1.............................
Description 1.................................
Specifications 2...............................
Educational Services 2.........................
Installation 4..................................
Spring Adjustment 5............................
Maintenance 6.................................
Valve Plug and Seat Ring 6......................
Valve Packing 8...............................
Actuator 10..................................
Parts Ordering 14...............................
Repair Kits 17..................................
Parts List 17...................................
Appendix A 19.................................
Figure 1. Fisher D4 Control Valve
W8531
Introduction
Scope of Manual
This instruction manual provides installation, maintenance, and parts information for the Fisher D4 control valve.
Do not install, operate, or maintain a D4 control 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 Process Management sales office before
proceeding.
Description
The D4 control valve is a compact, rugged valve designed primarily for high-pressure throttling applications. This valve
is ideal for use on pressure and flow control applications within the oil and gas production industry. The D4 valve also
makes an excellent dump valve for high-pressure separators and scrubbers.
The D4 control valve meets the metallurgical requirements of NACE MR0175/ISO 15156 without environmental limits
for temperatures below 135_C(275_F). If the temperature is above 135_C (275_F), the N07718 Belleville washers will
impose some limits, as shown in table 3.
www.Fisher.com
D4 Valve
November 2013
Table 1. Specifications
Instruction Manual
D103042X012
Available Configurations
Spring-to-Close
Spring-to-Open
Valve Body Sizes and End Connection Styles
See table 2
Maximum Inlet Pressures and Temperatures
If the valve nameplate shows an ASME
(1)
(1)
Material Temperature Capabilities
Actuator Assembly: -40 to 93C(-40to200F)
Valve Body Assembly:
Standard Bonnet O-Ring: -40 to 135C(-40to275F)
Optional Fluorocarbon Bonnet O-Ring: -23 to 204C
(-10 to 400F)
Flow Characteristic
Equal percentage
pressure-temperature class, maximum inlet pressure
and temperature is consistent with the applicable
class per ASME B16.34. If the nameplate does not
show an ASME class, it will show a maximum cold
working pressure at 38_C(100_F) (for example, 293
bar [4250 psi])
Flow Direction
Flow up only
Port Diameters
See table 2
Maximum Pressure Drops
Seetables4,5,6,and7
(1)
Valve Plug Travel
19 mm (0.75 inch)
Input Signal to Actuator
Seetables4,5,6,and7
Valve Plug Style
Micro-Form valve plug
Actuator Maximum Casing Pressure
3.4bar(50psig)
(1)
Actuator Diaphragm Effective Area
452 cm
2
(69 inches2)
Shutoff Classification per ANSI/FCI 70-2
and IEC 60534-4
Class IV
1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations shouldnot be exceeded.
Actuator Pressure Connection Size
1/4 NPT internal
(1)
Specifications
Table 1 lists specifications for the D4 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 actuator spring barrel.
Educational Services
For information on available courses for Fisher D4 valves, as well as a variety of other products, contact:
Emerson Process Management
Educational Services, Registration
P.O. Box 190; 301 S. 1
Marshalltown, IA 50158-2823
Phone: 800-338-8158 or
Phone: 641-754-3771
FAX: 641-754-3431
e-mail: education@emerson.com
2
st
Ave.
Instruction Manual
D103042X012
Table 2. Valve Sizes and Connection Styles
VALVE
SIZE,
NPS
1
2
X = Available construction.
PORT
DIAMETER,
(INCHES)
0.25, 0.375,
0.5, 0.75
0.25, 0.375, 0.5
0.75, 1, 1.25
Table 3. D4 Environmental Limits for NACE MR0175/ISO 15156 with Sour Trim
MAXIMUM TEMPERATURE MAXIMUM H2S PARTIAL PRESSURE
_C _F MPa psia
232 450 0.2 30 No
204 400 1.4 200 No
199 390 2.3 330 No
191 375 2.5 360 No
149 300 2.8 400 No
135 275 No Limit Yes
SCREWED RAISED FACE (RF) FLANGED
4250 psi CL150 CL300 CL600
X X X X X X X
X X X X X X X
CL900 and
CL1500
D4 Valve
November 2013
RING TYPE JOINT
(RTJ) FLANGED
CL600
COMPATIBLE WITH
ELEMENTAL SULFUR?
CL900 and
CL1500
Table 4. Maximum S hutoff Pressure Drops
When Used with Typical Control Instrumentation
INPUT SIGNAL TO
ACTUATOR
SPRING Light Rate Heavy Rate
INITIAL SPRING
SETTING
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
1. The pressure or temperature limits in the referenced tables andany applicable ASME code limitations should not be exceeded.
2. For example, use the column marked 0-1.4 bar (0-20 psig)for a 0.21-1.0 bar(3-15 psig) pneumaticcontroller with 1.4 bar (20 psig) supply pressure.
3. For applications with downstream pressure in excess of 196 bar (2845 psig), use 196 bar(2845 psig) for Maximum Shutoff Pressure.
0.25
0.375
0.5
0.75
1
1.25
0to1.2Bar
(0 to 18 Psig)
0.77 Bar
(11.2 Psig)
(3)
293
(3)
293
191
80
42
25
4250
4250
2765
1160
610
365
(3)
(3)
Table 5. Maximum S hutoff Pressure Drops
When Used with Instrumentation with Restricted Output Range
INPUT SIGNAL TO
ACTUATOR
SPRING Heavy Rate Heavy Rate
INITIAL SPRING
SETTING
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
1. The pressure or temperature limits in the referenced tables andany applicable ASME code limitations should not be exceeded.
2.Forexample,anElectro-PneumaticTransducercalibratedfor0.4-2.0bar(6-30psig)outputpressure.
3. For applications with downstream pressure in excess of 118 bar (1715 psig), use 118 bar(1715 psig) for Maximum Shutoff Pressure.
0.25
0.375
0.5
0.75
1
1.25
293
210
113
(3)
(3)
45
23
13
(1)
0to1.4Bar
(0 to 20 Psig)
0.77 Bar
(11.2 Psig)
(3)
293
(3)
293
191
80
42
25
(1)
0.4 to 2.0 Bar
(6 to 30 Psig)
0.97 Bar
(14.0 Psig)
for Fisher D4 Control Valves (Spring-to-Close)
(2)
4250
4250
2765
1160
610
365
(3)
(3)
0to2.0Bar
(0 to 30 Psig)
0.85 Bar
(12.4 Psig)
293
293
219
92
49
30
4250
4250
3180
1340
715
430
0to2.3Bar
(0 to 33 Psig)
1.05 Bar
(15.3 Psig)
293
293
288
123
67
41
4250
4250
4180
1785
965
590
for Fisher D4 Control Valves (Spring-to-Close)
(2)
(3)
4250
3045
1635
655
330
185
(3)
293
293
282
120
65
39
0to2.4Bar
(0 to 35 Psig)
1.18 Bar
(17.1 Psig)
293
293
293
143
78
48
0.14 to 2.3 Bar
(2 to 33 Psig)
4250
4250
4250
2080
1130
700
1.17 Bar
(17.0 Psig)
0to3.4Bar
(0 to 50 Psig)
1.18 Bar
(17.1 Psig)
293
293
293
143
78
48
4250
4250
4095
1750
945
580
4250
4250
4250
2080
1130
700
3
D4 Valve
November 2013
Instruction Manual
D103042X012
Table 6. Maximum S hutoff Pressure Drops
When Used with Typical Control Instrumentation
INPUT SIGNAL TO
ACTUATOR
SPRING Light Rate Heavy Rate
INITIAL SPRING
SETTING
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
1. The pressure or temperature limits in the referenced tables andany applicable ASME code limitations should not be exceeded.
2. For example, use the column marked 0-1.4 bar (0-20 psig)for a 0.21-1.0 bar(3-15 psig) pneumaticcontroller with 1.4 bar (20 psig) supply pressure.
3. For applications with downstream pressure in excess of 190 bar (2760 psig), use 190 bar(2760 psig) for Maximum Shutoff Pressure.
0.25
0.375
0.5
0.75
1
1.25
0to1.2Bar
(0 to 18 Psig)
0.23 Bar
(3.4 Psig)
(3)
293
(3)
293
187
78
41
24
4250
4250
2715
1135
600
355
(3)
(3)
Table 7. Maximum S hutoff Pressure Drops
When Used with Instrumentation with Restricted Output Range
INPUT SIGNAL TO
ACTUATOR
SPRING Heavy Rate Heavy Rate
INITIAL SPRING
SETTING
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
1. The pressure or temperature limits in the referenced tables andany applicable ASME code limitations should not be exceeded.
2.Forexample,anElectro-PneumaticTransducercalibratedfor0.4-2.0bar(6-30psig)outputpressure.
3. For applications with downstream pressure in excess of 202 bar (2925 psig), use 202 bar(2925 psig) for Maximum Shutoff Pressure.
0.25
0.375
0.5
0.75
1
1.25
293
293
196
(3)
(3)
82
43
26
(1)
0to1.4Bar
(0 to 20 Psig)
0.23 Bar
(3.4 Psig)
(3)
293
(3)
293
233
99
53
32
(1)
0.4 to 2.0 Bar
(6 to 30 Psig)
0.69 Bar
(10.0 Psig)
for Fisher D4 Control Valves (Spring-to-Open)
(2)
4250
4250
3380
1430
765
465
(3)
(3)
0to2.0Bar
(0 to 30 Psig)
0.28 Bar
(4.0 Psig)
293
293
293
147
80
49
4250
4250
4250
2130
1160
715
0to2.3Bar
(0 to 33 Psig)
0.28 Bar
(4.0 Psig)
293
293
293
178
97
60
4250
4250
4250
2575
1410
875
for Fisher D4 Control Valves (Spring-to-Open)
(2)
(3)
4250
4250
2845
1195
630
380
(3)
293
293
293
156
85
52
0to2.4Bar
(0 to 35 Psig)
0.28 Bar
(4.0 Psig)
293
293
293
198
109
68
0.14 to 2.3 Bar
(2 to 33 Psig)
4250
4250
4250
2875
1575
985
0.42 Bar
(6.1 Psig)
0to3.4Bar
(0 to 50 Psig)
0.28 Bar
(4.0 Psig)
293
293
293
293
195
123
4250
4250
4250
2265
1235
765
4250
4250
4250
4250
2830
1785
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 tables 1, 4, 5, 6, and 7.
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.
4
Instruction Manual
D103042X012
D4 Valve
November 2013
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. 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.
WARNING
Avoid personal injury or property damage caused by possible actuator failure. The use of a rigidly-mounted support on the
actuator casing may cause additional stress on the actuator leading to premature wear and/or failure of the actuator
components.
CAUTION
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. Remove any pipe scale, welding slag, and other foreign material from the pipeline.
3. The control valve can be installed in any position, 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.
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 valves, use suitable
gaskets between valve and pipeline flanges.
5. If continuous operation is required during maintenance and inspection, install a conventional three-valve bypass
around the valve.
6. Connect loading pressure for the Spring-to-Open configuration to the 1/4-18 NPT connection in the upper casing
assembly (key 23) as shown in figure 5. The Spring-to-Close configuration loading pressure connection is in the
lower casing assembly (key 39) as shown in figure 4.
Spring Adjustment
The spring has a fixed pressure span over which loading pressure will stroke the valve. Adjustment of the spring
compression shifts the span so that more or less loading pressure is required to start travel. Since the span does not
change, there will be a corresponding increase or decrease inthepressurerequirementsattheendofthevalvestroke.
In order to maximize shutoff pressure drop values, the actuator spring must be accurately adjusted for each Input
Signal Pressure Range. If the actuator has been disassembled or pressure conditions have changed, the spring may
require adjustment. Refer to tables 2 and 4 to determine the Initial Spring Set values based on the Input Signal range
that is available to the actuator. These values include packing friction.
5
D4 Valve
November 2013
Instruction Manual
D103042X012
Spring-to-Close
Refer to figure 4.
1. Loosen the adjusting screw nut (key 44).
2. Turn the adjusting screw (key 31) clockwise to compress the spring or counterclockwise to decrease spring
compression.
3. After adjustment, tighten the adjusting screw nut (key 44).
Spring-to-Open
Refer to figure 5.
1. Unscrew the spring case assembly (key 27).
2. Turn the adjusting stem nut (key 44) clockwise to compress the spring or counterclockwise to decrease spring
compression.
3. After adjustment, replace the spring case assembly (key 27).
Maintenance
Refer to figure 4.
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 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 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
The D4 control valve is designed to allow easy access to the valve plug and seat ring without disturbing the packing.
Refer to other sections of this instruction manual if additional maintenance is required.
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Instruction Manual
D103042X012
D4 Valve
November 2013
Disassembly
1. Remove the loading pressure tubing and any accessories that may hamper disassembly.
2. Break the hammer nut (key 6) loose with a hammer. Continue turning the hammer nut by using a hammer or a
large adjustable wrench, tightened around one ear of the hammer nut. If the bonnet is stuck on the valve, continue
to unscrew the hammer nut. The hammer nut will contact the spring pins (key 7) and will force the bonnet out of
the valve. Carefully lift the actuator, bonnet, and valve plug assembly from the valve body.
WARNING
The spring pins must always be in place during valve operation. They provide a safeguard against injury when the unit is
being disassembled.
3. Use a socket wrench to loosen the seat ring (key 3).
4. Remove the seat ring (key 3) and seat ring gasket (key 9) from the valve body.
5. Inspect parts for wear or damage that would prevent proper operation of the valve body. Carefully clean the seat
ring gasket surfaces and seat ring threads.
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.
Table 8. Torque for Seat Ring (Key 3)
VALVE SIZE RECOMMENDED TORQUE
NPS NSm LbfSft
1 407 300
2 698 515
6. For spring-to-close only: To remove the valve plug (key 2), drive out the groove pin (key 4) and unscrew the valve
plug from the stem (key 47). If the groove pin (key 4) is not exposed, verify that downward movement of the stem is
not restricted by instrument linkages attached to the stem (key 47).
If the valve plug cannot be easily unscrewed from the stem, use a punch to keep the stem from turning as the plug is
removed.
7. For spring-to-open only: Toremovethevalveplug(key2),firstremovethespringcaseassembly(key27).Remove
the adjustment screw nut (key 44), the upper spring seat (key 29), and the spring (key 30). Push the adjustment
stem (key 31) fully downward until the diaphragm plate (key 40) contacts the cap screws (key 38), exposing the
groove pin (key 4) in the plug. If the groove pin (key 4) is not exposed, verify that downward movement of the stem
is not restricted by instrument linkages attached to the stem (key 47). Drive out the groove pin (key 4) and unscrew
the valve plug from the stem (key 47).
If the valve plug cannot be easily unscrewed from the stem, use a punch to keep the stem from turning as the plug is
removed.
Assembly
1. Make sure the bonnet O-ring (key 8) is on the bonnet and lubricated with lithium grease (key 49).
7
D4 Valve
November 2013
2. Install the plug (key 2) on the stem (key 47) and insert a new groove pin (key 4).
3. Thoroughly clean the seat ring and bonnet threads in the valve body (key 1). Also clean the valve body seat ring
gasket surfaces.
4. Apply anti-seize lubricant (key 54) to the threads of the seat ring (key 3), and its mating threads in the valve body.
5. Apply anti-seize lubricant (key 54) to the seat ring gasket (key 9) and install into the valve body.
6. Screw the seat ring into the valve body. Use a s ocket wrench to tighten the seat ring to the torque values shown in
table8.Removeallexcesslubricant after tightening.
7. Lubricate (key 54) the threads on the valve body and hammer nut and the contact surfaces of the bonnet and
hammer nut flange. Install the bonnet and actuator assembly with pinned valve plug onto the valve body. Tighten
the hammer nut using an adjustable wrench until the nut stops turning. A few hammer blows will be required to
ensure that the assembly is tight.
8. See the actuator assembly and spring adjustment sections of this manual.
Instruction Manual
D103042X012
Valve Packing
Note
These instructions apply to valves manufactured with serial numbers equal to and greater than 18679262. See Appendix A for
information on packing constructions with serial numbers less than 18679262.
If your D4 valve assembly has a packing retainer lock ring (see figure 6), proceed to Appendix A.
WARNING
Observe the warning at the start of the Maintenance section.
The valve stem packing can only be accessed from within the valve body. If packing maintenance is required, first
disassemble per steps 1, 2, and 6 or 7 in the Valve Plug and Seat Ring Disassembly section of this document.
Disassembly
1. Unscrew the packing retainer (key 10) from the bonnet (key 5).
2. Remove the five Belleville springs (key 11), packing spacer (key 14), packing (key 13), and two anti-extrusion rings
(key 12) from the bonnet, using a formed wire h ook.
3. Clean and inspect the packing box wall to ensure that thepackingsurfacesarenotdamaged.Ifthesurface
condition is damaged, and cannot be improved by light sanding, replace the bonnet by contacting your Emerson
Process Management sales office.
4. Inspect the valve stem for scratches or wear, and valve plug for wear or damage. Replace if necessary.
8
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