Emerson Process Management FISHER 657 User Manual

Instruction Manual
Form 1900 February 2007
657 Actuator (30-70 and 87)
Type 657 Diaphragm Actuator Sizes 30-70 and 87
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . .
Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Actuator on the Valve 4. . . . . . . . .
Discussion of Bench Set 5. . . . . . . . . . . . . . . . . . .
Spring Verification 5. . . . . . . . . . . . . . . . . . . . . . . .
Installing the Stem Connector Assembly 6. . . . .
Deadband Measurement 6. . . . . . . . . . . . . . . . . .
Loading Connection 8. . . . . . . . . . . . . . . . . . . . . . .
Actuator Maintenance 8. . . . . . . . . . . . . . . . . . . . .
Top-Mounted Handwheel Assembly 10. . . . . . . .
Side-Mounted Handwheel for Sizes 34
through 60 Actuators 11. . . . . . . . . . . . . . . . . .
Side-Mounted Handwheel for Sizes 70
and 87 Actuators 12. . . . . . . . . . . . . . . . . . . . . .
Casing-Mounted Adjustable Travel Stops 14. . .
Parts Ordering 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kits for Side-Mounted Handwheels 17. . . . . . . . .
Kits for Top-Mounted Handwheels 17. . . . . . . . .
Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Assembly (figures 6, 7, or 8) 17. . . . . .
Top-Mounted Handwheel (figures 9 or 10) 18. .
Side-Mounted Handwheel (figure 11 or 13) 18. .
Casing-Mounted Adjustable Up Travel Stops
(figures 14 or 15) 22. . . . . . . . . . . . . . . . . . . . . .
Casing-Mounted Adjustable Down Travel Stops
(figure 16) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
W2174-2/IL
Figure 1. Type 657 or 657-4 Actuator Mounted
through 70 and size 87. The Type 657-4 actuator in sizes 70 and 87 is also covered. Refer to separate instruction manuals for information about the valve positioner and other accessories used with these actuators.
on an easy-e
R
Valve
Introduction
Scope of Manual
This instruction manual provides information on installation, adjustment, maintenance, and parts ordering for the Type 657 actuator in sizes 30
www.Fisher.com
Do not install, operate, or maintain a Type 657 actuator without first D being fully trained and qualified in valve, actuator, and accessory installation, operation, and maintenance, and D carefully reading and understanding the contents of this manual. If you have any questions about these instructions, contact your Emerson Process Managementt sales office before proceeding.
D100306X012
Instruction Manual
(1)
Acceptable Valve
Maximum Allowable
(2)
Maximum Diaphragm
Material Temperature
Pressure Connections
Form 1900
657 Actuator (30-70 and 87)
Table 1. Specifications
SPECIFICATION
2
Nominal Effective Area
Yoke Boss Diameters
Acceptable Valve
Stem Diameters
Maximum Allowable
Output Thrust
Maximum Travel
Maximum Casing
Pressure for
Actuator Sizing
Maximum Diaphragm
Casing Pressure
Material Temperature
Capabilities
Pressure Connections
(female)
Approximate Weights
1. These values also apply to the Type 657-4 actuator construction.
2. Actuator travel may be less than the value listed after connecting the actuator to the valve.
3. Maximum travel for Type 657-4 is 102 mm (4 inches).
4. Normal operating diaphragm pressure must not exceed maximum diaphragm casing pressure and must not produce a force on the actuator stem greater than the maximum allowable output thrust or the maximum allowable valve stem load. Contact your Emerson Process Management sales office with questions concerning maximum allowable valve stem load.
5. This maximum casing pressure is not to be used for normal operating pressure. Its purpose is to allow for typical regulator supply settings and/or relief valve tolerances.
(4)
(4)
(4)(5)
cm
2
Inch
mm 54 54 71 71 71 90 90 90 127
Inches 2-1/8 2-1/8 2-13/16 2-13/16 2-13/16 3-9/16 3-9/16 3-9/16 5
mm 9.5 9.5 12.7 12.7 12.7 19.1 19.1 19.1 25.4
Inches 3/8 3/8 1/2 1/2 1/2 3/4 3/4 3/4 1
N 10230 10230 12010 25131 33582 25131 30246 39142 39142
Lb 2300 2300 2700 5650 7550 5650 6800 8800 8800
mm 19 29 38 51 51 51 51 76
Inches 0.75 1.125 1.5 2 2 2 2 3
Bar 8.6 4.5 4.5 3.4 2.8 3.4 2.8 3.8 3.8
Psig 125 65 65 50 40 50 40 55 55
Bar 9.6 5.2 5.2 4.1 3.4 4.1 3.4 4.5 4.5
Psig 140 75 75 60 50 60 50 65 65
_C Nitrile Elastomers: –40 to 82_C, Silicone Elastomers: –54 to 149_C, Fluorocarbons: –18 to 149_C
_F Nitrile Elastomers: –40 to 180_F, Silicone Elastomers: –65 to 300_F, Fluorocarbons: 0 to 300_F
1/4 In. NPT X X X X X X X - - - - - -
1/2 In. NPT - - - - - - - - - - - - - - - - - - - - - X X
kg 16 22 23 37 49 42 53 107 116
Lb 36 48 51 82 107 92 116 235 255
30 34 40 45 46 50 60 70
297 445 445 677 1006 677 1006 1419 1419
46 69 69 105 156 105 156 220 220
ACTUATOR SIZE
February 2007
(1)
(3)
(3)
87
76
(1)
(3)
(3)
3
Note
Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use, and maintenance of any product remains with the purchaser and end-user.
Description
The Type 657 actuator (figure 1) and the Type 657-4 actuator are direct-acting, spring-opposed diaphragm actuators. They provide automatic operation of control valve body assemblies. The Type 657 actuator offers 76 mm (3 inches) maximum actuator travel. The Type 657-4 actuator provides 102 mm (4 inches) maximum actuator travel. Both actuators position the valve plug in response to varying pneumatic loading pressure on the actuator diaphragm. Figure 2 shows the operation of these actuators.
A Type 657 or 657-4 actuator can be equipped with either a top-mounted or a side-mounted handwheel
assembly. A top-mounted handwheel assembly is used as an adjustable up travel stop to limit actuator travel in the up direction (see figure 2). A side-mounted handwheel assembly is usually used as an auxiliary manual actuator. Adjustable casing-mounted up or down travel stops are also available for this actuator.
Note
If repeated or daily manual operation is expected, the actuator should be equipped with a side-mounted handwheel rather than a casing-mounted travel stop or top-mounted handwheel.
The side-mounted handwheel is designed for more frequent use as a manual operator.
Specifications
Refer to table 1 for Specifications of the Type 657 and 657-4 actuators. See the actuator nameplate for specific information about your actuator.
2
Instruction Manual
Form 1900 February 2007
657 Actuator (30-70 and 87)
AIR PUSHES STEM DOWN
SPRING LIFTS STEM UP
STEM
AF3833-A A0792-2/IL
Figure 2. Schematic of Type 657 and 657-4 Actuators
Installation
Key number locations are shown in figures 6, 7, and 8, unless otherwise indicated. Also, refer to figure 3 for location of parts.
WARNING
Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal injury.
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.
NPT FEMALE CONNECTION
DIAPHRAGM CASING
DIAPHRAGM AND STEM SHOWN IN UP POSITION
DIAPHRAGM PLATE
LOWER DIAPHRAGM CASING
ACTUATOR SPRING
ACTUATOR STEM
SPRING SEAT
SPRING ADJUSTOR
STEM CONNECTOR
YOKE
TRAVEL INDICATOR DISK
INDICATOR SCALE
W0363–1/IL
VALVE STEM
YOKE LOCK NUT
YOKE BOSS DIAMETER
BONNET
TYPICAL VALVE (REFER TO VALVE MANUAL)
W6199–1/IL
Figure 3. Actuator Mounting Components for Size 30
through 70 Actuators
MATCH LINE FOR ACTUATOR
CAUTION
To avoid parts damage, do not use an operating pressure that exceeds the Maximum Diaphragm Casing Pressure (table 1) or produces a force on the actuator stem greater than the Maximum Allowable Output Thrust (table 1) or the maximum allowable valve stem load. (Contact your Emerson Process Management sales office with questions concerning maximum allowable valve stem load.)
D Valve/Actuator Assembly: If the actuator and valve are shipped together as a control valve assembly, it has been adjusted at the factory, and may be installed in the pipeline. After installing the valve in the pipeline, refer to the Loading Connection procedures.
D Actuator Mounting: If the actuator is shipped separately or the actuator has been removed from the valve, it is necessary to mount the actuator on the valve before placing the valve in the pipeline. Refer to the actuator mounting procedures before placing the valve in service. You may perform the Bench Set Spring Adjustment procedures in this
3
657 Actuator (30-70 and 87)
Instruction Manual
Form 1900
February 2007
SPRING ADJUSTER
LOWER BENCH SET LOADING PRESSURE
UPPER BENCH SET PRESSURE MARK
NOTES:
1
THE LOWER PSIG LOADING PRESSURE (MARKED ON NAMEPLATE)
WHERE THE FIRST MOVEMENT OF ACTUATOR STEM IS DETECTED.
2
THE UPPER PSIG LOADING PRESSURE EXTEND ACTUATOR STEM.
3
MARK THIS POINT WITH TAPE OR A MARKER. MEASURE DISTANCE OF TRAVEL. IT SHOULD EQUAL THE TRAVEL SPAN
4
SHOWN ON THE TRAVEL INDICATOR SCALE.
40A8715–B B2426 / IL
VALVE STEM
1
3
RATED VALVE TRAVEL MEASURE
4
MARK VALVE STEM HERE
Figure 4. Bench Set Adjustment
section to confirm that the adjustment has not changed since it was shipped from the factory.
D Positioner: If a positioner is installed, or is to be installed on the actuator, refer to the positioner instruction manual for installation. During the adjustment procedures, it will be necessary to provide a temporary loading pressure to the actuator diaphragm.
Mounting the Actuator on the Valve
The Type 657 actuator spring loading pushes the actuator stem up towards the actuator diaphragm (see figure 2). This spring action moves the stem away from the valve while installing the actuator.
CAUTION
If the valve stem is allowed to remain in the up position (towards the actuator) during mounting, it can interfere with the actuator mounting, possibly damage valve stem threads or bend the valve stem. Be sure the valve stem is pushed down (into the
ACTUATOR STEM
UPPER BENCH SET
3
2
LOADING PRESSURE
valve body), away from the actuator while mounting.
Provide a temporary method of applying diaphragm loading pressure to the diaphragm to extend the actuator stem during bench set spring adjustments.
1. Provide a vise or some other method of supporting the valve and the weight of the actuator during assembly. For direct or reverse acting valves, push the valve stem down away from the actuator while mounting the actuator.
2. Screw the stem locknuts all the way onto the valve stem. With the concave side of the travel indicator disk (key 14) facing the valve, install the travel indicator disk on the valve stem. (Note: The travel indicator disk is not used with size 87 actuators.)
3. Lift or hoist the actuator onto the valve bonnet:
a. For size 87 actuators, insert the cap screws and tighten the hex nuts, securing the actuator to the bonnet.
b. For all other size actuators, screw the yoke locknut onto the valve bonnet and tighten the locknut. (Note: On small size actuators, it may be necessary to remove the indicator disk and re-install it while lowering the actuator on to the
4
Instruction Manual
Form 1900 February 2007
657 Actuator (30-70 and 87)
valve because the disk will not go through the actuator yoke opening).
4. Do not connect the actuator stem to the valve stem at this time. Whenever the actuator is installed on the valve, it is recommended to perform the Bench Set Spring Adjustment procedure to verify that the actuator is still adjusted correctly.
Discussion of Bench Set
The bench set pressure range is used to adjust the initial compression of the actuator spring with the valve-actuator assembly “on the bench.” The correct initial compression is important for the proper functioning of the valve-actuator assembly when it is put into service and the proper actuator diaphragm operating pressure is applied.
The bench set range is established with the assumption that there is no packing friction. When attempting to adjust the spring in the field, it is very difficult to ensure that there is no friction being applied by “loose” packing.
Accurate adjustment to the bench set range can be made during the actuator mounting process by making the adjustment before the actuator is connected to the valve (see the Spring Verification Procedure).
If you are attempting to adjust the bench set range after the actuator is connected to the valve and the packing tightened, you must take friction into account. Make the spring adjustment such that full actuator travel occurs at the bench set range (a) plus the friction force divided by the effective diaphragm area with increasing diaphragm pressure or (b) minus the friction force divided by the effective diaphragm area with decreasing diaphragm pressure.
For an assembled valve-actuator assembly, the valve friction may be determined by following the procedure described below:
1. Install a pressure gauge in the actuator loading pressure line that connects to the actuator diaphragm casing.
Note
Steps 2 and 4 require that you read and record the pressure shown on the pressure gauge.
2. Increase the actuator diaphragm pressure and read the diaphragm pressure as the actuator reaches its mid-travel position.
3. Increase the actuator diaphragm pressure until the actuator is at a travel position greater than its mid-travel position.
4. Decrease the actuator diaphragm pressure and read the diaphragm pressure as the actuator reaches its mid-travel position.
The difference between the two diaphragm pressure readings is the change in the diaphragm pressure required to overcome the friction forces in the two directions of travel.
5. Calculate the actual friction force:
Friction Force, = 0.5 pounds
Difference in pressure readings, psig
Effective
diaphragm area, inches
2
Refer to table 1 for the effective diaphragm area.
When determining valve friction, you can make diaphragm pressure readings at a travel position other than mid-travel if you desire. If you take readings at zero or at the full travel position, take extra care to ensure that the readings are taken when the travel just begins or just stops at the position selected.
It is difficult to rotate the spring adjustor (key 12, figure 6, 7, and 8) when the full actuator loading pressure is applied to the actuator. Release the actuator loading pressure before adjusting. Then re-apply loading pressure to check the adjustment.
Spring Verification
Ensure that the actuator stem is at the top of its travel as shown in figure 4 and not connected to the valve. (Note: Some spring compression is required to move the diaphragm to the top of its travel.) The bench set steps provided are the same for direct or reverse acting valves.
WARNING
When moving the actuator stem with diaphragm loading pressure, use caution to keep hands and tools out of the actuator stem travel path. Personal injury and/or property damage is possible if something is caught between the actuator stem and other control valve assembly parts.
Also, provide a certified pressure gauge suitable to accurately read the diaphragm pressure from 0 through the upper bench set pressure marked on the
5
657 Actuator (30-70 and 87)
Instruction Manual
Form 1900
February 2007
nameplate. Apply loading pressure to the diaphragm.
CAUTION
Stroke the actuator a few times to ensure that the pressure gauge is working correctly, and that the actuator is functioning properly. To prevent product damage, it is important to be sure that the actuator assembly is not any loading friction on the actuator stem movement.
1. If not already accomplished, provide a temporary means of applying an adjustable loading pressure to the actuator during bench set adjustments.
2. Set the diaphragm loading pressure at 0 psig. Then, slowly raise the pressure from 0 psig towards the lower bench set pressure while checking for the first movement of the actuator stem. The actuator stem should show movement at the lower bench set pressure. If movement occurs before or after the lower pressure is reached, adjust the spring adjuster (see figure 4) into or out of the yoke until the actuator stem’s movement is first detected at the lower bench set pressure.
3. Be sure the spring adjuster is adjusted to meet the requirements of step 2 above.
4. Apply the upper bench set loading pressure to the diaphragm. This pressure extends the actuator stem down towards the valve. (Note: the actuator stem may slide over the valve stem as shown in figure 4.) At the end of the actuator stem, use a marker or a piece of tape to mark the valve stem (see figure 4). (Note: If the actuator stem does not pass over the valve stem, provide a method to mark this point of stem travel.).
5. Slowly decrease the diaphragm loading pressure until the lower bench set pressure is applied. Measure the distance between the marker or tape on the valve stem to the end of the actuator stem. The distance should match the travel span shown on the travel indicator scale (key 18). If the span of travel is correct, bench set is complete. Proceed to the Installing the Stem Connector Assembly subsection.
6. If the travel span is not correct, a wrong or damaged spring has been installed in the actuator. To obtain the correct spring sizing information, refer to Catalog 14, Actuator Sizing and Sample Calculation sections to determine the correct spring
binding or producing
selection for your application. Or, contact your Emerson Process Management sales office for assistance. After replacing the spring, repeat the steps above.
Installing the Stem Connector Assembly
When installing the stem connector assembly (key 26), the actuator and valve stem threads should engage the threads of the stem connector by the distance of the diameter of the stem.
Note
Replacement stem connectors are an assembly of two stem connector halves, cap screws, and a spacer between the connector halves. Remove the spacer and discard, if present, before clamping the actuator and valve stems together.
1. If necessary, push the valve stem down so that it is touching the seat ring on direct acting valves. For reverse acting valves, push the stem down to the open position.
If necessary, screw the valve stem locknuts down, away from the connector location. For all actuators except size 87, ensure that the travel indicator disk (key 14) is located on top of the locknuts.
2. Slowly increase the diaphragm pressure to the upper bench set pressure. This should be the same pressure used in the bench set steps, and it is marked on the nameplate.
3. Place the stem connector half with the threaded holes, approximately half way between the actuator and valve stems. Refer to figures 6, 7, and 8 to help locate the connector position.
Be sure that the actuator and valve stem threads are engaging the threads of the stem connector by the distance of one diameter of the stem.
CAUTION
Incomplete engagement of either the valve stem or actuator stem in the stem connector can result in stripped threads or improper operation. Be sure that the length of each stem clamped in the stem connector is equal to or greater than one diameter of that stem. Damage to threads on either stem or in the stem connector can cause the parts to be replaced prematurely.
6
Instruction Manual
Form 1900 February 2007
657 Actuator (30-70 and 87)
CLOSING
UPPER BENCH SET PRESSURE
LOWER
DIAPHRAGM PRESSURE, PSIG
BENCH SET PRESSURE
NOTE:
1
DEADBAND IS CAUSED BY FRICTION.
A6763-2 / IL
15
9
3
0
OPEN
DIRECT ACTING VALVE REVERSE ACTING VALVE
VALVE
OPENING VALVE
MID RANGE
VALVE TRAVEL
Figure 5. Typical Valve Response to Deadband
RANGE OF DEADBAND
CLOSED
1.0
0.6
1
0.2
4. Install the other half of the stem connector and insert the cap screws and tighten them. If installing a positioner, also attach the feedback bracket at the same time.
5. Screw the valve stem locknuts up until the indicator disk contacts the bottom of the stem connector, or for size 87 actuators, the stem connector. Do not overtighten the locknuts.
6. Slowly decrease and then increase pressure several times stroking the valve from the lower bench set pressure to the upper pressure.
Be sure that the valve is in closed position (up or down, depending on valve action). Loosen the screws on the travel scale, and align it with the travel indicator disk or stem connector. Stroke the valve full travel to ensure that the travel matches the valve travel on the travel indicator plate. If valve travel is not correct, repeat the stem connector procedure.
Note
OPENING
UPPER BENCH SET PRESSURE
DIAPHRAGM PRESSURE, BAR
LOWER
DIAPHRAGM PRESSURE, PSIG
BENCH SET PRESSURE
15
9
3
0
CLOSED
VALVE
CLOSING VALVE
MID RANGE
VALVE TRAVEL
RANGE OF DEADBAND
OPEN
Deadband Measurement
Deadband is caused by packing friction, unbalanced forces, and other factors in the control valve assembly. Deadband is the range a measured signal can vary without initiating a response from the actuator (see figure 5). Each actuator spring has a fixed spring rate (force). You have verified that the right spring was installed in the actuator by completing the Bench Set Spring Adjustment steps.
Deadband is one factor that affects the control valve assembly operation during automatic loop control. The control loop tolerance for deadband varies widely depending on the loop response. Some common symptoms of the deadband being too wide are no movement, a “jump” movement, or oscillating movements of the actuator during automatic loop control. The following steps are provided to determine the span of deadband. The percent of deadband is helpful in troubleshooting problems with the process control loop.
1.0
0.6
1
DIAPHRAGM PRESSURE, BAR
0.2
For push-down-to-close valves, the valve plug seat is the limit for downward travel and the actuator up-stop is the limit for upward (away from the valve) movement. For push-down-to-open valves, the actuator down stop is the limit for downward movement, and the valve seat is the limit for upward (away from the valve) movement.
1. Start at a pressure near the lower bench set pressure, slowly increase pressure until the valve is approximately at mid-travel. Note this pressure reading.
2. Slowly decrease pressure until movement of the valve stem is detected, and note this pressure.
3. The difference between these two pressures is deadband, in psi.
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657 Actuator (30-70 and 87)
Instruction Manual
Form 1900
February 2007
4. Calculate the percent of deadband by:
Deadband, psi Deadband = —————————————— = nn% Bench Set Span, psi
Loading Connection
The loading pressure connections are made at the factory if the valve, actuator, and positioner come as a unit. Keep the length of tubing or piping as short as possible to avoid transmission lag in the control signal. If a volume booster, valve positioner or other accessory is used, be sure that it is properly connected to the actuator. Refer to the positioner instruction manual or other manuals as necessary.
For actuators shipped separately or whenever the actuator pressure connections are installed, use the following steps:
1. Connect the loading pressure piping to the NPT female connection in the top of the diaphragm casing.
2. For sizes 70 and 87 actuators, if necessary, remove the 1/4 inch NPT bushing if a 1/2 inch NPT female connection is needed to increase connection size. The connection can be made with either piping or tubing.
3. Cycle the actuator several times to be sure that the valve stem travel is correct when the correct pressure ranges are applied to the diaphragm.
WARNING
If valve stem travel appears to be incorrect, refer to the Bench Set Spring Adjustment procedures at the beginning of this section. To avoid personal injury or product damage, do not place the valve into service if it is not reacting correctly to diaphragm loading pressure changes.
Maintenance
Actuator parts are subject to normal wear and must be inspected and replaced when necessary. The frequency of inspection and replacement depends on the severity of service conditions.
WARNING
Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations:
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 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 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, or when loosening the packing box pipe plug.
D Check with your process or safety engineer for any additional measures that must be taken to protect against process media.
Actuator Maintenance
This procedure describes how the actuator can be completely disassembled and assembled. When inspection or repairs are required, disassemble only those parts necessary to accomplish the job; then, start the assembly at the appropriate step.
Key numbers refer to figures 6, 7, or 8 unless otherwise indicated. Figure 6 shows the sizes 30 through 60 actuators, figure 7 illustrates the sizes 70 actuator, and figure 8 shows the size 87 actuator.
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