Fisher Design ED series, Design EAD series Instruction Manual
Instruction Manual
Form 5032
January 2001
Design ED & EAD Class 125-600
Design ED and EAD easy-eR Valves
Class 125 through 600
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing Lubrication 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Packing Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . .
Replacing Packing 5. . . . . . . . . . . . . . . . . . . . . . . . . .
Trim Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lapping Metal Seats 9. . . . . . . . . . . . . . . . . . . . . . . .
Valve Plug Maintenance 10. . . . . . . . . . . . . . . . . . . .
Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retrofit: Installing C-seal Trim 11. . . . . . . . . . . . . . . .
Replacement of Installed C-seal Trim 14. . . . . . . . . .
Trim Removal (C-seal Constructions) 14. . . . . . . .
Lapping Metal Seats (C-seal Constructions) 15. . .
Remachining Metal Seats
(C-seal Constructions) 15. . . . . . . . . . . . . . . . . . .
Trim Replacement (C-seal Constructions) 16. . . . .
ENVIRO-SEAL
Replacing a Plain or Extension Bonnet with an
ENVIRO-SEAL Bellows Seal Bonnet
(Stem/Bellows Assembly) 16. . . . . . . . . . . . . . . .
Replacement of an Installed ENVIRO-SEAL
Bellows Seal Bonnet
(Stem/Bellows Assembly) 17. . . . . . . . . . . . . . . .
Purging the ENVIRO-SEAL
Bellows Seal Bonnet 19. . . . . . . . . . . . . . . . . . . . .
R
Bellows Seal Bonnet 16. . . . . . . . .
W1916-2/IL
Figure 1. Design ED Valve with Type 667 Actuator
Introduction
Parts Ordering 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual
This instruction manual includes installation,
maintenance, and parts information for 1- through
8-inch Design ED valves, and 1- through 6-inch
Design EAD valves, through Class 600 ratings. Refer
to separate manuals for instructions covering the
actuator and accessories.
D100390X012
Design ED & EAD Class 125-600
Table 1. Specifications
End Connection Styles
Shutoff Classifications per ANSI/FCI 70-2
and IEC 60534-4
Cast Iron Valves
Flanged: Class 125 flat-face or 250 raised-face
flanges per ASME B16.1
Screwed: Consistent with ASME B16.4
Steel and Stainless Steel Valves
Flanged: Class 150, 300, and 600 raised-face or
ring-type joint flanges per ASME B16.5
Screwed or Socket Welding: All available ASME
B16.11 schedules that are consistent with Class
600 per ASME B16.34
Buttwelding: 1- through 8-inch
Schedules 40 or 80 consistent with ASME B16.25
Standard: Class II
Optional: Class III—For valves with graphite piston
ring and 87 mm (3-7/16 inch) or larger port
diameter; Class IV—For valves with multiple
graphite piston rings and 111 mm (4-3/8 inch) or
larger port diameter
C-seal trim: High-temperature, Class V. See table 2
Flow Characteristics
Standard Cages: J Linear, J quick opening, or
J equal percentage
Whisper TrimR and WhisperFlot Cages: Linear
Flow Directions
Maximum Inlet Pressure
(1)
Linear, Quick Opening, or Equal Percentage
Cage: Normally down
Cast Iron Valves
Flanged: Consistent with Class 125B or 250B
pressure-temperature ratings per ASME B16.1
Screwed: Consistent with Class 125 or 250
pressure-temperature ratings per ASME B16.4
Steel and Stainless Steel Valves
Flanged: Consistent with Class 150, 300, and 600
pressure-temperature ratings per ASME B16.34
Screwed or Welding: Consistent with Class 600
pressure-temperature ratings per ASME B16.34
(2)
Whisper Trim and WhisperFlo Cages: Always up
Approximate Weights
1 & 1-1/4-inch valves: 14 kg (30 lb)
1-1/2 inch valves: 20 kg (45 lb)
2-inch valves: 30 kg (67 lb)
2-1/2 inch valves: 45 kg (100 lb)
3-inch valves: 57 kg (125 lb)
4-inch valves: 77 kg (170 lb)
6-inch valves: 159 kg (350 lb)
8-inch valves: 408 kg (900 lb)
1. The pressure/temperature limits in this manual and any applicable standard or code limitation for valve should not be exceeded.
2. Some flanged Class 600 valve bodies in 316 stainless steel do not comply with ASME B16.34.
Only persons qualified through training or experience
should install, operate, and maintain a Design ED or
EAD valve. If you have any questions about these
instructions, contact your Fisher sales office before
proceeding.
Description
These single-port valves have cage guiding,
quick-change trim, and balanced push-down-to-close
valve plug action. Valve configurations are as follows:
Design ED—Globe-style valve (figure 1) with
metal-to-metal seating for all general applications over
a wide variety of pressure drops and temperatures.
Design EAD—Angle version of Design ED, used to
facilitate piping or in applications where a self-draining
valve is required.
2
C-seal trim is available for Design ED valves, Class
150, 300, and 600, in sizes 2-1/2, 3, 4, 6, and 8.
C-seal trim is available for Design EAD valves, Class
150, 300, and 600, in sizes 3, 4, and 6.
With C-seal trim, a balanced valve can achieve
high-temperature, Class V shutoff. Because the C-seal
plug seal is formed from metal (N07718 nickel alloy,
Inconel 718) rather than an elastomer, a valve
equipped with the C-seal trim can be applied in
processes with a fluid temperature of up to 593_C
(1100_F), provided other material limits are not
exceeded.
Specifications
Typical specifications for these valves are shown in
table 1.
Design ED & EAD Class 125-600
Installation
WARNING
Personal injury or equipment damage
caused by sudden release of pressure
may result if the valve assembly is
installed where service conditions could
exceed the limits given in table 1 or on
the appropriate nameplates. To avoid
such injury or damage, provide a relief
valve for over-pressure protection as
required by government or accepted
industry codes and good engineering
practices.
CAUTION
When ordered, the valve configuration
and construction materials were
selected to meet particular pressure,
temperature, pressure drop, and
controlled fluid conditions. 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 Fisher sales office.
1. Before installing the valve, inspect the valve and
associated equipment for any damage and any foreign
material.
2. Make certain the valve body interior is clean, that
pipelines are free of foreign material, and that the
valve is oriented so that pipeline flow is in the same
direction as the arrow on the side of the valve.
Note
Depending on valve body materials
used, post weld heat treating may be
required. If so, damage to internal
elastomeric and plastic parts, as well as
internal metal parts is possible.
Shrink-fit pieces and threaded
connections may also loosen. In general,
if post weld heat treating is to be
performed, all trim parts should be
removed. Contact your Fisher sales
office for additional information.
5. With a leak-off bonnet construction, remove the
pipe plugs (keys 14 and 16, figure 18) to hook up the
leak-off piping. If continuous operation is required
during inspection or maintenance, install a three-valve
bypass around the control valve assembly.
6. If the actuator and valve are shipped separately,
refer to the actuator mounting procedure in the
appropriate actuator instruction manual.
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.
Valves with ENVIRO-SEAL live-loaded packing or
HIGH-SEALt live-loaded packing will not require this
initial re-adjustment. See the Fisher instruction
manuals, ENVIRO-SEAL Packing System for
Sliding-Stem Valves or HIGH-SEAL Live-Loaded
Packing System (as appropriate), for packing
instructions. If you wish to convert your present
packing arrangement to ENVIRO-SEAL packing, refer
to the retrofit kits listed in the Parts Kit sub-section
near the end of this manual.
3. The control valve assembly may be installed in any
orientation unless limited by seismic criteria. However,
the normal method is with the actuator vertical above
the valve. Other positions may result in uneven valve
plug and cage wear, and improper operation. With
some valves, the actuator may also need to be
supported when it is not vertical. For more information,
consult your Fisher sales office.
4. Use accepted piping and welding practices when
installing the valve in the line. For flanged valves, use
a suitable gasket between the valve and pipeline
flanges.
Maintenance
Valve parts are subject to normal wear and must be
inspected and replaced as necessary. Inspection and
maintenance frequency depends on the severity of
service conditions. This section includes instructions
for packing lubrication, packing maintenance, trim
maintenance, and ENVIRO-SEAL bellows seal bonnet
replacement. All maintenance operations may be
performed with the valve in the line.
3
Design ED & EAD Class 125-600
Equal Percentage, Linear, Whis er I
Design ED
diameters from 27/8
()
g
Table 2. Additional Shutoff Classification
Valve Design (Class) Valve Size, Inches Port Diameter, Inches Cage Style Leakage Class
Design ED
(Class 150-600)
2-1/2 2-7/8
3 3-7/16
3 2-7/8
4 2-7/8
4 4-3/8
5-3/8 Whisper III (A3, B3, D3, D3), Cavitrol III, 2 stage
6
8
7
7 Cavitrol III, 2 stage
8
Equal Percentage, Linear, Whisper I,
Cavitrol III, 1 stage
Cavitrol III, 2 stage
Equal Percentage, Linear, Whisper I,
Cavitrol III, 1 stage
Equal Percentage, Linear, Whisper I,
Cavitrol III, 1 stage
Equal Percentage, Linear, Whisper I,
Cavitrol III, 1 stage
,
V (for port
diameters from 2-7/8
through 8-inch with
optional C-seal trim)
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 pneumatic 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.
Note
Whenever a gasket seal is disturbed by
removing or shifting gasketed parts,
install a new gasket during reassembly.
This ensures a good gasket seal
because the used gasket may not seal
properly.
Because of the care Fisher takes in meeting all
manufacturing requirements (heat treating,
dimensional tolerances, etc.), use only replacement
parts manufactured or furnished by Fisher.
Packing Lubrication
Note
ENVIRO-SEAL or HIGH-SEAL packing
does not require lubrication.
If a lubricator or lubricator/isolating valve (figure 2) is
provided for PTFE/composition or other packings that
require lubrication, it will be installed in place of the
pipe plug (key 14, figure 18). Use a good quality
silicon-based lubricant. Do not lubricate packing used
in oxygen service or in processes with temperatures
over 260_C (500_F). To operate the lubricator, simply
turn the cap screw clockwise to force the lubricant into
the packing box. The lubricator/isolating valve
operates the same way except open the isolating valve
before turning the cap screw and then close the
isolating valve after lubrication is completed.
Packing Maintenance
Note
For valves with ENVIRO-SEAL packing,
see the Fisher instruction manual,
ENVIRO-SEAL Packing System for
Sliding-Stem Valves, Form 5306, for
packing instructions.
4
LUBRICATOR
Design ED & EAD Class 125-600
Replacing Packing
1. Isolate the control 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, also shut off all
pressure lines to the power actuator, and release all
pressure from the actuator. Use lock-out procedures to
be sure that the above measures stay in effect while
you work on the equipment.
2. Disconnect the operating lines from the actuator
and any leak-off piping from the bonnet. Disconnect
the stem connector, then remove the actuator from the
valve by unscrewing the yoke locknut (key 15, figure
18) or the hex nuts (key 26, figure 18).
10A9421-A
AJ5428-D
A0832-2/IL
Figure 2. Lubricator and Lubricator/Isolating Valve (optional)
LUBRICATOR/ISOLATING VALVE
For valves with HIGH-SEAL packing, see
the Fisher instruction manual,
HIGH-SEAL Live-Loaded Packing
System, Form 5263, for packing
instructions.
Key numbers refer to figure 3 for PTFE V-ring packing
and to figure 4 for PTFE/composition packing, unless
otherwise indicated.
For spring-loaded single PTFE V-ring packing, the
spring (key 8, figure 3) maintains a sealing force on
the packing. If leakage is noted around the packing
follower (key 13, figure 3), check to be sure the
shoulder on the packing follower is touching the
bonnet. If the shoulder is not touching the bonnet,
tighten the packing flange nuts (key 5, figure 18) until
the shoulder is against the bonnet. If leakage cannot
be stopped in this manner, proceed to the Replacing
Packing procedure.
3. Loosen the packing flange nuts (key 5, figure 18)
so that the packing is not tight on the valve stem.
Remove any travel indicator parts and stem locknuts
from the valve stem threads.
WARNING
To avoid personal injury or property
damage caused by uncontrolled
movement of the bonnet, loosen the
bonnet by following the instructions in
the next step. Do not remove a stuck
bonnet by pulling on it with equipment
that can stretch or store energy in any
other manner. The sudden release of
stored energy can cause uncontrolled
movement of the bonnet.
Note
The following step also provides
additional assurance that the valve body
fluid pressure has been relieved.
If there is undesirable packing leakage with other than
spring-loaded packing, first try to limit the leakage and
establish a stem seal by tightening the packing flange
nuts.
If the packing is relatively new and tight on the stem,
and if tightening the packing flange nuts does not stop
the leakage, the valve stem may be worn or nicked so
that a seal cannot be made. The surface finish of a
new valve stem is critical for making a good packing
seal. If the leakage comes from the outside diameter
of the packing, the leakage may be caused by nicks or
scratches around the packing box wall. If performing
any of the following procedures, inspect the valve stem
and packing box wall for nicks and scratches.
CAUTION
Avoid damaging the seating surface
caused by the valve plug and stem
assembly dropping from the bonnet (key
1, figure 18) after being lifted part way
out. When lifting the bonnet, temporarily
install a valve stem locknut on the valve
stem. This locknut will prevent the valve
plug and stem assembly from dropping
out of the bonnet.
If the cage starts to lift with the bonnet,
tap it with a plastic mallet, or other soft
material, to be sure it stays in the valve.
5
Design ED & EAD Class 125-600
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER
(KEY 13)
WASHER
(KEY 10)
SPRING
(KEY 8)
PACKING BOX
RING (KEY 11)
FOR 316 OR 17-4PH SST
FEMALE
ADAPTOR
PACKING RING
MALE
ADAPTOR
LOWER WIPER
1
1
1
1
1
PACKING RING
1
1
FEMALE
ADAPTOR
MALE
ADAPTOR
LOWER
WIPER
1
FOR ALL OTHER METAL PACKING
METAL PACKING BOX PARTS
12A7837-A
12A8187-C 12A7814-C 12A7839-A
ASSEMBLY 1
(POSITIVE
PRESSURES)
ASSEMBLY 2
(VACUUM)
ASSEMBLY 3
(POSITIVE
PRESSURES
& VACUUM)
ASSEMBLY 1
(POSITIVE
PRESSURES)
SINGLE ARRANGEMENTS
ASSEMBLY 2
(VACUUM)
ASSEMBLY 3
(POSITIVE
PRESSURES
& VACUUM)
ASSEMBLY 1
(POSITIVE
PRESSURES)
ASSEMBLY 2
(VACUUM)
9.5 mm (3/8 INCH) STEM 12.7 mm (1/2 INCH) STEM 19.1, 25.4, OR 31.8 mm
(3/4, 1, OR 1Ć1/4 INCH) STEM
BOX PART MATERIALS
ASSEMBLY 3
(POSITIVE
PRESSURES
& VACUUM)
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER
(KEY 13)
SPACER (KEY 8)
PACKING BOX
RING (KEY 11)
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER (KEY 13)
MALE
ADAPTOR
PACKING RING (KEY 7)
FEMALE
ADAPTOR
LANTERN
RING
(KEY 8)
1
PACKING BOX
RING (KEY 11)
LOWER
WIPER
1
1
1
1
NOTES:
MALE ADAPTOR, PACKING RING, FEMALE ADAPTOR,
1
AND LOWER WIPER ARE PART OF PACKING SET (KEY 6).
2 REQ’D FOR DOUBLE ARRANGEMENTS, EXCEPT LOWER WIPER.
C0783 / IL
DOUBLE ARRANGEMENTS
Figure 3. PTFE V-Ring Packing Arrangements for Plain or Extension Bonnets
4. Hex nuts (key 16, figure 19, 20, or 21) or cap
screws (not shown) attach the bonnet (key 1, figure
18) to the valve body (key 1, figure 19, 20, or 21).
Loosen these nuts or cap screws approximately 3 mm
(1/8 inch). Then loosen the body-to-bonnet gasketed
joint by either rocking the bonnet or prying between
the bonnet and valve. Work the prying tool around the
bonnet until the bonnet loosens. If no fluid leaks from
the joint, remove the nuts or cap screws completely
and carefully lift the bonnet off the valve.
5. Remove the locknut and separate the valve plug
and stem from the bonnet. Set the parts on a
protective surface to prevent damage to gasket or
seating surfaces.
6
6. Remove the bonnet gasket (key 10, figure 19, 20,
or 21) and cover the opening in the valve to protect the
gasket surface and prevent foreign material from
getting into the valve body cavity.
7. Remove the packing flange nuts, packing flange,
upper wiper, and packing follower (keys 5, 3, 12, and
13, figure 18). Carefully push out all the remaining
packing parts from the valve side of the bonnet using a
rounded rod or other tool that will not scratch the
packing box wall. Clean the packing box and the metal
packing parts.
8. Inspect the valve stem threads and packing box
surfaces for any sharp edges which might cut the
packing. Scratches or burrs could cause packing box
Design ED & EAD Class 125-600
Table 3. Body-to-Bonnet Bolt Torque Guidelines
Valve Size, Inches Bolt Torques
Design ED Design EAD
1-1/4 or less 1 129 95 64 47
1-1/2, 1-1/2 x 1, 2, or 2 x 1 2 or 2 x 1 96 71 45 33
2-1/2 or 2-1/2 x 1-1/2 3 or 3 x 1-1/2 129 95 64 47
3, 3 x 2, or 3 x 2-1/2 4 or 4 x 2 169 125 88 65
4, 4 x 2-1/2, or 4 x 3 6 or 6 x 2-1/2 271 200 156 115
6 - - - 549 405 366 270
8 - - - 746 550 529 390
1. Determined from laboratory tests.
2. SA193-B8M annealed.
SA193-B7 SA193-B8M
NSm LbfSft NSm LbfSft
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER (KEY 13)
PACKING RING (KEY 7)
LANTERN RING
(KEY 8)
PACKING BOX
RING (KEY 11)
(1)
(2)
9.5 mm
(3/8ĆINCH)
STEM
12A8088-A
12A7815-A
12A8173-A
A5904 / IL
Figure 4. PTFE/Composition Packing Arrangements for Plain or Extension Bonnets
12.7 mm
(1/2ĆINCH)
STEM
TYPICAL (DOUBLE) ARRANGEMENT
leakage or damage to the new packing. If the surface
condition cannot be improved by light sanding, replace
the damaged parts by following the appropriate steps
in the Trim Maintenance procedure.
9. Remove the cover protecting the valve body cavity
and install a new bonnet gasket (key 10, figure 19
through 21), making sure the gasket seating surfaces
are clean and smooth. Place the valve plug and stem
into the valve body, making sure it is properly centered
on the seat ring. Then slide the bonnet over the stem
and onto the stud bolts (key 16, figure 19, 20, or 21) or
onto the valve body cavity if cap screws (not shown)
will be used instead.
Note
Proper performance of the bolting
procedures in step 10 compresses the
spiral wound gasket (key 12, figure 19 or
20) or load ring (key 26, figure 21)
enough to both load and seal the seat
ring gasket (key 13, figure 19, 20, or 21).
It also compresses the outer edge of the
bonnet gasket (key 10, figure 19 through
19.1, 25.4, & 31.8 mm
(3/4, 1 & 1Ć1/4 INCH)
STEM
21) enough to seal the body-to-bonnet
joint.
The bolting procedures in step 10
include—but are not limited
to—ensuring that bolting threads are
clean, and evenly tightening the cap
screws, or the nuts onto the studs, in a
crisscross pattern. Tightening one cap
screw or nut may loosen an adjacent cap
screw or nut. Repeat the crisscross
tightening pattern several times until
each cap screw or nut is tight and the
body-to-bonnet seal is made. When the
operating temperature has been
reached, perform the torquing procedure
once again.
10. Install bolting, using accepted bolting procedures
during tightening, so that the body-to-bonnet joint will
withstand test pressures and application service
conditions. Use the bolt torques in table 3 as
guidelines.
7
Design ED & EAD Class 125-600
PACKING
FOLLOWER (KEY 13)
GRAPHITE
RIBBON
1
1
14A3411-C 13A9775-E 13A9776-D
9.5 mm
(3/8ĆINCH)
STEM
(1/2ĆINCH)
12.7 mm
STEM
1
19.1, 25.4, OR
31.8 mm
(3/4, 1, OR
1Ć1/4 INCH)
STEM
SINGLE ARRANGEMENTS DOUBLE ARRANGEMENTS
NOTES:
1
0.102 mm (0.004 INCH) THICK SACRIFICIAL ZINC WASHERS;
USE ONLY ONE BELOW EACH GRAPHITE RIBBON RING.
B2350 / IL
Figure 5. Graphite Ribbon/Filament Packing for Plain or Extension Bonnets
PACKING RING (KEY 7)
GRAPHITE
FILAMENT PACKING
RING (KEY 7)
LANTERN RING (KEY 8)
PACKING BOX
RING (KEY 11)
1
14A2153-D 14A1849-E 14A1780-D
9.5 mm
(3/8ĆINCH)
STEM
1
(1/2ĆINCH)
12.7 mm
STEM
1
1
19.1, 25.4, OR
(3/4, 1, OR
1Ć1/4 INCH)
31.8 mm
STEM
PACKING
FOLLOWER (KEY 13)
GRAPHITE
RIBBON
PACKING RING (KEY 7)
GRAPHITE
FILAMENT
PACKING RING (KEY 7)
LANTERN RING (KEY 8)
PACKING BOX
RING (KEY 11)
11. Install new packing and the metal packing box
parts according to the appropriate arrangement in
figure 3, 4, or 5. Place a smooth-edged pipe over the
valve stem and gently tap each soft packing part into
the packing box.
12. Slide the packing follower, upper wiper, and
packing flange (keys 13, 12, and 3, figure 18) into
position. Lubricate the packing flange studs (key 4,
figure 18) and the faces of the packing flange nuts
(key 5, figure 18). Install the packing flange nuts.
13. For spring-loaded PTFE V-ring packing, tighten
the packing flange nuts until the shoulder on the
packing follower (key 13, figure 18) contacts the
bonnet.
For graphite packing, tighten the packing flange
nuts to the maximum recommended torque shown in
table 4. Then, loosen the packing flange nuts, and
retighten them to the recommended minimum torque
shown in table 4.
For other packing types, tighten the packing flange
nuts alternately in small equal increments until one of
the nuts reaches the minimum recommended torque
shown in table 4. Then, tighten the remaining flange
nut until the packing flange is level and at a 90-degree
angle to the valve stem.
For ENVIRO-SEAL or HIGH-SEAL live-loaded
packing, refer to the note at the beginning of Packing
Maintenance.
14. Mount the actuator on the valve assembly and
reconnect the actuator and valve stem according to
the procedure in the appropriate actuator instruction
manual.
Trim Maintenance
For C-seal construction, see the appropriate C-seal
sections in this instruction manual.
Except where indicated, key numbers in this section
are referenced in figure 19 for standard 1-through
6-inch constructions, figure 20 for Whisper Trim III
cage detail, figure 21 for the 8-inch Design ED valve,
and figures 22 and 23 for WhisperFlo trim. Some valve
plug constructions require three piston rings (key 6).
Disassembly
1. Remove the actuator and the bonnet according to
steps 1 through 5 of the Replacing Packing procedure
in the Maintenance section.
WARNING
To avoid personal injury due to leaking
fluid, avoid damaging gasket sealing
surfaces. The graphite piston rings in a
Design ED or EAD valve are brittle and in
two pieces. Use care to avoid damage to
the piston rings caused by dropping or
rough handling.
8
VALVE STEM DIAMETER
9.5
3/8
12.7
1/2
19.1
3/4
mm Inches
9.5 3/8
12.7 1/2
19.1 3/4
25.4 1
31.8 1-1/4
Design ED & EAD Class 125-600
Table 4. Recommended Torque for Packing Flange Nuts
GRAPHITE TYPE PACKING PTFE TYPE PACKING
CLASS
125, 150 3 27 5 40 1 13 2 19
250, 300 4 36 6 53 2 17 3 26
600 6 49 8 73 3 23 4 35
125, 150 5 44 8 66 2 21 4 31
250, 300 7 59 10 88 3 28 5 42
600 9 81 14 122 4 39 7 58
125, 150 11 99 17 149 5 47 8 70
250, 300 15 133 23 199 7 64 11 95
600 21 182 31 274 10 87 15 131
300 26 226 38 339 12 108 18 162
600 35 310 53 466 17 149 25 223
300 36 318 54 477 17 152 26 228
600 49 437 74 655 24 209 36 314
Minimum
Torque
NSm LbfSin NSm LbfSin NSm LbfSin NSm LbfSin
Maximum
Torque
Minimum
Torque
Maximum
Torque
The surface finish of the valve stem
(key 7) is critical for making a good
packing seal. The inside surface of the
cage or cage/baffle assembly (key 3), or
cage retainer (key 31), is critical for
smooth operation of the valve plug and
for making a seal with the piston rings
(key 6). The seating surfaces of the valve
plug (key 2) and seat ring (key 9) are
critical for proper shutoff. Unless
inspection reveals otherwise, assume all
these parts are in good condition and
protect them accordingly.
2. Remove the packing flange nuts, packing flange,
upper wiper, and packing follower (keys 5, 3, 12, and
13, figure 18). Carefully push out all the remaining
packing parts from the valve side of the bonnet using a
rounded rod or other tool that will not scratch the
packing box wall. Clean the packing box and the metal
packing parts.
3. Inspect the valve stem threads and packing box
surfaces for any sharp edges which might cut the
packing. Scratches or burrs could cause packing box
leakage or damage to the new packing. If the surface
condition cannot be improved by light sanding, replace
the damaged parts.
4. Remove the load ring (key 26) from an 8-inch
Design ED valve, or the cage adaptor (key 4) from any
restricted-trim valve through 4 inches, and wrap it for
protection.
5. On a 6-inch Design ED valve with a Whisper Trim
III cage or WhisperFlo trim, remove the bonnet spacer
(key 32) and bonnet gasket (key 10) on top of the
spacer. Then on any construction with a cage retainer
(key 31), remove the cage retainer and its associated
gaskets. A Whisper Trim III and WhisperFlo cage
retainer has two 3/8-inch-16 NPT tappings in which
screws or bolts can be installed for lifting.
6. Remove the cage or cage/baffle assembly (key 3)
and the associated gaskets (keys 10, 11, and 12), and
shim (key 51 for the Design ED valve, key 27 for the
Design EAD valve). If the cage is stuck in the valve,
use a rubber mallet to strike the exposed portion of the
cage at several points around its circumference.
7. Remove the seat ring or liner (key 9), seat ring
gasket (key 13), and the seat ring adaptor (key 5) and
adaptor gasket (key 14) where used in a restricted-trim
seat ring construction.
8. Inspect parts for wear or damage which would
prevent proper operation of the valve. Replace or
repair trim parts according to the following procedure
for Lapping Metal Seats or other valve plug
maintenance procedures as appropriate.
Lapping Metal Seats
CAUTION
To avoid damaging the ENVIRO-SEAL
bellows seal bonnet assembly, do not
attempt to lap the metal seating
surfaces. The design of the assembly
prevents rotation of the stem and any
forced lapping rotation will damage
internal components of the
ENVIRO-SEAL Bellows Seal bonnet.
With metal-seat constructions, seating surfaces of the
valve plug and seat ring or liner (keys 2 and 9, figure
19, 20, or 21) can be lapped for improved shutoff.
(Deep nicks should be machined out rather than
ground out.) Use a good quality lapping compound of
a mixture of 280 to 600-grit. Apply compound to the
bottom of the valve plug.
9
Design ED & EAD Class 125-600
Assemble the valve to the extent that the cage and the
cage retainer and bonnet spacer (if used) are in place
and the bonnet is bolted to the valve. A simple handle
can be made from a piece of strap iron locked to the
valve plug stem with nuts. Rotate the handle
alternately in each direction to lap the seats. After
lapping, remove the bonnet and clean the seat
surfaces. Completely assemble as described in the
Assembly portion of the Trim Maintenance procedure
and test the valve for shutoff. Repeat the lapping
procedure if leakage is still excessive.
Valve Plug Maintenance
Except where indicated, key numbers in this section
are referenced in figure 19 for standard 1- through
6-inch constructions, figure 20 for Whisper Trim III
detail, figure 21 for the 8-inch Design ED valve, and
figures 22 and 23 for WhisperFlo trim. Some valve
plug constructions require three piston rings (key 6).
CAUTION
To avoid the piston ring (key 6) not
sealing properly, be careful not to
scratch the surfaces of the ring groove
in the valve plug or any of the surfaces
of the replacement ring.
1. With the valve plug (key 2) removed according to
the Disassembly portion of the Trim Maintenance
procedure, proceed as appropriate:
For the carbon-filled PTFE piston ring, The ring is
split in one place. If there is visible damage, spread
the ring slightly and remove it from the groove in the
valve plug.
To install a carbon-filled PTFE piston ring, Spread
the ring apart slightly at the split and install it over the
stem and into the groove in the valve plug. The open
side must face along the stem, depending on flow
directions, as shown in view A of figure 19.
For the graphite piston ring, The ring can be easily
removed since it is in two pieces. A new graphite
piston ring is furnished as a complete ring. Use a vise
with smooth or taped jaws to break this replacement
ring into halves. Place the new ring in the vise so that
the jaws will compress the ring into an oval. Slowly
compress the ring until it snaps on both sides. If one
side snaps first, do not try to tear or cut the other side.
Instead, keep compressing the ring until the other side
snaps. Be sure to match the broken ends when
installing the ring in the valve plug groove.
CAUTION
Never reuse an old stem or adaptor with
a new valve plug. Using an old stem or
adaptor with a new plug requires drilling
a new pin hole in the stem (or adaptor in
case an ENVIRO-SEAL bellows seal
bonnet is being used). This drilling
weakens the stem or adaptor and may
cause failure in service. However, a used
valve plug may be reused with a new
stem or adaptor.
Note
For plain bonnets and style 1 extension
bonnets, the valve plug (key 2), valve
stem (key 7), and pin (key 8) are
available completely assembled. Refer to
the Key 2, 7, and 8 Valve Plug and Stem
Assembly tables in the Parts List.
2. To replace the valve stem (key 7), drive out the pin
(key 8). Unscrew the valve plug from the stem or
adaptor.
3. To replace the adaptor (key 24, figure 18) on
ENVIRO-SEAL bellows seal bonnets, place the plug
stem assembly and valve plug in a soft-jaw chuck or
other type of vise so that the jaws grip a portion of the
valve plug that is not a seating surface. Drive out the
pin (key 36, figure 18). Reverse the plug stem
assembly and valve plug in the soft-jaw chuck or vise.
Grip the flat areas on the valve stem just below the
threads for the actuator/stem connection. Unscrew the
valve plug/adaptor assembly (key 24, figure 18) from
the valve stem assembly (key 20, figure 18).
4. Screw the new stem or adaptor into the valve plug.
Tighten to the torque value given in table 5. Refer to
table 5 to select the proper drill size. Drill through the
stem or adaptor, using the hole in the valve plug as a
guide. Remove any chips or burrs and drive in a new
pin to lock the assembly.
5. For ENVIRO-SEAL bellows seal bonnets, grip the
flats of the stem extending out of the top of the bellows
shroud with a soft-jaw chuck or other type of vise.
Screw the valve plug/adaptor assembly onto the valve
stem. Tighten as necessary to align the pin hole in the
stem with one of the holes in the adaptor. Secure the
adaptor to the stem with a new pin.
Assembly
Except where indicated, key numbers are referenced
in figure 19 for standard 1-through 6-inch
constructions, figure 20 for Whisper Trim III detail,
figure 21 for the 8-inch Design ED valve, and figures
22 and 23 for WhisperFlo trim.
10
Design ED & EAD Class 125-600
Table 5. Valve Stem Connection Torque and
VALVE STEM
CONNECTION (VSC)
mm Inch
9.5
12.7
19.1
25.4
31.8
Pin Replacement
3/8
1/2
3/4
1
1-1/4
TORQUE,
MINIMUM TO MAXIMUM
NSm LbfSft
40 to 47
81 to 115
237 to 339
420 to 481
827 to 908
25 to 35
60 to 85
175 to 250
310 to 355
610 to 670
DRILL
SIZE, INCH
3/32
1/8
3/16
1/4
1/4
1. With a restricted-trim seat ring construction, install
the adaptor gasket (key 14) and seat ring adaptor
(key 5).
2. Install the seat ring gasket (key 13), seat ring or
liner (key 9).
3. Install the cage or cage/baffle assembly (key 3).
Any rotational orientation of the cage or assembly with
respect to the valve is acceptable. A Whisper Trim III
cage designated by level A3, B3, or C3 may be
installed with either end up. The level D3 cage/baffle
assembly, however, must be installed with the hole
pattern end next to the seat ring. If a cage retainer
(key 31) is to be used, place it on top of the cage.
8. Mount the bonnet on the valve and complete
assembly according to steps 10 through 14 of the
Replacing Packing procedure. Be sure to observe the
note prior to step 10.
Retrofit: Installing C-seal Trim
Note
Additional actuator thrust is required for
a valve with C-seal trim. When installing
C-seal trim in an existing valve, contact
your Fisher sales office for assistance in
determining new actuator thrust
requirements.
Assemble the new valve plug/retainer assembly (with
C-seal plug seal) using the following instructions:
4. Slide the valve plug (key 2) and stem assembly, or
valve plug and ENVIRO-SEAL bellows seal assembly,
into the cage until the piston ring(s) is level with the top
of the cage (key 3) or cage retainer (key 31).
5. Installing piston rings (key 6):
a. For valve plugs with a single piston ring:
Make sure the piston ring is evenly engaged into
the entrance chamfer at the top of the cage or cage
retainer ring. Carefully press the piston ring into the
cage or cage retainer ring.
b. For valve plugs with multiple piston rings: As
each piston ring is slid into the cage, make sure the
ring is evenly engaged in the entrance chamfer at
the top of the cage or cage retainer. Also, make
sure to offset the fracture in the rings to minimize
leakage. Carefully press each piston ring into the
cage or cage retainer ring.
6. Place the gaskets (keys 12, 11 or 14 if used,
and 10) and the shim (key 27 or 51) if used on top of
the cage or cage retainer. If there is a cage adaptor
(key 4) or a bonnet spacer (key 32), set it on the cage
or cage retainer gaskets and place another flat sheet
gasket (key 10) on top of the adaptor or spacer. If
there is only a cage retainer, place another flat sheet
gasket on the retainer.
7. With an 8-inch Design ED valve, install the load
ring (key 26).
CAUTION
To avoid leakage when the valve is
returned to service, use appropriate
methods and materials to protect all
sealing surfaces of the new trim parts
while assembling the individual parts
and during installation in the valve body.
1. Apply a suitable high-temperature lubricant to the
inside diameter of the C-seal plug seal. Also, lubricate
the outside diameter of the valve plug where the
C-seal plug seal must be pressed into the proper
sealing position (figure 6).
2. Orient the C-seal plug seal for correct sealing
action based on the process fluid flow direction
through the valve.
D The open interior of the C-seal plug seal must
face up in a valve with flow-up construction (figure 6).
D The open interior of the C-seal plug seal must
face down in a valve with flow-down construction
(figure 6).
11
Design ED & EAD Class 125-600
FLOW DOWN FLOW UP
VIEW A
3
6
6
37B1045-A / DOC
Figure 6. Design ED with C-seal Trim
Note
An installation tool must be used to
properly position the C-seal plug seal on
the valve plug. A tool is available as a
spare part from Fisher or a tool could be
manufactured following the dimensions
given in Figure 7.
3. Place the C-seal plug seal over the top of the valve
plug and press the C-seal plug seal onto the plug
using the C-seal installation tool. Carefully press the
C-seal plug seal onto the plug until the installation tool
contacts the horizontal reference surface of the valve
plug (figure 8).
4. Apply a suitable high-temperature lubricant to the
threads on the plug. Then, place the C-seal retainer
onto the plug and tighten the retainer using an
appropriate tool such as a strap wrench.
5. Using an appropriate tool such as a center punch,
stake the threads on top of the plug in one place
(figure 9) to secure the C-seal retainer.
6. Install the new plug/retainer assembly with C-seal
plug seal on the new stem following the appropriate
instructions in the Trim Replacement section of this
manual.
7. Install piston rings by following instructions in the
Trim Replacement section of this manual.
37B1397-A / DOC
CAVITROL III 2ĆSTAGE
8. Remove the existing valve actuator and bonnet
following the appropriate instructions in the Replacing
Packing section of this manual.
CAUTION
Do not remove the existing valve stem
from the valve plug unless you are
planning to replace the valve stem.
Never reuse an old valve stem with a
new plug or reinstall a valve stem after it
has been removed. Replacing a valve
stem requires drilling a new pin hole in
the stem. This drilling weakens the stem
and may cause failure in service.
However, a used valve plug may be
reused with a new valve stem.
9. Remove the existing valve stem and plug, cage,
and seat ring from the valve body following the
appropriate instructions in the Trim Removal section of
this manual.
10. Replace all gaskets according to appropriate
instructions in the Trim Replacement section of this
manual.
12
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