www.Fisher.com
D100399X012
Design EWD, EWS, and EWT Valves
through NPS 12x8
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . .
Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inverted Globe Valve Applications
(Actuator below valve) 6. . . . . . . . . . . . . . . . . .
Maintenance 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing Lubrication 7. . . . . . . . . . . . . . . . . . . . . . .
Packing Maintenance 7. . . . . . . . . . . . . . . . . . . . .
Replacing Packing 9. . . . . . . . . . . . . . . . . . . . . . .
Trim Maintenance 11. . . . . . . . . . . . . . . . . . . . . . .
Trim Removal 12. . . . . . . . . . . . . . . . . . . . . . . . . .
Lapping Metal Seats 13. . . . . . . . . . . . . . . . . . . .
Valve Plug Maintenance 14. . . . . . . . . . . . . . . . .
Trim Replacement 15. . . . . . . . . . . . . . . . . . . . . .
Retrofit: Installing C-sealt Trim 16. . . . . . . . . . .
Replacement of Installed C-seal Trim 18. . . . . .
Trim Removal
(C-seal Constructions) 18. . . . . . . . . . . . . . . .
Lapping Metal Seats
(C-seal Constructions) 19. . . . . . . . . . . . . . . .
Remachining Metal Seats
(C-seal Constructions) 20. . . . . . . . . . . . . . . .
Trim Replacement
(C-seal Constructions) 20. . . . . . . . . . . . . . . .
ENVIRO-SEALr Bellows Seal Bonnet 21. . . . . .
Replacing a Plain or Extension Bonnet with an
ENVIRO-SEAL Bellows Seal Bonnet
(Stem/Bellows Assembly) 21. . . . . . . . . . . . .
Replacement of an Installed ENVIRO-SEAL
Bellows Seal Bonnet
(Stem/Bellows Assembly) 22. . . . . . . . . . . . .
Purging the ENVIRO-SEAL
Bellows Seal Bonnet 25. . . . . . . . . . . . . . . . .
Parts Ordering 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Kits 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1. NPS 12x6 EW Series Valve With
Type 667 Actuator
W2777-2*/IL
Introduction
Scope of Manual
This instruction manual includes installation,
maintenance, and parts information for NPS 4x2
through 12x8 Design EWD, EWS, and EWT valves
(figure 1). Refer to separate manuals for instructions
covering the actuator and accessories.
Do not install, operate, or maintain a Design EW
valve 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.
Instruction Manual
Form 2376
March 2007
EW Valve
EW Valve
Instruction Manual
Form 2376
March 2007
2
Table 1. Specifications
End Connection Styles
Flanged Ends: CL300, CL600, or CL900
Raised-face or ring-type joint flanges per ASME
B16.5
Buttwelding Ends: Styles per ASME B16.25
schedules consistent with ASME B16.34 are:
Schedules
J 40 or J 80 for all CL300 and CL600
valves, Schedule
J 80 or J XXS for NPS 8x6
CL900 valves, or Schedule
J 80, J 100, or
J 120 for NPS 12x8 CL900 valves.
Maximum Inlet Pressures, Temperatures, and
Pressure Drops
(1)
Consistent with applicable J CL300, J CL600
(2)
,
or
J CL900
(3)
pressure/temperature ratings per
ASME B16.34, but do not exceed the pressure,
temperature, and pressure drop conditions
specified when the valve was ordered. Also see
the Installation section.
Also see Bulletin 80.3:010 WhisperFlor
Aerodynamic Attenuation Trims
Shutoff Classifications
See table 2
C-seal trim: High-temperature, Class V per
ANSI/FCI 70-2 and IEC 60534-4
See table 3
WhisperFlo Trim:
J Class IV per ANSI/FCI 70-2 and IEC 60534-4
J Others per application
Flow Characteristics
Standard Cages:
J Linear, J quick opening, or
J equal percentage
Whisper Trimr and Cavitrolr Cages: Linear
WhisperFlo Trim: Linear (restricted linear cages
and special, characterized cages are
available—consult your Emerson Process
Management sales office)
Flow Directions
Design EWS and Standard Cage: Normally up
Design EWD or EWT with Standard Cage:
Normally down
Whisper Trim Cages: Always up
Cavitrol Cages: Always down
WhisperFlo Trim: Flow up (standard)—through
the seat ring and out through the cage orifices
Approximate Weights
See table 4
WhisperFlo Trim Material and Selection
J 410 Stainless Steel
J Others per application
See appropriate valve body bulletin
WhisperFlo Pressure/Temperature Capability
J –29 to 427_C (–20 to 800_F)
J Others per application
See appropriate valve body bulletin for
complementary information
WhisperFlo Aerodynamic Trim Pressure
Ratings
(1,2)
Up to 1500 psi drop
WhisperFlo Velocity Limits
WhisperFlo trim is designed for 0.3 MACH as an
inherent outlet velocity limit. Variations higher and
lower may be applied per special applications
WhisperFlo Rangeability
100:1
WhisperFlo Noise Attenuation
Approximately –40 dBA maximum depending on
the nP/P
1
ratio per IEC 534-8-3 calculation
procedure
See Fisherr Specification Manager
Additional Specifications
For specifications such as materials, port
diameters, valve plug travels, yoke boss
diameters, and stem diameters, refer to the Parts
List
1. The pressure or temperature limits in this manual and any applicable standard limitations should not be exceeded.
2. Certain bonnet bolting material selections may require a CL600 easy-e valve assembly to be derated. Contact your Emerson Process Management sales office.
3. There are two different CL900 NPS 8x6 valve bodies, one for use only with Cavitrol III cages and the other for use with all other constructions. A CL900 valve with Cavitrol III cage can
take full CL900 pressure drops. For information on other NPS 8x6 constructions that can take full CL900 pressure drops, contact your Emerson Process Management sales office. All other
trim constructions are limited to CL600 pressure/temperature limits even though installed in a CL900 valve.
EW Valve
Instruction Manual
Form 2376
March 2007
3
Figure 2. Cutaway Detail of the WhisperFlor Trim, Valve Body Typical
W6825-1/IL
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
These single-port globe-style valves have cage
guiding, clamped seat rings, and push-down-to-close
valve plug action. Valve configurations are as
follows:
Design EWD: Balanced valve plug with
metal-to-metal seating for all general applications
over a wide range of pressure drops and
temperatures.
C-seal trim is available for Design EWD valves,
CL300 and CL600, in sizes NPS 6x4x2.5, 6x4, 8x4,
8x6, 12x6, 10x8, and 12x8.
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) 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.
Design EWS: Unbalanced valve plug with
metal-to-metal or optional metal-to-PTFE seating for
all general applications requiring better shutoff
capabilities than can be obtained with the Design
EWD valve.
Design EWT: Balanced valve plug with either
metal-to-PTFE seating (standard for all except
Cavitrol III cages) for stringent shutoff requirements
or metal-to-metal seating (standard for Cavitrol III
cages, optional for all others) for higher
temperatures.
Control valves with WhisperFlo cages (figure 2)
provide additional attenuation for aerodynamic noise
in very demanding vapor or gas applications with
high-pressure drops. A WhisperFlo cage with an
appropriately sized valve body is designed to reduce
the noise level up to –40 dBA. For special
applications, –50 dBA attenuation can be achieved.
Specifications
Typical specifications for these valves are shown in
table 1.
EW Valve
Instruction Manual
Form 2376
March 2007
4
Table 2. Shutoff Classification Per ANSI/FCI 70-2 and IEC 60534-4
Valve Design Seating Shutoff Class
EWD Metal
II (standard)
III (optional for NPS 6x4 through 12x6 valves with optional single graphite piston ring or for
NPS 10x8 and 12x8 valves with optional double piston rings)
IV (optional for NPS 6x4 through 12x8 valves with optional multiple graphite piston rings)
EWS Metal
IV (standard)
S
V (optional, consult your Emerson Process Management sales office)
EWS PTFE VI
EWT with all except PTFE
Standard Air Test (maximum leakage is 0.05 mL/min/psid/inch port diameter)
p
Cavitrol III cages
V (optional)
Metal IV (standard)
Metal V (optional)
(1)
EWT with Metal
IV (standard)
1-stage Cavitrol III cage
V (optional)
EWT with 2-stage Cavitrol III cage Metal V
1. Class V shutoff for Design EWT requires spring loaded seal ring, radius-seat plug, wide-bevel seat ring, and seat lapping. Not available with 8-inch port, quick-opening cage. Not
available with S31600 (316 SST) valve plug and seat ring.
Table 3. Additional Shutoff Classification for C-seal Trim Per ANSI/FCI 70-2 and IEC 60534-4
Valve Valve Size, NPS Port Diameter, Inches Cage Style Leakage Class
6x4x2.5 2.875
Equal Percentage, Linear, Whisper I,
Cavitrol III (2-stage)
6x4
8x4
4.375
Equal Percentage, Linear, Whisper I,
Cavitrol III (1-stage)
V (for port
Design EWD
8x6 and 12x6 5.375 Whisper III (A3, B3, D3, D3), Cavitrol III (2-stage)
diameters from 2.875
-
(CL300, CL600)
8x6
12x6
7
Equal Percentage, Linear, Whisper I,
Cavitrol III (1-stage)
through 8-inch w
ith
optional C-seal trim)
10x8
12x8
8
Equal Percentage, Linear, Whisper I,
Cavitrol III (1-stage)
Installation
WARNING
Always wear protective gloves,
clothing, and eyewear when
performing any installation operations
to avoid personal injury.
Personal injury or equipment damage
caused by sudden release of pressure
or bursting of parts 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 overpressure protection as
required by government or accepted
industry codes and good engineering
practices.
Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
If installing into an existing
application, also refer to the WARNING
at the beginning of the Maintenance
section in this instruction manual.
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.
Before installing the valve, inspect the
valve and pipelines for any damage
and any foreign material which may
cause product damage.
EW Valve
Instruction Manual
Form 2376
March 2007
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Table 4. Approximate Weights
VALVE SIZE, NPS
END CONNECTION
4X2 6X4 8X4 8X6 10X8 12X6 12X8
END CONNECTION
Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb
CL300 (flanged only) 84 185 150 330 234 515 284 625 567 1250 500 1102 653 1440
Flanged 100 220 195 430 272 600 308 680 744 1640 721 1590 857 1890
CL600
Buttwelding 61 135 122 270 177 390 272 600 512 1130 526 1160 658 1450
Flanged - - - - - - - - - - - - - - - - - - 612 1350 - - - - - - - - - - - - 1361 3000
CL900
Buttwelding - - - - - - - - - - - - - - - - - - 454 1000 - - - - - - - - - - - - 1293 2850
CAUTION
If hoisting the valve, use a nylon sling
to protect the surfaces. Carefully
position the sling to prevent damage
to the actuator tubing and any
accessories. Also, take care to prevent
people from being injured in case the
hoist or rigging slips unexpectedly.
Refer to table 4 for valve assembly
weights. Be sure to use adequately
sized hoists and chains or slings to
handle the valve.
1. Before installing the valve, inspect the valve body
cavity 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.
3. Install the control valve assembly 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 in improper
operation. With some valves, the actuator may also
need to be supported when it is not vertical. For
more information, consult your Emerson Process
Management sales office.
Note
If installing a valve with small internal
flow passages, such as with
WhisperFlo, Whisper Trim, or Cavitrol
cages, consider installing an upstream
strainer to prevent the lodging of
particles in these passages. This is
especially important if the pipeline
cannot be thoroughly cleaned or if the
flowing medium is not clean.
4. Use accepted piping and welding practices when
installing the valve in the line. For flanged valve
bodies, use a suitable gasket between the valve
body and pipeline flanges.
CAUTION
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, remove all trim parts.
Contact your Emerson Process
Management sales office for additional
information.
5. With a leak-off bonnet construction, remove the
pipe plugs (keys 14 and 16, figure 21) from the
bonnet 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. Check with your process
or safety engineer for any additional
measures that must be taken to
protect against process media.
Valves with ENVIRO-SEAL live-loaded packing or
HIGH-SEAL live-loaded packing will not require this
EW Valve
Instruction Manual
Form 2376
March 2007
6
initial re-adjustment. See 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.
Inverted Globe Valve Applications
(Actuator below valve)
Due to space restrictions in your application, you
may be required to mount the valve/actuator
assembly in an inverted orientation, with the actuator
positioned below the valve. If so, the following
procedures will help you with disassembly and
assembly techniques.
WARNING
Avoid personal injury or property
damage caused by components
dropping.
With the valve/actuator upside down,
components may drop during
disassembly or assembly. Be careful
not to position yourself below the
valve in the path of falling parts.
As the bonnet/plug/cage is lowered
from the valve body, the center of
gravity will be above the lifting points.
Take care to prevent the assembly
from tipping over as it is lowered.
Either leave the actuator attached to
the plug and bonnet, attach straps to
the stem, or provide other means to
prevent tipping.
Disassembly
1. Provide adequate support to the actuator while
removing it from the bonnet.
2. Provide adequate support to the bonnet while
removing the bonnet nuts.
3. Be aware that the bonnet/plug/cage may tip over
as they are lowered from the valve body. Make
provision to prevent tipping.
4. Be aware that the cage and seat ring may not
come out with the bonnet and plug/stem assembly. If
this occurs, make provision to support these parts,
as they may fall out unexpectedly.
Assembly
1. Start this assembly procedure with the plug/stem
assembly already installed in the bonnet.
2. Put the gaskets and cage onto the bonnet and
plug.
3. Place the seat ring with the seat ring gasket onto
the cage, if applicable with the valve design.
4. Raise this bonnet/plug/cage assembly up into the
valve body. Make provision to prevent tipping of
these parts as they are being raised into the valve
body.
5. Torque the bonnet nuts.
6. Mount the actuator.
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, lapping metal seats,
and ENVIRO-SEAL bellows seal bonnet
replacement. All maintenance operations may be
performed with the valve in the line.
WARNING
Avoid personal injury or property
damage from sudden release of
process pressure. 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
EW Valve
Instruction Manual
Form 2376
March 2007
7
process pressure on 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.
D Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
CAUTION
Follow instructions carefully to avoid
damaging the product surfaces, which
could result in damage to the product.
Note
Whenever a gasket seal is disturbed
by removing or shifting gasketed
parts, install a new gasket upon
reassembly. This is necessary to
ensure a good gasket seal because the
used gasket may not seal properly.
Packing Lubrication
Note
ENVIRO-SEAL or HIGH-SEAL packing
does not require lubrication.
WARNING
To avoid personal injury or property
damage resulting from fire or
explosion, do not lubricate packing
Figure 3. Lubricator and Lubricator/Isolating Valve (optional)
LUBRICATOR
LUBRICATOR/ISOLATING VALVE
10A9421-A
AJ5428-D
A0832-2/IL
used in oxygen service or in
processes with temperatures over
260_C (500_F).
If a lubricator or lubricator/isolating valve (figure 3) is
provided for PTFE/composition or other packings
that require lubrication, it will be installed in place of
the pipe plug (key 14, figure 21). Use a good quality
silicon-base 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
live-loaded packing, see the Fisher
instruction manual, ENVIRO-SEAL
Packing System for Sliding-Stem
Valves, Form 5306, for packing
instructions. For valves with
HIGH-SEAL live-loaded packing, see
the Fisher instruction manual,
HIGH-SEAL Live-Loaded Packing
System, Form 5263, for packing
instructions.
Key numbers refer to figure 4 for PTFE V-ring
packing and to figure 5 for PTFE/composition
packing, unless otherwise indicated.
For spring-loaded single PTFE V-ring packing, the
spring (key 8, figure 4) maintains a sealing force on
EW Valve
Instruction Manual
Form 2376
March 2007
8
Figure 4. PTFE V-Ring Packing Arrangements
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER
(KEY 13)
WASHER
(KEY 10)
SPRING
(KEY 8)
PACKING BOX
RING (KEY 11)
FEMALE
ADAPTOR
PACKING RING
MALE
ADAPTOR
LOWER WIPER
FEMALE
ADAPTOR
PACKING RING
MALE
ADAPTOR
LOWER WIPER
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER
(KEY 13)
SPACER
(KEY 8)
PACKING BOX
RING (KEY 11)
1
1
FOR S31600 (316 SST) OR
S17400 (17Ć4PH SST)
METAL PACKING BOX PARTS
FOR ALL OTHER METAL PACKING
BOX PART MATERIALS
SINGLE ARRANGEMENTS
NOTE:
PACKING SET (KEY 6) (2 REQ’D FOR DOUBLE ARRANGEMENTS).
12A7837–A/IL
B2398/IL
1
1
1
1
1
1
1
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER (KEY 13)
LANTERN RING
(KEY 8)
PACKING BOX
RING (KEY 11)
MALE ADAPTOR
PACKING RING
FEMALE ADAPTOR
LOWER WIPER
ASSEMBLY 1
(POSITIVE
PRESSURES)
ASSEMBLY 2
(VACUUM)
ASSEMBLY 3
(POSITIVE
PRESSURES
& VACUUM)
ASSEMBLY 1
(POSITIVE
PRESSURES)
ASSEMBLY 2
(VACUUM)
ASSEMBLY 3
(POSITIVE
PRESSURES
& VACUUM)
ASSEMBLY 1
(POSITIVE
PRESSURES)
ASSEMBLY 2
(VACUUM)
ASSEMBLY 3
(POSITIVE
PRESSURES
& 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
DOUBLE ARRANGEMENTS
12A8187-C 12A7814-C 12A7839-A
B1428-2 / IL
the packing. If leakage is noted around the packing
follower (key 13, figure 4), 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 21)
until the shoulder is against the bonnet. If leakage
cannot be stopped in this manner, go to the
Replacing Packing procedure.
If there is undesirable packing leakage with other
than spring-loaded packing, first try to limit the
EW Valve
Instruction Manual
Form 2376
March 2007
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Figure 5. Detail of PTFE/Composition Packing Arrangements
UPPER WIPER
(KEY 12)
PACKING
FOLLOWER
(KEY 13)
LANTERN RING
(KEY 8)
PACKING BOX
RING (KEY 11)
PACKING RING
(KEY 7)
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
TYPICAL (DOUBLE) ARRANGEMENTS
12A8188-A
12A7815-A
12A8173-A
A2619-1 / IL
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.
Replacing Packing
WARNING
Refer to the WARNING at the
beginning of the Maintenance section
in this instruction manual.
1. Isolate the control valve from the line pressure,
release pressure from both sides of the valve, 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, and then remove the actuator
from the valve by unscrewing the yoke locknut (key
15, figure 21) or the hex nuts (key 26, figure 21).
3. Loosen the packing flange nuts (key 5, figure 21)
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 helps to
provide additional assurance that the
valve body fluid pressure has been
relieved.
4. Hex nuts (key 16, figure 22, 23 or 24) attach the
bonnet (key 1, figure 21) to the valve body (key 1,
figure 22, 23 or 24). Loosen these nuts
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
body. Work the prying tool around the bonnet until
the bonnet loosens. If no fluid leaks from the joint,
proceed with bonnet removal as described in the
following steps.
CAUTION
To avoid damage to the seating
surface caused by the valve plug and
stem assembly dropping from the
bonnet after being lifted part way out,
temporarily install a valve stem
locknut on the valve stem when lifting
the bonnet. The locknut prevents the
valve plug and stem assembly from
dropping out of the bonnet.
5. Completely remove the hex nuts (key 16) and
carefully lift the bonnet off the valve body.
6. Remove the locknut and separate the valve plug
and stem from the bonnet. Set the parts on a
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Instruction Manual
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NOTES:
0.102 mm (0.004 INCH) THICK SACRIFICIAL ZINC WASHERS;
USE ONLY ONE BELOW EACH GRAPHITE RIBBON RING.
Figure 6. Detail of Graphite Ribbon/Filament Packing
PACKING
FOLLOWER
(KEY 13)
LANTERN
RING (KEY 8)
PACKING BOX
RING (KEY 11)
1
12.7 mm
(1/2 INCH)
STEM
SINGLE ARRANGEMENTS
A6067 / IL
GRAPHITE
RIBBON
PACKING RING
(KEY 7)
GRAPHITE
FILAMENT
PACKING RING
(KEY 7)
1
19.1, 25.4, & 31.8 mm
(3/4, 1 & 1Ć1/4 INCH)
STEM
13A9775-B
13A9776-B
PACKING
FOLLOWER
(KEY 13)
LANTERN
RING (KEY 8)
PACKING BOX
RING (KEY 11)
1
12.7 mm
(1/2 INCH)
STEM
DOUBLE ARRANGEMENTS
GRAPHITE
RIBBON
PACKING RING
(KEY 7)
GRAPHITE
RIBBON
PACKING RING
(KEY 7)
GRAPHITE
FILAMENT
PACKING RING
(KEY 7)
1
19.1, 25.4, & 31.8 mm
(3/4, 1 & 1Ć1/4 INCH)
STEM
14A1849-B
14A1780-B
1
1
protective surface to prevent damage to gasket or
seating surfaces.
7. Remove the bonnet gasket (key 10, figure 22
through 24), and cover the opening in the valve body
to protect the gasket surface and prevent foreign
material from getting into the valve body cavity.
8. Remove the packing flange nuts, packing flange,
upper wiper, and packing follower (keys 5, 3, 12,
and 13, figure 21). 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.
9. Inspect the valve stem threads and packing box
surfaces for any sharp edges that 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 by following the
appropriate steps in the Trim Maintenance
procedure.
10. Remove the covering protecting the valve cavity
and install a new bonnet gasket (key 10, figure 22
through 24), making sure the gasket seating
surfaces are clean and smooth. Place the stem and
valve plug into the valve body and slide the bonnet
over the stem and onto the stud bolts (key 15,
figure 22, 23, or 24).
Note
Proper performance of the tightening
procedures in step 11 compresses the
spiral wound gasket (key 12, figure 22
through 23) or load ring (key 26, figure
24) enough to both load and seal the
seat ring gasket (key 13, figure 22, 23
or 24). It also compresses the outer
edge of the bonnet gasket (key 10,
figure 22 through 24) enough to seal
the body-to-bonnet joint.
The proper bolting procedures in step
11 include--but are not limited
to--ensuring that bolting threads are
clean, and evenly tightening the nuts
onto the studs in a criss-cross pattern.
Because of the bolt-up characteristics
of spiral wound gaskets, tightening
one nut may loosen an adjacent nut.
Repeat the criss-cross tightening
pattern several times until each nut is
tight and the body-to-bonnet seal is
made. When the operating temperature
has been reached, perform this
torquing procedure once again.
11. Lubricate the bolting (not necessary if factory
pre-lubricated stud bolt nuts are used) and install it,
using proper 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 5 as guidelines.
12. Install new packing and the metal packing box
parts according to the appropriate arrangement in
figure 4, 5, or 6. Place a smooth-edged pipe over the
valve stem and gently tap each soft packing part into
the packing box.
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Instruction Manual
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Table 5. Body-to-Bonnet Bolt Torque Guidelines
BOLT TORQUES
(1)
VALVE SIZE, NPS
NSm LbfSft
4x2 102 75
6x4 or 8x4 259 191
CL300 or CL600 548 404
8x6
CL900 1315 970
10x8 745 550
12x6 548 404
CL300 or CL600 732 540
12x8
CL900 2712 2000
1. Determined from laboratory tests.
Table 6. Recommended Torque for Packing Flange Nuts
VALVE STEM
GRAPHITE TYPE PACKING PTFE TYPE PACKING
VALVE STEM
DIAMETER
PRESSURE
Minimum Torque Maximum Torque Minimum Torque Maximum Torque
mm Inches
RATING
NSm LbfSIn NSm LbfSIn NSm LbfSIn NSm LbfSIn
12.7
CL300 7 59 10 88 3 28 5 42
12.7
1/2
CL600 9 81 14 122 4 39 7 58
19.1
CL300 15 133 23 199 7 64 11 95
19.1
3/4
CL600
21 182
31 274
10 87 15 131
25.4
CL300
26 226
38 339
12 108 18 162
25.4
1
CL600
35 310
53 466
17 149 25 223
31.8
CL300
36 318
54 477
17 152 26 228
31.8
1-1/4
CL600
49 437
74 655
24 209 36 314
13. Slide the packing follower, upper wiper, and
packing flange (keys 13, 12, and 3, figure 21) into
position. Lubricate the packing flange studs (key 4,
figure 21) and the faces of the packing flange nuts
(key 5, figure 21). Install the packing flange nuts.
14. For spring-loaded PTFE V-ring packing,
tighten the packing flange nuts until the shoulder on
the packing follower (key 13, figure 21) contacts the
bonnet.
For graphite packing, tighten the packing flange
nuts to the maximum recommended torque shown in
table 6. Then, loosen the packing flange nuts, and
retighten them to the recommended minimum torque
shown in table 6.
For ENVIRO-SEAL or HIGH-SEAL live-loaded
packing, refer to the note at the beginning of the
Packing Maintenance section.
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. Then, tighten the remaining
flange nuts until the packing flange is level and at a
90-degree angle to the valve stem.
15. 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
WARNING
Observe the warning at the start of the
Maintenance section.
CAUTION
In the following applicable procedures,
to avoid damaging parts, do not grip
the bellows shroud or other parts of
the stem/bellows assembly. Grip only
the flat areas on the stem where it
extends out of the top of the bellows
shroud.
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 22 for Design EWD
constructions, figure 22 for restricted trim detail,
figure 23 for Design EWS constructions, and
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Instruction Manual
Form 2376
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Figure 7. TSO (Tight Shutoff Trim), Detail of Protected Soft Seat
INNER PLUG
OUTER PLUG
CAGE
SEAT RING
PROTECTED SOFT SEAT
A7088 / IL
figure 24 for Design EWT constructions. Refer to
figures 26 and 27 for Cavitrol III, figure 27 for
Whisper Trim III, and figure 29 for WhisperFlo
construction.
Trim Removal
1. Remove the actuator and the bonnet according to
steps 1 through 5 of the Replacing Packing
procedure.
WARNING
Avoid personal injury or property
damage from valve or packing leakage.
When lifting the valve plug stem (key
7) and attached valve plug (key 2) out
of the valve, be certain that the cage
(key 3) remains in the valve (key 1).
This will prevent cage damage that
might be caused by the cage dropping
back into the valve after being lifted
part way out.
Use care to avoid damaging gasket
sealing surfaces.
Each graphite piston ring (key 6) in a
Design EWD valve is brittle and in two
pieces. Use care to avoid damage to
the piston ring(s) caused by dropping
or rough handling.
Any damage to the gasket sealing
surfaces could cause the valve to leak.
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
ring (key 6) or seal ring (key 28). The
seating surfaces of the valve plug (key
2) and the seat ring (key 9) on a
metal-seat construction are critical for
tight shutoff. Protect these parts
accordingly while disassembling the
trim.
2. Remove the packing flange nuts, packing flange,
upper wiper, and packing follower (keys 5, 3, 24,
and 25, figure 21). 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 NPS 10x8
or 12x8 valve or the cage adaptor (key 4) from any
restricted-trim valve through NPS 8x4, and wrap it
for protection.
5. On a 102 mm (4-inch) travel valve with Whisper
Trim I cage or on any NPS 8x6 or 12x6 valve with
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Instruction Manual
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Whisper Trim III cage, 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 cage retainer
has two 3/8-16 UNC threads 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).
With full-capacity constructions that have FGM
gasket sets, a shim (key 53) is used instead of the
cage gasket (key 11). 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. For constructions other than TSO (tight
shutoff trim), remove the seat ring (key 9) or disk
seat (key 22), seat ring gasket (key 13), and the seat
ring adaptor (key 5) and adaptor gasket (key 14)
where used in a restricted-capacity construction.
Design EWS and EWT PTFE-seat constructions use
a disk (key 23) sandwiched between the disk seat
and disk retainer (key 21). A CL900 NPS 8x6 Design
EWT construction with Cavitrol III cage has its spiral
wound gasket (key 12) on the side of the seat ring
opposite the seat ring gasket.
8. For TSO (tight shutoff trim) constructions,
perform the following steps (refer to figures 7 and 8):
D Remove the piston ring, anti-extrusion rings,
backup ring, and retainer.
D Remove the set screws that lock the outer plug
to the inner plug.
D Using a strap wrench or similar tool, unscrew
the outer plug from the inner plug. Do not damage
the outer plug guide surfaces.
D Remove the protected soft seat seal.
D Inspect the parts for damage and replace if
needed.
9. For all constructions, inspect parts for wear or
damage that would prevent proper operation of the
valve. Replace or repair trim parts according to the
following procedures for lapping metal seats or other
valve plug maintenance procedures, as appropriate.
Figure 8. Typical Balanced TSO Trim
VALVE PLUG
SEAL
PROTECTED
SOFT SEAT
A7096 / IL
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 rotation will damage internal
components of the ENVIRO-SEAL
bellows seal bonnet.
Except with respect to the ENVIRO-SEAL Bellows
Seal Bonnet assembly, with metal seat
constructions, seating surfaces of the valve plug and
seat ring (keys 2 and 9, figures 24 through 26) 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 the compound to the bottom of the
valve plug.
Assemble the valve to the extent that the cage (and
cage retainer and bonnet spacer, if used) is in place
and the bonnet is bolted to the valve. A simple
handle can be made from a piece of strap iron
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Instruction Manual
Form 2376
March 2007
14
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 the valve as
described in the Trim Replacement portion of the
Trim Maintenance section, 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 22 for Design EWD valve
plugs, figure 11 for Design EWS valve plugs, and
figure 24 for Design EWT valve plugs.
CAUTION
If replacing the piston ring (key 6) or
seal ring (key 28), be careful not to
scratch the surfaces of the ring groove
in the valve plug or any of the surfaces
of the replacement ring, or the
replacement ring may not seal
properly.
1. With the valve plug (key 2) removed, according to
the Trim Removal section, proceed as appropriate:
For the Design EWD 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 direction, as shown in view
A of figure 22.
For each Design EWD 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.
For the Design EWT two-piece seal ring, the ring
cannot be reused as it is a closed ring, which must
be pried and/or cut from the groove. Then the
elastomeric backup ring (key 29) can be spread
slightly and removed.
To install a new two-piece seal ring, apply a general
purpose silicone-base lubricant to both the backup
ring and seal ring (keys 29 and 28). Place the
backup ring over the stem (key 7) and into the
groove. Place the seal ring over the top edge of the
valve plug (key 2) so that it enters the groove on one
side of the valve plug. Slowly and gently stretch the
seal ring, and work it over the top edge of the valve
plug. The PTFE material in the seal ring must be
permitted time to cold-flow during the stretching
procedure; so avoid jerking sharply on this ring.
Stretching the seal ring over the valve plug may
make it seem unduly loose when in the groove, but it
will contract to its original size after insertion into the
cage.
For the Design EWT spring-loaded seal ring, the
ring used on a valve plug having a 136.5 mm (5.375
inch) or less port diameter may be removed
undamaged by first working the retaining ring
(key 27) off with a screwdriver. Then carefully slide
the metal backup ring (key 29) and seal ring (key 28)
off the valve plug (key 2). The spring-loaded seal
ring used on a valve plug having a 178 mm (7-inch)
or greater port diameter must be carefully pried
and/or cut from its groove. Therefore, it cannot be
reused.
A spring-loaded seal ring must be installed so that its
open side faces toward either the top or the bottom
of the valve plug, depending on flow direction, as
shown in view A of figure 22 or 24. To install a
spring-loaded seal ring on a valve plug with a 136.5
mm (5.375 inch) or less port diameter, slide the seal
ring (key 28) onto the valve plug followed by the
metal backup ring (key 29). Then install the retaining
ring (key 27) by inserting one end in the groove and,
while turning the plug, press the ring into the groove.
Again, be careful not to scratch any surfaces of the
ring or plug.
To install the seal ring on a valve plug with 178 mm
(7-inch) or greater port diameter, lubricate it with a
general purpose silicone-base lubricant. Then gently
stretch the seal ring, and work it over the top edge of
the valve plug. The PTFE material in the seal ring
must be permitted time to cold-flow during the
stretching procedure; so avoid jerking sharply on the
ring. Stretching the seal ring over the valve plug may
make it seem unduly loose when in the groove, but it
will contract to its original size after insertion into the
cage.
CAUTION
Never reuse an old stem or adaptor
with a new valve plug. Using an old
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Instruction Manual
Form 2376
March 2007
15
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 except with Cavitrol III trim.
Note
The valve plug and valve plug stem for
Cavitrol III trim are a matched set and
must be ordered together. If the
Cavitrol III valve plug or valve plug
stem is damaged, replace the entire
assembly (key 2, figure 26 and 27).
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 21) 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 21). 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 21) from the valve stem assembly (key 20,
figure 21).
4. Screw the new stem or adaptor into the valve
plug. Tighten to the torque value given in table 7.
Refer to table 7 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.
Trim Replacement
Except where indicated, key numbers in this section
are referenced in figure 22 for Design EWD
constructions, figure 22 for restricted trim detail,
figure 23 for EWS construction, and figure 24 for
Design EWT constructions. Refer to figures 26
Table 7. Valve Stem to Plug Torque and Pin Replacement
Data
VALVE STEM
DIAMETER
STEM TORQUE,
MINIMUM TO MAXIMUM
DRILL SIZE,
mm Inch
NSm LbfSft
INCHES
12.7 1/2 81 to 115 60 to 85 0.125
19.1 3/4 237 to 339 175 to 250 0.1875
25.4 1 420 to 481 310 to 355 0.25
31.8 1-1/4 827 to 908 610 to 670 0.25
and 27 for Cavitrol III, figure 16 for Whisper Trim III,
and figure 29 for WhisperFlo constructions.
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
(key 9), or disk seat (key 22). With a PTFE-seat
construction install the disk and disk retainer
(keys 21 and 23). With an NPS 8x6 CL900 Design
EWT valve with Cavitrol III cage, install the spiral
wound gasket (key 12) on the seat ring.
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 or Cavitrol III cage 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.
4. For constructions other than TSO (tight
shutoff trim), slide the valve plug (key 2) and stem
assembly or valve plug and ENVIRO-SEAL bellows
seal assembly into the cage. Make sure the piston
ring or seal ring (key 6 or 28) is evenly engaged in
the entrance chamfer at the top of the cage (key 3)
or cage retainer (key 31) to avoid damaging the ring.
5. For TSO (tight shutoff) trim constructions,
perform the following steps (refer to figures 7 and 8).
D Thread the outer plug onto the inner plug until
the parts seat metal to metal, using a strap wrench
or similar tool that will not damage the outer plug
guide surfaces.
D Mark the top of the inner plug and outer plug
with alignment marks in the assembled position.
D Disassemble the outer plug from the inner plug
and install the seal over the inner plug, so that the
seal rests below the threaded area.
D Thread the outer plug onto the inner plug and
tighten with a strap wrench or similar tool until the
EW Valve
Instruction Manual
Form 2376
March 2007
16
Figure 9. Design EWD with C-sealt Trim
A6790 / IL
FLOW DOWN
FLOW UP
A
VIEW A
64 64
9
2
64
65
8
7
alignment marks line up. This will ensure that the
plug parts are metal to metal and the seal is
compressed properly. Do not damage the outer plug
guide surfaces.
D Install set screws centering the inner plug in the
outer plug and torque to 11 NSm (8 lbfSft).
D Assemble the piston ring, anti-extrusion rings,
backup ring, and retainer.
6. For all constructions, place the gaskets
(keys 12, 11 or 14 if used, and 10) and the shim, if
used (key 53), 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 adapter or spacer. If there is only a cage
retainer or bonnet spacer, place another flat sheet
gasket on the retainer or spacer.
7. With an NPS 10x8 or 12x8 valve, install the load
ring (key 26).
8. Mount the bonnet on the valve, and complete
assembly according to steps 11 through 15 of the
Replacing Packing section. Be sure to observe the
note prior to step 11.
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 Emerson Process
Management 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:
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
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