Fisher Fisher CVX Hydro-Plug Fixture Manuals & Guides

Instruction Manual

D103630X012

Fisher™ CVX Hydro‐Plug Fixture

Contents

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

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

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

Educational Services 2.........................

Principle of Operation 2.........................

Maintenance 2.................................

Valve Disassembly 3...........................

Actuator Removal 3........................

Packing Box 3.............................

Bonnet and Trim 3.........................

Visual Inspection 5.........................

Installation of the Hydro-Plug 5..................

Piping Hydro Test with the Hydro-Plug Fixture

Installed 6.................................

Disassembly of the Hydro-Plug Fixture 6..........

Cleaning 7................................

Reassembly 7.................................

Ordering Information for Hydro-Plug Fixture 7......

Valve Information 7...........................

CVX Hydro-Plug Fixture

June 2017

Introduction

Scope of Manual

This instruction manual includes installation and operation information for the Fisher CVX Hydro‐Plug Fixture. The CVX
Hydro‐Plug Fixture can be very useful in establishing hydro test boundaries since most CVX valves are split class valves.
This manual is not intended to cover all details required for successful hydro testing.

Key numbers identified for valve disassembly are shown in the specific valve instruction manual. Refer to separate
instruction manuals for instructions covering the exact valve, actuator, and accessories associated with the
Hydro‐Plug.

Do not install, operate, or maintain a CVX Hydro-Plug Fixture without being fully trained and qualified in valve,
actuator, and accessory installation, operation, and maintenance. To avoid personal injury or property damage, it is

important to carefully read, understand, and follow all the contents of this manual, including all safety cautions and
warnings. If you have any questions about these instructions, contact your Emerson sales office

Partner before proceeding.

Description

The CVX Hydro‐Plug fixture provides a convenient way to establish hydrotest boundaries associated with using a split
class valve typical of the CVX. The Hydro‐Plug fixture is intended to be used so that the upstream piping can be tested
at the required pressure for body and inlet piping pressure class without overpressurizing the lower pressure class
outlet and outlet piping.

or Local Business

www.Fisher.com

CVX Hydro-Plug Fixture

June 2017

Instruction Manual

D103630X012

Educational Services

For information on available courses for the Fisher CVX Hydro-Plug Fixture, as well as a variety of other products,
contact:

Emerson Automation Solutions
Educational Services - Registration
Phone: [phone] or 1-800-338-8158
E-mail: [e-mail]
emerson.com/fishervalvetraining

Principle of Operation

The Hydro‐Plug replaces the valve plug and cage and allows pressurization of the valve inlet, valve body, and inlet
piping to the appropriate hydro pressure without overpressurizing the lower pressure class valve outlet and outlet
piping.

CAUTION

The Hydro‐Plug Fixture employs a rubber O‐ring to create a positive seal at the valve seat. The sealing integrity of this
O‐ring will be compromised if the Hydro‐Plug is installed when welding the valve body inline, or during welding preheat or
post weld heat treatment.

Maintenance

WARNING

To avoid personal injury or property damage from pressurized escape of process media, ensure that the system is
completely depressurized and appropriate safety measures have been taken prior to carrying out any of the following
procedures. Only trained competent individuals with the proper equipment should attempt to disassemble and install a
Hydro‐Plug Fixture, and reassemble a CVX valve.

D Do not remove the actuator from the desuperheater while the valve is still pressurized.

D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal

injury.

D Disconnect any operating lines providing air pressure, electric power or a control signal to the actuator. Be sure the

actuator cannot suddenly open or close the valve.

D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure

on both sides of the valve. Drain the process media from both sides of the valve.

D Vent the power actuator loading pressure and relieve any actuator spring precompression.

D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.

D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the

pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings, or when
loosening the packing box pipe plug.

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Instruction Manual

D103630X012

D Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

CVX Hydro-Plug Fixture

June 2017

Valve Disassembly

The following valve disassembly steps are intended as a quick reference only. Refer to the CVX instruction manual,
D103606X012, for further detail regarding valve disassembly.

Actuator Removal

The following actuator disassembly steps are intended as a quick reference only. Refer to the appropriate actuator
instruction manual for further detail regarding actuator removal.

1. Release the actuator seat load by either manually stroking the valve or applying the appropriate instrument signal.
The stem connector may be removed once the plug is off the valve seat.

2. If an instrument signal has been used to stroke the plug off the seat, remove the signal only after removing the
stem connector.

3. Isolate and disconnect the operating lines from the actuator.

4. Loosen the yoke locknut or the fasteners and remove the actuator from the valve.

Packing Box

Unbolt the packing stud nuts, (key 68), and remove the packing flange (key 66) and packing follower, (key 65)
(reference appropriate instruction manual for key numbers). Remove as much packing as possible from the packing
box.

CAUTION

Extreme care should be taken to avoid scratching the stem or the packing box.

Bonnet and Trim

1. Loosen the bonnet stud nuts (key 55), using an even and opposing pattern (for example, if the first nut loosened is
at the 1 o'clock position, the next nut to be loosened would be at the 7 o'clock position). This will prevent uneven
loading of the bonnet studs which may cause binding.

Individual nuts should not be completely loosened while the remaining nuts are tight. It is suggested that at least two
stages of loosening be used to avoid overloading the last few remaining studs.

2. Remove the bonnet (key 6) from the valve with uni‐axial pull. If the bonnet seems to bind in the valve body, check
the alignment of the hoist or pulling mechanism. Deviation from an axial pull of the parts may result in galling or
bending of the stem (key 23).

CAUTION

Do not attempt to over‐power any binding, as damage to the guide surfaces may result.

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CVX Hydro-Plug Fixture

June 2017

Instruction Manual

D103630X012

The bonnet may be lightly tapped back into alignment with a soft face mallet. The stem and plug should be pushed
back into the valve body while the bonnet is being removed. Once the bonnet is removed, dislodge any remaining
packing rings from the packing box.

3. Remove the packing ring (key 63) from the bottom of the packing box. Lightly sand the inside of the packing box
with 60 or 80 grit paper to remove any adherent packing material. Final cleanup should be made with 160 grit or
higher paper.

4. Inspect the bonnet guiding surfaces and gasket mating surfaces. Light damage on the guiding surface may be
repaired with an emery cloth or other suitable material. Damage to the gasket mating surface may require bonnet
replacement to avoid leakage.

5. Remove the plug assembly (key 22, 23, and 53) as a single unit by grasping the valve stem (key 23) and pulling the
assembly from the body cavity. The plug assembly contains sensitive guiding and sealing surfaces on its outside
diameter and care must be taken in its handling. The plug should be temporarily stored on a clean wooden or cloth
surface.

6. Remove the cage (key 21) from the valve body. Remove and discard the upper and lower cage gaskets (key 43).
Reference the CVX valve instruction manual for guidance in performing this disassembly. The cage contains
sensitive guiding surfaces on its outside diameter and care must be taken during handling. The cage should be
temporarily stored on a clean wooden or cloth surface.

7. Clean and inspect the guiding and sealing surfaces of the plug assembly. For balanced plug designs, inspect the
piston ring (key 45) and Bore Seal ring (key 46) for signs of excess wear or damage and replace if necessary. The
piston ring is a two piece design with an outer seal ring and an inner expander ring. The outer ring diameter should
be expanded beyond the diameter of the plug in its free state. It can be shifted within its groove to inspect for
uneven wear around its circumference. The piston ring should require some compression when installing the plug
into the cage. Lack of required compression indicates that the piston ring has worn or relaxed and should be
replaced. Vertical marks in the axial orientation also indicates wear that requires replacement of the ring. The Bore
Seal ring has a C‐shaped cross section with the open portion of the C‐shape facing the seating surface of the plug for
flow‐up designs and the open portion of the C-shape facing the seating surface of the plug for flow-down designs.
Any uneven marks around the circumference of the ring or any flattening of the ring shape at its outside diameter
are indications of wear and require replacement. Contact your Emerson sales office

or Local Business Partner for

Bore Seal ring replacement.

Table 1. Recommended Bonnet Bolt Torque

Bolt Size, Inch Threads per Inch Recommended Bolt Torque, lbfSft

1 8 405

1‐1/8 8 550

1‐1/4 8 730

1‐3/8 8 980

1‐1/2 8 1290

1‐5/8 8 1650

1‐3/4 8 2070

1‐7/8 8 2560

2 8 3130

2‐1/4 8 4490

1. Torques for studs with heavy hex nuts.

(1)

8. Clean and inspect the inside diameter surfaces of the cage. The entire length of the cage inside diameter is either a
sealing and/or guiding surface and any measurable wear requires that the cage be replaced.

9. Integral Diffuser Constructions Only: The seat ring remains retained inside the valve body regardless if it is bolted or
welded. Clean and inspect the angled seating surface. Any detectable damage around the circumference of the
seating surface is an indication of wear and requires reconditioning to ensure seating performance. Contact your
Emerson sales office or Local Business Partner for specific instructions on reconditioning the seating surface.

10. Bolted Seat Ring Removable Diffuser Only: The bolted seat ring and seat diffuser must be removed. Loosen the
seat ring bolts, (key 76) using an even and opposing pattern (for example, if the first nut loosened is at the 1 o'clock
position, the next nut to be loosened would be at the 7 o'clock position). This will prevent uneven loading of the

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