Instruction Manual
D103466X012
HPNS Valve
March 2022
Fisher
™
HPNS Control Valve
Contents
Introduction 1.................................
Scope of Manual 1.............................
Description 1.................................
Specifications 2...............................
Educational Services 2.........................
Principle of Operation 4.........................
Lifting Guidelines 5.............................
Installation 6..................................
Maintenance 8.................................
Bonnet Nut Torquing Considerations 9...........
Packing Lubrication 10.........................
Packing Maintenance 10........................
Replacing Conventional Packing 11...........
Replacing HIGH-SEAL Packing 17.............
Trim Removal 18..............................
Standard Balanced and Unbalanced
Trim Removal 18........................
Bore Seal Trim Removal 18..................
Trim Replacement 19..........................
Installing Dynamic Bore Seal Trim 23.............
Installing Static Bore Seal Trim 26................
Hermetically Sealed Bellows Valve 28..............
Packing Maintenance 28........................
Replacement of an Installed Bellow Seal 28........
Trim Removal 31..............................
Figure 1. HPNS Valve with 667NS2 Actuator
Trim Replacement 31..........................
Troubleshooting 40.............................
Parts Ordering 41...............................
Parts List 41...................................
Introduction
Scope of Manual
This instruction manual includes installation, maintenance, and parts information for NPS 1/2 through NPS 10 HPNS
valves with CL900 through CL2075 ratings. Note: Applications requiring lower pressure class ratings may use the same
casting as a higher rated valve of the required size. Refer to separate manuals for instructions covering the actuator,
positioner, and accessories.
Do not install, operate, or maintain HPNS valves 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
Description
HPNS valves (figure 1) have buttweld end connections in various schedules and are designed for use with Fisher
667NS2 and 657NS2 actuators and can also be used with a Fisher yoke and other piston actuator options. HPNS valves
are designed to handle high seismic environments.
before proceeding.
www.Fisher.com
HPNS Valve
March 2022
Table 1. Specifications
Instruction Manual
D103466X012
End Connection Styles and Ratings
(1,2)
Buttwelding: Consistent with Schedule 40-160
Flanges: Not available
Socket Welding: Not available
Also see table 2
Shutoff Classifications
See table 3
Bidirectional Trim: Class V. See table 4
Bore Seal trim: High‐temperature, Class IV and V.
See table 4
Flow Characteristic
Standard Cage: J Equal percentage, J Modified
equal percentage, J Linear or, J Quick opening
on/off
Micro‐Form Valve Plug: J Equal percentage
J Modified equal percentage or, J Quick opening
on/off
Flow Direction
Standard Cage
J HPNS Balanced: Normally flow up
J HPNS Unbalanced: Normally flow down or up
(3)
(4)
Cavitrol III Cage: Flow down
Whisper Trim III Cage: Flow up
Approximate Weights
(valve body and bonnet assemblies)
See table 2
Bolt Torque Tolerance
Torque values given are +/- 5%, unless otherwise
specified
Special Tools
Standard mechanics tools are used for
assembly/disassembly, except for:
Valves supplied with bore seal plugs:
J a bore seal installation tool is required for proper
installation of the bore seal (see figure 13 for dynamic
bore seal and figure 16 for static bore seal),
J a center punch is also used to stake the bore seal
retainer threads after installation, J a 1/8 inch
diameter drill bit is recommended for removing the
deformed section of thread on the bore seal retainer
during bore seal replacement
Valves supplied with hermetically-sealed bellows
seal:
J a loading fixture is required for performing
seal-weld between bellows flange and valve body (see
figure 19)
Cavitrolt III or Whisper Trimt III Cage: J Linear
Additional Specifications
For specifications such as materials, valve plug
Special cages: Special characterized flow cages are
available. Consult your Emerson sales office
1. EN (or other) ratings and other BWE can usually be supplied; consult your Emerson sales office.
2. The pressure or temperature limits in this manual and any applicable standard limitations should not be exceeded.
3. HPNS Balanced valves may be used flow down where required by design.
4. HPNS Unbalanced valves may be used flow down for on‐off service or where required by design.
travels, and port, yoke bolt circle, and stem
diameters, see the Parts List section
Specifications
Specifications for the HPNS valves are shown in table 1.
Educational Services
For information on available courses for the Fisher HPNS valve, as well as a variety of other products, contact:
Emerson Automation Solutions
Educational Services - Registration
Phone: 1-641-754-3771 or 1-800-338-8158
E-mail: education@emerson.com
emerson.com/fishervalvetraining
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D103466X012
Table 2. Valve Assembly Approximate Weights
VALVE SIZE, NPS PRESSURE RATING KG LBS
1/2
1 117 257
2 118 259
3 271 596
4
6 374 823
8
10 2064 4550
Table 3. Shutoff Classifications per ANSI/FCI 70‐2 and IEC 60534‐4
VALVE DESIGN VALVE SIZE, NPS
1/2 6.35 (0.25) Micro-Form V
1
Unbalanced HPNS
2
3 73.03 (2.875) Linear (std. cage) V
2075
900
1725
PORT DIAMETER,
mm (INCHES)
6.35 (0.25) to 25.4 (1) Micro-Form
25.4 (1) Micro-Form
25.4 (1) Special (Cavitrol III, 3-stage)
47.63 (1.875)
47.63 (1.875) Linear
136 300
261 574
940 2071
TRIM STYLE LEAKAGE CLASS
IV (forward)
V (reverse)
Equal %
(std or Whisper III, B3 cage)
Linear
(std or Whisper III, B3 cage)
IV (forward)
V (reverse)
HPNS Valve
March 2022
IV
V
V
Table 4. Additional Shutoff Classification per ANSI/FCI 70‐2 and IEC 60534‐4
VALVE DESIGN VALVE SIZE, NPS
3 73.0 (2.875)
4 92.1 (3.625) Modified Equal %
5 136.525 (5.375) Linear (std. cage)
Balanced HPNS
6
8
10 254 (10) Linear
PORT DIAMETER,
mm (INCHES)
Linear (Whisper III, C3) V
136.525 (5.375) Linear (std. cage) IV
133.35 (5.25) Special (Cavitrol III, 2-stage)
177.8 (7) Linear (std. cage)
111.125 (4.375) Special IV Bidirectional
CAGE STYLE LEAKAGE CLASS
Equal % III
IV
V
IV
V
V (forward)
IV (reverse)
IV
V
V (forward)
IV (reverse)
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March 2022
Instruction Manual
Table 5. Torque for Body‐to‐Bonnet Bolting Using Nuclear Grade Anti-Seize Lubricant
VALVE
SIZE,
NPS
1/2 676 711 818 498 524 603
1 883 929 1068 651 685 788
2 883 929 1068 651 685 788
3 1648 1735 1995 1216 1280 1472
4 1230 1295 1489 907 955 1098
6 2164 2278 2620 1596 1680 1932
8 4315 4542 5223 3183 3350 3853
10 10420 10968 12613 7686 8090 9304
Minimum Nominal Maximum Minimum Nominal Maximum
NSm lbfSft
TORQUE
Table 6. Recommended Torque for Packing Flange Nuts (non live‐loaded)
STEM
DIAMETER
mm Inches Min Max Min Max
12.7 0.5
19.05 0.75
25.4 1 600 34 50 25 37
CLASS
150 5 8 4 6
900 12 18 9 13
1500 18 24 13 18
1500 18 24 13 18
2075 41 61 30 45
NSm lbfSft
TORQUE
D103466X012
Principle of Operation
HPNS valves are control valves based on the Fisher HP valve product. The valve body and bonnet contain a fluid under
pressure, while the internal valve parts control the flow of the fluid through the valve. The internal parts consist of
gaskets, a seat ring, a plugstem assembly, and a cage. Additional seals might be used depending on the exact
function and design of the valve.
The gaskets, seat ring, and cage are stationary and held in place inside the valve body and bonnet by the force applied
by the body-to-bonnet bolting. The plugstem assembly is designed to move up and down (axially) inside the cage.
The stem passes through a hole in the bonnet, and can be moved up and down (axially) by an external actuator
attached to the valve body, or bonnet. Sealing packing is used between the valve bonnet and plug stem to prevent the
fluid from leaking out of the valve, while still allowing the plug stem to move axially.
Fluid enters one end of the valve. When the stem is pushed down, the plug moves to contact the seat ring, and
“closes” the valve, preventing the fluid from passing through the valve. When the stem is pulled up, the plug
disengages from the seat ring, and slides up through the center of the cage, exposing holes or flow passages in the
cage. This allows the fluid to flow through seat ring and cage, and exit the valve through the opposite end of the valve
which it entered. By positioning the plug at different "travels" in the cage, the amount of flow through the valve can be
controlled.
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Lifting Guidelines
WARNING
Failure to follow these lifting guidelines and accepted lifting and rigging practices could result in property damage and
personal injury or death.
All lifting and rigging must be completed in accordance with federal/national/provincial, state and local regulations and
applicable lifting and rigging equipment standards. Only personnel trained in proper lifting and rigging practices shall
perform valve/actuator assembly lifting, rigging and installation. Because each lift will be unique, the method of lifting the
valve assembly, the correct location for attaching and lifting the valve assembly, and what the valve assembly will do when
lifted shall be considered for each lift.
Lifting and rigging equipment used to lift, install or remove a valve assembly or component must be properly selected and
sized for the weight and configuration of the valve assembly or component being lifted. The weight of the complete valve
assembly, including attached accessories, must be taken in consideration for this purpose. The lifting and rigging
equipment must be properly maintained and inspected for damage before each use.
If the valve is supplied with an actuator or handwheel, do not use the actuator or handwheel to lift the complete valve
assembly. Lifting lugs attached to the actuator must not be used to lift the complete valve assembly unless clearly marked
as being rated to support the complete valve assembly weight.
Lifting lugs or other lifting equipment attached to the valve or actuator must never be used to lift or support the weight of
attached piping.
CAUTION
Care must be taken when lifting the valve/actuator assembly to ensure all accessories and tubing are not damaged in the
process. Accessories and tubing may need to be removed prior to lifting to prevent damage and properly reinstalled before
use. Protect valve flange faces, butt weld ends, and other connection surfaces from damage during lifting.
The quantity of eyebolts for lifting purpose is the minimum recommendation. More eyebolts can be used per customer
experience. When tightening the eyebolts and nuts, do not exceed the torque that is specified on the diaphragm casing cap
screws and nuts (keys 119 and 120) in the following sections, to avoid damage on the diaphragm.
Lifting Valve/Actuator Assembly
To lift the valve/actuator assembly, eyebolts should be used. Insert four 3/8 inch shouldered pattern eyebolts
positioned 90 degrees apart on the diaphragm casing flange for size 45 and 70. Use six 7/16 inch shouldered pattern
eyebolts positioned 60 degrees apart on the diaphragm casing flange for size 80. Two nuts are required with one on
each side of the diaphragm casing flange. A longer strap is recommended, so that the angle between the straps
connecting each eyebolt can be smaller, which helps the eyebolts hold more weight. The eyebolt should be ASTM
A489-K04800 or stronger material.
For a bellows seal valve, the valve/actuator assembly should be lifted using one or more lifting straps that are rigged to
choke around the actuator under the diaphragm casing. Use protective pads between the strap(s) and casing to help
prevent damage to the painted surface. A single hoist lift point on the strap(s) will balance and lift the valve/actuator
assembly in a level manner. If necessary, use additional slings around the valve inlet and outlet or around actuator legs
for body stabilization.
Lifting Valve Only
To lift the valve, eyebolts should be used. Insert 3/4-10 inch shouldered pattern eyebolts into two threaded holes
located on the top of the NPS 1/2 through NPS 6 valve bodies, positioned 180 degrees apart. For NPS 8 and NPS 10
valve bodies, insert two 3/4-10 shouldered pattern eyebolts into two threaded holes located on the top of the bonnet,
positioned 180 degrees apart. The eyebolt material should be ASTM A489-K04800 or stronger material. Be sure at
least 90% of the threads are engaged in the receiving hole, with a minimum thread engagement of at least 1-1/2 times
the thread diameter in steel. If necessary, place lifting slings around the inlet and outlet of the valve body for
stabilization. Use padding as needed to protect any painted surfaces. The valve can now be lifted using a hoist capable
of leveling the lifting points.
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March 2022
Instruction Manual
D103466X012
Lifting Actuator Only
To lift the actuator and accessories, eyebolts should be used. Insert two 3/8 inch shouldered pattern eyebolts
positioned 180 degrees apart on the diaphragm casing flange for size 45 and 70. Use four 7/16 inch shouldered
pattern eyebolts positioned 90 degrees apart on the diaphragm casing flange for size 80. Two nuts are required with
one on each side of the diaphragm casing flange. The eyebolt material should be ASTM A489-K04800 or stronger
material. For a bellows seal valve, the actuator should be lifted using one or more lifting straps that are rigged to choke
around the actuator under the diaphragm casing. Use protective pads between the strap(s) and casing to help prevent
damage to the painted surface. A single hoist lift point on the strap(s) will balance and lift the actuator in a level
manner.
Installation
When welding buttweld end valves in line, the control valve trim needs to be removed in order to prevent damage to
trim parts. The control trim also needs to be replaced with temporary sacrificial trim to be used while conducting the
system hydrostatic test and while flushing the system. Flushing the system helps to remove weld slag, rust, corrosion,
etc. that could otherwise flow through the valve and potentially damage valve seating surfaces or plug drilled hole
trims. The following installation description includes procedures and suggestions to follow for the flushing of the
system.
For the NPS 1/2 HPNS with hermetically sealed bellows (DS150), the trim should not be removed during assembly. The
position of the plug should be in the “up” position off the seat, with the bellows in the relaxed state. Because the
bellows flange is welded directly to the body, it should not be removed until the recommended replacement period,
see table 12.
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 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.
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.
WARNING
The valve configuration and construction materials were selected to meet particular pressure, temperature, pressure drop,
and controlled fluid conditions indicated when the valve was ordered. Responsibility for the safety of process media and
compatibility of valve materials with process media rests solely with the purchaser and end‐user. To avoid possible
personal injury and because some valve/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 sales office
.
WARNING
Some bonnet flanges have a tapped hole that was used to handle the bonnet during manufacture. Do not use this tapped
hole to lift the valve assembly or personal injury may result.
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HPNS Valve
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WARNING
If you are hoisting the valve, use lifting slings to protect the surfaces. Carefully position the slings 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 2 for valve assembly weights. It is important to use adequately sized hoists and chains or slings
when handling the valve.
1. Remove the actuator and disassemble the valve body by completing steps 1 through 10 of the Replacing
Conventional Packing section.
2. Before installing the valve, inspect it to ensure that the valve body cavity is free of foreign material.
3. Clean out all pipelines to remove scale, welding slag, and other foreign materials before installing the valve.
Note
If the valve body being installed has small internal flow passages, such as with Whisper Trim III or Cavitrol III cages, consideration
should be given to 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. Flow through the valve must be in the direction indicated by the flow arrow, which is stamped on or attached to the
valve body.
CAUTION
Depending on valve body materials used, post‐weld heat treating might be needed. Post‐weld heat treatment can damage
internal elastomeric, plastic, and metal parts. Shrink‐fit pieces and threaded connections might also loosen. In general, if
post‐weld heat treating is needed, remove all trim parts. Contact your Emerson sales office for additional information.
5. Install the valve in the line. Use accepted piping and welding practices when installing the valve in the pipeline.
6. Install a three‐valve bypass around the valve if continuous operation is required during maintenance.
7. After installing the valve, inspect it once again to ensure that the valve body cavity is free and clear of foreign
material to avoid damaging any internals during flushing.
8. If the actuator and valve body are shipped separately, refer to the actuator mounting procedure in the appropriate
actuator instruction manual.
9. If the valve body was shipped without packing installed in the packing box, install the packing
valve body or putting the valve into service
. Refer to instructions given in the Packing Maintenance procedure.
10. For valves that are not being flushed, a replacement soft kit is needed because the trim is removed while the valve is
installed. The new soft kit is then used during valve assembly after installation.
11. For valves that will be flushed, some valves are designed such that no damage to internals is expected if the
standard valve trim parts are used during flushing. However, it is recommended that that the soft parts (packing
and gaskets) be replaced after flushing. Other valves are designed so that the trim can be removed and the valve
assembled with a “flushing stem.” Lastly, other valves will require a full flushing trim to be installed instead of the
standard trim. Valves using trim with hard-facing and valves using trim with small drilled holes or a small flow path
where particulate up to 1/4 inch can become lodged will require flushing trim. Table 7 details which special trim
parts are needed based on flow direction.
before flushing the
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Instruction Manual
D103466X012
Table 7. Required Flushing Trim Items
FLOW CONDITION PARTS
Flow Up Soft Parts, Flushing System, and Flushing Nuts
Flow Down
1. For those datasheets that require only a flushing stem and flushing nuts, install the bonnet gasket. Refer to figure 26 for assemblies that do not require a flushing cage or flushing seat ring.
(1)
Soft Parts, Flushing System, Flushing Nuts, Flushing Cage and Flushing Seat
Ring
a. After installing the bonnet gasket, tighten 2 of the 4 flushing nuts to the base of the flushing stem. When
installing the nuts, ensure that the flat side of the upper nut (the side closest to the bonnet) is facing the bonnet
and that any of the grade markings are facing away from potentially contacting the bonnet.
b. Insert the flushing stem up through the bonnet (key 10), being careful not to scratch or otherwise damage the
stem.
c. Install new packing and the metal packing box parts according to steps 19 and 20 of the Replacing Conventional
Packing Section. If working on a valve with HIGHSEAL Packing, follow steps 2 through 7 of the HighSeal packing
installation section. At this point, do not tighten the packing bolts down.
d. Tighten the other two leftover flushing nuts to the top of the stem to secure the stem in position with the
bonnet.
e. Following step 17 of the Replacing Conventional Packing Section, place the bonnet on to the studs (key 7),
taking care to ensure that while moving the bonnet the flushing stem does not slide around and become
damaged.
f. Follow step 18 of the Replacing Conventional Packing Section to torque the bonnet into place. Because the stem
is not connected to the rest of the trim, the note about stroking the valve to center the trim can be omitted.
g. Now torque the packing bolts per table 6 if using conventional packing or step 8 of the HIGHSEAL Packing
Installation Section.
h. For those datasheets that require a full flushing trim, follow step 16 of the Replacing Conventional Packing
section up to the installation of the bonnet gasket (key 6), ensuring that the standard seat ring and standard
cage are replaced with the appropriate flushing cage and flushing seat ring. Then, follow the assembly directions
shown above for the installation of the flushing stem and nuts.
12. After system flushing is completed, remove the bonnet (key 10), bonnet gasket (key 6), and, if necessary, flushing
trim and seat ring gasket (key 5).
13. Assemble the valve as described in the Replacing Conventional Packing procedure, steps 11 through 20.
14. 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. Please read and follow the packing adjustment
procedures in the Packing Maintenance section of this manual.
Valves with HIGH‐SEAL Heavy‐Duty live‐loaded packing will not require this initial re‐adjustment. See the Replacing
HIGH‐SEAL Packing section in this manual for packing instructions.
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 maintenance
and trim maintenance. All maintenance operations may be performed with the valve in the line.
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WARNING
Avoid personal injury or damage to property from sudden release of pressure or uncontrolled process fluid. Before starting
disassembly:
D Do not remove the actuator from the valve while the valve is still pressurized.
D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal
injury.
D Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the
actuator cannot suddenly open or close the valve.
D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure
on both sides of the valve. Drain the process media from both sides of the valve.
D Vent the power actuator loading pressure and relieve any actuator spring precompression.
D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.
D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the
pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings.
D Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.
Note
The HPNS valve uses spiral‐wound gaskets which are crushed to provide their seal. A spiral‐wound gasket should never be reused.
Whenever a gasket seal is disturbed by removing or shifting gasketed parts, a new gasket must be installed upon reassembly. This
is necessary to ensure a good gasket seal, since the used gasket will not seal properly.
CAUTION
The spiral‐wound gaskets are of special design. Failure to use Fisher replacement parts may result in valve damage.
Note
If the valve has HIGH‐SEAL Heavy‐Duty live‐loaded packing installed (figure 4 or 5), see the Replacing HIGH‐SEAL Packing section in
this manual for packing instructions.
Bonnet Nut Torquing Considerations
When using a hydraulic torque wrench to tighten the bonnet nuts, use an extra socket or some other form of tooling
to prevent the reaction arm from contacting the adjacent bonnet nut. This will help prevent damage to the bonnet nut
faces. See figure 2 for a diagram of this procedure.
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D103466X012
Packing Lubrication
Note
No provisions for packing lubrication.
WARNING
Do not lubricate any parts or surfaces that may come into contact with the process media. Any use of lubricant can lead to
the contamination of the process media and could lead to property damage or failure.
Figure 2. Diagram of Procedure to Prevent Marring of Bonnet Nuts During Assembly
REQUIRED SOCKET
X0644
HYDRAULIC TORQUE WRENCH
REACTION ARM
EXTRA TOOLING
TO PROTECT
THE ADJACENT NUT
Packing Maintenance
If there is undesirable packing leakage in conventional packing, first try to limit the leakage and establish a stem seal
by tightening the packing flange nuts (key 14, figure 20, 22, 23, or 24) to at least the minimum recommended torque
in table 6. However, do not exceed the maximum recommended torque in table 6 or excessive friction may result. If
leakage continues, replace the packing by following the numbered steps presented in the Replacing Conventional
Packing procedure.
If the packing is relatively new and tight on the valve plug stem, and if tightening the packing flange nuts does not stop
the leakage, it is possible that the stem is worn or nicked so that a seal cannot be made. The surface finish of a new
stem is critical for making a good packing seal. If the leakage comes from the outside diameter of the packing, it is
possible that the leakage is caused by nicks or scratches around the packing box wall. While replacing the packing
according to the Replacing Packing procedure, inspect the valve plug stem and packing box wall for nicks or scratches.
If there is undesirable packing leakage in HIGH-SEAL packing, first try to limit the leakage and establish a stem seal by
tightening the packing flange nuts (key 14, figure 20, 22, 23, or 24) to at least the minimum spring load shown in
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figure 9. However, do not exceed the maximum spring load shown in figure 9 or excessive friction may result. If
leakage continues, replace the packing by following the numbered steps presented in the Replacing HIGH-SEAL
Packing procedure.
Replacing Conventional Packing
WARNING
Refer to the WARNING at the beginning of the Maintenance section in this instruction manual.
Key numbers referred to in this procedure are shown in figure 20, 22, 23, or 24, unless otherwise indicated.
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, 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. Exhaust all actuator pressure, if any was applied, and disconnect the actuator supply and any leakoff piping.
3. Using the appropriate actuator instruction manual for reference, relieve all spring compression from the actuator.
4. Remove the cap screws in the stem connector, and separate the two halves of the stem connector.
5. Remove the hex nuts, and remove the actuator from the body (key 1) or bonnet (key 10). If additional actuator
removal clearance is required for disassembly, loosen, then remove the packing flange nuts (key 14) per step 6.
Then lift the packing flange (key 9) to allow the actuator to pass underneath. Return the packing flange (key 19) and
packing flange nuts (key 14) to the packing flange studs (key 15). Thread the packing flange nuts (key 14) to the
packing flange studs (key 15) to realign with step 6.
6. Loosen the packing flange nuts (key 14) so that the packing (figure 3) is not tight on the valve plug stem (key 4).
Remove any stem locknuts from the valve plug stem threads.
CAUTION
Avoid damage to the seating surfaces caused by the valve plug and stem assembly (key 4) dropping from the bonnet (key
10) after being lifted part way out. When lifting the bonnet (key 10), either be sure that the valve plug and stem assembly
(key 4) remain in the valve and on the seat ring (key 3) or, 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.
Use care to avoid damaging gasket sealing surfaces.
The HPNS balanced trim piston rings (key 23) are brittle and in two pieces. Avoid damaging the piston rings by dropping or
rough handling.
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Figure 3. Conventional Packing
GE54622
Instruction Manual
D103466X012
Figure 4. Graphite HIGH-SEAL Packing
GE54625
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.
If the cage sticks to the bonnet, proceed carefully with bonnet removal and support the cage so that it will not fall
unexpectedly from the bonnet.
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Figure 5. PTFE HIGH-SEAL Packing
GE54626
Figure 6. Installing Graphite Ribbon/Filament Packing Rings One at a Time
HPNS Valve
March 2022
VALVE STEM
PACKING
FOLLOWER
BONNET
TOP OF
PACKING RING
EVEN WITH
BOTTOM OF
ENTRANCE
CHAMFER
INSTALLING
FIRST PACKING RING
A2207‐2
INSTALLING
SECOND PACKING RING
Note
The following step also provides additional assurance that the valve body fluid pressure has been relieved.
7. Hex nuts (key 8) and washers (key 24) attach the bonnet to the valve body. 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 to step 9
8. If leakage does occur from the joint, tighten the nuts and verify that the process is properly shut down or the valve is
properly bypassed.
9. Unscrew the hex nuts (key 8), remove the washers (key 24) and carefully lift the bonnet off the valve stem. If the
valve plug and stem assembly starts to lift with the bonnet, use a deadblow hammer on the end of the stem and tap
it back down. Set the bonnet on a cardboard or wooden surface to prevent damage to the bonnet gasket surface.
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10. Remove the bonnet gasket (key 6). Lift the valve plug and stem assembly (key 4) out of the valve body and set it on
a protective surface. If the valve plug is to be reused, protect the valve plug seating surface to prevent scratches.
Install screws or bolts into the tapped holes in the top of the cage (key 2) and cage retainer (key 37), if applicable,
and carefully lift it out of the valve body. If necessary, threaded rods can be installed in the threaded holes on the
top of the cage or cage retainer along with eye nuts or hoist nuts, as shown in figure 7, to help lift the cage or cage
retainer out of the valve body.
Carefully lift the seat ring (key 3) out of the valve body. Remove the cage gasket (key
5).
WARNING
Lifting of the cage and cage retainer must be done with a vertical, or straight, lift using the equipment shown in figure 7.
Lifting at an angle may damage the lifting equipment and cause property damage or personal injury.
Figure 7. Cage Removal and Installation Using Threaded Holes
HOIST NUT
HOIST ROD
BODY
CAGE
Note
The cage and cage retainer lifting holes are provided for ease of assembly/disassembly. To prevent damage to the lifting holes,
fully engage the threaded rod into the hole, but do not overtighten the hoist rod. It only needs to be hand tight. If it is hard to lift
the cage or cage retainer, a piece of wood and a hammer can be used to strike on the top chamfer of the cage or cage retainer to
loosen it from cage, body, or seat ring gasket. ASTM A193 B7 or comparable threaded rods are required for cage or cage retainer
removal. Contact your Emerson sales office
for more information.
CAUTION
Inspect the seat ring, cage, cage retainer (if applicable), bonnet, and body gasket surfaces. These surfaces must be in good
condition, with all foreign material removed. Small burrs less than approximately 0.076 mm (0.003 inches) in height (the
thickness of a human hair) can be ignored. Scratches or burrs that run across the serrations are not permitted under any
conditions, since they will prevent the gaskets from sealing properly.
11. Clean all gasket seating surfaces; refer to your process or safety engineer for appropriate cleaning tools. Clean in
the same direction as the surface serrations, not across them.
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12. Cover the opening in the valve body to protect the gasket seating surface and to prevent foreign material from
getting into the valve body cavity.
13. Remove the packing flange nuts (key 14), packing flange (key 9), and packing follower (key 17). 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.
14. Clean the packing box and the following metal packing parts: packing follower, packing box ring (key 11).
15. 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 or honing with a tool similar to a small honing stone, replace the damaged parts.
16. Remove the protective covering from the valve body cavity, and install the seat ring, cage, and cage retainer (if
applicable) using a new seat ring gasket (key 5), bonnet gasket (key 6), and cage gaskets (key 36) (if applicable).
Install the plug, then slide the bonnet over the stem and onto the studs (key 7).
17. If required, place a body/bonnet mounting washer (key 24) over each stud, taking care to ensure that the washers
are pushed as far as possible toward the center of the bonnet. Failure to do so could prevent successful actuator
mounting. Before installing the washers, inspect each one to ensure no wear or galling is present on the washer
faces. Replace if wear is detected. Also, lubricant is not required on the washers. All required lubricant will be
applied when the nuts are installed.
Note
The proper bolting procedures in step 18 include‐‐but are not limited to‐‐ensuring that the bonnet stud threads are clean, and that
the hex nuts are evenly tightened to the specified torque values.
WARNING
Personal injury or damage to equipment could occur if improper stud and nut materials or parts are used. Do not operate or
assemble this product with stud(s) and nut(s) that are not approved by Emerson/Fisher engineering and/or listed on the
serial card provided with this product. Use of unapproved materials and parts could lead to stresses exceeding the design
or code limits intended for this particular service. Contact your Emerson sales office
actual parts and approved parts is suspected.
immediately if a discrepancy between
CAUTION
Failure to comply with good bonnet‐to‐body bolting practices and the torque values shown in table 5 may result in damage
to the valve. Cheater bars or slug wrenches should not be used for this procedure.
Hot torquing is not recommended.
Note
Stud(s) and nut(s) should be installed such that the manufacturer's trademark and material grade marking is visible, allowing easy
comparison to the materials selected and documented in the Emerson/Fisher serial card provided with this product.
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18. Lubricate the stud threads (key 7) and the seating faces of the hex nuts (key 8) with Nuclear Grade anti-seize
lubricant (key 27). Replace the hex nuts and tighten them finger‐tight. Stroke the valve several times to center the
trim. Torque the nuts in a crisscross pattern (reference figure 8) to no more than 1/4 of the nominal torque value
specified in table 5.
Note
If using a hydraulic torque wrench, please see the Bonnet Nut Torquing Considerations section on page 9 to avoid any
unsatisfactory marring of parts.
When all nuts are tightened to that torque value, increase the torque by 1/4 of the specified nominal torque and
repeat the crisscross pattern. Repeat this procedure until all nuts are tightened to the specified nominal value. Apply
the final torque value again and, if any nut still turns, tighten every nut again.
Note
When installing packing rings, prevent entrapping air between the rings. Add the rings one at a time without forcing them below
the chamfer of the packing box entrance chamber. As each successive ring is added, the stack should not be pushed down more
than the thickness of the added ring (figure 6).
19. Install new packing and the metal packing box parts according to the arrangement in figure 3, 4, or 5. Place a
smooth-edged pipe over the valve stem, the top end higher than the valve stem is recommended. An alternative
way is to slide the packing follower over the valve stem. Gently tamp each soft packing part into the packing box,
being sure that air is not trapped between adjacent soft parts.
20. Slide the packing follower and packing flange into position. Lubricate the packing flange studs (key 15) and the
seating faces of the packing flange nuts (key 14) with Nuclear Grade anti-seize lubricant (key 27). Replace the
packing flange nuts.
Torque evenly in increments of 1/4 of the full torque value, alternating between the packing flange nuts. 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.
Figure 8. Bolting Diagram
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8 BOLT PATTERN
12 BOLT PATTERN
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