Instruction Manual
D102137X012
KALREZ System - Rotary-Shaft Valves
July 2017
KALREZ™ Packing System for
™
Fisher
Contents
Introduction 1.................................
Scope of Manual 1.............................
Description 1.................................
Installation 1..................................
Introduction
Scope of Manual
This instruction manual includes installation, maintenance, and parts information for KALREZ valve stem packing
(KVSP) systems. These systems are available for Fisher rotary valves with 12.7 through 38.1 mm (1/2 through 1‐1/2
inch) shaft diameters. The system can be used with many rotary valves, as shown in table 1. Refer to appropriate valve
and actuator instruction manuals for necessary information relating to the disassembly and assembly of the valve and
actuator.
Rotary‐Shaft Valves
Removing the Actuator 2.......................
Installing a KALREZ Packing System 4.............
Tightening Procedures 5....................
Other Considerations 5..........................
Do not install, operate, or maintain a KALREZ packing system 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.
or Local Business
Description
See table 1 for valve designs and shaft diameters where KALREZ packing systems can be applied.
Emerson Automation Solutions offers KALREZ packing systems that you can easily install into your existing valves or
that you can purchase with new valves. The KVSP 500 Series uses Vespel
rings.
The external live‐loading provides a constant load over the life of the packing material, which reduces the need for
packing box adjustment and maintenance.
™
CR‐6100 backup rings and KALREZ seal
Installation
Use these instructions to install KALREZ packing in valves that have standard packing, or when inspecting or replacing
KALREZ packing.
Table 2 lists part numbers for KALREZ packing sets only. When retrofitting valves to KALREZ packing, contact your
Emerson Automation Solutions sales office for information on additional parts needed.
www.Fisher.com
KALREZ System - Rotary-Shaft Valves
July 2017
Table 1. Specifications
Instruction Manual
D102137X012
Applicable Valve Designs
A41, 8510, 8510B (single arrangements only), 8550,
(1/2, 5/8, 3/4, 7/8, 1, 1‐1/4 and 1‐1/2 inches). See
table 2
and 8560 valves; V100, V150, V200, V300 and V500
Vee‐Ballt valves; and CV500 Cam‐Vee‐Ball valves.
See table 2
Applicable Shaft Diameters
Vee‐Ball and Eccentric Disc Valves:
J 19.1, J 22.2, J 25.4, J 31.8, and J 38.1 mm
1. The pressure/temperature limits in this manual, in the valve literature, and any applicable code or standard limitation should not be exceeded.
J 12.7, J 15.9,
Pressures and Temperatures
Maximum Application Temperature
260_C (500_F)
Maximum Application Pressure
Pressure is limited to the maximum valve rating
(1)
Removing the Actuator
WARNING
Avoid personal injury from sudden release of process pressure or uncontrolled movement of parts. Before performing any
installation operations:
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, or when
loosening the packing box pipe plug.
D Check with your process or safety engineer for any other hazards that may be present from exposure to process media.
You must remove the actuator from the valve when you install KALREZ packing systems. To allow proper readjustment
of the Vee‐Ball, eccentric disc, or valve disc position, it is recommended that you remove the valve from the pipeline.
Refer to appropriate valve and actuator instruction manuals.
WARNING
Avoid personal injury or equipment damage from uncontrolled movement of parts. If a spring‐return actuator is used, be
sure the actuator spring is resting on its travel stop. If something is obstructing shaft rotation, it is possible that
disconnecting the shaft connector will allow the spring to force the actuator to the end of its rotation. Refer to the
appropriate valve and actuator instruction manuals to remove the actuator.
2
Instruction Manual
D102137X012
Figure 1. KALREZ Packing Arrangements
KALREZ System - Rotary-Shaft Valves
July 2017
OUTBOARD END
44B7499-A
8510
STANDARD
PACKING BOX
V100 - 12.7, 19.1, 25.4, 31.8
(1/2, 3/4, 7/8, 1, 1‐1/4 ) SHAFT
V150 - 12.7, 19.1, 25.4
(1/2, 3/4, 1 SHAFT
V200 & V300 - 12.7, 15.9, 19.1, 25.4
(1/2, 5/8, 3/4, 1) SHAFT
V500 - 12.7, 15.9, 25.4, 31.8
(1/2, 5/8, 1, 1‐1/4) SHAFT
8510, 8550, 8560, & A41 - 12.7, 15.9, 19.1,
25.4,31.8 (1/2, 5/8, 3/4, 1, 1‐1/4) SHAFT
STANDARD
PACKING BOX
V100, V500, 8510, 8550, 8560 &
A41 - 38.1 (1‐1/2) SHAFT
8510 - 38.1 (1‐1/2) SHAFT
OUTBOARD END
PACKING BOX
8510 - 12.7, 15.9, 19.1, 25.4,
31.8 (1/2, 5/8, 3/4, 1, 1‐1/4)
SHAFT
OUTBOARD END
PACKING BOX
OPTIONAL DEEP
PACKING BOX
V100 - 12.7, 19.1, 25.4 (1/2,3/4, 7/8, 1) SHAFT
STANDARD
V150 - 31.8, 38.1 (1‐1/4, 1‐1/2) SHAFT
V200 - 31.8 (1‐1/4) SHAFT
V150 - 31.8, 38.1 (1‐1/4, 1‐1/2) SHAFT
PACKING BOX
OPTIONAL DEEP
PACKING BOX
V100 - 38.1 (1‐1/2) SHAFT
OPTIONAL DEEP
PACKING BOX
V100 - 31.8 (1‐1/4) SHAFT
mm(INCHES)
Figure 2. Belleville Spring Stacking Order
O-RING
BELLEVILLE
SPRINGS (9)
PACKING
FOLLOWER
12B8319-A
SIZE 12.7 & 15.9 mm
(1/2 & 5/8‐inch) SHAFT
B2409-1
12B8320-A
SIZE 19.1, 22.2 & 25.4 mm
(3/4, 7/8, & 1‐inch) SHAFT
O-RING
BELLEVILLE
SPRINGS (7)
PACKING
FOLLOWER
O-RING
BELLEVILLE
SPRINGS (5)
PACKING
FOLLOWER
12B8321-A
SIZE 31.8 & 38.1 mm
(1‐1/4 & 1‐1/2 inch) SHAFT
3
KALREZ System - Rotary-Shaft Valves
July 2017
Instruction Manual
D102137X012
Installing a KALREZ Packing System
Refer to figure 1.
Note
When installing a KALREZ packing system into an insulated valve, do not cover the Belleville packing springs with insulation.
CAUTION
Use caution when removing existing internal packing parts. Do not scratch, nick, or dent the valve shaft.
Note
The valve shaft surface condition is critical in obtaining a good seal. If the valve shaft surface is scratched, nicked, or worn, replace
the valve shaft before installing the KALREZ Packing System.
1. Remove old packing parts from the packing box by using the valve instruction manual procedures. Refer to the
appropriate valve instruction manual to replace the valve shaft and valve parts.
2. If the piping and valve are insulated, do not allow the insulation to cover the KALREZ Belleville springs.
3. If you are converting an existing valve to this packing, remove existing packing box studs from the valve body, and
replace them with longer studs (as required).
Note
KVSP packing systems should be installed as a complete set, NOT AS INDIVIDUAL PIECES OR COMPONENTS.
Note
Ensure that the Belleville springs are stacked properly (see figure 2) and packing box parts are assembled in the correct order (see
figure 1). Packing parts cannot function properly if the Belleville springs or other packing parts are not stacked correctly.
4. All kits include a single use packet of KRYTOX™ GPL 206 high performance fluorinated grease to maximize service
life and ease of assembly. KRYTOX lubricants are chemically inert to the chemicals regulated under the U.S. Clean
Air Act, non‐reactive to gaseous and liquid oxygen and chlorine services, with chemical compatibility consistent
with KALREZ and the KVSP Systems.
5. Apply the KRYTOX lubricant liberally to both the I.D. (inner diameter) and O.D. (outer diameter) surfaces of each
KVSP component before installing. All exposed surfaces of the packing assembly should be fully covered.
6. With the shaft in place in the valve, install the packing parts into the valve packing box. Carefully slide the packing
down the shaft while being careful not to force the packing and damage it on the shaft spline. Use figures 1 and 2 to
ensure that the packing parts and spring pack are assembled in the correct order.
7. Be careful NOT to position the KVSP packing system adjacent to any lubrication holes in the packing box which
could compromise its sealing performance.
4
Instruction Manual
D102137X012
KALREZ System - Rotary-Shaft Valves
July 2017
Tightening Procedures
A modified tightening procedure is recommended for live‐loading the KVSP System to help ensure the correct loading
force is used during the life of the packing and to help avoid any overcompression of the packing. This procedure also
creates open space within the spring set that allows dynamic movement of the packing system to compensate for any
volumetric changes that occur during thermal cycling.
Note
The following tightening procedure will change the final loading force to about 1/2 of a fully compressed disc spring.
1. Hand tighten the gland nuts on the Belleville disc springs and measure the uncompressed or free height.
2. Fully compress the Belleville disc springs alternately and evenly to the flat condition. The flat condition will be
evident by a sharp increase in the applied nut torque. Note that there may appear to be space left between the
springs; this is due to friction between the springs. Measure the compressed height.
3. Back off the disc spring deflection by 1/3 or 33% of the difference between (1) the free, uncompressed spring height
and (2) the fully compressed spring height.
4. The KVSP Systems are designed so the components move together during service to eliminate free space within the
packing system. This is part of the system's design and will occur automatically during service without further
adjustment from normal mechanical and thermal cycling. The resulting working height is then established half way
between (1) the free, uncompressed height and (2) the fully compressed position; this also provides approximately
50% of the load force available from the fully compressed disc spring. This new set position helps give the system an
ideal and balanced load, allowing for expansion and contraction due to temperature variations in the process and
maximizing the service life.
Other Considerations
When retrofitting an existing packing system or repacking a valve with KALREZ packing that has been in service, check
the condition of the packing bore after you have removed the packing. An easy method for cleaning debris and minor
imperfections from the bore is to use a brake cylinder hone attached to an electric drill. This method will do a good job
of cleaning the packing bore without changing the dimension of the bore.
When you have completed this exercise, a good guideline to use in checking the condition of the packing bore is the
20/20 rule. If less than 20% of the surface area of the bore is pitted and if there are no pits deeper than 0.020 inch, then
your packing should work fine. This does not need to be an exact measurement; visual inspection is adequate. If the
packing bore does not meet this criteria, however, you should replace the valve.
5
KALREZ System - Rotary-Shaft Valves
July 2017
Table 2. Rotary KALREZ Applications and Packing Set Part Numbers
Valve Valve Size, NPs
V100 (std or deep packing box)
V150
V200
V500
8510
8510 (outboard end)
8550
8560 (CL150)
A41 (CL150)
V200
V300
V500
8510
8510 (outboard end)
8550
8560 (CL150)
8560 (CL300)
A41 (CL150)
A41 (CL300)
V100 (std or deep packing box)
V150, V200, V300
8510
8510 (outboard end)
8550
8560 (CL150)
8560 (CL300)
A41 (CL150)
A41 (CL300)
V100
V100 (deep packing box)
V100 (std or deep packing box)
V150, V200, V300
V500
CV500
8510
8510 (outboard end)
8550
8560 (CL150)
8560 (CL300)
A41 (CL150)
A41 (CL300)
V100 (std or deep packing box)
V150, V200, V300
V500
CV500
8510
8510 (outboard end)
8550
8560 (CL150)
8560 (CL300)
A41 (CL150)
A41 (CL300)
V100 (std or deep packing box)
V150, V300
V500
CV500
8510
8510 (outboard end)
8550
8560 (CL150)
8560 (CL300)
A41 (CL150)
A41 (CL300)
1, 1-1/2, 2
2
1
1
2
2
2
3
3
1-1/2, 2
2
1-1/2, 2
3
3
3
4
3
4
3
3
3, 4
4
4
4
6
4
6
4
4
4
6
6
3
3
6
6
6
8
4
8
4
8, 10, 12
8, 10
4
4
8, 10
8, 10
8, 10
10
8
10
8
12
12
6, 8
6, 8
12
12
12
12
10
12
10
Instruction Manual
D102137X012
Shaft Diameter KVSP‐500 PACKING SET
mm Inches Part Number
12.7 1/2 24B6255X012
15.9 5/8 24B6255X022
19.1 3/4 24B6255X032
22.2 7/8 24B6255X042
25.4 1 24B6255X052
31.8 1‐1/4 24B6255X062
38.1 1‐1/2 24B6255X072
6
Instruction Manual
D102137X012
KALREZ System - Rotary-Shaft Valves
July 2017
WARNING
Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Automation Solutions should
not, under any circumstances, be used in any Fisher valve, because they may void your warranty, might adversely affect the
performance of the valve, and could cause personal injury and property damage.
7
KALREZ System - Rotary-Shaft Valves
July 2017
Instruction Manual
D102137X012
Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance
of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Fisher and Vee-Ball are marks owned by one of the companies in the Emerson Automation Solutions business division of Emerson Electric Co. Emerson
Automation Solutions, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. KALREZ, Vespel, and KRYTOX are marks
owned by E.I. du Pont De Nemours Co. All other marks are the property of their respective owners.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not
to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are
governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such
products at any time without notice.
Emerson Automation Solutions
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Cernay 68700 France
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com
8
E 1996, 2017 Fisher Controls International LLC. All rights reserved.
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