Fisher Z500 Instruction Manual

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Instruction Manual

D103803X012

Fisher™ Z500 Severe Service Ball Valves

Z500 Valve

July 2017

Contents

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

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

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

Specifications 1...............................

Installation 5

Operation 7...................................

Maintenance 8

Troubleshooting 9.............................

Packing Replacement 10.......................

Actuator Mounting 13.........................

Parts Ordering 18

Parts List 18.....................................

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Introduction

Scope of Manual

Figure 1. Fisher Z500 Severe Service Ball Valve

X1243

This instruction manual provides installation, operation, maintenance, and parts information for the Fisher Z500 Severe Service Ball Valve (see figure 1).

Do not install, operate, or maintain Z500 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 proceeding.

or Local Business Partner before

Description

The Z500 severe service ball valve is a split body bolted design, full or reduced port, with a blowout proof shaft. It can be lever operated, gear operated, or actuated. The Z500 severe service ball valve line is a simplistic two-piece floating ball design with integral metal seat meant to provide tight metal seating shutoff in high temperature, high pressure, corrosive, and erosive applications across all industries.

Specifications

Specifications for these valves are shown in table 1.

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Z500 Valve

July 2017

Table 1. Specifications

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Valve Sizes

Z500: NPS

J 1/2, J 3/4, J 1, J 1-1/2, J 2, J 3, J 4, J 6, J 8, J 10, J 12, J 14, J 16, J 18, J 20, J 24, J 26, J 28, J 30 and, J 36

Packing Constructions

Carbon Steel Valve Bodies: Wire reinforced graphite packing, AISI 4130 nitrided packing gland Stainless Steel: N06600 wire-reinforced graphite packing, S31600 nitrided packing gland

Maximum Working Pressures

(1)

Standard Flow Direction

Forged Steel Valves: Consistent with applicable pressure-temperature ratings in table 4 per ASME B16.34, but do not exceed the material temperature

Preferred Flow Direction: Preferred flow for optimal sealing is forward into the integral seat

capabilities shown below

Flow Coefficients

Shutoff Classification

Z500: Valves are tested to API 598 in the preferred

(1)

Contact your Emerson sales office or Local Business Partner

flow direction.

Maximum Ball Rotation

Class V type B per FCI 70-2 in reverse flow in bi-directional design (Must be specified). For other

90 degrees

shutoff requirements, please contact your Emerson

sales office or Local Business Partner.

Actuator Mounting

The preferred mounting orientation is vertical. Other

Construction Materials

orientations are acceptable

See tables 2 and 3

Approximate Weight

Temperature Capabilities

(1)

Contact your Emerson sales office or Local Business Partner

Welded and Threaded Ends: SA105 - 800_F, F22 1000_F, F91 1200_F, F316 1400_F

Flanged End Connections: SA105 - 600_F, F22 800_F, F91 1000_F, F316 1000_F

Lower Limits: Carbon steel: -29_C (-20_F), Stainless steel: -40_C (-40_F)

1. The pressure/temperature limits in this manual, and any applicable code or standard limitation, should not be exceeded.

Options

J Reduced port, J Expanded outlet, J Scraper

seats, sealing,

J Spray and fused coatings

J HVOF coating options, J Bi-directional

J High cycle constructions, J Lockouts,

Table 2. Standard Construction Materials for NPS 1/2 through 36 Valves

PART

(1)

Ball

Upstream seat

Seat Holder

Body gasket S17400 N07718 N07718 AISI 660

Spring N07718 N07718 N07718 AISI 660

Packing Flexible graphite with wire-reinforced braided graphite and stainless steel washers

Shaft adapter AISI 4130 Nitrided, 4140 Nitrided

Coatings HVOF Chrome Carbide (standard), HVOF Tungsten Carbide, Spray and Fused Nickel-Boron

1. Part is coated (HVOF chrome carbide standard)

2. Seat holder is standard on welded and threaded end connections in 0.65, 1.15, 1.5, and 2 inch bores only. Bidirectional option must be specified for all other constructions.

(1)

(2)

Shaft S17400 Nitrided N07718 Nitrided N07718 Nitrided AISI 660 Nitrided

SA105 F22 F91 F316

S41000 S41000 S41000 S31600

VALVE BODY AND END ADAPTER MATERIAL

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Table 3. Spray and Fused Coating Standard Construction Materials

PART

Ball and Upstream Seat

Shaft N07718 Nitrided AISI 660 Nitrided

Spring and Body Gasket N07718 AISI 660

1. Seat holder is standard on welded and threaded end connections in 0.65, 1.15, 1.5, and 2 inch bores only. Bidirectional option must be specified for all other constructions.

2. Part is coated.

(2)

SA105 F22 F91 F316

VALVE BODY AND END ADAPTER MATERIAL

F22 S31600

(1)

Table 4. Valve Body Materials, End Connections, and Ratings

Ratings Bore (inches) Size, NPS End Connection Valve Body Materials

1/2 3/4

1-1/2

2 2-1/2 1-1/2

2 2-1/2

3 Buttweld, RF, RTJ

2 2-1/2

‐continued‐

Buttweld, Socketweld, FNPT,

RF, RTJ

Buttweld, Socketweld, FNPT,

RF, RTJ

Buttweld, RF, RTJ

RF, RTJ

SA105, F22, F91, and F316

CL150 through 1500

0.65

1.15

1.5

10 10 12 12 14 14 16 16 18 18 20 20 24 24 26 26 28 28 30 30 36 36

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Table 4. Valve Body Materials, End Connections, and Ratings (continued)

Ratings Bore (inches) Size, NPS End Connection Valve Body Materials

1/2 3/4

1 1-1/2

2 2-1/2 1-1/2

2 2-1/2

3 Buttweld, RF, RTJ

2 2-1/2

10 1/2 3/4

1 1

1-1/2

2-1/2

1/2 3/4

1 1

1-1/2

2-1/2

CL2500

CL3200

CL4500

0.65

1.15

1.5

0.65

1.15

1.5

0.65

1.15

1.5

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Buttweld, Socketweld, FNPT,

RF, RTJ

SA105, F22, F91, and F316

RF, RTJ

Buttweld, RF, RTJ

RF, RTJ

Buttweld, Socketweld SA105, F22, F91, and F316

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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 may result if the valve assembly is installed where service conditions could exceed either the valve body rating or the mating pipe flange joint rating. 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.

WARNING

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. 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

or Local Business Partner.

WARNING

The valve drive shaft is not necessarily grounded to the pipeline when installed. Personal injury or property damage could result from an explosion caused by a discharge of static electricity from valve components if the process fluid or the atmosphere around the valve is flammable. If the atmosphere around the valve or the process fluid is flammable, electrically bond the drive shaft to the valve.

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.

When a valve is shipped bare shaft:

a. Valve is shipped in the open position with exposed shaft

b. Valve will include two shaft keys.

When a valve is shipped with mounting kit only:

a. Valve will ship in the in open position

b. Valve will have the mounting finger-tight to the valve

c. Customer shall ensure proper mounting of the actuator

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d. Customer shall ensure valve shaft has not been pushed or forced down into the valve

e. Customer shall ensure no binding occurs when mounting the actuator

i. Customer shall ensure the correct alignment is done when mounting the actuator ii. No hammering or forcing down of the shaft adapter is allowed

f. Customer shall ensure all bolts are torqued down appropriately

g. Customer shall ensure the actuator mounting surface is completely flush with the mounting bracket. For

additional information on actuator mounting, refer to the Actuator Mounting section in this instruction manual on page 13.

h. Customer shall ensure the mounting can allow for or can accommodate expansion of the shaft or adapter at high

temperatures. See table 7.

When a valve is shipped with actuator:

a. Valve will be shipped in the required fail position

b. All bolting will be torqued as required

c. Emerson recommends that the customer not remove the actuator for final installation in the line

1. Inspect the valve prior to installation into the piping system to ensure there is no shipping damage. End protectors and shipping materials must be removed to allow a complete inspection.

2. Inspect the actuator, if included, for damage and then cycle the valve with the actuator from open (the normal shipping position) to closed to open to ensure proper functioning.

CAUTION

Make sure the valve is installed in the correct orientation. Put the high pressure side (body side) on the upstream side. The arrow on the valve should point from the high pressure to low pressure side when the valve is closed. The valve could be damaged if installed incorrectly.

Weld End Valves

WARNING

Emerson Automation Solutions is not responsible for improper installation or inspection of any valve which falls outside the criteria presented in this instruction manual. Requests for additional information on unique situations should be directed to your Emerson sales office

CAUTION

or Local Business Partner.

Weld fill between the valve and pipe should never be used to correct for improper pipe installation length or misalignment. Additional welding beyond what is required may cause the valve to reach higher temperatures and have a larger heat-affected zone, which can cause permanent damage to the valve or its components.

For additional information, refer to ASME Boiler and Pressure Vessel Code Section IX.

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Procedure

Initial Preparation

1. Ensure the valve is in the fully open position so that vital sealing areas of the ball are not exposed to weld spatter.

2. Never make arc strikes on the valve body or end adapter except inside the groove intended for butt welding or inside the corner of the joint for socket welding. Arc strikes made on areas which are not intended to be welded can cause a localized increase in hardness and micro-cracks, and can otherwise compromise the intended mechanical properties of the material.

3. Attach the welding ground strap to the side of the valve being welded.

4. Install the valve into the piping system prior to welding in order to minimize piping loads. Orient the valve with the shaft vertical, if possible, and install the piping such that pipe loads are minimized on the valve.

5. Weld the valve into the line using welders and procedures fully qualified per ASME Boiler and Pressure Vessel Code Section IX.

6. Ensure that the valve body temperature always remains below 427_C (800_F).

Post-Weld Heat Treatment

CAUTION

Depending on valve body materials used, post weld heat treating may be required. If so, damage to internal parts is possible. Do not place the entire valve in a stress relief furnace, or cover the entire valve with stress relieving blankets, as this could damage the valve. Contact your Emerson sales office

1. Weld the valve into the line using qualified welders and procedures per Section IX of the ASME Boiler and Pressure Vessel Code. If specific procedures are required, contact your Emerson sales office or Local Business Partner for written guidance based on pipe and valve materials.

2. Apply post weld heat treat in accordance with valve material and code requirements. Only local post weld heat treat on each end of the valve must be used.

or Local Business Partner for additional information.

Final Inspection after Post-Weld Heat Treatment

After post weld heat treat, verify valve body studs and packing studs are tight.

CAUTION

Before cycling the valve in the line, make sure the line is clean of weld slag and other debris that could damage the valve. Cycle the valve after installation to ensure proper functioning.

1. Cycle the valve to verify proper operation. Ensure that the torque required to cycle the valve has remained within acceptable limits.

2. Verify that the body and packing bolting are tightened to the correct torque per tables 5 and 6.

3. Install proper insulation as required for insulated piping systems.

Operation

1. No routine maintenance or lubrication is required. No tightening of body studs should be necessary. Packing bolting may be retightened if a shaft packing leak is noted during operation.

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2. Actuators supplied with the valve may require maintenance per the actuator manufacturer's recommendations. For valves supplied with gears, the grease in the gearbox might need to be cleaned out and replaced periodically. Use only high temperature grease recommended for gearboxes.

3. Metal-seated ball valves have high torques. Consult your Emerson sales office

or Local Business Partner for more

information.

4. Valves operate clockwise to close and counterclockwise to open. Gears and actuators are marked with arrows and symbols to show valve position and operating direction. Lever operated valves have an integral lockplate so that only the correct operating direction is possible. The lockplate has the “O” for open and the “C” for closed marked to show proper position. The lever is always aligned with the ball bore for positive proof of ball position. Gears and actuators have adjustable stops for proper ball positioning.

5. The ball is mate lapped to the end adapter seat. The top of the shaft is marked to show the proper orientation of the lapped side of the ball.

6. This valve should be either normally open or normally closed. Throttling with this valve is not recommended for extended periods. Throttling for brief periods during startup or shutdown is allowed.

Maintenance

Valve parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and replacement depends upon the severity of service conditions.

WARNING

Avoid personal injury from sudden release of process pressure. Before performing any maintenance operations:

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

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

actuator cannot suddenly open or close the valve.

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

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

D Vent the 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 Always wear protective gloves, clothing, and eyewear when performing any maintenance operations.

D The valve packing area 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.

1. If valve maintenance is required, contact your Emerson sales office or Local Business Partner.

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Troubleshooting

Operation

D Shaft adapter/actuator may be misaligned-- Remove actuator and shaft adapter, then reassemble per assembly

procedures for actuators.

D Over-tightened shaft packing-- Loosen packing to hand tight, cycle valve and retighten per procedures following

torque table 6.

D Inadequate air supply-- Increase air supply or install larger solenoid or quick exhaust valve. Refer to actuator

manufacturer's specifications.

Valve will not Rotate

D Valve body ID or bore is clogged-- Flush or clean valve ID and try to cycle valve.

D Actuator is not operating correctly or has failed-- Replace or repair actuator and try to cycle valve.

D Shaft keys have sheared-- Remove shaft adapter and determine why keys sheared, insert new keys, reassemble and

try to cycle valve.

Valve Shaft Packing Leaking

D Packing flange bolting is loose-- Tighten packing bolting. See Packing Replacement section, step 7 on page 13 of

this instruction manual.

D Packing is damaged or improperly installed-- Depressurize valve, remove old packing and replace with new

assembly per assembly instruction steps 3 to 5.

D Actuator misalignment-- Check for actuator misalignment.

Valve Body Gasket Leaking

D Body bolting is loose-- Tighten body bolting per table 5 and figure 2.

D Body gasket damaged-- Contact your Emerson sales office

Table 5. Body Bolt Torque Values

BOLT SIZE RECOMMENDED TORQUE

mm Inch lbf•ft lbf•in N•m

13 1/2 20 240 27

16 5/8 40 480 54

19 3/4 65 780 88

22 7/8 110 1320 149

25 1 165 1980 224

29 1-1/8 240 2880 325

32 1-1/4 335 4020 454

35 1-3/8 450 5400 610

38 1-1/2 600 7200 814

41 1-5/8 725 8700 984

44 1-3/4 1000 12000 1356

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July 2017

Figure 2. Bolting Tightening Pattern

Valve Leaking through Ball or Seating Area

D Valve body ID or bore is clogged-- Flush or clean valve ID and try to cycle valve.

D Valve is not fully closed-- Close valve, taking care not to over torque.

D Actuator travel stops are not set correctly-- Set stops and cycle, checking for leaks.

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D Seat or Ball is damaged-- Contact your Emerson sales office

or Local Business Partner for repair.

D Belleville spring is collapsed — Contact your Emerson sales office or Local Business Partner for repair.

Note

If you need additional trouble-shooting assistance, please contact your Emerson sales office or Local Business Partner.

Packing Replacement