Baumann 24000C Carbon Steel Little Scotty Control Valve Instructions

Transcription

1 Instruction Manual D103356X C Control Valve Baumann 24000C Carbon Steel Little Scotty Control Valve Instructions CONTENTS Introduction...1 Scope...1 Safety Precautions...1 Maintenance...2 Flow Direction...3 Installation...3 Air Piping...3 Body Removal...3 Actuator Removal...3 Bonnet Disassembly...4 Bonnet Reassembly...4 Valve Calibration...4 Parts List...7 Flow Directions Dimensions and Weights INTRODUCTION Baumann 24000C Carbon Steel Little Scotty industrial control valves are intended for general utility service in pressure, flow and temperature control applications. SCOPE OF MANUAL This instruction manual includes installation, maintenance, and parts information for the 24000C control valves. No person may install, operate or maintain a 24000C control valve without first being fully trained and qualified in valve, actuator and accessory installation, operation and maintenance, and carefully reading and understanding the contents of this manual. If you have any questions about these instructions contact your Fisher sales office before proceeding. NOTE: Neither Emerson, Emerson Process Management, Fisher, 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.! Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal injury. Personal injury or property damage caused by sudden release of pressure or bursting of pressure retaining parts may result if service conditions exceed those for which the product was intended. To avoid 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.

2 24000C Control Valve Instruction Manual MAINTENANCE This valve is intended for a specific range of pressures, temperatures and other application specifications. Applying different pressures and temperatures to the valve could result in parts damage, malfunction of the control valve or loss of control of the process. Do not expose this product to service conditions or variables other than those for which the product was intended. If you are not sure what these conditions are you should contact your Fisher sales office for more complete specifications. Provide the product serial numbers (shown on the nameplate) and all other pertinent information.! If you move or work on an actuator installed on a valve with loading pressure applied, keep your hands and tools away from the stem travel path to avoid personal injury. Be especially careful when removing the stem connector to release all loading on the actuator stem whether it be from air pressure on the diaphragm or compression in the actuator springs. Likewise take similar care when adjusting or removing any optional travel stop. Refer to the relevant actuator Maintenance Instructions. If hoisting the valve, take precautions to prevent personal injury and property damage that could result if the rigging slips. Be sure to use adequate sized hoists and chains or slings to handle the valve.! Personal injury could result from packing leakage. Valve packing is tightened before shipment; however, the packing might require some readjustment to meet specific service conditions.! Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations: Do not remove the actuator from the valve while the valve is still pressurized. Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal injury. Disconnect any operating lines providing air pressure, electric power or a control signal to the actuator. Take precautions to prevent the actuator from suddenly opening and closing the valve. Use bypass valves or completely shut off the process to isolate the valve from the process pressure. Relieve the process pressure from both sides of the valve. Drain the process media from both sides of the valve. Depending on the actuator construction, it will be necessary to manage the pneumatic actuator spring precompression. It is essential to refer to the relevant actuator instructions in this manual to perform safe removal of the actuator from the valve. Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. 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. Check with your process or safety engineer for any additional measures that must be taken to protect against process media. 2

3 Instruction Manual 24000C Control Valve Whenever a gasket seal is disturbed by removing or shifting gasketed parts, install a new gasket during reassembly. This provides a good gasket seal because the used gasket may not seal properly. the actuating air pressure line to the 1/4 NPT opening in the lower diaphragm case. 2. Use 1/4 in (6.4 mm) O.D. tubing or equivalent for all air lines. If air line exceeds 25 ft (8 m) in length, 3/8 in (9.5 mm) tubing is preferred. Air pressure should not exceed 35 psig (2.5 barg).! Avoid personal injury or property damage by thoroughly cleaning the line of all dirt, welding chips, scale, oil or grease, and other foreign material. Failure to do so could result in damage to the seating and sealing surfaces of the valve and result in damage to the valve and release of process materials. INSTALLATION Refer to key (Fig. 1, page 5) unless otherwise specified. 1. Before installing the valve in the pipeline, thoroughly clean the line of all dirt, welding chips, scale, oil or grease, and other foreign material. 2. Install the valve so the controlled fluid will flow through the valve body in the direction indicated by the arrow cast on the valve body. 3. A three-valve bypass would permit removal of the control valve from the line without shutting down the system. 4. In case of a heat-insulated installation, insulate the valve body only, not the bonnet.! To avoid personal injury or property damage, do not attempt to do any work on a valve while the system is in operation, the valve must be isolated 100% from the active system and the isolated line voided of pressure and/or hazardous fluids. AIR PIPING 1. For an air-to-extend actuator (air-to-close action), connect the actuating air pressure line to the 1/4 NPT opening in the upper diaphragm case. For an air-to-retract actuator (air-to-open action) connect When assembling or disassembling the valve, do not turn the valve stem while the plug is touching the valve seat. This will damage the valve s seating surfaces. When adjusting the valve stem do not grip the stem directly with pliers or a wrench. This will damage the surface of the stem, and cause damage to the packing in the valve. Instead, counter-tighten the two locknuts (27) on the stem (5). This will allow you to turn the stem by turning the locknuts (27) with a wrench. When placing valve in vise, clamp the flat end faces of the valve. Do not clamp the rounded sides of the valve. This will distort the shape of the casting, and will ruin the valve. DISASSEMBLY 1. Mount the valve in a vise by clamping flat end faces of the valve (Fig.1). Caution must be taken not to damage the serrated flange faces. 2. Remove actuator, stem locknuts (27), travel indicator (58) and yoke drive nut (9). 3. Turn the bonnet (8) in a counter-clockwise direction from the valve body (1). Remove o-ring (12) and remove and discard the body gasket (49). A new gasket should be installed each time the valve is disassembled. 4. Pull the plug and stem assembly (4 & 5) out through the bottom of the bonnet. Rotate the assembly to prevent damage to the packing. Wipe the parts with a clean soft cloth and examine for signs of wear. 3

4 24000C Control Valve Instruction Manual Handle the parts carefully to avoid damaging the seating and guiding surfaces. 5. To remove the seat ring (2), fabricate a special wrench to engage the lugs on the ring. Turn the seat ring (2) counter-clockwise to remove it from the body (1). Clean thoroughly and examine for signs of wear. LAPPING THE METAL SEAT If valve seat leakage becomes excessive, it may be necessary to lap the valve seat. Lapping is the process of mating the valve plug to the seat ring, with an abrasive to produce a close fit. When valve seat leakage becomes excessive, lapping becomes necessary. The plug and seat ring seating surfaces should be free of large scratches or dents and the contact surface of the seats should be as narrow as possible. 1. Apply fine lapping compound (e.g. United States Products Co. Grade 600 Crystolon) at several spots around the plug seating surface. Replace the plug (4) in the bonnet (8). 2. Place the bonnet (8) loosely into the body (1) to serve as a guide during the lapping operation. 3. Lap the valve by applying a slight pressure on the stem and rotate the stem in short oscillating strokes approximately 8 to 10 times or until you see an even and complete lap line. The plug should be intermittently lifted and turned 90º while lapping to keep the plug and seat ring concentric. 4. Clean the valve seat and plug (4) thoroughly when the lapping is complete, removing all traces of lapping compound. 1. Disassemble the valve as directed earlier. Remove the locknuts (27) and indicator disk (58), and turn the plug and stem (4 & 5) out through the packing box. Remove the packing follower (10). Push out the old packing (14) by working from the underside of the bonnet (8). 2. Standard Spring Loaded PTFE V-Ring Packing (Fig. 1, page 5 and Fig. 2, page 9): Insert each piece in exact order shown in the illustration. Hand tighten the packing follower (10) until it shoulders on the bonnet (8). This will compress the packing spring (6) (Fig. 2, page 9), to enable constant stem sealing throughout the packing life. 3. Molded Graphite (Flexible Graphite) Packing (Fig. 3, page 9): Insert each piece in exact order shown in the illustration (page 9). Hand tighten packing follower (10). Use a wrench to increase tightness by turning the nut an additional 60º. ACTUATOR AND BODY REASSEMBLY 1. Insert a new body gasket (49) and install bonnet assembly (8) with plug and stem assembly in valve. The o-ring (12) must be reinstalled by gently stretching over the bonnet and snapping into the gap between the top of the body (1) and the bonnet (8). This o-ring acts as a dust/moisture seat. 2. Place the actuator yoke over the stem (5). While tilting actuator back, drop yoke drive nut (9) over stem (5). Run locknuts (27), and travel indicator (58), down as far as possible and counter tighten locknuts (27) to lock. See appropriate actuator instructions (D103352X012, ACT_IM for type 32, 54, or 70 actuator) for reassembly and bench range adjustment. REPLACING THE PACKING Refer to the standard packing construction and the optional packing illustrated (pages 5 & 9) to determine the packing that has been pre-installed in your valve. When assembling or disassembling the valve, do not turn the valve stem while the plug is in contact with the valve seat. This can damage the seating surface very quickly. 4

5 Instruction Manual 24000C Control Valve EB0010 Figure 1. Valve Body Assembly Shown with Standard PTFE Spring Loaded Packing Table 1. Common Parts DESCRIPTION NPS 1/2 (DN15) NPS 3/4 (DN20) VALVE SIZE NPS 1 (DN25) NPS 1-1/2 (DN40) NPS 2 (DN50) 1 Body, Carbon Steel, EN PN W W W W W Body, Carbon Steel, ASME CL150 RF W W W W W 8 Bonnet A Bonnet Bushing Drive Nut (Yoke) Packing Follower O-Ring * Packing Kit, Spring Loaded PTFE V-Ring (standard) 24494T001 Packing Kit, Molded Graphite (optional) 24492T Locknuts (2) Body Gasket, Copper (standard) * Body Gasket, 316 Stainless Steel reinforced Graphite (optional) Travel Indicator *Recommended Spare Parts 5

6 24000C Control Valve Instruction Manual Table 2A. Plug Table for NPS 1/2, 3/4, and 1 Valves - VALVE SIZE DESC. PLUG TYPE PLUG ORIFICE DIA. in (mm) Cv Kv NPS 1/2 (DN15) NPS 3/4 (DN20) NPS 1 (DN25), Micro Trim (6.3) 0.2 A 0.17 A A 0.17 A (6.3) 0.5 A 0.43 A A 0.86 A (Equal %) 548 (416 SST) (9.5) 1.5 A 1.29 A A 2.15 A (20.6) (26.9) (6.3) (Equal %) 588 (416 SST) (9.5) 1.5 A 1.29 A A 2.15 A * Plug & Stem Assy (20.6) (26.9) (6.3) (416 SST) (9.5) (20.6) (26.9) (6.3) (9.5) (20.6) (26.9) * Recommended Spare Parts NOTES: A. Matching seat ring (Key no. 2, Table 2B, Page 7) must be furnished with replacement plug orders. 6

7 Instruction Manual 24000C Control Valve Table 2B. Seat Ring Table for NPS 1/2, 3/4, and 1 Valves - DESCRIPTION ORIFICE DIAMeter in (mm) VALVE SIZE NPS 1/2 (DN15) NPS 3/4 (DN20) NPS 1 (DN25) 0.25 inch (6.3) Orifice Diameter Seat Ring 316 SST A inch (9.5) Orifice Diameter inch (20.6) Orifice Diameter * inch (26.9) Orifice Diameter inch (6.3) Orifice Diameter Seat Ring 416 SST A inch (9.5) Orifice Diameter inch (20.6) Orifice Diameter inch (26.9) Orifice Diameter * Recommended Spare Parts NOTES: A. Matching seat ring (Key no. 2) must be furnished with replacement plug orders. See Table 2A, Page 6. Table 2C. Plug and Seat Ring Table for NPS 1/2, 3/4, and 1 Valves- Soft Seat DESCRIPTION PLUG TYPE PLUG ORIFICE DIAMETER in (mm) Cv Kv VALVE SIZE NPS 1/2 (DN15) NPS 3/4 (DN20) NPS 1 (DN25) (9.5) PTFE Seat (Equal %) (20.6) * Plug & Stem Assy (26.9) PTFE Seat (9.5) (20.6) in (6.3 mm) Orifice Diameter * Seat Ring in (9.5 mm) Orifice Diameter in (20.6 mm) Orifice Diameter (26.9mm) Orifice Diameter * Recommended Spare Parts 7

8 24000C Control Valve Instruction Manual Table 3. Plug and Seat Ring Table for NPS 1-1/2 and 2 Valves 4* DESCRIPTION PLUG TYPE PLUG Plug & Stem Assy 2* Seat Ring * Recommended Spare Parts PTFE Seat (Equal %) PTFE Seat (Equal %) (Equal %) (416 SST) (416 SST) 688 ORIFICE DIAMETER in (mm) Cv Kv NPS 1-1/2 (DN40) VALVE SIZE NPS 2 (DN50) 1.25 (31.8) (38.1) (50.8) (38.1) 2.0 (50.8) 1.25 (31.8) 1.50 (38.1) 2.0 (50.8) 1.25 (31.8) 1.50 (38.1) 2.0 (50.8) 1.25 (31.8) 1.50 (38.1) 2.0 (50.8) 1.25 (31.8) 1.50 (38.1) 2.0 (50.8) inch (38.1 mm) Orifice Diameter, 316 SST inch (38.1 mm) Orifice Diameter, 316 SST inch (50.8 mm) Orifice Diameter, 316 SST inch (38.1 mm) Orifice Diameter, 416 SST inch (38.1 mm) Orifice Diameter, 416 SST inch (50.8 mm) Orifice Diameter, 416 SST

9 Instruction Manual 24000C Control Valve EB0007 Figure 2, Table 4. SPRING LOADED PTFE V-RING PACKING KIT P/N 24494T001 DESCRIPTION MATERIAL 6 Spring ASTM A313 S Packing Set PTFE/ carbon filled PTFE 16 Washer ASTM A240 S Spacer J-2000 (filled (Polytetrafluoroethylene) EB0008 Figure 3, Table 5. MOLDED GRAPHITE (FLEXIBLE GRAPHITE) PACKING KIT P/N 24492T001 (OPTIONAL) DESCRIPTION MATERIAL 13 Bushing (2) Carbon-Graphite 14A Packing Rings (3) Graphite 14B Packing Ring Graphite 9

10 24000C Control Valve Instruction Manual Type 54 Actuator ATO/Fails Closed Action with FIELDVUE DVC2000 Digital Valve Controller Type 70 Actuator ATO/Fails Closed Action with FIELDVUE DVC6010 Digital Valve Controller 24000C FLANGED with Type 32 Actuator and optional Positioner 3660/3661 Type 32 ATO/Fails Closed Actuator with Handwheel Type 32 ATC/Fails Open Actuator with Handwheel Type 54 ATO/Fails Closed Actuator with Handwheel Type 54 ATC/Fails Open Actuator with Handwheel Type 32 with Adjustable, Open/Close Dual Travel Stops Type NV Electric Actuator EB0011 Figure 4. Dimensional Drawings: inches [millimeters] NOTE: Actuator removal requires 4-1/2 inches (115 mm) vertical clearance. 10

11 Instruction Manual 24000C Control Valve Table 6. Valve Dimensions VALVE SIZE "A" FACE-TO-FACE "B" BONNET ASME EN CL150 EN NPS DN in mm in mm in mm 1/ / / NOTES: Actuator requires 4-1/2 inches (115 millimeters) vertical clearance. Face-to-Face Dimensions per ISA S75.03 / EN Table 7. Valve Assembly WEIGHTS Table 8. ACTUATOR WEIGHTS ASME VALVE SIZE EN WEIGHTS ACTUATOR TYPE lbs WEIGHTS kgs NPS DN lbs kgs 1/ / / MV VA NV24-MFT (non spring return) NVF24-MFT or NVF24-MFT-E (spring return)

12 24000C Control Valve Instruction Manual Fieldvue, PlantWeb, Fisher and Baumann are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. Emerson and the Emerson logo are a trademarks and service marks of Emerson Electric Co. All other marks are the property of their respective owners. This product may be covered under one or more patents or under pending patent applications. 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. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, Fisher, 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. Emerson Process Management Fisher Controls International LLC Portsmouth, NH USA T 1(603) F 1(603) Fisher Controls International LLC All Rights Reserved.