Instruction Manual

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Fisherr D3 FloPro Control Valve

Contents

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

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

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

Specifications 2...............................

Educational Services 3.........................

Installation 3..................................

Setting the Valve FloPro Flow Adjuster 4............

Maintenance 5.................................

Valve Plug and Seat Ring Maintenance 5..........

Packing Maintenance 10........................

Servicing the Actuator 12.......................

Changing Actuator Action 20....................

Parts Ordering 20...............................

Parts Kits 23...................................

Parts List 23...................................

Figure 1. Fisher D3 FloPro Control Valve

NPS 2 RF Flanged End Connection

W9249

Introduction

Scope of Manual

This instruction manual provides installation, maintenance, and parts information for the Fisher D3 FloPro control

valve and actuator.

Do not install, operate, or maintain D3 FloPro valves without being fully trained and qualified in valve, actuator, and

accessory installation, operation, and maintenance. To avoid personal injury or property d amage, 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 Process Management sales office before

proceeding.

Description

The D3 FloPro control valve (figure 1) is a compact, rugged valve designed for on-off control of a variety of fluids at

pressures up to 155 bar (2250 psig). This valve is ideal for use as a dump valve on gas separators and scrubbers. It is

also well suited for other high pressure applications in natural gas production, compression, and processing. NPS 1 and

NPS 2 D3 FloPro control valves are available in CL900 NPT end connections and CL600 raised face flanged end

connections.

Instruction Manual

D103221X012

D3 FloPro Valve

February 2014

Summary of content (24 pages)

PAGE 1
Instruction Manual D3 FloPro Valve D103221X012 February 2014 Fisherr D3 FloPro Control Valve Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Educational Services . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . .
PAGE 2
Instruction Manual D3 FloPro Valve D103221X012 February 2014 Table 1. Specifications Valve Body Sizes and End Connection Styles(1) See table 3 Maximum Travel Maximum Inlet Pressures and Temperatures(1) Material Temperature Capabilities(1) VALVE BODY SIZE MAXIMUM INLET PRESSURE bar (psig) 15 mm (0.
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Instruction Manual D3 FloPro Valve D103221X012 February 2014 Table 3. Valve Sizes and Connection Styles VALVE SIZE, NPS 1 PORT DIAMETER, (INCHES) 2 THREADED RAISED FACE (RF) FLANGED CL900 CL600 0.375, 0.75, 1 X X 0.375, 0.75, 1 X X X = Available construction. Educational Services For information on available courses for Fisher D3 valves, as well as a variety of other products, contact: Emerson Process Management Educational Services - Registration P.O.
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Instruction Manual D3 FloPro Valve D103221X012 February 2014 3. The control valve assembly may be installed in any orientation, but normally the actuator is vertical above the valve. Install the valve so the flow direction arrow on the side of the valve indicates the direction of the process flow. 4. Install the valve following local and national piping codes when they apply to the application. For screwed connections, treat the external pipe threads with a good grade pipe compound.
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Instruction Manual D103221X012 D3 FloPro Valve February 2014 3. Retighten the socket head screws (key 15) to 3 NSm (26 lbfSin). Maintenance Refer to figures 7 and 8. Valve parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and maintenance depends on the severity of the service conditions. WARNING Avoid personal injury from sudden release of process pressure or bursting of parts.
PAGE 6
D3 FloPro Valve Instruction Manual February 2014 D103221X012 4. Tighten the hex socket head cap screws to 3 NSm (26 lbfSin). 5. Relieve pressure to the actuator, shut off all pressure lines to the actuator, and disconnect. Use lockout procedures to ensure the above measures stay in effect while you work on the equipment. 6. Break the bonnet nut (key 5) loose with a hammer. Continue turning the bonnet nut by using a hammer or a large adjustable wrench, tightened around one ear of the bonnet nut.
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Instruction Manual D3 FloPro Valve D103221X012 February 2014 3. Loosen the hex socket head cap screws (key 15) and raise the flow adjustor (keys 13 and 14) to its highest position on the valve stem. 4. Tighten the hex socket head cap screws to 3 NSm (26 lbfSin). 5. Relieve pressure to the actuator and disconnect the air lines. Ensure the flow adjustor is touching the top of the bonnet window. Use lockout procedures to ensure the above measures stay in effect while you work on the equipment. 6.
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Instruction Manual D3 FloPro Valve D103221X012 February 2014 Figure 3. Packing and Belleville Spring Stacking Order UPPER PACKING SPACER (KEY 12) ANTI-EXTRUSION WASHER (KEY 10) FEMALE PACKING ADAPTER (KEY 11) PACKING RING (KEY 11) MALE PACKING ADAPTER (KEY 11) ANTI-EXTRUSION WASHER (KEY 10) LOWER PACKING SPACER (KEY 12) BELLEVILLE SPRINGS (KEY 9) PIN (KEY 43) VALVE PLUG (KEY 3) VALVE PLUG INSTALLED WITHOUT PACKING RETAINER Figure 4.
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Instruction Manual D3 FloPro Valve D103221X012 February 2014 Figure 5. Lubrication Locations on Packing FEMALE PACKING ADAPTER PACKING RING MALE PACKING ADAPTER LUBRICATE WITH 3mm (1/8 INCH BEAD) OF SUPPLIED HIGH PERFORMANCE FLUORINATED GREASE (KEY 44) LUBRICATE WITH 3mm (1/8 INCH BEAD) OF SUPPLIED HIGH PERFORMANCE FLUORINATED GREASE 6. Thoroughly clean the seat ring (key 2) threads and the mating threads in the valve body (key 1). 7.
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D3 FloPro Valve Instruction Manual February 2014 D103221X012 9. Lubricate the bonnet O-ring (key 4) with lithium grease and install on the bonnet. 10. Apply anti-seize lubricant to the threads on the valve body and bonnet nut (key 5) and the contact surfaces of the bonnet and bonnet nut flange. Install the bonnet and actuator assembly onto the valve body. Tighten the bonnet nut until the nut stops turning. A few hammer blows will be required to ensure that the assembly is tight. 11.
PAGE 11
Instruction Manual D103221X012 D3 FloPro Valve February 2014 2. Use the lower packing spacer (key 12) and a tube to push the upper anti-extrusion washer (key 10) into place. Using the lower packing spacer in this manner will ensure the upper anti-extrusion washer is fully seated and flat when installed in the packing bore. 3. Remove the lower packing spacer from the packing bore. CAUTION All D3 FloPro packing kits include a single use packet of high performance fluorinated grease.
PAGE 12
D3 FloPro Valve February 2014 Instruction Manual D103221X012 4. Apply a 3mm (1/8 inch) bead of the supplied high performance fluorinated grease (key 44) around the groove of the female packing adaptor as shown in figure 5 and install over the valve stem (key 16). 5. Apply a 3mm (1/8 inch) bead of the supplied high performance fluorinated grease (key 44) around the groove of the packing ring as shown in figure 5 and install over the valve stem. 6.
PAGE 13
Instruction Manual D103221X012 D3 FloPro Valve February 2014 2. Remove the ten short actuator casing cap screws (key 29). 3. Remove the two long actuator casing cap screws (key 31) by alternating between them as you loosen them. Keep the upper casing (key 32) level during this procedure. 4. Remove the upper casing and the springs (key 28). 5. Remove the stem nut (key 27) taking care not turn the valve stem (key 16).
PAGE 14
D3 FloPro Valve February 2014 Instruction Manual D103221X012 Inspect all parts for wear or damage during disassembly. Replace any worn or damaged parts with genuine Fisher replacement parts. If the diaphragm is replaced, a new diaphragm O-ring should also be installed. 1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body (key 1), and drain the process media from both sides of the valve. 2.
PAGE 15
Instruction Manual D3 FloPro Valve D103221X012 February 2014 Figure 6. Spring Locations As Seen From Above Lower Actuator Casing 6 SPRINGS 3 SPRINGS 2 SPRINGS 15. Remove the stem O-ring (key 25) and the bonnet bushing (key 18). 16. If the hammer nut needs to be removed from the bonnet, the spring pins (or pipe plugs) (key 6, figures 7 or 8) can be removed with locking pliers. Actuator Assembly Spring-to-Close (Air-to-Open) Key numbers are referenced in figure 7.
PAGE 16
D3 FloPro Valve February 2014 Instruction Manual D103221X012 2. Lubricate the stem O-ring (key 25) with lithium grease and install in the bonnet (key 7). 3. Press the bonnet bushing (key 18) with the slots upward into the upper hole in the bonnet. The bonnet bushing is installed correctly when it snaps into place. 4. Install the casing O-ring (key 17) in the provided groove at the top of the bonnet. 5. Position the lower casing (key 21) on the bonnet. 6.
PAGE 17
Instruction Manual D3 FloPro Valve D103221X012 February 2014 CAUTION Avoid possible product damage which may affect proper operation of the diaphragm. Ensure the washer is aligned with the hole in the diaphragm so the washer does not cut the diaphragm. 23. Install the diaphragm washer (key 22) over the valve stem threads with the lip facing upward. If you are unsure of the correct orientation for the diaphragm washer, see figure 7 view A for the correct orientation. 24.
PAGE 18
D3 FloPro Valve February 2014 Instruction Manual D103221X012 Make sure all parts are clean and in good condition before starting assembly. There should be no burrs or sharp edges on any threads or surfaces that might cut or damage soft parts in the valve assembly. CAUTION The threads on factory-produced valve stems have been specially machined to avoid O-ring, bushing, or packing damage during trim maintenance.
PAGE 19
Instruction Manual D3 FloPro Valve D103221X012 February 2014 13. Install the male packing adaptor, lower anti-extrusion washer (key 10), and lower packing spacer over the valve stem as shown in figure 3. 14. Firmly press all packing parts into the packing bore with a tube. 15. Install the five Belleville springs (key 9) over the valve stem as shown in figure 3. 16. Install the valve plug on the stem and insert a new pin (key 43). 17.
PAGE 20
D3 FloPro Valve February 2014 Instruction Manual D103221X012 29. Install the two long cap screws (key 31) opposite each other. Install the ten short cap screws (key 29) into the remaining holes and install hex nuts (key 30) on all cap screws. 30. Torque the hex nuts in a crossing pattern to 16 NSm (12 lbfSft). 31. Pressurize the actuator to a maximum of 2.41 bar (35 psi) to stroke the valve fully closed. 32.
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Instruction Manual D3 FloPro Valve D103221X012 February 2014 Figure 7.
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Instruction Manual D3 FloPro Valve D103221X012 February 2014 Figure 8.
PAGE 23
Instruction Manual D3 FloPro Valve D103221X012 February 2014 Parts Kits TRIM KITS Port Diameter (inches) 0.375 0.
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D3 FloPro Valve February 2014 Instruction Manual D103221X012 Neither Emerson, Emerson Process Management, 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 is a mark owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co.