Emerson 24000S Instruction Manual
Contents
1. a For Baumann 151 trim figure 4 unscrew the seat subassembly key 51 with a 5 8 inch socket wrench When reassembling hand tighten the subassembly key 51 and then rotate 1 8 of a turn with the 5 8 inch socket to lock in place Note If changing to Baumann 151 trim for correct flow characteristics be sure the valve is reversed in the pipeline so that flow direction is flow to close b For Baumann 177 trim figure 5 unscrew the retainer nut key 24 using a 3 4 inch socket wrench Remove the gland key 23 and insert key 25 Replace the insert key 25 making sure that the tapered portion faces up If replacement of the housing key 26 is required use a 5 8 inch socket wrench c For NOLEEK bellows trim figure 6 hold the bellows bonnet and push down on the stem to expose the plug retaining pin key 21 Using a small punch tap the pin key 21 out To replace the new plug retaining pin key 21 be sure the plug and stem is aligned to expose the hole refer to figure 6 and with needle nose pliers slide the pin key 21 into the hole WARNING sure the plug retaining pin key 21 is flush inside the hole and not exposed on either side of the plug or damage could happen to the bonnet interior Lapping the Valve Seat If valve seat leakage becomes excessive it may be necessary to lap the valve seat 240005 Valve Instruction Manual May 2011 D103359X012 Lapping is the process of mating the valve plug to the se2. 750 psig and process temperatures ranging from 46 to 232 C 50 to 4509 For non environmental applications this packing system offers excellent performance at the same temperature range up to the maximum valve working pressure Temperature limits apply to packing arrangements only Complete valve assembly temperature limits may differ Refer to appropriate pressure temperature ratings Reference Fisher Packing Selection Guidelines for Sliding Stem Valves bulletin 59 1 062 D101986X012 Instruction Manual 240005 Valve D103359X012 May 2011 Figure 8 Dimensional Drawings 333 279 013 1 E 011 0 BAUMANN 54 ACTUATOR w FIELDVUE DVC2000 DIGITAL VALVE CONTROLLER BAUMANN 70 ATO ACTUATOR FIELDVUE DVC6000 DIGITAL VALVE CONTROLLER 163 6 4 71 2 8 BAUMANN 32 CLOSE BAUMANN 32 BAUMANN 54 ATOJFAILCLOSE BAUMANN 54 FAIL ACTUATOR WITH HANDWHEEL OPEN ACTUATOR WITH ACTUATOR WITH HANDWHEEL OPEN ACTUATOR WITH HANDWHEEL 125 49 mm BAUMANN 32 ACTUATOR WITH ADJUSTABLE un OPEN CLOSE DUAL TRAVEL STOPS NV ELECTRIC ACTUATOR inch NOTE ACTUATOR REMOVAL REQUIRES 115 mm 4 5 INCHES VERTICAL CLEARANCE NOTE ELECTRIC ACTUATORS ARE AVAILABLE CONTACT YOUR EMERSON PROCESS MANAGEMENT SALES OFFICE FOR DETAILS 240005 Valve Instruction Manual May 2011 D103359X012 Table 12 Valve Dimensions ASME NPT Wafer Standard Extension Bon
3. furnished with replacement plug orders 10 Recommended spare parts Instruction Manual 240005 Valve D103359X012 May 2011 Table 3 Plug for NPS 1 1 2 2 and 3 Valves KEY PLUG ORIFICE VALVE SIZE No DESCRIPTION PLUG TYPE ES DIAMETER 31 8 1 25 24411 101 577 38 1 1 50 5 Equal d 3s Xm pemem m Metal Seat 548 416 Equal E 27021054 aE 35 itta _ 1185 151 305 262 24601101648 e 9 175 MAGUS _ Unear 2 DENN me FERRI HEBR 318035 175 151 Metal Seat 648 416 Linear E 35 54 289910168 7 395 x2 mones OO 88168 _ 595 247610268 Metal Seat Linear Recommended spare parts 11 240005 Valve Instruction Manual May 2011 D103359X012 Figure 4 Optional 151 Low Flow Trim Assembly E1270 Table 4 Baumann 151 Low Flow Trim Description Material Plug ASTM A479 S21800 Seat Sub Assembly Cage ASTM A276 531600 Seat PTFE C
4. 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 Emerson Process Management sales office for more complete specifications Provide the product serial numbers shown on the nameplate and all other pertinent information WARNING 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 care to prevent people from being injured in case the hoist or rigging slips Be sure to use adequate sized hoists and chains or slings to handle the valve WARNING 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 Instruction Manual 240005 Valve D103359X012 May 2011 Maintenance WARNING Avoid personal injury and property damage from sudden release of process pressure or bursting of parts Before performing any maintenance operations D
5. Instruction Manual 240005 Valve D103359X012 May 2011 Baumann 240005 Stainless Steel Control Valve Contents Figure 1 Baumann 240005 Control Valve Introduction 1 Scope 1 Safety Precautions 2 Maintenance 3 3 AEPD 4 Disassembly 4 Lapping the Metal Seat 5 Replacing Packing 6 Actuator and Valve Body Reassembly 6 Parts Ordering 7 Dimensions and Weights 17 Introduction The Baumann 240005 line of stainless steel pneumatic control valves figure 1 may be used for the control of pressure temperature level and flow NPS 1 2 through 2 valves are available with NPT end connections NPS 3 is available as wafer style only The 316 stainless steel valve body will withstand mildly corrosive fluids yet is economical enough to use in applications where carbon steel is normally specified Scope of Manual This instruction manual includes installation maintenance and parts information for the Baumann 240008 stainless steel control valve Do not install operate or maintain Baumann 240008 control valves without being fully trained and qualified in valve actuator and accessory installation operation and mai
6. S HEAT DISSIPATION IDEAL FOR HEAT TRANSFER FLUIDS TNTET m mx t E1367 Table 8 Common Baumann NOLEEK Bellows Parts VALVE SIZE DESCRIPTION PART NO Plug 15 80 1253 Contact your Emerson Process Management Sales Office 1 2 3 V Ring Packing Kit Standard 24494T001 ing Kit ing Kit ENVIRO SEAL Packing Kit Optional 244907001 15 25 1 2 1 24583 1 Complete Bellows Bonnet S A 24586 1 Plug Retaining Pin 971342 005 163 22 Hex Socket Pipe Plug 1 8 NPT Stainless Steel Included with Key 8 14 Recommended spare parts Instruction Manual 240005 Valve D103359X012 May 2011 Figure 7 Packing Kits SY E1240 E1241 E1248 Spring Loaded PTFE Molded Graphite Flexible ENVIRO SEAL V Ring P N 244947001 Graphite P N 244927001 P N 24490T001 Table 9 Spring Loaded PTFE V Ring Packing Kit P N 24494T001 _ 7 Table 10 Molded Graphite Flexible Graphite Packing Kit P N 24492T001 Table 11 ENVIRO SEAL Packing Kit P N 244907001 Belleville Spring ASTM B637 N07718 Washer qty 2 Modified PTFE Recommended spare parts 15 240005 Valve Instruction Manual May 2011 D103359X012 Special ENVIRO SEAL Packing Note The ENVIRO SEAL PTFE packing system is suitable for 100 ppm environmental applications on services up to 51 7 bar
7. at 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 Use a good quality lapping compound with a mixture that contains 280 to 600 grit Apply at several spots around the plug seating surface Replace the plug and stem carefully in the bonnet 2 Install the bonnet key 8 into the valve body without gasket and hand tighten The bonnet will serve as a quide 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 90 degrees while lapping to keep the plug and seat ring concentric 4 Clean the valve seat and plug key 4 thoroughly when lapping is complete removing all traces of lapping compound 5 Forthe NPS 1 through 3 integral seat valve body inspect the internal seating surface for wear or damage and replace if necessary Replacing Packing Refer to figure 2 and the standard and optional packing constructions figure 7 to determine the packing that has been preinstalled in your valve 1 Disassemble the valve as directed earlier Remove the locknuts key 27 and indicator disk key 58 and turn the plug and stem key
8. ey 58 and yoke drive nut key 9 4 Remove the actuator from the valve Air to Open Actuators 1 Using flexible tubing apply sufficient air pressure to the actuator to lift the plug off the seat 2 Loosen the drive nut key 9 and then remove the plug and stem keys 4 and 5 assembly by holding the actuator stem still while unthreading the plug and stem assembly counterclockwise 3 Remove the stem locknuts key 27 travel indicator key 58 and yoke drive nut key 9 Instruction Manual 240005 Valve D103359X012 May 2011 4 Remove the actuator from the valve 5 Disconnect the air supply to the actuator and remove the air tubing Valve Body Disassembly 1 After removing the actuator unscrew the bonnet key 8 and plug and stem keys 4 and 5 from valve body key 1 A new body gasket key 49 should be installed each time the valve is disassembled 2 Loosen the packing spring load by removing the packing follower key 10 Remove the plug and stem assembly by pulling it out through the bottom of the bonnet key 8 while rotating the stem key 5 This will help prevent damage to the packing components Note Handle the parts carefully to avoid damaging the seating and guiding surfaces Wipe the parts with a clean soft cloth and examine for signs of wear or damage 3 To remove the seat ring key 2 use a 5 8 inch socket wrench Clean the seat ring thoroughly and examine for signs of wear or damage 4 Low Flow Trims
9. gasket may not seal properly Installation 1 4 Before installing the valve in the pipeline thoroughly clean the line of all dirt welding chips scale oil or grease other foreign material 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 Athree valve bypass must be used to permit removal of the control valve from the line without shutting down the system In case of a heat insulated installation insulate the valve body only not the bonnet WARNING avoid personal injury property damage do not attempt to do any work 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 240005 Valve Instruction Manual May 2011 D103359X012 Air Pipinq 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 the actuating air pressure line to the 1 4 NPT in the lower diaphragm case 2 Use 6 4 mm 1 4 inch O D tubing or equivalent for all air lines If air line exceeds 8 m 25 ft in length 9 5 mm 3 8 inch tubing is preferred Air lines must not leak Air pressure not to exceed 2 5 bar 35 psig Disassembly WARNING If there is evidence of process f
10. ion Double Extension Bonnet Construction Triple Extension Bonnet Construction Substitute 104 for 101 Substitute 107 for 101 Substitute 110 for 101 105 for 102 108 for 102 111 for 102 Table 2 Plug for NPS 1 2 and 1 Valves KEY PLUG ORIFICE DIAMETER VALVE SIZE ER Se DN IS NPS DNZ5 NPST Metal Seat Micro Trim Linear omm 5 0375 PTFE Seat Equal 34 GE46393X012 6 3 0 25 GE46394X012 CE46392X012 Metal Seat Equal n 35 0 375 Du pue 24634 6 101 548 ee 24127 10 101 548 __ 24185 6 101 548 a2 20605100548 GEA6390X012 3 0 25 0 610 610 0 46391 012 GEAG389X012 4 5 Metal Seat Equal ose 129 24634 101 588 24171 101 588 EUN NN 24185 101 588 82 24061101588 E GEA6398X012 46397 012 5 7129 29 24669 1 101 648 Metal Seat Linear pon 540 375 21 24671 2 101 648 _____ 24757 5 101 648 060829 sz 01 0 24660 101 677 0 5 0 43 24617 101 677 PTFE Seat Linear 677 05 08 ERR 24631 101 677 20608125 24010 1 101 677 46395 012 Metal Seat L 688 5 0 375 K 24671 101 688 _ 2477100688 Lt 35 82 __ 247100688 3 8 in threaded 316 SST 24167 SUEDE 3 8 in threaded 416 SST 24167 3 1 Matching seat ring key 2 must be
11. luid under pressure leaking from the joint retighten the valve body joint nuts Return to the Warning at the beginning of the Maintenance section to ensure proper steps have been taken to isolate the valve and relieve process pressure CAUTION 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 key 27 on the stem key 5 This will allow you to turn the stem by turning the locknuts key 27 with a wrench When placing the valve in a vise do not clamp the rounded sides of the valve This will distort the shape of the casting and will ruin the valve Actuator Removal Access to the internal components of the valve body can be accomplished with the actuator removed For actuator maintenance see the following instruction manual Baumann Actuator Instructions D103352X012 Air to Close Actuators 1 Disconnect the air supply to the actuator and remove the air tubing NJ Loosen the drive nut key 9 and then remove the plug and stem keys 4 and 5 assembly by holding the actuator stem still while unthreading the plug and stem assembly counterclockwise 3 Remove the stem locknuts key 27 travel indicator k
12. net NOLEEK CLASS a mm 88 VALVE SIZE ON NS 40 3o 4s 45 35 26 89 M3 95 2357 928 3 o NA NA 65 95 20 257 928 Table 13 Valve Assembly Weights VALVE SIZE WEIGHT WEIGHTS ACTUATOR TYPE NV24 MFT non spring return NVF24 MDT or NF24 MDT E spring return 1 Electric actuators reference Baumann bulletin 52 1 NV ACT D103326X012 18 Instruction Manual D103359X012 240005 Valve May 2011 240005 Valve Instruction Manual May 2011 D103359X012 Baumann Fisher FIELDVUE and ENVIRO SEAL are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric 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 quarantees 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
13. notice 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 Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK Dubai United Arab Emirates Singapore 128461 Singapore lt gt x www Fisher com E M E R S i LJ BEL p g L g IE 4 Fisher Controls International LLC 2009 201 1 Rights Reserved a S ses
14. ntenance 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 Process Management sales office before proceeding eM www Fisher com Process Management 240005 Valve Instruction Manual May 2011 D103359X012 WARNING Always wear protective gloves clothing eyewear when performing 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 CAUTION 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
15. o 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 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 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 Depending on the actuator construction it will be necessary to manage the pneumatic actuator spring pre compression 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 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 Note 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
16. ollar ASTM A276 531600 Wee ASTM AZ76 531600 385 mm 7 ASTM A276 531600 Table 5 Plug and Seat for Baumann 151 Trim KEY ORIFICE VALVE No DESCRIPTION PLUG TYPE PLUG NO DIAMETER mnc WERT 24151 25 101 151 Seat Sub Assembly 24151 20 12 Recommended spare parts Instruction Manual 240005 Valve D103359X012 May 2011 Figure 5 Optional 177 Low Flow Trim Assembly E1271 Table 6 Baumann 177 Low Flow Trim KeyNo KeyNo Description 4 Plug see table 7 Gland MUS Seat Ring Sub bly P N 24241 Insert Pi Housing Table 7 Plug and Seat for Baumann 177 Trim KEY ORIFICE VALVE US VANESZE i O No DESCRIPTION PLUG TYPE PLUG NO DIAMETER mnc NER RS Seat Sub Assembly See table 6 24241 O Recommended spare parts 13 240005 Valve Instruction Manual May 2011 D103359X012 WARNING Baumann NOLEEK valve bonnet assembly is not intended for use lethal service applications Figure 6 Baumann NOLEEK Bellows Bonnet Assembly UNLIMITED STEM ROTATION T WITHOUT TWISTING ss BACKUP PACKING SYSTEM BELLOWS SEE FIGURE 7 7 TELL TALE CONNECTION 1 8 FOR REMOVAL OF PLUG TIME PROVEN DOUBLE SIMPLY PUSH OUT PIN AFTER WALLED BELLOWS MADE EXTENDING BELLOWS FROM S31600 RATED FOR UP TO 41 4 BAR 720 PSI PRESSURE u BELLOWS HOUSING FULL EXTENSION PROVIDE
17. rt a new valve body gasket key 49 and install the bonnet assembly key 8 For NPS 1 2 to 1 valves tighten the nuts key 12 to a torque of 9 5 17 6 Nem 7 13 Ibfeft NPS 1 1 2 to 2 valves tighten nuts key 12 to a torque of 21 7 42 0 Nem 16 31 Ibfeft 2 Place the actuator yoke over the stem key 5 While tilting the actuator back drop the yoke drive nut key 9 over the stem key 5 Run the locknuts key 27 and the travel indicator key 58 down as far as possible and counter tighten the locknuts key 27 to lock See the following instruction manual Baumann Actuator Instructions D103352X012 for reassembly and bench range adjustment CAUTION 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 Instruction Manual 240005 Valve D103359X012 May 2011 WARNING To avoid personal injury or equipment damage due to possible sudden shifting or falling of the valve assembly do not lift the valve assembly by the handwheel Parts Ordering When corresponding with your Emerson Process Management sales office about this equipment always mention the valve serial number When ordering replacement parts also specify the key number part name and desired material using the following parts tables WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management
18. s 4 and 5 out through the packing box Remove the packing follower key 10 Push out the old packing key 14 by working from the underside of the bonnet key 8 2 Standard Spring Loaded PTFE V Ring Packing figures 2 and 7 Carefully insert each piece in exact order shown in figure 7 Tighten the packing follower key 10 until it shoulders on the bonnet key 8 This will compress the packing spring key 7 to enable constant stem sealing throughout packing life 3 Molded Graphite Ribbon Packing figure 7 Carefully insert each piece in exact order shown in figure 7 Hand tighten the packing follower key 10 Use a wrench to increase tightness by turning the follower an additional 60 degrees 4 ENVIRO SEAL Packing figure 7 Carefully insert each piece in exact order as shown in figure 7 Tighten the packing follower key 10 until the Belleville springs are compressed This will be signaled by a significant increase in resistance Back off the follower 1 8 to 1 4 turn A gap of approximately 1 5 mm 1 16 inch between the packing follower and the bonnet will ensure the packing is seated properly 5 For Optional NOLEEK Bellows Seal Packing figure 6 Insert each piece in the exact order shown in the illustration Tighten the packing follower key 10 until it shoulders on the bonnet key 8 This will compress the packing springs key 7 to provide constant stem sealing throughout packing life Actuator and Valve Body Reassembly 1 Inse
19. 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 Note Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user 240005 Valve 2011 Figure 2 Baumann Flangeless NPT Threaded Valve Body Assembly with Standard Bonnet om E1266 Instruction Manual D103359X012 Figure 3 Baumann Flangeless NPT Threaded Valve Body Assembly with Single Extension Bonnet ____ jd Ly E1366 Instruction Manual 240005 Valve D103359X012 May 2011 Table 1 Baumann 240005 Common Parts HUNE NPS 1 2 5 1 1 2 NPS 3 mmi es Gee Pages through 1 L8 11 pertain ts abe Spgs 5 mex NA NA NA Lu 4 ms mus NR NA o e eeg I 2 Recommended spare parts 9 240005 Valve Instruction Manual May 2011 D103359X012 The guidelines below apply to tables 2 3 5 and 7 For Extension Bonnet Construct
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