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Fisherr Z500 Severe Service Ball Valves

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.....................................

Figure 1. Fisher Z500 Severe Service Ball Valve

X1200

Introduction

Scope of Manual

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 Process Management sales office

before

proceeding.

Description

The Z500 severe service ball valve is a split body bolted design, full or reduced port, with a blowout proof stem. 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.

Instruction Manual

D103803X012

Z500 Valve

April 2015 - rev B

Summary of content (20 pages)

PAGE 1
Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Fisherr Z500 Severe Service Ball Valves Contents Figure 1. Fisher Z500 Severe Service Ball Valve Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Installation . . . . . . . . . .
PAGE 2
Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Table 1. Specifications 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 Maximum Working Pressures(1) Forged Steel Valves: Consistent with applicable pressure-temperature ratings in table 2 per ASME B16.34, but do not exceed the material temperature capabilities shown below.
PAGE 3
Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Table 2. Valve Body Materials, End Connections, and Ratings Ratings Bore Size, NPS End Connection Valve Body Materials 1/2 0.65 3/4 1 1-1/2 1 1.15 1-1/2 2 Buttweld, Socketweld, FNPT, RF, RTJ 2-1/2 1-1/2 1.
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Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Table 2. Valve Body Materials, End Connections, and Ratings (continued) Ratings Bore Size, NPS End Connection Valve Body Materials 1/2 0.65 3/4 1 1-1/2 1 1.15 1-1/2 2 Buttweld, Socketweld, FNPT, RF, RTJ 2-1/2 1-1/2 1.5 CL2500 2 2 2-1/2 3 Buttweld, RF, RTJ 2 Buttweld, Socketweld, FNPT, RF, RTJ 2-1/2 3 4 SA105, F22, F91, and F316 Buttweld, RF, RTJ 3 3 4 6 4 6 8 4 6 RF, RTJ 6 8 8 10 1/2 0.
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Instruction Manual D103803X012 Z500 Valve April 2015 - rev B 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.
PAGE 6
Z500 Valve Instruction Manual April 2015 - rev B D103803X012 d. Customer shall ensure valve stem 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 stem adapter is allowed f. Customer shall ensure all bolts are torqued down appropriately g.
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Instruction Manual D103803X012 Z500 Valve April 2015 - rev B 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.
PAGE 8
Z500 Valve Instruction Manual April 2015 - rev B D103803X012 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 Process Management sales office for more information. 4.
PAGE 9
Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Troubleshooting Operation D Stem adapter/actuator may be misaligned-- Remove actuator and stem adapter, then reassemble per assembly procedures for actuators. D Over-tightened stem packing-- Loosen packing to hand tight, cycle valve and retighten per procedures following torque table 5. D Inadequate air supply-- Increase air supply or install larger solenoid or quick exhaust valve. Refer to actuator manufacturer's specifications.
PAGE 10
Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Figure 2. Bolting Tightening Pattern 3 1 3 1 5 5 8 1 3 2 4 2 4 6 4 7 6 2 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.
PAGE 11
Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Figure 3. Sectional View LOCKPLATE METAL BODY GASKET SUPPORT BUSHING (HIGH CYCLE BRACKET ONLY) SEAT HOLDER 1 STEM ADAPTER INTEGRAL METAL SEAT SIDE-MOUNTED BRACKET UPSTREAM SEAT BELLEVILLE SPRING END ADAPTER STEM PACKING STUD AND BELLEVILLE WASHERS PACKING GLAND BALL BODY STUD/NUT VALVE BODY X1207 Note: 1 Seat holder is standard on welded and threaded end connections in 0.65, 1.15, and 1.5 inch bores only.
PAGE 12
Z500 Valve Instruction Manual April 2015 - rev B D103803X012 1. Loosen the packing studs. 2. Remove the packing rings from the packing box, being careful not to damage the packing box. 3. Inspect the clean packing box to ensure all surfaces are clean and undamaged. 4. Insert the zero clearance washer. Us the packing flange to press the washer into position. 5. Insert the bottom end ring of the stem packing. Use the packing flange to press the bottom end ring into position. 6.
PAGE 13
Instruction Manual D103803X012 Z500 Valve April 2015 - rev B Figure 6. Use Packing Flange 8. Bolt up the packing flange. Use Belleville washers in the same orientation as removed. Contact your Emerson Process Management sales office for additional information. Make sure that the markings on the studs and nuts are facing out. Tighten the nuts in a star pattern (figure 2). Tighten the nuts with applicable torque (table 5). Figure 7.
PAGE 14
Z500 Valve April 2015 - rev B Instruction Manual D103803X012 Figure 8. Mount the Stem Adapter Figure 9. Position the Mounting Bracket 3. Place the actuator on top of the mounting bracket and stem adapter, in the fail position. Make sure the actuator is properly aligned with the stem adapter. If not, loosen the mounting bracket to assure proper alignment and retighten the mounting bracket. Use anti-seize lubricant on the actuator studs and nuts. Ensure the markings on the studs and nuts are facing out.
PAGE 15
Instruction Manual D103803X012 Z500 Valve April 2015 - rev B Figure 10. Place the Actuator on Top of the Mounting Bracket Figure 11. Install the Handwheel Hand Lever 6. Position the mounting bracket onto the body. Use anti-seize lubricant on the bracket studs and nuts. Make sure the markings on the studs and nuts are facing out. Leave the nuts finger tight. 7. Insert the support bushing into the allotted slot of the mounting bracket. 8. Mount the stem adapter on top of the stem with the two keys.
PAGE 16
Z500 Valve April 2015 - rev B Instruction Manual D103803X012 Figure 12. Stem Adapter 9. Place the lock plate on top of the mounting bracket. Note the orientation of the open “O” and closed “C” markings. Figure 13. Lock Plate 10. Thread on the socket head cap screws, using anti-seize lubricant, from the underside of the mounting bracket. 11. Tighten the mounting bracket and lockplate bolting to the applicable torque after everything is aligned properly. Figure 14. Handlever Assembly 12.
PAGE 17
Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Table 5. Packing Flange Bolt Torque Values BOLT SIZE RECOMMENDED TORQUE mm Inch lbf•ft lbf•in N•m 6 1/4 4 50 6 8 5/16 6 75 8 10 3/8 8 100 11 11 7/16 15 180 20 13 1/2 21 250 28 16 5/8 38 450 50 19 3/4 58 700 79 22 7/8 100 1200 135 25 1 150 1800 203 Table 6. Assembly Stand Off NOMINAL BALL SIZE(1) STANDOFF MINIMUM STANDOFF MAXIMUM mm Inch mm Inch mm Inch 13 1/2 0.69 0.027 0.89 0.
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Instruction Manual Z500 Valve D103803X012 April 2015 - rev B Parts Ordering A serial number is assigned to each valve and stamped on the nameplate. Always refer to the valve serial number when corresponding with your Emerson Process Management sales office regarding spare parts or technical information. WARNING Use only genuine Fisher replacement parts.
PAGE 19
Instruction Manual D103803X012 Z500 Valve April 2015 - rev B Figure 15.
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Z500 Valve April 2015 - rev B Instruction Manual D103803X012 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.