Emerson Fisher 644 And 645 Installation Instructions

2015-03-30

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Fisherr644 and 645 Differential Pressure Pump

Governors

Contents

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

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

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

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

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

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

Direct-Acting Actuators 4.......................

Reverse-Acting Actuators 5.....................

Overpressure 6.................................

Startup 6......................................

Adjustment 6.................................

Principle of Operation 7.........................

Maintenance 7.................................

Disassembly 8................................

Reassembly 8.................................

Parts Ordering 10...............................

Parts List 10...................................

Figure 1. Fisher 644 Actuator Mounted on a Typical

easy-e™ Valve

W2265-1

Introduction

Scope of Manual

This instruction manual provides information on installation, adjustment, maintenance, and parts ordering for the

Fisher 644 and 645 differential pressure pump governors. Refer to separate instruction manuals for information about

the valve and other accessories used with these governors.

Do not install, operate, or maintain 644 or 645 governors 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

644 and 645 actuators are used in combination with any of several sliding-stem valves to automatically control

steam-driven boiler feedwater pumps (reciprocating or turbine). The 644 or 645 actuator (see figures 1 and 2), when

used in combination with one of several push-down-to-close sliding-stem valves, forms a pump governor.

644 and 645 actuators may also be combined with push-down-to-open valves to be used as relief governors. Relief

governors are used to divert excess pump discharge back to the suction side of the pump.

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Table 1. Specifications

Actuator Sizes

See table 2

Actuator Travel

Chloroprene Diaphragm: 11 mm (0.4375 inch)

maximum

Stainless Steel Diaphragm: 3 mm (0.125 inch)

maximum

Operating Principle

JDirect-acting with push-down-to-close valve

JReverse-acting with push-down-to-open valve

Differential Pressure Ranges

See table 2

Maximum Casing Pressure

644 Actuator:

Cast-Iron Casing: 20.7 bar (300 psig)

Steel Casing:41.4 bar (600 psig)

645 Actuator:

Cast-Iron Casing: 34.5 bar (500 psig)

Steel Casing: 69.0 bar (1000 psig)

Maximum nPAcrossDiaphragm

13.8 bar (200 psi)

Effective Diaphragm Area

644:

Size 1: 146 cm2(8.9 inch2)

Size 2: 243 cm2(14.8 inch2)

Size 3: 364 cm2(22.2 inch2)

645:338cm

2(20.6 inch2)

Material Temperature Capabilities

644:

Chloroprene Diaphragm:-40 to 82_C

(-40 to 180_F)

Stainless Steel Diaphragm:

Cast-iron casing: -40 to 232_C(-40to450_F); Steel

casing: -40 to +399_C(-40to750_F)

645: -37 to 82_C(-35_to 180_F)

Casing Pressure Connections

1/4 NPT internal

Spring Ranges and Sensitivity

See table 2

Specifications

Specifications for the 644 and 645 pump governors are shown in table 1. Information for a specific pump governor is

also found on the nameplate of that pump governor.

Table 2. Spring Information

ACTUATOR DIFFERENTIAL PRESSURE RANGE SPRING RATE SENSITIVITY SPRING PART NUMBER

Bar Psi N/mm Lbf/in mm/N In/Psi

644

Size 3

Casing

0.3-1.2

1.2-1.9

5-18

18-27

107

314

609

26.1

13.5

0.0707

0.0365

1F945527032

1F945627032

Size 2

Casing

1.9-2.8

2.8-3.8

27-40

40-55

107

165

609

940

9.0

6.2

0.0244

0.0168

1F945627032

1F945727042

Size 1

Casing

3.8-4.7

4.7-6.9

55-68

68-100

107

165

609

940

5.4

3.7

0.0146

0.0101

1F945627032

1F945727042

645

1.0-1.7

1.7-2.4

2.4-3.2

3.2-4.1

4.1-4.3

14-24

24-35

35-47

47-59

59-62

107

129

246

368

490

612

735

21.0

14.0

10.5

11.0

7.1

0.057

0.038

0.0286

0.0299

0.0191

1F714427112

1F176727032

1F176827092

1F176927092

1E792327092

4.3-5.9

5.9-6.8

6.8-8.2

8.2-9.7

9.7-10.7

62-85

85-99

99-119

119-140

140-155

145

221

257

310

368

830

1260

1470

1770

2100

6.2

4.1

3.5

2.9

2.5

0.0169

0.0111

0.0095

0.0079

0.0067

1F714327092

1E795327082

1E792427082

1E795427082

1E793327082

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Educational Services

For information on available courses for Fisher 644 and 645 pump governors, as well as a variety of other products,

contact:

Emerson Process Management

Educational Services - Registration

P.O. Box 190

Marshalltown, IA 50158-2823

Phone: 800-338-8158 or 641-754-3771

FAX: 641-754-3431

e-mail: education@emerson.com

Figure 2. Typical Pump Governor Sectionals

W2263-1 W2264-1

644 ED 645 ED

WARNING

These governors must be installed, operated, and maintained in accordance with Fisher instructions and all applicable

federal, state, and local codes, laws, rules and regulations.

If a leak develops in the system or if any of the equipment is damaged, service is required. Failure to investigate problems

immediately may cause a hazardous condition.

Call a serviceman in case of trouble. Only a qualified person must install or service the actuator.

Installation

WARNING

Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal

injury.

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

To avoid personal injury or property damage caused by bursting of pressure-retaining parts, be certain the service

conditions do not exceed the casing pressure limit (maximum nP across the diaphragm) of 13.8 bar (200 psi). Use

pressure-limiting or pressure-relieving devices to prevent service conditions from exceeding this limit.

Check with your process or safety engineer for any other hazards that may be present from exposure to process media.

If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this

instruction manual.

Normal operating temperature range for the 644 actuator is from -40 to 82_C(-40to180_F). For the 645 actuator, the

range is from -37 to 82_C(-35to180_F).

Figure 3. Typical Installation for a Direct-Acting Governor

14A2729-A

A1762

AFB

645-ED PUMP

ACTUATOR

CONNECT TO BOILER PRESSURE

STEAM

SUPPLY

PUMP

DISCHARGE

SUCTION

Direct-Acting Actuators

Proceed as follows to install 644 and 645 actuators that are used with push-down-to-close valves (644-ED, 645-ED).

Refer to figure 3.

1. Place the governor in the steam line between a hand operated throttle valve (C) and the steam inlet to the pump.

The governor may be installed in any position, as long as the flow is in the direction of the arrow cast on the valve

body. However, when used for steam service, the unit should be installed so condensate will drain back into the

diaphragm casing and maintain a water seal on the diaphragm. Failure to do so may impact performance.

2. Install a hand-operated throttle valve (E) between the governor and the steam supply line.

3. Runa1/4-inchcontrollinefromtheupperdiaphragmcasingtothesideortopofthepumpdischargeline.Keepthe

controllineawayfromanynipple,swage,orelbow.

4. Install a lock-shield needle valve (B) and a pressure gauge in this control line.

5. Run a second 1/4-inch control line from the lower diaphragm casing to the boiler steam pressure line. Install a

needle valve (A) in this line. Slope the line toward the actuator in order to form a water seal on the diaphragm.

6. Connect the two control lines with an equalizing line in which a needle valve (F) has been installed.

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Figure 4. Typical Installation for a Relief Governor

SUCTION

PUMP

DISCHARGE

14A2789-A

A1763

EQUALIZING

VALVE BOILER

PRESSURE

RELIEF

ACTUATOR

CAUTION

The equalizing line helps prevent damage to the diaphragm when the system is started up.

Reverse-Acting Actuators

Proceed as follows to install 644 and 645 actuators that are used with push-down-to-open valves (644-EDR, 645-EDR).

Table 3. Maximum Static Casing Pressures

Diaphragm Casing Material Cast Iron Steel

Valve Body Ratings CL125 and CL250 CL150, CL300 and CL600

Actuator 644 300 psig 600 psig

645 500 psig 1000 psig

1. Place the governor in the steam line. It may be installed in any position as long as the flow is in the direction of the

arrow cast on the valve body. However, when used for steam service, the unit should be installed so condensate will

drain back into the diaphragm casing and maintain a water seal on the diaphragm. Failure to do so may impact

performance.

2. Run a bypass line from the pump's discharge line to the suction line of the pump. In this line, install a hand-operated

throttle valve (D).

3. Run a 1/4-inch control line from the upper diaphragm casing to the pump discharge line. Install a needle valve (B) in

this line.

4. Extend a second 1/4-inch control line from the lower diaphragm casing to the boiler steam pressure line. Place a

needle valve (A) in this line.

5. Connect the two control lines with an equalizing line in which a needle valve (F) has been installed.

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Overpressure

WARNING

Overpressuring any portion of this equipment may cause damage to the governor parts, leaks in the system, or personal

injury due to bursting of pressure-containing parts.

To avoid overpressure, provide an appropriate overpressure protection device to ensure that none of the limits listed in

table 3 will be exceeded.

Check the system for damage after any overpressure condition.

Startup

Proceed as follows to start up direct-acting actuators (644-ED, 645-ED). See figure 3.

1. Close all valves except the bypass valve (D).

2. Open the equalizing valve (F).

3. Opentheneedlevalve(B)inthepumpdischargelineapproximately1/2turn.

4. Open needle valve (A) in the pressure control line and close equalizing valve (F).

5. Openvalve(C)thatisdownstreamofthegovernor.Closebypassvalve(D).

6. Slowly open valve (E) which is upstream of the governor.

7. To increase the discharge pressure, if it is too low, turn the lower spring seat (key 19, figures 6 and 7) clockwise into

the yoke.

8. If the discharge pressure is too high, slightly open needle valve (B). If the pressure does not fall to the desired

setting, turn the lower spring seat counterclockwise out of the yoke.

9. Open or close the lock-shield needle valve (B) to a point where a very slight movement of the valve stem

(approximately 1/64-inch) is noticeable with each stroke of the pump. Greater stem movement will result in erratic

operation and shorten the life of the diaphragm.

To start up reverse-acting actuators (644-EDR, 645-EDR) proceed as follows. See figure 4.

1. Close all valves except the bypass valve (D).

2. Open the equalizing valve (F).

3. Open valve (A) that is in the boiler pressure control line.

4. When the pump has built up the discharge pressure, open valve (B) that is in the discharge pressure control line.

Close equalizing valve (F).

5. Valve(C),downstreamofthegovernor,should now be opened. Close bypass valve (D).

6. Slowly open upstream valve (E).

7. To increase the discharge pressure if it is too low, turn the lower spring seat (key 19, figures 6 and 7) clockwise into

the yoke.

8. If discharge pressure is too high, slightly open equalizing valve (F). If the pressure does not fall low enough, turn the

lower spring seat counterclockwise out of the yoke.

9. Open or close valve (B) to a point where very slight movement (approximately 1/64-inch) of the stem is noticeable

with each stroke of the pump. Greater stem movement will result in erratic operation and shorten the life of the

diaphragm.

Adjustment

No adjustment is required other than that described in the procedure for putting the governor into operation. If it is

necessary to change the setting, turn the lower spring seat clockwise into the yoke to increase the pressure setting.

Turn the lower spring seat counterclockwise, out of the yoke, to decrease the pressure setting.

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Principle Of Operation

Figure 3 shows a 645-ED being used to directly maintain a differential setting between the pump discharge pressure

and the boiler steam pressure in a boiler feedwater system.

If pump discharge pressure increases, the change is registered on the top of the actuator diaphragm. The increased

pressure forces the diaphragm and valve plug downward. With the steam supply thus restricted, less steam reaches

the pump. This causes the discharge pressure to drop so that a difference between the discharge pressure and the

boiler pressure will return to the desired differential setting.

In figure 4, a 644-EDR is being used as a relief governor maintaining a differential pressure between the boiler and

pump discharge.

An increase in the pump discharge pressure is registered on the top of the actuator diaphragm. The increased pressure

forces the diaphragm and valve plug downward. Since this governor is reverse-acting, this action opens the valve and

allows the excess pump discharge to flow to the pump suction line. The pump discharge pressure drops and the

difference between the boiler pressure and the pump discharge pressure returns to the desired level.

Maintenance

Actuator parts are subject to normal wear and must be inspected and replaced when necessary. The frequency of

inspection and replacement depends on the severity of service conditions.

WARNING

Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing

any maintenance operations:

DDo not remove the actuator from the valve while the valve is still pressurized.

DAlways wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal

injury.

DDisconnect 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.

DUse 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.

DVent the power actuator loading pressure and relieve any actuator spring precompression.

DUse lock-out procedures to be sure that the above measures stay in effect while you work on the equipment.

DThe 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.

DCheck with your process or safety engineer for any other hazards that may be present from exposure to process media.

WARNING

To avoid personal injury and equipment damage, isolate the pump governor from all pressure before beginning

disassembly. The pump governor can be isolated by throttling valve (D) and closing the shut-off valves (A, B, C, and E).

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Disassembly

Refer to figures 6 and 7.

1. Remove the control line from the upper casing.

2. Relieve spring compression by turning the lower spring seat (key 19) clockwise into the yoke.

3. Disconnect the stem (key 22) and the diaphragm rod (key 14) by unscrewing the locknuts (key 31).

CAUTION

To avoid damage to the valve plug and seating surface, do not turn the stem while the valve plug is seated.

4. Unscrew hex nuts (key 9) and remove the packing box flange (key 7) and the packing follower (key 6).

5. Remove cap screws (key 23) and hex nuts (key 24) and lift off the upper diaphragm casing (key 1).

6. Lift off the upper diaphragm head (key 29). Pull the diaphragm (key 3), lower diaphragm head (key 13), and the

diaphragm rod (key 14) out of the lower diaphragm casing (key 2). (A travel stop or washer, key 17, figure 6, may

also be present between the lower diaphragm head and locknut.) Do not change the position of the lower

diaphragm head and locknut (key 15) on the diaphragm rod because they are set to give the proper clearance for

valve travel.

7. Withawirehook,pullthepacking(key11,figure6;key12,figure7)fromthebottomofthelowerdiaphragm

casing. Remove the spacer (key 5) and the upper piece of packing (key 12, figure 6; key 11, figure 7) in the same

manner.

Reassembly

Note

Bearings and adjusting screw threads should be lubricated with antiseize prior to the reassembly steps below.

644 (figure 6)

1. Install packing onto the diaphragm rod (key 14) from the bottom of the lower diaphragm casing (key 2) in the

following order:

For PTFE packing:

a. Bushing (key 10, if previously removed), packing spring (key 5), special washer (key 37), male adaptor (key 28),

packing rings (key 12, 3 required), female adaptor (key 38), packing follower (key 6) and felt wiper ring (key 39.)

For graphite packing:

a. Bushing (key 10, if previously removed), packing ring (key 11), packing ring (key 12, with zinc washer), packing

ring (key 11), lantern ring (key 5), packing ring (key 11), packing ring (key 12, with zinc washers between, 2 each

required), packing ring (key 11) and packing follower (key 6).

2. Replace the packing flange (key 7.)

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

3. Lubricate the packing flange studs (key 8) and the faces of the packing flange nuts (key 9) and install the packing

flange nuts (torque: 26 lbf•in for PTFE, 53 lbf•in for graphite.)

4. Place a new diaphragm (key 3) on the lower diaphragm head (key 13).

5. Put the upper diaphragm head (key 29) onto the diaphragm. Set the upper diaphragm casing (key 1) onto the

lower casing, lubricating and tightening the diaphragm casing cap screws (key 23) and hex nuts (key 24)

finger-tight only.

6. Reconnect the connecting rod (key 22) and the diaphragm rod.

7. Turn the lower spring seat counterclockwise out of the yoke to remove slack from the diaphragm. Torque the

diaphragm casing cap screws and nuts to the following:

a. Size 1: 29 lbf•ft.

b. Sizes 2 and 3: 67 lbf•ft.

Note

For 644 reverse-acting, travel stops (key 17) are required to be installed between the lower diaphragm head and the hex jam nut

(key 15.) See the Parts List for the type and quantity of travel stops required for each actuator size.

645 (figure 7)

1. Install packing onto the diaphragm rod (key 14) from the bottom of the lower diaphragm casing (key 2) in the

following order:

For PTFE packing:

a. Packing box ring (key 10, if previously removed), packing spring (key 5), special washer (key 28), packing set (key

11), and packing follower (key 6).

For graphite packing:

a. Packing box bushing (key 10, if previously removed packing ring (key 11), packing ring (key 12, with zinc

washer), packing ring (key 11), lantern rings (key 5, 2 required), packing ring (key 11), packing rings (key 12, with

zinc washers between, 2 each required), packing ring (key 11) and packing follower (key 6).

2. Replace the packing flange (key 7.)

3. Lubricate the packing flange studs (key 8) and the faces of the packing flange nuts (key 9) and install the packing

flange nuts (torque: 58 lbf•in for PTFE, 122 lbf•in for graphite.)

4. Place a new diaphragm (key 3) on the lower diaphragm head (key 13).

5. Put the upper diaphragm head (key 29) onto the diaphragm. Set the upper diaphragm casing (key 1) onto the

lower casing, lubricating and tightening the diaphragm casing studs (key 23) and hex nuts (key 24) fingertight

only.

6. Reconnect the connecting rod (key 22) and the diaphragm rod.

7. Turn the lower spring seat counterclockwise out of the yoke to remove slack from the diaphragm. Torque the

diaphragm casing studs and hex nuts to 385 lbf•ft.

Note

For 645 reverse-acting, two washers (key 17) are required to be installed as shown in figure 7.

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Parts Ordering

Each actuator has a serial number stamped on the nameplate. Always mention this number when corresponding with

your Emerson Process Management sales office regarding technical information or replacement parts. Also, reference

the complete 11-character part number of each needed part as found in the following Parts List.

WARNING

Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Process Management 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.

Parts List

Note

Recommended spare parts are included in the Parts Kits shown at the

top of this page. For additional information or for part numbers not

shown, contact your Emerson Process Management sales office.

Key Description Part Number

1 Upper Diaphragm Casing

2 Lower Diaphragm Casing

3* Diaphragm

Neoprene

644

Size 1 1F939502192

Size 2 1F939302192

Size 3 1F939602192

645 0F092802162

SST

644 only

Size 1 1J8430X0012

Size 2 1U5770X0012

Size 3 1H5791X0012

4Yoke

5 Lantern Ring or Packing Spring

6 Packing Follower

7 Packing Box Flange

8StudBolt

9HexNut

10* Bushing, SST

644 1E943835012

Packing Box Ring, SST

645 1E839135012

11* Packing, 644 (4 req'd)

Graphite 1F3370X0322

Packing Ring, 645, (4 req'd)

Graphite 1E3190X0222

Packing Set, 645

PTFE 1R290201012

12* Packing, 644 (3 req'd)

Graphite 1V3160X0022

PTFE 1C752601012

Packing Ring, 645 (3 req'd)

Graphite 1V3802X0022

Key Description Part Number

13 Lower Diaphragm Head

14 Diaphragm Rod

15 Hex Jam Nut

16 Yoke Lock Nut

17 Travel Stops

644 Reverse-Acting

Size 1, washer (2 req'd)

Size 2, washer (1 req'd)

Size 3, bearing retainer

645 Reverse-Acting

Washer (2 req'd)

18 Upper Spring Seat

19 Lower Spring Seat

20 Spring

21 Adjusting Screw

22 Connecting Rod

23 Cap Screw

24 Nut

25 Set Screw

26 Bearing Retainer

27 Pipe Plug

Lubricator

Lubricator/Isolating Valve

28* Male Adaptor, PTFE

(with PTFE packing) 1F124801012

Special Washer (645 with

PTFE packing) 1F125136042

29 Upper Diaphragm Head

30 Bearing

31 Hex Nut

32 Hex Jam Nut

33 Name Plate

34 Drive Screw

35 Hex Nut

36 Needle Valve

37 Special Washer (644 with PTFE packing)

38* Female Adaptor, PTFE (PTFE packing)

644 only 1F124401012

39* Wiper Ring, felt

644 only 1J872606332

40 Nipple

41 Tee

42 Nipple

43 Union

44 Elbow

45 Nipple

47 Stem Disk

*Recommended spare parts

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Figure 5. Equalizing Piping Configuration

10A8251-A

Figure 6. Fisher 644 Actuator Assembly

SIZE 3

40A5422-C

Instruction Manual

D100302X012

644 and 645 Pump Governors

February 2014

Figure 7. Fisher 645 Actuator Assembly

DF9840-A

PARTS NOT

SHOWN: KEY 28

Emerson Process Management

Marshalltown, Iowa 50158 USA

Sorocaba, 18087 Brazil

Chatham, Kent ME4 4QZ UK

Dubai, United Arab Emirates

Singapore 128461 Singapore

www.Fisher.com

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they arenot

to be construed as warranties or guarantees, 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 notice.

Fisher and easy-e are marks owned by one of the companies in the Emerson Process Management business unit 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.

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.