Emerson Fisher D4 Instruction Manual

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FisherrD4 Control Valve Assembly

Contents

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

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

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

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

Educational Services 2.........................

Installation 4..................................

Spring Adjustment 5............................

Maintenance 6.................................

Valve Plug and Seat Ring 6......................

Valve Packing 8...............................

Actuator 10..................................

Parts Ordering 14...............................

Repair Kits 17..................................

Parts List 17...................................

Appendix A 19.................................

Figure 1. Fisher D4 Control Valve

W8531

Introduction

Scope of Manual

This instruction manual provides installation, maintenance, and parts information for the Fisher D4 control valve.

Do not install, operate, or maintain a D4 control valve 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 D4 control valve is a compact, rugged valve designed primarily for high-pressure throttling applications. This valve

is ideal for use on pressure and flow control applications within the oil and gas production industry. The D4 valve also

makes an excellent dump valve for high-pressure separators and scrubbers.

The D4 control valve meets the metallurgical requirements of NACE MR0175/ISO 15156 without environmental limits

for temperatures below 135_C(275_F). If the temperature is above 135_C (275_F), the N07718 Belleville washers will

impose some limits, as shown in table 3.

Instruction Manual

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D4 Valve

November 2013

Instruction Manual

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D4 Valve

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Table 1. Specifications

Available Configurations

Spring-to-Close

Spring-to-Open

Valve Body Sizes and End Connection Styles(1)

See table 2

Maximum Inlet Pressures and Temperatures(1)

If the valve nameplate shows an ASME

pressure-temperature class, maximum inlet pressure

and temperature is consistent with the applicable

class per ASME B16.34. If the nameplate does not

show an ASME class, it will show a maximum cold

working pressure at 38_C(100_F) (for example, 293

bar [4250 psi])

Maximum Pressure Drops(1)

Seetables4,5,6,and7

Input Signal to Actuator

Seetables4,5,6,and7

Actuator Maximum Casing Pressure(1)

3.4bar(50psig)

Shutoff Classification per ANSI/FCI 70-2

and IEC 60534-4

Class IV

Material Temperature Capabilities(1)

Actuator Assembly: -40 to 93C(-40to200F)

Valve Body Assembly:

Standard Bonnet O-Ring: -40 to 135C(-40to275F)

Optional Fluorocarbon Bonnet O-Ring: -23 to 204C

(-10 to 400F)

Flow Characteristic

Equal percentage

Flow Direction

Flow up only

Port Diameters

See table 2

Valve Plug Travel

19 mm (0.75 inch)

Valve Plug Style

Micro-Form valve plug

Actuator Diaphragm Effective Area

452 cm2(69 inches2)

Actuator Pressure Connection Size

1/4 NPT internal

1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.

Specifications

Table 1 lists specifications for the D4 control valve. Some of the specifications for a given control valve as it originally

comes from the factory are stamped on a nameplate located on the actuator spring barrel.

Educational Services

For information on available courses for Fisher D4 valves, as well as a variety of other products, contact:

Emerson Process Management

Educational Services, Registration

P.O. Box 190; 301 S. 1st Ave.

Marshalltown, IA 50158-2823

Phone: 800-338-8158 or

Phone: 641-754-3771

FAX: 641-754-3431

e-mail: education@emerson.com

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Table 2. Valve Sizes and Connection Styles

VALVE

SIZE,

NPS

PORT

DIAMETER,

(INCHES)

SCREWED RAISED FACE (RF) FLANGED RING TYPE JOINT

(RTJ) FLANGED

4250 psi CL150 CL300 CL600 CL900 and

CL1500 CL600 CL900 and

CL1500

10.25, 0.375,

0.5, 0.75 XXXXXXX

20.25, 0.375, 0.5

0.75, 1, 1.25 XXXXXXX

X = Available construction.

Table 3. D4 Environmental Limits for NACE MR0175/ISO 15156 with Sour Trim

MAXIMUM TEMPERATURE MAXIMUM H2S PARTIAL PRESSURE COMPATIBLE WITH

ELEMENTAL SULFUR?

_C_FMPa psia

232 450 0.2 30 No

204 400 1.4 200 No

199 390 2.3 330 No

191 375 2.5 360 No

149 300 2.8 400 No

135 275 No Limit Yes

Table 4. Maximum Shutoff Pressure Drops(1) for Fisher D4 Control Valves (Spring-to-Close)

When Used with Typical Control Instrumentation(2)

INPUT SIGNAL TO

ACTUATOR

0to1.2Bar

(0 to 18 Psig)

0to1.4Bar

(0 to 20 Psig)

0to2.0Bar

(0 to 30 Psig)

0to2.3Bar

(0 to 33 Psig)

0to2.4Bar

(0 to 35 Psig)

0to3.4Bar

(0 to 50 Psig)

SPRING Light Rate Heavy Rate

INITIAL SPRING

SETTING

0.77 Bar

(11.2 Psig)

0.77 Bar

(11.2 Psig)

0.85 Bar

(12.4 Psig)

1.05 Bar

(15.3 Psig)

1.18 Bar

(17.1 Psig)

1.18 Bar

(17.1 Psig)

PORT DIAMETER Maximum Pressure Drop

mm Inches Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi

6.4

9.5

12.7

19.1

25.4

31.8

0.25

0.375

0.5

0.75

1

1.25

293(3)

293(3)

191

80

42

25

4250(3)

4250(3)

2765

1160

610

365

293(3)

293(3)

191

80

42

25

4250(3)

4250(3)

2765

1160

610

365

293

293

219

92

49

30

4250

4250

3180

1340

715

430

293

293

288

123

67

41

4250

4250

4180

1785

965

590

293

293

293

143

78

48

4250

4250

4250

2080

1130

700

293

293

293

143

78

48

4250

4250

4250

2080

1130

700

1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.

2. For example, use the column marked 0-1.4 bar (0-20 psig) for a 0.21-1.0 bar (3-15 psig) pneumatic controller with 1.4 bar (20 psig) supply pressure.

3. For applications with downstream pressure in excess of 196 bar (2845 psig), use 196 bar (2845 psig) for Maximum Shutoff Pressure.

Table 5. Maximum Shutoff Pressure Drops(1) for Fisher D4 Control Valves (Spring-to-Close)

When Used with Instrumentation with Restricted Output Range(2)

INPUT SIGNAL TO

ACTUATOR

0.4 to 2.0 Bar

(6 to 30 Psig)

0.14 to 2.3 Bar

(2 to 33 Psig)

SPRING Heavy Rate Heavy Rate

INITIAL SPRING

SETTING

0.97 Bar

(14.0 Psig)

1.17 Bar

(17.0 Psig)

PORT DIAMETER Maximum Pressure Drop

mm Inches Bar Psi Bar Psi

6.4

9.5

12.7

19.1

25.4

31.8

0.25

0.375

0.5

0.75

1

1.25

293(3)

210(3)

113

45

23

13

4250(3)

3045(3)

1635

655

330

185

293

293

282

120

65

39

4250

4250

4095

1750

945

580

1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.

2.Forexample,anElectro-PneumaticTransducercalibratedfor0.4-2.0bar(6-30psig)outputpressure.

3. For applications with downstream pressure in excess of 118 bar (1715 psig), use 118 bar (1715 psig) for Maximum Shutoff Pressure.

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Table 6. Maximum Shutoff Pressure Drops(1) for Fisher D4 Control Valves (Spring-to-Open)

When Used with Typical Control Instrumentation(2)

INPUT SIGNAL TO

ACTUATOR

0to1.2Bar

(0 to 18 Psig)

0to1.4Bar

(0 to 20 Psig)

0to2.0Bar

(0 to 30 Psig)

0to2.3Bar

(0 to 33 Psig)

0to2.4Bar

(0 to 35 Psig)

0to3.4Bar

(0 to 50 Psig)

SPRING Light Rate Heavy Rate

INITIAL SPRING

SETTING

0.23 Bar

(3.4 Psig)

0.23 Bar

(3.4 Psig)

0.28 Bar

(4.0 Psig)

0.28 Bar

(4.0 Psig)

0.28 Bar

(4.0 Psig)

0.28 Bar

(4.0 Psig)

PORT DIAMETER Maximum Pressure Drop

mm Inches Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi

6.4

9.5

12.7

19.1

25.4

31.8

0.25

0.375

0.5

0.75

1

1.25

293(3)

293(3)

187

78

41

24

4250(3)

4250(3)

2715

1135

600

355

293(3)

293(3)

233

99

53

32

4250(3)

4250(3)

3380

1430

765

465

293

293

293

147

80

49

4250

4250

4250

2130

1160

715

293

293

293

178

97

60

4250

4250

4250

2575

1410

875

293

293

293

198

109

68

4250

4250

4250

2875

1575

985

293

293

293

293

195

123

4250

4250

4250

4250

2830

1785

1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.

2. For example, use the column marked 0-1.4 bar (0-20 psig) for a 0.21-1.0 bar (3-15 psig) pneumatic controller with 1.4 bar (20 psig) supply pressure.

3. For applications with downstream pressure in excess of 190 bar (2760 psig), use 190 bar (2760 psig) for Maximum Shutoff Pressure.

Table 7. Maximum Shutoff Pressure Drops(1) for Fisher D4 Control Valves (Spring-to-Open)

When Used with Instrumentation with Restricted Output Range(2)

INPUT SIGNAL TO

ACTUATOR

0.4 to 2.0 Bar

(6 to 30 Psig)

0.14 to 2.3 Bar

(2 to 33 Psig)

SPRING Heavy Rate Heavy Rate

INITIAL SPRING

SETTING

0.69 Bar

(10.0 Psig)

0.42 Bar

(6.1 Psig)

PORT DIAMETER Maximum Pressure Drop

mm Inches Bar Psi Bar Psi

6.4

9.5

12.7

19.1

25.4

31.8

0.25

0.375

0.5

0.75

1

1.25

293(3)

293(3)

196

82

43

26

4250(3)

4250(3)

2845

1195

630

380

293

293

293

156

85

52

4250

4250

4250

2265

1235

765

1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.

2.Forexample,anElectro-PneumaticTransducercalibratedfor0.4-2.0bar(6-30psig)outputpressure.

3. For applications with downstream pressure in excess of 202 bar (2925 psig), use 202 bar (2925 psig) for Maximum Shutoff Pressure.

Installation

WARNING

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

injury.

To avoid personal injury or property damage caused by bursting of pressure-retaining parts or by uncontrolled process

fluid, be certain the service conditions do not exceed the limits shown on the valve nameplate and in tables 1, 4, 5, 6, and 7.

Use pressure-relieving devices 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.

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WARNING

When ordered, the valve configuration and construction materials were selected to meet particular pressure, temperature,

pressure drop, and controlled fluid conditions. Responsibility for the safety of process media and compatibility of valve

materials with process media rests solely with the purchaser and end-user. Since some body/trim material combinations

are limited in their pressure drop and temperature ranges, do not apply any other conditions to the valve without first

contacting your Emerson Process Management sales office.

WARNING

Avoid personal injury or property damage caused by possible actuator failure. The use of a rigidly-mounted support on the

actuator casing may cause additional stress on the actuator leading to premature wear and/or failure of the actuator

components.

CAUTION

To avoid product damage, inspect the valve before installation for any damage or any foreign material that may have

collected in the valve body. Also remove any pipe scale, welding slag, or other foreign material from the pipeline.

1. Before installing the control valve assembly, inspect it for any damage and for any foreign material that may have

collected in the valve body.

2. Remove any pipe scale, welding slag, and other foreign material from the pipeline.

3. The control valve can be installed in any position, 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. For flanged valves, use suitable

gaskets between valve and pipeline flanges.

5. If continuous operation is required during maintenance and inspection, install a conventional three-valve bypass

around the valve.

6. Connect loading pressure for the Spring-to-Open configuration to the 1/4-18 NPT connection in the upper casing

assembly (key 23) as shown in figure 5. The Spring-to-Close configuration loading pressure connection is in the

lower casing assembly (key 39) as shown in figure 4.

Spring Adjustment

The spring has a fixed pressure span over which loading pressure will stroke the valve. Adjustment of the spring

compression shifts the span so that more or less loading pressure is required to start travel. Since the span does not

change, there will be a corresponding increase or decrease inthepressurerequirementsattheendofthevalvestroke.

In order to maximize shutoff pressure drop values, the actuator spring must be accurately adjusted for each Input

Signal Pressure Range. If the actuator has been disassembled or pressure conditions have changed, the spring may

require adjustment. Refer to tables 2 and 4 to determine the Initial Spring Set values based on the Input Signal range

that is available to the actuator. These values include packing friction.

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Spring-to-Close

Refer to figure 4.

1. Loosen the adjusting screw nut (key 44).

2. Turn the adjusting screw (key 31) clockwise to compress the spring or counterclockwise to decrease spring

compression.

3. After adjustment, tighten the adjusting screw nut (key 44).

Spring-to-Open

Refer to figure 5.

1. Unscrew the spring case assembly (key 27).

2. Turn the adjusting stem nut (key 44) clockwise to compress the spring or counterclockwise to decrease spring

compression.

3. After adjustment, replace the spring case assembly (key 27).

Maintenance

Refer to figure 4.

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. 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

on 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.

DCheck with your process or safety engineer for any additional measures that must be taken to protect against process

media.

Valve Plug and Seat Ring

The D4 control valve is designed to allow easy access to the valve plug and seat ring without disturbing the packing.

Refer to other sections of this instruction manual if additional maintenance is required.

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Disassembly

1. Remove the loading pressure tubing and any accessories that may hamper disassembly.

2. Break the hammer nut (key 6) loose with a hammer. Continue turning the hammer nut by using a hammer or a

large adjustable wrench, tightened around one ear of the hammer nut. If the bonnet is stuck on the valve, continue

to unscrew the hammer nut. The hammer nut will contact the spring pins (key 7) and will force the bonnet out of

the valve. Carefully lift the actuator, bonnet, and valve plug assembly from the valve body.

WARNING

The spring pins must always be in place during valve operation. They provide a safeguard against injury when the unit is

being disassembled.

3. Use a socket wrench to loosen the seat ring (key 3).

4. Remove the seat ring (key 3) and seat ring gasket (key 9) from the valve body.

5. Inspect parts for wear or damage that would prevent proper operation of the valve body. Carefully clean the seat

ring gasket surfaces and seat ring threads.

WARNING

Becarefultoavoiddamagingtheseatingsurfaceonthevalveplugorseatringasdamageintheseareaswillallow

excessive leakage at shutoff. Avoid damaging the highly polished valve stem surface. A damaged valve stem could cut the

packing and allow process fluid to leak to the atmosphere.

Table 8. Torque for Seat Ring (Key 3)

VALVE SIZE RECOMMENDED TORQUE

NPS NSmLbfSft

1407 300

2698 515

6. For spring-to-close only: To remove the valve plug (key 2), drive out the groove pin (key 4) and unscrew the valve

plug from the stem (key 47). If the groove pin (key 4) is not exposed, verify that downward movement of the stem is

not restricted by instrument linkages attached to the stem (key 47).

If the valve plug cannot be easily unscrewed from the stem, use a punch to keep the stem from turning as the plug is

removed.

7. For spring-to-open only: Toremovethevalveplug(key2),firstremovethespringcaseassembly(key27).Remove

the adjustment screw nut (key 44), the upper spring seat (key 29), and the spring (key 30). Push the adjustment

stem (key 31) fully downward until the diaphragm plate (key 40) contacts the cap screws (key 38), exposing the

groove pin (key 4) in the plug. If the groove pin (key 4) is not exposed, verify that downward movement of the stem

is not restricted by instrument linkages attached to the stem (key 47). Drive out the groove pin (key 4) and unscrew

the valve plug from the stem (key 47).

If the valve plug cannot be easily unscrewed from the stem, use a punch to keep the stem from turning as the plug is

removed.

Assembly

1. Make sure the bonnet O-ring (key 8) is on the bonnet and lubricated with lithium grease (key 49).

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2. Install the plug (key 2) on the stem (key 47) and insert a new groove pin (key 4).

3. Thoroughly clean the seat ring and bonnet threads in the valve body (key 1). Also clean the valve body seat ring

gasket surfaces.

4. Apply anti-seize lubricant (key 54) to the threads of the seat ring (key 3), and its mating threads in the valve body.

5. Apply anti-seize lubricant (key 54) to the seat ring gasket (key 9) and install into the valve body.

6. Screw the seat ring into the valve body. Use a socket wrench to tighten the seat ring to the torque values shown in

table8.Removeallexcesslubricant after tightening.

7. Lubricate (key 54) the threads on the valve body and hammer nut and the contact surfaces of the bonnet and

hammer nut flange. Install the bonnet and actuator assembly with pinned valve plug onto the valve body. Tighten

the hammer nut using an adjustable wrench until the nut stops turning. A few hammer blows will be required to

ensure that the assembly is tight.

8. See the actuator assembly and spring adjustment sections of this manual.

Valve Packing

Note

These instructions apply to valves manufactured with serial numbers equal to and greater than 18679262. See Appendix A for

information on packing constructions with serial numbers less than 18679262.

If your D4 valve assembly has a packing retainer lock ring (see figure 6), proceed to Appendix A.

WARNING

Observe the warning at the start of the Maintenance section.

The valve stem packing can only be accessed from within the valve body. If packing maintenance is required, first

disassemble per steps 1, 2, and 6 or 7 in the Valve Plug and Seat Ring Disassembly section of this document.

Disassembly

1. Unscrew the packing retainer (key 10) from the bonnet (key 5).

2. Remove the five Belleville springs (key 11), packing spacer (key 14), packing (key 13), and two anti-extrusion rings

(key 12) from the bonnet, using a formed wire hook.

3. Clean and inspect the packing box wall to ensure that thepackingsurfacesarenotdamaged.Ifthesurface

condition is damaged, and cannot be improved by light sanding, replace the bonnet by contacting your Emerson

Process Management sales office.

4. Inspect the valve stem for scratches or wear, and valve plug for wear or damage. Replace if necessary.

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Figure 2. Fisher D4 Packing Installation

VALVE PLUG, BELLEVILLE SPRINGS, AND PACKING RETAINER

CORRECTLY INSTALLED AND TIGHTENED

BELLEVILLE SPRINGS FULLY ENCLOSED BY

THE PACKING RETAINER

PACKING RETAINER

(KEY 8)

UNTIGHTENED,

NOTE THE GAP

FULLY TIGHTENED,

NO GAP

UPPER PACKING

SPACER (KEY 48)

Figure 3. Lubrication Locations on Packing

FEMALE PACKING ADAPTER

MALE PACKING ADAPTER

PACKING RING LUBRICATE WITH 3mm (1/8 INCH

BEAD) OF SUPPLIED HIGH PERFORMANCE

FLUORINATED GREASE

LUBRICATE WITH 3mm (1/8 INCH

BEAD) OF SUPPLIED HIGH PERFORMANCE

FLUORINATED GREASE

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Assembly

Refer to figures 2, 3, 4, and 5.

Note

If your D4 valve assembly has a packing retainer lock ring (see figure 6), proceed to Appendix A.

1. Ensure the upper packing spacer (key 48) is installed, as shown in figure 2.

2. Using a non-marring installation tool, such as a 12-inch length of 1/2 inch PVC pipe, push the first anti-extrusion

washer (key 12) fully into the packing box by hand. Then, use the packing spacer (key 14) to fully seat the

anti-extrusion washer by firmly tapping the packing spacer against the anti-extrusion washer with a hammer and

the PVC pipe.

3. Remove the packing spacer from the packing bore.

CAUTION

All D4 packing kits include a single use packet of high performance fluorinated grease. This is the only acceptable D4

packing lubricant.

Note

In the following procedure, carefully install each packing ring individually over the valve stem and push completely into the

packing box with a non-marring tube. A 12-inch length of 1/2 inch PVC pipe works well for this. It is recommended that the

lubricated packing rings be installed individually rather than pushed in as a set.

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 3 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 3 and install over the valve stem.

6. Install the male packing adaptor, lower anti-extrusion washer (key 10), and lower packing spacer over the valve

stem as shown in figure 2.

7. Firmly press all packing parts into the packing bore with a tube.

8. Install the five Belleville springs (key 11) over the valve stem. The Belleville springs should be single-stacked with the

inside diameter of the inner spring contacting the packing spacer (key 14), and the outside diameter of the outer

spring contacting the packing retainer (key 10).

9. Lubricate the threads of the packing retainer with anti-seize and install into the bonnet using a 1-5/8 inch wrench.

Make sure the Belleville springs are completely enclosed by the packing retainer as shown in figure 2.

10. Torque the packing retainer to 136 NSm(100lbfSft). The packing retainer has been installed correctly when a

metal-to-metal contact has been made between the packing retainer end and the bonnet (key 5). The packing

retainer threads should be completely enclosed by the bonnet.

Actuator (Spring-to-Close)

WARNING

Observe the warning at the start of the Maintenance section.

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Refer to figure 4.

Before disassembling the actuator, disassemble the valve plug, seat ring, and packing according to instructions in this

manual.

Disassembly

1. Loosen the adjusting screw nut (key 44) and turn the adjusting screw (key 31) counterclockwise to remove all

spring compression.

2. Unscrew the casing cap screws and hex nuts (keys 45 and 46), and remove the upper casing assembly (key 23) from

the lower casing (key 39).

3. Remove the spring seat (key 29) and actuator spring (key 30).

4. Lift out the diaphragm, diaphragm plate, and stem assembly. Remove the travel indicator (key 32) when the

bottom of the stem enters the yoke window.

5. To replace the diaphragm (key 15), separate the diaphragm assembly by using a wrench on the hex nuts (key 42) to

unscrew the assembly.

6. Separate the parts--diaphragm washer, actuator O-ring (keys 41 and 25), diaphragm, and diaphragm plate, (keys 15

and 40).

7. Inspect the diaphragm and the actuator O-ring for damage or deterioration, and replace if necessary. If the

diaphragm is replaced, a new O-ring should also be installed.

8. Inspect the stem O-ring (key 19) and bonnet bushing (key 20); replace if necessary. To inspect the casing O-ring

(key 18), remove the cap screws (key 38) and lift off the lower casing (key 39). Replace the O-ring if necessary.

9. Ifthehammernutneedstoberemovedfromthebonnet,thespringpins(key7)canberemovedwithlocking

pliers.

Assembly

1. Before starting assembly, make sure all parts are clean and in good condition. There should be no burrs or sharp

edgesonanythreadsorsurfacesthatmightcutordamage an O-ring, bushing, the packing, or the diaphragm.

When replacing O-rings and bushings, be sure the O-ring or bushing groove is clean and undamaged. Using a

general purpose lubricant (key 49), lubricate all bushings and O-rings and the threads of parts that have to pass

through the bushings and O-rings.

CAUTION

The threads on factory-produced valve stems have been specially machined to avoid O-ring, bushing, or packing damage

during trim maintenance. Use of other than a factory-produced valve stem may result in early stem O-ring, bushing, and

packing failure.

Note

Do not lubricate cap screws (key 38) before inserting them in the following procedure.

2. Place the hammer nut and spring pins on the bonnet, if removed. Install the casing O-ring (key 18), the stem O-ring

(key 19), and the bonnet bushing (key 20). Position the lower casing (key 39) on the bonnet. Insert the

nonlubricated cap screws (key 38), and torque to 49 NSm(36lbfSft).

WARNING

The spring pins must always be in place during valve operation. They provide a safeguard against injury when the unit is

being disassembled.

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3. Assemble the diaphragm plate assembly. Place the patterned side of the diaphragm (key 15) against the diaphragm

plate(key40).Besuretoturnthediaphragmwasher(key41)sothatthesidethatisbeveledontheinsidediameter

is against the O-ring (key 25). Also, make sure that it is assembled for installation with the diaphragm on the loading

pressure side and the lockwasher (key 43) and lower spring seat (key 28) are on the spring side.

4. Fasten the diaphragm and diaphragm plate assembly on the stem with hex nuts (key 42). Place the diaphragm and

diaphragm plate, and stem assembly into the lower casing and bonnet. Install the travel indicator (key 32) on the

stemasthebottomofthestementerstheyokewindow.

CAUTION

Over-tightening the diaphragm casing cap screws and nuts (keys 45 and 46) can damage the diaphragm. Do not exceed 27

NSm (20 lbfSft) torque.

5. Replace the spring (key 30) on the diaphragm plate (key 40). Replace the upper spring seat (key 29). Position the

upper casing (key 23) on the lower casing (key 39). Insert the cap screws (key 45) and tighten the hex nuts (key 46).

Torque the casing cap screws evenly to 27 NSm(20lbfSft) using a crisscross pattern.

6. Adjust the initial spring set per the Spring Adjustment section in this manual.

Actuator (Spring-to-Open)

WARNING

Observe the warning at the start of the Maintenance section.

Refer to figure 5.

Before disassembling the actuator, disassemble the valve plug, seat ring, and packing according to instructions in this

manual.

Disassembly

1. Unscrew the spring case assembly (key 27). Turn the adjusting screw nut (key 44) counterclockwise to remove all

spring compression. Remove the adjusting screw nut, upper spring seat, and spring (keys 44, 29, and 30)

2. Unscrew the casing cap screws and hex nuts (keys 45 and 46), and remove the upper casing assembly (key 23) from

the lower casing (key 39). Remove the cotter pin (key 36) and unscrew the adjusting stem (key 31).

3. Lift out the diaphragm (key 15), diaphragm plate (key 40), and stem assembly. Remove the travel indicator (key 32)

whenthebottomofthestementerstheyokewindow.

4. To replace the diaphragm (key 15), separate the diaphragm assembly by using a wrench on the hex nuts (key 42) to

unscrew the assembly.

5. Separate the parts--diaphragm washer, actuator O-ring (keys 41 and 25), diaphragm, and diaphragm plate, (keys 15

and 40).

6. Inspect the diaphragm and the actuator O-ring for damage or deterioration, and replace if necessary. If the

diaphragm is replaced, a new O-ring should also be installed.

7. Inspect the stem O-ring (key 19) and bonnet bushing (key 20); replace if necessary. To inspect the casing O-ring

(key 18), remove the cap screws (key 38) and lift off the lower casing (key 39). Replace the O-ring if necessary.

Inspect the adjusting stem bushing (key 26) and actuator stem O-ring (key 53). Replace if necessary.

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8. Ifthehammernutneedstoberemovedfromthebonnet,thespringpins(key7)canberemovedwithlocking

pliers.

Assembly

1. Before starting assembly, make sure all parts are clean and in good condition. There should be no burrs or sharp

edgesonanythreadsorsurfacesthatmightcutordamage an O-ring, bushing, the packing, or the diaphragm.

When replacing O-rings and bushings, be sure the O-ring or bushing groove is clean and undamaged. Using a

general purpose lubricant (key 49), lubricate all bushings and O-rings and the threads of parts that have to pass

through the bushings and O-rings.

CAUTION

The threads on factory-produced valve stems have been specially machined to avoid O-ring, bushing, or packing damage

during trim maintenance. Use of other than a factory-produced valve stem may result in early stem O-ring, bushing, and

packing failure.

Note

Do not lubricate cap screws (key 38) before inserting them in the following procedure.

2. Place the hammer nut and spring pins on the bonnet, if removed. Install the casing O-ring (key 18), the stem O-ring

(key 19), and the bonnet bushing (key 20). Position the lower casing (key 39) on the bonnet. Insert the

nonlubricated cap screws (key 38), and torque to 49 NSm(36lbfSft).

3. Assemble the diaphragm plate assembly. Place the patterned side of the diaphragm (key 15) against the diaphragm

plate(key40).Besuretoturnthediaphragmwasher(key41)sothatthesidethatisbeveledontheinsidediameter

is against the O-ring (key 25). Also, make sure that it is assembled for installation with the diaphragm on the loading

pressure side and the lockwasher (key 43) and diaphragm washer (key 41) are on the upper side.

WARNING

The spring pins must always be in place during valve operation. They provide a safeguard against injury when the unit is

being disassembled.

4. Fasten the diaphragm and diaphragm plate assembly on the stem with hex nuts (key 42). Place the diaphragm and

diaphragm plate, and stem assembly into the lower casing and bonnet. Install the travel indicator (key 32) on the

stemasthebottomofthestementerstheyokewindow.

5. Screw the adjusting stem (key 31) onto the stem (key 47) and secure the cotter pin (key 36). Make sure the bushing

and O-ring are in place in the upper casing.

CAUTION

Over-tightening the diaphragm casing cap screws and nuts (keys 45 and 46) can damage the diaphragm. Do not exceed 27

NSm (20 lbfSft) torque.

6. Position the upper casing (key 23) on the lower casing (key 39). Insert the cap screws (key 45) and tighten the hex

nuts (key 46). Torque the casing cap screws evenly to 27 NSm(20lbfSft) using a crisscross pattern.

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7. Replace the spring (key 30), spring seat (key 29), and adjusting stem nut (key 44) over the adjusting stem. Replace

thespringcaseassembly(key27).

8. Adjust the initial spring set per the Spring Adjustment section in this manual.

Parts Ordering

Each D4 control valve is assigned a serial number, which can be found on the nameplate. Refer to the number when

contacting your Emerson Process Management sales office for assistance or when ordering replacement parts.

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.

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Figure 4. Fisher D4 Valve Assembly (Spring-to-Close)

GE02332-C

BELLEVILLE SPRING

AND PACKING ARRANGEMENT

APPLY LUB

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Figure 5. Fisher D4 Valve Assembly (Spring-to-Open)

BELLEVILLE SPRING

AND PACKING ARRANGEMENT

APPLY LUB

GE02334-E

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Repair Kits

Note

All repair kits are supplied with hydrogenated nitrile bonnet O-ring. FKM

(fluorocarbon) bonnet O-ring must be ordered separately when

required.

Description Part Number

* Packing Repair Kit

Includes key numbers 4, 8, 12 (2 req'd),

13, and high performance fluorinated grease RD4X0000012

* ActuatorRepairKit

Includes key numbers 4, 8, 12 (2 req'd), 13,

15, 18, 19, 20, 25, 26, 36, 53, and

high performance fluorinated grease RD4X0000022

Parts List

Note

For part numbers not shown, contact your Emerson Process

Management sales office.

Key Description Part Number

1ValveBody

2* Valve Plug

S41000 / S41600 HT

NPS 1 valve

0.25 inch port diameter 20C3692X012

0.375 inch port diameter 20C3693X012

0.5 inch port diameter 20C3694X012

0.75 inch port diameter GE01557X012

NPS 2 valve

0.25 inch port diameter GE00992X012

0.375 inch port diameter GE00993X012

0.5 inch port diameter GE00994X012

0.75 inch port diameter GE01558X012

1-inch port diameter GE01561X012

1.25 inch port diameter GE01555X012

S17400 H1150 Dbl

NPS 1 valve

0.25 inch port diameter 20C3692X032

0.375 inch port diameter 20C3693X032

0.5 inch port diameter 20C3694X032

0.75 inch port diameter GE01557X032

NPS 2 valve

0.25 inch port diameter GE00992X032

0.375 inch port diameter GE00993X032

0.5 inch port diameter GE00994X032

0.75 inch port diameter GE01558X032

1-inch port diameter GE01561X032

Key Description Part Number

1.25 inch port diameter GE01555X032

Tungsten Carbide

NPS 1 valve

0.25 inch port diameter 20C3696X012

0.375 inch port diameter 20C3697X012

0.5 inch port diameter 20C3698X012

0.75 inch port diameter 20C3699X012

NPS 2 valve

0.25 inch port diameter 20C3682X012

0.375 inch port diameter 20C3683X012

0.5 inch port diameter 20C3685X012

0.75 inch port diameter 20C3686X012

1-inch port diameter 20C3687X012

1.25 inch port diameter 20C3688X012

3* Seat Ring

S17400 H1150 Dbl

NPS 1 valve

0.25 inch port diameter GE00982X032

0.375 inch port diameter GE00983X032

0.5 inch port diameter GE00984X032

0.75 inch port diameter GE00985X032

NPS 2 valve

0.25 inch port diameter GE00986X032

0.375 inch port diameter GE00987X032

0.5 inch port diameter GE00988X032

0.75 inch port diameter GE00989X032

1-inch port diameter GE00990X032

1.25 inch port diameter GE00991X032

Tungsten Carbide

NPS 1 valve

0.25 inch port diameter GE07347X012

0.375 inch port diameter GE07363X012

0.5 inch port diameter GE07364X012

0.75 inch port diameter GE07365X012

NPS 2 valve

0.25 inch port diameter GE07389X012

0.375 inch port diameter GE07394X012

0.5 inch port diameter GE07397X012

0.75 inch port diameter GE07398X012

1-inch port diameter GE07399X012

1.25 inch port diameter GE07406X012

4* Groove Pin GE01163X012

5 Bonnet

6HammerNut

7 Spring Pin

8* Bonnet O-ring

Hydrogenated Nitrile

-46 to 149_C (-50 to 300_F) 10C3680X012

FKM, -23 to 204_C(-10to400_F) 10C3680X022

9* Seat Ring Gasket

For NPS 1 valve 1B198636042

For NPS 2 valve 1B198836042

10 Packing Retainer

11 Belleville Springs, 5 req'd

12* Anti-Extrusion Washer, 2 req'd 12B6335X022

13* Packing Set 12B6667X012

14 Packing Spacer

15* Diaphragm 22B3521X012

16 Nameplate

17 Drive Screw

18* Casing O-ring 1F9141X0142

19* Stem O-ring 1K7561X0072

20* Bonnet Bushing 17A7112X012

23 Upper Casing Assembly

*Recommended spare parts

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Key Description Part Number

25* Actuator O-ring 1K7561X0072

26* Adjusting Stem Bushing (spring-to-open only) 17A4059X012

27 Spring Case Assembly

28 Lower Spring Seat

29 Upper Spring Seat

30 Spring

Spring-to-Close, Light Rate 1F176827092

Spring-to-Close, Heavy Rate 1E792427082

Spring-to-Open, Light Rate 1F176727032

Spring-to-Open, Heavy Rate 1F714327092

31 Adjustment Screw or Stem

32 Travel Indicator

34 Vent Assembly

36* Cotter Pin (spring-to-open only) 1C608035022

37 Pipe Plug

38 Cap Screw

39 Lower Casing

Key Description Part Number

40 Diaphragm Plate

41 Diaphragm Washer

42 Hex Nut

43 Lockwasher

44 Adjustment Screw Nut

45 Cap Screw

46 Hex Nut

47* Valve Stem

S20910, Reverse Acting 20C3681X022

S20910, Direct Acting 20C3716X022

48 Upper packing spacer

49 Lubricant (lithium grease)

51 Drive Screw

53* Actuator Stem O-ring (spring-to-open only) 1C7821X0182

54 Lubricant (anti-seize)

55 Spring Setting Label (not shown)

56 High Performance Fluorinated Grease

Packing Lubricant

*Recommended spare parts

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Appendix A

Note

These instructions apply to valves manufactured with serial numbers less than 18679262.

Valve Packing

WARNING

Observe the warning at the start of the Maintenance section.

The valve stem packing can only be accessed from within the valve body. If packing maintenance is required, first

disassemble per steps 1, 2, and 6 or 7 in the Valve Plug and Seat Ring Disassembly section of this document.

Disassembly

1. Loosen the packing retainer locknut (key 22) with a spanner wrench or with a punch and hammer.

2. Unscrew the packing retainer (key 10) from the bonnet (key 5).

3. Remove the three Belleville springs (key 11), packing spacer (key 14), packing (key 13), and two anti-extrusion rings

(key 12) from the bonnet, using a formed wire hook.

4. Clean and inspect the packing box wall to ensure that thepackingsurfacesarenotdamaged.Ifthesurface

condition is damaged, and cannot be improved by light sanding, replace the bonnet by contacting your Emerson

Process Management sales office.

5. Inspect the valve stem for scratches or wear, and valve plug for wear or damage. Replace if necessary.

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Figure 6. Fisher D4 Belleville Spring Procedure

BELLEVILLE SPRINGS REASONABLY TIGHT

TO SEAT THE PACKING

BELLEVILLE SPRINGS FINGER TIGHT, THEN TIGHTEN

1/2TURN(3FLATSONTHERETAINER)

BONNET DESIGN FOR VALVES (2006 AND NEWER) WITH SERIAL NUMBERS LESS THAN 18679262

BONNET DESIGN FOR VALVES (BEFORE 2006) WITH SERIAL NUMBERS LESS THAN 18679262

BELLEVILLE SPRINGS REASONABLY TIGHT

TO SEAT THE PACKING BELLEVILLE SPRINGS FINGER TIGHT, THEN TIGHTEN

1/2TURN(3FLATSONTHERETAINER)

NOTE: RECOMMENDED SPARE PARTS, INCLUDING PACKING KITS, ARE THE SAME FOR BOTH BONNET DESIGNS.

NOTE: FOR SERIAL NUMBERS GREATER THAN 18679262, SEE THE STANDARD SECTION OF THIS INSTRUCTION MANUAL.

PACKING RETAINER

LOCK RING

(KEY 22)

PACKING RETAINER

LOCK RING

(KEY 22)

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Figure 7. Lubrication Locations on Packing

FEMALE PACKING ADAPTER

MALE PACKING ADAPTER

PACKING RING LUBRICATE WITH 3mm (1/8 INCH

BEAD) OF SUPPLIED HIGH PERFORMANCE

FLUORINATED GREASE

LUBRICATE WITH 3mm (1/8 INCH

BEAD) OF SUPPLIED HIGH PERFORMANCE

FLUORINATED GREASE

Assembly

Refer to figures 6 and 7.

1. Install new packing and Belleville springs according to the packing arrangement shown in figure 6.

2. Using a non-marring installation tool, such as a 12-inch length of 1/2 inch PVC pipe, push the first anti-extrusion

washer (key 12) fully into the packing box by hand. Then, use the packing spacer (key 14) to fully seat the

anti-extrusion washer by firmly tapping the packing spacer against the anti-extrusion washer with a hammer and

the PVC pipe.

3. Remove the packing spacer from the packing bore.

CAUTION

All D4 packing kits include a single use packet of high performance fluorinated grease. This is the only acceptable D4

packing lubricant.

Note

In the following procedure, carefully install each packing ring individually over the valve stem and push completely into the

packing box with a non-marring tube. A 12-inch length of 1/2 inch PVC pipe works well for this. It is recommended that the

lubricated packing rings be installed individually rather than pushed in as a set.

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 7 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 7 and install over the valve stem.

6. Install the male packing adaptor, lower anti-extrusion washer (key 10), and lower packing spacer over the valve

stem as shown in figure 6.

7. Firmly press all packing parts into the packing bore with a tube.

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8. Install the Belleville springs (key 11). The Belleville springs (key 11) should be single stacked with the I.D. of the

inner spring contacting the packing spacer (key 14) and the O.D. of the outer spring contacting the packing retainer

(key 10). The final Belleville spring should be within the 1.26 inch diameter bore of the bonnet.

9. Adjust the packing retainer by hand until it makes contact with the Belleville springs. Do not tighten by hand, simply

install the packing retainer until it makes contact with the Belleville springs. Tighten the packing retainer clockwise

precisely 1.16 turns (7 flats on the retainer) to seat the packing. This should fully compress the Belleville springs as

detected by an increase in torque between 6 and 7 flats.

10. Loosen the packing retainer completely. Adjust the packing retainer by hand until it makes contact with the

Belleville springs. Do not tighten by hand, simply install the packing retainer until it makes contact with the

Belleville springs. Tighten the packing retainer clockwise precisely 1/2 turn (3 flats on the retainer).

11. Lock the packing retainer (key 10) solidly in place by tightening the packing retainer locknut (key 22) using a

spanner wrench or a hammer and punch or chisel.

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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.

E2002, 2013 Fisher Controls International LLC. All rights reserved.

Fisher is a mark 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.