Emerson Fisher Posi Seal A41 Instruction Manual
2015-03-30
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Instruction Manual A41 Valve D500211X012 November 2012 Fisherr A41 High Performance Butterfly Valve Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Educational Services . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Packing Maintenance . . . . . . . . . . . . . . . . . . . . . . . 12 Seal Ring Maintenance for NPS 3 through 12 . . . . 13 Seal Ring Maintenance for NPS 2 . . . . . . . . . . . . . . 19 Disc, Drive Shaft and Bearing Maintenance for NPS 3 through 12 . . . . . . . . . . . . . . . . . . . . . . . . 20 Disc, Drive Shaft and Bearing Maintenance for NPS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Actuator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Retrofit Kits for ENVIRO-SEALt Packing . . . . . . . . 27 Repair Kits for ENVIRO-SEAL Packing . . . . . . . . . . . 28 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Figure 1. Fisher A41 Valve W9269 Introduction Scope of Manual This instruction manual includes installation, maintenance, and parts information for Fisher A41 high performance butterfly valves (figure 1). Refer to separate instruction manuals for information covering the power on-off actuator and accessories. Do not install, operate, or maintain A41 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 A41 high performance butterfly valves have eccentrically mounted discs to reduce wear and reduce torque requirements. The valve includes filled-PTFE or graphite packing rings that electrically bond the shaft to the valve body. This valve has a Double D drive shaft end, and soft or metal seal rings for use in a wide variety of applications. www.Fisher.com Instruction Manual A41 Valve November 2012 D500211X012 Table 1. Specifications Valve Sizes and End Connection Styles NPS J 2, J 3, J 4, J 6, J 8, J 10, and J 12 valves in wafer or single flanged style (NPS 2 available in wafer style only) Maximum Inlet Pressures(1) Carbon Steel, Stainless Steel, and CN7M Valves: Consistent with CL150 and 300 pressure-temperature ratings per ASME B16.34, unless limited by material temperature capabilities. NPS 2 is also consistent with CL600 Maximum Pressure Drops(1) Consistent with CL150 and 300 pressure/ temperature ratings per ASME B16.34 except for PTFE, UHMWPE, and Phoenix III seals that are derated at some higher pressure/temperatures values. (See figure 2) Shutoff Classifications Flow Characteristic Approximately linear Flow Direction See figure 4 Disc Rotation Clockwise to close (when viewing the drive shaft end) through 90 degrees of disc rotation (see figure 7) Valve Classification Face-to-face dimensions of NPS 3 through 12 in CL150 or 300, and meets API 609 or MSS-SP68 standards for face-to-face dimensions of wafer-style and single-flange valves Actuator/Valve Action With the diaphragm or piston actuators, the valve action is field-reversible. Refer to information in the Installation section and in figures 6 and 7. J PTFE, Reinforced PTFE, and UHMWPE(2) Seal: No visible leakage for this bidirectional seal per MSS SP-61 Shaft Diameters J NPS 2 Metal Seal: Bidirectional shutoff. 0.001% of maximum valve capacity (1/10) of Class IV per ANSI/FCI 70-2 and IEC 60534-4. Pressure Drop is 740 psig forward and 100 psig reverse Approximate Weights J NOVEX Seal: Unidirectional shutoff is MSS SP-61 in the preferred flow direction J Phoenix III Seal: No visible leakage for this bidirectional seal per MSS SP-61. For optional Phoenix III Fire-Tested seal, consult your Emerson Process Management sales office See table 2 See table 2 ENVIRO-SEAL Packing This optional PTFE or graphite packing system provides excellent sealing, guiding, and transmission of loading force to control liquid and gas emissions (see figure 6). See Bulletin 59.3:041 ENVIRO-SEAL Packing System for Rotary Valves for more information 1. The pressure/temperature limits in this manual and any applicable standard or code limitation for valve should not be exceeded. 2. UHMWPE stands for ultra high molecular weight polyethylene. Educational Services For information on available courses for the Fisher A41 high performance butterfly valve, 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 2 Instruction Manual A41 Valve D500211X012 November 2012 Table 2. Valve Size, Shaft Diameter, and Approximate Weight VALVE SIZE, NPS PRESSURE CLASS 2 3 4 6 8 10 12 APPROXIMATE WEIGHT SHAFT DIAMETER Wafer-Style Single-Flange mm Inches kg Pounds kg Pounds 150/300/600 12.7 1/2 4.3 9.5 --- --- 150 12.7 1/2 4.5 10 6.4 14 300 15.9 5/8 5.9 13 11 25 150 15.9 5/8 8.6 19 11 24 300 19.1 3/4 10 23 18 39 150 19.1 3/4 13 29 16 35 300 25.4 1 15 33 27 59 150 25.4 1 21 47 27 59 300 31.8 1-1/4 24 53 42 93 150 31.8 1-1/4 34 75 40 88 300 38.1 1-1/2 44 96 78 172 150 38.1 1-1/2 49 107 62 137 300 44.5 1-3/4 64 141 131 288 Table 3. Maximum Allowable Inlet Pressure for M35-1 and CW2M Valve Bodies(1) TEMPERATURE M35-1 CW2M Bar _C -46 to 38 93 149 204 260 15.8 13.8 13.1 12.7 11.7 41.3 36.5 34.1 33.1 32.8 82.7 72.7 68.2 65.8 65.5 20.0 17.9 15.9 13.8 11.7 51.7 51.7 50.3 48.6 45.9 103.4 103.4 100.3 97.2 91.7 TEMPERATURE CL150 CL300 CL600(2) CL150 CL300 CL600(2) 230 200 190 185 170 600 530 495 480 475 1200 1055 990 955 950 290 260 230 200 170 750 750 730 705 665 1,500 1,500 1,455 1,410 1,330 Psig _F -50 to 100 200 300 400 500 1. M35-1 and CW2M valve material are not included in ASME B16.34 pressure/ temperature ratings. The designations 150 and 300 for this valve material are used only to indicate relative pres sure/retaining capabilities and are not ASME pressure/ temperature rated classes. 2. CL600 is only available in NPS 2. 3 Instruction Manual A41 Valve November 2012 D500211X012 Figure 2. Maximum Pressure/Temperature Ratings DIFFERENTIAL PRESSURE, PSI OPERATING TEMPERATURE, _C PHOENIX III SEAL WITH PTFE INSERT PTFE AND REINFORCED PTFE SEAL UHMWPE SEAL OPERATING TEMPERATURE, _F NOTE: TEMPERATURE LIMITATIONS DO NOT ACCOUNT FOR THE ADDITIONAL 1 LIMITATIONS IMPOSED BY THE BACKUP RING USED WITH THIS SEAL. TO DETERMINE THE EFFECTIVE TEMPERATURE LIMITATION OF THE APPROPRIATE SEAL/BACKUP RING COMBINATION, REFER TO TABLE 4. A6306-2 Table 4. Construction Material Temperature Limits COMPONENTS AND MATERIALS OF CONSTRUCTION TEMPERATURE LIMITS _C _F -29 to 427 -198 to 538 -198 to 538 -20 to 800 -325 to 1000 -325 to 1000 -198 to 538 -198 to 538 -325 to 1000 -325 to 1000 -198 to 538 -62 to 427 -325 to 1000 -80 to 800 -73 to 260 -198 to 538 -100 to 500 -325 to 1000 -46 to 232 -198 to 438 -50 to 450 -325 to 1000 PTFE (Standard) -46 to 232 -50 to 450 Reinforced PTFE Soft Seal Ring -46 to 232 -50 to 450 UHMWPE Soft Seal Ring -18 to 93 0 to 200 NOVEX Metal Seal Ring -46 to 538 -50 to 1000 NPS 2 Metal Seal ring -46 to 538 -50 to 1000 -40 to 232 -40 to 450 (1) (1) Valve Body Material Carbon Steel CF8M CG8M Disc Material S31600 CG8M Shaft Material S20910 S17400 Bearing Material PEEK / PTFE lined Metal Packing Material PTFE V-rings Graphite rings Seal Ring Phoenix III Metal Seal Ring Fluorocarbon backup ring Phoenix III Fire-Tested(1) Metal Seal Ring Fluorocarbon backup ring (Specify metal bearings and graphite packing) 1. For component selection and applicable fire-tested standards and codes, consult your Emerson Process Management sales office. 4 Instruction Manual A41 Valve D500211X012 November 2012 Hex Head Cap Screw and Stud Bolt Data(1) WAFER STYLE VALVE SIZE, NPS CL150 SINGLE FLANGE STYLE CL300 A Dimension, Inch No. of Stud Bolts CL150 Size Dia Inch & Thread A Dimension, Inch No. of Cap Screws CL300 Size Dia Inch & Thread B Dimension, Inch --- --- --- 16 3/4-10 2 2 16 3/4-10 2.25 3/4-10 2 24 3/4-10 2.5 3/4-10 2.25 24 7/8-9 3 24 7/8-9 2.5 32 1-8 3.5 24 7/8-9 2.75 32 1-1/8-8 3.75 Size Dia Inch & Thread B Dimension, Inch No. of Cap Screws No. of Stud Bolts Size Dia Inch & Thread 2(2) 4 5/8-11 5 8 5/8-11 5.25 --- --- --- 3 4 5/8-11 5.75 8 3/4-10 6.5 8 5/8-11 1.875 4 8 5/8-11 6 8 3/4-10 7 16 5/8-11 6 8 3/4-10 6.5 12 3/4-10 7.5 16 8 8 3/4-10 7 12 7/8-9 9 16 10 12 7/8-9 8 16 1-8 10 12 12 7/8-9 8.5 16 1-1/8-8 11 1. Thread engagement in accordance with ASME B31.3. 2. The NPS 2 valve is only available in wafer style and is multirated to CL150, 300 and 600. The CL600 stud bolts require 8 bolts, have a dia. of 5/8-11, and are 6 inches long. Figure 3. Cap Screws and Stud Bolts for Installation A A3887 STUD BOLT A3886 B CAP SCREW Installation The valve is normally shipped as part of a valve assembly, with the actuator, handlever, or handwheel mounted on the valve. If the valve or actuator have been purchased separately, or if the actuator has been removed for maintenance, mount the actuator on the valve, and adjust actuator travel before inserting the valve body into the line. This is necessary due to the measurements that must be made during the actuator calibration adjustment process. Refer to the Actuator Mounting section of this manual and to the separate actuator or handlever instruction manual for mounting and adjustments before proceeding. WARNING Always wear protective gloves, clothing and eyewear when performing any installation or maintenance operations to avoid personal injury. To avoid personal injury or property damage resulting from the sudden release of pressure, do not install the valve assembly where service conditions could exceed the limits given in this manual, the limits on the appropriate nameplates, or the matching pipe flange rating. Use pressure-relieving devices 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. 5 Instruction Manual A41 Valve November 2012 D500211X012 CAUTION The valve configuration and construction materials were selected to meet particular pressure, temperature, pressure drop, and controlled fluid conditions specified in the customer's order. Because some body/trim material combinations are limited in their pressure drop and temperature range capabilities (especially due to differences in thermal expansion rates), do not apply any other conditions to the valve without first contacting your Emerson Process Management sales office. 1. Install a three-valve bypass around the control valve assembly if continuous operation is necessary during inspection and maintenance of the valve. 2. Inspect the valve to be certain that it is free of foreign material. 3. Be certain that adjacent pipelines are free of any foreign material, such as pipe scale or welding slag, that could damage the valve sealing surfaces. CAUTION Damage to the disc will occur if any pipe flanges or piping connected to the valve interfere with the disc rotation path. If the piping flange has a smaller inner diameter than specified for schedule 80 piping, measure carefully to be certain the disc rotates without interference before putting the valve into operation. Valve Orientation When installing the valve, it is highly recommended that the valve drive shaft be horizontal as shown in figure 4. Valve Direction The high performance butterfly valve is designed to allow flow in either direction when in the open position. When in the closed position, high pressure should be applied to a specific side of the disc to provide best performance and optimal valve life (see list of seal types below). See figure 4. Table 5. Special Spiral Wound Gasket Dimensions, Inches Valve Size, NPS Class Gasket Internal Diameter Gasket Outside Diameter Centering Outside Diameter(1) 3 150 4.25 5.00 5.375 3 300 4.25 5.00 5.875 4 150 5.25 6.125 6.875 4 300 5.25 6.125 7.125 1. Dimension per API 601 and ASME B16.5 Flanges. Applications with bi-directional seals, such as soft or Phoenix III, under normal operating conditions can (at different times) experience pressure in both directions; the highest of the two pressures should be exerted on the preferred side of the disc. If the two pressures are equal, then the one lasting the longest period of time should be applied to the preferred side. 1. For PTFE, reinforced PTFE, or UHMWPE seal rings: This seal is bidirectional. For best performance, high pressure should be applied to the front (retaining ring) side of the disc. 2. For metal seal rings: a. NOVEX seal: The NOVEX seal is uni-directional. High pressure at the closed position MUST be at the back (waterway side) of the disc. 6 Instruction Manual D500211X012 A41 Valve November 2012 b. Phoenix III Seal: This seal is bidirectional. For best performance, high pressure at the closed position should be applied to the back (waterway side) of the disc. c. NPS 2 Seal: The preferred direction of installation is with high pressure at the front (retaining ring side) of the disc. Reverse shutoff is permissible at lower pressure (see specifications table). Installing the Valve in the Pipeline WARNING The edges of a rotating disc have a shearing effect that may result in personal injury. To help prevent such injury, stay clear of the disc edges when rotating the disc (figure 4). CAUTION Damage to the disc (key 3, figure 12) sealing surfaces may occur if the disc is not closed when the valve is being installed or removed from the pipeline. If necessary, provide a loading pressure to the actuator temporarily to retain the disc in the closed position while installing or removing the valve from the pipeline. 1. For Fail-Open Actuators: It will be necessary to provide a temporary loading pressure to the actuator diaphragm to move the valve disc to the closed position. Observe the above Warning when closing the valve. If a loading pressure is required, use caution when working with the valve. If the loading pressure is disconnected, the disc will open rapidly. 2. With the disc in the closed position, install line flange gaskets, and insert the valve between the pipeline flanges. WARNING If spiral wound gaskets are to be used with an NPS 3 or 4 CL150 or 300 single flange valve, special spiral wound gaskets conforming to the dimensions listed in table 5 MUST be used. Improperly sized gaskets may increase the likelihood of 1) excessive seat leakage, 2) damage due to contact with valve internals, and 3) external leakage; which may result in personal injury due to a sudden increase or decrease of pressure within -- or release of pressure from -- the pipeline. The special dimension spiral wound gaskets can be obtained from your local spiral wound gasket vendor. The remaining single flange valve sizes (NPS 6 through 12) and all wafer style valves (NPS 2 through 12) use the standard size spiral wound gaskets. Only the single flange valves in the sizes and pressures listed in the table above require special spiral wound gaskets. Select the appropriate gaskets for the application. Flat sheet, spiral wound (NPS 6 through 12), or other gasket types made to ASME 16.5 group or a user's standards can be used for A41 valves depending on the service conditions and applications. 3. Install the flange studs: Note Lubricate line flange studs or bolts before inserting into flanges. If necessary, provide additional support for the control valve assembly because of its combined weight. 7 A41 Valve Instruction Manual November 2012 D500211X012 D Flange Studs: Install two or more line flange studs into the line flanges to help hold the valve in position while centering the valve. Carefully center the valve on the flanges to ensure disc clearance. D Select and install two pipeline gaskets. D Flange Cap Screws: If line flange cap screws are used, be certain the cap screw threads engage the tapped holes to a depth equal to the flange cap screw diameter. 4. Install the remaining line flange bolts to secure the valve in the pipeline. Tighten the bolts in a crisscross pattern to ensure proper alignment of the valve with the flanges. Packing Adjustment and Shaft Bonding WARNING Personal injury could result from packing leakage. Valve packing was tightened before shipment; however, the packing might require some readjustment to meet specific service conditions. CAUTION Excessive tightening of packing will accelerate wear and could produce higher rotating friction loads on the valve stem. 1. For PTFE or graphite packing: Tighten standard packing follower nuts only enough to prevent shaft leakage. Excessive tightening of packing will accelerate wear and could produce higher rotating friction loads on the valve stem. If necessary, refer to the Packing Maintenance section. 2. ENVIRO-SEAL Packing Systems will not require this initial re-adjustment. Refer to the separate ENVIRO-SEAL Packing System for Rotary Valves Instruction Manual (D101643X012) for repair and adjustment procedures. 3. For hazardous atmosphere or oxygen service valves, read the following Warning, and provide the bonding strap assembly mentioned below if the valve is used in an explosive or hazardous atmosphere. WARNING The valve drive shaft is not necessarily grounded to the pipeline when installed. If the process fluid or the atmosphere around the valve is flammable, personal injury or property damage could result from an explosion caused by a discharge of static electricity from the valve components. Standard PTFE packing is composed of a partially conductive carbon-filled PTFE female adaptor with PTFE V-ring packing. Standard graphite packing is composed of all conductive graphite ribbon packing rings. Alternate shaft-to-valve body bonding is available for hazardous service areas where you feel the the standard packing is not sufficient to bond the shaft to the valve (see the following steps). For oxygen service applications it is necessary to provide alternate shaft-to-valve body bonding (see the following steps). 4. Attach the bonding strap assembly (key 131, figure 5) to the shaft with the clamp (key 130, figure 5). 5. Connect the other end of the bonding strap assembly to the valve flange cap screws. 6. For more information, refer to the Packing Maintenance section below. 8 Instruction Manual A41 Valve D500211X012 November 2012 Figure 4. Flow Direction RETAINER RING SIDE RETAINER RING SIDE MFG LABEL MFG LABEL FLOW ARROW ARROW SHOWS PREFERRED FLOW DIRECTION FOR SOFT SEALS AND NPS 2 METAL SEAL FORWARD FLOW FLOW ARROW ARROW SHOWS FLOW DIRECTION FOR NOVEX METAL SEAL, AND PREFERRED FLOW DIRECTION FOR PHOENIX METAL SEAL REVERSE FLOW REVERSE FLOW FORWARD FLOW NOTES: 1. BY EMERSON PROCESS MANAGEMENT DEFINITION: D FORWARD FLOW IS INTO THE FACE SIDE OF THE DISC. D REVERSE FLOW IS INTO THE HUB SIDE OF THE DISC. FACE SIDE OF DISC 75B1181-A A6881-2 Maintenance Valve parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and replacement depends upon the severity of service conditions. Instructions are given in this section for replacing packing, seal ring, disc, shaft, bearings, and other valve parts. Also, instructions are provided for changing valve action, mounting, and adjusting the actuator. Refer to the actuator instruction manual for additional information for mounting and adjusting the actuator. 9 A41 Valve Instruction Manual November 2012 D500211X012 CAUTION It is possible to damage the valve if the actuator travel stops are not properly adjusted before stroking the valve. WARNING Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before performing any maintenance operations: D Do not remove the actuator from the valve while the valve is still pressurized. D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal injury. D 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. D Use 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. D Vent the pneumatic actuator loading pressure and relieve any actuator spring precompression. D Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. D 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. D Check with your process or safety engineer for any additional measures that must be taken to protect against process media. WARNING The edges of a rotating disc have a shearing effect that may result in personal injury. To help prevent such injury, stay clear of the disc edges when rotating the disc (key 3). CAUTION During the following steps, do not rotate the disc past 90 degrees in the open direction. Rotating the disc past 90 degrees can damage the seal ring. Use caution when tightening the packing flange nuts. Overtightened nuts can damage packing box parts. 10 Instruction Manual A41 Valve D500211X012 November 2012 Figure 5. Optional Shaft-to-Valve Body Bonding Strap Assembly VALVE BODY 37A6528-A A3143-2 VIEW A-A ACTUATOR A A Stopping Leakage For PTFE-filled or graphite standard packing arrangements covered in this manual, often leakage from the packing can be stopped by tightening the packing flange nuts just enough to stop the leak. Use caution when tightening the nuts, overtightened nuts can damage packing box parts. D If tightening the packing flange nuts does not stop the leakage, use the following procedures to remove the control valve assembly from the pipeline, remove the actuator, and to remove and replace the packing parts. D If the leakage comes from the outside diameter of the packing box, it is possible that the leakage is caused by scratches on the packing box wall. Carefully inspect the packing box bore and valve drive shaft when the packing is removed. Use the following steps to remove the actuator, and to remove and replace the packing parts. Removing the Actuator WARNING Refer to the WARNING at the beginning of the Maintenance section in this instruction manual. 1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. If using a power actuator, also shut off all pressure lines to the power actuator, and release all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment. WARNING The edges of a rotating disc have a shearing effect that may result in personal injury. To help prevent such injury, stay clear of the disc edges when rotating the disc (figure 4). 11 A41 Valve November 2012 Instruction Manual D500211X012 CAUTION Damage to the disc (key 3) sealing surfaces may occur if the disc is not closed when the valve is being removed from the pipeline. For fail open actuators, it may be necessary to apply loading pressure to the actuator to retain the disc in the closed position while removing the valve from the pipeline. 2. Be sure the disc is in the closed position before attempting to remove the valve from the pipeline or flanges. For Fail-Open Actuators: It will be necessary to provide a temporary loading pressure to the actuator to move the valve disc to the closed position. Observe the above Warning when closing the valve. If a loading pressure is required, use caution when working with the valve. If the loading pressure is disconnected, the disc will open rapidly. 3. With the disc in the closed position, remove line bolting. Remove the valve assembly from the pipeline, and place the actuator/valve assembly on a flat working surface. 4. If a grounding strap is used (see figure 5), remove the hex nut to release the end of the strap. Remove the clamp (key 130) and strap (key 131). 5. Note the orientation of the actuator with respect to the valve body. Also, remove the actuator cover to note the orientation of the actuator with respect to the valve drive shaft (see figure 7). When re-assembling the valve assembly, you will need to correctly position the mark on the end of the valve drive shaft and the valve body, with respect to the actuator drive shaft. Refer to the Actuator Mounting section and figure 7 for the location of the mark on the actuator end of the valve drive shaft. Additional information is provided in the actuator manual to assist with disassembly, re-assembly, and travel adjustments. 6. Remove the actuator mounting screws (key 14). 7. Remove the actuator from the valve, and remove the valve/actuator coupling. Packing Maintenance WARNING Refer to the WARNING at the beginning of the Maintenance section in this instruction manual. Standard graphite packing is composed of all conductive packing rings. PTFE-filled packing has a partially conductive packing ring (such as a carbon-filled PTFE female adaptor) to electrically bond the shaft to the valve body. If the valve is equipped with the optional ENVIRO-SEAL Packing System, refer to the separate ENVIRO-SEAL Packing System for Rotary Valves Instruction Manual (D101643X012) for packing maintenance procedures. When replacing the packing, it is recommended that you remove the control valve assembly from the pipeline. Valve/actuator travel adjustments must be made with the valve out of the pipeline. Disassembly Part locations and key numbers are shown in figures 5 and 11. 1. Remove the packing flange nuts (key 101) and the packing flange (key 114). 2. Remove the old packing rings, using a formed hook. CAUTION Carefully use the hook. Avoid scratching the drive shaft or packing box wall. Scratches on valve surfaces can cause leakage. [Note: the packing box ring (key 107) can remain in place when replacing the packing only.] 12 Instruction Manual D500211X012 A41 Valve November 2012 Clean all accessible metal parts and surfaces to remove particles that would prevent the packing from sealing. Assembly Inspect the shaft. If it is damaged, it cannot make a good seal with the packing and it must be replaced. If the leakage comes from the outside diameter of the packing, it is possible that the leakage is caused by nicks or scratches around the packing box wall. Inspect the packing box wall for nicks and scratches when performing the following procedures. If the valve is equipped with the ENVIRO-SEAL packing system, refer to the separate ENVIRO-SEAL Packing System for Rotary Valves Instruction Manual (D101643X012) for assembly. Note Except with oxygen service, lightly lubricate new PTFE V-rings with silicone-base lubricant to aid in assembly. WARNING Do not lubricate parts when used in oxygen service, or where the lubrication is incompatible with the process media. Any use of lubricant can lead to the sudden explosion of media due to the oil/oxygen mixture, causing personal injury or property damage. 1. Install the new packing parts (see figure 6). Install the packing follower and finger tighten the packing flange nuts onto the studs only enough to stop leakage. 2. If the valve was equipped with a bonding strap assembly (figure 5), re-install the assembly. 3. Refer to the Actuator Mounting section of this manual. If necessary, refer to the separate actuator instruction manual for adjustment procedures. 4. When the valve is being placed into operation, check around the packing follower for leakage. For PTFE-filled or graphite standard packing arrangements covered in this manual, often leakage from the packing can be stopped by tightening the packing flange nuts just enough to stop the leak. CAUTION Use caution when tightening the nuts, overtightening nuts can damage packing box parts and result in increased drive shaft friction. Seal Ring Maintenance for NPS 3 through 12 Perform this procedure if the control valve is not shutting off properly (that is, if it is leaking downstream). It is recommended, but not required, to remove the actuator for easier handling of the valve during the following procedures. Key numbers are shown in figure 12 unless otherwise noted. 13 Instruction Manual A41 Valve November 2012 D500211X012 Figure 6. Typical Packing Arrangements PACKING FOLLOWER (KEY 102) PACKING SET (KEY 105) 1 PACKING RING (KEY 105) PTFE V-RING PACKING PACKING BOX RING (KEY 107) GRAPHITE RIBBON PACKING STANDARD PACKING PACKING FLANGE (KEY 102) PACKING FLANGE NUT (KEY 101) REDUNDANT SHAFT RETENTION LUBRICANT (KEY 113) SPRING PACK ASSEMBLY (KEY 103) SPRING COMPRESSED PACKING FLANGE STUD (KEY 100) ANTI-EXTRUSION RING (KEY 106) SHAFT STEP PACKING SET (KEY 105) ENVIRO-SEAL PTFE PACKING SYSTEM PACKING FLANGE (KEY 102) PACKING FLANGE NUT (KEY 101) REDUNDANT SHAFT RETENTION LUBRICANT (KEY 113) SPRING PACK ASSEMBLY (KEY 103) 11B5895-A 10B6817-A B2435 C0785-2 14 SPRING COMPRESSED PACKING FLANGE STUD (KEY 100) SHAFT STEP PACKING SET (KEY 105) NOTE: 1 INCLUDES ZINC WASHERS FOR GRAPHITE RIBBON PACKING ONLY VALVE BODY (KEY 1) PACKING BOX RING (KEY 107) VALVE BODY (KEY 1) PACKING BOX RING (KEY 107) ENVIRO-SEAL GRAPHITE PACKING SYSTEM Instruction Manual A41 Valve D500211X012 November 2012 Figure 7. Disc Rotation Indication INDICATES APPROXIMATE DISC POSITION DISC STOP INDICATES APPROXIMATE DISC POSITION TO OPEN ROTATE DISC IN DIRECTION SHOWN ONLY ACTUATOR END OF SHAFT ROTATE DISC IN DIRECTION SHOWN ONLY 2 RETAINER RING (KEY 2) Note: DISC IN THE CLOSED POSITION 2 DISC IN THE OPEN POSITION SET ACTUATOR TRAVEL STOPS TO OBTAIN AN EQUAL DISTANCE T DISC SURFACE AS SHOWN. 2 LOCATION OF C MARKINGS FOR NPS 2 ONLY. A6358 CAUTION: DO NOT ROTATE DISC INTO THIS SECTOR ROTATE DISC IN EITHER DIRECTION A2879-2 DISC ROTATION INDICATION FOR NPS 2 DISC ROTATION INDICATION FOR NPS 2 THROUGH 12 Figure 8. Removing the Retainer Ring FLAT END PUNCH KNOCK-OUT FLAT A6359 CAUTION During any of the following steps, do not rotate the disc past 90 degrees in the open direction. Rotating the disc past 90 degrees can damage the seal ring. Disassembly Refer to removing the actuator steps in the Packing Maintenance section. Most maintenance procedures will require the actuator to be removed. 15 A41 Valve November 2012 Instruction Manual D500211X012 1. Removing the retainer ring (key 2): For valves with press-fit retainer rings: D Place the valve on blocks with the seal retainer facing down. (Note: Position blocks so they do not restrict the retainer ring removal.) D Rotate the disc to the open position as shown in figure 7. D On the seal ring side of the retainer ring, locate one of the knock-out points machined on the retainer ring. Using a hammer and flat end punch on the knock-out point, pop-out the retainer ring from the valve body (see figure 8). CAUTION When popping out the retainer ring, be very careful to hit only the knock-out points. Hitting anywhere else can cause non-repairable damage to the t-slot area. D For valves with PTFE seal rings, remove the spring (key 5) as it may be necessary to re-install the spring into the new PTFE seal ring. D Clean all sealing surfaces and parts before re-assembly. Proceed to step 3 below. For valves with screwed retainer rings: D Place the valve on blocks with the seal retainer facing up. D Remove the retainer ring screws (key 23). If necessary, use two of the retainer screws, in the tapped holes in the retainer ring (key 2) to jack the retainer ring loose from the valve body surface. 2. Remove the seal ring from the valve body seal ring slot. D For valves with PTFE seal rings, remove the spring (key 5) as it may be necessary to re-install the spring into the new PTFE seal ring. D For valves with metal seals, remove the gasket (key 16) from the valve body surface, and discard it as replacement is recommended. 3. If it is necessary to replace the disc, drive shaft, and the bearings, refer to the Disc, Drive Shaft, and Bearing Maintenance section before proceeding with the assembly procedures for the seal ring and retainer. The seal ring could be damaged if it is in place while removing the disc. CAUTION Follow instructions in this manual to avoid damage to the seal ring while either removing or installing the disc. Assembly Place the valve on blocks with the seal retainer facing up. If the replacement disc, shaft, and bearings have not been installed in the valve body, go to the Assembly procedures to install them. Do not install the seal ring without the disc being in place. The seal ring could be damaged while installing the disc. 16 Instruction Manual D500211X012 A41 Valve November 2012 WARNING Do not lubricate parts when used in oxygen service, or where the lubrication is incompatible with the process media. Any use of lubricant can lead to the sudden explosion of media due to the oil/oxygen mixture, causing personal injury or property damage. CAUTION Do not rotate the disc past 90 degrees in the open direction. Rotating the disc past 90 degrees can damage the seal ring or other component parts. Note PTFE, NOVEX, and Phoenix Ill seal rings used in other valve types are not interchangeable with seal rings used in the A41 valve. The A41 seal rings are not interchangeable with seal rings in any other valve type. To order seal rings for this valve, provide the serial number on the valve. 1. Installing PTFE seal rings: a. The valve disc should be open while installing the seal ring. If not, rotate the disc to the open position as shown in figure 7. b. Hook the spring ends together, insert the spring (see figure 9) into the groove in the seal ring, and work the spring into the recess in the PTFE seal ring. c. Install the seal ring (key 4) assembly into the slot in the valve body as shown in figure 9. Refer to installing the retainer ring steps below. 2. Installing metal seals: Note For metal seals only, it may be necessary to apply dry film lubricant or equivalent moly disulfide to the sealing surfaces of the disc, seal, and the seal retainer groove. Prior to applying the lubricant, the sealing surfaces should be inspected for injurious defects. Surfaces can be polished using a scouring pad or equivalent. The edge of the seal that contacts the retaining ring groove should also be inspected and polished if necessary. a. Rotate the disc to the open position as shown in figure 7. The seal ring will be damaged if the disc remains in the closed position during seal and retainer ring assembly. WARNING Do not lubricate parts when used in oxygen service, or where the lubrication is incompatible with the process media. Any use of lubricant can lead to the sudden explosion of media due to the oil/oxygen mixture, causing personal injury or property damage. b. Install the metal seal ring assembly (see figure 9). 17 Instruction Manual A41 Valve November 2012 D500211X012 Figure 9. Available Seal Configuration VALVE BODY RETAINING RING RETAINING RING (KEY 2) VALVE BODY (KEY 1) SPRING (KEY 5) PRESSURE-ASSISTED SEAL SEAL RING (KEY 4) HIGH PRESSURE SHUTOFF DISC FACE DISC FACE BIDIRECTIONAL SEAL B1558-3 NPS 2 METAL SEAL GRAPHITE GASKET (KEY 16) PTFE SEAL VALVE BODY (KEY 1) SEAL RING (KEY 4) HUB SIDE OF DISC RETAINING RING (KEY 2) UNIDIRECTIONAL SEAL HIGH PRESSURE SHUTOFF FLOW DIRECTION NOVEX METAL SEAL A6360-1 RETAINING RING GRAPHITE GASKET (KEY 16) BACKUP O-RING (KEY 15) VALVE BODY (KEY 1) SEAL RING (KEY 4) HUB SIDE OF DISC RESILIENT INSERT BIDIRECTIONAL SEAL PHOENIX III METAL SEAL 3. Installing the retainer ring: a. Valves with PTFE seal rings do not require a retainer ring gasket (key 16). b. Valves with metal seals require a retainer ring gasket (key 16). The gasket is not pre-punched for insertion of retainer screws. The holes are not necessary for press-fit retainer rings. CAUTION When handling the new retainer ring gasket, be sure to avoid kinking, cracking, or breaking the gasket. Damage to the gasket can cause leakage between the seal retainer and valve body. c. Lay the gasket (key 16) down so that it is accurately centered on the valve body. 4. For valves with press-fit retainer rings a. Wipe excessive oil off the retainer ring outside diameter, and off the retainer counterbore in the valve body. b. Rotate the disc to the open position. 18 Instruction Manual D500211X012 A41 Valve November 2012 c. Lay the retainer ring on the valve body. d. Use a press or a soft-faced hammer to press the retainer ring into its groove in the valve body. CAUTION It takes a considerable amount of force with a hammer to drive the retainer ring into place. Be sure not to damage retainer ring surfaces when installing the ring. e. The retainer ring is properly seated when the face of the retainer ring is flush with the face of the valve body. f. To ensure proper seal performance for metal seals, you may need to use the hammer to drive the disc open for the first few times. When closing the valve, use the C clamps discussed in the next few steps. CAUTION Do not damage the gasket seating surfaces on either the valve body or the retainer ring when installing or removing the C-clamps. Protect the gasket surface by using a soft material between the clamp and valve body/retaining ring serrations to avoid damage. g. Use three C-clamps to hold the retainer in place. Locate one of the C-clamps near the travel stop in the valve body, and the other two at 120 degrees from the stop. h. When cycling the disc for the first three times, use a dead-blow hammer, with a soft head to drive the disc closed. Also, you may need to use the hammer to drive the disc open for the first few times. 5. For valves with screwed retainer rings a. Match the retainer ring with the holes in the valve by punching two holes in the gasket to locate where the screw holes are in the valve. b. Lay the retainer ring over the gasket, while lining it up with the punched holes. Also insert two retainer screws (key 17). Finger tighten them. c. Press the remaining screws through the gasket material and finger tighten them. When all retainer screws are in place, tighten them in a crisscross pattern. d. The retainer ring is properly seated when the retainer face is flush with the face of the valve. 6. Turn the disc into and out of the seal ring several times, to help break in the seal and reduce actuator torque requirements during adjustment. 7. If replacing the packing, remove all packing parts from the valve body. Upon re-assembly of the valve, refer to the Packing Maintenance procedures to replace the packing. Seal Ring Maintenance for NPS 2 This procedure is to be performed if the control valve is not shutting off properly (that is, leaking downstream). This procedure does not require removing the actuator from the valve body. Part key numbers are shown in figure 12. WARNING Refer to the WARNING at the beginning of the Maintenance section in this instruction manual. 19 A41 Valve Instruction Manual November 2012 D500211X012 1. Isolate the control valve from line pressure, and relieve pressure from the valve body. Shut off and disconnect all lines from the power actuator. WARNING The edges of a rotating disc have a shearing effect that may result in personal injury. To help prevent such injury, stay clear of the disc edges when rotating the disc (key 3). CAUTION Damage to the disc (key 3) may occur if the disc is not closed when the valve is being removed from the pipeline. If necessary, pressure the actuator temporarily to retain the disc in the closed position while removing the valve from the pipeline. 2. Unscrew the flange bolts, and remove the valve from the pipeline. 3. Unscrew the machine screws (key 8), and remove the seal retainer (key 2). Also remove the retainer clip (key 34). 4. Remove the seal ring or seal ring assembly (key 4). The spring (key 5) is removed with a PTFE seal ring. 5. For S31600 stainless steel seal ring assemblies, replace the gaskets (key 4C) if the entire seal ring assembly is not replaced. Scrape off the old gaskets from both sides of the seal ring and the seal ring sides of the valve body (key 1) and seal retainer. Clean the gasket surfaces. 6. Reconnect or mount the actuator (if it was removed) before proceeding. For an actuator with adjustable travel, also adjust the actuator before proceeding. This is necessary due to the measurements that must be made during the actuator adjustment process. Refer to the Actuator Mounting section of this manual and to the separate actuator instruction manual for mounting and adjusting instructions. 7. The valve should be closed during seal ring installation to permit accurate centering of the seal. To install the new seal ring: For a PTFE seal, if the spring (key 5) was disassembled, hook the spring ends together. Work the spring into the recess in the seal ring (key 4). Install the seal ring and spring assembly into the recess in the valve body as shown in figure 13. For a complete S31600 stainless steel seal ring assembly, install the seal ring assembly as shown in figure 13. 8. For an S31600 stainless steel seal ring on which the gaskets will be replaced, lay the following parts down in order so that they are accurately centered on the valve: one new gasket; the seal ring oriented as shown in figure 13; and the second new gasket. 9. Attach the seal retainer and, if used, the retainer clips and washers to the valve body and secure with the machine screws. Tighten the machine screws evenly so as not to crack or break the S31600 stainless steel seal ring gaskets, if used. Be certain the disc is closed before installing the valve according to the Installation section of this instruction manual. Disc, Drive Shaft, and Bearing Maintenance for NPS 3 through 12 This procedure is to be performed when replacing the valve disc, drive shaft, taper pins, hollow pins, and bearings due to wear or damage to one or more component parts. Part locations and key numbers are shown in figures 9 and 11 unless otherwise noted. 20 Instruction Manual D500211X012 A41 Valve November 2012 Disassembly 1. If necessary, loosen the packing flange nuts (key 101). This allows the drive shaft (key 8) to turn without the friction caused by the packing. 2. Remove the actuator, using the steps provided in the packing maintenance procedures above, and remove the seal ring using the steps provided in the seal ring maintenance procedures above. 3. Place the valve on a flat working surface with the seal ring slot facing down. 4. Use blocks to raise the valve body high enough to allow the disc to be rotated to the fully open position (figure 7). 5. Rotate the disc (key 3) to the fully open position. 6. Locate the small ends of the taper pins. Drive the two taper pins (key 10) out towards the larger end of pins. (Note: Attempting to drive the taper pins in the opposite direction only tightens the pins.) Also, remove the hollow pins (key 9) from the disc/shaft connection using the tool shown in figure 11. Note Make the tools for removing and installing the hollow pin shown in figure 11. 7. Unscrew and remove the packing flange nuts (key 101), and the packing flange (key 102). WARNING Once the shaft has been removed in the following step, the disc may fall out of the valve body cavity. To avoid personal injury and damage to disc sealing surfaces, support the disc to prevent it from falling as the shaft is being removed. 8. Pull the shaft out of the valve body, and remove the disc (key 3) from the valve body bore. 9. If the packing is to be replaced, remove all packing parts from the valve body. Upon re-assembly of the valve, refer to the Packing Maintenance procedures to replace the packing. 10. Remove both of the bearings (key 6) from the valve body. For CL150 valves with metal bearings, refer to the following note. Note CL150 valves with metal bearing assemblies have three parts. A disc spacer, bearing, and bearing spacer (keys 7, 6, and 13) are used in place of a single piece bearing. The disc spacers may fall out of the valve when the disc is removed. If needed for re-assembly, retain the disc spacer and bearing spacer parts. 11. Clean all of the sealing surfaces and parts, and inspect and/or replace before assembly. Assembly 1. Install the bearings (key 6): When installing the bearings in the opposite side of the valve body bore, repeat the following procedure. D For PEEK/PTFE CL150 and CL300 metal bearings, one piece bearings: Position the bearing edge to match the valve body bore, and insert the one piece bearing/disc spacer into the bearing bore with the bearing/spacer tab facing away from the disc stop as shown in figure 10. 21 Instruction Manual A41 Valve November 2012 D500211X012 Figure 10. Orientation of Bearing/Spacer Tab CENTER LINE OF SHAFT BORE DISC STOP A6357 CENTER LINE OF BODY & DISC SPACER BEARING TAB OR DISC SPACER TAB D For CL150 metal bearings, three piece assemblies: Metal bearings for CL150 valves are an assembly made up of three parts: disc spacer, bearing, and bearing spacer (keys 13, 6, and 7) as shown in the orientation of bearing/spacer tab shown in figure 10. a. Install the bearing spacer (key 13) into the bearing bore. b. Install the bearing into the bearing bore until the bearing is flush with the valve body bore. c. When installing the disc spacer (key 7) position the curved side to match the valve body bore, and position it with the tab on the spacer pointing away from the disc stop as shown in figure 10. Note The disc spacer will have to be held in place when installing the disc and inserting the shaft through the valve body, bearings, bearing spacer, and disc. To help hold the spacer in place, apply lubricant. 2. Position the disc to be certain that the holes in the disc are towards the actuator side of the valve. Carefully insert the disc into the valve body bore while protecting the disc sealing surfaces. 3. Install the shaft (key 8): D For PEEK/PTFE CL150 and CL300 metal bearings, one piece bearings: Slide the shaft through the valve body bore and bearing. Position the disc as stated above and slide the shaft through the disc and outer bearing. Refer to step 4 below. D For CL150 metal bearing, three piece assemblies: Slide the shaft into the valve body bore and bearing spacer. Position the disc spacer as stated above and hold it in place. Slide the shaft through the bearing and into the disc. Position the second disc spacer, and hold it in place. Slide the shaft through the disc spacer and into the outer bearing. 22 Instruction Manual A41 Valve D500211X012 November 2012 Figure 11. Taper Pin and Hollow Pin Removal and Installation REMOVAL TOOL DIMENSIONS Shaft Diameter A B 12.7 3.91 15.88 INSTALLATION TOOL DIMENSIONS C D Shaft Diameter 28.43 6.35 4.19 12.7 12.7 4.60 38.10 7.87 23.37 15.88 19.05 5.13 44.45 9.65 5.41 25.4 7.00 59.44 12.70 31.75 9.50 76.20 38.1 10.82 44.45 12.37 C D E 3.68 6.35 127.0 4.83 12.7 4.57 7.62 127.0 4.83 19.05 12.7 5.23 8.89 127.0 4.83 7.26 25.4 12.7 7.00 10.41 127.0 4.83 19.05 9.78 31.75 19.05 10.00 13.59 146.0 6.35 88.90 19.05 11.10 38.1 19.05 11.56 15.24 146.0 6.35 114.30 22.35 12.65 44.45 19.05 31.21 16.76 146.0 6.35 A B mm mm Inch Inch 0.5 0.154 1.12 0.25 0.165 0.5 0.50 0.145 0.250 5.00 0.19 0.625 0.181 1.50 0.31 0.192 0.625 0.50 0.180 0.300 5.00 0.19 0.75 0.202 1.75 0.36 0.213 0.75 0.50 0.206 0.350 5.00 0.19 1 0.275 2.34 0.50 0.286 1 0.50 0.275 0.410 5.00 0.19 1.25 0.374 3.00 0.75 0.385 1.25 0.75 0.395 0.535 5.75 0.25 1.5 0.426 3.50 0.75 0.437 1.5 0.75 0.455 0.600 5.75 0.25 1.75 0.487 4.50 0.88 0.498 1.75 0.75 0.520 0.660 5.75 0.25 D B C E 15_ A 0.03 X 45 DISC HUB C A B 0.010 X 45 0.010 UNDERCUT PER SIDE 0.06 X 45 REVERSE FLOW INSTALLATION TOOL REMOVAL TOOL VALVE DISC NOTE: 1 REMOVE THE HOLLOW PIN FROM THIS SIDE OF THE DISC HUB. INSTALL THE HOLLOW PIN FROM THE OPPOSITE SIDE OF DISC HUB. A6356 HOLLOW PIN FORWARD FLOW TAPER PIN AND HOLLOW PIN LOCATION 1 FACE SIDE OF DISC 23 A41 Valve November 2012 Instruction Manual D500211X012 Installing the Hollow Pin and Taper Pin 4. Place the valve body on a flat working surface with the slot for the seal ring facing up. Block the valve body high enough to allow the disc to be rotated into the open position as shown in figure 11. Note Make sure that the taper pins and hollow pins are free of particulate matter before continuing. 5. Rotate the disc to the open position. Locate the disc position mark on the end of the drive shaft. Rotate the shaft until it is in the appropriate disc position as shown in figure 7. 6. Line up both holes in the disc hub with the holes in the drive shaft (key 8). (Note: The hole in the drive shaft is offset to prevent the shaft from being installed in the wrong position. Be sure the hole in the shaft is lined up with the hole in the disc hub.) 7. Insert the hollow pins (key 9), into the disc hub as shown in figure 11. Using the tool shown in figure 11, tap the hollow pin down into the disc hub and shaft until the pin bottoms on the stop in the disc. 8. Insert the taper pins (key 10) into the hollow pins. Using a flat end punch, drive the taper pins into the hollow pins until solid contact is felt. Anchor the pins in place by staking them with a center-punch and hammer. The disc and shaft should rotate smoothly. 9. Install the seal ring assembly using the appropriate instructions in the Seal Ring Maintenance procedures. 10. Install the packing parts using the appropriate instructions provided in the Packing Maintenance procedures. Refer to the Actuator Mounting and Adjustment procedures before installing the valve in the pipeline. Disc, Shaft Assembly and Bearing Maintenance for NPS 2 This procedure is to be performed to replace the valve disc, shaft, and taper pin assembly if the disc does not rotate in response to rotation of the actuator end of the valve shaft. Unless otherwise indicated, part key numbers are shown in figure 13. Disassembly 1. Remove the seal ring according to steps 1 through 5 of the Replacing Seal Ring section. CAUTION Use a wheel puller to separate actuator parts from the valve shaft. Driving the parts off the valve shaft could move the valve bearings and disc away from the centered position, damaging the disc and valve. 2. Remove the cap screws and if used the hex nuts. Remove the clamp if the strap is used. Remove the actuator from the valve body while referring to the separate actuator instruction manual for assistance. 3. Rotate the disc (key 3) to the fully open position. 4. Locate the half of the disc that has two C markings cast into it as shown in figure 7. Drive the two taper pins (key 3C) out toward the C-marked side of the disc. Attempting to drive the taper pins in the opposite direction only tightens the pins. 24 Instruction Manual A41 Valve D500211X012 November 2012 5. Unscrew and remove the packing flange nuts (key 12), packing followers (keys 15 and 16), and packing flanges (keys 9 and 10) if used, from both sides of the valve. Table 6. Recommended Bolt Torques for Actuator/Mounting Cap Screws and Nuts VALVE SIZE, NPS RECOMMENDED BOLT TORQUE NSm lbSft CL150 Valves 2, 3, 4, 6, & 8 88 65 10 & 12 135 100 CL300 Valves 2, 3, 4, & 6 88 65 8 & 10 135 100 12 183 135 WARNING Once the shaft has been removed in the following step, the disc may fall from the valve body. To avoid personal injury and disc damage, support the disc to prevent it from falling as the shaft is being removed. 6. Pull the shaft out through the actuator side of the valve. 7. Remove the disc from the valve. 8. Remove the packing rings (key 13), the packing washers (key 27, figure 6) if used, and the packing box ring (key 14). 9. If either of the bearings (key 6) require maintenance or replacement, remove them. CAUTION When replacing a valve disc or shaft, a new disc/shaft/taper pin assembly (key 3) should be used. Using a new disc with a used shaft requires drilling and reaming new taper pin holes in the shaft. The extra set of taper pin holes weakens the shaft and may cause it to fail in service. 10. Clean the packing boxes and metal packing box parts. Assembly 1. Drop in the new bearings. Make sure to orient the tab in the bearing with the slot in the seal. 2. Insert the disc into the valve body. Be certain the taper pin holes in the disc are on the actuator side of the valve. Also be certain the letter C stamped on either face of the disc is on the same side of the valve as the letter C stamped on the outside of the valve (figure 7). 3. Slide the shaft through the valve body and disc. 4. Install the disc and spacers into the valve body. Insert the shaft into the valve body and through the disc. 5. Slide the shaft all the way into the valve body. 6. To ensure that the direction of taper in the shaft taper pin holes matches that of the disc taper pin holes, temporarily install the packing follower (key 15) or, if used, the packing flange (key 9) with rotation tag (key 19). With the disc fully opened, rotate the shaft until the line on the end of the shaft indicates the OPEN position as shown in figure 7. Insert the taper pins (key 3C), small end first, into the taper pin holes on the C-marked side of the disc. Do not drive in the pins. Remove the packing follower or flange. 7. Insert a packing box ring (key 14) into each packing box. 25 A41 Valve November 2012 Instruction Manual D500211X012 8. Install the packing according to the appropriate instructions presented in steps 5 through 8 of the Replacing Packing section. 9. Drive in the taper pins securely. 10. Rotate the disc to the closed position. To install the seal ring and complete the assembly, follow the procedures presented in steps 5 through 9 of the Replacing Seal Ring section. Actuator Mounting Re-install the seal ring and packing rings using the appropriate procedures before installing the actuator or handlever. Mount the actuator on the valve in accordance with the Actuator Mounting section in the actuator or handlever instruction manual. In the Packing Maintenance/Removing the Actuator steps, you should have noted the position of the mark on the end of the valve shaft, and its relationship to the actuator shaft. If not, determine the configuration needed to match your application. Be certain that the disc is rotating counterclockwise to open when viewed from the actuator side of the valve and that the disc is not rotated beyond its limits. 1. Orientate the valve drive shaft correctly to match the actuator or handlever position, install the actuator coupling, and hold it in place while matching the actuator mounting pads with each other. 2. Tighten the actuator-mounting cap screws to the appropriate bolt torque from table 6. CAUTION The valve disc travel stop in the valve body bore is not to be used as a power actuator travel stop (see figure 7). Use the actuator travel stops to limit the rotation of the valve disc. It is possible damage to the valve component parts may occur if full actuator thrust is applied to the valve disc travel stop. Note To obtain proper shutoff, the closed position of the A41/8560 valves must be set with the disc parallel to the retaining ring. Don't use the disc stop to set the actuator travel stops. 3. Adjust the actuator travel stop to limit the open and closed positions of the valve disc. (If necessary, refer to the actuator instruction manual for more information about adjustments.) Do not use the disc stop as a actuator travel stop as discussed in the Caution above. 4. For actuators with adjustable turnbuckles, adjust the turnbuckle to bring the disc to the fully closed position at the end of the actuator stroke. If necessary, refer to the appropriate actuator instruction manual for assistance. 5. If using a manual handwheel or handlever actuator, refer to the appropriate actuator instruction manual for mounting positions and adjustments. 6. To determine the fully closed disc position (zero degrees of disc rotation), measure the distances between the positions on the disc face as shown in figure 7. Use the actuator to rotate the disc while re-checking the two measurements. Repeat adjustment until the two measurements are equal. 26 Instruction Manual A41 Valve D500211X012 November 2012 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, desired material, using the Parts List table. 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. ENVIRO-SEAL Packing Arrangements Retrofit kits and repair kits are listed in the following tables. For additional parts and repair information, refer to the ENVIRO-SEAL Packing System for Rotary Valves Instruction Manual (D101643X012) or contact your Emerson Process Management sales office for assistance. Retrofit Kits for ENVIRO-SEAL Packing Retrofit kits include new parts for the key numbers listed in the table below (see figure 6 for part locations). PARTS INCLUDED IN KIT Key Description 100 Packing stud 101 Packing nut 102 Packing flange 103 Spring pack ass'y 105 Packing set 106 Anti-extrusion washer 107 Packing box ring 111 Tag 112 Tie cable 1. Diameter through the packing box. ENVIRO-SEAL Packing System Retrofit Kits For Fisher A41 SHAFT DIAMETER SHAFT DIAMETER SINGLE PTFE PACKING GRAPHITE PACKING mm Inches For Actuator End Packing Box For Actuator End Packing Box 12.7 15.9 19.1 25.4 31.8 38.1 1/2 5/8 3/4 1 1-1/4 1-1/2 RRTYXRT0972 RRTYXRT0982 RRTYXRT0992 RRTYXRT1012 RRTYXRT1022 RRTYXRT1032 RRTYXRT1072 RRTYXRT1082 RRTYXRT1092 RRTYXRT1102 RRTYXRT1112 RRTYXRT1122 27 Instruction Manual A41 Valve November 2012 D500211X012 Repair Kits for ENVIRO-SEAL Packing Repair kits include replacement parts for key 105 and 106 for the shaft diameters listed below. ENVIRO-SEAL Packing Repair Kits SHAFT DIAMETER(1) mm Inches 12.7 1/2 15.9 5/8 19.1 3/4 25.4 1 31.8 1-1/4 38.1 1-1/2 Parts Included in Kit Key Description 105 Packing set 106 Anti-extrusion washer 1. Diameter through the packing box. Parts List Key Note Part numbers are shown for recommended spares only. For part numbers not shown, contact your Emerson Process Management sales office. Key 1 2* 3 3 4* 28 Description Part Number Valve Body If you need a new valve body, please order by valve size, serial number and desired material. Seal Retainer See following table Valve Disc Disc/Shaft Assembly, NPS 2 only Seal Ring PTFE NPS 2 75B0387X012 NPS 3 75B0020X012 NPS 4 75B0042X012 NPS 6 75B0003X012 NPS 8 75B0311X012 NPS 10 75B0312X012 NPS 12 75B0313X012 UHMWPE NPS 2 75B0387X022 NPS 3 75B0020X022 NPS 4 75B0042X022 NPS 6 75B0003X022 NPS 8 75B0311X022 NPS 10 75B0312X022 NPS 12 75B0313X022 Glass filled PTFE NPS 2 75B0387X032 NPS 3 75B0020X032 NPS 4 75B0042X032 5* Description NPS 6 NPS 8 NPS 10 NPS 12 NOVEX S31600 SST NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 NOVEX S21800 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 Phoenix III S31600/PTFE NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 Spring S31600 SST NPS 2 NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 R30003 NPS 2 NPS 3 NPS 4 *Recommended spare parts Part Number 75B0003X032 75B0311X032 75B0312X032 75B0313X032 17A7544X022 75B1108X012 75B1109X012 75B1110X012 75B0341X012 75B1112X012 75B1113X012 75B1108X022 75B1109X022 75B1110X022 75B0341X022 75B1112X022 75B1113X022 75B1115X012 75B1116X012 75B1117X012 75B0351X012 75B0337X012 75B0339X012 12A9022X012 75B0021X012 75B0043X012 75B0004X012 75B0012X012 75B0029X012 75B0036X012 12A9022X062 75B0021X052 75B0043X052 Instruction Manual A41 Valve D500211X012 Key 6* 7* 8* 9* 10* 13* Description November 2012 Part Number NPS 6 75B0004X052 NPS 8 75B0012X052 NPS 10 75B0029X052 NPS 12 75B0036X052 Bearing (2 req'd) PEEK/PTFE NPS 2 75B0620X012 NPS 3 CL150 75B1066X012 CL300 75B1073X012 NPS 4 CL150 75B1067X012 CL300 75B1074X012 NPS 6 CL150 75B1068X012 CL300 75B1075X012 PEEK/PTFE NPS 8 CL150 75B1069X012 CL300 75B1076X012 NPS 10 CL150 75B1070X012 CL300 75B1077X012 NPS 12 CL150 75B1071X012 CL300 75B1078X012 316/Nitride NPS 2 75B0599X012 NPS 3 CL150 75B1136X012 CL300 75B1099X012 NPS 4 CL150 75B1136X022 CL300 75B1100X012 NPS 6 CL150 75B1136X032 CL300 75B1101X012 NPS 8 CL150 75B1136X042 CL300 75B1102X012 NPS 10 CL150 75B1136X052 CL300 75B1103X012 NPS 12 CL150 75B1136X062 CL300 75B1104X012 Disc Spacer w/ Metal Bearings, CL150 only (2 req'd) NPS 3 75B1176X012 NPS 4 75B1176X022 NPS 6 75B1176X032 NPS 8 75B1176X042 NPS 10 75B1176X052 NPS 12 75B1176X062 Drive Shaft See following table Hollow Pin See following table Taper Pin See following table Bearing Spacer (2 req'd) w/ Metal Bearings, CL150 only NPS 3 75B1137X012 NPS 4 75B1137X022 NPS 6 75B1137X032 NPS 8 75B1137X042 NPS 10 75B1137X052 NPS 12 75B1137X062 *Recommended spare parts Key 14 14 15* 16* 17 18 19 20 21 22 23 24 25 27* 29 30 Description Part Number Hex Head Cap Screw, Steel Stud Bolt, SST Backup Ring Gasket, Graphite w/ Metal and Phoenix III seals NPS 3 NPS 4 NPS 6 NPS 8 NPS 10 NPS 12 Hex Socket Cap Screw Mfg Label Drive Screw, w/ nameplate Hex Nut Nameplate Lead Seal & Wire Bottom Cap, NPS 12 only Bottom Cap Stud, NPS 12 only Bottom Cap Hex Nut, NPS 12 only Bottom Cap Gasket, NPS 12 only PTFE Graphite Flow Arrow, NPS 3-12 Retainer Clip, NPS 2 only See following table 75B1124X022 75B1124X032 75B1124X042 75B1545X012 75B1545X022 75B1545X032 75B1186X022 75B1186X012 Packing SHAFT DIAMETER VALVE SIZE CL150 CL300 1/2 2&3 2 5/8 4 3 3/4 6 4 1 8 6 1-1/4 10 8 1-1/2 12 10 1-3/4 --- 12 Note Part numbers in this section are listed by shaft diameter (inches). Key 100 101 102 103 105* Description Packing Stud (2 req'd) Packing Nut (2 req'd) Packing Flange Spring Pack Assembly, ENVIRO-SEAL & KALREZr Packing Set PTFE/Carbon filled PTFE 1/2 inch 5/8 inch 3/4 inch 1-inch 1-1/4 inch Part Number 12A9016X022 1R5795X0012 12A8995X022 12A8832X022 12A8951X022 29 Instruction Manual A41 Valve November 2012 Key Description 1-1/2 inch 1-3/4 inch ENVIRO-SEAL PTFE 1/2 inch 5/8 inch 3/4 inch 1-inch 1-1/4 inch 1-1/2 inch 1-3/4 inch ENVIRO-SEAL Graphite 1/2 inch 5/8 inch 3/4 inch ENVIRO-SEAL Graphite 1-inch 1-1/4 inch 1-1/2 inch 1-3/4 inch KALREZ/PTFE 1/2 inch 5/8 inch 3/4 inch 1-inch 1-1/4 inch 1-1/2 inch KALREZ/CRCC 1/2 inch 5/8 inch 3/4 inch 1-inch 1-1/4 inch 1-1/2 inch 106* Anti-Extrusion Ring, ENVIRO-SEAL PTFE 1/2 inch 5/8 inch 3/4 inch 30 D500211X012 Part Number 12A8935X022 12A9057X022 12B7053X012 12B7402X012 12B7414X012 12B7438X012 12B7450X012 12B7462X012 14B3049X012 13B8816X012 13B8816X032 13B8816X052 13B8816X092 13B8816X112 13B8816X142 13B8816X152 24B6254X012 24B6254X022 24B6254X032 24B6254X052 24B6254X062 24B6254X072 24B6255X012 24B6255X022 24B6255X032 24B6255X052 24B6255X062 24B6255X072 12B7054X012 12B7406X012 12B7418X012 Key Description 1-inch 1-1/4 inch 1-1/2 inch 1-3/4 inch 107* Packing Box Ring Standard and ENVIRO-SEAL Packing 1/2 inch 5/8 inch 3/4 inch 1-inch 1-1/4 inch 1-1/2 inch 1-3/4 inch KALREZ 1/2 inch 5/8 inch 3/4 inch 1-inch 1-1/4 inch 1-1/2 inch 108* Packing Ring, Graphite Ribbon 1/2 inch 5/8 inch 3/4 inch 1-inch 1-1/4 inch 1-1/2 inch 1-3/4 inch 111 Tag 114 Packing Follower 115 Packing Washer, Graphite Ribbon 1/2 inch 5/8 inch 1-inch 1-1/4 inch 1-1/2 inch 1-3/4 inch *Recommended spare parts Part Number 12B7442X012 12B7454X012 12B7466X012 14B3045X012 16A6082X012 16A6083X012 16A6084X012 16A6085X012 16A6086X012 16A6087X012 12A9058X012 14B6188X012 14B6190X012 14B6191X012 14B6195X012 14B6197X012 14B6198X012 12A9134X012 12A9135X012 12A9136X012 12A9137X012 12A9138X012 12A9139X012 12A9140X012 14A8362X012 14A9771X012 14A8365X012 14A8366X012 14A8367X012 14A9772X012 Instruction Manual A41 Valve D500211X012 November 2012 Key 2*. Seal Retainer VALVE STYLE VALVE SIZE, NPS MATERIAL Steel CF8M CG8M CN7M CW2M M35-1 PTFE Seal Ring Wafer 2 75B0385X012 75B0385X022 75B0385X032 75B0385X042 75B0385X062 75B0385X052 3 75B0019X012 75B0019X022 75B0019X032 75B0019X042 75B0019X062 75B0019X052 4 75B0041X012 75B0041X022 75B0041X032 75B0041X042 75B0041X062 75B0041X052 6 75B0002X012 75B0002X022 75B0002X032 75B0002X042 75B0002X062 75B0002X052 8 75B0010X012 75B0010X022 75B0010X032 75B0010X042 75B0010X062 75B0010X052 10 75B0027X012 75B0027X022 75B0027X032 75B0027X042 75B0027X062 75B0027X052 12 75B0034X012 75B0034X022 75B0034X032 75B0034X042 75B0034X062 75B0034X052 NOVEX and Phoenix III Seal Ring Wafer 2 21B4667X012 21B4667X022 --- --- --- --- 3 75B1040X012 75B1040X072 75B1040X082 --- --- --- 4 75B1041X012 75B1041X072 75B1041X082 --- --- --- 6 75B1042X012 75B1042X072 75B1042X082 --- --- --- 8 75B1539X012 75B1539X022 75B1539X032 --- --- --- 10 75B1540X012 75B1540X022 75B1540X032 --- --- --- 12 75B1541X012 75B1541X022 75B1541X032 --- --- --- PTFE Seal Ring Single Flange 3 75B0085X012 75B0085X022 75B0085X032 75B0085X042 75B0085X062 75B0085X052 4 75B0078X012 75B0078X022 75B0078X032 75B0078X042 75B0078X062 75B0078X052 6 75B0050X012 75B0050X022 75B0050X032 75B0050X042 75B0050X062 75B0050X052 8 75B0060X012 75B0060X022 75B0060X032 75B0060X042 75B0060X062 75B0060X052 10 75B0067X012 75B0067X022 75B0067X032 75B0067X042 75B0067X062 75B0067X052 12 75B0074X012 75B0074X022 75B0074X032 75B0074X042 75B0074X062 75B0074X052 NOVEX and Phoenix III Seal Ring Single Flange 3 75B1047X132 75B1047X072 75B1047X082 --- --- --- 4 75B1048X132 75B1048X072 75B1048X082 --- --- --- 6 75B1049X132 75B1049X072 75B1049X082 --- --- --- 8 75B1542X012 75B1542X022 75B1542X032 --- --- --- 10 75B1543X012 75B1543X022 75B1543X032 --- --- --- 12 75B1544X012 75B1544X022 75B1544X032 --- --- --- Key 8*. Shaft VALVE SIZE, NPS MATERIAL S17400 H1075 S20910 N08020 N10276 N05500 CL150 2(1) 75B0608X012 75B0608X022 75B0608X032 75B0608X042 75B0608X052 3 75B1105X012 75B1105X072 75B1105X132 75B1105X252 75B1105X192 4 75B1105X022 75B1105X082 75B1105X142 75B1105X262 75B1105X202 6 75B1105X032 75B1105X272 75B1105X152 75B1105X272 75B1105X212 8 75B1105X042 75B1105X102 75B1105X162 75B1105X282 75B1105X222 10 75B1105X052 75B1105X112 75B1105X172 75B1105X292 75B1105X232 12 75B1105X062 75B1105X122 75B1105X182 75B1105X302 75B1105X242 CL300 3 75B1106X022 75B1106X092 75B1106X162 75B1106X302 75B1106X232 4 75B1106X032 75B1106X102 75B1106X172 75B1106X312 75B1106X242 6 75B1106X042 75B1106X112 75B1106X182 75B1106X322 75B1106X252 8 75B1106X052 75B1106X122 75B1106X192 75B1106X332 75B1106X262 10 75B1106X062 75B1106X132 75B1106X202 75B1106X342 75B1106X272 12 75B1106X072 75B1106X142 75B1106X212 75B1106X352 75B1106X282 1. The NPS 2 valve is multi-rated to CL150, 300 and 600. *Recommended spare parts 31 Instruction Manual A41 Valve November 2012 D500211X012 Key 9*. Hollow Pin (2 req'd) VALVE SIZE, NPS CL150 CL300 Shaft Material Shaft Material N08020 N10276 N05500 3 S17400 H1075 & S20910 75B1122X012 N08020 N10276 N05500 75B1122X152 S17400 H1075 & S20910 75B1122X022 75B1122X082 75B1122X222 4 75B1122X022 75B1122X092 75B1122X232 75B1122X092 75B1122X232 75B1122X162 75B1122X162 75B1122X032 75B1122X102 75B1122X242 6 75B1122X032 75B1122X102 75B1122X172 75B1122X242 75B1122X172 75B1122X042 75B1122X112 75B1122X252 8 75B1122X042 75B1122X182 75B1122X112 75B1122X252 75B1122X182 75B1122X052 75B1122X122 75B1122X262 10 75B1122X192 75B1122X052 75B1122X122 75B1122X262 75B1122X192 75B1122X062 75B1122X132 75B1122X272 12 75B1122X202 75B1122X062 75B1122X132 75B1122X272 75B1122X202 75B1122X072 75B1122X142 75B1122X282 75B1122X212 Key 10*. Taper Pin (2 req'd) VALVE SIZE, NPS CL150 CL300 Shaft Material Shaft Material N08020 N10276 N05500 2 S17400 H1075 & S20910 12A9019X072 N08020 N10276 N05500 12A9019X032 S17400 H1075 & S20910 12A9019X072 12A9019X052 12A9019X042 3 19A3749X012 19A3749X042 --- 12A9019X052 12A9019X042 12A9019X032 19A3749X032 F14119X0052 F14119X0062 F14119X0072 4 F14119X0052 F14119X0062 F14119X0072 F14119X0082 F14119X0082 G11299X0032 G1129940092 G1129940152 G1129940022 6 G11299X0032 G1129940092 G11299400152 G1129940022 F13668X0022 F1366840092 F13668X0032 F1366840022 8 F13668X0022 F1366840092 F13668X0032 F1366840022 G13725K0022 G1372540092 G13725X0082 G1372540022 10 G13725K0022 G1372540092 G13725X0082 G1372540022 75B0333X012 75B0333X022 75B0333X032 75B0333X042 12 75B0333X012 75B0333X022 75B0333X032 75B0333X042 75B0334X012 75B0334X022 75B0334X032 75B0334X042 Key 15*. Backup Ring (Use w/ Phoenix III Seal) VALVE SIZE, NPS 32 MATERIAL EPR FKM Fluorocarbon CR Chloroprene Filled Silicone NBR 3 75B1123X022 75B1123X092 75B1123X162 75B1123X502 75B1123X442 4 75B1123X032 75B1123X102 75B1123X172 75B1123X512 75B1123X452 6 75B1123X042 75B1123X112 75B1123X182 75B1123X522 75B1123X462 8 V110611X032 V110611X022 V110611X042 V110611X072 V110611X062 10 75B0344X012 75B0344X022 75B0344X032 75B0344X062 75B0344X052 12 75B0340X012 75B0340X022 75B0340X032 75B0340X062 75B0340X052 *Recommended spare parts Instruction Manual A41 Valve D500211X012 November 2012 Figure 12. Wafer Valve Assembly for the NPS 3 through 12 ALLOY FOLLOWER ASSY PTFE SEAL METAL BEARING CL150 NOVEX SEAL SIZE 12 CL300 PHOENIX III SEAL NOTE: KEYS 21, 22, AND 28 ARE NOT SHOWN. 75B0094-B 33 Instruction Manual A41 Valve November 2012 D500211X012 Figure 12. Wafer Valve Assembly for the NPS 3 through 12 (continued) 34B5064-A GRAPHITE PACKING ALLOY FOLLOWER ASSY PTFE SEAL METAL BEARING CL150 NOVEX SEAL PHOENIX III SEAL NOTE: KEYS 21, 22, AND 28 ARE NOT SHOWN 75B0096-B 34 SIZE 12 CL300 Instruction Manual A41 Valve D500211X012 November 2012 Figure 13. Valve Assembly for NPS 2 GRAPHITE PACKING 34B5064-A TWO PIECE FOLLOWER PTFE SEAL METAL SEAL NOTE: PARTS 21 AND 22 NOT SHOWN 75B0625 35 A41 Valve November 2012 Instruction Manual D500211X012 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 and ENVIRO-SEAL 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. KALREZ is a mark owned by E.I. DuPont De Nemours 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 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. 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 36 E 1994, 2012 Fisher Controls International LLC. All rights reserved.
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