Emerson 1808 Series Relief Valve or Backpressure Regulators Instruction Manual
Contents
1. SPRING DIAPHRAGM as LO VALVE PLUG MAIN VALVE Figure 2 Type 1808 with 6358 Series Operational Schematics Relief Valve As long as the inlet pressure is below set pressure the pilot control spring keeps the valve plug closed Inlet pressure passes through the pilot restriction and registers as loading pressure on top of the diaphragm Force from the main spring in addition to inlet pressure bleeding through the pilot restriction provide downward loading pressure to keep the main valve closed When the inlet pressure rises above the set pressure the pressure on the pilot diaphragm overcomes the pilot control spring and opens the pilot valve plug The pilot then exhausts the loading pressure from the top of the main valve diaphragm The pilot continuously exhausts gas when the inlet pressure is above the set pressure The inlet pressure unbalance overcomes the main spring force and opens the main valve As the inlet pressure drops the pilot control spring begins to close the pilot valve plug and the exhaust slows This causes the inlet pressure to build in the main valve diaphragm casing allowing the control spring to close the main valve Once the main valve is closed the pilot valve plug closes and the exhaust stops Backpressure Regulator As long as inlet pressure remains below setpoint the pilot spring keeps the valve p2. Fit the upper casing key 1 in place and install the cap screws key 15 and hex nuts key 16 Tighten the hex nuts in a crisscross pattern with approximately 15 foot pounds 20 Nem of torque Install the O rings keys 9 10 and 11 and back up rings key 19 into place on the valve plug key 6 Slide the valve plug key 6 and O ring retainer key 7 over the cap screw key 13 Tighten the hex nuts key 14 against the O ring retainer with approximately 5 to 7 foot pounds 6 8 to 9 5 Nem of torque Note Before performing step 7 it is recommended that the gaskets key 21 be replaced Fit the lower casing into the valve body aligning the cap screws key 17 with the holes in the body Tighten the hex nuts key 18 using approximately 20 foot pounds 27 Nem of torque Replace the pilot and tubing if removed When all maintenance is complete perform the Startup procedure if the unit will immediately be returned to service Types 6358 and 6358B Pilots This procedure is performed if inspecting or replacing any pilot parts Key numbers are shown in Figure 6 Note All pilot maintenance may be performed with the pilot body key 1 attached to the pipe nipple unless the body is removed or the entire pilot replaced as a unit If only the control spring key 7 or spring seat key 8 needs to be replaced perform only steps 1 2 and 6 below Remove the closing cap key 12 loosen the
3. a vent valve When all pressure has been released tighten the fitting Backpressure Installations Slowly close the upstream shut off valve while opening the bypass valve if an isolating bypass is used Then close the downstream shut off valve and open both vent valves to release all pressure from the main valve and pilot Types 1808 and 1808A Maintenance Parts are subject to normal wear and must be inspected and replaced as necessary Frequency of inspection and maintenance depend upon severity of service conditions The main valve body need not be removed from the line prior to maintenance Avoid personal injury or property damage from sudden release of pressure or explosion of accumulated gas Before starting disassembly isolate the relief valve or backpressure regulator from line pressure release trapped pressure from the body and any isolated piping and vent any trapped loading pressure Main Valve This procedure is performed when inspecting cleaning or replacing any main valve parts Key numbers are referenced in Figures 3 and 4 Note If the trim is to be inspected and no further maintenance is required it is unnecessary to remove the pilot from the upper casing key 1 or separate the upper casing from the lower casing key 2 Disassembly 1 Remove the two hex nuts key 18 from the cap screws key 17 that hold the lower casing key 2 to the body key 8 2 Lift the lower casing away from the
4. locknut key 11 and turn the adjusting screw key 10 counterclockwise to remove the spring compression Remove the machine screws key 17 spring case key 2 control spring key 7 and spring seat key 8 from the body Remove the connector cap and gasket from the top of the diaphragm assembly key 5 and then remove the valve spring key 14 Unclip the E ring if used and remove the diaphragm assembly Remove the stem guide key 9 to gain access to the valve plug key 4 and the O ring key 37 if used Make sure the restriction or restriction plug key 20 registration hole and valve plug seating surfaces are free from debris Inspect and replace parts as necessary making sure that the restriction or restriction plug and valve plug key 4 are installed and then secure the valve plug with the stem guide key 9 With a Type 6358 pilot coat the restriction plug threads with a good quality sealant before installation Install the diaphragm plate connector portion of the diaphragm assembly key 5 clip the E ring if used to the grooved end of the valve plug key 4 and install the valve plug spring key 14 connector cap gasket key 36 and connector cap key 6 into the top of the diaphragm assembly connector Install the control spring key 7 spring seat key 8 spring case key 2 and machine screws key 17 After assembly make sure of the proper control spring setting according t
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6. body 3 With the lower casing positioned so that the valve plug key 6 is accessible remove the hex nut key 14 4 Remove the O ring retainer key 7 the valve plug key 6 the O rings keys 9 10 and 11 and the back up rings key 19 5 Inspect the O rings and back up rings and replace as necessary Check all parts for wear 6 If no further maintenance is required proceed to steps 5 through 8 of the Assembly section If maintenance inside the casings is required proceed with the following steps Types 1808 and 1808A Disconnect the pilot tubing and unscrew the pilot from the upper casing key 1 Remove the cap screws key 15 and the hex nuts key 16 holding the upper casing key 1 and the lower casing key 2 together Lift off the upper casing and remove the spring key 12 10 Remove the upper hex nut key 14 holding the upper diaphragm plate key 4 lower diaphragm plate key 5 and diaphragm key 3 together Slide the upper and lower diaphragm plates and the diaphragm off the cap screw key 13 Assembly 1 Assemble the upper diaphragm plate key 4 the diaphragm key 3 and the lower diaphragm plate key 5 on the cap screw key 13 Tighten the upper hex nut key 14 against the lower diaphragm plate key 5 with approximately 5 to 7 foot pounds 6 8 to 9 5 Nem of torque Position the diaphragm so that its holes align with those in the lower casing key 2
7. 8M Stainless steel Aluminum 2 Spring Case 316 Stainless steel Aluminum 3 Body Plug 316 Stainless steel Aluminum 4 Valve Plug 303 Stainless steel Nitrile NBR standard UHMWPE 5 Diaphragm Assembly Steel Nitrile NBR standard Steel Neoprene CR Steel Fluorocarbon FKM Steel Nitrile NBR for Type 6358B only 2 to 10 psig 0 14 to 0 69 bar Recommended spare part Inconel is a marked owned by Special Metals Corporation 10 Part Number 1E312414012 1E3124xX0022 1E312606992 1E312514012 1E3125xX0022 1J500218992 1J500209012 1J500018992 1J500010062 1H885128982 1F826804022 1U7581X0022 Part Number 39A5972X012 39A0138X012 28A9277X012 25A6220X012 1B797535072 1B797509032 14B6372X012 16A2924X012 15A6216X072 15A6216X212 15A6216X172 15A6216X182 Key Description 6 Connector Cap 18 8 Stainless steel 316 Stainless steel 7 Spring 3 to 18 psig 0 21 to 1 2 bar Green 15 to 40 psig 1 0 to 2 8 bar Yellow 35 to 125 psig 2 4 to 8 6 bar Red Spring Seat Steel Stem Guide 416 Stainless steel standard 174 Stainless steel 10 Adjusting Screw Zinc plated steel 11 Locknut Steel 12 Closing Cap Plastic 303 Stainless steel 13 Body Plug Gasket Composition 14 Valve Spring 302 Stainless steel standard Inconel 16 Vent Assembly 2 required 17 Machine Screw 6 required Stainless steel Steel 20 Restriction Type 6358 Steel Stainless steel Type 6358B High Gain Yel
8. Instruction Manual Form 5116 July 2010 Types 1808 and 1808A Types 1808 and 1808A Pilot Operated Relief Valves or Backpressure Regulators Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion and or fire causing property damage and personal injury or death Fisher backpressure regulators or relief valves must be installed operated and maintained in accordance with federal state and local codes rules and regulations and Emerson Process Management Regulator Technologies Inc instructions If a leak develops or if the outlet continually vents gas service to the unit may be required Failure to correct trouble could result in a hazardous condition Only a qualified person must install or service the unit Call a gas service person to service the unit Only a qualified person must install or service the regulator Introduction Scope of the Manual This manual provides installation adjustment maintenance and parts ordering information for Types 1808 and 1808A pilot operated relief valves or backpressure regulators The manual also includes coverage of the Types 6358 and 6358B pilots and if used a P590 Series filter Instructions and parts lists for other equipment used with these regulators are found in separate manuals Description Types 1808 globe body and 1808A angle body pilot operated backpressure regulators or relief valves www fisher
9. Ring Nitrile NBR O Ring Nitrile NBR Recommended spare part Part Number R1808X00012 25A7831X012 25A7828X012 10A0288X012 15A7834X012 14A9681X012 15A7826X012 15A7827X012 25A7830X012 25A7926X022 37A7694X012 15A8508X012 10628006992 1F358106992 Types 1808 and 1808A Key Description Part Number 12 Spring Zinc plated steel 15A8775X012 13 Cap Screw Zinc plated steel 15A7839X012 14 Hex Nut Steel 2 required 1V136228982 15 Cap Screw Zinc plated steel 12 required 1E760324052 16 Hex Nut Zinc plated steel 12 required 1A346524122 17 Cap Screw Zinc plated steel 2 required Type 1808 15A7835X012 Type 1808A 17A9766X012 18 Hex Nut Zinc plated steel 2 required 1E944524112 19 Back up Ring Polytetrafluoroethylene PTFE 2 required 1U529406992 20 Valve Plug Guide Stainless steel 15A7832X012 21 Gasket Nitrile NBR 2 required 15A7836X012 36 Elbow Copper Tube eee eee Steel Tube we eee ener Stainless steel wwe weer ener 36 Pipe Plug Steel with upstream registration Pilot Mounting Parts Key Description Part Number 21 Filter Standard Brass Type P594 1 Corrosive Aluminum Type P593 1 Corrosive NACE Brass Type P593 1 22 Pipe Nipple Galvanized steel standard Zinc plated steel NACE www ee eee eee 24 Pipe Tee Malleable iron standard ww ww 316 Stainless steel NACE 25 Connector Fitting Without upstream registration Withou
10. e to monitor inlet pressure On backpressure applications using an isolating bypass open the downstream shut off valve and close the bypass valve 2 If set pressure adjustment is necessary adjust a Type 6358 or 6358B pilot by following the procedures in the adjustment section Adjustment The allowable spring range is stamped on the nameplate Ifa pressure setting beyond the indicated range is required substitute the appropriate spring Be sure to label the valve to indicate the new pressure range Always use a pressure gauge to monitor pressure when making adjustments Remove the closing cap key 12 Figure 6 then loosen the locknut key 11 To increase the setting turn the adjusting screw key 10 clockwise Turn the adjusting screw counterclockwise to decrease the setting Tighten the locknut to maintain position and install closing cap To avoid personal injury or equipment damage never adjust the pilot control spring to produce a set pressure higher than the upper limit of the set pressure range for that particular spring Set pressure is defined as the pressure at which the pilot starts to discharge Each unit is factory set for the set pressure specified on the order If no set pressure is specified the unit is factory set at approximately the midrange of the spring Shutdown Relief Installations Slowly close the upstream shut off valves Release all pressure from the main valve and pilot by opening
11. es Inc USA Headquarters McKinney Texas 75069 1872 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Singapore Singapore 128461 Tel 65 6777 8211 Europe Bologna Italy 40013 Tel 39 051 4190611 Gallardon France 28320 Tel 33 0 2 37 33 47 00 TESCOM Emerson Process Management Tescom Corporation USA Headquarters Elk River Minnesota 55330 2445 USA Tel 1 763 241 3238 Europe Selmsdorf Germany 23923 Tel 49 0 38823 31 0 The Emerson logo is a trademark and service mark of Emerson Electric Co All other marks are the property of their prospective owners Fisher is a mark owned by Fisher Controls Inc a business of Emerson Process Management 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 We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Emerson Process Management product remains solely with the purchaser Emerson Process Management Regulator Technologies Inc 1978 2010 All Rights Reserved
12. f vented gas or liquid that has accumulated To prevent such injury and damage provide piping or tubing to vent the gas to a well ventilated location Also when venting a hazardous gas or liquid piping or tubing should be located far enough from any buildings or windows so as not to create a further hazard Protect the main valve body pilot exhaust and pilot spring case vent against anything that could clog them For safety during shutdown of backpressure regulators install vent valves immediately upstream and downstream of the main valve 4 The pilot exhaust may be piped directly into the main valve outlet if the exhaust is to be retained as in liquid service or vented to the atmosphere In either case the diameter of the exhaust line or stack should be as large as practical with a minimum number of bends or other restrictions When installing this unit in relief service be sure to consider the jet thrust effect that will occur when it relieves Overpressure Protection Relief ranges are from 3 to 125 psig 0 21 to 8 6 bar The individual spring range of your relief valve is stamped on the nameplate Maximum inlet pressures depend upon body material and temperature See the Specifications section for the maximum inlet pressure of the valve The valve should be inspected for damage after any overpressure condition Startup 1 With installation completed slowly open the upstream shut off valve while using a gaug
13. low Steel Stainless steel 20 Restriction Type 6358B Medium Gain Steel Red Low Gain Steel Blue 36 Gasket Fluorocarbon FKM 2 required 37 O ring Nitrile NBR Fluorocarbon FKM Part Number 16A2921X012 16A2921X022 1B986027212 1E392527022 1K748527202 1B798525062 16A2923X012 16A2923X022 10B7192X012 1A946324122 23B9152X012 1H2369X0032 10495704022 1E701337022 19A8179X012 Type Y602 12 10B6189X022 1V4360X0022 1A346128982 1V7435xX0012 17A7279X012 17A7279X032 17A2029X012 17A7277X012 1U1716X0012 16A2920X012 16A2920X022 Types 1808 and 1808A 12 11 10 e 16 14 4 4 1 37 13 3 _ TYPE 6358 PILOT INTERIOR VIEW 10 12 19 11 14 37 A 5 D TE B2619 2 TYPE 6358B PILOT INTERIOR VIEW Figure 6 Types 6358 and 6358B Pilot Assemblies Types 1808 and 1808A Industrial Regulators Emerson Process Management Regulator Technologies Inc USA Headquarters McKinney Texas 75069 1872 USA Tel 1 800 558 5853 Outside U S 1 972 548 3574 Asia Pacific Shanghai China 201206 Tel 86 21 2892 9000 Europe Bologna Italy 40013 Tel 39 051 4190611 Middle East and Africa Dubai United Arab Emirates Tel 971 4811 8100 For further information visit www fisherregulators com Natural Gas Technologies Emerson Process Management Regulator Technologi
14. lug closed Inlet pressure passes through the upper port around the upper portion of the valve plug then through the hollow passage in that valve plug Force from the main spring along with inlet pressure bleeding through the pilot provide downward loading pressure to keep the main valve closed When inlet pressure rises above the set pressure pressure on the pilot diaphragm overcomes the control spring to close the upper port and stroke the valve plug to open the lower port The pilot then exhausts loading pressure from the top of the main valve diaphragm The pilot exhausts only while repositioning the main valve The inlet pressure unbalance overcomes the spring force and opens the main valve As the inlet pressure drops the pilot control spring begins to close the pilot valve plug and the exhaust slows This causes the inlet pressure to build in the main valve diaphragm casing allowing the control spring to close the main valve Once the main valve is closed the pilot valve plug closes and the exhaust stops Types 1808 and 1808A Installation Installing a Type 1808 or 1808A where its capabilities can be exceeded or where proper operation might be impaired may cause personal injury property damage or leakage due to bursting of pressure containing parts or explosion of accumulated gas or liquid To avoid such conditions install the Type 1808 or 1808A backpressure regulator or relief valve where service conditions are within
15. o the Adjustment section and remark the nameplate if necessary P590 Series Filter This procedure is to be performed if it is necessary to clean or replace filter parts in a Type P593 1 or P594 1 filter assembly 1 Remove the following as shown in Figure 5 filter body key 1 machine screw key 4 spring washer key 6 gasket key 7 two flat washers key 5 and filter element key 2 2 Upon reassembly one of the flat washers must go between the filter element and filter head key 3 and the other must go between the filter element and gasket 3 Use pipe thread sealant on the filter head pipe threads Parts Ordering When corresponding with your local Sales Office about this equipment always reference the equipment serial number or FS number that can be found on the nameplate When ordering replacement parts reference the 11 character key number of each needed part as found in the following parts list Separate kits containing all recommended spare parts are available Parts List Main Valve Types 1808 and 1808A Key 3 6 gt 10 11 Description Parts Kit includes keys 3 9 10 11 19 and 21 Upper Casing Steel Lower Casing Steel Diaphragm Assembly Nitrile NBR Upper Diaphragm Plate Zinc plated steel Lower Diaphragm Plate Zinc plated steel Valve Plug Stainless steel O Ring Retainer Steel Body Type 1808 Cast iron WCC Steel NACE Type 1808A Cast iron O Ring Nitrile NBR O
16. regulators com wa716 TYPE 1808 GLOBE BODY TYPE 1808A ANGLE BODY Figure 1 Types 1808 and 1808A Pilot Operated Relief Valves or Backpressure Regulators are economical compact devices used in either gas or liquid service to maintain pressure on oil and gas separators and in pressure relief applications in gas distribution systems The Type 6358 pilot is used in backpressure regulation and pressure relief applications throughout the oil and gas production industry and is used in either gas or liquid service Pressure relief and liquid service applications in amp EMERSON Process Management D100347X012 Types 1808 and 1808A Specifications Body Size and End Connection Style 2 NPT Maximum Relief Inlet Pressure 150 psig 10 3 bar including buildup Set Pressure Ranges See Table 1 Differential Pressures Maximum 125 psig 8 6 bar Minimum 5 psig 0 34 bar Type 6358 Pilot Bleed Bleeds only when repositioning the main valve Type 6358B Pilot Bleed Continuously bleeds while inlet pressure is above set pressure Flow and Sizing Coefficients See Table 2 Pressure Registration Internal standard or External optional Pilot Tubing and Connections 1 4 NPT with or without P590 Series filter Temperature Capabilities 20 to 180 F 29 to 82 C Approximate Weights Type 1808 22 pounds 10 kg Type 1808A 25 pounds 11 kg Options e Upstream control line construction e Press
17. t Filter Steel standard sis wee ee errr 316 Stainless steel NACE 26 Elbow Fitting Without upstream registration With Filter Standard ee ene ener 316 Stainless steel NACE 27 Vent Assembly Type Y602 11 28 Tubing 316 Stainless steel without upstream registration 29 Gauge 0 to 160 psig O to 11 0 bar 0 to 1 1 MPa 11B8579X042 29 Pipe Plug Zinc plated steel NACE 316 Stainless steel NACE Types 1808 and 1808A E 20909006 l Figure 3 Type 1808A Assembly 21 Types 1808 and 1808A cz d 12 of 1 oO Jo 8 13 15 4 19 2 36 5 h E 17 7 j lt 18 20 9 14 7 8 Figure 4 Type 1808 Assembly NSAN p a we K ie J p oe Ne Figure 5 P590 Series Filter Assembly Types 1808 and 1808A P590 Series Key Description 1 Filter Body Type P594 1 Brass Type P593 1 NACE Aluminum 2 Filter Element Cellulose 3 Filter Head Type P594 1 Brass Type P593 1 NACE Aluminum 4 Machine Screw Type P594 1 Brass Type P593 1 NACE Aluminum 5 Washer 2 required Type P594 1 Brass Type P593 1 Aluminum 6 Spring Washer Steel 7 Gasket Composition 12 Seal Wire 304 Stainless Steel for Type P593 1 NACE only Types 6358 and 6358B Pilots Key Description 1 Body CF
18. the unit capabilities given in the Specifications section and unit is protected from exposure to physical damage and or corrosive substances 1 When installing the relief valve or backpressure regulator make sure that the system installation complies with applicable local state and federal codes and regulations Use qualified personnel when installing operating and maintaining the relief valve or backpressure regulator Before installing the unit inspect the main valve body pilot and pipelines for any damage or foreign material that may have collected Apply pipe compound to the external pipeline threads only Do not use pipe compound on any internal threads The relief valve or backpressure regulator may be installed in any position as long as pipeline flow complies with the flow arrow on the main valve body Type 1808 or runs in through the bottom connection and out the side connection Type 1808A Superior performance may be obtained by disconnecting the pilot supply tubing from the elbow key 36 Figures 3 and 4 removing the elbow installing 1 4 NPT pipe plug into the lower casing key 2 and connecting the pilot supply tubing to an upstream location Types 1808 and 1808A relief valves or backpressure regulators vent gas or liquid from the main valve outlet pilot exhaust and pilot vent In hazardous or flammable gas or liquid service personal injury or property damage may occur due to fire or explosion o
19. ure gauge 0 to 160 psig O to 11 0 bar 0 to 1 1 MPa e P590 Series Pilot Supply Filter 1 The pressure temperature limits in this Instruction Manual and any applicable standard or code limitation should not be exceeded Table 1 Types 6358 and 6358B Set Pressure Ranges Pressure Ratings and Pilot Spring Information PILOT SPRING INFORMATION SET PRESSURE RANGES PSIG bar Part Number Color 3 to 18 0 21 to 1 2 1B986027212 Green 15 to 40 1 0 to 2 8 1E392527022 Yellow 35 to 125 2 4 to 8 6 1K748527202 Red Wire Diameter Free Length Inches mm Inches mm 0 120 3 05 2 12 54 0 0 148 3 76 2 00 51 0 0 192 4 88 2 19 55 6 Table 2 Types 1808 and 1808A Flow Coefficients FLOW COEFFICIENTS IEC SIZING COEFFICIENTS TYPE WIDE OPEN K c 1808 1410 40 1 0 79 35 2 0 78 0 50 0 89 1808A 1800 51 4 0 76 35 0 0 78 0 50 0 87 the oil and gas industry are typically handled by the Type 6358B pilot With either pilot the set pressure is varied to individual requirements by the adjusting screw on the pilot Pilot exhaust can be piped into the downstream line or vented into the atmosphere on gas service and should be piped downstream or to a safe location on liquid service Specifications The Specifications section provides ratings and specifications for Types 1808 and 1808A relief valves or backpressure regulators Some of the specifications for a gi
20. ven unit as it comes from the factory appear on the nameplate attached to the upper diaphragm case The Type 6358B pilot restriction 2 diameter is indicated by a letter stamped on the bottom of the pilot body next to the tapped side outlet an H for the yellow high gain restriction and an L for the blue low gain restriction The pilot spring range appears on the pilot spring case Principle of Operation A pressure relief valve is a control device that opens to relieve fluid to atmosphere during an overpressure occurrence A backpressure regulator is a control device that maintains a constant upstream pressure throughout a given flow range It functions in the same manner as a relief valve that opens on increasing upstream pressure The Type 1808 or 1808A cannot be used as an ASME safety relief valves UPPER PORTION OF VALVE PLUG DIAPHRAGM TO EXHAUST ASSEMBLY PORT HOLLOW PASSAGE IN VALVE PLUG STEM LOWER PORTION OF VALVE PLUG TO MAIN VALVE DIAPHRAGM RESTRICTION PLUG TYPE 6358 BACKPRESSURE SERVICE UPPER PORTION OF VALVE PLUG TO EXHAUST PORT DIAPHRAGM ASSEMBLY HOLLOW PASSAGE IN VALVE PLUG STEM LOWER PORTION OF VALVE PLUG TO MAIN VALVE DIAPHRAGM FIXED RESTRICTION TYPE 6358B RELIEF SERVICE Gly INLET PRESSURE ATMOSPHERIC PRESSURE OUTLET EXHAUST PRESSURE LOADING PRESSURE E0075 Types 1808 and 1808A f PILOT EXHAUST
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