Emerson Process Management 99 User's Manual
Contents
1. EHE INLET PRESSURE E OUTLET PRESSURE G tE LOADING PRESSURE C ATMOSPHERIC PRESSURE A6814 Type 99 OUTLET PIPE Figure 2 Schematic of Type 99 Regulator with Type 61L Low Pressure Pilot Principle of Operation The key to the operation of a Type 99 regulator is the yoked double diaphragm pilot letter keys in this section refer to both Figures 2 and 3 unless otherwise noted Fast response and accuracy are made possible by the amplifying effect of the pressure balanced pilot and by the two path control system The function of the pilot is to sense change in the controlled pressure and amplify it into a larger change in the loading pressure Any changes in outlet pressure act quickly on both the actuator diaphragm and the loading pilot thus providing the precise pressure control that is characteristic of a two path system A typical pilot has an approximate gain of 20 which means the outlet pressure needs to droop only 1 20 as much as a self operated regulator in order to obtain the same pressure differences across the main diaphragm Advantages of a pilot operated regulator are high accuracy and high capacity Upstream or inlet pressure is utilized as the operating medium which is reduced through pilot operation to load the main diaphragm chamber Tubing connects the inlet pressure to the pilot through a filter assembly Downstream or outlet pressure registers underneath the main diaphragm E through the dow2. 303 Stainless steel Pilot Body Cast iron Diaphragm Neoprene CR Fluorocarbon FKMyDacron Diaphragm Plate 416 Stainless steel 4 required Control Spring Plated steel blue Spring Case Cast iron Standard Part Number 1D692214012 15A6002X602 15A6002XW22 1A930424052 1B860828992 13A9837X012 1D318135032 33A9845X012 13A9841X022 13A9841X012 13A9839X012 1D387227022 2P969419012 19 Type 99 Type 61HP Extra High Pressure Pilot EI CODESERDHOR Part Number Figure 12 continued Ld ae Brass 1D904914012 T 303 Stainless steel 1D904935072 lla ana Pare Numer 119 Relief Valve Body 45 Adjusting Screw Plated carbon steel Brass 1D904814012 Standard 10216032992 316 Stainless steel 1D904835072 47 Cap Screw Plated steel 8 required 1B787724052 120 Spring Seat 49 Relief Valve Spring 316 Stainless steel 1C374037022 Brass 1K377718992 50 Relief Valve Plug 316 Stainless steel 1K377535162 SHETE 1K377735072 52 Bleed Orifice 121 Spring Seat Washer Brass 1B329014012 Brass 1B495118992 53 Loading Tubing 316 Stainless steel 1K377835072 For use with all standard regulators 122 Pipe Bushing Carbon plated steel 10379026232 Copper 1D7702000A2 123 Cap Screw Plated steel 6 required 1P327028982 317 Stainless steel 0500213809W 124 Valve Spring 316 Stainless steel 1B797937022 For use with 1000 psig 69 0 bar maximum n Flange Adaptor Steel 23A9846X012 inlet regulator Steel 1K5466X0042 126 Gasket Composition 0U0365X0032 55 P
3. 14500010062 1H885128982 1F826804022 Pilot and Tubing Parts Low or High Pressure Pilot Figure 9 Key 13 23 24 30 31 Description Hex Nut Plated steel 13 required Elbow 2 required Brass 316 Stainless steel Pilot Supply Tubing disk or O ring main valve seat Copper Copper for oxygen service 316 Stainless steel Upper Relay Diaphragm Nitrile NBR Fluorocarbon FKM Upper Relay Diaphragm Plate Plated steel For use with all low pressure pilots except LE For use with all high pressure pilots and LE low pressure pilot Part Number 1A340324122 15A6002X292 15A6002X612 1D8793000A2 0500201701W 0500213809W 1B885202052 1N162802332 1B989225072 1D558425072 17 Type 99 Pilot and Tubing Parts Low or High Pressure Pilot Figure 9 continued Key 33 34 37 38 39 40 41 42 43 44 45 46 47 48 Description O ring Seal Nitrile NBR Fluorocarbon FKM Connector Brass 316 Stainless steel Yoke Zinc Relay Orifice Stainless steel For use with 25 psi 1 72 bar maximum allowable pressure drop actuator main spring For use with all other main springs For use with oxygen service Relay Valve Body Cast iron Lower Relay Diaphragm Low pressure pilot Nitrile NBR Fluorocarbon FKM High pressure pilot Nitrile NBR Fluorocarbon FKM Lower Relay Diaphragm Plate Plated steel Low pressure pilot High pressure pilot Spring Seat Plated
4. Type 61L 61LD 61LE Low or 61H High Pressure Pilots This procedure is to be performed if changing the control spring for one of a different range or if inspecting cleaning or replacing any other pilot parts Key numbers are referenced in Figure 9 1 Remove the closing cap key 46 if used and unscrew the adjusting screw key 45 to relieve control spring compression 2 Disconnect the loading tubing key 53 and pilot supply tubing key 24 3 Unscrew the eight cap screws key 47 and remove the pilot assembly from the lower casing key 29 4 Use the projecting prong in the relay valve body key 39 as the restraining member and remove the diaphragm nuts keys 13 and 51 Separate the parts and inspect the diaphragms keys 30 and 40 and O ring seal key 33 Replace if worn or damaged 5 Unscrew the bleed orifice key 52 from the yoke key 37 Also removed with the bleed orifice are the relay disk assembly key 48 and bleed valve key 50 These parts can be unscrewed for inspection and replacement if necessary 6 When reassembling the pilot the relay disk holder assembly and both diaphragms should be tightened on the yoke after it is placed in the body Note Before putting the relay spring case over the diaphragm make certain the yoke is square with respect to the prong in the relay body The yoke can bind on the prong if it is not square 7 Use care in reassembly to be sure the edges of the di
5. seal washers and the flange adapter Unscrew the relief valve body key 119 and remove a diaphragm plate diaphragm and another diaphragm plate Inspect the diaphragm inserts key 150 and both diaphragms Replace if worn or damaged The relief valve assembly can be further disassembled for inspection by unscrewing the relief valve cap key 118 8 Four machine screws key 130 hold both yoke caps keys 37 and 116 to the yoke legs key 31 Separate these parts to expose the pilot valve 9 Unscrew the inlet orifice key 38 to inspect its seat the inlet valve plug key 117 and valve spring key 124 Note Make certain that the yoke assembly is square with respect to the cross member of the body casting so that it will not bind on the body 10 When reassembling screw in the inlet orifice all the way and secure the yoke caps to the yoke legs Replace two diaphragm plates the diaphragms and inserts two more diaphragm plates the hex nut and the relief valve assembly 11 Assemble the control spring and spring seat into the body and spring case being careful that the diaphragms are free of wrinkles and properly in place and evenly installing the cap SCrews in a crisscross pattern to avoid placing a strain on the unit Install the body flange adapter with seal washers and cap screws Install a new gasket and secure the pilot to the lower casing with eight cap screws Set the control spring according to the
6. Stainless steel 5 Diaphragm Rod Guide Assembly Brass with bronze insert 316 Stainless steel 6 Collar Brass 316 Stainless steel 7 Pusher Post Gasket Composition for standard construction Fluorocarbon FKM for oxygen service 8 Pusher Post Assembly Brass with bronze insert 316 Stainless steel 316 Stainless steel for oxygen service 9 Lever Steel 10 Diaphragm Plate Plated steel 11 Diaphragm Nitrile NBR Fluorocarbon FKM 12 Cap Screw Plated steel 12 required 13 Hex Nut Plated steel 13 required 14 Union Nut Iron 15 Body Snap Ring Plated steel 16 Body Gasket Composition Graphite for oxygen service 17 Valve Body 2 inch NPT Cast iron Steel Brass Brass for oxygen service 2 inch DN 50 CL125 FF flanged Cast iron 2 inch DN 50 CL250 RF flanged Cast iron Recommended Spare Parts IIIT Rey 7 LUBRICANT Part Number 1C277127022 1N801927022 1B883327022 0W019127022 1B883435232 1D9712000A2 1B883535072 1B883614012 1B883635072 1B883704022 1N430306382 1D9714000A2 1B883835072 14B1320X012 2F823423072 1B989225072 1B884102052 1N378902312 1B884224052 1A340324122 0Z20176X0032 0Y095828982 1A348004032 1A3480X0022 1C254619012 2N153522012 1C254612012 1C2546X0012 2D986519012 2D986619012 Type 99 r wv FF AL y A LLL G ANT D V a ANNAN EE 82 v8 Figure 8 O ring Sealed Handwheel Bae E
7. a hazard in enclosed conditions such as in a pit underground or indoors the relief valve must be repiped to carry the gas to a safe location A regulator may vent some gas to the atmosphere in hazardous or flammable gas service vented gas might accumulate and cause personal injury death or property damage due to fire or explosion Vent a regulator in hazardous gas service to a remote safe location away from air intakes or any hazardous location The vent line or stack opening must be A repiped vent line or stack must be protected against condensation located to avoid venting gas near or clogging buildings air intakes or any hazardous Type 99 Table 4 Working Monitor Performance MONITORING PILOT INFORMATION Pilot Spring Construction Spring Range Wire Diameter Free Length Part Number Inches cm Inches cm 5 to 15 inches w c 12 to 37 mbar 1B653927022 0 105 0 27 3 3 4 9 52 1B537027052 0 114 0 29 11 to 28 inches w c 27 to 70 mbar 4 5 16 11 0 1B537127022 1B537227022 1B537327052 1D892327022 1D751527022 1D665927022 1D755527142 1E543627142 MINIMUM PRESSURE AT WHICH WORKING MONITOR REGULATOR CAN BE SET 3 inches w c 7 mbar over normal distribution pressure 0 5 psi 0 03 bar over normal distribution pressure Type 161AYW with 1 8 inch 3 18 mm port diameter and 150 psig 10 3 bar maximum allowable inlet pressure 1 to 2 5 psig 0 069 to 0 17 bar 2 25 to 4 5 psig 0 16 to
8. adjustment information in the Startup section Converting the Pilot Note A complete pilot assembly rather than individual parts may be ordered for the following conversion procedure When a low pressure pilot is ordered for field conversion of a high pressure pilot or vice versa the replacement pilot assembly comes complete with a pilot cover key 132 Figure 9 Remove this cover before installing replacement pilot on the existing regulator The cover can then be installed on the removed pilot to form a complete Type 61 low or high pressure pilot for use elsewhere When changing one pilot construction low pressure high pressure or extra high pressure for another all parts attached to the lower casing key 29 Figure 9 may need to be replaced with those appropriate for the desired construction At the very least when changing from a Type 99 low to high pressure pilot or vice versa everything below the lower pilot diaphragm key 40 Figure 9 except the cap screws and the hex nut keys 47 and 13 Figure 9 will need to be replaced Actuator and main valve parts may remain unchanged unless a change in service conditions requires a change in seat construction main spring or main spring seat See the Parts List sections for obtaining the appropriate conversion parts Main Valve Trim with Disk or O ring Seat This procedure is to be performed if inspecting cleaning or replacing trim parts Part key numbers for a Typ
9. due to the pipe arrangement it may be better to make the control line tap nearer the regulator outlet rather than downstream of a block valve Do not make the tap near any elbow swage or nipple which might cause turbulence In many instances it will be necessary to enlarge the downstream piping to keep flow velocities within good engineering practices Expand the piping as close to the regulator outlet as possible Adjustment of the pilot control spring to produce an outlet pressure higher than the upper limit of the outlet pressure range for that particular spring can cause personal injury or equipment damage due to bursting of pressure containing parts or the dangerous accumulation of gases if the maximum actuator emergency casing pressure in the Specifications section is exceeded If the desired outlet pressure is not within the range of the pilot control spring install a spring of the proper range according to the Maintenance section Each regulator is factory set for the pressure setting specified on the order If no setting was specified outlet pressure was factory set at the midrange of the pilot control spring In all cases check the control spring setting to make sure it is correct for the application Startup Key numbers are referenced in Figure 9 for a low or high pressure pilot and in Figure 12 for an extra high pressure pilot With proper installation completed and downstream equipment properly adjusted perfo
10. feeding the system Two methods of using Type 99 regulators in monitoring systems are as follows Working Monitor On a working monitor installation Figure 4 the control line of the monitoring pilot is connected downstream of the working regulator During normal operation distribution pressure causes the monitoring pilot to stand wide open Full pilot supply pressure enters the working monitor pilot and permits the working monitor regulator to control at its intermediate pressure setting Open failure of the working regulator increases distribution pressure as the working regulator goes wide open Intermediate pressure is then ignored by the monitoring regulator which controls downstream pressure at its own pressure setting slightly higher than the normal control pressure TYPE 161AYW MONITORING PILOT ALSO REPRESENTATIVE OF TYPE 627 109 i WORKING MONITOR PILOT PILOT SUPPLY LINE LOADING PRESSURE OPTIONAL UPSTREAM PRESSURE n aa 20A1389 A B2484 PILOT SUPPLY REGULATOR Type 99 DISTRIBUTION PRESSURE CONTROL LINE 1x INTERMEDIATE PRESSURE CONTROL LINE INTERMEDIATE PRESSURE K X WORKING HX WORKING REGULATOR MONITOR REGULATOR na OPTIONAL PILOT SUPPLY DISTRIBUTION REGULATOR PRESSURE R n S WHEN PILOT IS REQUIRED TO BE SUPPLIED FROM UPSTREAM PRESSURE Figure 4 Working Monitor Installation The monitoring pilot should be upst
11. steel Low pressure pilot High pressure pilot Control Spring Plated steel For use only with LD low pressure pilot 0 to 4 inches w c 0 to 10 mbar Orange 3 to 12 inches w c 7 to 30 mbar Silver For use with all low pressure pilots 0 25 to 2 psig 0 02 to 0 14 bar Red 1 to 5 psig 0 07 to 0 34 bar Yellow 2 to 10 psig 0 14 to 0 69 bar Blue 5 to 15 psig 0 34 to 1 03 bar Brown 10 to 20 psig 0 69 to 1 38 bar Green For use with high pressure pilot Green stripe Spring Case Cast iron Low pressure pilot High pressure pilot Standard For use with closing cap not shown Adjusting Screw Low pressure pilot Standard Zinc Handwheel style Plated steel O ring seated handwheel assembly High pressure pilot Standard Plated steel For use with closing cap 1H236514012 Closing Cap For use with standard low pressure pilot Plastic For use with handwheel style low pressure pilot Brass not shown For use with O ring sealed handwheel For use with high pressure pilot with spring case 1H232619012 Brass not shown Cap Screw Plated steel 8 required Relay Disk Assembly Brass Nitrile NBR 303 Stainless steel Nitrile NBR Recommended Spare Parts 3 An entire pilot assembly may be ordered from your local Sales Office by specifying a Type 61L a 61H or a 61HP pilot for field conversion Part Number 1B885506992 1B8855X0012 1D692214012 15A6002X602 1D662544012 1D373735032 1C520135032 1N162314042 2581919012 1B88600
12. tapped spring case remove the screwed in vent assembly key 72 Figure 9 from the high pressure pilot spring case or the pressed in vent assembly from the extra high pressure pilot spring case and install obstruction free tubing or piping into the 1 4 inch 6 35 mm vent tapping Provide protection on a remote vent by installing a screened vent cap into the remote end of the vent pipe An upstream pilot supply line is not required because of the integral pilot supply tubing key 24 Figure 9 or 11 However as long as the 1 4 inch NPT tapping in the main valve body is plugged this tubing may be disconnected from both the main valve and filter assembly key 75 Figure 9 in order to install a pilot supply line from a desired remote location into the filter If the maximum pilot inlet pressure will be exceeded by main valve pressure install a separate reducing regulator if not already provided in the pilot supply line A Type 99 regulator has two 1 2 inch threaded NPT control line pressure taps on opposite sides of the lower casing key 29 Figure 9 The regulator normally comes from the factory with the tap closest to the regulator outlet left unplugged for the downstream control line as shown in Figure 1 and with opposite tap plugged Attach the control line from the unplugged tap 2 to 3 feet 0 61 to 0 91 meter downstream of the regulator in a straight run of pipe If impossible to comply with Type 99 this recommendation
13. 0 31 bar 4 5 to 7 psig 0 31 to 0 48 bar 5 to 15 psig 0 34 to 1 03 bar 10 to 25 psig 0 69 to 1 72 bar 20 to 35 psig 1 38 to 2 41 bar 0 156 0 40 4 1 8 10 5 0 187 0 47 3 15 16 10 0 0 218 0 55 4 1 8 10 5 0 168 0 43 2 15 16 7 46 0 187 0 47 2 13 16 7 14 Type 627 109 with 1 8 inch 0 218 0 55 2 15 32 6 27 3 18 mm port diameter and 150 psig 10 3 bar maximum allowable inlet pressure for cast 25 to 60 psig 1 2 to 4 14 bar 0 500 1 27 9 1 4 23 5 iron body or 750 psig 51 7 bar maximum allowable inlet pressure 1P901327142 over normal 40 to 80 psig 2 76 to 5 52 bar 0 283 0 72 2 15 16 7 46 80 to 150 psig 5 52 to 10 3 bar 0 240 0 61 2 5 8 6 67 for malleable iron body 130 to 200 psig 9 00 to 13 8 bar 1P9013271422 0 240 0 61 2 5 8 6 67 distribution pressure 1 With large diaphragm plate 2 With small diaphragm plate 3 0 psi 0 21 bar over normal distribution pressure 5 0 psi 0 34 bar x x location The line or stack opening must be protected against condensation freezing and clogging Clean out all pipelines before installation and check to be sure the regulator has not been damaged or collected foreign material during shipping Apply pipe compound to the male pipe threads only with a screwed body or use suitable line gaskets and good bolting practices with a flanged body This regulator may be i
14. 2052 1N536102332 1B894202192 1N162702302 1B989425072 1D558325072 1B886225072 1D558525072 1B558527052 1C680627222 1B886327022 14857827022 1B886427022 14857927142 1B886527022 0Y066427022 1B983919012 1B984119012 1H232619012 1B537944012 1J496428982 1R759414012 1A279128982 14881524102 T11069X0012 14926114012 1R759314012 1H236514012 1B989624052 1B8868000A2 1B8868000B2 Key 48 49 50 51 52 53 54 55 59 68 71 72 78 79 80 81 82 114 115 132 152 154 Description Relay Disk Assembly continued Brass Fluorocarbon FKM 303 Stainless steel Fluorocarbon FKM Bleed Valve Spring Stainless steel For use with low pressure pilot with relay orifice 1D373735032 or bleed valve 1H951635132 For use with all low and high pressure pilots Inlet pressure up to 250 psig 17 2 bar Inlet pressure over 250 psig 17 2 bar Bleed Valve Stainless steel For use with LD low pressure pilot with bleed valve spring 1E643637022 For use with all low and high pressure pilots Diaphragm Nut Brass 316 Stainless steel Bleed Orifice 316 Stainless steel Loading Tubing Copper 316 Stainless steel Connector Brass 316 Stainless steel Pipe Nipple Plated steel 1 required with copper tubing and 2 required with aluminum tubing 316 Stainless steel Pipe plug Steel not shown Type Y602 1 Vent Assembly Spring Seat Handwheel style low pressure pilot Steel not shown Hi
15. 541506992 1A351124122 1A352224122 1B487099202 14881624092 2C518619012 1A368228982 1A368228982 A S APPLY ANTI SEIZE COMPOUND 130 A6804 31 29 40 a 116 SS 0 9 didum d LL d bu TEX es ZA PES ES ET LZ ze LE RORON M we ER A SAANAN Y AL N i Of O Ca EO baat aa TEE 2 NUNNNN tm NNNNNN innt Type 99 aH Pb y Type 61HP Extra High Pressure Pilot Figure 12 Key Description 23 Elbow For use with all standard regulators Brass 316 Stainless steel For use with 1000 psig 69 0 bar maximum inlet regulator Steel 24 Pilot Supply Tubing For use with all standard regulators Copper 316 Stainless steel For use with 1000 psig 69 0 bar maximum inlet regulator Steel 30 Diaphragm Neoprene CR Fluorocarbon FKM Dacron 31 Yoke Leg 416 Stainless steel 2 required Recommended Spare Parts 4 Dacron is a mark owned by E I du Pont de Nemours and Co Part Number 15A6002X292 15A6002X202 13139628982 1D7703000A2 0500213809W 0500213809W 13A9840X012 13A9840X022 13A9838X012 Key 34 41 43 44 AE Figure 12 Type 61HP Extra High Pilot Pilot Description Connector 3 required For use with all standard regulators Brass 316 Stainless steel For use with 1000 psig 69 0 bar maximum inlet regulator Steel Cap Screw Plated steel 6 required Elbow Plated steel Yoke Cap 416 Stainless steel Inlet Orifice
16. ATMOSPHERIC PRESSURE 54A2767 a A2505 INLET PRESSURE TUBING CONNECTION Figure 3 Schematic of Type 99 Regulator with Type 61HP Extra High Pressure Pilot through the relief valve body J Figure 4 Since loading pressure needs to exceed outlet pressure only moderately to stroke the main valve fully open a continued increase in loading pressure differential extends the main diaphragm E and the pusher post assembly K far enough to separate the bleed valve D and the bleed orifice H This permits quick dumping of excess loading pressure into the downstream system With a decrease in loading pressure on top of the main diaphragm E the main spring B exerts an upward force on the diaphragm rod connected to the main diaphragm E pulling it upward This moves the main valve toward its seat decreasing flow to the downstream system Diaphragm G in the pilot valve acts as a sealing member for the loading chamber and as a balancing member to diaphragm F These two diaphragms are connected by a yoke so any pressure change in the pilot chamber has little effect on the position of the pilot valve Therefore the active diaphragm in the pilot is F and the pressure on the top side of this diaphragm opposes the force of the pilot control spring A Monitoring Systems Monitoring regulators serve as overpressure protection devices to limit system pressure in the event of open failure of a working regulator
17. BLE ARRANGEMENT THAT PERMITS WIDE OPEN MONITOR TO BE EITHER UPSTREAM OR DOWNSTREAM Figure 5 Typical Wide Open Monitor Installations Type 99 Table 3 Maximum Allowable Drop and Minimum Differential Pressures MAXIMUM MAIN VALVE SPRING MINIMUM MAXIMUM PORT ALLOWABLE DIFFERENTIAL OP PSIG b m Diameter Free Length PRESSURE FOR FULL SEAT MATERIAL DIAMETER Number DROP PSIG bar Inches cm Inches cm STROKE PSIG bar INCHES mm 25 1 72 10277127022 0 148 0 38 6 15 2 0 75 0 05 ies ee D 1 1 8 28 6 50 3 45 1N801927022 0 156 0 40 7 1 8 18 1 1 5 0 10 ih od a 1 1 8 28 6 150 10 3 1B883327022 0 187 0 47 Nitrile NBR Neoprene CR 6 5 8 16 8 3 0 21 Fluorocarbon FKM 1 1 8 28 6 itri 2 2 175 12 1 1B883327022 0 187 0 47 6 5 8 16 8 3 0 21 Nitrile Scd uds om 7 8 22 2 0 187 0 47 6 5 8 16 8 3 0 21 7 8 22 2 0 281 071 6 15 2 10 0 69 1 1 8 28 6 ia orn swa 69 18 286 sae m amas 10060 ZEE 600 41 4 0 281 0 71 6 15 2 10 0 69 5 8 15 9 0 281 071 6 15 2 10 0 69 Nylon PA 1 2 12 7 1 Can use all port diameters up to maximum size listed 2 CL125 FF flanged body only 3 O ring seat only 4 1 2 inch 12 7 mm is the only orifice available for 1000 psig 69 0 bar maximum inlet pressure regulator Installation Like most regulators the Type 99 regulator has a outlet pressure rating lower than its inlet pressure rating A
18. Brass 1C780414012 316 Stainless steel 1C780435072 7 8 inch 22 2 mm orifice Brass 1C394714012 316 Stainless steel 1C394735072 1 inch 25 4 mm orifice Brass 13A5017X012 1 1 8 inch 28 6 mm orifice Brass 1B884414012 316 Stainless steel 1B884435072 1 2 inch 12 7 mm disk seat for 1000 psig 69 0 bar maximum inlet regulator 416 Stainless steel 14A8410X012 O ring seat for all regulators 7 8 inch 22 2 mm orifice Brass 1E603014012 316 Stainless steel 1E603035072 1 1 8 inch 28 6 mm orifice Brass 1E342514012 316 Stainless steel 1E342535072 21 Retainer Disk seat 3 4 inch 19 1 mm All except 3 4 inch 19 1 mm or 1 1 8 inch 28 6 mm orifice or 1000 psig 69 0 bar maximum inlet regulator Brass 1C394814012 303 Stainless steel 1C394835032 3 4 inch 19 1 mm orifice Brass 1C780314012 316 Stainless steel 1C7803X0012 1 1 8 inch 28 6 mm orifice Brass 1B884514012 316 Stainless steel 1B884535072 O ring seat for all regulators 7 8 inch 22 2 mm orifice Brass 1E603114012 316 Stainless steel 1E603135072 1 1 8 inch 28 6 mm orifice Brass 1E342614012 316 Stainless steel 1E342635072 22 Cap Screw Plated steel 1A391724052 25 Cotter Pin 316 Stainless steel 1B108438992 26 Valve Carrier Brass 1E597114072 416 Stainless steel 1E597135132 27 Lever Pin 316 Stainless steel 1B884935162 303 Stainless steel 1C911635032 28 Retaining Ring for brass trim Plated steel 2 required 1B8850X0012 Cotter Pin for Stainless steel trim 316 Stainless stee
19. Instruction Manual Form 589 April 2008 Type 99 Type 99 Pressure Reducing Regulators Introduction Scope of the Manual This manual describes and provides instructions and parts lists for Type 99 pressure reducing regulators complete with standard P590 Series integral filter However complete instructions and parts listing for the Type 1301F pilot supply regulator and other Fisher equipment such as monitoring pilots will be found in separate instruction manuals Description The Type 99 gas regulators provide a broad capacity for controlled pressure ranges and capacities in a wide variety of distribution industrial and commercial applications A Type 99 regulator has a Type 61L low pressure Type 61H high pressure or a Type 61HP extra high pressure pilot integrally mounted to the actuator casing as shown in Figure 1 The Type 99 regulator can handle up to 1000 psig 69 0 bar inlet pressures the 1000 psig 69 0 bar regulator requires a Type 1301F pilot supply regulator and a Type H110 pop relief valve The pilot supply regulator reduces inlet pressure to a usable 200 psig 13 8 bar for the extra high pressure pilot This regulator comes standard with O ring seals on the guide bushing and valve carrier key 26 Figure 7 to keep main valve body outlet pressure from interfering with outlet pressure in the lower casing assembly key 29 Figure 9 Specifications Since a pilot operated regulator is construct
20. N WARNING Complete downstream overpressure protection is needed if the actual inlet pressure can exceed the e Personal injury equipment damage or regulator outlet pressure rating or the pressure ratings leakage due to escaping gas or of any downstream equipment Although the Type H110 bursting of pressure containing relief valve provides sufficient relief capacity to protect parts might result if this regulator the extra high pressure pilot of the 1000 psig 69 0 bar is overpressured or is installed where maximum inlet regulator in case the Type 1301F supply service conditions could exceed regulator fails open this protection is insufficient if the the limits for which the regulator was main valve body fails open Regulator operation within designed or where conditions exceed ratings does not preclude the possibility of damage from any ratings of the adjacent piping or external sources or from debris in the lines A regulator piping connections To avoid such should be inspected for damage periodically and after injury or damage provide pressure any overpressure condition relieving or pressure limiting devices as required by the appropriate code regulation or standard to prevent ZN WARNING service conditions from exceeding those limits The 1000 psig 69 0 bar maximum inlet regulator must not be used on hazardous gas service unless the Type H110 relief valve can be vented into a safe area If vented gas can accumulate and become
21. S i L ri yt e y a A6802 Key Description 17 Valve Body continued 2 inch DN 50 CL150 RF flanged Steel 2 inch DN 50 CL300 RF flanged Steel 18 Holder for Type 99 regulator Disk seat Brass 316 Stainless steel O ring Seat 7 8 inch 22 2 mm orifice Brass 316 Stainless steel 1 1 8 inch 28 6 mm orifice Brass 316 Stainless steel 18 Disk and Holder Assembly for 1000 psig 69 0 bar maximum inlet regulator Nylon PA 316 Stainless steel 19 Disk for Type 99 Regulator 250 psid 17 2 bar d maximum allowable pressure drop Neoprene CR Nitrile NBR Fluorocarbon FKM 400 psid 27 6 bar d maximum allowable pressure drop Nylon PA Polytetrafluoroethylene PTFE 19 O ring 7 8 inch 22 2 mm orifice Nitrile NBR Fluorocarbon FKM 1 1 8 inch 28 6 mm orifice Nitrile NBR Fluorocarbon FKM 20 Orifice Disk seat for all regulators 3 8 inch 9 52 mm orifice 416 Stainless steel 1 2 inch 12 7 mm orifice 416 Stainless steel 5 8 inch 15 9 mm orifice 416 Stainless steel 7 8 inch x 3 8 inch 22 2 x 9 52 mm orifice Brass 316 Stainless steel 46 45 60 Part Number 2E275622012 2E275722012 1B884314012 1B884335072 1E603214012 1E603235072 1E342414012 1E342435072 1C1860000B2 1C997403032 1C158703332 1C9974X0012 1E480603152 1C997406242 1D237506992 1D237506382 1H8498X0012 1H8498X0032 19A7390X012 14A8410X012 19A7391X012 1N878114012 1N8781X0012 13 Typ
22. 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 For further information visit www emersonprocess com regulators 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 eT EMERSON Fisher Controls International Inc 1979 2008 All Rights Reserved
23. aphragms slip properly into the recess on the lower casing and relay valve body With the pilot in place check to see if it can be rocked If it does not rock it is in place and the diaphragm is free of wrinkles With both diaphragms firmly in place install the cap screws using torque 150 inch pounds 16 9 Nem of torque Tighten using a crisscross pattern to avoid placing a strain on the unit Set the pilot control spring key 43 according to the adjustment information in the Startup section Reinstall the closing cap key 46 if used If you have a plastic closing cap be sure that you have a vent key 60 in place of the pipe plug installed in the low pressure pilot spring case Type 61HP Extra High Pressure Pilot This procedure is to be performed if changing the control spring for one of a different range or if inspecting cleaning or replacing any other pilot parts Key numbers are referenced in Figure 12 1 Unscrew the adjusting screw key 45 to relieve control spring compression Disconnect the loading tubing and pilot supply tubing Remove the six cap screws key 123 which fasten the spring case key 44 spring seat key 68 and control spring key 43 to the pilot body Unscrew the diaphragm nut key 128 and remove a diaphragm plate key 41 diaphragm key 40 and another diaphragm plate Unscrew the eight cap screws and remove the pilot body key 39 and gasket Remove six cap screws
24. bing key 24 Figure 9 or 11 remove the filter assembly key 75 Figure 9 and blow through it to check for filter clogging If necessary to clean or replace filter parts in a standard P590 Series filter assembly remove the following as shown in Figure 10 filter body key 1 machine screw key 4 spring washer key 6 gasket key 7 washer key 5 and filter element key 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 If the lower casing was removed install a new body gasket key 16 Figure 9 and with a disk or O ring seat slide the valve carrier into the casing Then slide the entire assembly into the valve body disk or O ring seat and secure with the union nut Secure the lever to the valve carrier with the retaining ring or cotter pin 10 Loosely reassemble the diaphragm and diaphragm plate so that the bolt holes and loading connection hole in the diaphragm can be properly aligned with the corresponding holes in the casing when the lever is fitted properly into the pusher post When this orientation is made install the collar key 6 Figure 9 and tighten the diaphragm rod into the pusher post key 8 Figure 9 unscrewing the diaphragm rod key 4 Figure 9 11 In order for the regulator to operate properly the from the pusher post Inspect the diaphragm assembled collar diaphragm diaphragm p
25. e 1000 psig 69 0 bar maximum inlet regulator are referenced in Figure 11 and part key numbers for a Type 61HP extra high pressure pilot is referenced in Figure 12 1 Access to all internal actuator parts can be gained without removing the main valve body from the line Disconnect the loading tubing from the upper casing If the regulator has an indicator assembly perform the following step carefully to avoid bending the travel indicator stem key 103 Figure 6 Note The O rings and gaskets keys 111 and 108 Figure 6 in the indicator assembly are static seals and need not be disturbed unless they are leaking Remove the four cap screws key 58 Figure 9 and lift off the spring case key 1 Figure 9 Remove the travel indicator stem if any by unscrewing the indicator stem adapter key 101 Figure 6 Remove the main spring seat key 2 Figure 9 and main spring key 3 Figure 9 Remove the 12 cap screws key 12 Figure 9 and hex nuts key 13 Figure 9 and lift off the upper casing Remove the diaphragm key 11 Figure 9 and diaphragm plate key 10 Figure 9 by tipping it so that the lever key 9 Figure 9 slips out of the pusher post key 8 Figure 9 Separate the diaphragm and diaphragm plate by part of the lower casing assembly on a stem seal unit and normally does not require replacement If clogging is suspected in the upstream regulator passages disconnect the pilot supply tu
26. e 99 AS APPLY ANTI SEIZE COMPOUND PTS APPLY PIPE THREAD SEALANT LUB APPLY LUBRICANT i SS SS SN D U o 9660902 EE Ire ee T L e ge Sg RL POO ies v zS 7S CONTROL LLL eS i izzx LINE TAP A dd OTHER TAP 180 OPPOSITE 3 jam Y We SSSAAA e 7777 E E 5 ssi i M E N SN Ye S ems D INCH 6 35 E VENT SHOWN 90 COUNTERCLOCKWISE FROM NORMAL DJ6642 NSS y PILOT RELAY ASSEMBLY Figure 9 Type 99 Regulator with Type 61L Low or 61H High Pressure Pilot 30A6800 ZZZ a p ZZ S P LZ YS 47 S Type 99 WHO fa Lak 7 XT arm Vi d a EANN E e Li _ Jo O O i E Ng A TY Swear NAP wW de tit SE Bn d B ut HIGH PRESSURE PILOT PARTS ez MR Q7 AE 2 Z EAR A CEE T e Y M EP CER m pA SS Le PILOT RELAY AND COVER ASSEMBLY Figure 9 Type 99 Regulator with Type 61L Low or 61H High Pressure Pilot continued Type 99 Actuator and Main Body Assembly Figures 6 7 8 9 10 and 11 continued Key Description Part Number 20 Orifice continued Disk seat for all regulators 7 8 inch x 1 2 inch 22 2 x 12 7 mm orifice Brass 1C942314012 316 Stainless steel 1C942335072 7 8 inch x 5 8 inch 22 2 x 15 9 mm orifice Brass 1C942414012 316 Stainless steel 1C9424X0012 3 4 inch 19 1 mm orifice
27. e 99 regulator with disk or O ring seat are referenced in Figure 9 and part key numbers for the disk seat unique to the 1000 psig 69 0 bar maximum inlet regulator are referenced in Figure 11 Note All trim maintenance may be performed with the valve body key 17 Figure 9 or 11 in the line and with the elbow key 23 Figure 9 or 11 pilot supply tubing key 24 Figure 9 or 11 and pilot supply regulator key 155 Figure 11 if used attached to the valve body unless the valve body itself will be replaced 1 Disconnect the pilot supply tubing and downstream control line 2 Loosen the union nut key 14 Figure 9 and remove the lower casing key 29 Figure 9 with the cap screw key 22 Figure 9 or disk and holder assembly key 18 Figure 11 on disassembly or reassembly A thin walled socket may be used to remove the orifice 3 Access to the disk or O ring key 19 Figure 9 can be gained by removing the cap screw and retainer key 21 Figure 9 while on the 1000 psig 69 0 bar maximum inlet regulator the entire disk and holder assembly is removed as a unit If necessary the holder key 18 Figure 9 or 11 or adapter key 157 Figure 11 can be removed by taking out the cotter pin key 25 Figure 9 or 11 4 Install a new body gasket key 16 Figure 9 and a new disk O ring or disk and holder assembly as necessary Then slide the entire assembly into the valve body and secure with the union nut 5 Connect the pi
28. ed of both a pilot and a main valve care should be used not to exceed www emersonprocess com regulators W2676 Figure 1 Type 99 Regulator with Type 61H high pressure Pilot the maximum inlet pressure shown on the nameplate of either unit When inlet pressure exceeds the pilot limitation a pilot supply reducing regulator and or relief valve will be required Specifications and ratings for various Type 99 constructions are listed in the Specifications section on page 2 Some specifications for a given regulator as it originally comes from the factory are stamped on nameplates located on the pilot and actuator spring cases A tag key 159 Parts List additionally may be installed on the pilot to indicate a regulator with O ring stem seal These regulators and their installations should be checked for compliance with applicable codes amp EMERSON Process Management D100260X012 Type 99 Specifications Body Size and End Connection Styles Maximum Actuator Pressures 2 inch DN 50 body with NPT CL125 CL150 Operating 100 psig 6 90 bar CL250 or CL300 flanged or SWE Emergency 110 psig 7 58 bar Maximum Allowable Inlet Pressure Maximum Pilot Spring Case Pressure for 160 psig 11 0 bar When using Type 61LD pilot Pressure Loading 400 psig 27 6 bar When using Types 61L Types 61L 61LD and 61LE 50 psi 3 45 bar 61H pilots with special steel closing cap 600 psig 41 4 bar Type 61HP pilot Ty
29. gh pressure pilot Zinc Closing Cap Gasket for use only with low pressure pilot Neoprene CR Type Y602 1 Vent Assembly for use only with standard high pressure pilot spring case Zinc 18 8 Stainless steel Handwheel for use only with handwheel style low pressure pilot Zinc Machine Screw for use only with handwheel style low pressure pilot Plated steel Lockwasher for use only with handwheel style low pressure pilot Steel O ring for use only with O ring sealed handwheel assembly Hex nut For use only with O ring sealed handwheel assembly For use with high pressure pilot Plated steel Gasket for use only with high pressure pilot with spring case 1H232619012 Steel Composition not shown Adaptor for use only with high pressure pilot with spring case 1H232619012 Steel not shown Pilot Cover used only with complete replacement pilot assembly for field conversion Cast iron Drive Screw 18 8 Stainless steel 4 required for low pressure pilot and 6 required for high pressure pilot Drive Screw for use only with low pressure pilot 18 8 Stainless steel 2 required Part Number 1B8868X0012 1B8868X0022 1E643637022 1C911537022 1N859137022 1H951635132 1D986735132 1B989514012 1B989535072 1B887335032 1J4928000A2 0500213809W 1H628114012 15A6002X992 1C488226232 1C488238982 1A369224492 2 A5516X012 19618124092 16A9812X012 1P753306992 17A6570X012 1J496144012 16A5763X012 1A352332992 1D
30. ipe Nipple Plated steel 2 required 1C488226232 128 Diaphragm Nut Plated steel 1A346524122 60 Pipe plug Steel not shown 1A649528982 129 Valve Spring Seat Aluminum 1L251135072 68 Spring Seat Plated steel 1042963x012 9E Machina Screw lt 04 H 72 Type Y602 12 Vent Assembly for use only steel 4 required 14866935032 with tapped spring case 20A4735X012 131 Pipe plug Steel not shown 14369224492 Zinc with 18 8 Stainless steel screen 27A5516X012 150 Diaphragm Insert 2 required 82 Locknut Plated steel 1352224122 Nitrile NBR 13A9842X012 116 Yoke Cap 416 Stainless steel 13A9836X012 Fluorocarbon RM 13A9842X022 117 Inlet Valve Plug 152 Drive Screw 18 8 Stainless 304 Stainless steel Nitrile NBR 1D5604000B2 eee equ 14368228982 304 Stainless steel Fluorocarbon FKM 1N3798000C2 193 Seal Washer Nitrile NBR Plated steel 6 required 13A9849X012 Recommended Spare Parts Industrial Regulators Regulator Division Emerson Process Management USA Headquarters McKinney Texas 75070 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 Natural Gas Technologies Regulator Division Emerson Process Management USA Headquarters McKinney Texas 75070 Tel 1 800 558 5853 TESCOM Regulator Division Emerson Process Management USA Headquarters Elk River Minnesota 55330 USA Tel 1 763 241 3238 Outside
31. l 2 required 14866537022 Recommended Spare Parts 1 Required with lower casing 2N379419012 2 Pilot supply regulator parts are found in Types 1301F and 1301G Instruction manual AJ5004 A A2135 IL Key 29 32 57 58 61 62 63 64 73 75 133 134 152 155 156 159 Wa ay i m rs 377 3 paie PIPE THREAD SEALANT Figure 10 Standard P590 Series Filter Assembly Description Lower Casing Cast iron Standard For use with optional protector spring washer and machine screw keys 61 62 and 63 Lower Casing Assembly for use with O ring stem seal Cast iron with SST guide bushing Complete with Nitrile NBR O ring Complete with Fluorocarbon FKM O ring Nameplate Aluminum Upper Casing Cast iron Spring Case Gasket Composition Graphite for oxygen service Cap Screw Plated steel 4 required Lower casing protector not shown Brass Optional Spring Washer not shown Plated brass 2 required Optional Machine Screw not shown Plated brass 2 required O ring for use only with O ring stem seal Nitrile NBR Fluorocarbon FKM Pipe plug Plated steel not shown Standard P590 Series Filter Assembly parts listed under separate heading Type P594 1 Brass Type P593 1 Aluminum Pipe Elbow Plated steel Pipe Nipple Plated steel Drive Screw 18 8 Stainless steel 4 required for low pressure pilot and 6 required for high pressure pilot Type 1301F Pilot Supply Reg
32. late Key 11 Figure 9 and pusher post gasket key 7 pusher post and diaphragm rod must be Figure 9 Either part must be replaced if it is mounted on the ball of the lever so that the damaged or no longer pliable pusher post key 8 Figure 9 orientation is as If the unit has a stem seal O ring key 64 shown in Figure 9 Figure 7 or 11 this O ring may be replaced by 12 Install the upper casing and secure it to the removing the retaining ring or cotter pin key 28 Figure 9 and disconnecting the lever from the valve carrier key 26 Figure 9 or 11 removing the union nut key 14 Figure 9 or 11 lower casing with the twelve cap screws torque 580 to 920 inch pounds 65 5 to 104 N m and hex nuts Put lower casing back on body and install union nut Type 99 To avoid part damage due to over compressing the main spring seat always use main spring seat 1E242724092 with main spring 0W019127022 13 Install the main spring and main spring seat turning the main spring seat until its bottom shoulder is even with the bottom thread of the diaphragm rod 14 Install a new spring case gasket key 57 Figure 9 the spring case and the four cap screws with 340 to 420 inch pounds 38 4 to 47 5 Nem of torque making sure the indicator stem O ring and gaskets keys 103 111 and 108 Figure 6 are installed If used 15 Connect the loading tubing then refer to the Startup section for putting the regulator into operation
33. listed below Spring Case Cast iron Indicator Stem Adaptor Aluminum Indicator Cap Aluminum Indicator Stem Aluminum Disk Nut Plastic Machine Screw Nut Plated steel 2 required Retainer Aluminum Indicator Window Glass 108 Gasket Neoprene CR 2 required 109 Indicator Cover Plastic 2 required 110 Machine Screw Plated steel 8 required 111 O ring Nitrile NBR 2 required Indicator Scale Stainless steel f 108 Travel Indicator Assembly Figure 6 Part Number 20A7146X0C2 2L296219012 1R395909012 1L290809012 1L296509022 1F 730506992 1A342024152 1L291009012 1L296706992 1L291103012 1L296405032 1A899028982 1E591406992 14511638982 Actuator and Main Body Assembly Figures 6 7 8 9 10 and 11 Key Description 1 2 Standard Spring Case without travel indicator Cast iron Main Spring Seat Plated steel 250 psid 17 2 bar d maximum allowable pressure drop Cast iron 1000 psid 69 0 bar d maximum allowable pressure drop Part Number 1B883119012 1B883219042 1E242724092 SEALANT LUBRICANT SEALANT 20A7148 B Figure 7 O ring Stem Seal Key Description 3 Main Spring Plated steel 25 psid 1 72 bar d maximum allowable pressure drop 50 psid 3 45 bar d maximum allowable pressure drop 250 psid 17 2 bar d maximum allowable pressure drop 1000 psid 69 0 bar d maximum allowable pressure drop requires main spring seat 1E242724092 4 Diaphragm Rod 416
34. lot supply tubing and downstream control line then refer to the Startup section for putting the regulator into operation Type 99 Figure 6 Travel Indicator Assembly 20A7146 B Parts Ordering b A serial number is assigned to each regulator and it is stamped on both the actuator and pilot nameplates If the pilot is replaced the new pilot will have its own serial number different from the main valve serial number Always indicate one or both serial numbers when communicating with your local Sales Office When ordering a replacement part be sure to include the complete eleven character part number Parts List Key Description Part Number Repair kits include parts for regulator with composition trim only key numbers 7 11 16 19 20 and 57 Also included are parts for pilot key numbers 30 33 38 40 48 49 50 52 71 117 126 129 150 153 and P590 Series filter key numbers 2 and 7 With low pressure pilot 7 8 inch 22 2 mm orifice 1 1 8 inch 28 6 mm orifice With high pressure pilot 7 8 inch 22 2 mm orifice 1 1 8 inch 28 6 mm orifice With extra high pressure pilot 7 8 inch 22 2 mm orifice 1 1 8 inch 28 6 mm orifice Recommended Spare Parts R99LX000012 R99LX000022 R99HX000012 R99HX000022 R99HPX00012 R99HPX00022 S or Say aS As Key 1 101 102 103 104 105 106 TOT 112 Description Complete Assembly includes individual parts
35. nstalled in any position desired as long as the flow through the body is in the direction indicated by the arrow on the body Install a three valve bypass around the regulator if continuous operation is necessary during maintenance or inspection Although the standard orientation of the actuator and pilot to the main valve body is as shown in Figure 1 this orientation may be changed as far as the inlet tubing key 24 Figure 9 or 11 will permit by loosening the union nut key 14 Figure 9 rotating the actuator lower casing key 29 Figure 9 as desired and tightening the union nut To keep the pilot spring case from being plugged or the spring case from collecting moisture corrosive chemicals or other foreign material the vent must be pointed down oriented to the lowest possible point on the spring case or otherwise protected Vent orientation may be changed by rotating the spring case with respect to the pilot body or on the extra high pressure pilot with optional tapped spring case by rotating the vent with respect to the spring case To remotely vent a low pressure pilot install the vent line in place of the pressed in vent assembly key 60 Figure 9 Install obstruction free tubing or piping into the 1 4 inch 6 35 mm vent tapping Provide protection on a remote vent by installing a screened vent cap into the remote end of the vent pipe To remotely vent a high pressure pilot or an extra high pressure pilot with optional
36. nstream control line In operation assume the outlet pressure is less than the setting of pilot control spring A The top side of pilot diaphragm assembly F will have a lower pressure than the setting of spring A Spring A forces the diaphragm head assembly upward opening the relay or inlet orifice C Additional loading pressure is supplied to the pilot body and to the top side of main diaphragm E This creates a higher pressure on the top side of the main diaphragm E than on the bottom side forcing the diaphragm downward This motion is transmitted through a lever which pulls the valve disk open allowing more gas to flow through the valve When the gas demand in the downstream system has been satisfied the outlet pressure increases The increased pressure is transmitted through the downstream control line and acts on top of the pilot diaphragm head assembly F This pressure exceeds the pilot spring setting and forces the head assembly down closing orifice C The loading pressure acting on the main diaphragm E bleeds to the downstream system through a small slot between the pilot bleed valve D and the bleed orifice H Normally excess loading pressure slowly escapes downstream around bleed valve D Figure 3 or Type 99 DOWNSTREAM CONTROL LINE COT JU FLANGE ADAPTOR dT E INLET PRESSURE E OUTLET PRESSURE LOADING PRESSURE
37. pes 61H and 61HP 100 psi 6 90 bar 5 8 inch 15 9 mm orifice maximum E 1000 psig 69 0 bar Type 61HP pilot along with Minimum Differential Pressure Required for Type 1301F pilot supply regulator and Type H110 Full Stroke relief valve 1 2 inch 12 7 mm orifice only See Table 3 Outlet Control Pressure Ranges Maximum Rated Travel See Table 1 1 4 inch 6 35 mm Approximate Proportional Bands Temperature Capabilities See Table 2 With Nitrile NBR Neoprene CR Maximum Allowable Pressure Drop 20 to 180 F 29 to 82 C See Table 3 With Fluorocarbon FKM 0 to 300 F 18 to 149 C 1 The pressure temperature limits in this Instruction manual and any applicable standard or code limitation should not be exceeded 2 For stability or overpressure protection a pilot supply regulator may be installed in the pilot supply tubing between the main valve and pilot 3 Type 61LD construction has narrower proportional band than does the standard Type 61L pilot 4 Type 61LE construction has broader proportional band than does the standard Type 61L pilot Table 1 Outlet Pressure Ranges MAXIMUM PILOT PILOT CONTROL SPRING SUPPLY PRESSURE EEG Wire Diameter Free Length PSIG bar COIEDRIIDEE i Color Code Inches cm Inches cm 61L 400 27 6 2 to 4 inches w c 5 to 10 mbar 1B558527052 Orange 3 to 12 inches w c 7 to 30 mbar 1C680627222 Unpainted 0 25 to 2 psig 0 02 to 0 14 bar 1B886327022 Red 61LD 160 11 0 1 to5
38. psig 0 07 to 0 34 bar 2to 10 psig 0 14 to 0 69 bar 1B886427022 Blue 61LE 400 27 6 5to15 psig 0 34 to 1 03 S 1J857927142 Brown 1J857827022 Yellow 10 to 20 psig 0 69 to 1 38 bar 1B886527022 Green 400 27 6 10 to 65 psig 0 69 to 4 48 bar 0Y0664000A2 0 363 0 92 6 15 2 61HP 600 41 4 35 to 100 psig 2 41 to 6 90 bar 1D387227022 0 200 0 51 1 11 16 4 29 1 Type 61LD construction has narrower proportional band than does the standard Type 61L Pilot 2 Type 61LE construction has broader proportional band than does the standard Type 61L Pilot Table 2 Proportional Bands PILOT CONTROL SPRING PILOT TYPES ire Di PROPORTIONAL BANDS Part Number Color Code Wire Diameter Free Length Inches cm Inches cm 1B558527052 Orange 0 075 0 19 4 1 8 10 5 p 61LD 1C680627222 0 080 0 20 3 1 4 8 26 0 1 to 0 5 inch w c 0 25 to 1 0 mbar 1B886327022 Red 0 109 0 28 2 3 4 7 00 1 to 2 inches w c 2 to 5 mbar 61LD 18886327022 Red 0 109 0 28 2 3 4 7 00 0 25 to 1 inch w c 0 62 to 2 mbar Red 0 109 0 28 2 3 4 7 00 5 to 8 inches w c 12 to 20 mbar 61LE 1B886327022 1B886527022 0 207 0 53 1J857927142 0 187 0 47 1B886427022 0 172 0 44 61L 61LD 61LE 0 1 to 0 3 psi 0 007 to 0 02 bar 1J857827022 0 142 0 36 0Y0664000A2 0 363 0 92 0 1 to 0 3 psi 0 007 to 0 02 bar 1 to 2 psi 0 069 to 0 14 bar
39. ream of the working monitor regulator This enables a closer setpoint between the working regulator and the monitoring pilot Special Types 161AYW and 627 109 monitoring pilots with quick bleed operation have been designed to give faster response to abnormal downstream conditions Table 4 gives the spread between normal distribution pressure and the minimum pressure at which the working monitor regulator can be set to take over if the working regulator fails open Wide Open Monitor The control line of the upstream regulator is connected downstream of the second regulator Figure 5 so that during normal operation the monitoring regulator is standing wide open with the reduction to distribution pressure being taken across the working regulator Only in case of open failure of the working regulator does the wide open monitoring regulator take control at its slightly higher setting The upstream regulator must have an O ring seal on the valve carrier assembly This seals off the leak path that otherwise would let line pressure ahead of the working regulator inlet try to close the wide open monitoring regulator UPSTREAM REGULATOR REQUIRES O RING STEM SEAL E N 0 gt 10A1388 A A2504 gt SUPPLY REGULATOR MONITOR TO BE EITHER UPSTREAM OR DOWNSTREAM UPSTREAM z REGULATOR REQUIRES O RING WORKING STEM SEAL REGULATOR 10A1386 A b 1 T A2503 pg m OPTIONAL PILOT SUPPLY REGULATOR FLEXI
40. rm the following procedure while using pressure gauges to monitor pressure 1 Very slowly open the upstream block valve 2 Slowly open the hand valve if used in the control line The unit will control downstream pressure at the pilot control spring setting See the adjustment paragraph following these numbered steps if changes in the setting are necessary during the startup procedure 3 Slowly open the downstream block valve 4 Slowly close the bypass valve if any 5 Check all connections for leaks The only adjustment on the regulator is the reduced pressure setting affected by the pilot control spring key 43 Figure 9 or 11 Remove the closing cap assembly key 46 Figure 9 and turn the adjusting screw key 45 Figure 9 or 11 Turning the adjusting screw clockwise into the spring case increases the controlled or reduced pressure setting Turning the screw counterclockwise decreases the reduced pressure setting Always replace the closing cap if used after making the adjustment Shutdown Isolate the regulator from the system Vent the downstream pressure first then vent inlet pressure to release any remaining pressure in the regulator Maintenance Regulator parts are subject to normal wear and must be inspected and replaced as necessary The frequency of inspection and replacement of parts depends on the severity of service conditions or the requirements of local state and federal rules and regulations A
41. ulator only with extra high pressure pilot Type H110 Pop Relief Valve for use only with extra high pressure pilot brass with Nitrile NBR disk and 316 Stainless steel spring Tag for use only with O ring stem seal and extra high pressure pilot alloy 1100 not shown for use Part Number 4B983719012 2N379419012 2R7230000A2 2R7230X0022 3B887619012 1B8877X0012 1B8877X0022 1A675124052 1N379514012 1N339518992 1H340518992 1E220206992 1R620106382 1A767524662 FSP594 1 FSP593 1 1B860828992 1B218826232 1A368228982 See footnote 2 Consult Factory 16A0957X012 294 64 290 25 57 2 55 22 Type 99 34 298 26 8 65 24 56 Figure 11 1000 Psig 69 0 bar Maximum Inlet Regulator Partial Detail A6803 Standard P590 Series Filter Assembly Figure 10 Key Description 1 Filter Body Type P594 1 Brass Type P593 1 Aluminum 2 Filter Element Cellulose 3 Filter Head Type P594 1 Brass Type P593 1 Aluminum 4 Machine Screw Type P594 1 Brass Type P593 1 Aluminum 5 Washer 2 required Type P594 1 Brass Type P593 1 Aluminum 6 Spring Washer Plated carbon steel 7 Gasket Composition Recommended Spare Parts 3 An entire pilot assembly may be ordered from your local Sales Office by specifying a Type 61L a 61H or a 61HP pilot for field conversion Part Number 1E312414012 1E3124X0022 1E312606992 1E312514012 1E3125X0022 14500218992 14500209012 14500018992
42. void personal injury or damage to property from sudden release of pressure or uncontrolled gas or other process fluid Before starting to disassemble isolate the pilot or regulator from all pressure and cautiously release trapped pressure from the pilot or regulator Use gauges to monitor inlet loading and outlet pressures while releasing these pressures On reassembly of the regulator it is recommended that a pipe thread sealant be applied to pressure connections and fittings as indicated in Figures 7 and 9 and lubricant be applied to sliding and bearing surfaces as indicated in Figures 7 and 9 and that an anti seize compound be applied to adjusting screw threads and other areas indicated Figures 9 and 11 Actuator and Standard P590 Series Filter This procedure is to be performed if changing the main spring and spring seat for those of a different range or if inspecting cleaning or replacing any other parts Unless otherwise indicated part key numbers for a Type 99 regulator with low or high pressure pilot and Type 99 disconnecting the pilot supply tubing key 24 Figure 9 or 11 and sliding the lower casing key 29 Figure 9 away from the valve body key 17 Figure 9 with a disk or O ring seat the valve carrier must be pulled out of the lower casing to gain access to the O ring Another O ring held captive by the pressed in bushing is disk or O ring seat are referenced in Figure 9 part key numbers unique to th
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