Emerson 1098H-EGRs, 1098-EGR Instruction Manual

Instruction Manual Form 5084

October 2014

Types 1098-EGR and 1098H-EGR

Types 1098-EGR and 1098H-EGR Pressure Reducing Regulators

WARNING

Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion,



causing property damage and personal injury or death.

Fisher® regulators must be installed, operated and maintained in accordance with federal, state and local codes, rules and regulations and Emerson Process Management Regulator Technologies, Inc. (Emerson™) instructions.

If the regulator vents gas or a leak develops in the system, service to the unit may be required. Failure to correct trouble could result in a hazardous condition.

Installation, operation and maintenance



personnel may result in improper adjustment and unsafe operation. Either condition may result in equipment



personnel when installing, operating and maintaining the Types 1098-EGR and 1098H-EGR pressure reducing regulator.

W6956

Figure 1. Type 1098-EGR

valve is also covered when a 61 Series pilot is used.

Instructions and parts lists for monitoring pilots and other equipment used with this regulator are found in

separate manuals.

Description

Introduction

Scope of the Manual

This manual describes and provides instructions and parts list for Type 1098-EGR or 1098H-EGR regulator complete with a standard P590 Series

 lter and either a 6350 Series regulator, a 61 Series pilot or a Type Y600AM pilot. The Type 1806 relief

www.fisherregulators.com

Types 1098-EGR and 1098H-EGR regulators provide economical and accurate pressure control in a wide variety of applications: natural gas distribution

systems; fuel gas supply to industrial boilers, furnaces,

ovens and mixers; and large commercial/industrial

establishments such as shopping centers and schools.

They are also used in plant air service and in liquid service where a slow stroking time (approximately 30 to 90 seconds) is desired on both opening and

closing the main valve.

D100339X012

Types 1098-EGR and 1098H-EGR



The Specications section lists pressure limitations and other specications for various Types 1098-EGR and 1098H-EGR constructions. Specications for a given regulator as it originally comes from the factory are stamped on nameplates located on both the actuator and main valve body, while the pilot control spring range is displayed on the pilot spring case and the pilot restriction code is stamped on the pilot body (S = standard gain, L = low gain and H = high gain).

Body Sizes and End Connection Styles

See Table 1

Main Valve Maximum Inlet Pressure

(1)

400 psig / 27.6 bar or body rating limit whichever is lower

Maximum Pilot Supply Pressure

(1)(2)

600 psig / 41.4 bar

Outlet Pressure Ranges

See Table 2

Main Valve Flow Direction

In through the seat ring and out through the cage

Pressure Registration

External

Temperature Capabilities

Nitrile (NBR):

-20 to 180°F / -29 to 82°C

Fluorocarbon (FKM):

0 to 300°F / -18 to 149°C,

Water is limited to 0 to 200°F / -18 to 93°C

Maximum and Minimum Differential Pressures

See Table 4

Actuator Sizes and Maximum Pressures

See Table 3

Main Valve Flow Characteristic

Linear (standard), Whisper Trim

™

Quick opening

1. The pressure/temperature limits in this Instruction Manual or any applicable standard limitation should not be exceeded.

2. For stability or overpressure protection, a reducing regulator may be installed upstream of the pilot according to the Installation section.

Ethylenepropylene (EPDM):

-20 to 275°F / -29 to 135°C

Options

• NACE Construction

• Boiler Fuel Construction

• Aqueous Service Construction

• Monitor Conguration

• Noise Abatement Trim

(1)

Table 1. Body Sizes and End Connection Styles

BODY SIZE

N PS DN

1 or 2 25 or 50 NPT, CL125 FF or CL250 RF NPT, CL150 RF, CL300 RF, CL600 RF, BWE, SWE or PN 16/25/40

3, 4 or 6 80, 100 or 150 CL125 FF or CL250 RF CL150 RF, CL300 RF, CL600 RF, BWE or PN 16/25/40

8 x 6 or 12 x 6 200 x 150 or 300 x 150 - - - - CL150 RF, CL300 RF, CL600 RF or BWE

CAST IRON STEEL OR STAINLESS STEEL

Types 1098-EGR and 1098H-EGR

Table 2. Outlet Pressure Ranges

PILOT TYPE

6351

6352

14 in. w.c. to 2 psig

6353

(1)

6354L

(2)

6354M

(2)

6354H

61L 61LD 61LE

7 in. w.c. to 2 psig

61H 10 to 65 0.69 to 4.5 Green Stripe 0Y066427022

61HP

7 to 16 in. w.c.

Y600AM

1. Without diaphragm limiter.

2. With diaphragm limiter.

15 in. w.c. to 1.2 psig

ACTUATOR TYPE ACTUATOR SIZE

1098

40 (standard)

1098H 30 350 24.1 400 27.6

OUTLET PRESSURE RANGE

psig bar

3 to 20 5 to 35

35 to 100

2 to 10 3 to 40

35 to 125

35 mbar to 0.1 bar

0.21 to 1.4

0.35 to 2.4

2.4 to 6.9

0.14 to 0.69

0.21 to 2.8

2.4 to 8.6

SPRING COLOR SPRING PART NUMBER

Green

Unpainted

Red

Yellow

Black

Yellow

Red

1B986027212 1B788327022

1K748527202

14A9672X012 14A9673X012

1E392527022 1K748527202

85 to 200 5.9 to 13.8 Blue 1L346127142

175 to 220 12.1 to 15.2 Blue 1L346127142

200 to 300 13.8 to 20.7 Green 15A9258X012

1 to 5 2 to 10 5 to 15

10 to 20

15 to 45

35 to 100

100 to 300

4 to 8 in. w.c.

1.2 to 2.5

2.5 to 4.5

4.5 to 7

17 mbar to 0.1 bar

0.07 to 0.3

0.14 to 0.69

0.35 to 1.0

0.69 to 1.4

1.0 to 3.1

2.4 to 6.9

6.9 to 20.7

10 to 20 mbar

17 to 4 mbar

37 mbar to 0.08 bar

0.08 to 0.17

0.17 to 0.31

0.31 to 0.48

Red

Yellow

Blue

Brown

Green

Yellow

Blue

Red Red

Unpainted

Yellow Green

Light Blue

Black

1B886327022

1J857827022

1B886427022

1J857927142

1B886527022

1E392527022 1D387227022

1D465127142 1B653827052 1B653927022 1B537027052 1B537127022 1B537227022 1B537327052

Table 3. Actuator Sizes and Maximum Pressures

OUTLET CONTROL PRESSURE EMERGENCY CASING PRESSURE

psig bar psig bar

100

75 50

6.9

5.2

3.4

115

7.9

5.6

4.5

Table 4. Maximum and Minimum Differential Pressures for Main Valve Selection

BODY SIZE

SPRING PART

NUMBER

SPRING

COLOR

MAXIMUM ALLOWABLE

DIFFERENTIAL PRESSURE

(1)

Size 30 Actuator Size 40 Actuator Size 70 Actuator

NPS DN psig bar psig bar psig bar psig bar

14A9687X012 Green 60 4.1 3.5 0.24 2.5 0.17 1 0.07

1 25

14A9680X012 Blue 125 8.6 5 0.34 3 0.21 1.5 0.10

14A9679X012 Red 400

(3)

27.6

(3)

7 0.48 5 0.34 2.5 0.17

14A6768X012 Yellow 20 1.4 - - - - - - - - - - - - - - - - 1 0.07

2 50

14A6626X012 Green 60 4.1 4 0.28 3 0.21 1.5 0.10

14A6627X012 Blue 125 8.6 6 0.41 5 0.34 2 0.14

14A6628X012 Red 400

(3)

27.6

(3)

11 0.76 10 0.69 3 0.21

14A6771X012 Yellow 20 1.4 - - - - - - - - - - - - - - - - 1 0.07

3 80

14A6629X012 Green 60 4.1 5 0.34 4 0.28 2 0.14

14A6630X012 Blue 125 8.6 8 0.55 6 0.41 2.5 0.17

14A6631X012 Red 400

(3)

27.6

(3)

14 0.97 11 0.76 4 0.28

14A6770X012 Yellow 20 1.4 - - - - - - - - - - - - - - - - 1.3 0.09

4 100

14A6632X012 Green 60 4.1 10 0.69 5 0.34 2.5 0.17

14A6633X012 Blue 125 8.6 13 0.90 8 0.55 3 0.21

14A6634X012 Red 400

(3)

27.6

(3)

22 1.5 13 0.90 5 0.34

15A2253X012 Yellow 20 1.4 - - - - - - - - - - - - - - - - 2.2 0.15

6, 8 x 6

or 12 x 6

1. Maximum inlet pressure is equal to set pressure plus maximum differential.

2. Requires special 6300 Series pilot construction without integral relief valve and with external Type 1806 40 psid / 2.8 bar d relief valve.

3. Should not exceed the body rating limit. Use this pressure value or the body rating limit, whichever is lower.

150, 200 x 150

or 300 x 150

14A9686X012 Green 60 4.1 13 0.90 9.5 0.66 4 0.28

14A9685X012 Blue 125 8.6 19 1.3 14 0.97 6 0.41

15A2615X012 Red 400

(3)

27.6

(3)

(2)

MINIMUM DIFFERENTIAL PRESSURE

REQUIRED FOR FULL STROKE

(2)

1.9

19 1.3 8 0.55

Types 1098-EGR and 1098H-EGR

Table 5. Supply Pressure Settings Required for the Type 95H Regulator

SUPPLY PRESSURE

BODY SIZE

NPS DN psig bar psig bar psig bar psig bar psig bar psig bar

1 25

2 50

3 80

4 100

6 or 8 x 6

1. The pressures shown in the table are the minimum supply pressures required by the pilot. If the inlet pressure is less than shown, an external pilot supply is necessary.

150 or

200 x 150

TYPE EGR

SPRING COLOR

Green

Blue

Red

Green

Blue

Red

Green

Blue

Red

Green

Blue

Red

Green

Blue

Red

Red Unpainted Yellow Green Light Blue Black

0.41

0.48

0.55

0.41

0.55

0.90

0.48

0.62

0.97

0.55

0.76

1.1

0.90

1.2

1.5

0.41

0.48

0.55

0.41

0.55

0.90

0.48

0.62

0.97

0.55

0.76

1.1

0.90

1.2

1.5

Type Y600AM Spring Color

0.48

0.55

0.62

0.48

0.62

0.97

0.55

0.69

1.0

0.62

0.83

1.2

0.97

1.2

1.6

8 10 11

9 11

10 12 17

11 14 19

15 20 25

0.55

0.69

0.76

0.62

0.76

1.1

0.69

0.83

1.2

0.76

0.97

1.3

1.0

1.4

1.7

0.76

0.90

0.97

0.83

0.97

1.3

0.90

1.0

1.4

0.97

1.2

1.5

1.2

1.6

1.9

0.90

0.97

1.0

0.90

1.0

1.4

0.97

1.1

1.5

1.0

1.2

1.6

1.4

1.7

2.0

Principle of Operation

The pilot-operated Types 1098-EGR and 1098H-EGR regulators both use inlet pressure as the operating

medium, which is reduced through pilot operation to load the actuator diaphragm. Outlet or downstream pressure

opposes loading pressure in the actuator and also

opposes the pilot control spring. The Type 1098-EGR regulator operation schematic is shown in Figure 2.

In operation, assume that outlet pressure is below the pilot control setting. Control spring force on the

pilot diaphragm opens the pilot valve plug providing

additional loading pressure to the actuator diaphragm.

This loading pressure forces the actuator stem

forward, opening the main valve plug via a bump connection. The upward motion of the plug allows gas to ow through the cage into the downstream system.

When downstream demand has been satised, outlet pressure tends to increase, acting on the pilot and actuator diaphragms. This pressure exceeds the pilot control spring setting, moving the pilot diaphragm away and letting the valve plug spring (Type 6351, 61 Series or Type Y600AM pilots) or bellows (Types 6352 through 6354M pilots) close the pilot valve plug (unbalanced in the Type 6351 or 61 Series pilots but balanced in the Types 6352 through 6354M pilots). Excess loading pressure on the

actuator diaphragm escapes downstream through the

bleed hole (Type 6351 pilot), bleed orice (61 Series pilot), restriction (Types 6352 through 6354M pilots) or xed restrictor (Type Y600AM pilot).

Reduced actuator loading pressure permits the main

valve to close. The combination of main valve spring

force and valve plug imbalance provides positive valve

plug shutoff against the port and upper seals.

To protect the Type 1098 or 1098H actuator diaphragm

from excessive differential pressure, the 6300 Series

pilots have a relief valve that allows loading pressure

to bleed downstream at approximately 25 psig / 1.7 bar differential across the actuator diaphragm. An external relief valve (Type 1806) is required when differential is higher than 25 psi / 1.7 bar or when using the 61 Series or Y600AM pilots.



A mounting assembly for a 40 psi / 2.8 bar differential relief valve is available for the Type 1098-EGR. The standard 25 psi / 1.7 bar differential relief valve

construction is integrally mounted between the loading

and downstream pressures in the 6351 through 6354 Series regulating pilots. Both differential relief

valves protect the main regulator diaphragm from damage that may occur from too high differential

between the loading pressure and downstream pressure.

The 40 psi / 2.8 bar differential relief valve construction is designed specically for the red main valve spring selection in the NPS 6 / DN 150 Type 1098-EGR-6354 with the size 30 actuator. This construction uses the Type 1806H relief valve (with a setting of 40 psi / 2.8 bar)

to relieve excess loading pressure and does not interfere

with the normal operation of the regulator.

TYPE 6351

TYPE 6352, 6353 OR 6354

Types 1098-EGR and 1098H-EGR

TYPE 1098-EGR

A6563

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE

TYPE 1098-EGR WITH 6350 SERIES PILOT

TYPE 1098-EGR

TYPE 1806

A6641

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE

TYPE 61LD

TYPE 1098-EGR WITH TYPE 61LD PILOT AND TYPE 1806 RELIEF VALVE

Figure 2. Operational Schematics

Types 1098-EGR and 1098H-EGR

TYPE 95H

TYPE 1098-EGR

OPTIONAL:

TYPE 112 RESTRICTOR

TYPE Y600AM

M1008

TYPE 1098-EGR WITH TYPE Y600AM PILOT AND TYPE 95H PRESSURE SUPPLY REGULATOR

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE PILOT SUPPLY PRESSURE

Installation and Startup

WARNING

Personal injury, equipment damage or leakage due to escaping accumulated gas or bursting of pressure-containing parts may result if this regulator is overpressured or is installed where service conditions could exceed the limits given



appropriate nameplate or where conditions exceed any ratings of the adjacent piping or piping connections. To avoid such injury or damage, provide pressurerelieving or pressure-limiting devices to prevent service conditions from exceeding those limits.

FIXED RESTRICTOR

Figure 2. Operational Schematics (continued)

Additionally, physical damage to the regulator may result in personal injury and property damage due to escaping accumulated gas. To avoid such injury and damage, install the regulator in a safe location.

Standard Single-Pilot Regulator (Figure 3)

Installations

A Type 1098-EGR or Type 1098H-EGR regulator bleeds no gas to the atmosphere, making it suitable for

installation in pits or other enclosed locations without

elaborate venting systems. This regulator can also be installed in pits subject to ooding by venting the pilot spring case above the expected ood level so that the pilot diaphragm is exposed to atmospheric pressure.

Types 1098-EGR and 1098H-EGR

48A6566-A B1622

4 MAIN PIPE

DIAMETERS

 PIPE

PILOT SUPPLY LINE

FILTER

VENT

10 MAIN PIPE DIAMETERS

TYPE 1098-EGR OR 1098H-EGR REGULATOR WITH STANDARD 6350 SERIES PILOT

Figure 3. Standard Single-Pilot Installation

CONTROL LINE

TO PILOT LIGHT (IF USED FOR BOILER FUEL INSTALLATION)

n 13 mm PIPE

 I 13 mm PIPE

FILTER

TYPE Y600AM AUXILIARY PILOT

48A6566-A B1622

4 MAIN PIPE DIAMETERS

VENT

PILOT SUPPLY LINE

VENT

10 MAIN PIPE DIAMETERS

CONTROL LINE

TYPE 1098-EGR SIZE 70 REGULATOR WITH QUICK OPENING CAGE AND STANDARD TYPE 6352 WORKING PILOT

Figure 4. Typical Dual-Pilot Boiler Fuel Installation

TO PILOT LIGHT

n. 13 mm PIPE

Types 1098-EGR and 1098H-EGR

Note

Normal pressure drop assists shutoff. Therefore, leakage may result during any reverse pressure drop condition.

1. Use qualied personnel when installing, operating and maintaining regulators. Before installing, inspect the main valve, pilot and tubing for any

shipment damage or foreign material that may

have collected during crating and shipment. Make

certain the body interior is clean and the pipelines

are free of foreign material. Apply pipe compound

only to the external pipe threads with a screwed body or use suitable line gaskets and good bolting

practices with a anged body.

With a weld end body, be sure to remove the trim

package, including the gasket, according to the

Maintenance section before welding the body into

the line. Do not install the trim package until any post-weld heat treatment is completed. If heat treating, prevent scale buildup on all machined

guiding and sealing surfaces inside the body and

at the bonnet ange / body joint.

Note

 

the valve body.

2. Install a three-valve bypass around the regulator

if continuous operation is necessary during

maintenance or inspection. The pilot may be eld-

changed to the opposite-side mounting position by swapping the pilot pipe nipple to the opposite

bonnet tapping.

3. To keep the pilot spring case vent from being plugged or the spring case from collecting moisture, corrosive chemicals or other foreign material, point the vent down or otherwise protect it. To remotely vent the standard pilot, remove the vent and install obstruction-free tubing or piping into the 1/4 NPT vent tapping. Provide protection on a remote vent by

installing a screened vent cap into the remote end of

the vent pipe.

4. Run a 3/8 in. / 9.5 mm outer diameter or larger

pilot supply line from the upstream pipeline to

the lter inlet as shown in Figure 3. Do not make

the upstream pipeline connection in a turbulent

area, such as near a nipple, swage or elbow. If

the maximum pilot inlet pressure could exceed the

pilot rating, install a separate reducing regulator in the pilot supply line. Install a hand valve in the

pilot supply line and provide vent valves to properly

isolate and relieve the pressure from the regulator.

5. Attach a 1/2 NPT downstream pressure control

line downstream of the regulator in a straight run

of pipe, as shown in Figure 3. Do not make the tap near any elbow, swage or nipple that might cause turbulence. Connect the other end of the control line to the bonnet connection. Install a hand valve

in the control line to shut off the control pressure

when the bypass is in use.

6. If a quick acting solenoid is to be installed downstream of the regulator, the regulator

and solenoid should be located as far apart as

practical. This maximizes the gas piping volume

between the regulator and solenoid and improves the regulator response to quick-changing

ow rates.

WARNING

A regulator may vent some gas to the atmosphere. In hazardous or



accumulate and cause personal injury,



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 protected against condensation or clogging.

7. Consult the appropriate instruction manual for installation of an optional Type 662 pneumatic or electric remote control drive unit. For optional remote pneumatic loading of a 6350 or 61 Series pilot, make the loading piping connections to the 1/4 NPT vent connection.

Pre-startup Considerations

Before beginning the startup procedures in this section,

make sure the following conditions are in effect:

• Block valves isolate the regulator.

• Vent valves are closed.

• Hand valves are closed.

Types 1098-EGR and 1098H-EGR

CAUTION

Introduce pilot supply pressure into the regulator before introducing any downstream pressure or internal damage may occur due to reverse pressurization of the pilot and main valve components.

Always use pressure gauges to monitor downstream pressure during startup. Procedures used in putting

this regulator into operation must be planned accordingly if the downstream system is pressurized

by another regulator or by a manual bypass.

Note

For proper operation, pilot supply pressure must exceed control pressure



the actuator nameplate as minimum differential pressure.

The only adjustment necessary on a Type 1098-EGR or 1098H-EGR regulator is the pressure setting of

the pilot control spring. Turning the adjusting screw

clockwise into the spring case increases the spring

compression and pressure setting. Turning the

adjusting screw counterclockwise decreases the spring

compression and pressure setting.

Pilot Adjustment

To adjust standard 6350 Series pilots: Loosen the

locknut and turn the adjusting screw. Then tighten the locknut to maintain the adjustment position. On a standard Types 6352 through 6354M pilots, closing

cap must be removed before adjustment and

replaced afterward.

WARNING

To avoid possible personal injury from a pressure-loaded pilot, carefully vent the spring case before removing the closing cap. Otherwise, trapped loading pressure could forcefully eject the freed closing cap.

To adjust the 61 Series or Type Y600AM pilots:

Remove the closing cap and turn the adjusting screw. Any adjustments made should set the controlled

pressure within the appropriate spring range shown

in the Table 2.

Startup

1. Slowly open the pilot supply line hand valve.

2. Slowly open the upstream block valve and partially

open the downstream block valve for minimum

ow. Slowly open the hand valve in the control line.

3. Adjust the pilot setting, if necessary.

4. Completely open the downstream block valve.

5. Slowly close the bypass valve, if any.

Dual-Pilot Boiler Fuel Control

Applications

Boiler Fuel Pressure Control

To enhance proper operation and adequate response to negative pressure shock condition in low differential

pressure boiler fuel control applications, use the Type 1098-EGR boiler fuel conguration:

• Type 1098-EGR with Type 6352 pilot

• Size 70 Actuator

• Quick Opening Cage

• Yellow Main Spring

• Type Y600AM or 627M Auxiliary Pilot

mounted in parallel with the Type 6352 pilot

To provide faster response, two pilots mounted in parallel sense the downstream pressure. The Type 6352 pilot is the primary controlling pilot and the Type Y600AM or 627M auxiliary pilot stands by until it senses a negative pressure shock condition. The auxiliary pilot opens, allowing additional ow into the actuator, increasing the stroking speed and providing faster response. See Figure 5 for schematic. The quick-opening cage allows maximum

capacity at shorter travels to decrease stroking time

in opening and closing directions. The service conditions should not exceed 20 psig / 1.4 bar maximum inlet pressure and 10 psi / 0.69 bar maximum differential pressure.

Supply the boiler pilot light gas with the Type 1098-EGR.

The pilot light gas supply line should branch off the main fuel line downstream of the Type 1098-EGR and

include a separate regulator to control the nal pilot light gas pressure, if required (see Figure 6). This

allows the Type 1098-EGR to have its main valve plug just off the seat waiting for the sudden negative shock created when the boiler solenoid valve is opened to

light the boiler to the high re load. This installation practice signicantly increases the stroking speed of the Type 1098-EGR. See Figure 6 for schematic.

Types 1098-EGR and 1098H-EGR

TYPE 1098-EGR SIZE 70

WITH QUICK OPENING CAGE

20 psibar MAXIMUM

GAS

SUPPLY

SAFTEY SHUT-OFF VALVE

TO BOILER

TYPE 6352

WORKING PILOT

TYPE Y600AM

AUXILIARY PILOT

E0711

Figure 5. Boiler Fuel Conguration

Note

Modulating solenoid load valves provide



one position to the other, effectively preventing sudden pressure changes in the system. Alternately, a snap-acting solenoid valve can be furnished with a characterized valve plug that, by allowing maximum capacity to be reached at a greater proportion of total travel, slows the action slightly. This action does not control shock as effectively as modulating solenoid valves.

Installation

1. Perform the Standard Single-Pilot Regulator Installation section through step 3, making sure

that the regulator is installed with the actuator

below the main valve as shown in Figure 4.

2. Run a 1/2 in. / 13 mm or larger pilot supply line from the upstream pipeline to the 1/2 NPT supply connection in the pipe tee as shown in Figure 4. Do not make the connection in a turbulent area, such as near a nipple, swage or elbow. If the maximum pilot

TYPE 1098-EGR

PILOT

GAS

SUPPLY

PILOT GAS

REGULATOR

E0710

Figure 6. Boiler Fuel Conguration Installation Guide

FAST-ACTING

LOAD VALVE

TO PILOT LIGHT

inlet pressure could exceed the pilot rating, install a

separate regulator in the pilot supply line and provide vent valves so that pressure can be properly isolated

and relieved from the regulator.

3. Attach a 1/2 NPT downstream pressure control line

ten pipe diameters downstream of the regulator in

a straight run of pipe. Do not make the tap near any elbow, swage or nipple, which might cause turbulence. Connect the other end of the control line to the 1/4 NPT connection in the control pipe tee as shown in Figure 4. Install a hand valve in the

control line to shut off the control pressure when

the bypass is in use. Also use the hand valve to dampen out pulsations, which may cause instability or cycling of the regulator.

4. Consult the appropriate instruction manual for

installation of an optional pneumatic or electric

remote control drive unit. For optional remote pneumatic loading of 6350 or 61 Series pilots,

make the loading piping connections to the

1/4 NPT vent connection.

Types 1098-EGR and 1098H-EGR

Type 1098-EGR

1098-EGR Working Monitor

6350 SERIES PILOT

March 2007

Type 1098-EGR

TYPE Y600M OR 627-109 MONITORING PILOT

6350 SERIES PILOT

A6788

INLET PRESSURE

OUTLET PRESSURE

ATMOSPHERIC PRESSURE

LOADING PRESSURE

INTERMEDIATE PRESSURE

Startup

TYPE Y600M OR 627-109 MONITORING PILOT

Figure 7. Typical Working Monitor Installation

2. Connect another downstream pressure control line

1. Slowly open the pilot supply line hand valve.

2. Slowly open the upstream block valve and partially open the downstream block valve for minimum ow.

3. Slowly open the hand valve in the control line and

make sure that the standby pilot is set far enough below the working pilot so that the standby pilot

remains closed during normal operation. For example, with nal desired settings of 11 in. w.c. /

For two typical monitoring pilots, Table 7 gives

27 mbar for the working pilot and 10 in. w.c. / 25 mbar for the standby pilot, begin by reducing

the working pilot setting far enough below

10 in. w.c. / 25 mbar for the working pilot to shut off. Then set the standby pilot for an outlet pressure of 10 in. w.c. / 25 mbar. Finally, set the working pilot for an outlet pressure of 11 in. w.c. / 27 mbar. Table 6 shows how close the standby pilot can be set to the working pilot setting.

4. Completely open the downstream block valve.

Startup

On a working monitor installation (Figure 7), be sure that

the second-stage working regulator is set to operate at a pressure lower than the Type 1098-EGR or 1098H-EGR

working monitor regulator. To do this, increase the setting

5. Slowly close the bypass valve, if any.

Working Monitor (Figure 7)

Installation

of the monitoring pilot until the working pilot is in control of the intermediate pressure and the second-stage working

regulator is in control of the downstream pressure. If this is not done, the monitoring pilot tries to take control of the downstream pressure.

6350 SERIES PILOT

and hand valve (Figure 7) to the monitoring pilot

according to the monitoring pilot instruction manual. Attach a 1/2 NPT pressure control line and hand

valve from the intermediate pressure pipeline to the

working monitor regulator. Pipe supply pressure

between the monitoring pilot and the working monitor regulator according to the monitoring

pilot manual.

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 to open.

1. For both working monitor regulator and working regulator, perform the Standard Single-Pilot Regulator Installation section through step 6.

1. Slowly open the upstream block valve and the hand valves in both pilot supply lines. This

energizes both pilots so that their setpoints can

be adjusted. Partially open the downstream block valve for minimum ow.

Types 1098-EGR and 1098H-EGR

Table 6. Auxiliary Pilot Selection (Fast Stroke Dual Pilot)

SIZE CONSTRUCTION

Type Y600AM 1/4 6.4

3/4

NPT

Type 627M 1/2 13 5 to 10 0.34 to 0.69 10B3076X012 Yellow

Construction

Type 161AYW pilot and 150 psig /

10.3 bar maximum allowable

pilot inlet pressure

Type 627-109 pilot and 150 psig /

10.3 bar maximum allowable pilot

inlet pressure for cast iron body

or 750 psig / 51.7 bar maximum

allowable pilot inlet pressure for

malleable iron or steel body

ORIFICE SPRING RANGE

In. mm psi bar

4 to 8 in. w.c. 10 to 20 mbar 1B653827052 Red

7 to 16 in. w.c. 17 to 40 mbar 1B653927022 Unpainted

15 in. w.c. to 1.2 psi 37 mbar to 0.08 bar 1B537027052 Yellow

1.2 to 2.5 0.08 to 0.17 1B537127022 Green

2.5 to 4.5 0.17 to 0.31 1B537227022 Light Blue

4.5 to 7 0.31 to 0.48 1B537327052 Black

Table 7. Working Monitor Performance

MONITORING PILOT INFORMATION

Spring Range

psig bar

3 to 12 in. w.c.

11 to 25 in. w.c.

25 in. w.c. to 2.5 psi

2.5 to 4.5 psi

4.5 to 7 psi

5 to 20 15 to 40 35 to 80

70 to 150

130 to 200

7 to 30 mbar

27 to 62 mbar

62 mbar to 0.17 bar

0.17 to 0.31

0.31 to 0.4

0.34 to 1.4

1.0 to 2.8

2.4 to 5.5

4.8 to 10.3

9.0 to 13.8

SPRING

NUMBER

Spring Part Number

1B653927022 1B537027052

1B537127022 1B537227022 1B537327052

10B3076X012 10B3077X012 10B3078X012

10B3079X012

SPRING

COLOR

MINIMUM PRESSURE AT WHICH

WORKING MONITOR REGULATOR

3 in. w.c. / 7 mbar over

normal distribution pressure

14 in. w.c. / 34 mbar over

normal distribution pressure

5.0 psig / 0.34 bar over

normal distribution pressure

MINIMUM PRESSURE AT WHICH AUXILIARY

PILOT CAN BE SET

1 in. w.c. / 2 mbar

Under working

pilot setpoint

6 in. w.c. / 14 mbar

Under working

pilot setpoint

8 in. w.c. / 21 mbar

Under working

pilot setpoint

CAN BE SET

3.0 psig / 0.21 bar over

2. To enable intermediate pressure adjustment with the working monitor regulator, slowly open the hand valve in the intermediate pressure control line.

3. To enable downstream pressure adjustment with the second-stage working regulator, slowly open the hand valve in the control line to this regulator.

4. Adjust the setting of the monitoring pilot to

establish the desired emergency downstream

pressure, which is to be maintained in the event

of open failure of the second-stage working

regulator. The emergency downstream pressure

should exceed the desired downstream pressure

by at least the amount listed in Table 7. The steps

followed to set the monitoring pilot may vary with

each piping situation; however, the basic method remains the same. The following sub steps a

and b may be used as examples for setting the monitoring pilot:

a. Increase the outlet pressure setting of the second-

stage working regulator until the monitoring pilot

takes control of the downstream pressure. Adjust

the monitoring pilot setting until the desired

emergency downstream pressure is achieved. Then, readjust the second-stage working regulator to establish the desired downstream pressure.

b. Install special piping (not shown in Figure 7) so

that the monitoring pilot senses the intermediate

pressure. The intermediate pressure then appears

to the monitoring pilot as if it was increased downstream pressure and the monitoring pilot

controls and reduces the intermediate pressure. Adjust the monitoring pilot setting until the desired

emergency downstream pressure is achieved

at the intermediate pressure stage. Then slowly

close the special piping and open up the monitoring downstream control line for

normal service.

5. Slowly open the downstream block valve.

6. Slowly close the bypass valve, if any.

Type 1098-EGR

Type 1098-EGR Upstream or Downstream “Wide-Open” Monitor

6350 SERIES PILOT

PILOT SUPPLY REGULATOR

6350 SERIES PILOT

July 2011

Type 1098-EGR

A6789

INLET PRESSURE

OUTLET PRESSURE

LOADING PRESSURE

MONITOR LOADING PRESSURE

ATMOSPHERIC PRESSURE

INTERMEDIATE PRESSURE

PILOT SUPPLY REGULATOR

6350 SERIES PILOT

Figure 8. Typical Wide-Open Monitor Installations

Types 1098-EGR and 1098H-EGR

6350 SERIES PILOT

NOTICE

Adjustment Recommendations for Monitor Applications

Low amplitude/high frequency monitor trim oscillations can occur if the monitor regulator pressure setting is adjusted too closely to the working regulator pressure setting and/or if the monitor pilot supply regulator pressure setting is adjusted too closely to the monitor

regulator pressure setting. The monitor pressure

setting should be adjusted so it is at minimum two times the pilot proportional band pressure above the

working regulator pressure setting. The monitor pilot

supply pressure setting should be adjusted so it is at

minimum 5 psig / 0.34 bar plus the monitor minimum

differential pressure above the working regulator

pressure setting. These adjustments must be made such that other governing pressure limits, such as casing ratings, pilot maximum differential pressures or regulatory limits, are not exceeded.

Wide-Open Monitor (Figure 8)

Either the upstream or downstream regulator can be

the monitor regulator. 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.

Regardless of which regulator is used as the monitor,

it should be equipped with a pilot supply regulator set

to limit the pilot supply pressure to 10 to 15 psig / 0.69 to 1.0 bar above control pressure. Since the pilot on

the monitoring regulator is wide open during normal

operation, the pilot supply regulator prevents differential relief valve chatter on the monitoring regulator pilot.

Installation

1. For both the wide-open monitoring regulator and the working regulator, perform the Standard SinglePilot Regulator Installation section through step 6.

2. Connect the control line of the wide-open

monitoring regulator (Figure 8) to downstream piping near the working regulator control line

connection. During normal operation the wide-

open monitoring regulator stands wide-open with the pressure reduction being taken across

the working regulator. Only in case of working

regulator failure does the wide-open monitoring

regulator take control at its slightly higher setting.

Startup

Repeat this procedure in turn for each regulator in

the installation.

1. Slowly open the pilot supply line hand valve.

2. Slowly open the upstream block valve and

partially open the downstream block valve for

minimum ow.

Types 1098-EGR and 1098H-EGR

BODY FLANGE

SEAT RING SCREWS INTO CAGE

P1507

Figure 9. Trim Package Removal

CAGE SCREWS INTO BODY FLANGE

3. Slowly open the hand valve in the control line and adjust the pilot setting if necessary. Set the

monitoring regulator at a slightly higher control

pressure than the working regulator.

4. Completely open the downstream block valve.

5. Slowly close the bypass valve, if any.

Shutdown

Installation arrangements vary, but in any installation it

is important that the valves be opened or closed slowly and that the outlet pressure be vented before venting inlet pressure to prevent damage caused by reverse

pressurization of the pilot or main valve. The following steps apply to the typical installation as indicated.

P1508

Figure 10. Seat Ring / Cage Removal or Installation

Using Body as Holding Fixture

4. Slowly open the upstream pipeline vent valve. Allow all pressure to bleed out of both the piping and the pilot.

Working Monitor

1. Slowly close the downstream block valve and the hand valve in the downstream pressure control line.

2. Slowly close the upstream block valve and the hand valves in both pilot supply lines.

3. Slowly open all vent valves and permit all pressures to bleed out of the piping and regulators.

Maintenance

Single-Pilot, Dual-Pilot Regulator or Wide-Open Monitor

As well as applying to a single-pilot regulator (Figure 3),

the steps in this procedure are also valid for a dualpilot regulator (Figure 4) or a wide-open monitoring installation (Figure 8) and just need to be repeated for

each regulator in such an installation.

1. Slowly close the downstream block valve. If the control line is downstream of the block valve, also close the hand valve in the control line.

2. Slowly close the upstream block valve and the hand valve in the pilot supply line.

3. Slowly open the vent valve in the downstream pipeline. If the control line is downstream of the block valve, also open the vent valve in the control line. Permit all pressure to bleed out.

Regulator parts are subject to normal wear and must be

inspected and replaced as necessary. The frequency

of inspection and replacement of parts depends upon the severity of service conditions or the requirements

of local, state and federal regulations. Due to the

care Emerson™ takes in meeting all manufacturing

requirements (heat treating, dimensional tolerances, etc.), use only replacement parts manufactured or furnished by Emerson.

The stem O-rings (key 6, Figure 14) on the Type 1098

or 1098H actuator can be lubricated during regularly

scheduled maintenance, using the grease  tting (key 28, Figure 14). Stem O-rings can be checked

for damage during normal operation by line pressure leakage or unexpected grease extrusion from the

actuator vent (key 27, Figure 14). All O-rings, gaskets

and seals should be lubricated with a good grade of general-purpose grease and installed gently rather

than forced into position. Be certain that the nameplates

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