Emerson Fisher 1098-EGR, Fisher 1098H-EGR Instruction Manual
Instruction Manual
Form 5084
February 2016
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 check
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
www.fisherregulators.com
Types 1098-EGR and 1098H-EGR
The Specications section lists pressure limitations and other specications for various Types 1098-EGR and
1098H-EGR constructions. Specications 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). To determine maximum pressure ratings, the individual ratings for the main valve, actuator and
pilot must all be considered.
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
Actuator Sizes and Maximum Pressures
See Table 3
Maximum and Minimum Differential Pressures
See Table 4
Main Valve Flow Characteristic
Linear (standard), Whisper Trim
™
or
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.
Table 1. Body Sizes and End Connection Styles
Ethylenepropylene (EPDM):
-20 to 275°F / -29 to 135°C
Options
• NACE Construction
• Boiler Fuel Construction
• Aqueous Service Construction
• Monitor Conguration
• Noise Abatement Trim
(1)
BODY SIZE
NPS 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
2
CAST IRON STEEL OR STAINLESS STEEL
PILOT TYPE
6351
6352
6353
(1)
6354L
(2)
6354M
(2)
6354H
61L
61LD
61LE
61H 10 to 65 0.69 to 4.5 Green Stripe 0Y066427022
61HP
Y600AM
1. Without diaphragm limiter.
2. With diaphragm limiter.
Types 1098-EGR and 1098H-EGR
Table 2. Outlet Pressure Ranges
OUTLET PRESSURE RANGE
psig bar
3 to 20
5 to 35
35 to 100
14 in. w.c. to 2 psig
2 to 10
3 to 40
35 to 125
0.21 to 1.4
0.35 to 2.4
2.4 to 6.9
35 mbar to 0.1 bar
0.14 to 0.69
0.21 to 2.8
2.4 to 8.6
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
7 in. w.c. to 2 psig
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.
7 to 16 in. w.c.
15 in. w.c. to 1.2 psig
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 40 mbar
37 mbar to 0.08 bar
0.08 to 0.17
0.17 to 0.31
0.31 to 0.48
SPRING COLOR SPRING PART NUMBER
Green
Unpainted
Red
Yellow
Black
Yellow
Red
Red
Yellow
Blue
Brown
Green
Yellow
Blue
Red
Red
Unpainted
Yellow
Green
Light Blue
Black
1B986027212
1B788327022
1K748527202
14A9672X012
14A9673X012
1E392527022
1K748527202
1B886327022
1J857827022
1B886427022
1J857927142
1B886527022
1E392527022
1D387227022
1D465127142
1B653827052
1B653927022
1B537027052
1B537127022
1B537227022
1B537327052
Table 3. Actuator Sizes and Maximum Pressures
ACTUATOR TYPE ACTUATOR SIZE
1098
30
40 (standard)
70
1098H 30 350 24.1 400 27.6
OUTLET CONTROL PRESSURE EMERGENCY CASING PRESSURE
psig bar psig bar
100
75
50
6.9
5.2
3.4
115
82
65
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 - - - - - - - - 2 0.14 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 - - - - - - - - 2.5 0.17 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 - - - - - - - - 3.5 0.25 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 - - - - - - - - 6 0.42 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 check valve and with external Type 1806H 40 psid / 2.8 bar d check 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)
28
MINIMUM DIFFERENTIAL PRESSURE
REQUIRED FOR FULL STROKE
(2)
1.9
19 1.3 8 0.55
3
Types 1098-EGR and 1098H-EGR
Table 5. Recommended Type MR95H Pressure Settings for Use with the Type Y600AM Pilot
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
6
0.41
7
0.48
8
0.55
6
0.41
8
0.55
13
0.90
7
0.48
9
0.62
14
0.97
8
0.55
11
0.76
16
1.1
13
0.90
17
1.2
22
1.5
6
0.41
7
0.48
8
0.55
6
0.41
8
0.55
13
0.90
7
0.48
9
0.62
14
0.97
8
0.55
11
0.76
16
1.1
13
0.90
17
1.2
22
1.5
Principle of Operation
Type Y600AM Spring Color
7
0.48
8
0.55
9
0.62
7
0.48
9
0.62
14
0.97
8
0.55
10
0.69
15
1.0
9
0.62
12
0.83
17
1.2
14
0.97
18
1.2
23
1.6
8
10
11
9
11
16
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
11
0.76
13
0.90
14
0.97
12
0.83
14
0.97
19
1.3
13
0.90
15
1.0
20
1.4
14
0.97
17
1.2
22
1.5
18
1.2
23
1.6
28
1.9
13
0.90
14
0.97
15
1.0
13
0.90
15
1.0
20
1.4
14
0.97
16
1.1
21
1.5
15
1.0
18
1.2
23
1.6
20
1.4
24
1.7
29
2.0
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 satised, 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 orice (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 6350 Series
pilots have an integral check valve that allows loading
pressure to bleed downstream at approximately
25 psig / 1.7 bar differential across the actuator
diaphragm. An external check valve (Type 1806)
is required when differential is higher than 25 psi /
1.7 bar or when using the 61 Series or Y600AM pilots.
with the normal operation of the regulator.
4
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
TYPE 61LD
A6641
INLET PRESSURE
OUTLET PRESSURE
ATMOSPHERIC PRESSURE
LOADING PRESSURE
TYPE 1098-EGR WITH TYPE 61LD PILOT
Figure 2. Operational Schematics
5
Types 1098-EGR and 1098H-EGR
TYPE MR95H
TYPE 1098-EGR
OPTIONAL:
TYPE 112 RESTRICTOR
TYPE Y600AM
M1008
INLET PRESSURE
OUTLET PRESSURE
ATMOSPHERIC PRESSURE
LOADING PRESSURE
PILOT SUPPLY PRESSURE
TYPE 1098-EGR WITH TYPE Y600AM PILOT AND TYPE MR95H PRESSURE SUPPLY REGULATOR
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.
6
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
7
Types 1098-EGR and 1098H-EGR
Note
Normal pressure drop assists shutoff.
Therefore, leakage may result during any
reverse pressure drop condition.
1. Use qualied 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.
2. The regulator maybe installed in any orientation,
as long as ow through the regulator matches the
direction of the ow arrow attached to the valve
body. However, mounting the main valve with the
valve stem in a horizontal position may experience
stem wear on units with a size 70 actuator or
NPS 4 and larger.
3. 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.
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.
4. 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.
5. 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.
6. 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.
7. 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.
8. 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.
8
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
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 conguration:
• 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 4 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.
If a pilot light is present, supply it 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 5). 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 signicantly increases the
stroking speed of the Type 1098-EGR. See Figure 5
for schematic.
9
Types 1098-EGR and 1098H-EGR
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 4, 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
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.
GAS
SUPPLY
TYPE 1098-EGR
PILOT
SUPPLY
E0710
Figure 5. Boiler Fuel Conguration Installation Guide
SAFETY SHUT-OFF VALVE
GAS
PILOT GAS
REGULATOR
FAST-ACTING
LOAD VALVE
TO PILOT LIGHT
TO BOILER
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. /
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.
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.
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.
5. Slowly close the bypass valve, if any.
Working Monitor (Figure 6)
Installation
1. For both working monitor regulator and working
regulator, perform the Standard Single-Pilot
Regulator Installation section through step 7.
2. Connect another downstream pressure control line
and hand valve (Figure 6) 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.
For two typical monitoring pilots, Table 7 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 to open.
10
Types 1098-EGR and 1098H-EGR
Type 1098-EGR
1098-EGR Working Monitor
6350 SERIES PILOT
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
TYPE Y600M OR 627-109
MONITORING PILOT
Figure 6. Typical Working Monitor Installation
Startup
On a working monitor installation (Figure 6), 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
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.
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.
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
a. Increase the outlet pressure setting of the
b. Install special piping (not shown in Figure 6) so
5. Slowly open the downstream block valve.
6. Slowly close the bypass valve, if any.
6350 SERIES PILOT
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:
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.
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.
11
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 1000 psi /
69 bar maximum allowable pilot
inlet pressure
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
normal distribution pressure
14 in. w.c. / 34 mbar over
normal distribution pressure
normal distribution pressure
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 in. w.c. / 7 mbar over
3.0 psig / 0.21 bar over
5.0 psig / 0.34 bar over
Wide-Open Monitor (Figure 7)
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.
Note that if using a downstream monitor setup, the
upstream worker regulator actuator must be rated to the
application’s full inlet pressure or be protected from it in
case it fails wide-open.
Regardless of which regulator is used as the monitor, it
should be equipped with a pilot supply regulator set to
5 psig / 0.34 bar plus the monitor minimum differential
presure above the working regulator pressure setting.
Since the pilot on the monitoring regulator is wide open
during normal operation, the pilot supply regulator
prevents differential check valve chatter on the
monitoring regulator pilot.
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. 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.
Installation
1. For both the wide-open monitoring regulator
and the working regulator, perform the Standard
Single-Pilot Regulator Installation section through
step 7.
12
A6789
INLET PRESSURE
OUTLET PRESSURE
LOADING PRESSURE
PILOT SUPPLY PRESSURE
ATMOSPHERIC PRESSURE
INTERMEDIATE PRESSURE
FILTER
FILTER
Types 1098-EGR and 1098H-EGR
PILOT SUPPLY REGULATOR
6350 SERIES PILOT
Figure 7. Typical Wide-Open Monitor Installations
6350 SERIES PILOT
2. Connect the control line of the wide-open
monitoring regulator (Figure 7) 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.
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.
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 dual- pilot
regulator (Figure 4) or a wide-open monitoring
installation (Figure 7) 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.
4. Slowly open the upstream pipeline vent valve.
Allow all pressure to bleed out of both the piping
and the pilot.
13
Types 1098-EGR and 1098H-EGR
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
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 13) on the Type 1098
or 1098H actuator should be lubricated during regularly
scheduled maintenance, using the grease tting
(key 28, Figure 13). 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 13). Unless otherwise
speci ed, 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 (key 13,
Figure 13) are updated to accurately indicate any eld
changes in equipment, materials, service conditions or
pressure settings.
WARNING
!
To avoid personal injury resulting
from sudden release of pressure,
isolate the regulator from all pressure
and cautiously release trapped
pressure from the regulator before
attempting disassembly.
Type EGR Main Valve
Replacing Quick-Change Trim Package
Perform this procedure if the entire trim package is
replaced. Key numbers for both the complete main
valve and its trim package are referenced in Figures 11
and 12. Some replacement trim package assembly
numbers are listed in a table in the parts list.
SEAT RING
SCREWS INTO CAGE
P1507
All disassembly, trim change and
reassembly steps in this section may be
performed with the regulator in the main
line and without disconnecting the pilot
supply or control lines.
1. Remove the cap screws (key 3) with a cast iron
body or remove the stud bolt nuts (key 29, not
shown) with a steel body. Pry the body ange
(key 2) from the valve body (key 1) and lift out the
trim package.
2. Perform any required inspection, cleaning or
maintenance on the exposed surfaces of the valve
body (key 1) or trim package. Replace the gasket
(key 4) or cage O-ring (key 17) as necessary.
3. On a pre-built replacement trim package, check
indicator zeroing by unscrewing the indicator
protector (key 19) and seeing if the ange of the
indicator nut (key 22) lines up evenly with the
bottom marking on the indicator scale (key 18).
If not, remove the indicator scale and separate
the indicator nut and hex nut (key 8). Hold the
indicator scale against the indicator tting (key 5)
with the scale base resting against the shoulder of
the tting and turn the indicator nut until its ange
is aligned with the bottom scale marking. Then
lock both nuts against each other and install the
indicator scale and protector.
4. Coat the cage seating surface of the valve body
(key 1) web and the body ange (key 2) seating
surfaces of the valve body neck with a good
grade of general-purpose grease. Install the trim
package and secure it evenly with the cap screws
(key 3) or stud bolt nuts (key 29, not shown).
No particular trim package orientation in the body
is required.
Figure 8. Trim Package Removal
Note
BODY FLANGE
CAGE SCREWS INTO
BODY FLANGE
14
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