Emerson S402Y User's Manual

Instruction Manual Form 5319
March 2009
Type S402Y
Type S402Y Pressure Reducing Regulator
!
Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion,
re and/or chemical contamination
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 manufacturer’s 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.
Call a gas service person to service
the unit. Only a qualied person must
install or service the regulator.
Introduction
This installation manual covers the installation and startup procedures for Type S402Y pressure reducing regulators.
Figure 1. Type S402Y Pressure Reducing Regulator Assembly
Scope of the Manual
This instruction manual provides information on installation, maintenance, and replacement parts for Type S402Y pressure-reduction regulators.
Product Description
The Type S402Y is generally employed in residential or small commercial applications in order to reduce
gas distribution pressures to a specied pressure
range from 4.5-inches w.c. to 2.5 psig (11,0 mbar to 0,17 bar). The Type S402Y has an integral high capacity internal relief valve.
The Type S402Y is typically used in residential or small commercial applications to reduce gas distribution pressures down to a reduced pressure range from 4.5-inches w.c. to 2.5 psig (11,0 mbar to 0,17 bar). The Type S402Y has an integral high capacity internal relief valve.
www.emersonprocess.com/regulators
Specications
Specications for Type S402Y construction are found
on page 2. The following information is stamped on
the regulator at the factory: Type number, orice size,
spring range, and date of manufacture.
D101838X012
Type S402Y
Specications
Body Size and End Connection Styles
(1)
NPS 3/4 or 1, NPT
Maximum Operating Inlet Pressure
(2)
125 psig (8,6 bar)
Maximum Allowable Emergency Inlet Pressure
175 psig (12,1 bar)
Allowable Outlet Pressures (Casing)
(2)
Emergency: 10 psig (0,69 bar) Maximum Operating to Avoid Internal Part Damage: 5 psig (0,35 bar)
Outlet Pressure Ranges
(2)
See Table 2
Orice Sizes
Temperature Capabilities
-20° to 160°F (-29° to 71°C)
Pressure Registration
Internal
(2)
Spring Case Vent Connection
1 NPT with removable screen (standard) 3/4 NPT with removable screen (optional)
Spring Case Vent and Body Mounting Positions
See Figure 5
External Dimensions
See Figure 6
Approximate Weight
4 pounds (2 kg)
(2)
See Table 1
1. End connections threaded to other than ASME standards can usually be supplied.
2. The pressure/temperature limits in this Instruction Manual and any applicable standard or code limitation should not be exceeded.
Table 1. Orice Sizes and Cg Coecients
ORIFICE SIZE
Inches mm Psig bar
1/8
3/16
1/4
1. Maximum operating inlet pressure is 125 psig (8,6 bar) for all orice sizes. The optimum performance is based on 2-inches w.c (5 mbar) boost or 1-inch w.c. (2 mbar) droop.
3,2 4,8 6,4
ORIFICE
COLOR CODE
Blue Green Brown
WIDE-OPEN C
RELIEF SIZING
12.5
28.2
50.0
FOR
g
MAXIMUM OPERATING PRESSURE FOR
OPTIMUM PERFORMANCE
125
80 60
(1)
8,6 5,5 4,1
Table 2. Outlet Pressure Ranges and Control Spring Data
OUTLET PRESSURE RANGES
4.5 to 6-inches w.c. (11 to 15 mbar) T13539T0012 Red 0.070 (1,78) 2.50 (63,5)
5.5 to 8-inches w.c. (14 to 20 mbar) T13527T0012 Yellow 0.067 (1,70) 2.59 (65,8)
7.5 to 9.5-inches w.c. (19 to 24 mbar) T13563T0012 Olive drab 0.067 (1,70) 3.24 (82,3)
9.5 to 13-inches w.c. (24 to 32 mbar) T13529T0012 Green 0.075 (1,91) 3.00 (76,2)
13-inches w.c. to 1.5 psig (32 mbar to 0,10 bar) T13564T0012 Unpainted 0.120 (3,05) 1.93 (49,0)
1.5 to 2.5 psig (0,10 to 0,17 bar) T13536T0012 Blue 0.120 (3,05) 2.60 (66,0)
Part Number Color Wire Diameter, Inches (mm) Free length, Inches (mm)
Principle of Operation
CONTROL SPRING DATA
assembly. When downstream demand is reduced, the pressure under the diaphragm increases. This pressure
Inlet pressure ows through the open orice around
the valve disk and disk holder, around the cam stem
down the remaining length of the orice tube and into
the outlet of the regulator body. However, not all of the pressure passes directly from the inlet to the outlet of
overcomes the regulator setting (which is set by a spring) and moves the diaphragm assembly upwards. This upward motion is transferred to the cam stem which in turn bears against the sliding contact point on the back side of the disk holder.
the regulator. Pressure is channelled through openings
in the orice tube and pressurizes the cavity formed by
the body and diaphragm/diaphragm head/cam stem
The inclined surface of the cam then forces the disk
holder toward the orice and reduces gas ow. If a higher
2
INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE
DRILLED CLOSING CAP WITH TRAVEL STOP TO OPEN RELIEF VALVE
FLAPPER
LOWER CASING
Type S402Y
MAIN SPRING
RELIEF VALVE SPRING
DIAPHRAGM
INLET SCREEN
ORIFICE TUBE ASSEMBLY
M1162
INLET PRESSURE
OUTLET PRESSURE
ATMOSPHERIC PRESSURE
Figure 2. Type S402Y Operational Schematic
volume ow rate is demanded downstream, the pressure
under the diaphragm decreases. The control spring force pushes the diaphragm/diaphragm head/cam stem assembly downward and the valve disk moves away
from the orice.
At the lockup (complete shutoff) position the ratio of the diaphragm travel to disk travel is 4 to 1 giving the regulator an effective 4 to 1 lever ratio for positive lockup.
The cam stem is characterized for higher downstream
demand to produce a mechanical boost effect.
Type S402Y regulator includes an internal relief valve for overpressure protection. If the downstream pressure exceeds the regulator setting and the regulator is not able to achieve complete shutoff (lockup) due to foreign
matter lodged between the orice and the valve disk
or a failure in the valve disk, the regulator diaphragm assembly moves upwards trying to push the valve
disk against the orice. The valve disk and disk holder being pressed against the orice will prevent the cam
stem from being able to travel any further upward in conjunction with the diaphragm assembly. The continued leakage of the inlet pressure into the regulator cavity will then force the diaphragm and diaphragm head up off of the seating area of the relief valve overcoming
CAM STEM
DISK HOLDER ASSEMBLY
VALVE DISK
the relief valve spring which was pressing them together. The resulting gap will allow pressure to exit the regulator cavity and exhaust through the openings in the diaphragm head and out the spring case vent to atmosphere.
Installation
!
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 in Specication Section.
To avoid such injury or damage, provide pressure-relieving or pressure-limiting devices (as required by Title 49, Part 192, of the U.S. Code of Federal Regulations, by the National Fuel Gas Code Title 54 of the National Fire Codes of the National Fire Protection Association, or by other
3
Type S402Y
applicable codes) to prevent service conditions from exceeding those limits.
Additionally, physical damage to the regulator could result in personal injury or property damage due to escaping gas.
To avoid such injury and damage, install the regulator in a safe location.
1. Only personnel qualied through training and experience should install, operate, and maintain a regulator. Before installing a Type S402Y regulator, check for damage which have might ocurred in shipment. Also check for dirt or foreign materials which may have accumulated in the regulator body or in the pipeline.
2. The Type S402Y may be installed in any position
(vertical or horizontal). Apply a good grade of
pipe compound to the male threads (being
sure not to apply pipe compound to ow path
of the pipe) of the pipe and install the regulator
so the ows is in the direction of the arrow cast
on the body. Use approved piping procedures when installing the regulator. The spring case can be rotated to any position relative to the body.
require additional vent protection from the elements. Such protection may be with separate hood, shields, or the Fisher
4. Regulator operation within the ratings does not preclude the possibility of damage from the debris in the lines or from external sources. A regulator should be inspected for damage periodically and after any overpressure condition.
5. With proper installation completed, slowly open the upstream and downstream shutoff valves. Check all connections for leaks. Check the downstream equipment for proper operation.
6. If outlet pressure adjustment is necessary, monitor downstream pressure with a gauge during the adjustment procedure. To increase the outlet pressure, the adjusting screw (key 12, Figure 1) must be turned clockwise. This requires removal of the closing cap (key 11, Figure 1). To reduce the outlet pressure setting, turn the adjusting screw counter-clockwise. Do not adjust the spring to procedure an outlet pressure setting above the limit stamped on the regulator.
®
Y602 Series vents.
Overpressure Protection
!
A regulator may vent some gas to the atmosphere. In hazardous or
ammable gas service, vented gas
may accumulate, and cause personal injury, death, or property damage due
to re 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 protected against condensation or clogging.
Under enclosed conditions or indoors, escaping gas may accumulate and be an explosion hazard. In these cases, the Type S402Y vent should be piped away from the regulator to a safe location outdoors.
3. On outdoors installations, regulators installed with vents in positions other than vertically down
The wide-open Cg for relief sizing along with the capacity information should be used in choosing appropriate overpressure protection devices to
ensure that none of the limits in the Specications
section, Table 1, or Table 2 are exceeded.
Overpressuring any portion of a regulator or associated equipment may cause leakage, parts damage, or personal injury due to bursting of pressure-containing parts or explosion of accumulated gas. Regulator operation within ratings does not prevent the possibility of damage from external sources or from debris in the pipeline. A regulator should be inspected for damage after any overpressure condition.
Startup
!
In order to avoid an overpressure condition and possible equipment damage, pressure gauges should always be used to monitor pressures during startup.
4
Type S402Y
1. Check to see that all downstream equipment is turned off.
2. Slowly open the upstream shutoff valve.
3. Slowly open the downstream shutoff valve.
4. Check all connections for leaks.
5. Light the downstream equipment pilot lights if applicable.
Adjustment
If set pressure adjustment is necessary, monitor downstream pressure with a gauge during the adjustment procedure. To increase the outlet pressure, the adjusting screw (key 12) must be turned clockwise. This requires removal of the closing cap (key 11). To reduce the outlet pressure setting, turn the adjusting screw counterclockwise. Do not adjust the spring to produce an outlet pressure setting above the limit stamped on the regulator.
The range of allowable pressure settings is stamped on the regulator. If a pressure setting beyond this range is necessary, substitute the appropriate regulator control spring. When changing the spring, also change the range stamped on the regulator to indicate the actual pressure range of the spring in use.
Before increasing the setting, refer to Table 1. Review the pressure limits for the control spring range being used and be certain that the new pressure setting will not result in an overpressure condition. After the spring adjustment has been completed, replace the closing cap.
Maintenance
!
To avoid personal injury or equipment damage from sudden release of pressure or uncontrolled gas, do not attempt any maintenance or disassembly without
rst isolating the regulator from
system pressure and relieving all internal pressure as described in the shutdown procedure.
Regulators that have been diassembled for repair must be tested for proper operation before being returned to service. Due to the care Fisher takes in meeting all manufacturing requirements (heat treating, dimensional tolerances, etc.), use only replacement parts manufactured or furnished by Fisher to repair Fisher® regulators. Relight pilot lights according to normal startup procedures.
Due to normal wear or damage that may occur from external sources, this regulator should be inspected and maintained periodically. The frequency of inspection and replacement of parts depends upon the severity of service conditions or the requirements of local, state, and federal rules and regulations.
A program of periodic regulator inspection should be established. Visually inspect the regulator for:
Shutdown
Installation arrangements may vary, but in any installation it is important that the shutoff 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
regulator. The steps below apply to the typical installation as indicated.
1. Slowly close the upstream shutoff valve.
2. Release downstream pressure and be sure the upstream pressure has been exhausted.
1. Improper installation.
2. Plugged or frozen vent.
3. Wrong regulator in the system.
4. Internal or external corrosion.
5. Age of the regulator.
6. Any other condition that could cause the uncontrolled escape of gas.
Failure to establish an inspection program, as outlined above, could result in personal injury or property damage.
5
Type S402Y
Make sure the regulator vent, vent assembly, or vent pipe does not become plugged by mud, insects, ice, snow, paint, or etc. The vent screen aids in keeping the vent from becoming plugged, and the screen should be clean and properly installed.
Replace any regulators that have had water in their spring case and/or show evidence of external or internal corrosion. Checking for internal corrosion may require complete removal of the adjusting screw and shutdown of the gas system.
Older regulators are more likely to fail because of worn, damaged or corroded parts. Periodic
repair of the diaphragm assembly, orice tube
assembly, and other parts subject to wear and/ or corrosion; or a systematic replacement program should be based on the regulator’s performance, the service area’s environment, installation practices, and historical experience.
The following procedures are for complete regulator disassembly and assembly. All pressure must be released from the regulator before the following steps can be performed. While using the maintenance procedures, refer to Figure 3 for key number locations.
Note
The regulator may remain in the pipeline during maintenance procedures unless the body (key 1) is replaced or removed for repairs.
5. Reassemble in the reverse order of the above procedures. Place the diaphragm assembly into position in the lower casing, being sure the cam stem (key 10) is properly inserted into the
orice tube assembly (key 7). Note that the
diaphragm plate is marked with “Inlet” and “Outlet”. Install the spring case assembly (key 3) and using a crisscross pattern, tighten the spring case screws (key 13).
Orice Tube Assembly Replacement
1. Remove the spring case screws (key 13) which hold the lower casing to the body (key 1).
Note
When the actuator assembly is separated from the body, do not rotate
the diaphragm/relief valve assembly
without removing the spring case screws (key 13). The assembly incorporates an anti-rotation design, any rotational movement will damage
the cam stem/diaphragm assembly.
2. Remove the diaphragm/relief valve assembly (key 10) by tilting it toward the outlet so that the
cam stem slides up and out of the orice tube
assembly (key 7).
3. Remove the orice tube screws (key 9) and then the orice tube assembly (key 7).
Control Spring or Diaphragm Assembly Replacement
1. Remove the closing cap (key 11) and turn the adjusting screw (key 12) counterclockwise until all compression is removed from the control spring (key 6).
2. If changing the control spring (key 6) is the only maintenance required, remove and replace the control spring.
3. To replace or reposition the spring case, remove the spring case screws (key 13) and lift off the spring case assembly (key 3).
4. For diaphragm maintenance, remove the diaphragm assembly by tilting it toward the outlet so that the cam stem may be
pulled up and out of the orice tube
assembly (key 7).
4. Reassemble in the reverse order of the above
procedure. Be sure to use a new orice tube
O-ring (key 8), body with O-ring lubricant.
5. Tighten the spring case screws (key 13) to
80-inch-pounds (9.0 N•m) of torque.
6. If necessary, refer to the installation and/or the startup and adjustment procedures.
Parts Ordering
When corresponding with your local Sales Ofce about
this equipment, always reference the Type number that can be found stamped on the regulator.
When ordering replacement parts, reference the key number of each needed part as found in the following parts list. Separate kits containing all recommended spare parts are available. If construction changes
are made in the eld, be sure that the information on the regulator is also changed to reect the most
recent construction.
6
Type S402Y
3
11
12 6
10
9
1
22
- Apply Lub / Sealant
4
5
16
8
7
13
T80288
Figure 3. Type S402Y Pressure Reducing Regulator Assembly
7
Type S402Y
Parts List
Key Description Part Number
1 Body, Cast Iron No Gauge Tap NPS 3/4, NPT T80281T0012 NPS 1, NPT T80282T0012 Outlet Gauge Tap NPS 3/4, NPT T13649T0012 NPS 1, NPT T13649T0022 3 Spring Case Assembly For 1 NPT vent T20932T0012 For 3/4 NPT vent T20932T0032 4 Screen-Vent, 18-8 Stainless Steel T1121338982 5 Retaining Ring, Zinc-plated Steel T1120925072 6 Control spring
4.5 to 6-inches w.c. (11 to 15 mbar), 302 SST T13539T0012
5.5 to 8-inches w.c. (14 to 20 mbar), Zinc-plated steel T13527T0012
7.5 to 9.5-inches w.c. (19 to 24 mbar), Zinc-plated steel T13563T0012
9.5 to 13-inches w.c. (24 to 32 mbar), Zinc-plated steel T13529T0012 13-inches w.c. to 1.5 psig (0,03 to 0,10 bar), 302 SST T13564T0012
1.5 to 2.5 psig (0,10 to 0,17 bar), Steel T13536T0012
Key Description Part Number
7 Orice Tube Assembly T13651T0012
1/8-inch T13651T0012 3/16-inch T13651T0112 1/4-inch T13651T0032
8* Orice Tube, O-Ring, Nitrile (NBR) 18B3438X012 9 Orice Tube Screw, Steel T13526T0012
10 Diaphragm/Relief Valve Assembly Relief Valve Spring Color Blue T20930T0012 Orange T20930T0022 Green T20930T0032 Red T20930T0042 Brown T20930T0052 11 Closing Cap, ASA 309, Gray T13524T0062 12 Adjusting Screw
4.5 to 6-inches w.c. (11 to 15 mbar), Delrin
5.5 to 8-inches w.c. (14 to 20 mbar), Delrin T13523T0012
7.5 to 9.5-inches w.c. (19 to 24 mbar), Delrin T13523T0012
9.5 to 13-inches w.c. (24 to 32 mbar), Delrin T13523T0012 13-inches w.c. to 1.5 psig (32 mbar to 0,10 bar), Zinc 1B537944012
1.5 to 2.5 psig (0,10 to 0,17 bar), Zinc 1B537944012 13 Machiine Screw, Steel (4 required) T13646T0012 16 Pipe Plug, 304 Stainless Steel 1E823135042 22 Screen, 18-8 Stainless steel For 3/4 NPT vent T13643T0012 For 1 NPT vent T13644T0012 23* Gasket, Neoprene (CR) (not shown) 1P753306992
®
T13523T0012
*Recommended spare part. Delrin® is a mark owned by E. I. du Pont de Nemours and Co.
Industrial Regulators
Emerson Process Management Regulator Technologies, Inc.
USA - Headquarters McKinney, Texas 75069-1872 USA Tel: 1-800-558-5853 Outside U.S. 1-972-548-3574
Asia-Pacic
Shanghai, China 201206 Tel: +86 21 2892 9000
Europe Bologna, Italy 40013 Tel: +39 051 4190611
Middle East and Africa Dubai, United Arab Emirates Tel: +971 4811 8100
For further information visit www.emersonprocess.com/regulators
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 eort 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 specications 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.
Natural Gas Technologies
Emerson Process Management Regulator Technologies, Inc.
USA - Headquarters McKinney, Texas 75069-1872 USA Tel: 1-800-558-5853 Outside U.S. 1-972-548-3574
Asia-Pacic
Singapore, Singapore 128461 Tel: +65 6777 8211
Europe Bologna, Italy 40013 Tel: +39 051 4190611 Gallardon, France 28320 Tel: +33 (0)2 37 33 47 00
TESCOM
Emerson Process Management Tescom Corporation
USA - Headquarters Elk River, Minnesota 55330-2445 USA Tel: 1-763-241-3238
Europe Selmsdorf, Germany 23923 Tel: +49 (0) 38823 31 0
©Emerson Process Management Regulator Technologies, Inc., 1992, 2009; All Rights Reserved
Loading...