Fisher 589 Instruction Manual

Instruction Manual Form 589

February 2016

Type 99 Pressure Reducing Regulator

WARNING

Since a pilot-operated regulator is constructed of both a pilot and a main valve, care should be used not to exceed the maximum inlet pressure shown on the nameplate of either unit. When inlet pressure exceeds the pilot limitation, a pilot supply reducing regulator and/or relief valve is required.

Type 99

WARNING

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

and/or re 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. 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.

W2676

Figure 1. Type 99 Regulator with Type 61H (High Pressure) Pilot

Introduction

Scope of the Manual

This manual describes and provides instructions for installation, startup, adjustment and parts ordering information of Type 99 pressure reducing regulator

complete with standard P590 Series integral lter.

Information on other equipment used with this

regulator can be found in separate manuals.

www.fisherregulators.com

D100260X012

Type 99

Specications

Specications and ratings for various Type 99 constructions are listed in the Specications section below. Some specications for a given regulator as it originally comes from the factory are stamped on the nameplates located on the pilot and actuator spring cases. An additional nameplate may be installed on the pilot to indicate a regulator with O-ring stem seal. These regulators and their installations should be checked for compliance with applicable codes.

Available Constructions Type 99L - Type 99 with Type 61L pilot which

has 2 in. w.c. to 20 psig / 5 mbar to 1.4 bar

pressure range

Type 99LD - Type 99 with Type 61LD pilot

which has a narrower proportional band than the standard Type 61L pilot

Type 99LE - Type 99 with Type 61LE pilot which

has a broader proportional band than the standard Type 61L pilot

Type 99H - Type 99 with Type 61H pilot which has

10 to 65 psig / 0.69 to 4.5 bar pressure range

Type 99HP - Type 99 with Type 61HP pilot has

35 to 100 psig / 2.4 to 6.9 bar pressure range

Body Size and End Connection Styles

NPS 2 / DN 50 body with NPT, CL125 FF, CL150 RF, CL250 RF and CL300 RF end connections

Maximum Allowable Inlet Pressure

(1)

160 psig / 11.0 bar: Type 61LD pilot 400 psig / 27.6 bar: Type 61L, 61LE or 61H pilots 1000 psig / 69.0 bar: Type 61HP pilot, along with

Type 1301F pilot supply regulator and Type H110

relief valve (1/2 in. / 13 mm orice only)

Outlet (Control) Pressure Ranges

(1)

See Table 1

Approximate Proportional Bands

See Table 2

Maximum Allowable Pressure Drop

(1)

See Table 3

Maximum Actuator Pressures

(1)

Operating: 100 psig / 6.9 bar Emergency: 110 psig / 7.6 bar

Maximum Pilot Spring Case Pressure for Pressure Loading

(1)(2)

Types 61L, 61LD and 61LE: 50 psi / 3.4 bar

with special steel closing cap

Types 61H and 61HP: 100 psi / 6.9 bar

Minimum Di󰀨erential Pressure Required for

Full Stroke

See Table 3

Maximum Rated Travel

1/4 in. / 6.4 mm

Temperature Capabilities

(1)

With Nitrile (NBR) / Neoprene (CR) / Nylon (PA):

-20 to 180°F / -29 to 82°C With Fluorocarbon (FKM):

0 to 300°F / -18 to 149°C

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

2. For stability or overpressure protection, a pilot supply regulator may be installed in the pilot supply tubing between the main valve and pilot.

Description

The Type 99 gas regulator provides a broad capacity for controlled pressure ranges and capacities in a wide variety of distribution, industrial and

commercial applications.

A Type 99 regulator has a Type 61L, 61LE or 61LD (low pressure); Type 61H (high pressure); or Type 61HP (extra high pressure) pilot integrally mounted to the

actuator casing as shown in Figure 1. The Type 99 regulator can handle up to 1000 psig / 69.0 bar inlet

pressure (the 1000 psig / 69.0 bar regulator requires

a Type 1301F pilot supply regulator and a Type H110

pop relief valve). The pilot supply regulator reduces

inlet pressure to a usable 200 psig / 14 bar for the

extra high-pressure pilot. The standard Type 99

regulator comes with O-ring seals on the guide bushing and valve carrier to keep main valve body outlet pressure from interfering with outlet pressure in

the lower casing assembly.

Type 99

MAIN VALVE SPRING

MAIN DIAPHRAGM

PUSHER POST ASSEMBLY

PILOT DIAPHRAGM ASSEMBLY

A6814

INLET PRESSURE

OUTLET PRESSURE

ATMOSPHERIC PRESSURE

LOADING PRESSURE

OUTLET PIPE

INLET

PILOT DIAPHRAGM

PILOT CONTROL SPRING

Figure 2. Schematic of Type 99 Regulator with Type 61L (Low Pressure) Pilot

BLEED VALVE

BLEED ORIFICE

PILOT ORIFICE

Principle of Operation

The key to the operation of a Type 99 regulator is the

yoked double-diaphragm pilot. Fast response and

accuracy are made possible by the amplifying effect of the pressure-balanced pilot and by the two-path

control system. The function of the pilot is to sense

change in the controlled pressure and amplify it into a

larger change in the loading pressure. Any changes

in outlet pressure act quickly on both the actuator diaphragm and the loading pilot, thus providing the precise pressure control that is a characteristic of a

two-path system.

A typical pilot has an approximate gain of 20, which means the outlet pressure needs to droop only 1/20 as much as a direct-operated regulator in order to obtain the same pressure differences across the main

diaphragm. Advantages of a pilot-operated regulator are high accuracy and high capacity.

Upstream or inlet pressure is utilized as the operating medium, which is reduced through pilot operation to

load the main diaphragm chamber. Tubing connects the inlet pressure to the pilot through a lter assembly.

Downstream or outlet pressure registers underneath the

main diaphragm through the downstream control line.

In operation, assume the outlet pressure is less than

the setting of the pilot control spring. The top side

of the pilot diaphragm assembly will have a lower

pressure than the setting of the spring. Spring forces

the diaphragm head assembly upward, opening the

relay or inlet orice. Additional loading pressure is

supplied to the pilot body and to the top side of the

main diaphragm.

This creates a higher pressure on the top side of the main diaphragm than on the bottom side, forcing the

diaphragm downward. This motion is transmitted

through a lever, which pulls the valve disk open,

allowing more gas to ow through the valve.

When the gas demand in the downstream system

has been satised, the outlet pressure increases.

The increased pressure is transmitted through the downstream control line and acts on top of the pilot

diaphragm head assembly. This pressure exceeds

the pilot spring setting and forces the head assembly

down, closing the orice. The loading pressure acting

on the main diaphragm bleeds to the downstream system through a small slot between the pilot bleed

valve and the bleed orice.

Type 99

DOWNSTREAM CONTROL LINE

MAIN DIAPHRAGM

PUSHER POST ASSEMBLY

54A2767-a A2505

INLET PRESSURE

OUTLET PRESSURE

ATMOSPHERIC PRESSURE

LOADING PRESSURE

MAIN VALVE SPRING

BLEED ORIFICE

BLEED VALV E

RELIEF VALV E BODY

YOKE CAP

YOKE LEG

INLET PRESSURE TUBING

PILOT DIAPHRAGM

FLANGE ADAPTOR

CONNECTION

PILOT SPRING

YOKE CAP

Figure 3. Schematic of Type 99 Regulator with Type 61HP (Extra High Pressure) Pilot

RELIEF VALV E CAP

DIAPHRAGM

RELAY VALV E

ORIFICE

Table 1. Outlet Pressure Ranges

PILOT

TYPE

MAXIMUM PILOT

SUPPLY PRESSURE

psig bar psig bar In. mm In. mm

61L 400 27.6

61LD 160 11.0

61LE 400 27.6

OUTLET (CONTROL)

PRESSURE RANGE

2 to 4 in. w.c.

3 to 12 in. w.c.

0.25 to 2

1 to 5 2 to 10 5 to 15

10 to 20

(1)

5 to 10 mbar 7 to 30 mbar

0.02 to 0.14

0.07 to 0.35

0.14 to 0.69

0.35 to 1.0

0.69 to 1.4

Part Number Color Code

(1)

1B558527052

(1)

1C680627222 1B886327022 1J857827022 1B886427022 1J857927142 1B886527022

61H 400 27.6 10 to 65 0.69 to 4.5 0Y066427022 Green stripe 0.36 9.22 6.00 152

61HP 600 41.4 35 to 100 2.4 to 6.9 1D387227022 Blue 0.20 5.08 1.69 42.9

1. Type 61LD pilot only.

PILOT CONTROL SPRING

Wire Diameter Free Length

Orange

Unpainted

Red

Yellow

Blue Brown Green

0.07

0.08

0.11

0.14

0.17

0.19

0.21

1.83

2.03

2.77

3.61

4.37

4.75

5.26

3.78

3.00

2.75

2.88

3.03

3.13

Table 2. Proportional Bands

PILOT CONTROL SPRING

PILOT TYPE

61LD

Part Number Color Code

1B558527052 1C680627222

Orange

Unpainted

Wire Diameter Free Length

In. mm In. mm In. w.c. mbar

0.075

0.080

1.91

2.03

4.13

3.25

105

82.6

61L 1B886327022 Red 0.109 2.77 2.75 69.9 1.0 to 2.0 2 to 5

61LD 1B886327022 Red 0.109 2.77 2.75 69.9 0.3 to 1.0 0.62 to 2

61LE 1B886327022 Red 0.109 2.77 2.75 69.9 5.0 to 8.0 12 to 20

61L, 61LD and 61LE

1J857827022 1B886427022 1J857927142 1B886527022

Yellow

Blue Brown Green

0.142

0.172

0.187

0.207

3.61

4.37

4.75

5.26

2.75

2.88

3.13

69.9

73.2

79.5

61H 0Y066427022 Green stripe 0.363 9.22 6.00 152 0.1 to 0.3 psi 0.01 to 0.02 bar

61HP 1D387227022 Blue 0.200 5.08 1.69 42.9 1.0 to 2.0 psi 0.07 to 0.14 bar

PROPORTIONAL BAND

0.1 to 0.5 0.25 to 1

0.1 to 0.3 psi 0.01 to 0.02 bar

96.0

76.2

69.9

73.2

77.0

79.5

TYPE 161AYW MONITORING PILOT (ALSO REPRESENTATIVE OF TY PE 627-109)

PILOT SUPPLY LINE

WORKING MONITOR PILOT

DISTRIBUTION PRESSURE CONTROL LINE

INTERMEDIATE PRESSURE CONTROL LINE

Type 99

20A1389-A B2484

10A1386-A A2503

UPSTREAM PRESSURE

LOADING PRESSURE

OPTIONAL PILOT SUPPLY REGULATOR

INTERMEDIATE PRESSURE

WORKING MONITOR REGULATOR

PILOT SUPPLY PIPING FOR WORKING REGULATOR WHEN PILOT IS REQUIRED TO BE SUPPLIED FROM UPSTREAM PRESSURE

OPTIONAL PILOT SUPPLY REGULATOR

Figure 4. Working Monitor Installation

UPSTREAM REGULATOR (REQUIRES O-RING STEM SEAL)

OPTIONAL PILOT SUPPLY REGULATOR

FLEXIBLE ARRANGEMENT THAT PERMITS WIDE-OPEN MONITOR TO BE EITHER UPSTREAM OR DOWNSTREAM

WORKING REGULATOR

DISTRIBUTION PRESSURE

10A1388-A A2504

UPSTREAM REGULATOR (REQUIRES O-RING STEM SEAL)

OPTIONAL PILOT SUPPLY REGULATOR

MINIMUM PIPING ARRANGEMENT THAT REQUIRES WIDE-OPEN MONITOR TO ALWAYS BE UPSTREAM

Figure 5. Typical Wide-Open Monitor Installations

Type 99

Table 3. Maximum Allowable Pressure Drop and Minimum Differential Pressures

MAXIMUM

ALLOWABLE

PRESSURE DROP

psig bar In. mm In. mm psig bar In. mm

25 1.7 1C277127022 0.148 3.76 6.00 152 0.75 0.05 Nitrile (NBR), Fluorocarbon (FKM) 1-1/8 29

50 3.4 1N801927022 0.156 3.96 7.13 181 1.50 0.10 Neoprene (CR), Fluorocarbon (FKM) 1-1/8 29

150 10.3 1B883327022 0.187 4.75 6.63 168 3.00 0.21

(2)

175

250 17.2 1B883327022 0.187 4.75 6.63 168 3.00 0.21

300 20.7 0W019127022 0.281 7.22 6.00 152 10.0 0.69 Nylon (PA) 1-1/8

400 27.6 0W019127022 0.281 7.22 6.00 152 10.0 0.69 Nylon (PA) 7/8 22

1000 69.0 0W019127022 0.281 7.22 6.00 152 10.0 0.69 Nylon (PA) 1/2

1. Can use all orice sizes up to maximum size listed. See Table 4.

2. CL125 FF anged body only.

3. 1-1/8 in. / 29 mm is the only orice available for 300 psig / 20.7 bar maximum inlet pressure regulator.

4. 1/2 in. / 13 mm is the only orice available for 1000 psig / 69.0 bar maximum inlet pressure regulator.

5. O-ring seat construction is only available for 7/8 and 1-1/8 in. / 22 and 29 mm orice sizes.

1. 1/2 in. / 13 mm is the only orice size available for 1000 psig / 69.0 bar maximum inlet pressure regulator.

2. Maximum inlet rating is equivalent to the 7/8 in. / 22 mm orice.

12.1

(2)

1B883327022 0.187 4.75 6.63 168 3.00 0.21

Composition or Nylon (PA) disk seat only

MAIN VALVE SPRING MINIMUM

Part

Number

Wire Diameter Free Length

Table 4. Orifice Sizes

TRIM CONSTRUCTION

Restricted capacity trim,

Straight bore —

(2)

Restricted capacity trim

Stepped bore —

Full capacity trim,

Composition or Nylon (PA) disk

or O-ring seat

DIFFERENTIAL

PRESSURE FOR FULL

STROKE

DISK MATERIAL

Nitrile (NBR), Neoprene (CR),

Fluorocarbon (FKM)

Nitrile (NBR), Neoprene (CR),

Fluorocarbon (FKM)

Nitrile (NBR), Neoprene (CR),

Fluorocarbon (FKM)

ORIFICE SIZE

In. mm

(1)

1/2

3/4

7/8 x 3/8 7/8 x 1/2 7/8 x 5/8

7/8

1-1/8

ORIFICE SIZE

1-1/8 29

(1)

22 x 10 22 x 13 22 x 16

22 29

MAXIMUM

7/8 22

(3)

(4)

(1)(5)

(3)

(4)

Normally, excess loading pressure slowly escapes downstream around the bleed valve (Figure 2)

or through the relief valve body (Figure 3). Since

loading pressure needs to exceed outlet pressure only moderately to stroke the main valve fully open, a continued increase in loading pressure differential extends the main diaphragm and the pusher post assembly far enough to separate the bleed valve and

the bleed orice. This action permits quick dumping of excess loading pressure into the downstream system.

With a decrease in loading pressure on top of the main diaphragm, the main spring exerts an upward force on the diaphragm rod connected to the main diaphragm,

pulling it in an upward direction. This moves the main valve towards the seat, decreasing the ow to the downstream system.

The pilot valve diaphragm acts as a sealing member for the loading chamber and as a balancing member

to the upper pilot diaphragm. These two diaphragms

are connected by a yoke so any pressure change in the pilot chamber has little effect on the position of the

pilot valve. Therefore, the active diaphragm in the pilot

is the upper pilot diaphragm and the pressure on the top side of this diaphragm opposes the force of the

pilot control spring.

Monitoring Systems

Monitoring regulators serve as overpressure protection

devices to limit system pressure in the event of an

open failure of a working regulator feeding the system.

Two methods of using Type 99 regulators in monitoring applications are:

Construction

Type 161AYW with

1/8 in. / 3.2 mm orice size and

150 psig / 10.3 bar maximum

allowable inlet pressure

3/4 NPT Type 627-109 with

1/8 in. / 3.2 mm orice size and

1000 psig / 69.0 bar maximum

inlet pressure / body rating

for ductile iron body

Table 5. Working Monitor Performance

MONITORING PILOT INFORMATION

Spring Range

psig bar In. mm In. mm

3 to 12 in. w.c. 11 to 25 in. w.c.

0.9 to 2.5

2.5 to 4.5

4.5 to 7

5 to 20 15 to 40

35 to 80

70 to 150

7 to 30 mbar

27 to 62 mbar

0.06 to 0.17

0.17 to 0.31

0.31 to 0.48

0.34 to 1.4

1.0 to 2.8

2.1 to 5.5

4.8 to 10.3

Part Number

1B653927022 1B537027052

1B537127022 1B537227022 1B537327052

10B3076X012 10B3077X012

10B3078X012 10B3079X012

Pilot Spring

Wire Diameter Free Length

0.105

0.114

0.156

0.187

0.218

0.170

0.207

0.262

0.313

2.67

2.90

3.96

4.75

5.54

4.32

5.26

6.65

7.95

3.750

4.312

4.060

3.937

3.980

3.190

3.200

3.070

Type 99

MINIMUM PRESSURE AT WHICH WORKING

MONITOR REGULATOR

CAN BE SET

95.2

109

103 100 101

81.0

81.3

78.0

3 in. w.c. / 7 mbar

distribution pressure

0.5 psi / 0.03 bar

distribution pressure

3.0 psi / 0.21 bar

distribution pressure

5.0 psi / 0.34 bar

distribution pressure

over normal

Working Monitor

On a working monitor installation (Figure 4), the control line of the monitoring pilot is connected

downstream of the working regulator. During

normal operation, distribution pressure causes

the monitoring pilot to stand wide open. Full pilot

supply pressure enters the working monitor pilot and permits the working monitor regulator to control at its

intermediate pressure setting.

Open failure of the working regulator increases distribution pressure as the working regulator goes

wide open. Intermediate pressure is then ignored by

the monitoring regulator, which controls downstream pressure at its own pressure setting (slightly higher

than the normal control pressure).

The monitoring pilot should be upstream of the working

monitor regulator. This enables a closer setpoint

between the working regulator and the monitoring

pilot. Special Types 161AYW and 627-109 monitoring

pilots with quick-bleed operation have been designed to give faster response to abnormal downstream

conditions. Table 5 gives the spread between normal

distribution pressure and the minimum pressure at which the working monitor regulator can be set to take

over if the working regulator fails open.

Wide-Open Monitor

The control line of the upstream regulator is connected downstream of the second regulator (Figure 5), so that during normal operation the monitoring regulator is standing wide open with the reduction to distribution pressure being taken across

the working regulator. Only in case of open failure of

the working regulator does the wide-open monitoring

regulator take control at its slightly higher setting.

The upstream regulator must have an O-ring seal

on the valve carrier assembly. This seals off the leak

path that otherwise would let line pressure ahead of the working regulator inlet try to close the wide-open

monitoring regulator.

Installation

WARNING

Personal injury, equipment damage or leakage due to escaping gas or bursting of pressure containing parts might result if this regulator is overpressured or is installed where service conditions could exceed the limits for which the regulator was designed or where conditions exceed any ratings of the adjacent piping or piping connections. To avoid such injury or damage, provide pressure relieving or pressure limiting devices (as required by the appropriate code, regulation or standard) to prevent service conditions from exceeding those limits.

A regulator may vent some gas to the atmosphere in hazardous or

ammable gas service, vented gas might

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.

Type 99

Clean out all pipelines before installation and check to be sure the regulator has not been damaged or

collected foreign material during shipping.

Apply pipe compound to the external pipe threads only with a threaded body or use suitable line gaskets

and good bolting practices with a anged body. This

regulator may be installed in any position desired as

long as the ow through the body is in the direction indicated by the arrow on the body. Install a three-valve

bypass around the regulator if continuous operation is

necessary during maintenance or inspection.

Although the standard orientation of the actuator and pilot to the main valve body is as shown in Figure 1, this orientation may be changed as far as the inlet tubing (key 24, Figure 9 or 17) will permit by loosening the union nut (key 14, Figure 9), rotating the actuator lower casing (key 29, Figure 9) as desired and tightening

the union nut. To keep the pilot spring case from being

plugged or the spring case from collecting moisture, corrosive chemicals or other foreign material, the vent must be pointed down, oriented to the lowest possible

point on the spring case or otherwise protected. Vent

orientation may be changed by rotating the spring case

with respect to the pilot body.

To remotely vent a low-pressure pilot, install the vent line in place of the pressed-in vent assembly (key 60,

Figure 9). Install obstruction-free tubing or piping into the 1/4 in. / 6.4 mm vent tapping. Provide protection

on a remote vent by installing a screened vent cap into

the remote end of the vent pipe.

To remotely vent a high-pressure pilot, remove the threaded-in vent assembly (key 72, Figure 12) from the high-pressure pilot spring case and install

obstruction-free tubing or piping into the 1/4 in. /

6.4 mm vent tapping. Provide protection on a remote

vent by installing a screened vent cap into the remote

end of the vent pipe.

An upstream pilot supply line is not required because of the integral pilot supply tubing (key 24,

Figure 9 or 17). However, as long as the 1/4 NPT

tapping in the main valve body is plugged, this tubing may be disconnected from both the main

valve and lter assembly (key 75, Figures 9 and 16)

in order to install a pilot supply line from a desired

remote location into the lter.

If the maximum pilot inlet pressure will be exceeded by main valve pressure, install a separate pressure reducing regulator (if not already provided) in the pilot

supply line.

A Type 99 regulator has two 1/2 NPT control line pressure taps on opposite sides of the lower casing

(key 29, Figure 9). The regulator normally comes from

the factory with the tap closest to the regulator outlet left unplugged for the downstream control line as shown in

Figure 1 and with opposite tap plugged.

Attach the control line from the unplugged tap 2 to

3 ft / 0.61 to 0.91 meter downstream of the regulator in a straight run of pipe. If impossible to comply with

this recommendation due to the pipe arrangement, it may be better to make the control line tap nearer the regulator outlet rather than downstream of a block

valve. Do not install the tap near any elbow, swage or nipple which might cause turbulence.

In many instances, it will be necessary to enlarge the

downstream piping to keep ow velocities within good engineering practices. Expand the piping as close to the regulator outlet as possible.

WARNING

Adjustment of the pilot control spring to produce an outlet pressure higher than the upper limit of the outlet pressure range for that particular spring can cause personal injury or equipment damage due to bursting of pressure-containing parts. Dangerous accumulation of gases may also cause bursting if the maximum actuator emergency casing pressure in

the Specications section is exceeded. If

the desired outlet pressure is not within the range of the pilot control spring, install a spring of the proper range according to the Maintenance section.

Each regulator is factory-set for the pressure setting

specied on the order. If no setting was specied, outlet

pressure was factory-set at the midrange of the pilot

control spring. In all cases, check the control spring setting to make sure it is correct for the application.

Overpressure Protection

The Type 99 regulator has an outlet pressure

rating lower than its inlet pressure rating. Complete

downstream overpressure protection is required if the actual inlet pressure can exceed the regulator outlet pressure rating or the pressure ratings of any

downstream equipment. Although the Type H110 relief valve provides sufcient relief capacity to protect

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