289P-6358 Instruction Manual

Type 289P-6358

Instruction Manual Form 5098

Type 289P-6358 Pilot Operated Relief Valve Introduction WARNING To avoid injury or damage, this relief valve should be installed, operated and maintained in accordance with federal, state and local codes, rules and regulations, and Fisher instructions. Not all codes or regulations permit this valve to be used as a final over-pressure protection device. Only qualified personnel should install or service the relief valve.

Be certain the nameplate or spring range label is updated to accurately indicate any field changes in equipment, materials, service conditions or pressure settings.

Immediately call qualified service personnel in case of trouble. If a leak develops in the system, it indicates that service is required. Failure to correct the situation immediately may create a hazardous condition.

Scope of Manual This manual provides specifications, instructions for installation, adjustment, maintenance and parts information for the Type 289P-6358 pilot operated relief valve. Instructions and parts lists for any other Fisher equipment used with this relief valve will be found in separate manuals.

Only personnel qualified through training or experience should install, operate and maintain this regulator. If there are any questions concerning these instructions, contact your Fisher Sales Office or Sales Representative before proceeding.

7/97

W6834/IL

Figure 1. Type 289P-6358 Pilot Operated Relief Valve

Description The Type 289P-6358 pilot-operated relief valve is used to provide protection from overpressuring a downstream system. This relief valve is suitable for service on natural gas, air, propane or any other operating medium not corrosive to the internal parts. Very little buildup over the set pressure is required for the main valve to go wide open for maximum relief capacity. Smooth opening action minimizes system pressure surges during emergency action.

Specifications Table 1 lists Type 289P-6358 specifications. Some of the specifications for a given relief valve as it comes from the factory appear on a control spring label attached to the Type 6358 pilot spring case and a nameplate attached to the Type 289P main valve spring case.

Type 289P-6358 Table 1. Specifications

Body Size and End Connection 1-inch NPT screwed; outlet connection has a removable screen Maximum Relief (Inlet(1)) Pressure(2) 50 psi (3.4 bar) over relief pressure setting or 110 psig (7.6 bar) whichever is lower Relief Pressure Ranges and Control Springs See Table 2 Temperature Capabilities(2) Standard Elastomers: -20 to 150_F (-29 to 66_C) High-temperature Elastomers: 20 to 300_F (-7 to 149_C)

Pressure Registration Relief (inlet) pressure registers internally on the main valve diaphragm; an external control line is required for registration of relief pressure on the pilot diaphragm Pilot Connections 1/4-inch NPT screwed control line and vent connections Approximate Weight 5 lbs. (2.7 kg)

1. Relief pressure plus maximum allowable buildup over setting.

2. The pressure/temperature limits in this manual and any applicable standard or code limitation for valve should not be exceeded.

Table 2. Relief Pressure Ranges and Control Springs CONTROL SPRINGS PRESSURE RANGES 10 to 18 psig (0.7 to 1.2 bar) 18 to 30 psig (1.2 to 2.0 bar) 30 to 100 psig (2.0 to 6.9 bar)

Spring Type

Part Number

Free Length Inches (mm)

Wire Diameter Inches (mm)

Pilot Spring

1B986027212

---

2.125 (54)

0.120 (3.0)

Main Spring

1F826927052

pink

3.188 (81)

0.120 (3.0)

Pilot Spring

1B788327022

---

2.125 (54)

0.142 (3.6)

Main Spring

1F826927052

pink

3.188 (81)

0.120 (3.0)

Pilot Spring

1K748527202

red

2.125 (54)

0.187 (4.7)

Main Spring

1D892327022

red

2.938 (75)

0.168 (4.3)

Principle of Operation Inlet pressure registers on the underside of the diaphragm of the main valve (figure 2) and enters the pilot through the control line tubing, where it registers on the underside of the pilot diaphragm. As long as the inlet pressure is lower than the set pressure, the pilot control spring pushes the pilot valve plug down, closing the exhaust. With the Type 6358 pilot, inlet pressure passes between the diaphragm assembly and the upper portion of the pilot valve plug and into the hollow stem to load the main valve above the diaphragm, keeping it closed.

When the inlet pressure is at set pressure, the diaphragm assembly in the Type 6358 pilot moves upward enough to close off the inlet pressure path into the hollow stem; the exhaust port remains closed by the lower portion of the valve plug. Thus pressure is

2

Color Code

unable to enter or leave the space above the main diaphragm.

As the inlet pressure rises above set pressure, the diaphragm continues to move upward, opening the exhaust port and allowing pressure on the top of the main valve diaphragm to bleed to atmosphere or to the vent stack. The inlet pressure on the bottom of the main valve diaphragm then overcomes the main valve spring force, and the main valve opens, reducing the inlet pressure to set pressure. The pilot spring closes the exhaust, and inlet pressure loads the main valve diaphragm casing above and below the diaphragm, allowing the main valve spring to close the main valve.

Note that, while the main valve is throttling, the Type 6358 pilot keeps the exhaust port closed. The pilot bleeds only when it repositions the main valve plug.

Type 289P-6358 HOLLOW PASSAGE IN VALVE PLUG STEM DIAPHRAGM ASSEMBLY

ADJUSTING SCREW

LOCKNUT

TYPE 6358

UPPER PORTION OF VALVE PLUG TO EXHAUST PORT

TO MAIN VALVE DIAPHRAGM

TYPE 289P

LOWER PORTION OF VALVE PLUG

PILOT CONTROL SPRING

TYPE 6358 PILOT DETAIL VALVE GUIDE ORIFICE REGISTRATION HOLE

EXHAUST LINE (MAY BE VENTED TO ATMOSPHERE OR CONNECTED TO MAIN VALVE OUTLET)

A

C D

FROM MAIN LINE

INLET (CONTROLLED PRESSURE) LOADING EXHAUST A6970/IL

TO VENT STACK

Figure 2. Type 289P-6358 Principle of Operation

Installation WARNING Personal injury or system damage may result if this relief valve is installed where service conditions could exceed the limits given on the pilot control spring label or main valve nameplate.

Installations should be adequately protected from physical damage. Overpressuring any portion of this equipment may cause equipment damage, leaks in the relief valve, or personal injury due to bursting of pressure-containing parts or explosion of accumulated gas. System operation within table 1 limitations does not eliminate the possibility of damage from external sources or from debris in the gas line. The relief valve should be inspected for damage regularly and after any overpressure condition.

Before installing, inspect the main valve and pilot for any damage and any foreign material. Make sure that the valve is oriented so that pipeline flow is in the same direction as the arrow on the side of the main valve body. Use a good grade of pipe compound on the pipe threads, but do not apply pipe compound to the internal body threads. A schematic of a typical installation arrangement is given in figure 2.

A complete Type 289P-6358 unit requires a control line attached to the 1/4-inch NPT pilot control port D (figure 3). The control line should be connected from port D to the point where the pressure is to be controlled. Relief valve inlet piping should be as short, smooth and large as practical to minimize capacity loss due to pipe restriction effects. If the flowing medium is dirty, an appropriate filter in this control line is recommended, or a common filter or strainer can be used in the main or relief inlet line upstream from the control line.

3

Type 289P-6358 WARNING To avoid personal injury or equipment damage, the vent in the Type 289P-6358 spring cover must be oriented such that it is kept clear and protected. If venting gas will accumulate and be an explosion hazard under enclosed conditions such as in a pit or underground installations, remote venting to a safe area is necessary.

A vent line or stack must be located to avoid venting gas near buildings, air intakes or any hazardous location. The line or stack openings must be protected against condensation and clogging.

Install a 1/4-inch exhaust line into the 1/4-inch NPT pilot exhaust port A. This exhaust line may be vented either directly into the main valve outlet or separately to the atmosphere. In either case, a vent line or stack pipe diameter should be as large as practical with a minimum number of bends or other restrictions.

Set pressure is defined as the pressure at which the main valve starts to discharge. The unit has been designed such that less than 3 psig (0.2 bar) buildup in the pilot set pressure will assure the main valve to be wide open, and will permit the relief valve to yield full open capacity. The set pressure of the unit is adjusted by changing the pilot control spring comression.

WARNING To avoid possible injury or equipment damage, never adjust the pilot control spring to produce a set pressure higher than the upper limit of the set pressure range for that particular spring.

Each unit is factory set for the pressure setting specified on the order. If no set pressure is specified it will be factory set at approximately the mid range of the spring.

Adjustment If the relief valve begins exhausting, it is necessary to either lower main line system pressure or increase the set point pressure of the relief valve. If adjustment is necessary, use a pressure gauge to monitor the pressure. Loosen the locknut (figure 2) and turn the pilot adjusting screw clockwise to increase the set pressure or counterclockwise to decrease the set pressure.

Then tighten the locknut to maintain the adjustment position.

Shutdown If the pilot and main lines are separate, slowly close the main block valve and the the pilot block valve. If they are not separate, slowly close the main block valve.

Maintenance Relief valve parts are subject to normal wear and must be inspected and replaced as necessary. Inspection and maintenance frequency depend upon severity of service conditions.

WARNING To avoid personal injury or equipment damage, isolate the relief valve from the pressure system and release all pressure from the pilot and main valve before performing maintenance operations.

Type 6358 Pilot Key numbers are referenced in figure 3 unless otherwise noted. The pilot may remain on the pipe nipple during maintenance procedures unless the body assembly (key 1) is replaced or removed for repairs.

Disassembly

Startup If the pilot and main lines are separate, slowly open the pilot block valve and then slowly open the main block valve. If they are not separate, slowly open the main block valve.

4

1. If necessary to check the outlet end of the body cavity and the seating surfaces for moisture or debris, remove the body plug (key 3) and body plug gasket (key 13) from the body assembly (key 1).

2. Remove the closing cap (key 12), loosen the locknut (key 11), and back out the adjusting screw (key

Type 289P-6358 10) until compression is removed from the control spring (key 7).

3. Remove the machine screws (key 17) and separate the spring case (key 2) from the body assembly (key 1). Remove the control spring seat (key 8), and the control spring (key 7).

4. Remove the diaphragm and plug/stem assemblies (keys 5 and 4) and make sure the plug/stem guide (key 9) and the hollow passage in the plug stem assembly, are not damaged or plugged with moisture or debris.

Note If installing a control spring of a different range from the one that was removed, be sure to delete the spring range originally appearing on the spring case and indicate the new spring range.

7. Stack the control spring (key 7), the control spring seat (key 8) onto the diaphragm assembly (key 5).

8. Install the spring case (key 2) on the body (key 1) with the vent assembly (key 16) oriented to prevent clogging or entrance of moisture. Install the machine screws (key 17) and, using a crisscross pattern, torque them to 5 to 7 foot-pounds (7 to 9 NSm).

5. If necessary to replace the diaphragm assembly, the plug/stem assembly, the plug/stem spring (key 14), or the plug/stem O-ring (key 37), remove the connector cap and connector cap gasket (keys 6 and 36) from the top of the diaphragm assembly.

9. When all maintenance is complete, refer to the startup and adjustment section to put the relief valve back into operation and adjust the pressure setting.

Tighten the locknut (key 11), replace the closing cap gasket (key 19) if necessary, and install the closing cap (key12).

Assembly

Type 289P Main Valve

1. If they were removed, install the body plug gasket (key 13) over the body plug (key 3), and then install the body plug into the body assembly.

This procedure is to be preformed if inspecting, cleaning, or replacing main valve parts. Key numbers are referenced in figure 4 unless otherwise indicated.

2. Install the plug/stem guide (key 9) if it was removed, making sure that a connector cap gasket (key 36) is installed between the body and the plug/stem guide.

Note

3. Install the restriction plug (key 20) if it was removed. Coat the threads with Plastic Seal sealant or equivalent before installation.

4. If replacing the plug/stem O-ring (key 37), sparingly apply Lubriplate lubricant or equivalent to the replacement O-ring, and install the O-ring over the plug/stem assembly (key 4).

5. If they were removed, install the plug/stem assembly and plug/stem spring (keys 4 and 14) into the diaphragm assembly (key 5). Install a replacement connector cap gasket (key 36) on the diaphragm assembly connector, and secure with the connector cap (key 6).

6. Install the diaphragm assembly (key 5) and push down on it to see if the plug/stem assembly (key 4) moves smoothly. The diaphragm assembly should stroke approximately 1/16-inch (2 mm) after the valve plug contacts the port.

The main valve body (key 1) may remain in the line unless it must be removed for maintenance or replacement. Grease replacement O-rings upon reassembly.

Disassembly 1. Disconnect the lines from the Type 289P relief valve (figure 2).

2. Loosen the set screw (key 6) until compression is removed from the spring.

3. Unscrew machine screws (key 8) and remove the spring case (key 2), spring (key 7) and spring seat (key 4).

4. Unscrew the hex nut (key 24) and remove lower spring guide (key 17), diaphragm head (key 3), and inspect diaphragm (key 5).

5. Remove screws (key 29) from the stem guide assembly (key 31).

6. Slide washer (key 27), gasket (key19), stem guide assembly (key 31) and bushing (key 23) from Pitot tube (key 18).

7. Remove upper O-ring (key 30), O-ring holder (key 21), O-ring (key 20), O-ring washer (key 22) and lower O-ring (key 30) from around Pitot tube (key 18).

5

Type 289P-6358 8. Inspect and replace parts as necessary.

Key

Description

Part Number

Assembly

6 7

16A2921X012

8 9

Connector Cap, 18-8 stainless steel Control Spring, Zn pl steel spring wire 10 to 18 psig (0.7 to 1.2 bar) 18 to 30 psig (1.2 to 2.0 bar) 30 to 100 psig (2.0 to 6.9 bar) Control Spring Seat, pl steel Plug/Stem Guide, stainless steel

1B986027212 1B788327022 1K748527202 1B798525062 16A2923X012

10 11 12 13*

Adjusting Screw, pl steel Locknut, zn pl steel Closing Cap, aluminum Body Plug Gasket, composition

1H305028982 1A946324122 1H2369X0012 1C495704022

14 16 17 19

Plug/Stem Spring, stainless steel Type Y602-12 Vent Assembly, plastic Machine Screw, carbon steel (6 req) Closing Cap Gasket, composition

1E701337022 27A5516X012 1H421728992 15A6218X012

20 36*

Restriction Plug, plated carbon steel Connector Cap Gasket, fluoroelastomer (2 req) Plug/stem O-ring, nitrile rubber Plastic Seal Sealant

1V743528982

1. Slide lower O-ring (key 30), O-ring washer (key 22), O-ring (key 20), O-ring holder (key 21), upper Oring (key 30), bushing (key 23), stem guide assembly (key 31), gasket (key 19) and washer (key 27) on to Pitot tube (key 18) as shown in figure 4.

2. Position diaphragm (key 5) so the holes line up with those in the body (key 1).

3. Slide the diaphragm head (key 3) and lower spring guide (key 17) onto the Pitot tube. Tighten hex nut (key 24).

4. Replace spring (key 7), spring seat (key 4), and spring case (key 2).

5. Compress the spring slightly with the adjusting screw (key 6) to insure there are no wrinkles in the diaphragm.

6. Tighten machine screws (key 8) in a criss-cross pattern. Tighten down adjusting screw (key 6) until snug.

7. Reconnect lines to the Type 289P relief valve.

1 2 3 4

Body, aluminum Spring Case, aluminum Siaphragm Head, aluminum Spring Seat, cadmium plated steel

3U88208012 2P901508012 1D666428982 1D667125072

5* 6 7

1E606602052 1F710532982

8

Diaphragm, nitrile Adjusting Screw, steel Spring, steel 10 to 30 psi (0.7 to 2.0 bar) 30 to 100 psi (2.0 to 6.9 bar) Machine Screw, steel (8 req’d)

1F826927022 1D892327022 1A345928982

9 11* 13* 15

Screen, Monel(1) Gasket, composite (2 req’d) Snap Ring, carbon steel Gasket, composite

1E564843122 0Y008915042 13A9938X012 13A9929X012

16 17 18 19*

Nameplate, alluminum Lower Spring Guide, cadmium plated steel Pitot tube, aluminum Gasket, composite

--1D666625072 1F826209012 1F826804022

20* 21 22 23

O-ring, nitrile O-ring Holder, aluminum O-ring Washer,aluminum Spacer, 303 stainless steel

1F269206992 1F826409012 1F826509012 1F826335242

24 27 28 29

Hex Nut, cadmium plated steel Washer, aluminum Pipe Plug, cadmium plated steel Machine Screw, steel (2 req’d)

1A499724122 1F826709012 1D754828982 1D386928982

39A0138X012 25A6220X012 1B797509032 16A2924X012

30* 31

1D687506992

15A6216X072

36

O-ring, Synthetic rubber (2 req’d) Stem Guide Assembly, 303 stainless steel Brass Pitot Tube Plug

When ordering a replacement part, be sure to include the complete eleven-character part number from the following parts list.

Parts List Type 6358 Pilot (figure 3)

6

Description

Part Number

Parts Kit (included are keys 4, 5, 13, 14, 19, 36, and 37)

R6358X00012

Body Assembly, aluminum Spring Case, aluminum Body Plug, aluminum Plug/Stem Assembly, polyethylene Diaphragm Assembly (includes heat-treated 416 stainless steel diaphragm plate)

Type 289P Main Valve (figure 4) Description

When corresponding with a Fisher representative or the factory concerning this relief valve, include the type number and all other pertinent information stamped on the pilot control spring label and main valve nameplate. If construction changes are made in the field, be sure that the nameplate is also changed to reflect the most recent construction.

1 2 3 4* 5*

1U1716X0012 16A2920X012 1M330706992

Key

Parts Ordering

Key

37* 41

*Recommended spare parts 1. Trademark of International Nickel Co.

Part Number

1F8272X0012 1F8272000A2 1B561428982

Type 289P-6358

A7028/IL

Figure 3. Type 6358 Pilot Assembly

14A8406 A/DOC

Figure 4. Type 289P Main Valve Assembly

7

Type 289P-6358

Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners.

EFisher Controls International, Inc. 1978, 1997; All Rights Reserved

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they arenot tobe construedas warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA 28320 Gallardon France Sao Paulo 05424 Brazil Singapore 128461 8

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