289P-6365 Instruction Manual

Type 289P-6365

Fisher Controls

Instruction Manual

Type 289P-6365 Pilot-Operated Relief Valve

June 1990

Form 5120

Introduction Scope of Manual This manual describes and provides installation, maintenance and parts information for the Type 289P6365 pilot-operated pressure relief valve. Information for any other Fisher equipment used with this relief valve is found in separate manuals.

Description

Specifications Table 1 lists Type 289P-6365 relief valve specifications.

Some specifications, such as spring ranges and maximum inlet and outlet pressures, for the relief valve are stamped on the main valve closing cap and pilot spring case (figure 2).

Installation WARNING The pilot could break off the main valve, the relief valve could develop a leak, or the installation could be in violation of local,

ŠFisher Controls International, Inc., 1980, 1990; All Rights Reserved

W3167-2

Figure 1. Type 289P-6365 Pilot-Operated Relief Valve state, and Federal codes and regulations.

Any of these may result in personal injury or property damage due to bursting of pressure-containing parts or explosion of accumulated gas. Install a relief valve in a safe location, isolate the valve and call qualified help in case of leaks, and check that the installation is in compliance with all applicable codes and regulations.

Use qualified personnel when installing, maintaining, or operating this relief valve. Before installing, inspect the main valve and pilot for any damage and for the presence of any foreign material in the main valve body.

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 pipe compound on the pipe threads, but do not apply the pipe compound to the internal body threads.

D100281X012

The Type 289P-6365 pilot-operated pressure relief valve is used to provide protection from overpressuring a downstream system. This relief valve is suitable for service on natural gas, air, propane, water, light oils, and other fluids and gases compatible with the internal parts.

A high-gain version of the Type 6365 pilot is used for gas service. A low gain pilot version is used for liquid service.

The external control line provides quick, accurate pressure registration resulting in very little buildup over the set pressure before the main valve opens wide for maximum relief capacity.

Type 289P-6365 Table 1. Specifications Body Size and End Connection Style of Main Valve 2-inch NPT screwed Pilot Connections 1/4-inch NPT screwed Maximum Relief (Inlet(1)) Pressure(2) 15 psig (1.0 bar) Relief Pressure (Set Pressure(3)) Range n 0.5 to 2 psig (0.03 to 0.14 bar), n 2 to 10 psig (0.14 to 0.69 bar) Pilot Restrictions

Material Temperature Capabilities(2) –20 to 180°F (–29 to 82°C) Pressure Registration External through upstream control line Main Valve Closing Speed Gas Service: Opening and closing time 2 to 3 seconds (high-gain pilot) Liquid Service: Opening time 2 to 3 seconds, Closing time approximately 30 seconds (low-gain pilot) Approximate Weight 15 lb (6.8 kg)

High-gain: 0.028-inch (0.71 mm) diameter Low-gain: 0.078-inch (1.99 mm) diameter

1. Relief pressure plus maximum allowable buildup over setting.

2. Pressure/temperature limits in this manual and any applicable codes should not be

A complete Type 289P-6365 unit requires a control line attached to the 1/4-inch NPT pilot control port D (figure 3). The underside of the pilot has identifying letters stamped at each port. Connect the external control line from port D to the point where pressure is to be sensed.

If an external control line is not used, remove the main valve pipe plug (key 28, figure 5), drill out the valve body restriction to at least 1/8 inch (3.2 mm), and connect the pilot control line from port D to the 1/4-inch NPT tapped main valve body connection. Make the relief valve inlet and pilot control line piping as short, as smooth, and as large as practical to minimize capacity loss due to pipe restriction effects.

Options n Pilot spring case closing cap, n Tapped pilot spring case exceeded.

3. Set pressure is defined as the inlet pressure at which the pilot plug starts to open.

26A0323-G

Figure 2. Type 289P Main Valve Closing Cap

WARNING Relief valves vent gas from the main valve outlet, the pilot exhaust, and the pilot spring case vents. In hazardous gas service, vented gas may accumulate, causing personal injury or equipment damage due to fire or explosion. Provide piping or tubing to vent the gas to a safe location, and protect all vent openings from condensation, freezing, or any substance that could clog the vents.

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 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.

2

Set pressure is defined as the pressure at which the main valve starts to discharge. Buildup above set pressure is the additional inlet pressure required to completely open the main valve. Seven inches water column (17 mbar) buildup opens the main valve completely. The set pressure of the unit is adjusted by changing the pilot control spring compression; however, the buildup required to completely open the main valve is the same for each set pressure.

Each unit is factory set for the pressure setting specified on the order. If no set pressure is specified, the relief valve will be factory set at approximately the midrange of the pilot control spring. Check the spring setting to make sure it is correct for the application.

Type 289P-6365

TYPE 289P RELIEF VALVE MAIN VALVE SPRING CASE TYPE 6358 PILOT REGISTRATION HOLE PILOT RESTRICTION SUPPLY PORT D PORT C PORT A EXHAUST

PILOT CONTROL MAY BE VENTED TO ATMOSPHERE OR CONNECTED TO MAIN VALVE EXHAUST PILOT CONTROL LINE

INLET LOADING

36A0569-F A2474-1

EXHAUST

EXHAUST

Figure 3. Principle of Operation

Startup

Principle of Operation

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

Inlet pressure registers on the pilot diaphragm through the control line connection (port D, figure 3) and also registers under the main valve diaphragm through the registration hole in the stem guide plate. As long as inlet pressure remains below set pressure, the pilot control spring force closes the pilot valve plug and stem assembly against the pilot exhaust port (port A, figure 3). Inlet pressure passes through the pilot restriction and the pipe nipple, loads the main valve spring case, and keeps the main valve closed. An inlet pressure rise above the set pressure overcomes the pilot control spring force, and the pilot valve plug and stem assembly opens the pilot exhaust port. Spring case loading pressure bleeds downstream through the pilot exhaust port more quickly than inlet pressure can pass through the pilot restriction.

The loading pressure in the main valve spring case decreases, and inlet pressure under the main valve diaphragm opens the main valve.

If adjustment is necessary, use a pressure gauge to monitor the pressure. Loosen the locknut (figure 3), 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 then the pilot block valve. If they are not separate, slowly close the main block valve.

As inlet pressure drops back to set pressure, the pilot control spring force pushes the valve plug and stem assembly back against the pilot exhaust port. Inlet pressure again loads the spring case and closes the main valve.

3

Type 289P-6365

2. Install the plug/stem guide (key 9) if it was removed.

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

WARNING To avoid personal injury or equipment damage caused by sudden release of pressure or explosion of accumulated gas, do not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all internal pressure from the regulator.

Type 6365 Pilot Key numbers are referenced in figure 4 unless otherwise noted. The pilot may remain on the pipe nipple (key 29) during maintenance procedures unless the body assembly (key 1) is replaced or removed for repairs.

Disassembly 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 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 registration hole in the pilot restriction (key 20), are not damaged or plugged with moisture or debris.

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

Note In step 3, if installing a restriction of a different diameter from the one that was removed, be sure to delete the code letter originally appearing on the bottom of the pilot body and indicate the new letter.

3. Install the restriction plug (key 20) if it was removed.

4. 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).

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

Note In step 6, 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.

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

7. 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 N•m).

8. When all maintenance is complete, refer to the startup 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 (key 12).

Type 289P Main Valve Assembly 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.

4

This procedure is to be performed if inspecting, cleaning, or replacing the main valve parts. Key numbers and thread lubrication requirements are indicated in figure 5 unless otherwise indicated.

Type 289P-6365

Note The main valve body (key 1) may remain in the line unless it must be removed for maintenance or replacement. The pilot control line and, if used, the remote vent piping must be removed before removing the main valve spring case.

1. Remove the closing cap (key 14), and loosen the adjusting screw (key 6) to remove all spring compression.

2. If a special spring case orientation is required, etch a mark on the spring case flange for use in assembly, unscrew the cap screws (key 8), and remove the spring case (key 2) and spring (key 7).

•

Hex nut (key 11)

Tighten the hex nut.

7. Inspect the O-ring (key 20) and orifice (key 10). If just the orifice is to be replaced, remove the O-ring and unscrew the orifice from the body (key 1). If only the O-ring (key 20) is to be replaced, leave the orifice in the body (key 1). Coat the threads of the new orifice with lead seal, and screw the orifice into the body. Coat the O-ring with a lubricant, and place the O-ring in the orifice.

8. Position the diaphragm assembly and stem guide assembly in the valve body (key 1) so that the O-ring washer sits squarely on the O-ring and so that the machine screw holes in the stem guide assembly match the holes in the valve body. Inser t and tighten the machine screws (key 29).

3. Lift the edges of the diaphragm (key 5), and remove the machine screws (key 29), securing the stem guide assembly (key 31).

9. Turn the diaphragm to line up with the spring case cap screw holes.

4. Remove the stem guide assembly. The diaphragm assembly (keys 3, 17, 5, and 26) and the pitot tube (key 18) and associated parts (keys 19, 22, 23, 11, and 25) will lift out with the stem guide assembly.

10. Place the spring case (key 2) on the valve body, and, if a special spring case orientation is required, line up the etched mark made on the side of the spring case flange in step 2 of this section. Insert and tighten the cap screws (key 8).

5. Inspect the par ts removed in step 4. If par t replacement is necessary, unscrew the hex nut (key 11), and separate the parts, one piece at a time.

11. Put the spring (key 7) squarely on the lower spring seat.

6. Assemble the parts using new gaskets (key 19). Also replace the diaphragm (key 5), if necessary. During assembly, use lubricants or sealants on the par ts indicated in figure 5. The following parts are listed in the order with which they are placed on the pitot tube (key 18):

•

One gasket (key 19)

•

O-ring washer (key 22)

•

Another gasket (key 19)

12. Coat the adjusting screw (key 6) threads with a suitable anti-seize compound, and thread the screw into the spring case/until top of adjusting screw is 1-inch (25.4 mm) below top of spring case.

13. Lift the lifting stem (key 25) to test that the O-ring (key 20) and O-ring washer (key 22) do not stick together.

14. Reconnect the pilot control line and, if used, reconnect the remote vent piping, and adjust the pilot control spring compression by following the instruction in the “Startup” section.

• Stem guide assembly (key 31) secured with screws (key 29) •

The third gasket (key 19)

•

Lower diaphragm plate (key 26)

•

Diaphragm (key 5) installed, patterned side up, toward spring (key 7)

•

Diaphragm plate (key 3)

•

Lower spring seat (key 17) and the

Parts Ordering The Type 289P-6365 pilot-operated relief valve has specifications on the pilot spring case and on the main valve closing cap. When corresponding with your Fisher representative about the equipment, always reference this information. Also, when ordering replacement parts, give the complete 11-character part number of each required part as found in the following parts list.

5

Type 289P-6365

39A0177-A

Figure 4. Type 6365 Pilot

Key

Parts List Key

Description

Part Number

Type 6365 Pilot (figure 4) Parts Kits (included are keys 4, 5, 13, 14, 19 and 36) 0.5 to 10 psig (0.03 to 0.69 bar) spring range 1 2 3 4*

5*

6 7

Body Assembly, aluminum Spring Case, aluminum Body Plug, aluminum Plug/Stem Assembly Nitrile plug w/stainless steel stem Diaphragm Assembly (includes heattreated 416 stainless steel diaphragm plate) Connector Cap, 18-8 stainless steel Control Spring, zinc plated steel spring wire 14-inches w.c. to 2 psig 2 to 10 psig

R6365 X00012 39A0138 X012 25A6220 X012 1B7975 09032 19A0137 X012

15A6216 X182 16A2921 X012

Description

8

Control Spring Seat, plated steel

1B7985 25062

9 10 11 12

Plug/Stem Guide, stainless steel Adjusting Screw, plated steel Locknut, zinc plated steel Closing Cap, aluminum

16A2923 X012 10B3692 X012 1A9463 24122 1H2369 X0012

13* 14* 16 17

Body Plug Gasket, composition Plug/Stem Spring, inconel(1) X750 Type Y602-12 Vent Assembly, plastic Machine Screw, carbon steel (6 req’d)

1C4957 04022 17A2328 X012 27A5516 X012 1H4217 28992

19* Closing Cap Gasket, composition 20 Restriction, plated carbon steel No. 47 drill size or 0.078-inch (1.99 mm) diameter (indicated by L for low gain stamped on pilot body & blue color code) No. 70 drill size or 0.028-inch (0.71 mm) diameter, standard (indicated by H for high gain stamped on pilot body & yellow color code) 36* Connector Cap Gasket, fluoroelastomer

14A9672 X012 14A9673 X012

*Recommended sprare part.

1. Trademark of International Nickel Co.

6

Part Number

15A6218 X012

17A7277 X012

17A7279 X012 1U1716 X0012

Type 289P-6365

26A0323-G

Figure 5. 2-inch Type 289P Relief Valve

Key

Description

Part Number

Main Valve Parts (figure 5)

Key

Description

15* 17 18 19*

Gasket, neoprene Spring Seat, zinc plated steel Pitot Tube, brass Gasket, composition (3 req’d)

1P7533 06992 1D7799 25062 17A8788 X012 1D7798 04022

20* 22 23 24

O-Ring, nitrile O-Ring Washer, stainless steel Spacer, brass Hex Nut, plated carbon steel

1P3361 1E7021 1E7022 1B2282

06992 36072 14172 28982

Lifting Stem, plated steel Lower Diaphragm Head, plated steel Washer, aluminum Pipe Plug, plated carbon steel

1D7802 1E7031 1C6805 1D7548

24092 25072 11032 28982

Parts Kits (Included are keys 5, 9, 15, 19, 20 and 38) 2-inch body, nitrile

R289H X00022

1 2 3 5*

Valve Body, cast iron Spring Case, aluminum Diaphragm Head, plated steel Diaphragm, nitrile

31B1992 X012 3K1294 44022 0W0202 25072 1D7800 02052

6 7 8 9*

Adjusting Screw, zinc Spring, plated steel Cap Screw, plated carbon steel (8 req’d) Screen

1B5379 44012 1B5364 27152 1A4078 24052 11B1994 X012

25 26 27 28

Orifice, brass Hex Nut, zinc plated steel Snap Ring Closing Cap, zinc

1E7026 13012 1D7801 24272 10B9241 X012 1B5416 44012

29 Machine Screw, pl carbon steel (4 req’d) 31 Stem Guide Assembly, cast iron plate 38* Gasket

10* 11 13 14

Part Number

1F3865 28992 1E7028 000A2 11B1993 X012

*Recommended spare part.

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Type 289P-6365

While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding the performance, merchantability, fitness

Fisher Controls

or any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the products described herein.

For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France

Sao Paulo 05424 Brazil Singapore 2158 Printed in USA