EMERSON Q Series Pilots Spence Back Pressure Regulators Equipped Instruction Manual

Instruction Manual
VCIMD-16077
November 2021
Q Series

Spence Back Pressure Regulators Equipped with Q Series Pilots

WARNING

Failure to follow these instructions or to properly install and maintain this equipment could result in property damage and personal injury or death. Q Series pilots 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 pilot vents gas or a leak develops in the system, service to the unit may be required. Failure to correct the issue could result in a hazardous condition. Installation, operation, and maintenance procedures performed by unqualified personnel may result in improper adjustment and unsafe operation. Either condition may result in equipment damage or personal injury. Only a qualified person shall install or service the Q Series pilot. 

Introduction

Scope of the Manual
This manual provides instructions for the installation, troubleshooting, maintenance, valve setting, and parts ordering for Q Series pilots with E Series main valves.
Product Description The Q Series pilot is separated from the main valve and connected to it with a male union. It is normally closed, designed with backless construction, and interchangeable on all sizes of main valves. A strainer screen shall be built into the pilot inlet.
These regulators are designed to maintain a constant back pressure by discharging excess flow to a lower system pressure or atmosphere. The EQ Series are intended primarily for steam service and provide dead-end shutoff. A Spence™ back pressure regulator is not a safety valve and should never be used as such.

Specifications

This section lists the specifications for the Q Series pilot. Factory specifications are stamped on the nameplate fastened on the regulator at the factory.
Available Types
Type Q: For ± 1 psig / 0.07 bar accuracy controlling backpressures between 3 and 150 psig / 0.21 to 10.3 bar
Type Q2: For ± 2 psig / 0.14 bar accuracy controlling backpressures between 100 and 300 psig / 6.89 to 20.7 bar
Type Q73: Air adjusted for ± 1 psig / 0.07 bar accuracy controlling backpressure at high retained pressures when available loading air is at low pressure. Delivery to loading, pressure is 6-2/3 to 1 psig / 0.28 to 0.07 bar
Available Size and End Connection Style 1/4 NPT
Maximum Inlet Pressure (1) 150 psig / 10.3 bar Maximum Operating Temperature (1)  Cast Iron: 400°F / 204°C Cast Steel: 500°F / 250°C
Spring Pressure Range
Type Q: 3 to 20 psig / 0.21 to 1.38 bar 5 to 50 psig / 0.35 to 3.45 bar 10 to 100 psig / 0.69 to 6.90 bar 20 to 150 psig / 1.38 to 10.3 bar
Type Q2: 100 to 300 PSIG / 6.90 to 20.7 bar
Construction Materials
Body: Cast Iron and Cast Steel Disc, Seat, and Diaphragm: Stainless steel Spring: Steel
Approximate Weight
Type Q: 7 lbs / 3.2 kg Type Q2: 10 lbs / 4.5 kg
Type Q73: 15 lbs / 6.8 kg
Options
Enclosed Spring Chamber
Adjusting Handle
High Pressure

Principle of Operation

The main valve is normally closed. The backpressure regulator responds to changes in upstream pressure. Pressure changes register to the pilot diaphragm through a control line. If the upstream pressure increases, the pilot opens and fluid starts to fill the connecting tubing. Orifice coupling (No. 4A bleed port) restricts flow and builds pressure under the main valve diaphragm, opening the main valve. Opening the main valve relieves pressure in the inlet pipe and control line, relaxing pressure on the pilot diaphragm. As pressure at the pilot diaphragm approaches a balance with the control spring force, the regulator is under throttling operation. Once the pressure at the pilot is less than the force of the control spring, the pilot closes and allows the main valve to close until an increase in back pressure occurs.

Installation

WARNING
Personal injury or system damage may result if this regulator is installed, without appropriate overpressure protection, where service conditions could exceed the limits given in the Specifications section and/or regulator nameplate. Additionally, physical damage to the regulator may result in personal injury or property damage due to escaping of accumulated gas. To avoid such injury and damage, install the regulator in a safe location.

Under enclosed conditions or indoors, escaping gas may accumulate and be an explosion hazard. In this case, the vent should be piped outdoors. Before Installation:

1. Install the main valve in a straight run of horizontal pipe. The diaphragm chamber must be down and the flow arrow pointing in the direction of flow. (See Figure 2)
2. Carefully clear the piping system of foreign matter at assembly.
3. Provide a three-valve bypass to facilitate inspection of the regulator.
4. Install a strainer ahead of the regulator.

Pilot Installation (See Figure 3)

1. Mount the Q Series pilot on either side of the main valve using the 1/4 in. / 6.35 mm blind nipple and union provided.Install the provided fittings in their proper locations. These fittings are vital to the operation of the regulator and must be properly installed and unobstructed.

2. Install a 1/2 in. / 12.7 mm control pipe with gate valve to connect the pilot to the selected control point in the backpressure pipe. The control pipe transmits the backpressure signal to the pilot and also provides the small amount of fluid required to operate the main valve. The control of the pipe should be as short as practical and must connect to the backpressure pipe at a point of minimum turbulence.

3. Install a 1/2 in. / 12.7 mm control pipe with gate valve to connect the pilot to the selected control point in the backpressure pipe. The control pipe transmits the backpressure signal to the pilot and also provides the small amount of fluid required to operate the main valve. The control pipe should be as short as practical and must connect to the backpressure pipe at a point of minimum turbulence.
   Note
   **** Avoid selecting a control point near a turn or enlargement in pipe size. On steam service, install the control pipe so that a water leg or pocket will not occur. If necessary, install a float and thermostatic trap for drainage.

4. Insulation may be applied to the upper portion of the main valve (globe and flange). Do not insulate the diaphragm chamber,  condensation chamber (if supplied) or any part of the pilot

Start-up

1. Use the bypass valve to regulate the flow at normal back pressure.
2. Open the control pipe valve. Open the outlet stop valve wide.
3. Crack open the inlet stop valve. Put a small amount of compression on the pilot control spring to close the pilot.
4. Gradually open the inlet stop valve and choke down on the bypass until the regulator is on the line.
5. Turn the control spring nuts slowly and evenly until the desired back pressure is reached. Compressing the pilot control spring increases the back pressure.

Dismantling

Pilot

1. Remove the compression on the control spring.
2. Remove the diaphragm bolts and lift off the cowl and diaphragm. As the diaphragm is lifted, the disk will be drawn out from its seat.

Main Valve

1. Remove the top flange.
2. Attach the adjustable pressure source as shown in Figure 4. Apply about 30 psig / 2.07 bar or 10 psig / 0.69 bar for Type E2 to jack open the valve.
3. Lift out the balance or dashpot cylinder if your valve is so equipped.
4. Remove the stem nuts after applying penetrating oil to the threads.
5. Lift out the piston, if so equipped.
6. Lift out the disk.
7. Remove the diaphragm loading pressure.
8. Remove the diaphragm bolts. The hood, diaphragms, main spring, and stem will drop from the valve.

Grinding In (Metal Seat and Disk Only)

1. Seats and disks never require more than a light touch-up using a very fine (400 Grit) compound. Heavy grinding will damage the metal-to-metal seal.
2. The pilot disk is slotted for rotation with a screw driver.
3. The main valves are ground in with the main spring removed, and one stem installed.
4. After grinding, disassemble and clean all parts with kerosene or trichloroethane.

Troubleshooting

Erratic Operation

1. Partial clogging of No. 4A fitting – Check fitting.
2. Steam service only: Water pocket in 1/2 in. control line – Provide for proper drainage.
3. Binding Pilot – Dismantle the pilot and check for scale or dirt buildup.

Excessive Back Pressure or Failure to Open

1. Inlet or outlet stop valve not fully open – Check.
2. Control pipe valve not open – Check.
3. Clogged strainer – Blow down the strainer.
4. Pilot improperly adjusted – Check adjustment.
5. Missing No. 4A fitting – Check orifice.
6. The main valve diaphragm is broken – Use auxiliary pressure to load the diaphragm. If the valve does not open with 30 psig / 2.07 bar or 10 psig / 0.69 bar for Type E2, then the diaphragm is broken.

Low Back Pressure or Failure to Close

1. Bypass valve leaking – Check.
2. Pilot improperly adjusted – Check adjustment.
3. Clogged No. 4A fitting – Check orifice.
4. The main valve or pilot valve hung open. Pinpoint the problem by closing the valve tight. a. If the backpressure rises, the pilot is hung open –
   Dismantle and clear.
   b. If back pressure does not rise, the main valve is hung open – Dismantle and clear.

Maintenance

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

1. Under normal conditions, the periodic dismantling of the regulator is not recommended. A valve kept relatively free of dirt will function for years with minimal attention.
2. The following inspections should be made after the first ten days of operation and twice a year thereafter:
   a. Check the No. 4A bleed port restriction for dirt accumulation. Clean as required.
   b. Check the pilot for dirt accumulations on the upper surface of its pressure plate. Clean as required.
   c. Inspect all joints for leakage. Keep bolts and fittings tight. Never allow a leak to persist. Parts Ordering When corresponding with your local Sales Office about the Q Series pilot, always reference the assembly number. When ordering replacement parts, specify the complete character part number from the following parts list.

Parts List

1 Adjusting Nut, Steel
2 Spring Yoke, Iron
3 Standard, Stainless steel
4 Adjusting Spring, Steel
3 to 20 psi / 0.21 to 1.38 bar
5 to 50 psi / 0.35 to 3.45 bar
10 to 100 psi / 0.69 to 6.90 bar
20 to 150 psi / 1.38 to 10.3 bar
5 Spring Button, Steel
6 Pressure Plate, Steel
7 Diaphragm Screw, Stainless steel
8 Diaphragm Nut, Steel
9 Cowl, Iron
10* (1)  Diaphragm, Stainless steel
11 Diaphragm Bolt, Steel
11 Diaphragm Nut, Steel
12 Disc Adjusting Scree, Stainless steel
13 Dowel Pin, Stainless steel
14  Body Iron Bronze Steel
15 Disc, Stainless steel
16  Seat Ring, Stainless steel
17 Handwheel, Mall Iron
18 Handwheel Nut, Steel
19 Adjusting Screw, Steel
20 Adjusting Screw, Locknut, Steel
21 Cowl Yoke Iron (2)   Ductile Iron (3)
22 Yoke Bushing, Locknut, Steel
23 Yoke Bushing, Bronze
24  Adjusting Screw, Steel
25 Locknut, Steel
26  Spring Chamber Iron Bronze Steel
27 Padlock, Brass
28 Lock Pin, Steel
29 Lock Bar, Steel
30 Spring Yoke, Iron
30 Lock Pin, Steel
32 Diaphragm Nut, Steel| Part Number
WAL5-02874-0
WAL5-06183-0
WAL4-05219-0
WAL5-05007-0
WAL5-05003-0
WAL5-05005-0
WAL5-05012-0
WAL4-01040-0
WAL4-03679-0
WAL4-04823-0
WAL5-02871-0
WAL4-01508-0
WAL4-01623-0
WAL5-04764-0
WAL5-02871-0
WAL4-04761-0
WAL5-03242-0
WAL4-00737-0
WAL4-00739-0
WAL4-00738-0
WAL4-01712-0
WAL4-04381-0
WAL5-06139-0
WAL5-02872-0
WAL4-04752-0
WAL5-02952-0
WAL4-06166-0
WAL4-06167-0
WAL5-02947-0
WAL4-01152-0
WAL5-04860-0
WAL5-02942-0
WAL4-01393-0
WAL4-01395-0
WAL4-01394-0
WAL5-03204-0
WAL4-03272-0
WAL4-00436-0
WAL4-06182-0
WAL4-03272-0
WAL5-02871-0

* Recommended Spare Parts

1. Requires 2 per set
2. Applies to iron pilot
3. This applies to Bronze and steel pilots

VCIMD-16077 © 2021 Emerson Electric Co. All rights reserved. 11/21 Spence is a mark owned by one of the companies in the Emerson Automation Solutions business unit of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners.
The contents of this publication are presented for informational purposes only, and while every effort 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. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
Emerson Electric Co. does not assume responsibility for the selection, use, or maintenance of any product. Responsibility for proper selection, use, and maintenance of any Emerson Electric Co. product remains solely with the purchaser.

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