Emerson Fisherr 4660 User manual

www.Fisher.com

Fisherr4660 High‐Low Pressure Pilot

Contents

Introduction 2.................................

Scope of Manual 2.............................

Description 2.................................

Educational Services 2.........................

Specifications 2...............................

Installation 5..................................

Mounting 7..................................

Actuator Mounting 7.......................

Panel Mounting 7..........................

Pipestand Mounting 7......................

Pressure Connections 8........................

Supply Pressure 8..........................

Process Pressure 9.........................

Output Pressure 9.........................

Vent 9.......................................

Operating Information 9.........................

Pilots without Optional Set Point Indication 10.....

Preliminary Adjustments 10.................

Setting the High Set Point 11................

Setting the Low Set Point 11.................

Alternate Set Point Adjustment Procedure 12..

Pilots with Optional Set Point Indication 14........

Setting the High and/or Low Set Point(s) 15....

Prestartup Checks 15..........................

Alignment of the Nozzle Beam 15................

Startup 16...................................

Performance 16................................

Principle of Operation 17........................

Maintenance 17................................

Bourdon Tube/Flapper Assembly

Replacement 18............................

Block‐and‐Bleed Relay Assembly

Replacement 18............................

Low or High Set Point Assembly

Replacement 19............................

Pilots without Set Point Indication 19.........

Pilots with Set Point Indication 19............

Parts Ordering 20...............................

Parts Kits 20...................................

Parts List 22...................................

FRONT VIEW

LEFT SIDE WITH CASE COVER OFF

Figure 1. Fisher 4660 High‐Low Pressure Pilot with

Relay

X0231

X0232

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Introduction

Scope of Manual

This instruction manual provides installation, operating, maintenance, and parts ordering information for the Fisher

4660 high‐low pressure pilot. Refer to separate instruction manuals for information regarding the control valve

actuator.

Do not install, operate, or maintain a 4660 pressure pilot without being fully trained and qualified in valve, actuator,

and accessory installation, operation and maintenance. To avoid personal injury or property damage it is important to

carefully read, understand, and follow all of the contents of this manual, including all safety cautions and warnings. If

you have any questions about these instructions, contact your Emerson Process Management sales office.

Description

The 4660 high‐low pressure pilot (figure 1) activates emergency shutdown systems for flowlines, production vessels,

and compressors. The pilot can be used with either a single or dual set point capability to maintain full output pressure

when the process is operating within the set point range. The primary switching mechanism in this pilot is a

block‐and‐bleed relay assembly.

Unless otherwise noted, all NACE references are to NACE MR0175‐2002.

Specifications

Specifications for the 4660 high‐low pressure pilot are listed in table 1.

Educational Services

For information on available courses for the 4660 high‐low pressure pilot, as well as a variety of other products,

contact:

Emerson Process Management

Educational Services, Registration

P.O. Box 190

Marshalltown, IA 50158-2823

Phone: 800-338-8158 or 641-754-3771

FAX: 641-754-3431

e‐mail: [email protected]

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Table 1. Specifications

Available Configurations

High‐low, low‐only, or high‐only set point capability

Input Signal

Type: Process pressure sensed with Bourdon tube

Bourdon Tube Ratings: See table 2 or 3

Overpressure Protection: Maximum allowable

emergency process pressures and maximum

allowable process pressures to ensure set point

readjustability are shown in table 4

Output Signal

Zero or full supply pressure (automatically resets)

Supply Pressure(1)

Normal Operating Pressures: 1.4 to 4.4 bar

(20 to 65 psig)

Medium: Air or natural gas

Air: Supply pressure must be clean, dry air that meets

the requirements of ISA Standard 7.0.01. A maximum

40 micrometer particle size in the air system is

acceptable. Further filtration down to 5 micrometer

particle size is recommended. Lubricant content is

not to exceed 1 ppm weight (w/w) or volume (v/v)

basis. Condensation in the air supply should be

minimized

Natural Gas: Natural gas must be clean, dry, oil‐free,

and noncorrosive. H2S content should not exceed 20

ppm.

Steady‐State Air Consumption(2)(3)

Output Signal at Zero:

≤0.134 normal m3/hr (≤5 scfh)

Output Signal at Full Supply Pressure: ≤0.00134

normal m3/hr (≤0.05 scfh)

Set Point Adjustments

Continuously adjustable between 3 and 97% of

Bourdon tube rating; see table 2 or 3 for ranges

Performance in Percentage of Bourdon Tube

Rating

Repeatability: ≤0.25%

Set Point DPmin (see table 2 or 3)

Single High‐Low Unit: 10% for up to 172.4 bar (2500

psig) Bourdon tubes; 15% for 344.8 and 517.1 bar

(5000 and 7500 psig) Bourdon tubes

Low‐Only and High‐Only Pair: 3%

Trip‐to‐Reset Zone (see table 2 or 3): ≤1.5%

Exhaust Capacity

Cg≥15

Pilot Supply Flow Requirement(2)

Pilot requires minimum of 4.02 normal m3/hr

(150 scfh) to activate relay

Operating Conditions(1)

Condition Normal Operating

Limits

Nominal

Reference

Ambient

temperature -59 to 71C (-75 to 160F) 21C (70F)

Operating Influences on Switch Point Sensitivity

Supply Pressure: ≤0.05% of Bourdon tube rating for a

10% change in supply pressure

Ambient Temperature: ≤2% Bourdon tube rating

throughout normal operating limits with nominal

reference

Time: ≤1% of Bourdon tube rating over 30 days at

ambient temperature nominal reference

Process Pressure: Range shift or set point drift can

occur if process pressure exceeds Bourdon tube

rating

Pressure Connections

1/4 NPT internal

Mounting

Panel, rack, pipestand, or actuator

Hazardous Area Classification

Complies with the requirements of ATEX Group II

Category 2 Gas and Dust

-continued-

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Table 1. Specifications (continued)

Safety Instrumented System Classification

SIL3 capable  certified by exida Consulting LLC

Approximate Weight

2.3 kg (5 pounds)

Options

Visual output indication, stainless steel panel

mounting flange, set point indication,

tamper‐resistant front cover

Declaration of SEP

Fisher Controls International LLC declares this

product to be in compliance with Article 3 paragraph

3 of the Pressure Equipment Directive (PED) 97 / 23 /

EC. It was designed and manufactured in accordance

with Sound Engineering Practice (SEP) and cannot

bear the CE marking related to PED compliance.

However, the product may bear the CE marking to

indicate compliance with other applicable European

Community Directives.

NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology.

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

2. Normal m3/hr—normal cubic meters per hour (0C and 1.01325 bar absolute). Scfh—standard cubic feet per hour (60F and 14.7 psia).

3. Supply pressure at 2.1 bar (30 psig).

Table 2. Additional Specifications, Bar

BOURDON TUBE RATING(1) SET RANGE(1)

SET POINT DPMIN

(MINIMUM ALLOWABLE DIFFERENCE

BETWEEN HIGH AND LOW SETTINGS) TRIP‐TO‐RESET ZONE

Single High‐

Low Unit

High‐Only/

Low‐Only Pair

6.9

17.2

34.5

69.0

0.3 to 6.6

0.6 to 16.6

1.1 to 33.4

2.1 to 67.9

0.7

1.7

3.5

6.9

0.3

0.6

1.1

2.1

0.2

0.3

0.6

1.1

103.4

172.4

344.8

517.2

689.5(2)

3.2 to 100.2

5.2 to 167.2

10.4 to 334.4

15.6 to 501.5

20.7 to 668.8

10.4

17.3

34.5

51.8

103.4

3.2

5.2

10.4

15.6

20.7

1.6

2.6

5.2

7.8

10.3

1. Rating indicated on Bourdon tube and set range on front panel are in kPa (1 bar = 100 kPa).

2. NACE compliant material only.

Table 3. Additional Specifications, Psig

BOURDON TUBE

RATING SET RANGE

SET POINT DPMIN

(MINIMUM ALLOWABLE DIFFERENCE

BETWEEN HIGH AND LOW SETTINGS) TRIP‐TO‐RESET ZONE

Single High‐

Low Unit

High‐Only/

Low‐Only Pair

100

250

500

1000

3 to 97

8 to 242

15 to 485

30 to 970

100

3.0

7.5

15.0

30.0

1.5

3.8

7.5

15.0

1500

2500

5000

7500

10,000(1)

45 to 1455

75 to 2425

150 to 4850

225 to 7275

300 to 9700

150

250

750

1025

1500

150

225

300

113

150

1. NACE compliant material only.

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Table 4. Maximum Allowable Process Pressure(1)

BOURDON TUBE RATING MAXIMUM ALLOWABLE EMERGENCY PROCESS PRESSURE

Stainless Steel Bourdon Tubes NACE Compliant Bourdon Tubes

Bar(2) Psig Bar(2) Psig Bar(2) Psig

6.9

17.2

34.5

69.0

100

250

500

1000

13.8

34.2

69.0

138.0

200

500

1000

2000

13.8

34.2

69.0

138.0

200

500

1000

2000

103.4

172.4

344.8

517.2

689.5

1500

2500

5000

7500

10,000

206.8

344.8

517.2

646.3

N/A

3000

5000

7500

9375

N/A

206.8

258.6

430.9

568.8

758.5

3000

3750

6250

8250

11,000

Maximum Allowable Process Pressure to Insure Set Point Readjustability(3)

6.9

17.2

34.5

69.0

100

250

500

1000

13.8

34.8

51.7

103.5

200

500

750

1500

13.8

22.3

53.4

89.7

200

325

775

1300

103.4

172.4

344.8

517.2

689.5

1500

2500

5000

7500

10,000

155.1

172.4

517.2

646.3

N/A

2250

2500

7500

9375

N/A

124.0

227.5

344.8

517.2

689.5

1800

3300

5000

7500

10,000

1. Normal operating process pressures should not exceed the Bourdon tube rating.

2. Ratings indicated on Bourdon tube are in psig and kPa (1 bar = 100 kPa).

3. Values listed for NACE compliant Bourdon tubes are for a 2% deviation from set point due to overpressure.

Installation

If using natural gas as the pneumatic supply medium, natural gas will be used in the pressure connections of the unit

to any connected equipment. The unit will vent natural gas into the surrounding atmosphere, unless it is remote

vented.

WARNING

To avoid personal injury or property damage caused by a sudden release of pressure:

 Always wear protective clothing, gloves, and eyewear when performing any installation operations.

 Personal injury or property damage may result from fire or explosion if natural gas is used as the supply medium and

appropriate preventative measures are not taken. Preventative measures may include, but are not limited to, one or

more of the following: Remote venting of the unit, re‐evaluating the hazardous area classification, ensuring adequate

ventilation, and the removal of any ignition sources. For information on remote venting of the 4660 pressure pilot,

refer to page 9.

 Do not exceed the process pressure values in table 4 or the maximum supply pressure values in table 1.

 If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this

instruction manual.

 Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

The following instructions describe various mounting and connecting procedures. Pilots may be connected together

to accommodate requirements for single and dual outputs as well as single and dual process pressure lines. Figure 2

shows some typical connections. When a pair of high‐only and low‐only pilots are used to obtain closer set points as

specified by the set point ‐DPMIN values in tables 2 and 3 connect the pilots as shown in examples A and D in figure 2.

For a two‐segment flow line configuration that adheres to API Specification RP14C, connect as shown in example B

or C.

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Figure 2. Typical Connection Schematics

PROCESS

OUTPUT

SUPPLY

PROCESS

NO. 1

OUTPUT

SUPPLY

PROCESS

NO. 2

SUPPLY

PROCESS NO. 1 PROCESS

NO. 2

OUTPUT TO SUPPLY PROCESS

SUPPLY

PROCESS

OUTPUT

ELECTRICAL

PRESSURE

SWITCH

A. HIGH-ONLY AND LOW-ONLY PILOTS

SENSING A SINGLE PROCESS POINT

AND HAVING A SINGLE OUTPUT

B. LOW-ONLY AND HIGH/LOW PILOTS

WITH DUAL OUTPUTS AND DIFFERENT

PROCESS PRESSURES

C. LOW-ONLY AND HIGH/LOW PILOTS

WITH SINGLE OUTPUT AND

DIFFERENT PROCESS PRESSURES

D. LOW-ONLY AND HIGH-ONLY PILOTS

WITH DUAL OUTPUTS AND

COMMON PROCESS PRESSURE

E. HIGH/LOW PILOT INTERFACED

WITH A PRESSURE SWITCH

C0584-1

39A1578-A

38A6087-B 38A6086-B

38A6084-B

38A6085-B

OUTPUT OUTPUT

OUTPUT

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Mounting

Normal installation is with the pilot mounted vertically and with process, supply, and output connections facing

downward as shown in figure 1. All key numbers are shown in figure 8 unless otherwise indicated.

Actuator Mounting

Pilots can be mounted on a control valve actuator as described below.

To yoke‐mount the pilot to an actuator, attach the two‐holed side of the yoke mounting plate (key 75, not shown) to

the spring barrel of the actuator with cap screws and lockwashers (keys 84 and 85, not shown). Then attach the

three‐bossed side of the pilot case (key 2) to the three‐holed side of the yoke mounting plate with the remaining cap

screws and lock washers.

To mount the pilot to the diaphragm casing of an actuator, attach the two‐holed side of the casing mounting plate

(key 75, not shown) to the diaphragm casing of the actuator with the actuator cap screws and nuts. Then attach the

three‐bossed side of the pilot case (key 2) to the three‐holed side of the casing mounting plate with cap screws and

lock washers (keys 84 and 85, not shown).

Panel Mounting

If the pilot is not already equipped with a panel mounting plate (key 75), remove the cover screws (key 6), the cover

(key 4), and the screws (key 21).

For pilots without set point indication, loosen the set screws and remove the knobs (key 67), the locking discs (key 69),

and the front plate (key 74). Insert the panel mounting plate, and reattach the front plate, the locking discs, the knobs,

the cable assembly (key 12), the screws, the cover, and the cover screws.

For pilots with set point indication, loosen the module set screws, and remove the modules and the front plate

(key 74). Insert the panel mounting plate, and reattach the front plate, the modules, the cable assembly (key 12), the

screws, the cover, and the cover screws.

Choose the panel mounting style required to allow for either front or rear removal of the pilot from the panel. Cut a

hole in the panel surface and drill mounting screw holes using the dimensions shown in figure 3.

Note

For either mounting style, the process, output, and supply pressure fittings may be attached to the pilot prior to sliding the pilot

into the cutout. Also, these fittings do not need to be detached from the pilot when removing the pilot from the panel.

Peel off the backing on the panel mount gasket. Apply pressure to the gasket surface to adhere the gasket to the face

of the panel. Slide the pilot into the cutout from the front or rear side of the panel and attach the panel mounting plate

to the panel.

Pipestand Mounting

Pipestand mounting parts are available to mount the pilot to a 2 inch (nominal) horizontal or vertical pipe. Attach the

three‐bossed side of the pilot case (key 2) to the three‐holed side of the pipestand mounting plate (key 75, not shown)

with cap screws and lock washers (keys 84 and 85, not shown). Then attach two pipe clamps (key 86, not shown) to

the pipestand mounting plate, and fasten the pilot to the pipe.

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Figure 3. Cutout Dimensions for Panel Mounting

REAR REMOVAL FRONT REMOVAL

(INCH)

18A3804‐F

A3299‐1

5.2 (0.20)

DIAMETER

HOLES

195

(7.69)

(3.84)

4 (0.16)

109

(4.29)

117

(4.62)

(0.16)

4 (0.16)

117

(4.62)

109

(4.29)

(3.84)

195

(7.69)

5.2 (0.20)

DIAMETER

HOLES

186

(7.31)

205

(8.06)

Pressure Connections

Standard pressure connections on the 4660 pilot are 1/4 NPT internal. Use 1/4‐ or 3/8‐inch pipe or tubing for process,

output, and supply pressure piping. The locations of pressure connections are shown in figure 4. The vent location is

shown in figure 8.

Figure 4. Location of Pressure Connections

18A3804‐G

Supply Pressure

WARNING

Severe personal injury or property damage may occur from an uncontrolled process if the instrument supply medium is not

clean, dry air or noncorrosive gas. While use and regular maintenance of a filter that removes particles larger than 40

micrometers in diameter will suffice in most applications, check with an Emerson Process Management field office and

industry instrument air quality standards for use with corrosive gas or if you are unsure about the proper amount or

method of air filtration or filter maintenance.

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

Supply pressure must be clean, dry air or noncorrosive gas that meets the requirements of ISA Standard 7.0.01. A

maximum 40 micrometer particle size in the air system is acceptable. Further filtration down to 5 micrometer particle

size is recommended. Lubricant content is not to exceed 1 ppm weight (w/w) or volume (v/v) basis. Condensation in

the air supply should be minimized.

Alternatively, natural gas may be used as the supply pressure medium. Gas must be clean, dry, oil‐free, and

noncorrosive. H2S content should not exceed 20 ppm.

Use a suitable filter regulator, such as the 67CFR regulator with standard 5 micrometer filter, to remove solid particles

and to maintain the supply pressure source within the normal operating range of 1.4 to 4.4 bar (20 to 65 psig). Refer to

table 1 for the pilot supply flow requirement (relay construction only). As shown in figure 4, connect supply pressure to

the connection marked SUPPLY on the bottom of the pilot case.

Process Pressure

Connect process pressure to the connection marked PROCESS on the bottom of the pilot case as shown in figure 4.

When installing process pressure piping, follow accepted practices to ensure accurate transmission of the process

pressure to the pilot. Install shutoff valves, vents, drains, or seal systems as needed in the process pressure line. Install

a needle valve in the process pressure line to dampen pulsations.

Output Pressure

Connect output pressure piping to the connection marked OUTPUT on the bottom of the pilot case as shown in figure

4. Refer to the appropriate control valve or actuator instruction manual to complete the connection of output pressure

piping from the pilot to the loading connection of the control valve actuator.

Vent

WARNING

Personal injury or property damage could result from fire or explosion of accumulated gas, or from contact with hazardous

gas, if a flammable or hazardous gas is used as the supply pressure medium. Because the instrument case and cover

assembly do not form a gas‐tight seal when the assembly is enclosed, a remote vent line, adequate ventilation, and

necessary safety measures should be used to prevent the accumulation or flammable or hazardous gas. A remote vent pipe

alone cannot be relied upon to remove all flammable and hazardous gas.

Vent line piping should comply with local and regional codes, should have adequate inside diameter, and should be be as

short as possible to reduce case pressure buildup.

If a remote vent is required, use 19 mm (3/4‐inch) (minimum inside diameter) pipe for runs up to 6.09 meters (20

feet). For vent piping runs from 6.09 to 30.5 meters (20 to 100 feet), use 25.4 mm (1‐inch) (minimum inside diameter)

pipe. Remove the vent screen (key 20, figure 8) and install a remote vent pipe to exhaust the vented gas to a safe,

well‐ventilated area. The vent, as shown in figure 8, or the end of a remote vent pipe must be protected against the

entrance of all foreign matter that could block the vent. Check the vent periodically to be certain it is not plugged.

Operating Information

For high‐only and low‐only constructions, perform the procedures that are outlined in the adjustments portion of this

section. For high‐only constructions, perform only those procedures that pertain to setting and checking the high set

Instruction Manual

D200163X012

4660 Pressure Pilot

May 2014

point. For low‐only constructions, perform only those procedures that pertain to setting and checking the low set

point. For high‐low constructions, perform procedures that pertain to both the high and low set points.

WARNING

Avoid personal injury or property damage from an uncontrolled process or sudden release of process pressure. Before

starting any adjustments:

 Always wear protective clothing, gloves, and eyewear to avoid personal injury when making adjustments.

 Do not remove the actuator from the valve while the valve is still pressurized.

 Provide some temporary means of process control before taking the pilot out of service.

 Shut off the process pressure line and the supply pressure line, and bleed all of the supply pressure.

 Bleed all process pressure from the pilot so that no pressure is contained in the Bourdon tube.

 When bleeding the supply or process pressure, natural gas, if used as the supply medium, will seep from the unit into

the surrounding atmosphere. Personal injury or property damage may result from fire or explosion if preventative

measures are not taken, such as adequate ventilation and the removal of any ignition sources.

 Use lock‐out procedures to be sure that the above measures stay in effect while you are working on the equipment.

 Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

Pilots Without Optional Set Point Indication

Preliminary Adjustments

Make sure the following steps have been performed completely before setting either the high or low set point

pressures. Key numbers are shown in figure 8.

1. Refer to the WARNING at the beginning of the Operating Information section. Make sure the Bourdon tube contains

no pressure.

2. Install either a pressure gauge or an optional output indicator in the output pressure line.

3. Remove the cover screws and the cover (keys 6 and 4).

4. Unlock each locking disc (key 69) that holds each set point knob in place. Turn the HIGH SET knob clockwise until it

has reached the end of its travel. Turn the LOW SET knob (key 67) counterclockwise until it has reached the end of

its travel.

WARNING

Before continuing on with step 5, read this Warning:

Natural gas, if used as the supply medium, will seep from the unit into the surrounding atmosphere when the SUPPLY TEST

button is pushed in the next step. Personal injury or property damage may result from fire or explosion if preventative

measures are not taken, such as adequate ventilation and the removal of any ignition sources.

5. Turn on the supply pressure. To check that the supply pressure is turned on, push the SUPPLY TEST button located

in the cleanout assembly (key 54) on the front plate (key 74) until a flow sound is heard.

WARNING

To avoid personal injury or property damage caused by a sudden release of pressure, do not exceed the process pressure

values in table 4.

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