Fisher Type EZR Pilot-Operated Regulator
Instruction Manual D103681X012 | January 2020
Summary
This document provides a comprehensive overview of the Fisher Type EZR Pilot-Operated Regulator, detailing its specifications, operation, installation, and maintenance procedures.
- Introduction: 1
- Description: 1
- Characteristics: 2
- Labelling: 4
- Operation: 5
- Dimensions and Weights: 6
- Installation: 7
- Commissioning: 9
- Maintenance: 10
- Spare Parts: 13
Introduction
The Type EZR is a pilot-operated regulator designed for use in transmission and distribution networks, as well as industrial and commercial pipeline applications. It can be equipped with an optional Type OS2 slam shut for rapid gas flow cutoff in cases of under or over outlet pressure.
Description
Main Valve
The Type EZR consists of:
- A version without integral slam shut: A body, a bonnet, a regulation subassembly (slotted cage and diaphragm/plug), a travel indicator, an inlet screen, and a pilot assembly (filter, restrictor, pilot).
- A version with integral slam shut: Includes a body, bonnet, connecting part, regulation subassembly, travel indicator, pilot assembly, slam shut orifice, integral O-ring tightshut valve/bypass assembly, and a release relay Type OS2 (mechanism box and safety manometric box).
The Type EZR conforms to the PED 2014/68/EU and is classified in Category IV.
Pilot Options
- Type PRX/120: Outlet pressure range 1 to 40 bar. Suitable for single-stage, monitor, or working pilot applications.
- Type PRX/120-AP: Outlet pressure range 30 to 80 bar. Similar applications to PRX/120.
- Type PRX/125: Identical to PRX/120 but with the restriction screw removed. Used as a monitor override pilot.
- Type PRX/125-AP: Identical to PRX/120-AP with the restriction screw removed. Used as a monitor override pilot.
- Type 161EB: High accuracy pilot, 0.34 to 24.1 bar range. Bleeds downstream through the sense line.
- Type 161EBM: Monitor version of 161EB. Pilot bleed is isolated from the sense line.
- Type 161EBΗ: High pressure version of 161EB, 17.2 to 48.3 bar range.
- Type 161EBΗΜ: High pressure monitor version of 161EBM, 17.2 to 48.3 bar range.
Regulator Options
- Travel Indicator
- Relief Size-reduction Trim
Characteristics
Table 1. General Characteristics for Type EZR Regulator
| Characteristic | PS | TS | SLAM SHUT Accuracy | Set point range | Accuracy |
|---|---|---|---|---|---|
| Operating pressure | 72.4 bar(1) | -17/66°C(1) | - | - | - |
| Outlet pressure | - | - | 0.35 to 69 bar | 2.5-5 | 2.5-5 |
| Minimum differential | PN 20: 2 to 3 bar | - | - | - | - |
| Maximum operating differential | PN 50: 18.6 bar | - | - | - | - |
| Max emergency differential | PN 100: 50.0 bar | - | - | - | - |
| Accuracy | 72.4 bar | - | - | - | 5 (Piston) up to 100 bar |
(1) Values correspond to the characteristics of the regulator diaphragm.
Table 2. Pressure and Temperature Characteristics
| Body | Pmax (bar) | Tmin (°C) | Tmax (°C) |
|---|---|---|---|
| A216WCB | 96.7 | -20 | 71 |
| A352LCC | 100 | -30 | 71 |
The regulator body and the slam shut have been designed to support different pressure and temperature levels.
Flow Coefficients and Valve Plug Travel
Table 3. Flow Coefficients and Valve Plug Travel Information
| Coefficients | Capacity | DN 25 | DN 50 | DN 80 | DN 100 | DN 150 |
|---|---|---|---|---|---|---|
| Cg | 100% | 480 | 1800 | 3400 | 5550 | 11200 |
| 60% | 290 | 1020 | 1970 | 3300 | 7150 | |
| 30% | 140 | 560 | 970 | 1690 | 3570 | |
| C1 | 100% | 33 | 36 | 37 | 38 | 36 |
| 60% | 29 | 28 | 29 | 27 | 30 | |
| 30% | 30 | 29 | 26 | 26 | 26 | |
| Valve plug travel (mm) | 35 | 35 | 50 | 50 | 50 | |
Pilot Pressure Ranges
Table 4. Pilot Pressure Ranges
| Type | Outlet Pressure Range, bar | Spring Color | Part Number |
|---|---|---|---|
| PRX/120 PRX/125 |
1.0 to 1.8 | Yellow | M0255240X12 |
| 1.8 to 3.0 | Green | M0255230X12 | |
| 3.0 to 5.5 | Blue | M0255180X12 | |
| 5.5 to 8.5 | Black | M0255220X12 | |
| 8.5 to 14.5 | Silver | M0255210X12 | |
| 14.5 to 23.0 | Gold | M0255200X12 | |
| 23.0 to 30.0 | Aluminium | M0255860X12 | |
| 30.0 to 40.0 | Red | M0255190X12 | |
| PRX/120-AP PRX/125-AP |
30.0 to 80.0 | Clear | M0273790X12 |
| 161EB 161EBM |
0.35 to 1.0 | White | 17B1260X012 |
| 0.69 to 2.8 | Yellow | 17B1262X012 | |
| 2.1 to 5.2 | Black | 17B1259X012 | |
| 4.8 to 9.7 | Green | 17B1261X012 | |
| 9.0 to 13.8 | Blue | 17B1263X012 | |
| 13.8 to 24.1 | Red | 17B1264X012 | |
| 161EBΗ 161EBΗΜ |
17.2 to 31.0 | Blue | 17B1263X012 |
| 27.6 to 48.2 | Red | 17B1264X012 |
Materials
Regulator:
- Body: Steel
- Bonnet: Steel
- Slotted disc: Stainless steel
- Diaphragm, O-rings: Nitrile (NBR)
- Slam shut: Steel
- Connecting part: Stainless steel
- Orifice: Stainless steel
- Valve plug: Stainless steel or Steel
Pilot:
- Body: Stainless steel or Steel
- Manometric box: Stainless steel or Aluminium
- Restrictor: Stainless steel
- Filter: Aluminium or Steel
- Cartridge: Polythene
Connections
Inlet / Outlet:
- Flanges: CL150 RF - CL300 RF - CL600 RF, PN 16B - PN 25B - PN 40B (Other configurations available upon request).
- Pilot Impulse line (IP): 1/4" NPT tapped
- Pilot Monitor impulse line (IM): 1/4" NPT tapped
- Intermediate impulse line (PI): 1/4" NPT tapped
- Slam shut impulse line (IS): 1/4" NPT tapped
- Mechanism box vent (E): 1/4" NPT tapped
- Impulse diameter: Pipe interior Ø 8/10 mm min.
Labelling
The regulator label provides essential information including model, size (DN), pressure ratings (PN), certifications, serial number, and manufacturing date. Figure 2 shows a typical regulator label, and Figure 3 shows a label for a regulator with an OS2 Slam Shut.
Key information on the label includes:
- DN: Nominal Diameter
- PN: Pressure Nominal
- Class: Pressure/Temperature rating (e.g., 150, 300, 600 RF)
- Cg, C1: Flow coefficients
- Pumax, PT, PS: Maximum allowable pressures
- Temp TS: Temperature range
- Date Fab/Test: Manufacturing/Test Date
- Serial Number: Unique identifier
- CE0062: CE Marking
Operation
Regulator
The Type EZR is a pilot-driven, diaphragm/plug regulator. Tight shutoff is achieved through the combined force of the diaphragm/plug against the slotted cage, the closing spring, and inlet pressure.
- Opening: As flow increases, outlet pressure (Pd) decreases. This causes the pilot to open, increasing pressure loss through the restrictor, reducing modulated pressure (Pm). When the force from the closing spring and Pm becomes less than the force from inlet pressure (Pi), the regulator opens.
- Closing: As flow decreases, outlet pressure (Pd) increases. The pilot diaphragm force is overcome by the spring force, causing the pilot to close. Pressure loss through the restrictor decreases, and the force from the closing spring and Pm becomes greater than Pi, causing the regulator to close.
Slam Shut
The safety manometric box (BMS) senses the pressure in the protected zone. If this pressure exceeds the set tripping pressure, the release relay opens the valve plug, causing it to close on the orifice due to spring force and fluid pressure. Flow is obstructed until the fault is corrected and the mechanism box is manually reset. Reopening requires equal pressure balance on inlet and outlet sides.
Dimensions and Weights
Detailed dimensions and weights for various configurations of the Type EZR and EZR-OS2 regulators, including different pilot types and flange ratings, are provided in the following tables and figures.
Table 5. Dimensions (mm) - Type EZR-OS2 (part 1)
| Body DN | B | C | E | H | Type 161EB Pilot | Type PRX Pilot |
|---|---|---|---|---|---|---|
| 25 | 233 | 315 | 348 | 252 | 250 | - |
| 50 | 243 | 330 | 357 | 261 | 265 | - |
| 80 | 361 | 366 | 410 | 314 | 301 | - |
| 100 | 393 | 410 | 454 | 358 | 345 | - |
| 150 | 423 | 396 | 468 | 372 | 332 | - |
Table 6. Weights (kg) - Type EZR-OS2
| Body DN | CL150 RF | CL300 RF | CL600 RF |
|---|---|---|---|
| 25 | 20 | 21 | 22 |
| 50 | 39 | 41 | 43 |
| 80 | 63 | 69 | 71 |
| 100 | 104 | 113 | 123 |
| 150 | 192 | 211 | 244 |
Table 7. Dimensions (mm) - Type EZR (part 1)
| Body DN | B | C | E | Type 161EB Pilot | Type PRX Pilot |
|---|---|---|---|---|---|
| 25 | 220 | 62 | 335 | 239 | - |
| 50 | 226 | 83 | 340 | 245 | - |
| 80 | 343 | 105 | 392 | 297 | - |
| 100 | 372 | 137 | 433 | 336 | - |
| 150 | 420 | 178 | 465 | 368 | - |
Table 8. Weights (kg) - Type EZR
| Body DN | CL150 RF | CL300 RF | CL600 RF |
|---|---|---|---|
| 25 | 12 | 14 | 16 |
| 50 | 26 | 27 | 31 |
| 80 | 50 | 51 | 57 |
| 100 | 67 | 73 | 88 |
| 150 | 97 | 108 | 161 |
Table 9. Dimensions (mm) - Types EZR and EZR-OS2 (part 2)
| Body DN | PN | CLASS | A | D | J | M | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| 25 | 16 25 40 | 150 300 600 | - | 193.5 | 193.5 | 193.5 | 184 | 197 | 210 | 68 | 54 |
| 50 | - | 254 | 267 | 267 | 254 | 267 | 286 | 165 | 68 | 54 | |
| 80 | 5.0 | 317 | 317 | 298 | 317 | 337 | 181 | 95 | 54 | ||
| 100 | - | 350 | 368 | 368 | 352 | 368 | 394 | 187 | 95 | 54 | |
| 150 | - | 451 | 473 | 473 | 451 | 473 | 508 | 249 | 95 | 54 |
Table 10. Dimensions (mm) - BMS (Safety Manometric Box)
| Type | F | G |
|---|---|---|
| Diaphragm | 162 | 181 |
| Piston | 71 | 204 |
| Bellows | 74 | 223 |
Installation
All interventions on the equipment should only be performed by qualified and trained personnel.
WARNING
Personal injury or equipment damage, due to bursting of pressure-containing parts may result if this regulator is over-pressured or is installed where service conditions could exceed the limits given in the Specification section and on the appropriate nameplate, or where conditions exceed any rating of the adjacent piping or piping connections. To avoid such injury or damage, provide pressure-relieving or pressure-limiting devices to prevent service conditions from exceeding those limits. Also, be sure the installation is in compliance with all applicable codes and regulations.
Additionally, physical damage to the regulator could break the pilot off the main valve, causing personal injury and property damage due to bursting of pressure-containing parts. To avoid such injury and damage, install the regulator in a safe location.
WARNING
Only personnel qualified through training and experience should install, operate and maintain a regulator. Before installation, make sure that there is no damage to, or debris in, the regulator. Also make sure that all tubing and piping are clean and unobstructed.
- The regulator is installed on horizontal pipeline. Version with slam shut, the release relay is situated towards the bottom (see schematic).
- Installation according to EN12186 recommended.
- Install according to direction of fluid flow (arrow).
- When assembling with adjacent elements care must be taken not to create pressure force on the body and the assembling elements (bolts, O-rings, flanges) should be compatible with the geometry and working conditions of the equipment.
Figure 7 illustrates Type EZR Installation Configurations for Regulator, Monitor, and Working Monitor setups.
Operation Schematic
Figure 8 provides a schematic of the Type EZR-OS2 Regulator, illustrating the flow paths for inlet pressure (Pu), modulated pressure (Pm), outlet pressure (Pd), and atmospheric pressure (Pb).
WARNING
If the case arises a support must be used to avoid pressure force on the body (a support can be installed under the flanges). Version with integral slam shut, connect the safety manometric box (IS) to the impulse at 4D on a straight run of the outlet pipe. It is recommended to separate the slam shut impulse line (IS) from that of the pilot (IP). Do not connect the impulses on the lower generator line. It is recommended to install an isolation valve and an atmospheric valve, which can be useful for slam shut tripping and verifications. No modification should be made to the structure of the equipment (drilling, grinding, soldering...). It is recommended to install a servicing valve on the outlet pipeline to facilitate adjustments and bleeding off to the atmosphere. Verify that the inlet side is protected by an appropriate device(s) to avoid exceeding the limits of utilization (PS, TS).
WARNING
Verify that the limits of utilization correspond to the appropriate operating conditions. Version with integral slam shut, verify that the safety manometric box (BMS) and spring correspond to the appropriate operating conditions on the outlet side of the regulator. The equipment should not receive any type of shock, especially the release relay. The user should verify or carry out a protection adapted to the environment. Fire, seismic and lightening are not taken into consideration in standard regulators. If required, a special product selection and/or specific calculations may be supplied according to specific requirements. Version without integral slam shut, verify that a pressure limiting device on the outlet side of the regulator guarantees a pressure limit inferior or equal to the pilot PS.
Commissioning
Operations concerning the integral slam shut version are in italic. All interventions on equipment should only be performed by qualified personnel.
Preliminary Verifications
- Start-up positions: Inlet and outlet valves closed; verify absence of pressure; slam shut valve plug closed; Pilot A unloaded; Restriction B in START position.
- Slam shut set point verification: Inject pressure equal to required regulator pressure using the atmospheric valve. Set 1st release relay stage (Stage 1). Open slam shut valve plug (Stages 2 and 3). Progressively increase pressure to reach tripping. Adjust setting if necessary and note set point.
Positions before commissioning
- Impulse line isolating valve: Open
- Impulse line atmospheric valve: Closed
- Slam shut valve plug: Closed
- Servicing valve: Closed
The equipment is ready for commissioning.
Commissioning (Act slowly)
- Inlet valve: Open very slowly
- 1st release relay stage: Set (Stage 1)
- Slam shut valve plug: Bypass (Stage 2), Open (Stage 3)
- Servicing valve: Open slightly
- Pilot: Screw to set outlet pressure
- Outlet valve: Open slowly
- Restriction: Set to "RUN" by successive fractions 2, 4 or 6
- Servicing valve: Closed
The equipment is commissioned. It is recommended to seal the release relay.
Maintenance
Servicing Check
Recommended frequency: Twice yearly minimum.
Verification: Set point verification, regulator valve plug tightness, tripping and set point value, slam shut valve tightness.
Departure positions
- Inlet valve: Open
- Outlet valve: Open
- Regulator: In operation
- Slam shut valve plug: Open
Inlet and outlet sides of regulator under pressure.
Tightshut verification (and tripping verification for integral slam shut versions)
- Inlet valve: Closed
- Outlet valve: Closed
- Regulator: Observe the evolution of the outlet pressure (control regulator tightness).
Table 11. Troubleshooting for Types EZR and EZR-OS2 Regulators
| Symptom | Cause | Action |
|---|---|---|
| If the outlet pressure increases | Internal leak | Control the regulator valve plug, Control the regulator orifice, Control the pilot, or contact after-sales |
| If the outlet pressure decreases | External leak | Locate and seal the leak, or contact after-sales |
| If the outlet pressure is constant | The regulator is tightshut | Increase the set point until tripping occurs (without exceeding the outlet limits) |
| If the slam shut valve plug will not close | Operation faulty | Control the release relay, Control the slam shut valve plug, or contact after-sales |
| If the slam shut valve plug closes | Operation correct | Observe the evolution of the outlet pressure (control tightness) |
| If the outlet pressure is constant | Internal leak | Purge the outlet side of the regulator, Control the slam shut valve plug, Control the slam shut orifice, Control the bypass, or contact after-sales |
| If the outlet pressure increases | Internal leak | Control the slam shut valve plug |
| If the outlet pressure is constant | Slam shut valve plug is tightshut | Control the bypass |
Filter verification
- Purge the filter C
- Verify the filter element
Troubleshooting
Table 13. Troubleshooting for Type EZR Regulator
| SYMPTOMS | CAUSE | ACTIONS |
|---|---|---|
| If outlet pressure increases | Internal leak | Control the regulator valve plug, Control the regulator seat, Control the pilot, or contact after-sales |
| If inlet pressure decreases | External leak | Locate and repair leak, or contact after-sales |
| If inlet pressure is stable | The regulator is tightshut | Increase the set point until tripping occurs (without exceeding the outlet limits) |
| If the slam shut valve plug will not close | Operation faulty | Control the release relay, Control the slam shut valve plug, or contact after-sales |
| If the slam shut valve plug closes | Operation correct | Observe the evolution of the outlet pressure (control tightness) |
| If the outlet pressure is stable | Internal leak | Purge the outlet side of the regulator |
| If the outlet pressure increases | Internal leak | Control the slam shut valve plug, Control the slam shut seat, Control the bypass, or contact after-sales |
| If the outlet pressure is stable | Valve plug is tightshut | Control the bypass |
Disassembly
Recommended frequency: Every 2 to 6 years (or less depending on operating conditions).
Verification: Condition of O-rings, diaphragms, lubrication.
Replacement: O-rings, diaphragm.
Tools: Dimensions according to tables below.
Preliminary Operations
- Valve plug closed
- Inlet and outlet valves closed
- Bleed off outlet pressure
- Bleed off inlet pressure
- Unscrew the pilot impulse connection
- Unscrew the screws (key 1) fixing the bonnet (key 2)
- Remove the bonnet (key 2)
- Remove the diaphragm/plug assembly (key 3)
- Remove the slotted cage (key 4), the O-ring (key 5), the strainer (key 6) (or the space washer (key 6))
- Clean parts and replace them if necessary
Pilot
- Unscrew the manometric box screws
- Remove the diaphragm
Slam Shut (Version with slam shut)
- Unscrew the BMS impulse line connector (IS)
- Remove the BM cover (key 7)
- Unscrew the BM fixing screw (key 8)
- Remove the holding pin (key 10)
- Remove the BM (key 9)
- Unscrew the screws (key 11) from the connecting part (key 12)
- Remove the connecting part (key 12)
- Remove the spring (key 13) and the valve plug (key 14)
- Unscrew the bypass (key 15)
- Unscrew the screws CHC (key 16) (DN 100 and 150)
- Removing the orifice (key 17) (not recommended) requires a special extraction tool
Reassembly
- Perform the above operations in reverse order (respect tightening torques)
- Replace the O-rings and diaphragm at each disassembly
Slam Shut Reassembly (Version with slam shut)
- The valve plug should be held in an upper position using a packing gland and a box to facilitate reassembly
- Precaution must be taken concerning the passage of the valve plug over the segments
- Lubricate screws before tightening
- Lightly lubricate the O-rings (silicone grease) except for the valve plug O-ring
- Lightly lubricate the stem (silicone grease)
- Lubricate the release relay mechanism (yoke and bolt) (molybdenum graphite grease)
- Lubricate the BMS spring (molybdenum graphite grease)
- A special tool is required for reassembling a new orifice
Spare Parts
Figures 10, 11, and 12 show various pilot types, filters, and restrictors. Table 14 lists the spare parts for the 161EB Series Pilot, Type 112 Restrictor, and Type 252 Filter.
Table 14. 161EB Series Pilot, Type 112 Restrictor and Type 252 Filter Spare Parts List
| Description | Key | Reference | Pilot Type |
|---|---|---|---|
| Pilot kit 0.34 to 13.8 bar | 15 | R161X000012 | 161EB |
| Pilot kit 13.8 to 24.1 bar | 15 | R161X000022 | 161EB |
| Pilot kit EBH(M) | 16 | R161HX00012 | 161EBH |
| O-ring | 17 | 1C8538X0052 | - |
| Filter cartridge | 18 | 17B6813X012 | - |
| O-ring | 19 | 1F269206992 | - |
| SAV kit 0.34 to 13.8 bar(1) | 197435 | 161EB | |
| SAV kit 13.8 to 24.1 bar(1) | 197436 | 161EBM | |
| SAV kit 24.1 to 48.3 bar(1) | 197437 | 161EBΗΜ | |
| Pilot kit 0.34 to 13.8 bar | 15 | R161MX00012 | 161EBM |
| Pilot kit 13.8 to 24.1 bar | 15 | R161MX00022 | 161EBM |
| Pilot kit EBH(M) | 16 | R161HMX0012 | 161EBΗΜ |
| SAV kit 0.34 to 13.8 bar(1) | 197438 | 161EBM | |
| SAV kit 13.8 to 24.1 bar(1) | 197439 | 161EBΗΜ | |
| SAV kit 24.1 to 48.3 bar(1) | 197440 | - | |
| (1) The SAV kits include item numbers 15 or 16, 17, 18 and 19. |
Table 15. Types EZR and EZR-OS2 Spare Parts List
| Regulator, Type EZR | Description | Key | DN / In. | Reference | |||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| O-ring | 1 | 400009 | 25/1 | 400024 | 50/2 | 400091 | 80/3 | 400045 | 100/4 | 400262 | 150/6 |
| O-ring | 2 | 19B2838X012 | 18B2124X012 | 18B8514X012 | 18B2140X012 | 19B0359X012 | |||||
| Guide | 3 | 401950 | 401951 | 401952 | 401953 | 401954 | |||||
| O-ring | 4 | 400527 | 400263 | 400258 | 400260 | 400261 | |||||
| Bypass | 5 | 180977 | 180977 | 180977 | 180977 | 180977 | |||||
| SAV kit PN 20 | 1 to 14 | 197421 | 197422 | 197424 | 197425 | 197427 | |||||
| SAV kit PN 50/100 | 1 to 14 | 197421 | 197423 | 197424 | 197426 | 197427 | |||||
| SAV kit PN 20 | 6 to 14 | 197428 | 197429 | 197431 | 197432 | 197434 | |||||
| SAV kit PN 50/100 | 6 to 14 | 197428 | 197430 | 197431 | 197433 | 197434 | |||||
| O-ring | 6 | 18B3438X012 | 18B3438X012 | 10A8931X012 | 10A8931X012 | 10A3800X012 | |||||
| O-ring | 7 | 1H2926X0032 | 1H2926X0032 | 1D191706992 | 1D191706992 | 1D191706992 | |||||
| O-ring | 8 | 13A1584X052 | 13A1584X052 | 10A3803X062 | 10A3803X062 | T12050X0012 | |||||
| O-ring | 9 | 19B2838X012 | 18B2124X012 | 18B8514X012 | 18B2140X012 | 19B0359X012 | |||||
| PN 20 diaphragm | 10 | 39B2397X012 | 29B2715X022 | 39B2726X012 | 38B5965X012 | 49B0357X012 | |||||
| PN 50/100 diaphragm | 10 | 39B2397X012 | 28B2123X052 | 39B2726X012 | 39B3996X012 | 49B0357X012 | |||||
| O-ring | 11 | 13A1584X052 | 13A1584X052 | 10A3803X062 | 10A3803X062 | T12050X0012 | |||||
| O-ring | 12 | 1E216306992 | 1E216306992 | 1J4888X0052 | 1J4888X0052 | 11A8741X052 | |||||
| O-ring | 13 | 14A5713X012 | 10B4428X012 | 10B4366X012 | 10B4373X012 | 1H862306992 | |||||
| O-ring | 14 | - | - | - | - | 1D269206992 | |||||
| Safety manometric box | - | See D103683X012_OS2_IM manual | - | - | - | - |
