Emerson Type 92C Self Powered Control Valve Instruction Manual
2015-03-30
: Emerson Emerson-Type-92C-Self-Powered-Control-Valve-Instruction-Manual-681424 emerson-type-92c-self-powered-control-valve-instruction-manual-681424 emerson pdf
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Type 92C Instruction Manual Form 5135 December 2012 Type 92C Steam Regulator ! WARNING Fisher® regulators 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. Introduction Scope of the Manual This instruction manual provides installation, maintenance, and parts ordering information for the Type 92C steam self-powered control valve and the Type 6392 pilot. Both the pilot-operated and the pressure-loaded constructions are covered. The Type 92C is also available with a Type 6492HM or 6492HTM safety override pilot. The pressure-loading device and accessories used with this valve are covered in other manuals. W3111_2 Figure 1. Type 92C Pilot-Operated Regulator 1301 Series regulator or 670 Series panel-mounted regulator may be used as the loading regulator. A Type 6492HM (or 6492HTM) safety override pilot is also available for the Type 92C. The Type 6392 pilot is used in a series installation with the Type 6492HM (or 6492HTM) safety override pilot installed on the upstream valve. The Type 6492HM (or 6492HTM) safety override pilot senses pressure downstream of the second valve, and prevents pressure from rising above safe operating pressure in the event the downstream valve fails. This system is approved by ASME B31.1-1989, 122.14.2.A, and can replace an ASME safety valve when vent piping is not practical and upstream pressure does not exceed 400 psig / 27.6 bar. Local codes and standards may require approval by an appropriate authority prior to installation. ! Description The Type 92C steam regulator is a gray cast iron, steel, or stainless steel pressure-reducing regulator for steam or hot air service. This regulator is available with a Type 6392 pilot for use as a pilot-operated regulator (Figure 1) or without a pilot for use as a pressure-loaded regulator. The pilot-operated version uses inlet pressure as the operating medium; no separate air supply is required. The pressureloaded version is used where remote adjustment of the regulator pressure setting is required; a 67 or WARNING The Type 92C safety override system does not provide positive shutoff in dead end service. It is intended for large distribution systems where steam leakage will condense before steam pressure builds up. Downstream piping and components must be rated for maximum upstream steam pressure for dead end service. Failure to do so could cause personal injury or death. www.fisherregulators.com D100255X012 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. Use qualified personnel when installing, operating, and maintaining the Type 92C regulator. Type 92C Specifications This section lists the specifications for Type 92C regulator. Additional specifications for an individual regulator are found on the regulator body and pilot nameplates. Body Sizes and End Connection Styles SIZE NPS 1/2, 3/4, or 1 / DN 15, 20, or 25 BODY MATERIAL Gray Cast Iron Steel or CF8M Stainless Steel NPT NPT, CL150 RF, CL300 RF, or PN 16/25/40 Maximum Allowable Inlet and Pilot Supply Pressures* Gray Cast Iron Construction: 250 psig / 17.2 bar Steel and Stainless Steel Construction: 300 psig / 20.7 bar Regulator Pressure Drops* Minimum: 15 psi / 1.0 bar Maximum Operating: 150 psi / 10.3 bar for outlet pressure settings equal to or below 50 psig / 3.4 bar; 200 psi / 13.8 bar for outlet pressure settings above 50 psig / 3.5 bar Maximum Emergency Gray Cast Iron construction: 250 psi / 17.2 bar Steel and Stainless Steel construction: 300 psi / 20.7 bar Outlet Control Ranges See Table 1 Maximum Outlet Pressures* Maximum Operating Outlet Pressure: 150 psig / 10.3 bar Maximum Emergency Outlet (Casing) Pressure Gray Cast Iron construction: 250 psig / 17.2 bar Steel and Stainless Steel construction: 300 psig / 20.7 bar Loading Pressure for Pressure-Loaded Regulator* See Figure 2 to determine loading pressure. Maximum allowable loading pressure is 250 psig / 17.2 bar for gray cast iron construction and 300 psig / 20.7 bar for steel or stainless steel construction; the maximum allowable diaphragm differential pressure of 150 psi / 10.3 bar for gray cast iron, steel, and stainless steel constructions must not be exceeded. Orifice Sizes NPS 1/2 / DN 15 Main Valve: 9/16 inch / 14 mm NPS 3/4 and 1 / DN 20 and 25 Main Valves: 3/4 inch / 19 mm is standard; 9/16 inch / 14 mm is optional Maximum Material Temperature Capabilities(1) Gray Cast Iron Construction: 406°F / 208°C Steel and Stainless Steel Construction: 500°F / 260°C Optional High-Temperature Steel or Stainless Steel Body: 650°F / 343°C Pressure Registration With Pilot: External Without Pilot: Internal Downstream Control Line Connection 1/4 NPT (internal) in pilot body (downstream control line not required for pressureloaded regulator) Loading Pressure Connection 1/4 NPT (internal) in main valve diaphragm flange (this connection is factory-piped to the pilot on pilot-operated regulator) Pilot Spring Case Vent 3/32-inch / 2.4 mm drilled hole Approximate Weights Gray Cast Iron, Steel, or Stainless Steel Body with Pilot: 20 pounds / 9.1 kg Gray Cast Iron, Steel, or Stainless Steel Body without Pilot: 16 pounds / 7.3 kg 1. Pressure/temperature limits in this Instruction Manual and any applicable code limitations must not be exceeded. 2 Type 92C Note TYPE 92C REGULATOR To determine required loading pressure, add the diaphragm differential pressure to the desired outlet pressure setting. PILOT LOADING LINE PILOT SUPPLY DIAPHRAGM DIFFERENTIAL (psi) 2 4 20 6 8 10 12 3/4-inch / 19 mm orifice size 15 1 10 0.5 9/16 inch / 14 mm orifice size 5 0 50 100 150 200 DIAPHRAGM DIFFERENTIAL (bar) PRESSURE DROP ACROSS VALVE (bar) DOWNSTREAM CONTROL LINE TYPE 6392 PILOT TOP VIEW OF REGULATOR AND PILOT CONNECTIONS TYPE 6392 PILOT DOWNSTREAM CONTROL LINE STRAINER TYPE 92C REGULATOR PRESSURE DROP ACROSS VALVE (psi) 26A3808-A A2508-1 16A1548-B A2522-1 BYPASS LINE Figure 3. Typical Pilot-Operated Type 92C Regulator Installation Figure 2. Diaphragm Differential Pressure for Pressure-Loaded Regulator Table 1. Safety Pilot Outlet (Control) Pressure Ranges SPRING RANGE TYPE 6492HM 6492HTM SPRING COLOR MINIMUM PRESSURE AT WHICH MONITORING PILOT CAN BE SET 0.69 to 2.1 Yellow 5 psig / 0.34 bar over normal distribution pressure 1.7 to 5.2 Green 70 to 150 4.8 to 10.3 Red 80 to 250 5.4 to 17.2 15 to 100 1.0 to 6.9 psig bar 10 to 30 25 to 75 10 psig / 0.69 bar over normal distribution pressure Unpainted Table 2. Outlet Pressure Ranges SPRING USAGE Standard use up to 500°F / 260°C High-pressure and/or High temperature over 500°F / 250°C OUTLET PRESSURE RANGE psig bar SPRING PART NUMBER AND COLOR 5 to 70 0.34 to 4.8 20 to 150 15 to 100 80 to 200 SPRING WIRE DIAMETER SPRING FREE LENGTH Inches mm Inches mm 1E392627012, Green 0.170 4.32 2.00 50.8 1.4 to 10.3 1E392727142, Red 0.207 5.26 1.94 49.0 1.0 to 6.9 14B9941X012, Unpainted 0.192 4.88 5.5 to 17.2 14B9940X012, Unpainted 0.282 7.16 1.96 49.8 Table 3. Flow Coefficients(1) ORIFICE SIZE WIDE-OPEN FOR RELIEF SIZING Inches mm Cg Cs Cv 9/16 14 170 8.5 5 3/4 19 240 12 7.1 C1 Km 34 0.67 1. Cv = Cs x 20 ÷ C1 Table 4. IEC Sizing Coefficients ORIFICE SIZE BODY SIZE 9/16 inch / 14 mm NPS DN 1/2 15 3/4 or 1 20 or 25 XT 0.73 FD 0.38 0.44 3/4 inch / 19 mm FL 0.82 XT FD FL ---- ---- ---- 0.73 0.38 0.82 3 Type 92C TYPE 92C MAIN VALVE TYPE 92C MAIN VALVE TYPE 6392 PILOT TYPE 6392 PILOT TYPE 6492HM SAFETY OVERRIDE PILOT TOP VIEW TYPE 6492HM SAFETY OVERRIDE PILOT TYPE 6392 PILOT TYPE 6392 PILOT TYPE 92C MAIN VALVE TYPE 92C MAIN VALVE SIDE VIEW E0656 BLOCK VALVE TYPE 6492HM SAFETY OVERRIDE PILOT TYPE 6392 PILOT TYPE 6392 PILOT GAUGE GAUGE GAUGE BLOCK VALVE E0657 TYPE 92C MAIN VALVE BLOCK VALVE TYPE 92C MAIN VALVE TYPICAL TYPE 92C WITH TYPE 6492HM OR 6492HTM SAFETY OVERRIDE PILOT INSTALLATION Figure 3. Typical Pilot-Operated Type 92C Regulator Installations (continued) 4 Type 92C Principle of Operation Pilot-Operated Regulator Refer to Figure 5. Pilot supply pressure is piped from the inlet side of the main valve to the pilot inlet connection. Downstream pressure registers under the main valve diaphragm through the pitot tube and under the pilot diaphragm through the downstream control line. When downstream pressure decreases to a value below the setting of the pilot regulator spring, the pilot spring forces the pilot valve plug open, increasing the loading pressure on the top of the main valve diaphragm. The increased loading pressure on top of the main valve diaphragm and decreased downstream pressure under the main valve diaphragm force the main valve diaphragm and stem downward. This opens the main valve plug, and increases flow to the downstream system, thus restoring downstream pressure to the setting of the pilot regulator spring. When downstream pressure increases it registers under the pilot diaphragm and overcomes the force of the pilot spring. This allows the pilot valve spring to close the pilot valve plug and causes excess loading pressure to bleed to the downstream system through the pilot bleed hole. At the same time, increased downstream pressure registers under the main valve diaphragm. The decreased loading pressure on top of the main valve diaphragm and increased downstream pressure under the main valve diaphragm force the main valve diaphragm upward. This allows the main valve plug spring to close the main valve plug, reducing flow to the downstream system. Pressure-Loaded Regulator Refer to Figure 7. With a pressure-loaded regulator, a remote, adjustable loading regulator provides loading pressure to the top of the main valve diaphragm. Downstream pressure registers under the main valve diaphragm through the pitot tube. When downstream pressure decreases, it registers under the diaphragm and allows the stem and plug to move downward, thereby opening the valve to increase downstream pressure. When downstream pressure increases, it registers under the diaphragm and forces the stem and plug to move upward. The upward force of the spring causes the valve to close, which decreases flow to the downstream system thus decreasing downstream pressure. In hot air service, supply air above the diaphragm becomes compressed and is vented to the atmosphere. If a steam supply is used, the steam is vented downstream. Safety Override Pilot Principle of Operation Refer to Figure 6. Once placed in operation, the upstream Type 6392 pilot senses the intermediate pressure between both valves, and the Type 6492HM (or 6492HTM) pilot senses downstream pressure of the second valve. As demand for flow increases, intermediate pressure will fall causing the Type 6392 pilot to open. As the Type 6392 pilot valve opens, loading pressure to the main valve increases, opening the main valve. The Type 6492HM (or 6492HTM) safety override pilot remains open because its setpoint is above the setpoint of the downstream valve. In the unlikely event that the downstream valve fails open, downstream pressure will rise above the downstream valve’s setpoint. This pressure is sensed by the Type 6492HM (or 6492HTM) safety override pilot. As downstream pressure increases the safety override pilot closes, reducing loading pressure to the main valve, which positions the main valve to maintain downstream pressure as specified per ASME Boiler and Pressure Vessel Code, section VIII. In the event that the upstream valve fails, the downstream regulator will prevent downstream pressure from rising above safe operating levels. It is recommended to install some type of warning system, such as a sentinel relief valve, to warn the operator that a valve has failed in the system. This will prevent prolonged operation with one valve, which could cause valve trim wear and noise associated with operation at high differential pressures. When operating in most steam systems, valve setpoints should be in strict accordance to ASME Boiler and Pressure Vessel Code, section VIII. The Type 6492HM (or 6492HTM) safety override pilot should be set at 10 psig / 0.69 bar or 10% above maximum downstream operating pressure of the second valve, whichever pressure is greater. For example, most HVAC systems operate at 15 psig / 1.0 bar, so the safety override pilot should be set no higher than 25 psig / 1.7 bar. 5 Type 92C LOADING REGULATOR BLEED RESTRICTION OPTIONAL PIPING FOR STEAM LOADING STRAINER TYPE 92C REGULATOR BYPASS LINE 16A1547-A A2523-1 Figure 4. Typical Pressure-Loaded Type 92C Regulator Installation Installation ! WARNING Personal injury, equipment damage, or leakage due to escaping steam or bursting of pressure-containing parts may result if this regulator is overpressured or is installed where service conditions could exceed the limits given in Specifications section on page 2 and on the appropriate nameplate, or where conditions exceed any ratings of the downstream 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. Type 92C regulators and their installations should be checked for compliance with all applicable codes such as the ANSI B31.1-1977 Power Piping standard and the ASME Boiler and Pressure Vessel code. Use a qualified personnel when installing, operating, and maintaining a Type 92C regulator. Make sure that there is no damage to or foreign material in the regulator and that all tubing and piping are clean and unobstructed. Install the regulator so that flow direction matches the arrow marked on the regulator body. Some typical Type 92C regulator installations are shown in Figures 3 and 4. The Type 92C regulator may be installed in any orientation. However, the regulator should not be 6 installed in a tall vertical pipeline where condensate could collect and create a pressure head affecting regulator performance. Apply steam-compatible pipe compound to the external pipeline threads. Then, using acceptable piping procedures, install the regulator into the pipeline. If continuous operation of the system is required during inspection and maintenance, install a threevalve bypass around the regulator. If the flowing medium contains solids, install a proper size strainer upstream of the regulator. Pilot-Operated Regulator The Type 6392 pilot has three 1/4 NPT connections located in the pilot body. For proper operation of a pilot-operated regulator, the pilot supply and the regulator loading connections should be installed parallel to the flow direction arrow marked on the pilot body as shown in Figure 10, and the downstream control line should be installed in the pilot body connection as shown in Figures 3 and 10. If a pilotoperated regulator is ordered, the pilot supply and the regulator loading connections will be made at the factory. Note Pilot is shown here above the main valve body for illustration purposes only. See Figures 1 and 10 for actual pilot position and appearance of pilot-supply line and loading-pressure tubing. Type 92C July 2008 Type 92C Safety Override System Typ PILOT REGULATING SPRING PILOT DIAPHRAGM DOWNSTREAM BLEED HOLE DOWNSTREAM CONTROL LINE PILOT SUPPLY PILOT VALVE PLUG PILOT VALVE SPRING MAIN VALVE DIAPHRAGM PITOT TUBE Typ MAIN VALVE PLUG July 2008 MAIN VALVE SPRING Type 92C Safety Override System 36A1546-B A2520-1 Type 92C INLET PRESSURE INLET PRESSURE OUTLET PRESSURE July 2008 OUTLET PRESSURE ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE LOADING PRESSURE Type 92CPRESSURE Safety Override System INTERMEDIATE Figure 5. Operational Schematic of Pilot-Operated Type 92C Regulator TYPE 6492HM SAFETY OVERRIDE PILOT TYPE 6392 PILOT TYPE 6392 PILOT TYPE 92C MAIN VALVE INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE INLET PRESSURE INLET PRESSURE LOADING PRESSURE OUTLET PRESSURE OUTLET PRESSURE INTERMEDIATE PRESSURE ATMOSPHERIC PRESSURE ATMOSPHERIC PRESSURE LOADING PRESSURE LOADING PRESSURE INTERMEDIATE PRESSURE INTERMEDIATE PRESSURE TYPE 92C MAIN VALVE E0557 E0658 Figure 6. Type 92C with Type 6492HM Safety Override Pilot Operational Schematic 7 Type 92C Note Since a clogged vent may cause improper regulator functioning, install and maintain the Type 92C regulator so that the Type 6392 pilot spring case vent remains clear and unobstructed. To install a pilot-operated regulator: 1. C onnect a downstream control line of at least 1/4-inch / 6.4 mm diameter pipe bushed down to the 1/4 NPT control line connection in the pilot body. 2. F or both body-sized and swaged pipelines, locate the pipeline control line connection in a section of straight pipe at least 10 pipe diameters away from the regulator or swage. device. In all cases, check the pressure setting to make sure it is correct for the application. Startup The maximum inlet pressure for a specific construction is stamped on the main valve nameplate. Use pressure gauges to monitor upstream and downstream pressures during startup. To put the regulator into operation: 1. Open the control line shutoff valve. 2. For a pilot-operated regulator, open the downstream block valve. For a pressure-loaded regulator, open the shutoff valve in the pressure-loading piping or tubing. 3. D o not locate the pipeline control line connection in an elbow, swage, or other area where turbulence or abnormal velocities may occur. 3. Slowly open the upstream block valve. 4. If the pilot is mounted with the control line in a position other than horizontal, make sure the control line is sloped away from the pilot so that condensate can drain into the pipeline. 5. T o adjust the downstream pressure, follow the appropriate procedure: 4. If a bypass line is used, slowly close the bypass line block valve. a. F or a pilot-operated regulator, loosen the jam nut (key 15, Figure 9). Turn the adjusting screw (key 16, Figure 9) into the spring case to increase the downstream pressure. Turn the adjusting screw out of the spring case to decrease the downstream pressure. When the required downstream pressure is maintained for several minutes, tighten the jam nut to lock the adjusting screw in position. b. F or a pressure-loaded regulator, refer to the Instruction Manual of the pressureloading device for downstream pressure adjustment procedures. 5. Install a shutoff valve (not a needle valve) in the control line to completely isolate the pilot during maintenance. 6. Install a pressure gauge in the control line or near the regulator to aid in setting the outlet pressure. Each pilot-operated regulator is factory-set for the pressure setting specified on the order. If no setting is specified, the unit is factory-set at 30 psig / 2.1 bar. In all cases, check the spring setting to make sure it is correct for the application. Pressure-Loaded Regulators To install a pressure-loaded regulator: 1. Install a shutoff valve in the pressure-loading piping or tubing. 2. C onnect the piping or tubing to the 1/4 NPT connection in the diaphragm flange (key 2, Figure 8). If the loading regulator used with the pressureloaded regulator does not provide internal relief, an atmospheric bleed (e.g., no. 60 drill size) is required if the loading supply is air, or a downstream bleed line is required if the loading supply is steam. This installation is shown in Figure 4. The pressure setting of a pressure-loaded regulator is adjusted and determined by the pressure-loading 8 Safety Override Pilot Startup and Adjustment 1. Loosen adjusting screws of the Type 6492HM (or 6492HTM) safety override pilot and Type 6392 intermediate pilot on the upstream valve until there is no spring load. The screws should turn freely by hand. 2. Loosen the adjusting screw of the Type 6392 pilot on the downstream valve until there is no spring load. 3. T ighten the Type 6492HM (or 6492HTM) safety override pilot of the upstream valve all the way in to its highest spring setting. Type 92C LOADING REGULATOR BLEED RESTRICTION OPTIONAL PIPING FOR STEAM LOADING 8 9 2 15 9 26A1538-A STEEL/STAINLESS STEEL CONSTRUCTION MAIN VALVE DIAPHRAGM 14 12 PITOT TUBE 13 8 9 1 2 10 9 4 6 S 11 7 S MAIN VALVE PLUG MAIN VALVE SPRING 36A1546-B A2947 5 3 26A1536-A INLET PRESSURE LOADING PRESSURE DOWNSTREAM PRESSURE Figure 7. Operational Schematic of Pressure-Loaded Type 92C Regulator GRAY CAST IRON CONSTRUCTION APPLY SEALANT: S = ANTI-SEIZE COMPOUND Figure 8. Type 92C Steam Regulator Assembly 4. Tighten the Type 6392 pilot of the upstream valve all the way in to its highest spring setting. Shutdown 5. Tighten the Type 6392 pilot of the downstream valve to the desired downstream pressure. To take the regulator out of operation: 6.* Loosen the Type 6392 intermediate pilot on the upstream valve to the desired intermediate pressure (normally 50% of inlet pressure). 7. Loosen the Type 6492HM (or 6492HTM) safety override pilot of the upstream valve until there is no spring load. 8. Tighten the Type 6392 pilot of the downstream valve all the way in to its highest spring setting. 9. Tighten the Type 6492HM (or 6492HTM) safety override pilot of the upstream valve to desired pressure as specified per ASME Boiler and Pressure Vessel Code, section VIII. 10.* L oosen the Type 6392 pilot of the downstream valve to the desired downstream pressure setpoint. *Fisher® recommends establishing setpoint by tightening the adjusting screw. 1. If a bypass line is used, slowly open the bypass line block valve while monitoring the downstream pressure. 2. Close the upstream block valve. 3. F or a pilot-operated regulator, close the downstream block valve. For a pressure-loaded regulator, close the shutoff valve in the pressure-loading piping or tubing. 4. Close the control line shutoff valve. 5. Vent the regulator, the control line, and the pilot supply line to release any trapped pressure. Maintenance Regulator parts are subject to normal wear and must be inspected periodically and replaced as necessary. The frequency of inspection and replacement depends upon the severity of service conditions and upon applicable Federal, state, and local codes and regulations. 9 Type 92C ! WARNING Avoid personal injury or property damage from sudden release of pressure or uncontrolled steam or other process fluid. Before starting disassembly: • Isolate the regulator from the process, • Release process pressure, and • V ent the pilot supply and main valve loading pressures. 4. Install the stem assembly (key 11) in the stem guide bushing (key 6). Place one diaphragm gasket (key 9) in the regulator body (key 1). For Steel/Stainless Steel constructions, place the diaphragm ring (key 15) and another diaphragm gasket (key 9) on top of the first gasket. For all constructions, place the two molded diaphragms (key 8) with the raised circle up, another diaphragm gasket, and the diaphragm flange (key 2) on the body. Insert and tighten the cap screws (key 12). This section contains separate procedures for regulator and pilot maintenance. 5. F or the pilot-operated regulator, reconnect the elbow, the loading tubing, and the connector (keys 25, 22, and 24, Figure 10). Type 92C Regulator For the pressure-loaded regulator, reconnect the pressure-loading tubing. Perform these procedures when replacing diaphragm, the stem assembly, the valve plug, or the orifice. Refer to the correct section for the required instructions. Key numbers refer to Figure 8 unless otherwise indicated. The regulator may remain in the pipeline during maintenance procedures unless the valve body is to be replaced or removed for repairs. For pilot-operated regulators, the pilot may remain on the pipe nipple (key 23, Figure 10) unless the pilot body (key 1, Figure 9) is to be removed or the entire pilot replaced as a unit. Replacing Diaphragm and Stem Assembly 1. F or the pilot-operated regulator, unscrew the elbow and connector (keys 25 and 24, Figure 10) so that the loading tubing (key 22, Figure 10) can be removed. 6. When maintenance is completed, refer to the Startup section to put the regulator back in operation and to adjust the pressure setting. Replacing Valve Plug and Orifice 1. Remove the valve plug guide (key 5). 2. Remove the valve plug (key 4) and the valve plug spring (key 7). Inspect the valve plug seating surface for nicks or scratches. Replace as necessary. 3. Unscrew the orifice (key 3), and inspect the seating surface for nicks and scratches. Replace if necessary. 4. Clean the valve plug guide, the valve plug, the valve plug spring, and the orifice (keys 5, 4, 7, and 3, respectively). For the pressure-loaded regulator, unscrew the loading tubing (customer supplied) from the 1/4 NPT connection in the regulator diaphragm flange (key 2). 5. Coat the orifice threads with Never-Seez* or equivalent lubricant. Then, being careful not to damage the seating surface, thread the orifice (key 3) into the regulator body (key 1). 2. Remove the cap screws (key 12) and the diaphragm flange (key 2). 6. Place the valve plug spring (key 7) into the valve plug guide (key 5). Then slide the valve plug (key 4) over the spring and into the valve plug guide. Lift out the upper diaphragm gasket (key 9), the diaphragms (key 8), the lower diaphragm gasket, and for Steel/Stainless Steel constructions, the diaphragm ring (key 15), and another diaphragm gasket (key 9). 3. L ift out the stem assembly (key 11) consisting of the pusher plate and the stem. Check that the pitot tube (key 10) is clear and free of obstructions. Clean the parts. Check for wear, scratches, nicks and other damage, and replace parts as necessary. 10 7. A pply Lok-Cease 20/20† sealant or equivalent to the valve plug guide threads, and screw the valve plug guide (key 5) with attached parts into the regulator body (key 1), applying 130 to 160 foot-pounds / 176 to 217 N•m of torque. * Trademark of Never-Seez Corp. † Trademark of Certified Laboratories Type 92C 15 16 L 2 18 14 19 13 9 17 8 7 L 26 1 4 10 S 6 11 3 5 12 16A1520-B APPLY LUBRICANT/SEALANT: L = ANTI-SEIZE LUBRICANT S = ANTI-SEIZE COMPOUND Figure 9. Type 6392 Pilot Assembly 25 22 24 23 1/4 NPT PILOT SUPPLY CONNECTION 1/4 NPT REGULATOR SUPPLY CONNECTION 1/4 NPT DOWNSTREAM CONTROL LINE CONNECTION 36A1545-A A2521-1 Figure 10. Type 6392 Pilot Mounting Parts 11 Type 92C 8. W hen maintenance is completed, refer to the Startup section to put the regulator back in operation and to adjust the pressure setting. Type 6392 Pilot Perform this procedure if inspecting, cleaning, or replacing any pilot parts. Key numbers refer to Figure 9 unless otherwise specified. All pilot maintenance may be performed with the pilot body (key 1) attached to the pipe nipple and connector (keys 23 and 24, Figure 10) unless the pilot body must be removed or the pilot is to be replaced as a unit. 1. L oosen the jam nut (key 15), and turn the adjusting screw (key 16) counterclockwise until all compression is removed from the control spring (key 13). Remove the loading tubing from the pilot outlet connection. Remove the cap screws (key 17), spring case (key 2), control spring (key 13), and upper spring seat (key 14) from the body. 2. Remove the lower spring seat (key 9), the diaphragm (key 7), and the diaphragm gasket (key 8) from the body. Lift out the stem assembly (key 6) consisting of the stem and the pusher plate. Clean the 1/16-inch / 1.6 mm diameter pilot bleed hole. Clean and replace parts as necessary, and assemble the stem assembly, the gasket, the diaphragm, and the spring seat in the order shown in Figure 9. 3. Install the control spring (key 13), the lubricated upper spring seat (key 14), and the spring case (key 2). Insert and tighten the cap screws (key 17). Lubricate the adjusting screw (key 16) with Never-Seez* or equivalent lubricant, and thread it into the spring case. 4. Unscrew the valve plug guide (key 5). Remove the strainer screen (key 12), the valve plug (key 4), the valve plug cap (key 26), and the valve plug spring (key 11). Unscrew the orifice (key 3). Clean and replace parts as necessary. Apply Never-Seez* or equivalent lubricant to the orifice threads, and screw the orifice into place. 5. P lace the valve plug spring (key 11) into the valve plug guide (key 5). Insert the valve plug cap (key 26) into the valve plug (key 4), and then slide both parts over the spring and into the valve plug guide. Place the strainer screen (key 12) onto the valve plug guide. Apply Lok-Cease 20/20† sealant * Trademark of Never-Seez Corp. † Trademark of Certified Laboratories 12 or equivalent (key 21) to the valve plug guide threads, and screw the valve plug guide with the attached parts into the pilot body (key 1). 6. When maintenance is completed, refer to the Startup section to put the regulator back into operation, and adjust the pressure setting. Types 6492HM and 6492HTM Safety Override Pilots These procedures are to be performed if inspecting, cleaning, or replacing any pilot parts, or of cycling, erratic control, or too high or too low an outlet (control) pressure is noted. Perform only those procedures in this section required to correct the problem. Key numbers refer to Figure 11. Note Before performing any maintenance, loosen the hex nut (key 16), if used, and turn the adjusting screw (key 15) or handwheel (key 31) counterclockwise until all compression is removed from the control spring (key 12). Remove the pilot spring from the pipe nipple and connectors (keys 82 and 83, Figure 12). 1. Unscrew the plug guide (key 2). Remove the screen (key 77), inner valve (key 4), plug spring (key 3), and stem (key 7). Unscrew the orifice (key 5). Examine the orifice and plug seating surfaces for damage. 2. Clean and replace parts as necessary. Apply sealant to the orifice threads. Thread the orifice into place and tighten using 19 to 25 foot-pounds / 26 to 34 N•m of torque. 3. Handle parts carefully, and place the plug spring (key 3) in the plug guide (key 2). Slide the inner valve (key 4) over the spring and into the plug guide. Place the screen (key 77) onto the plug guide. Place the stem (key 7) in the center hole of the plug guide. Apply sealant to the plug guide threads, and screw the guide plus attached parts into the body (key 1). 4. Remove the pipe plug (key 74). Then remove the pipe plug (key 94). Clean and replace the pipe plugs as necessary. 5. A pply sealant to the threads of the pipe plug (key 94) and install. Type 92C 15 16 13 11 14 12 20 10 9 18 8 5 7 19 95 17 94 77 1 74 78 4 3 2 E0660 Figure 11. Type 6492HM or 6492HTM Safety Override Pilot Assembly TYPE 6492HM TYPE 6392 84 82 81 83 91 82 E0659 Figure 12. Type 92C with Safety Override Pilot Assembly 13 Type 92C 6. Apply sealant to the threads of the pipe plug (key 74). Thread the pipe plug into place and tighten using 5 to 15 foot-pounds / 6.8 to 20 N•m of torque. 7. Remove the cap screws (key 17), spring case (key 14), control spring (key 12), and upper spring seat (key 13) from the body (key 1). 8. Remove the lower spring seat (key 11), diaphragms (key 10), and diaphragm gasket (key 18) from the body. Inspect and clean the diaphragm gasket, and replace if necessary. 9. Unscrew the bellows retainer (key 8) and remove the bellows (key 9). Replace worn parts as necessary, and install the bellows and bellows retainer. Tighten the bellows retainer using 19 to 25 foot-pounds / 26 to 34 N•m of torque. 10. Install the diaphragm gasket. Install both diaphragms with their raised performed centers facing toward the spring case. 11. L ubricate the upper spring seat and the exposed threads of the adjusting screw. Install the lower spring seat (key 11), control spring (key 12), upper spring seat (key 13), and spring case (key 14). Insert and tighten the cap screws (key 17) in a crisscross bolting pattern using 12 to 18 foot-pounds / 16 to 24 N•m of torque. Parts Ordering When corresponding with your local Sales Office about this equipment, always specify the equipment serial number as found on the regulator nameplate. When ordering replacement parts, specify the complete 11-character part number of each needed part as found in the following parts list. Parts List Regulator Key Description 1 Regulator Body Assembly with Bushing (See key 6 for bushing) Gray Cast Iron NPS 1/2 / DN 15 NPS 3/4 / DN 20 NPS 1 / DN 25 Steel 1/2 NPT 3/4 NPT 1 NPT Part Number 36A1539X012 36A1540X012 36A1541X012 36A1542X012 36A1543X012 36A1544X012 Key Description *Recommended spare part 14 Part Number 1 Regulator Body Assembly with Bushing (continued) Steel (continued) CL150 RF NPS 1/2 / DN 15 14B3428X012 NPS 3/4 / DN 20 14B3428X022 NPS 1 / DN 25 19A5459X012 CL300 RF NPS 1/2 / DN 15 14B3428X032 NPS 3/4 / DN 20 14B3428X042 NPS 1 / DN 25 14B0037X012 PN 16/25/40 RF NPS 1/2 / DN 15 14B3428X052 NPS 3/4 / DN 20 14B3428X062 NPS 1 / DN 25 14B3428X072 Stainless Steel 1/2 NPT 36A1542X022 3/4 NPT 36A1543X032 1 NPT 36A1544X022 CL150 RF NPS 1/2 / DN 15 14B3428X082 NPS 3/4 / DN 20 14B3428X092 NPS 1 / DN 25 19A5459X022 CL300 RF NPS 1/2 / DN 15 14B3428X102 NPS 3/4 / DN 20 14B3428X112 NPS 1 / DN 25 14B0037X022 PN 16/25/40 RF NPS 1/2 / DN 15 14B3428X122 NPS 3/4 / DN 20 14B3428X132 NPS 1 / DN 25 14B3428X142 2 Diaphragm Flange Gray Cast Iron 26A1533X012 Steel 26A1534X012 Stainless Steel 26A1534X022 3 Orifice For 1/2 and 3/4 NPT body, 9/16 inch / 14 mm, 416 Stainless Steel 16A1529X012 For 1 NPT body 3/4 NPT / 19 mm, 416 Stainless Steel 16A1529X012 For 3/4 and 1 NPT body, 9/16 inch / 14 mm, Ethylenepropylene (EPDM), 410/416 Stainless Steel 1E399535132 4 Valve Plug, heat-treated, 416 Stainless Steel 1E398146172 5 Valve Plug Guide Brass (for Gray Cast Iron body) 1E398214012 416 Stainless Steel (for Steel/Stainless Steel body) 1E398235132 6 Stem Guide Bushing, heat-treated 416 Stainless Steel (included in key 1) For Gray Cast Iron body 1E398535132 For Steel/Stainless Steel body 16A1530X012 7 Valve Plug Spring, Stainless Steel 1E398837022 8* Diaphragm, Stainless Steel (2 required) 1E399236012 9* Diaphragm Gasket (2 required for Gray Cast Iron body; 3 required for Steel/Stainless Steel body with Ethylenepropylene (EPDM) seat) 16A1526X012 Steel/Stainless Steel body with metal seat, 3 required 1E3993X0012 Steel/Stainless Steel body with metal seat (High temperature), 3 required 16A1526X022 10 Pitot Tube For Gray Cast Iron body, Copper NPT 16A1525X012 For Steel body, Copper NPT 1E399417012 CL150 RF 16A1525X012 CL300 RF and PN 16/25/40 1E399417012 Type 92C Key Description 10 Pitot Tube (continued) For Stainless Steel body, 304 Stainless Steel NPT CL150 RF CL300 RF and PN 16/25/40 11 Stem Assembly, 416 Stainless Steel 12 Cap Screw, Zinc-plated steel (8 required) For Gray Cast Iron body For Steel/Stainless Steel body 14 Drive Screw, Stainless Steel (2 required) 15 Diaphragm Ring For Steel body, Steel For Stainless Steel body, Stainless Steel Part Number Key Description 1E399438072 16A1525X022 1E399438072 16A1524X012 1A914524052 1A782024052 1A368228982 16A1531X012 16A1531X022 Type 6392 Pilot (See Figure 10) Key Description 1 Pilot Body Gray Cast Iron Steel Stainless Steel 2 Spring Case Gray Cast Iron Steel Stainless Steel 3 Orifice, heat-treated 416 Stainless Steel 4 Valve Plug, heat-treated 416 Stainless Steel 5 Valve Plug Guide Brass (for Gray Cast Iron pilot) Heat-treated, 416 Stainless Steel (For Steel pilot) For Gray Cast Iron and Steel pilot, Heat-treated, 416 Stainless Steel For Stainless Steel pilot 6 Stem Assembly, 416 Stainless Steel For Stainless Steel seat For Ethylenepropylene (EPDM) seat 7 Diaphragm, Stainless Steel (2 required) 8* Diaphragm Gasket Elastomer seat Stainless Steel seat, Graphite 9 Lower Spring Seat, Aluminum 10 Stem Guide Bushing, 416 Stainless Steel 11 Valve Plug Spring, Stainless Steel 12 Strainer Screen, Stainless Steel 13 Control Spring, Standard springs, 416 Stainless Steel 5 to 70 psig / 0.34 to 4.8 bar, Green 20 to 150 psig / 1.4 to 10.3 bar, Red Spring for use over 500°F / 260°C, 17-7 PH Stainless Steel 15 to 100 psig / 1.0 to 6.9 bar 20 to 25 psig / 1.4 to 1.7 bar 14 Upper Spring Seat, Zinc-plated steel 15 Jam Nut, Plate steel 16 Adjusting Screw, Plated steel 17 Cap Screw, Zinc-plated steel (6 required) For Gray Cast Iron body For Steel/Stainless Steel body 26 Valve Plug Cap, heat-treated 416 Stainless Steel Type 6392 Pilot Mounting Parts Part Number 26A1518X012 26A1517X012 26A1517X022 2E391219012 2J127522012 2J1275X0012 16A1511X012 16A1516X012 1E391814012 1E391835132 1E391835132 1E391835072 16A1515X012 16A1515X022 1E392836012 1E393104022 1E3931X0012 1E392309012 1E392235132 1E392437022 16A1512X012 1E392627012 1E392727142 14B9941X012 14B9940X012 1B798525062 1A352224122 1E639928992 1A407824052 1A391724052 16A1549X012 22 Loading Tubing Copper Stainless Steel 23 Pipe Nipple, Steel 24 Connector Brass Stainless Steel 25 Elbow Brass Stainless Steel Part Number 16A1527X012 16A1527X022 1N584226232 15A6002X212 15A6002X642 15A6002X172 15A6002X632 Types 6492HM and 6492HTM Safety Override Pilots (See Figure 12) Key Description 1 Pilot Valve Body WCC Steel CF8M Stainless Steel 2 Valve Guide, Stainless Steel Steel body, 416 Stainless Steel Stainless Steel body, 316 Stainless Steel 3 Valve Spring, 302 Stainless Steel 4 Inner Valve Steel body, 416 Stainless Steel Stainless Steel body, 316 Stainless Steel 5 Orifice Steel body, 416 Stainless Steel Stainless steel body, 316 Stainless Steel 7 Valve Stem Steel body, 410/416 Stainless Steel Stainless Steel body, 316 Stainless Steel 8 Bellows Retainer Steel body, Brass Stainless Steel body, 316 Stainless Steel 9 Bellows Steel body, Brass Stainless Steel body, 321 Stainless Steel 10 Diaphragm, 302 Stainless Steel (2 required) 11 Lower Spring seat Type 6492HM, Aluminum Type 6492HTM Steel Stainless Steel 12 Spring Type 6492HM, Steel 10 to 30 psig / 0.69 to 2.2 bar 25 to 75 psig / 1.7 to 5.2 bar 70 to 150 psig / 4.8 to 10.3 bar Type 6492HTM, Stainless Steel 15 to 100 psig / 1.0 to 6.9 bar 80 to 250 psig / 5.5 to 17.2 bar 13 Upper Spring seat, Steel Type 6492HM Type 6492HTM 14 Spring Case Steel With standard adjusting screw With sealed adjusting screw Stainless Steel With standard adjusting screw With sealed adjusting screw 15 Adjusting Screw, Steel Standard Handwheel 16 Hex Nut, Zinc-plated steel Part Number 22A0403X052 22A0403X072 1E391835132 1E391835072 1E392437022 1F967446172 1F9674X0012 1H564446172 1H5644X0012 1F967835132 1F9678X0012 1F971214012 1F9712X0012 1F971318992 1F9713X0012 1E395836012 1E395408012 1E3954X0052 14B9948X012 1E395627022 1D7455T0012 1E395727192 14B9943X012 14B9942X012 1D667125072 14B9951X012 2L416322012 2L442022012 2L416333092 2L4420X0012 1D995448702 1J496428982 1A353724122 *Recommended spare part 15 Type 92C Types 6492HM and 6492HTM Safety Override Pilots (See Figure 12) (continued) Key Description 17 Cap Screw (8 required) Type 6492HM Steel Stainless Steel Type 6492HTM Steel Stainless Steel 18 Diaphragm Gasket Type 6492HM, Composition Type 6492HTM, Graphite 34 Machine Screw for use with handwheel, Steel 38 Handwheel, Zinc 39 Lock Washer for use with handwheel, Steel 74 Pipe Plug Steel Stainless Steel 77 Screen, 304 Stainless Steel 78 Reducing Bushing Steel Stainless Steel 87 Sealed Adjusting Screw Sealing Washer 94 Pipe Plug, Stainless Steel 95 Warning Label Type 6492HM Pilot Mounting Parts Key Description Part Number 1A381624052 1A3816X0152 1A3816X0132 1A3816X0152 Part Number 81 Tubing 82 Pipe Nipple (2 required) Steel Stainless Steel 83 Connector Steel Stainless Steel 84 Elbow Steel Stainless Steel 0500103809W 1C559926232 1C5599X0012 15A6002XY72 15A6002X642 15A6002XY52 15A6002X632 1E396104022 1E3961X0012 16A5763X012 1J496144012 1A352332992 0Z020128992 0Z020135072 16A1512X012 1C379026232 1C3790X0012 1V205699012 1E823135042 19B0429X0A2 Industrial Regulators Natural Gas Technologies TESCOM Emerson Process Management Regulator Technologies, Inc. Emerson Process Management Regulator Technologies, Inc. Emerson Process Management Tescom Corporation USA - Headquarters McKinney, Texas 75069-1872, USA Tel: +1 800 558 5853 Outside U.S. +1 972 548 3574 USA - Headquarters McKinney, Texas 75069-1872, USA Tel: +1 800 558 5853 Outside U.S. +1 972 548 3574 USA - Headquarters Elk River, Minnesota 55330-2445, USA Tels: +1 763 241 3238 +1 800 447 1250 Asia-Pacific Shanghai 201206, China Tel: +86 21 2892 9000 Asia-Pacific Singapore 128461, Singapore Tel: +65 6770 8337 Europe Selmsdorf 23923, Germany Tel: +49 38823 31 287 Europe Bologna 40013, Italy Tel: +39 051 419 0611 Europe Bologna 40013, Italy Tel: +39 051 419 0611 Chartres 28008, France Tel: +33 2 37 33 47 00 Asia-Pacific Shanghai 201206, China Tel: +86 21 2892 9499 Middle East and Africa Dubai, United Arab Emirates Tel: +971 4811 8100 For further information visit www.fisherregulators.com The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners. Fisher is a mark owned by Fisher Controls International LLC, a business of Emerson Process Management. 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. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Process Management Regulator Technologies, Inc., does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Process Management Regulator Technologies, Inc. product remains solely with the purchaser. ©Emerson Process Management Regulator Technologies, Inc., 1979, 2012; All Rights Reserved
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2012:08:29 18:17:14+08:00, 2012:08:29 18:41:43+08:00, 2012:08:29 18:42:23+08:00, 2012:08:29 18:43:50+08:00, 2012:08:29 19:01:24+08:00, 2012:08:29 19:05:09+08:00, 2012:08:29 19:14:44+08:00, 2012:08:29 19:17:26+08:00, 2012:08:29 19:27:40+08:00, 2012:08:29 20:10:54+08:00, 2012:08:29 20:11:45+08:00, 2012:08:29 20:14:01+08:00, 2012:08:29 20:14:17+08:00, 2012:08:29 20:58:03+08:00, 2012:08:29 21:21:12+08:00, 2012:08:29 21:22:39+08:00, 2012:08:29 21:23:20+08:00, 2012:08:29 21:26:29+08:00, 2012:08:29 21:30:41+08:00, 2012:08:29 21:33:10+08:00, 2012:08:29 21:34:02+08:00, 2012:08:29 21:36:13+08:00, 2012:08:29 22:37:09+08:00, 2012:08:29 22:37:26+08:00, 2012:08:29 22:38:12+08:00, 2012:08:29 22:40:16+08:00, 2012:08:29 23:06:12+08:00, 2012:08:29 23:06:37+08:00, 2012:08:29 23:07:21+08:00, 2012:08:30 00:12:27+08:00, 2012:08:30 15:18:55+08:00, 2012:08:30 15:19:25+08:00, 2012:08:30 15:20:43+08:00, 2012:08:30 15:32:35+08:00, 2012:08:30 15:41:04+08:00, 2012:08:30 16:10:31+08:00, 2012:08:30 16:49:34+08:00, 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InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe InDesign 7.5, Adobe 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