Air Liquide SGA2 User manual

Operating Instructions
SGA2
OP 350
Version: 1.3
Date: 10.2022
Owner: SWE
Language : EN
Operating Instructions
Gas Manifolds and Gas Panels
SGA2
Panels
Manifold Semi-Auto
Manifold manual
Chromed-brass
SGA2 P V 300-15-25
SGA2 SA 300-12-15
SGA2 M 300-15-25
SGA2 P 300-50-100
SGA2 SA V 300-12-15
SGA2 SA 300-50-100
Stainless steel
SGA2 P.S 300-3-5
SGA2 SA.S V 300-10-15
SGA2 P.S V 300-15-25
SGA2 SA.S 300-25-40
SGA2 P.S V 300-25-40
SGA2 P.S 30-3-5 NH3
Warning
To preserve the quality of our product throughout its usage in the best safety conditions, please
read this manual carefully and strictly follow the instructions that it contains. Non-compliance with
these instructions or modification of the product may result in serious accidents or bodily injuries.
AIR LIQUIDE shall not be held responsible in case of non approved usage of the product. Air Liquide
reserves the right to make all necessary modifications to the specifications described hereafter
without notice.
Operating Instructions for SGA2

CONTENTS
1 GENERAL INFORMATIONS 3
1.1 Safety 3
1.2 Air Liquide Commitments 4
1.3 Designation and marking 5
2 FIELD OF USE AND CHARACTERISTICS 7
2.1 Functions 7
2.2 Technical characteristics 8
2.3 Gas Compatibility 8
3. INSTALLATION 10
3.1Installation of the gas manifold 10
3.2 Assembly of a compression fitting 10
4. ACTIVATION 11
4.1 Washing of the network and seal checks 11
4.2 Activation 11
5.USAGE 13
5.1 Use 13
5.2 Cylinders or Bundles change 13
5.3 After use 14
6 MAINTENANCE 15
6.1 Troubleshooting 15
6.2 Maintenance 16
6.3 Spare Parts 17
6.4 Decommissioning - Disposal 20
7 NOMENCLATURE AND DRAWINGS 21
7.1 Nomenclature 21
7.2 Drawing of a gas Panel 22
7.3 Drawing of a manual Manifold 23
7.4 Drawing of a gas Manifold 24
7.5 Connections 25
7.6 Extension ramps 26
7.7 Drawing of the fluid (P&ID) 26
8 FLOW CURVES 28
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 2/32

1 GENERAL INFORMATIONS
1.1 Safety
First of all, it is ESSENTIAL to read and respect the safety instructions described in the
document “General Safety Instructions” delivered with the product.
NEVER use the SGA2 equipment with a different gas than the one specified in the
“compatibility table”.
This product meets the safety requirements of the laws in force and has been designed
and tested to guarantee safety.
The product is available in two versions :
- Gas Panel : for one inlet (one pressure reducer)
- Gas Manifold : for two cylinders sources inlet (two pressure reducers)
It is ESSENTIAL to follow conscientiously the instructions described in this manual to
install, use and perform maintenance tasks safely.
We therefore disclaim any liability for damages caused by non-compliance with the
instructions herein and by anything else not contemplated herein.
Safety warning :
The SGA2 is equipped with a relief valve for the discharge of overpressure; the sole
purpose of this valve is to protect the regulators but not the pipeline or the elements
downstream of the manifold; the relief valve vent should be channeled for the
combustibles and neutral gas if the location is insufficiently ventilated.
It is the user’s responsibility to protect its installation, taking into consideration the
maximum operating pressure, by installing a relief valve gauged with respect to
maximum pressure risks and maximum theoretical flow.
Seat diameter
(Equivalent
diameter in mm)
Max theoretical nitrogen flow
200 bar
300 bar
SGA2*
1,35
174 Nm3/h
232 Nm3/h
* For use with helium or hydrogen, the SGA2 are equipped with a calibrated orifice (d=1mm).
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 3/32

1.2 Air Liquide Commitments
Air Liquide certifies that this equipment is manufactured, tested and controlled, in
accordance with the technical specifications described in the AIR LIQUIDE specifications.
In addition to technical specifications, a degreasing process consistent with oxygen
service is applied.
It is the responsibility of the end user to ensure that such equipment is installed and used
in accordance with the regulations.
●Directive 2014/68/CE : Pressurized equipment (PED).
●
Technical requirements of Article 4§3 indicates that Pressure equipment and assemblies
below or equal to the limits set out in points (a), (b) and (c) of paragraph 1 and in
paragraph 2 respectively shall be designed and manufactured in accordance with the
sound engineering practice of a Member State in order to ensure safe use.
Without prejudice to other applicable Union harmonization legislation providing for its
affixing, such equipment or assemblies shall not bear the CE marking referred to in
Article 18.
By design, these equipment may integrate pressure relief valves or burst disks. In this
case, those ones shall neither be CE marked according to paragraph 2 of annex II.
In all other cases, pressure relief valves and burst disks shall be CE marked.
●Directive 2014/34/UE ATEX :
The equipment are not in the scope defined in points a), b) et c) of the article of the ATEX
Directive: consequently, they shall not bear the CE marking.
The equipment is not capable of causing an explosion through their own potential
sources of ignition: then, they can be installed in ATEX zone 1 or 2, as far as respecting
up to date regulations, rules, operating instructions, in accordance with the sound
engineering practice that are followed during installation and use.
Reminder: it belongs to the end user to define the ATEX zone.
●REACH regulation (EC) n°1907/2006
The equipment is made of brass parts, essentially the body, which is a copper alloy with
a lead content between 1% and 4% w/w.
As requested by art.33 of REACH Regulation (Registration, Evaluation and Authorisation
of Chemicals) and with reference to current list of SVHC (substances of very high
concern) available on ECHA website, we inform that lead may be present in a
concentration above 0,1% w/w in our products made of brass.
Lead inclusion in the SVHC list in June 2018 does not modify the use conditions
described in operating instructions.
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 4/32

Lead will not be released to the surrounding environment or the gas used during normal
use.
After product end of life, the pressure reducers must be scrapped by an authorized metal
recycler.
Cleaning :
Each equipment is subject to a grease removal and high quality cleaning to preserve the
purity of gas in the equipment as well as for use with oxygen for compatible equipment.
A suitable packaging protects the equipment from exterior pollutants during storage and
transport.
Take care to avoid polluting the equipment during the installation.
Plant inspections :
Each equipment is inspected and has undergone a sealing test (Helium test) before
packing.
A pressure test is performed with 200 bar or 300 bar helium gas.
After 12 hours, the leakage rate must be less than 1.10-9scm3/s.
Leakage rate internal/external : <10-7 mbar.l/s helium.
Warranty :
The warranty period of this equipment supplied by Air Liquide is one year, (6 months if
the equipment is used with corrosive gas), with spare parts and labor and does not
include packing and transport fees.Excluded from warranty: seals and relief valves.
These components are subject to natural wear.
Warranty is not valid on deterioration which results from wrong or poor use, from use of
spare parts which are not marked Air Liquide, or if operating instructions are not
respected.
For more information, refer to the general sales conditions of Air Liquide
1.3 Designation and marking
A plate is affixed to the system's metal structure of the SGA2, providing the following
information:
Model : Change over manifold or Panel
AL Designation, example: SGA2 SA 300-10-15
Maximum working pressure : P1=310 bar
Maximum outlet pressure : P2
Maximum flow rate: Qmax= xx Nm3/h
NORMATIVE REFERENTIAL :
ISO 7291 Gas welding equipment – Pressure regulators for manifold systems used in
welding, cutting and allied processes up to 30 MPa.
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 5/32

2 FIELD OF USE AND CHARACTERISTICS
2.1 Functions
Single stage gas manifolds SGA2 are used to :
- connect one or several cylinders or bundles at the head of the pipeline
- reduce the pressure of a gas packaged under high pressure (200 or 300 bar at
15°C) in a cylinder or a bundle.
The Panel SGA2 P aims at adjusting an outlet pressure with a single gas source.
The manual manifold SGA2 M allows adjusting the operating pressure, with two gas
sources with a manual change.
Given that there is only one outlet, only the regulator with the highest set pressure
release.
The semi automatic Manifold SGA2 SA provides a fixed outlet pressure, with a slight gap
between the two sides when the semi-automatic change between the two gas sources
occurs.
The user has only to operate the switch for cylinders/bundles, once the handwheel is
turned on the new operating source side to restore the normal outlet pressure (hence the
phrase "semi-automatic with manual reset” used for these manifolds).
If a stable pressure is required on the customer application, it is necessary to install a
second-stage on line regulator, just after the manifold.
Model
Adjustable
Pressure
Connection
cylinder/bundle
Continuity of
supply
Cylinder change
without stop
Panel
SGA2 P
Yes
1 X 1
No
No
Semi-Auto
Manifold
SGA2 SA
No
2 X 1
Yes
Yes
Manual
manifold
SGA2 M
Yes
2 X 1
No
No
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 6/32

2.2 Technical characteristics
Operating temperature : -20 °C to +50 °C
Fittings :
- Gas inlet HP on the valve block : M16x 1,336 SI F
- Gas outlet toward user application : G 3/8” F
- Relief valve vent outlet : G 1/4” F
- Vent of the block valve purge : G 1/4” F
- Connexions for pressure transmitter : G 1/4” F
- Outlet toward extension ramps: G 1/4” F
2.3 Gas Compatibility
IMPERATIVE : check the gases compatibility of this equipment by referring to the "Gas
Compatibility Table".
The SGA2 single-stage manifolds are mainly designed for the implementation of pure
gases and mixtures with purity (< N60), including ALPHAGAZ 1 & 2.
- Air gases (O2, N2, Air, Ar, He...)
- Carbon dioxide and Ar/CO2mixtures
- Hydrogen (H2),
- Nitrous oxide (N2O) and oxidizing mixtures
In case of doubt about the use of the equipment, its compatibility with the gas or a new
application, please consult Air Liquide.
Panels
material
N2
CO2
CO
Air*
O2
N2O
H2
CnHm**
SGA2 P V 300-15-25
Chromed
brass
Y
N
N
Y
Y
Y
Y
Y
SGA2 P 300-50-100
Chromed
brass
Y
Y
N
Y
Y
Y
Y
N
SGA2 P.S 300-3-5
stainless
steel
Y
Y
Y
Y
N
N
Y
N
SGA2 P.S V 300-15-25
stainless
steel
Y
N
N
Y
N
N
Y
Y
SGA2 P.S 300-25-40
stainless
steel
Y
Y
Y
Y
N
N
Y
N
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 7/32

Panel for low
pressure liquid gas
material
Pmax
NH3
(8.4 bar)*
SO2
(3.4 bar)*
H2S
(18.4 bar)*
SGA2 P.S 30-3-5-NH3
stainless
steel
30 bar
Y
Y
Y
* Cylinder pressure at 20°C.
NB: for corrosive gas, add a purging system with inert gas
Manual Manifolds :
Panels
material
N2
CO2
CO
Air*
O2
N2O
H2
CnHm**
SGA2 M 300-15-25
Chromed
brass
Y
Y
N
Y
Y
Y
Y
N
Semi automatic Manifolds :
Panels
material
N2
CO2
CO
Air*
O2
N2O
H2
CnHm**
SGA2 SA 300-12-15
Chromed
brass
Y
Y
N
Y
Y
Y
Y
N
SGA2 SA V 300-12-15
Chromed
brass
Y
N
N
Y
Y
Y
Y
Y
SGA2 SA 300-50-100
Chromed
brass
Y
Y
N
Y
Y
Y
Y
N
SGA2 SA.S V 300-10-15
stainless
steel
Y
N
N
Y
N
N
Y
Y
SGA2 SA.S 300-25-40
stainless
steel
Y
Y
Y
Y
N
N
Y
N
*Air: compressed air not breathable
**CnHm: propane (6bar), propylene (8bar), ethylene (70 bar), methane (200 bar)
The Panels in stainless steel are usable with corrosive gas.
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 8/32

3. INSTALLATION
3.1Installation of the gas manifold
Set the manifold (see drawing).
The surface on which the support plate will be mounted, must be flat. Any deformation of
the chassis during the installation could affect the proper operation of the equipment.
If needed, mount and connect the extension ramps (see Options).
Fix the racks (in case of cylinder use).
Attach the panels "Cylinders/bundles change procedure" and the "Safety precautions"
corresponding to the gas used. They have to be visible and in close range.
Install the intermediary connections that correspond to the expected use.
Put the cylinders in the racks with the safety chain.
Install the flexible hoses or the pigtails following the indications written in the user
manual.
Attach the safety cables. Use the holes for that purpose on the support plate. In case of
bundles, attach the anti-flapping cable to a solid anchor plate fixed to the ground (ref AL:
190489).
In case of SGA2 used with hydrogen or Helium, install at the outlet the calibrated orifice
adapted to the gas used and delivered with the equipment.
Connect the outlet of the support plate to the pipe network.
Install a shut-off valve between the support plate and the pipeline, (see options).
If necessary, collect the purges and the relief valve (particularly for the combustible
gases) and channel them separately to a safe area (tube 10mm ext. and h > 2,5m). In
case of combustible gases, connect the platine to the ground and ensure the electrical
continuity between the different components.
3.2 Assembly of a compression fitting
Check dimensions and respect material compatibility between connection and pipe :
Connection and pipe must always be made from the same material, example: Stainless
steel connection for stainless steel pipe <Rockwell hardness B90 (exception : brass
connection with copper pipe).
Connector pre-assembled by hand.
- After cutting, deburring and blowing on the tube (use preferably a tube cutter),
pre-assemble the nut and the ferrules, following the order and the direction
indicated in the figure.
- Introduce the tube inside the connector up to the stop limit on the body.
- Clamp the nut completely by hand.
- Complete the clamping using a wrench by turning the nut a 1-1/4 turn.
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 9/32

4. ACTIVATION
4.1 Washing of the network and seal checks
Even though the different components of the equipment have been carefully checked in
the factory, it is nevertheless necessary to make a verification of the sealing of the
mounted assembly before commissioning:
Once installed and before use the distribution network and the manifold system must be
vented of any air contained therein, in order to prevent the formation of explosive
mixtures within the mains and the equipment.
WARNING :
➢Purge the equipment with inert gas or nitrogen (never use compressed air).
➢For the tightness check, use only products without any grease or lubricants.
➢Never use the purge valves of the manifold to purge the pipe downstream the
manifold (high risk of polluting the pressure reducers).
4.2 Activation
❏First stage: Flexible hoses purging.
Initial state :
- Closed HP shut-off valves (2) and purge valves (3).
- Closed outlet shut-off valve.
- Purge all flexible hoses or pigtails, by at least 3 compressions-reductions
cycles, ie: open the cylinder/bundle valves (1) and close it before reaching the
pressure of the cylinder (high pressure gauge (5)), wait 1 minute, slowly open
the purge valve (3) and then close it before falling to atmospheric pressure.
❏Second stage: function control
Initial state :
Closed cylinder/bundle valves
- Closed HP shut-off valves (2) and purge valves (3).
- Closed outlet shut-off valve.
Indicate the main gas source to use first by using the lever (4). (Case of the SGA2 SA)
●On the right: lever to the right
●On the left: lever to the left
Operating Instructions for SGA2 ref.: OP350_v1.3_EN page 10/32