PIETRO FIORENTINI APERVAL User manual

Aperval
Medium-low pressure gas regulator
EN
Revision A - Edition 02/2023
USE, MAINTENANCE
AND WARNING
MANUAL

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APERVAL
EN Use, maintenance and warning manual
MEDIUM PRESSURE REGULATOR |INTRODUCTION |REV. A
Use, maintenance and warning manual

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APERVAL
Use, maintenance and warning manual
MEDIUM PRESSURE REGULATOR |INTRODUCTION |REV. A EN
1 - INTRODUCTION
FOREWORD
All rights reserved. No part of this publication may be reproduced, distributed, translated into other languages or trans-
mitted by any electronic or mechanical media, including photocopies, recording or any other storage and retrieval system,
for any other purposes that are not exclusively the personal use of the buyer, without the express written permission of
the Manufacturer.
The manufacturer is in no way responsible for the consequences of operations carried out in a manner not in accordance
with the manual.
GENERAL REMARKS
All operating, maintenance instructions and recommendations described in this manual must be observed. In order to
-
tenance operations be carried out regularly.
It is of particular importance that the personnel responsible for the equipment be trained in its use, maintenance and ap-
plication of the safety instructions and procedures indicated in this manual.
Revision: A
COPYRIGHT 2023
© PIETRO FIORENTINI S.P.A.
Use, maintenance and warning manual

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MEDIUM PRESSURE REGULATOR |INTRODUCTION |REV. A

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1.1 - REVISION HISTORY
Revision
index Date Revision contents
A02/2023 First issue
Tab. 1.1.

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INDEX
1 - INTRODUCTION .................................................................................................................. 3
1.1 - REVISION HISTORY.................................................................................................................................. 5
2 - GENERAL INFORMATION ................................................................................................ 11
2.1 - MANUFACTURER IDENTIFICATION........................................................................................................ 11
2.2 - IDENTIFICATION OF THE PRODUCT ...................................................................................................... 11
2.3 - REGULATORY FRAMEWORK................................................................................................................. 11
2.4 - WARRANTY............................................................................................................................................ 11
2.5 - SYMBOLS USED IN THE MANUAL......................................................................................................... 12
2.6 - ADDRESSEES, SUPPLY AND STORAGE OF THE INSTRUCTION MANUAL........................................... 13
2.7 - LANGUAGE ............................................................................................................................................ 13
2.8 - APPLIED RATING PLATES...................................................................................................................... 14
2.8.1 - GLOSSARY FOR NAMEPLATES ...........................................................................................................16
2.9 - GLOSSARY OF MEASUREMENT UNITS................................................................................................. 18
2.10 -QUALIFIED PROFESSIONAL FIGURES................................................................................................... 19
3 - SAFETY .............................................................................................................................. 21
3.1 - GENERAL SAFETY WARNINGS.............................................................................................................. 21
3.2 - PERSONAL PROTECTIVE EQUIPMENT.................................................................................................. 22
3.3 - RESIDUAL RISKS ................................................................................................................................... 23
3.3.1 - TABLE SHOWING RESIDUAL RISKS DUE TO PRESSURE ...................................................................24
3.3.2 - TABLE OF RESIDUAL RISKS FOR POTENTIALLY EXPLOSIVE ATMOSPHERES ...................................26
3.4 - OBLIGATIONS AND PROHIBITIONS ....................................................................................................... 28
3.5 - SAFETY PICTOGRAMS .......................................................................................................................... 29
3.6 - RISK LEVEL ............................................................................................................................................ 29

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4 - DESCRIPTION AND OPERATION .................................................................................... 31
4.1 - GENERAL DESCRIPTION ....................................................................................................................... 31
4.1.1 - REGULATOR REACTION MODES.........................................................................................................32
4.2 - OPERATION............................................................................................................................................ 32
4.3 - INTENDED USE ...................................................................................................................................... 34
4.3.1 - ENVISAGED USE ..................................................................................................................................34
4.3.2 - REASONABLY FORESEEABLE MISUSE ...............................................................................................34
4.3.3 - TYPES OF FLUIDS ................................................................................................................................34
4.4 - TECHNICAL FEATURES/PERFORMANCE .............................................................................................. 35
4.5 - POSSIBLE CONFIGURATIONS ............................................................................................................... 36
4.5.1 - BUILT-IN SILENCER ..............................................................................................................................37
4.5.2 - MONITOR .............................................................................................................................................38
4.5.2.1 - V/25 AND M/A ACCELERATOR VALVES .....................................................................................42
4.5.3 - SLAM-SHUT VALVE ..............................................................................................................................44
4.5.3.1 - BUILT-IN SLAM-SHUT VALVE SA..................................................................................................44
5 - TRANSPORT AND HANDLING......................................................................................... 47
5.1 - SPECIFIC WARNINGS FOR TRANSPORT AND HANDLING ................................................................... 47
5.1.1 - PACKAGING AND FASTENERS USED FOR TRANSPORT ....................................................................48
5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT ........................................................................... 49
5.2.1 - APERVAL ..............................................................................................................................................49
5.2.2 - APERVAL + DB .....................................................................................................................................50
5.2.3 - APERVAL + PM/182..............................................................................................................................51
5.2.4 - APERVAL + SA .....................................................................................................................................52
5.2.5 - APERVAL + DB + PM/182 ....................................................................................................................54
5.2.6 - APERVAL + DB + SA ............................................................................................................................56
5.3 - EQUIPMENT ANCHORING AND LIFTING METHOD................................................................................ 58
5.3.1 - FORKLIFT HANDLING METHOD...........................................................................................................59
5.3.2 - CRANE HANDLING METHOD...............................................................................................................61
5.4 - PACKAGING REMOVAL.......................................................................................................................... 62
5.4.1 - PACKAGING DISPOSAL .......................................................................................................................62
5.5 - STORAGE AND ENVIRONMENTAL CONDITIONS .................................................................................. 63
5.5.1 - PRE-INSTALLATION WARNINGS AFTER PROLONGED STORAGE ......................................................63

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6 - INSTALLATION .................................................................................................................. 65
6.1 - INSTALLATION PRE-REQUISITES........................................................................................................... 65
6.1.1 - ALLOWED ENVIRONMENTAL CONDITIONS.........................................................................................65
6.1.2 - CHECKS BEFORE INSTALLATION........................................................................................................66
6.2 - SPECIFIC SAFETY INSTRUCTIONS FOR THE INSTALLATION STEP ...................................................... 67
6.3 - GENERAL INFORMATION ON CONNECTIONS ...................................................................................... 68
6.4 - REGULATOR INSTALLATION POSITIONS............................................................................................... 69
6.5 - INSTALLATION PROCEDURES............................................................................................................... 70
6.5.1 - EQUIPMENT INSTALLATION PROCEDURE ..........................................................................................70
6.5.2 - CONNECTION OF THE SENSING LINES TO THE DOWNSTREAM PIPING...........................................70
6.6 - POST-INSTALLATION AND PRE-COMMISSIONING CHECKS ................................................................ 72
7 - COMMISSIONING/MAINTENANCE EQUIPMENT........................................................... 73
7.1 - LIST OF EQUIPMENT.............................................................................................................................. 73
7.2 - EQUIPMENT NEEDED FOR THE DIFFERENT CONFIGURATIONS .......................................................... 75
8 - COMMISSIONING ............................................................................................................. 77
8.1 - GENERAL WARNINGS ........................................................................................................................... 77
8.1.1 - SAFETY REQUIREMENTS FOR COMMISSIONING ...............................................................................77
8.2 - PRELIMINARY PROCEDURES FOR COMMISSIONING .......................................................................... 78
8.3 - PROPER COMMISSIONING CHECK ...................................................................................................... 79
8.4 - CALIBRATION OF ANY ACCESSORIES.................................................................................................. 79
8.5 - REGULATOR COMMISSIONING PROCEDURE ...................................................................................... 80
8.6 - PROCEDURE FOR COMMISSIONING THE APERVAL REGULATOR WITH PM/182 BUILT-IN MONITOR 82
8.7 - START-UP PROCEDURE FOR APERVAL REGULATOR WITH INCORPORATED MONITOR PM/182 AND
ACCELERATOR VALVE V/25................................................................................................................... 84
8.8 - START-UP PROCEDURE FOR APERVAL REGULATOR WITH INCORPORATED MONITOR PM/182 AND
ACCELERATOR VALVE M/A.................................................................................................................... 88
8.9 - COMMISSIONING PROCEDURE FOR THE APERVAL REGULATOR WITH INTEGRATED SA BLOCK
VALVE ..................................................................................................................................................... 92
8.9.1 - CHECKING THE CLOSING TIGHTNESS OF THE SA BUILT-IN SLAM-SHUT VALVE ........... 92
8.9.2 - COMMISSIONING OF THE REGULATOR APERVAL WITH SA SLAM-SHUT VALVE ..............................93
8.9.5 - PRESSURISING WITH EXTERNAL SOURCE.........................................................................................95
8.9.3 - CALIBRATION PROCEDURE FOR PRESSURE SWITCHES MOD. SA...................................................96
8.9.4 - DEVICE CALIBRATION........................................................................................................................100
8.9.4.1 - V/25 ACCELERATOR VALVE CALIBRATION ...............................................................................100
8.9.4.2 - CALIBRATION OF 300, 200 SERIES PILOTS AND M/A ACCELERATOR VALVE .........................100
8.9.4.3 - CALIBRATION OF PRESSURE SWITCHES MOD. SA .................................................................101

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9 - MAINTENANCE AND FUNCTIONAL CHECKS.............................................................. 103
9.1 - GENERAL WARNINGS ......................................................................................................................... 103
9.2 - PERIODICALLY CHECKING AND INSPECTING THE EQUIPMENT FOR PROPER OPERATION ............ 105
9.3 - ROUTINE MAINTENANCE .................................................................................................................... 106
9.3.1 - GENERAL SAFETY WARNINGS..........................................................................................................106
9.3.2 - REPLACEMENT FREQUENCY FOR COMPONENTS SUBJECT TO WEAR .........................................107
9.4 - ROUTINE MAINTENANCE PROCEDURES............................................................................................ 109
9.4.1 - TIGHTENING TORQUES APERVAL.....................................................................................................110
9.4.2 - REPLACING ELEMENTS SUBJECT TO WEAR AND ABRASION.........................................................131
9.4.3 - REGULATOR MAINTENANCE PROCEDURE APERVAL .....................................................................132
9.4.4 - MAINTENANCE OF THE 300/A SERIES PILOT + AR100 LAMINATION VALVE....................................144
9.4.5 - DB APERVAL SILENCER MAINTENANCE...........................................................................................164
9.4.6 - PM/182 BUILT-IN MONITOR MAINTENANCE......................................................................................172
9.4.7 - 200/A SERIES PILOT + PRE-REGULATORS R31/A AND R14/A MAINTENANCE ...............................192
9.4.8 - V/25 ACCELERATOR VALVE MAINTENANCE .....................................................................................214
9.4.9 - M/A ACCELERATOR VALVE MAINTENANCE ......................................................................................218
9.4.10 - SEALING OF THE SA BUILT-IN SLAM-SHUT VALVE ...........................................................................222
9.4.11 - MAINTENANCE OF PRESSURE SWITCH MOD. SA ...........................................................................226
9.4.12 - PROCEDURE FOR RECOMMISSIONING AFTER MAINTENANCE ......................................................237
10 - TROUBLESHOOTING...................................................................................................... 239
10.1 -GENERAL WARNINGS ......................................................................................................................... 239
10.2 -OPERATOR QUALIFICATION SPECIFICATION...................................................................................... 240
10.3 -TROUBLESHOOTING PROCEDURES .................................................................................................. 240
10.4 -TROUBLESHOOTING TABLES ............................................................................................................. 241
10.4.1 - TROUBLESHOOTING APERVAL REGULATOR ...................................................................................241
10.4.2 - DB SILENCER TROUBLESHOOTING..................................................................................................243
10.4.3 - PM/182 BUILT-IN MONITOR TROUBLESHOOTING ............................................................................244
10.4.4 - TROUBLESHOOTING OF THE SA SLAM-SHUT VALVE ......................................................................248

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11 - UNINSTALLATION AND DISPOSAL ............................................................................... 249
11.1 -GENERAL SAFETY WARNINGS............................................................................................................ 249
11.2 -QUALIFICATION OF THE OPERATORS IN CHARGE............................................................................. 249
11.3 -UNINSTALLATION................................................................................................................................. 249
11.4 -INFORMATION REQUIRED IN CASE OF RE-INSTALLATION................................................................. 249
11.5 -DISPOSAL INFORMATION.................................................................................................................... 250
12 - RECOMMENDED SPARE PARTS................................................................................... 251
12.1 -GENERAL WARNINGS ......................................................................................................................... 251
12.2 -HOW TO REQUEST SPARE PARTS...................................................................................................... 251
13 - CALIBRATION TABLES................................................................................................... 253
13.1 -300 SERIES PILOT CALIBRATION TABLES .......................................................................................... 253
13.2 -200 SERIES PILOT CALIBRATION TABLES .......................................................................................... 254
13.3 -PRESSURE SWITCH CALIBRATION TABLES MOD. SA........................................................................ 255

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2 - GENERAL INFORMATION
2.1 - MANUFACTURER IDENTIFICATION
Manufacturer PIETRO FIORENTINI S.P.A.
Address
Via Enrico Fermi, 8/10
36057 Arcugnano (VI) - ITALY
Tel. [phone] Fax [phone]
www.orentini.com arcugnano@orentini.com
Tab. 2.2.
2.2 - IDENTIFICATION OF THE PRODUCT
Equipment REGOLATORE PER MEDIA PRESSIONE
Model APERVAL
Tab. 2.3.
2.3 - REGULATORY FRAMEWORK
PIETRO FIORENTINI S.P.A.-
sibility that the equipment of the APERVAL series described in this manual is designed, manufactured, tested and checked
in compliance with the requirements of EN 334 standard on gas pressure regulators.
The equipment complies with the requirements of Directive 2014/68/EU ("Pressure Equipment Directive" PED). The as-
sessment procedure adopted is in accordance with module H1 as per Annex III of the Directive.
NOTICE!
The declaration of conformity in its original version is delivered together with the equipment and this oper-
ating and warning manual.
2.4 - WARRANTY
PIETRO FIORENTINI S.P.A. guarantees that the equipment was manufactured using the best materials, with high quality

The warranty shall be considered null and void and PIETRO FIORENTINI S.P.A. shall not be liable for any damage and/or
malfunctions:
• due to any acts or omissions of the purchaser or end-user, or any of their carriers, employees, agents, or any third
party or entity;
• in the event that the purchaser, or a third party, makes changes to the equipment supplied by PIETRO FIORENTINI S.P.A.
without the prior written approval of the latter;
• in the event of failure by the purchaser to comply with the instructions contained in this manual, as provided by
PIETRO FIORENTINI S.P.A.
NOTICE!
The warranty conditions are specied in the commercial contract.

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2.5 - SYMBOLS USED IN THE MANUAL
Symbol Denition
Symbol used to identify important warnings for the safety of the operator and/or equipment.
Symbol used to identify information of particular importance in the instruction manual.
The information may also concern the safety of the personnel involved in using the equipment.
Obligation to consult the instruction manual/booklet.
Indicates a requirement for the personnel to refer to (and understand) the operating and warning
instructions of the machine before working with or on it.
Tab. 2.4
HAZARD!
Alerts to a hazard with a high level of risk, an imminent hazardous situation which, if not prevented, will
result in death or severe damage.
WARNING!
Alerts to a hazard with a medium level of risk, a potentially hazardous situation which, if not prevented,
may result in death or severe damage.
ATTENTION!
Alerts to a hazard with a low level of risk, a potentially hazardous situation which, if not prevented, could
result in minor or moderate damage.
NOTICE!
Alerts to specic warnings, directions or notes of particular concern, that are not related to physical injury,
as well as practices for which physical injury is not likely to occur.

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2.6 - ADDRESSEES, SUPPLY AND STORAGE OF THE INSTRUCTION MANUAL
              
throughout its service life.
It contains the necessary information to properly use the equipment and keep its functional and qualitative characteristics
unchanged over time. All information and warnings for safe, correct use are also provided.

and must always accompany it whenever it is moved or resold. It is up to the user to keep this documentation intact for
reference throughout the lifespan of the equipment.
WARNING!
Removing, rewriting or editing the pages of the manual and their contents is not allowed.
Keep the instruction manual near the equipment, in an accessible place known by all qualied technicians
involved in using and running it.
PIETRO FIORENTINI S.p.A. shall not be held liable for any damage to people, animals and property caused
by failure to adhere to the warnings and operating procedures described in this instruction manual.
2.7 - LANGUAGE
The original instruction manual was drawn up in Italian.
Any translations into additional languages are to be made from the original instruction manual.
HAZARD!
The Manufacturer is not responsible for any incomplete translations. If any inconsistency is found, please
refer to the text of the original manual.
If inconsistencies are found or the text does not make sense:
• stop any actions;
• immediately contact the relevant ofces of PIETRO FIORENTINI S.p.A.
WARNING!
PIETRO FIORENTINI S.p.A. shall be held liable for the information provided in the original manual only.

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2.8 - APPLIED RATING PLATES
WARNING!
Removing nameplates and/or replacing them with other plates is strictly not allowed.
Should the plates be unintentionally damaged or removed, the customer must notify
PIETRO FIORENTINI S.p.A.
The equipment and its accessories are provided with nameplates (from Id.1 to Id.8).

PIETRO FIORENTINI S.p.A.
Tab. 2.5 shows the nameplates applied:
Id. Type Image
1NAMEPLATE
REGULATOR (EC version)
2NAMEPLATE
PILOT
3NAMEPLATE
PRE-REGULATOR
4NAMEPLATE
SILENCER

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Id. Type Image
5NAMEPLATE
MONITOR
6NAMEPLATE
SLAM-SHUT VALVE
7NAMEPLATE
PRESSURE SWITCH
8NAMEPLATE
ACCELERATOR VALVE
Tab. 2.5.

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2.8.1 - GLOSSARY FOR NAMEPLATES
The terms and abbreviations used on nameplates are described in Tab. 2.6:
Term Description
AC Accuracy class.
AG max Accuracy class of pressure boosting slam-shut valves.
“OPSO” (Over pressure shut off).
AG min Accuracy class of safety devices for pressure drop.
”UPSO”(Under pressure shut off).
bpu Range of inlet pressure for which the regulator ensures a given accuracy class.
CE Marking certifying compliance with applicable European directives.
Cg 
Class
Alphanumeric designation used for reference purposes related to a combination of mechanical

series, which includes the word Class followed by a dimensionless whole number.
DN Nominal size of connections.
Fail safe mode Regulator reaction mode (Fail open or Fail close).
Flange 
Fluid 
ID no. 
Pilot Pilot family.
PS Maximum permissible pressure for which the equipment was designed.
Pumax -
tions.
REGULATOR Equipment family.
SG Shut-off pressure class.
Slam-shut device Slam-shut valve family.
S.n. Equipment serial number.
Strength type Strength class: Integral strength or differential strength (DS).
TPermissible temperature range (min. and max.) for which the equipment was designed.
Tripping unit Pressure switch family.
Type Accessory type and family.
Wd Full setpoint range that can be obtained from the regulator by adjusting and/or replacing certain
components (e.g. replacement of valve seat or control element, e.g. spring).
Wdo
Full setpoint range with regard to tripping caused by increased pressure in the pressure switch
incorporated in the slam-shut valve.
This range can be obtained by adjusting and/or replacing the components (for example, spring
or sensitive element).
Wds Full setpoint range that can be obtained from the regulator by adjusting but not replacing the
components.
Wdso
Full setpoint range with regard to tripping caused by increased pressure in the pressure switch
incorporated in the slam-shut valve.
This range can be obtained by adjusting but not replacing the components.

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Term Description
Wdu
Full setpoint range with regard to tripping caused by decreased pressure in the pressure switch
incorporated in the slam-shut valve.
This range can be obtained by adjusting and/or replacing the components (for example, spring
or sensitive element).
Term Description
Wdsu
Full setpoint range with regard to tripping caused by decreased pressure in the pressure switch
incorporated in the slam-shut valve.
This range can be obtained by adjusting but not replacing the components.
Tab. 2.6.

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2.9 - GLOSSARY OF MEASUREMENT UNITS
Type of measurement Unit of measurement Description
Volumetric ow rate Sm³/h Standard cubic metres per hour
Scfh Standard cubic feet per hour
Pressure
bar Unit of measurement in the CGS system
psi Pounds per square inch
“wc inch of water column
Pa Pascal
Temperature
°C Degree centigrade
°F Fahrenheit degree
K Kelvin
Tightening torque Nm Newton-metre
ft-lbs Foot per pound
Sound pressure dB Decibel
Other measures
V Volt
W Watt
Ohm
Tab. 2.7.

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2.10 - QUALIFIED PROFESSIONAL FIGURES

Professional gure Denition
Mechanical
maintenance techni-
cian

• perform preventive/corrective maintenance operations on all mechanical parts of the
equipment subject to maintenance or repair;
• access all device parts for visual inspection, equipment checks, adjustments and cali-
brations.
The maintenance mechanical technician is not authorised to operate on live electrical sys-
tems (if any).
Electrical
maintenance techni-
cian

• perform preventive/corrective maintenance operations on all electrical parts of the de-
vice subject to maintenance or repair;
• read wiring diagrams and check the correct functional cycle;
• perform adjustments and operate on electrical systems for maintenance, repair and
replacement of worn parts.
The electrical maintenance technician can operate in the presence of voltage inside electri-
cal panels, junction boxes, control equipment etc. only if he/she is deemed to be suitable
(S.P.).
For general requirements, refer to the IEC EN 50110-1:2014 standard.
Worker in charge of
transport,
handling,
unloading and place-
ment on site

• use lifting equipment;
• handle materials and equipment.
The equipment must be lifted and handled strictly in accordance with the instructions pro-
vided by the manufacturer as well as the regulations in force at the place where the equip-
ment is installed.
Installer

• carry out all the operations necessary to properly install the equipment;
• perform all the operations necessary for the proper functioning of the equipment and
the system in safety.
User’s
technician
Technician trained and authorized to use and manage the equipment for the activities for
which it was supplied. They must:
• be able to perform all operations required to properly run the equipment and the sys-
tem, ensuring their own safety and that of any personnel on site;
• have proven experience in properly using the equipment similar to that described in this
instruction manual, and be trained, informed and instructed in this regard.

Tab. 2.8.

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