PIETRO FIORENTINI REFLUX 819/FO User manual

PRESSURE REGULATOR
REFLUX 819/FO
TECHNICAL MANUAL MT103
INSTALLATION, COMMISSIONING AND MAINTENANCE INSTRUCTIONS
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TECHNICAL MANUAL MT103
REFLUX 819/FO
Issue March 2003
204/A/FO
R14/A/FO
Inlet pressure.
Outlet pressure.
Feed pilot. Motorisation.
Inlet pressure.
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TECHNICAL MANUAL MT103
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The PIETRO FIORENTINI SPA with registered office in Milan (Italy) – via Rosellini, 1, declares under its sole
responsibility that the apparatus bearing the CE marking showed in this manual are designed, manufactured,
tested and inspected in accordance with the provisions of Pressure Equipment Directive 97/23/EC (PED).
Following conformity assessment procedure has been carried out:
➤EC type-examination (module B) by DVGW (ID n° 0085).
In this report both the versions incorporating the safety shut-off devices series SB/82 or HB/97 when
controlling overpressure and the monitor PM/819, are classified as safety accessories according to clause
2.1.3 of art.1 of PED.
➤Production quality assurance (module D) by BUREAU VERITAS (ID n° 0062) – Attestation d’Approbation
de System de Qualitè N° CE-PED-D-FIO001-02-ITA issued 15th May 2002.
Further it declares that the classification of the performances characteristics has been verified by DVGW
according to the procedures given by European standard EN 334 and/or by standard DIN 3381 and, only for the safety
device HB/97, also according to the procedure given by prEN 14382. The classification is detailed in the aforesaid
DVGW report.
Arcugnano 25/9/2002 The Pietro Fiorentini SpA
DECLARATION OF CONFORMITY
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TECHNICAL MANUAL MT103
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GENERAL PRECAUTIONS
-The apparatus described in this manual is a device subject to pressure installed in systems under pressure;
-the apparatus in question is normally installed in systems for transporting flammable gases (natural gas, for
example).
PRECAUTIONS FOR THE OPERATORS
Before proceeding with installation, commissioning or maintenance, operators must:
-examine the safety provisions applicable to the installation in which they must work;
-obtain the authorisations necessary for working when so required;
-use the necessary means of individual protection (helmet, goggles, etc.);
-ensure that the area in which they operate is fitted with the means of collective protection envisaged and with
the necessary safety indications.
HANDLING
The handling of the apparatus and of its components must only be carried out after ensuring that the lifting gear
is adequate for the loads to lift (lifting capacity and functionality). The apparatus must be handled using the lifting
points provided on the apparatus itself.
Motorised means must only be used by the persons in charge of them.
PACKING
The packing for trasportation of equipment and of relevant spare parts are designed and shaped to avoid damage to any
part during transportation, warehousing and handling activities. Therefore the equipment and spare parts shall be kept
into their packing until their installation in the final site. After packing is open, check that no damage occured to any
goods. If damage occured inform the supplier and keep packing for any verification.
INSTALLATION
If the installation of the apparatus requires the application of compression fittings in the field, these must be
installed following the instructions of the manufacturer of the fittings themselves. The choice of the fitting must
be compatible with the use specified for the apparatus and with the specifications of the system when envisaged.
PRECAUTIONS
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TECHNICAL MANUAL MT103
COMMISSIONING
Commissioning must be carried out by adequately trained personnel.
During the commissioning activities, the personnel not strictly necessary must be ordered away and the no-go
area must be properly signalled (signs, barriers, etc.).
Check that the settings of the apparatus are those requested; if necessary, reset them to the required values in
accordance with the procedures indicated in the manual.
When commissioning, the risks associated with any discharges into the atmosphere of flammable or noxious
gases must be assessed.
In installations in natural gas distribution networks, the risk of the formation of explosive mixtures (gas/air) inside
the piping must be considered.
CONFORMITY TO DIRECTIVE 97/23/EC (PED)
Pressure regulator Reflux 819/FO is classified as fail open regulator according to the standard EN 334 therefore
it is categorized as pressure accessory according to directive 97/23/EC (PED).
The incorporated safety device monitor PM/819 (as well as the in-line monitor REFLUX 819) being classified as
fail close regulators according to the standard EN 334 is categorized as safety accessory according PED, therefore
it can be used both as pressure accessory and safety accessory to PED. The regulator REFLUX 819/FO when
incorporating slam shut valve SB/82 or HB/97 with pressure switches for overpressure is categorized as safety
accessory according to PED, therefore it can be used both as pressure accessory and safety accessory to PED.
Conformity with Directive 97/23/EC and CE marking of pressure regulator and relevant accessory require
installation in the system with minimum requirements according to: EN 12286.
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TECHNICAL MANUAL MT103
INDEX
1.0 INTRODUCTION...........................................................................................................PAGE 9
1.1 MAIN SPECIFICATIONS..............................................................................................................................................9
1.2 OPERATION................................................................................................................................................................9
1.3 SETTING SPRINGS ..................................................................................................................................................12
2.0 INSTALLATION...................................................................................................................13
2.1 GENERAL .................................................................................................................................................................13
3.0 ACCESSORIES ...................................................................................................................15
3.1 RELIEF VALVE ..........................................................................................................................................................15
3.1.1 DIRECT INSTALLATION IN THE LINE.......................................................................................................................16
3.1.2 INSTALLATION WITH ON/OFF VALVE ......................................................................................................................17
3.2 ACCELERATOR.........................................................................................................................................................17
4.0 MODULARITY....................................................................................................................18
4.1 INCORPORATED SLAM-SHUT VALVE......................................................................................................................18
4.2 INCORPORATED SB/82 SLAM-SHUT VALVE ...........................................................................................................18
4.2.1 SB/82 SLAM-SHUT OPERATION..............................................................................................................................19
4.2.2 SB/82 SLAM-SHUT SETTING SPRINGS ..................................................................................................................21
4.3 INCORPORATED HB/97 SLAM-SHUT VALVE ...........................................................................................................22
4.3.1 HB/97 OPERATION...................................................................................................................................................23
4.3.2 HB/97 SLAM-SHUT SETTING SPRINGS ..................................................................................................................25
4.4 MONITOR.................................................................................................................................................................26
4.4.1 PM/819 INCORPORATED MONITOR........................................................................................................................26
4.4.2 IN-LINE MONITOR ...................................................................................................................................................27
4.4.3 SETTING SPRINGS ..................................................................................................................................................28
5.0 START UP ........................................................................................................................29
5.1 GENERAL .................................................................................................................................................................29
5.2 GAS INPUT, CONTROL OF EXTERNAL TIGHTNESS AND SETTING .........................................................................30
5.3 COMISSIONING THE REGULATOR WITH INCORPORATED SB/82 SLAM-SHUT .....................................................31
5.4 COMMISSIONING THE REGULATOR WITH INCORPORATED PM/819 MONITOR AND
ACCELERATING VALVE ............................................................................................................................................34
5.5 COMMISSIONING THE REGULATOR WITH REFLUX 819 IN-LINE MONITOR WITH INCORPORATED SB/82
SLAM-SHUT VALVE .................................................................................................................................................35
5.6 COMMISSIONING THE REGULATOR PLUS REFLUX 819/FO IN-LINE MONITOR WITH
SB/82 SLAM-SHUT VALVE.......................................................................................................................................36
6.0 TROUBLE-SHOOTING...........................................................................................................39
6.1 REFLUX 819/FO REGULATOR ..................................................................................................................................39
6.2 PM/819 MONITOR ...................................................................................................................................................41
6.3 SB/82 SLAM-SHUT..................................................................................................................................................42
7.0 MAINTENANCE ..................................................................................................................43
7.1 GENERAL .................................................................................................................................................................43
7.2 REFLUX 819/FO REGULATOR MAINTENANCE PROCEDURE...................................................................................44
7.3 PM/819 MONITOR MAINTENANCE PROCEDURE ....................................................................................................51
7.4 DB/819 SILENCER MAINTENANCE PROCEDURE ....................................................................................................57 .
7.5 SLAM-SHUT DEVICE SB/82 MAINTENANCE PROCEDURE......................................................................................59
8.0 FINAL OPERATIONS ............................................................................................................62
8.1 TIGHTNESS SETTING CHECK ..................................................................................................................................62
8.2 START UP ................................................................................................................................................................62
9.0 WEIGHT OF THE COMPONENTS ..............................................................................................65
9.1 WEIGHT OF THE COMPONENTS IN KG ...................................................................................................................65
10.0 LIST OF RECOMMENDED SPARES ...........................................................................................66
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TECHNICAL MANUAL MT103
The scope of this manual is to provide essential information for the, commissioning, disassembly, re-assembly
and maintenance of the REFLUX 819/FO regulator.
At the same time we consider it appropriate to provide a brief illustration of the main features of the regulator and
its accessories.
1.1 MAIN SPECIFICATIONS
The REFLUX 819/FO pressure regulator is a regulator for medium and high pressures.
The REFLUX 819/FO as a fail open regulator and it opens in following conditions:
-rupture of the main diaphragm;
-rupture of the pilot diaphragm;
-no feed in the pilot circuit.
The main specifications of this regulator are:
•Design pressure: up to 100 bar;
•Working temperature range: -20 °C to +60 °C;
•Ambient temperature: -20 °C to + 60 °C;
•Inlet pressure range bpe: 3 to 85 bar
•Regulating range possible Wh: 1 to 74 bar (depending on the pilot installed);
•Minimum differential pressure: 2 bar;
•Precision class RG: up to 1;
•Closing pressure class SG: up to 3.
1.2 OPERATION (FIG. 1)
In the absence of pressure, the obturator 5 is maintained in the open position by the spring 54 (fig. 1). The
upstream pressure, even if variable, does not change this position as the obturator is completely balanced and is
therefore subject to equal pressures, even if the sections are different.
The rod 6 is also between two equal pressures as the pressure upstream is also conveyed to the chamber C throu-
gh the hole A.
The obturator is controlled by the diaphragm 50 on which the following forces act:
•upwards: the load of the spring 54 and the thrust deriving from the motorisation pressure Pm in the chamber
E, supplied by the pilot;
•downwards: the weight of the mobile assembly and the thrust deriving from the regulated pressure Pep in the
chamber D.
The motorisation pressure is obtained by drawing gas from gas the regulator at the upstream pressure. The gas
is filtered through the filter 13 and is subjected to initial decompression in the preregulator R14/A/FO (fig. 2) com-
posed essentially of an obturator 5, a spring 12 and a diaphragm 10 to a value, Pep, which depends on the pres-
sure set-point of the regulator. The pressure, Pep, then passes from the chamber G through the hole F in the
204/A/FO pilot which adjusts it by means of the obturator 17 until the inlet value, Pm, in the head of the regulator.
The regulation of Pm is obtained by the comparison of the force exerted by the setting spring 22 of the pilot and
the action of the regulated pressure, Pa, acting in the chamber B on the diaphragm 16.
The set-point can be changed by turning the adjustment screw 10; clockwise rotation increases Pm and therefo-
re the regulated pressure, Pa; the opposite occurs when the ring is turned anticlockwise. If, for example, the down-
stream pressure, Pa, drops during operation (because of an increase in the requested flow rate or a drop in the
upstream pressure) an imbalance occurs in the mobile assembly 15 of the pilot, which is displaced to increase the
opening of the obturator 17.
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1.0 INTRODUCTION
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TECHNICAL MANUAL MT103
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As a result, the motorisation pressure value, Pm, increases and, by acting in the chamber E under the diaphragm
50 (fig. 1), causes the obturator 5 to move upwards and therefore an increase in the opening of the regulator until
the set-point of the regulated pressure is restored.
Vice versa, when the regulated pressure begins to increase, the force it exerts on the diaphragm 16 of the pilot
moves the mobile assembly 15 displacing the obturator 17, towards the closed position. The pressure, Pm, then
drops because of the transfer through the orifice 21, and the force exerted by
pressure Pep causes the downward displacement of the obturator 5, to restore the regulated pressure to the
set-point. In normal working conditions, the obturator 17 of the pilot positions itself so that the motorisation
pressure value, Pm, is such as to maintain the downstream pressure value, Pa, around the set-point.
Fig. 1
Fig. 2
PILOT DISCHARGE
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TECHNICAL MANUAL MT103
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Fig. 2A
vent
204/A/FO PILOT
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TECHNICAL MANUAL MT103
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The REFLUX 819/FO regulator uses the 204/A/FO and 205/A/FO and 207/A/FO pilots. The regulation range of the
different pilots is given in the tables below.
205/A/FO Pilot setting springs
Code Colour De Lo d i it Setting range in bar
2703045 BROWN 7.5 7.5 9.5 30 ÷ 44
2703224 GREY 35 100 87.5 9.5 44 ÷ 60
207/A/FO Pilot setting springs
Code Colour De Lo d i it Setting range in bar
2703224 GREY 35 100 8 7.5 9.5 41 ÷ 74
The operating principle of the pilot has already been briefly illustrated in par. 1.2. Variation of the setting is obtained
by turning the adjustment screw 10 (fig. 2). Clockwise rotation leads to an increase in the regulated pressure while
anticlockwise rotation leads to a decrease. When the desired setting has been reached, the adjustment screw can
be blocked by means of the provided nut 9.
De = Ø external diameter d = Ø wire diameter i = active coils Lo = Lenght it = total coils
204/A/FO Pilot setting springs
Code Colour De Lo d i it Setting range in bar
2701541 WHITE 4 7.75 9.75 1 ÷ 3.2
2701800 YELLOW 4.5 8.25 10.25 3.2 ÷ 5.2
2702080 ORANGE 35 100 5 8.75 10.75 5.2 ÷ 8.2
2702290 RED 5.5 8.5 10.5 8.5 ÷ 17
2702460 GREEN 6 8.25 10.25 12 ÷ 25
2702660 BLACK 6.5 8.25 10.25 17 ÷ 26
2702820 BLUE 7 7 9 25 ÷ 33
1.3 Tab. 1 SETTING SPRINGS
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TECHNICAL MANUAL MT103
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2.1 GENERAL
Pressure regulator does not require any supplementary upstream safety accessory for protection against
overpressure compared with its design pressure PS, when upstream reducing station is sized for a max
downstream incidental pressure MIPd ≤1,1 PS.
Before installing the regulator it is necessary to ensure that:
-the regulator can be inserted in the space provided and that subsequent maintenance operations will be
sufficiently practicable;
-the upstream and downstream piping is at the same level and capable of supporting the weight of the regulator;
-the inlet/outlet flanges of the piping are parallel;
-the inlet/outlet flanges of the regulator are clean and the regulator itself has not been subject to damage during
transport;
-the piping upstream has been cleaned to expel residual impurities such as welding scale, sand, paint residues,
water, etc.
The normally raccomended set-up is:
2.0 INSTALLATION
Fig. 3 (Standard regulator)
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TECHNICAL MANUAL MT103
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Tab. 2 CONNECTING THE APPARATUSES
The connections between the apparatus and the main piping must be made using stainless steel pipe with
minimum internal diameter of 8 mm.
IN-LINE INSTALLATION
Regulator
Pilot discharge
Sensing line
Control pressure gauge
Bleed cock
On/Off valve
INSTALLATION AT RIGHT ANGLES
Regulator
Pilot discharge
Sensing line
Control pressure
gauge
Bleed cock
On/Off valve
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TECHNICAL MANUAL MT103
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1and 2Connect to regulators heads
3and 4Connect to pilots
5and 6Connect to accelerator and slam-shut
The regulator must be installed in the line with the arrow on the body pointing in the gas flow direction.
It is indispensable for good regulation that the position of the downstream pressure take-offs and the speed of the
gas at the take-off point respect the values given in tables 2 and 3 (positioning) and 4 (speed).
The pressure regulator, when installed on a reducing station, shall be installed at least according to the
requirements of standard EN 12186.
All venting connections shall be connected as required by above mentioned standard.
The following is recommended so as to prevent the accumulation of impurities and condensate in the lines
of the pressure take-offs:
a) the lines themselves must slope down towards the downstream piping connectors with a slope of about 5-10%;
b) the connectors on the piping must always be welded on the top of the piping itself and there must be no burr
or inward protrusions in the hole in the piping.
NB.WE RECOMMEND NOT TO PUT ON/OFF VALVES ON THE IMPULSE TAKE-OFFS
Tab. 3 DETAIL OF MULTIPLE TAKE - OFF WITH OF THE IMPULSE TAKE - OFF REFERENCE NUMBERS
Tab. 4
The speed of the gas must not exceed the following values in the piping downstream from the regulator:
Vmax= 30 m/s for Pa > 5 bar
Vmax= 25 m/s for 1 < Pa < 5 bar
3.0 ACCESSORIES
3.1 RELIEF VALVE
The relief valve is a safety device which releases a certain quantity of gas to the exterior when the pressure at the
control point exceeds the set-point as a result of short-lasting events such as, for example, the very fast closing
of the on/off valves and/or overheating of the gas with zero flow rate demand. The release of the gas to the exterior
can, for example, delay or block intervention of the slam-shut valve for transitory reasons deriving from damage
to the regulator.
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TECHNICAL MANUAL MT103
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Fig. 4
Fig. 5
Obviously the quantity of gas released depends on the extent of the overpressure with respect to the set-point. The
different models of relief valve available are all based on the same operating principle which is illustrated below with
reference to the valve VS/AM 56 (fig. 4).
It is based on the contrast between the thrust on the diaphragm 24 deriving from the pressure of the gas to being
controlled and the thrust from the setting spring 20. The weight of the mobile assembly, the static thrust and the
residual dynamic thrust on the obturator 4 also contribute to this contrast.
When the thrust deriving from the pressure of the gas exceeds that of the setting spring, the obturator 4 is raised
and a certain quantity of gas is released as a result.
As soon as the pressure drops below the set-point, the obturator returns to the closed position. Proceed as
indicated below to control and adjust intervention of the relief valve.
3.1.1 DIRECT INSTALLATION IN THE LINE (FIG. 5)
When the relief valve is fitted directly in the line, that is without inserting an on-off valve, proceed as follows:
1) Ensure that the downstream on-off valve V2 and the bleed cock 6 are closed.
2) Increase the pressure in the downstream section up to the value envisaged for intervention in one of the
following ways:
- if the spring fitted on the pilot permits it (see table 1), increase the setting of the pilot itself until the desired
value is obtained;
- connect a controlled auxiliary pressure to the cock 6 and stabilize it at the desired value;
3) Check the intervention of the relief valve and adjust it if necessary by turning the adjustament plug 13
appropriately (clockwise to increase and anticlockwise to decrease).
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TECHNICAL MANUAL MT103
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3.1.2 INSTALLATION WITH ON/OFF VALVE (FIG. 6)
1) Close the on-off valve 16.
2) Connect a controlled auxiliary pressure to the nipple 17 and increase it slowly up to the value envisaged for
intervention.
3) Check the intervention of the relief valve and adjust if necessary by turning the adjustament plug 13
appropriately (clockwise to increase and anticlockwise to decrease).
3.2 ACCELERATOR
An accelerator (fig. 7) is installed on the PM/819 icorporated monitor and on the REFLUX 819 regulator (use as
in-line monitor) to speed up their intervention in the event of failure of the active regulator (racommended when
used safety accessory according to Directive 97/23/EC “PED”).
On the basis of a pressure signal from downstream this device discharges the gas into the monitor's motorization
chamber into the atmosphere, thereby permitting rapid intervention. The set point of the accelerator must
obviously be higher than that of the monitor.
Setting is made by turning the adjustment screw 17,clockwise to increase the value, anticlockwise to reduce it.
M/A range of intervention Who: 0,3 to 43 bar
Fig. 7
vent
vent
Accelerator M/A
Fig. 6
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TECHNICAL MANUAL MT103
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4.0 MODULARITY
The modular-type design of REFLUX 819/FO series regulators means that it is also possible to feitner the
emergency monitor regulator PM/819 or it the slam-shut incorporated with the body itself even after the
installation of the regulator without any modifications.
4.1 INCORPORATED SLAM-SHUT VALVE
When closing the slam shut incorporated into pressure regulator to be considered as safety accessory according
to Directive PED, cuts off the feeding of gas both to pressure regulator and to its pilot.
4.2 INCORPORATED SB/82 SLAM-SHUT VALVE
This is a device (fig. 8) which immediately blocks the gas flow if, following some kind of failure, the downstream
pressure reaches the set-point for its intervention, or is operated manually.
On the REFLUX 819/FO regulator, it is possible to have the SB/82 slam-shut incorporated both with the service
regulator and on the one functioning as in-line monitor.
The main characteristics of the slam-shut device are:
•intervention with pressure increase and/or decrease;
•design pressure: 100 bar for all the components;
•intervention accuracy (AG): ± 1% of the pressure set-point for pressure increases; ± 5% for pressure drops;
•manual resetting with internal by-pass operated by the resetting lever.
Fig. 8
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TECHNICAL MANUAL MT103
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4.2.1 SB/82 SLAM-SHUT OPERATION
The SB/82 slam-shut device (see fig. 9) consists of an obturator A, a releasing lever system, a control head B and
a resetting system which is controlled manually by the lever C. The pressure in the circuit to control acts on the
diaphragm in the control head B. This diaphragm, which is integral with a control rod D, receives a counter-force
by means of the minimum pressure springs 17 and the maximum pressure springs 11, set at the preset values.
The translation movement of this rod provokes the displacement of the lever L which controls the release of the
entire mobile system and frees the obturator which is closed by the action of the spring 48.
To reset the device, operate the lever C. This opens an internal by-pass in the first part of its stroke. This leads to
the filling of the downstream zone and balances the pressure on the obturator. Then, complete resetting of the
entire mobile system is obtained in the second part of the stroke of the lever C. Releasing can also be carried out
manually by means of the button 101.
Fig. 9
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TECHNICAL MANUAL MT103
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CONTROL DEVICE
SLAM-SHUT CONTROL HEADS
Fig. 10
Fig. 11
MOD. 102 -106 MOD. 103 -106
MOD. 104 -107 MOD. 105-108 - 109
Mod. 102 - 103 - 104 - 105 Mod. 106 - 107 - 108 - 109
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