Gascat URANO FA Benutzerhandbuch

Installation Manual, Maintenance and Operation

Pressure Regulating Valve

Installation Manual, Maintenance and Operation

Pressure Regulating Valve

Model URANO FA/FF

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 2 de 61

INDEX

1.0 - GENERAL WARNINGS .......................................................................................................................................................... 4

1.1

–

INSTRUCTIONS

FOR

COMMISSIONING .................................................................................................................................... 4

1.2

–

HEALTH

AND

SAFETY ............................................................................................................................................................... 4

1.2.1 – NOISE ............................................................................................................................................................................... 4

1.2.2 – INSTALLATION ................................................................................................................................................................. 4

1.2.3 – OPERATION ...................................................................................................................................................................... 4

1.2.4 – MAINTENANCE ................................................................................................................................................................ 5

2.0 – INTRODUCTION ................................................................................................................................................................... 5

2.1

SCOPE

MANUAL .................................................................................................................................................................... 5

2.2

DESCRIPTION .............................................................................................................................................................................. 5

2.3

SPECIFICATIONS ......................................................................................................................................................................... 6

2.3.1 AVAILABLE SETTINGS .......................................................................................................................................................... 6

2.3.2 AVAILABLE CONNECTIONS.................................................................................................................................................. 6

2.3.3 TEMPERATURE LIMITS ........................................................................................................................................................ 6

2.3.4 COEFFICIENTS FLOW ........................................................................................................................................................... 6

2.3.5 APPROXIMATE WEIGHT ...................................................................................................................................................... 7

2.3.6 MAXIMUM WORKING PRESSURE ...................................................................................................................................... 7

2.3.7 SETTING PRESSURES SET-POINT) ....................................................................................................................................... 7

2.3.8 ACCURACY AND LOCK UP ................................................................................................................................................... 8

3.0 – PRINCIPLE OF OPERATION ................................................................................................................................................... 8

3.1

REGULATOR

SPRING

(FAIL

CLOSE) .............................................................................................................................. 8

3.2

REGULATOR

SPRING

OPEN

(FAIL

OPEN) .............................................................................................................................. 10

3.3

OOSTER

(G-43

G-44) ........................................................................................................................................................... 12

3.4

PILOTS

(G-40

G-42) ............................................................................................................................................................... 13

3.5

FILTERS ..................................................................................................................................................................................... 14

3.6

MOUNT

MONITOR

AND

ACTIVE ............................................................................................................................................... 14

4.0 – INSTALLATION ................................................................................................................................................................... 15

4.1

FILTER ....................................................................................................................................................................................... 15

4.2

CLEANING ................................................................................................................................................................................. 16

4.3

DIRECTION

FLOW

AND

SYSTEM

INTEGRITY ......................................................................................................................... 16

4.4

SENSE ....................................................................................................................................................................................... 17

4.5

SCHEME

RECOMMENDED

INSTALLATION ................................................................................................................................ 19

4.5.1 SINGLE REGULATOR ......................................................................................................................................................... 19

4.5.2 SISTEM MONITOR AND ACTIVE ........................................................................................................................................ 21

4.5.3 TWO SSV AND A REGULATOR FF ...................................................................................................................................... 23

4.6

START-UP ................................................................................................................................................................................. 25

4.6.1 GENERAL RECOMMENDATIONS ....................................................................................................................................... 25

4.6.2 COMMISSIONING SINGLE REGULATOR) ......................................................................................................................... 26

4.6.3 ADJUSTING THE LINE BOOKING ........................................................................................................................................ 27

4.6.4 COMMISSIONING SISTEM MONITOR AND ACTIVE)......................................................................................................... 28

4.6.5 ADJUSTING THE LINE BOOKING MONITOR - ACTIVE) ...................................................................................................... 31

4.6.6 LIST OF RECOMMENDED TOOLS ....................................................................................................................................... 32

5.0 TROUBLE SHOOTING ............................................................................................................................................................ 33

6.0 MAINTENANCE .................................................................................................................................................................... 34

6.1

RECOMMENDED

REPAIR

PARTS

AND

KITS ............................................................................................................................... 35

6.2

PROCEDURE

FOR

REMOVAL

THE

REGULATOR

URANO

(FF) ................................................................................................ 43

6.3

PROCEDURE

FOR

ASSEM LY

REGULATOR

URANO

(FF) ....................................................................................................... 45

6.4

PROCEDURE

FOR

REMOVAL

THE

REGULATOR

URANO

(FO) ................................................................................................ 46

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 3 de 61

6.5

PROCEDURE

FOR

ASSEM LY

REGULATOR

URANO

(FO) ...................................................................................................... 50

6.6

PROCEDURE

FOR

REMOVAL

THE

PILOT

G-40

42 .................................................................................................................... 50

6.7

PROCEDURE

FOR

ASSEM LY

THE

PILOT

G-40

42 .................................................................................................................... 53

6.8

PROCEDURE

FOR

REMOVAL

OOSTER

(PRE-EGULATOR)

G-43 ................................................................................................ 54

6.9

PROCEDURE

FOR

ASSEM LY

OOSTER

(PRÉ

REGULATOR)

G-43 .............................................................................................. 57

6.10

PROCEDURE

FOR

REMOVAL

OOSTER

(PRE-REGULADOR)

G-44 ................................................. E

RRO

NDICADOR NÃO DEFINIDO

6.11

PROCEDURE

FOR

ASSEM LY

OOSTER

(PRE-REGULADOR)

G-44 ........................................................................................... 60

6.12

LIST

RECOMMENDED

TOOLS

FOR

MAINTENANCE .................................................................. E

RRO

NDICADOR NÃO DEFINIDO

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 4 de 61

1.0 - GENERAL WARNINGS

1.1 – INSTRUCTIONS FOR PRE COMMISSIONING

It should be clearly understood that with the information presented in Commissioning Instructions that follow, it is not

intended to repeal or replace the instructions determined by any other competent body and should be reference to the

relevant standards and / or existing recommendations on this subject.

Before any commissioning, is implied the performance of the appropriate "Cleaning and Purification Procedures" that

must be observed and all the instructions on "Pressurization" and "Work Standards for Health and Safety", must be strictly

met.

The recommendations of valves suppliers, such as "open slowly" or "open very slowly" should be strictly observed.

1.2 – HEALTH AND SAFETY

Regulators, valves, and other pressurized components that contain toxic gases, flammable or other hazardous

products, are potentially dangerous if not operated and maintained properly. It is imperative that all users of this equipment

are adequately educated and guided to the potential hazards and make sure that staff responsible for the installation,

testing, commissioning, operation and plant maintenance are competent to do this. Instruction manuals are provided for the

guidance of operators, but it is assumed that they have a basic level of knowledge. If any doubts or ambiguities that affect

the proper procedures ask Gascat Ind e Com. Ltda. who will be happy to advise or provide the relevant service or

instruction. NO RISK. Our phone number, fax number and e-mail are described below:

Gascat Indústria e Comércio Ltda.

Rodovia SP 73, 1141 – Indaiatuba / São Paulo.

CEP 13347-990

Telefone: +55 19 3936-9300

Fax: +55 19 3935-6009

Email:

[email protected]om.br

The comments that follow, while not exhaustive, provide guidance possible sources of danger to health and safety.

1.2.1 – NOISE

Regulators, valves and pressure reducers can produce high noise levels, which may be harmful to persons exposed to

them for long periods of time. Users should ensure that adequate precautions are taken in order to provide security to the

health of employees and / or third parties as the standards and recommendations in force.

1.2.2 – INSTALLATION

All equipment, piping and vessels are designed to withstand mechanical stress, for example, torque and moments of

"bending" in addition to internal pressure. However, care must be taken during installation to not impose excessive strain,

which may cause cracks that may result in a more serious break when the regulator is put into operation. Excessive stress

can also be caused due to not supporting the length of the pipe, which must be adequately supported.

All regulators, valves shut off, relief valves, etc., should be installed with the correct flow.

Impulse lines are important components of any control system and it is essential that they are properly installed and

without isolation valves.

Impulse lines should be adequately supported to reduce excessive vibration which may cause disruption due to fatigue.

They should also be positioned so that they can not serve as a footrest or hands. Impulse lines should be slightly inclined

so that condensed liquids and to flow into the main pipe.

When necessary (in underground facilities or indoor area) should be installed a pipe ventilation from Ø threaded ¼

"NPT, positioned in the bell or diaphragm housing, which should be extended and positioned in a safe place and ventilated,

with the departure of protected vent to prevent water entering the rain and insects that may cause obstruction of ventilation.

Auxiliary systems should not be altered or modified without the knowledge of operating conditions and permission of the

people responsible.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 5 de 61

1.2.3 – OPERATION

Depending on the type of regulator, the valve may even be positioned fully open. Consequently, when a regulator put in

operation, the shutoff valves should be opened slowly so that the regulator valve can assume its regulating position. If the

valves are quickly opened the upstream pressure can pass downstream through the regulator and over-pressurize

downstream the main line.

All regulators, etc., should operate with the spring adjustment specified by the manufacturer. This is especially important

when operating relief valve or shutoff valves, since incorrect springs may prevent the relief valve to open and close the

shutoff valve.

Precautions should be taken to prevent water from entering through the openings for breathing and ventilation.

1.2.4 – MAINTENANCE

Regulators and valves contain gases at pressures that are sometimes greater than atmospheric pressure. Before trying

to investigate any problem or perform maintenance work on equipment, they must be safely depressurised. Furthermore,

as most gases may be flammable, toxic, corrosive, or hazardous, it may be necessary to purge the system with an inert

gas such as nitrogen. Special precautions are necessary for operation with gases such as oxygen or hydrochloric gas and

the user must be sure that the appropriate procedures are in place.

Eventually it is not enough to isolate the high pressure device, since high pressures can be retained downstream of

isolation valves. Do not try to remove covers, plugs, etc., before this device is properly released. Still, it is wise to consider

that the high pressure gas may be present when removing covers and plugs.

Most regulators use spiral springs as a charging device. It is important to reduce the burden these springs away your

presser as possible. In some cases, there may be some cargo residue, even when the spring is relaxed within the limits of

their house.

2.0 – INTRODUCTION

2.1 SCOPE OF MANUAL

This manual aims to provide operational information, installation and maintenance of the pressure regulators URANO

model manufactured by GASCAT.

2.2 DESCRIPTION

The pilot operated pressure regulator model URANO was developed by the Engineering GASCAT, to meet the most

varied applications and can operate in various operating conditions, however, it is particularly applicable in situations where

requires high flow rates associated with high pressures, typically found in natural gas transportation and custody transfer in

natural gas delivery point and can operate with a maximum inlet pressure of 150 kgf/cm² and outlet pressures from 1.0 to

80.0 kgf/cm².

The pressure regulator of URANO GASCAT model has CE mark (product identification Number: CE-0085BU0263) and

certified tests performed in the laboratory DVGW attesting its efficiency and compliance with DIN EN 334 (Gas pressure

regulators for inlet pressures up to 100 bar) and 97/23 / EG (PED), the DVGW certificates and reports are available for

inspection at GASCAT if some of the documents necessary for your application, please contact our Headquarters in

Indaiatuba and request copies of these documents.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 6 de 61

2.3 SPECIFICATIONS

2.3.1 AVAILABLE SETTINGS

URANO FA: Pilot operated pressure regulator fail open

URANO FF: Pilot operated pressure regulator failure close

The URANO pressure regulators are classified as FA and FF according to the guidelines reported in DIN EN 334, for fault

condition

2.3.2 AVAILABLE CONNECTIONS

DN FLANGE ASME B16.5 FLANGE DIN 2634 / 2635

1” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

2” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

3” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

4” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

6” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

8” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

2.3.3 TEMPERATURE LIMITS

Operating temperature: -20°C a 60°C

Ambient temperature: -20°C a 60°C

Temperature limits reported in this manual or any standard should not be exceeded under any circumstances, at the

risk of damage to the equipment, installation and security of the people involved in the operation.

2.3.4 COEFFICIENTS FLOW

DN CV KG

1” 15 440

2” 63 1950

3” 123 3800

4” 220 6850

6” 486 15080

8” 900 28250

Note:

1) We suggest that is considered a 20% safety factor on the calculated value.

2) When scaled active-monitor system finds 25% restriction on the CV / KG of both valves.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 7 de 61

2.3.5 APPROXIMATE WEIGHT

DN 150# 300# 600# 900#

1” 24 26 30 34

2” 95 100 112 128

3” 99 105 130 149

4” 185 195 215 247

6” 475 500 570 655

8” 570 600 690 793

Note:

1) Weights reported in kilograms (Kg)

2) Considered body in carbon steel SA-216 WCB

3) For the exact weights contact the GASCAT for verification of the model.

2.3.6 MAXIMUM WOR ING PRESSURE

150# 300# 600# 900# PN 25 PN 40

19 bar 51 bar 100 bar 150 bar 25 bar 40 bar

Pressure limits reported in this manual or any standard should not be exceeded under any circumstances, at the risk of

damage to the equipment, installation and security of the people involved in the operation.

2.3.7 SET-POINT

Pressure regulators, model URANO using two models of pilots for pressure control called G-40 and G-42, here are the

adjustment ranges available for each model:

PILOT G-40

SPRING COLOR CODE ADJUSTMENT RANGE

RED 01.51.94A 25,0 – 50,0 bar

YELLOW 01.51.94 47,0 – 80,0 bar

PILOT G-42

SPRING COLOR CODE ADJUSTMENT RANGE

GREEN 01.49.65 1,0 – 4,5 bar

GRAY 01.49.64 4,5 – 12,0 bar

BLUE 01.49.33 11,0 – 17,0 bar

RED 01.51.94A 16,0 – 30,0 bar

YELLOW 01.51.94 27,0 – 55,0 bar

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 8 de 61

2.3.8 ACCURACY AND LOC UP

Accuracy; Closing: AC até 1; SG até 2,5

3.0 – PRINCIPLE OF OPERATION

3.1 REGULATOR SPRING TO CLOSE (FF)

In the absence of pressure, the obturator (A) is kept in closing position by the closing spring (B) which keeps the gasket

pressed against (C). Importantly, even when subjected to pressure the variation of pressure upstream will have no

influence on the setting of the valve due to the balancing of the forces acting on it, as well as the actuator shaft (D) which is

also balanced.

By pressurizing the leg, the gas passes through a filter element (E) reaches a pre controller (booster) (F) reduces to a

near value of the output pressure and delivering the pilot (G) as compared to the output pressure sensed by the pilot

diaphragm (M), which controls the flow is injected under the main regulator diaphragm (L).

If a decrease in the downstream pressure (for consumption or increasing the amount of pressure drop) occurs an

imbalance between the force of the spring (R) on the pilot diaphragm (M) and the force generated by the outlet pressure

under the same diaphragm, causing the shutter driver (K) to a larger aperture, causing an increase in pressure under the

main regulator diaphragm (L), which combined with downstream pressure drop which acts on the main regulator

diaphragm and opposite the pilot pressure acting on it, determine the displacement of the shutter (A) up, thereby

increasing the passage restoring the pressure (set point).

When the pressure begins to increase, causes the shutter driver (K) to reduce the opening. The increased pressure

which operated under the regulator diaphragm (L) flows through the restriction of Bleed (M) (adjustable) that discharges

into downstream. The strength of the main regulator of the closing spring (B) plus the reduction in pilot pressure causes

displacement of the main shutter (A) down, thus making the pressure back to the preset value.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 9 de 61

FIGURE 1 - URANO FAIL CLOSED

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Urano

MI-31

Elaborate Verified / Approved CSQ Date Review Page

Raphael Pereira Vanízio Lizo Gustavo Nieto

05/06/14

04 10 de 61

3.2 REGULATOR SPRING TO OPEN (FA)

In the absence of pressure, the obturator (A) is in the open position by the main regulator spring (B) which keeps away

from the sleeve (C). Importantly, even when subjected to pressure the variation of pressure upstream will have no

influence on the setting of the valve due to the balancing of the forces acting on it, as well as the actuator shaft (D) which is

also balanced.

To pressurize the leg, the gas passes through a filter element and reaches the pre regulator (booster) (F) that reduces

to a value near the outlet pressure, and delivery to the pilot (G), it is important to note that unlike what happens in URANO

artifact closes regulator, the pressure provided by the booster is also injected directly into the upper chamber of the

diaphragm, it is necessary for the regulator to close at normal operating conditions, since the main regulator spring

pressing this the shutter so that it is in the open position.

The pilot compares the output pressure sensed by the diaphragm (M) and controls the flow that is injected under the

main regulator diaphragm (G) to open the valve.

If a decrease in the downstream pressure (for consumption or increasing the amount of pressure drop) occurs an

imbalance between the force of the spring (R) on the pilot diaphragm (M) and the force generated by the outlet pressure

under the same diaphragm, causing the shutter driver (K) to a larger aperture, causing an increase in pressure under the

main regulator diaphragm (L), determining the displacement of the shutter (A) up, thereby increasing the pressure restoring

passage (Sept -point).

When the pressure begins to increase, causes the shutter driver (K) to reduce the opening. Most operated under

pressure regulator diaphragm (L) flows through the restriction of Bleed (M) (variable) discharges into the downstream,

thereby causing the pressure acting on the diaphragm is greater than the driving force and the strength of the combined

spring, moving the shutter down and closing the main valve.

Andere Handbücher für URANO FA

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