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TECHNICAL MANUAL MT103 DECLARATION OF CONFORMITY 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).
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TECHNICAL MANUAL MT103 PRECAUTIONS 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).
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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.
COMMISSIONING THE REGULATOR WITH INCORPORATED PM/819 MONITOR AND ACCELERATING VALVE ............................34 COMMISSIONING THE REGULATOR WITH REFLUX 819 IN-LINE MONITOR WITH INCORPORATED SB/82 SLAM-SHUT VALVE ..............................35 COMMISSIONING THE REGULATOR PLUS REFLUX 819/FO IN-LINE MONITOR WITH SB/82 SLAM-SHUT VALVE............................36 TROUBLE-SHOOTING......................39 REFLUX 819/FO REGULATOR ..........................39 PM/819 MONITOR ..............................41...
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;...
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TECHNICAL MANUAL MT103 Fig. 1 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.
TECHNICAL MANUAL MT103 Tab. 1 SETTING SPRINGS 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. 204/A/FO Pilot setting springs Code Colour Setting range in bar...
TECHNICAL MANUAL MT103 INSTALLATION 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;...
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TECHNICAL MANUAL MT103 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 Sensing line Regulator Control pressure gauge Pilot discharge Bleed cock On/Off valve INSTALLATION AT RIGHT ANGLES...
TECHNICAL MANUAL MT103 Tab. 3 DETAIL OF MULTIPLE TAKE - OFF WITH OF THE IMPULSE TAKE - OFF REFERENCE NUMBERS 1 and 2 Connect to regulators heads 3 and 4 Connect to pilots 5 and 6 Connect 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.
TECHNICAL MANUAL MT103 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.
TECHNICAL MANUAL MT103 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).
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.
TECHNICAL MANUAL MT103 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 is a device (fig.12) 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 HB/97 slam-shut incorporated both with the service regulator or on the one functioning as in-line monitor.
TECHNICAL MANUAL MT103 4.3.1 HB/97 OPERATION (FIG. 13) The cut-off device consist principally of the following parts: • on/off valve (pos. 12); • single action pneumatic actuator (pos. 11); • line-off device (from pos.1 until pos. 10); When there is no pressure, the valve obturator is held in the closed position by the spring, (pos. 13), and rests on the valve seat.
Installation of accelerator is recommended fo use as safety accessory according to Directive 97/23/EC (PED). Two alternative solutions are offered for this safety device associated to Reflux 819/FO regulators: incorporated monitor or in-line monitor. 4.4.1 PM/819 INCORPORATED MONITOR This emergency device (fig.
TECHNICAL MANUAL MT103 4.4.2 IN-LINE MONITOR With this kind of application, the emergency regulator is installed upstream from the service one (Fig. 17). Fig. 17 | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
TECHNICAL MANUAL MT103 4.4.3 Tab. 7 SETTING SPRINGS The REFLUX 819 regulator and the monitor PM/819 uses the 204/A, 205/A and 207/A pilots. The regulation range of the different pilots is given in the tables below. Pilot 204/A, 204/A/1 Code Colour Setting range in bar 2701260...
TECHNICAL MANUAL MT103 START UP GENERAL After installation, check that the inlet/output on-off valves, any by-pass and the bleed cock are closed. Before starting up, checking is recommended to ascertain that the conditions of use are in conformity with the specifications of the equipment.
TECHNICAL MANUAL MT103 The list of symbols used and their meanings are listed below: = According to Directive PED Pemax= maximum inlet operating pressure of the apparatus bpe= range of variability of the inlet pressure of the pressure regulator in normal operating conditions PS= maximum pressure which can be supported by the structure of the body of the apparatus in safety conditions Wa= range of setting of the pressure regulator/pilot/pre-regulator which can be obtained using the parts and the setting spring fitted at the moment of testing (without changing any components of the apparatus, that is).
TECHNICAL MANUAL MT103 In installations consisting of two lines, we suggest commissioning one line at a time, starting from the one with the lower set-point, known as the “reserve” line. The set-points of the apparatuses in this line will obviously deviate from those specified in the tables 8 and 9.
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TECHNICAL MANUAL MT103 Rest position (A and B in communication) Safety device Control position (A and C in communication) Chamber with controlled pressure Euvironment with pressure to be checked Fig. 21 B) On devices without the "push" valve (fig. 22) we recommend separately connecting the control head to a controlled auxiliary pressure and repeat the operations described above.
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12) It is recommended check that the flow of the line stops when the slam-shut is tripped manually. Settings of on-line apparatuses consistings Tab. 8 of regulator REFLUX 819/FO + Slam shut + Relief valve Regulator set-point Set-point Set-point...
TECHNICAL MANUAL MT103 COMMISSIONING THE REGULATOR WITH INCORPORATED PM/819 MONITOR AND ACCELERATING VALVE (FIG. 23) If there is also a relief valve in the line, refer to par. 3.1 to check it. Fig. 23 Fig. 23/A 1) Partially open the bleed cock 6. 2) Very slowly open the inlet on/off valve V1.
TECHNICAL MANUAL MT103 COMMISSIONING THE REGULATOR PLUS REFLUX 819 IN-LINE MONITOR WITH SB/82 SLAM- SHUT VALVE (FIG. 24) If there is also a relief valve in the line, refer to par. 3.1 to check it. Fig. 24 Check and adjust the intervention of the slam-shut 7 as follows: A) For slam-shuts connected to the downstream piping by a three-way deviator push valve 11, proceed as follows (fig.
12) It is recommended check that when you operate the slam-shut manually, the flow in the line stops. COMMISSIONING THE REGULATOR PLUS REFLUX 819/FO IN-LINE MONITOR WITH SB/82 SLAM-SHUT VALVE (FIG. 25) If there is also a relief valve in the line, refer to par.
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9) Reduce the setting of the pilot 3 to the selected working value for the service regulator. 10) Check that the REFLUX 819/FO monitor is fully open by controlling the position of the stroke indicator throu- gh the window.
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TECHNICAL MANUAL MT103 Tab. 9: Settings of in-line apparatuses consisting of Regulator REFLUX 819/FO + Monitor + Slam-shut + Relief valve Set-point Set-point Set-point Set-point Set-point Set-point Regulator MONITOR ACCELERATING RELIEF-VALVE SLAM-SHUT Max SLAM-SHUT Min (Pas) bar VALVE Pas x 1.1 Pas x 1.2...
Tampering with the apparatuses by unsuitable personnel relieves us from all responsibility of any kind. You must therefore train your maintenance personnel or avail yourself of the service centres officially authorised by us. REFLUX 819/FO REGULATOR (FIG. 26, 27 and 28) Tab. 10 PROBLEM POSSIBLE CAUSES...
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TECHNICAL MANUAL MT103 Tab. 10 REGULATOR (FIG. 26-27 and 28) PROBLEM POSSIBLE CAUSES APPARATUS REMEDY Reinforced gasket [7] damaged Replace Tightness Obturator guide ring [35] damaged Replace Regulator (Fig. 26) failure Q=0 Ice formation between the seat and the plug Increase the gas inlet temperature to the regulator Diaphragm [20] ruptured...
TECHNICAL MANUAL MT103 Tab. 11 PM/819 MONITOR (FIG. 29 and 30) PROBLEM POSSIBLE CAUSES APPARATUS REMEDY Guide ring [20] damaged R14/A Pre-regulator Replace Diaphragm [10] ruptured (fig. 30) Replace Obturator [17] damaged Replace Obturator [17] stuck in the open position 204/A Pilot (fig.
TECHNICAL MANUAL MT103 Tab. 12 SB/82 SLAM-SHUT (FIG. 31) PROBLEM POSSIBLE CAUSES REMEDY Slam-shut obturator Control head diaphragm [4] broker Change diaphragm does not close Leakage from Seal of obturator [40] deteriorated Change seal slam-shut obturator Seat of obturator deteriorated Change the seat Seal by-pass deteriorated Change seal...
TECHNICAL MANUAL MT103 MAINTENANCE GENERAL Periodical inspection and maintenance shall be carried out according to the regulations in force (kind and frequencies). Before carrying out any operation it is important to ascertain that the regulator has been cut off both upstream the regulator and the on/off valves.
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TECHNICAL MANUAL MT103 Procedure for disassembing, completely changing the spare parts, and reassembling of REFLUX 819/FO pressure regulator with 204/A/FO + R14/A/FO pilot (PREVENTATIVE PROGRAMMED MAINTENANCE) PRELIMINARY OPERATIONS Put the regulator into conditions of safety; Ensure that the upstream and downstream pressures are 0.
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TECHNICAL MANUAL MT103 19) Reassemble the guide rod, pos. 20) Reassemble the bottom cover, pos. , on the obturator guide, pos. , remembering to align the downstream sensing line hole properly. 21) Reassemble and fix the screws, pos. 22) Reassemble and fix the screws of the diaphragm-holder assembly, remember to align the hole for the transfer nozzle.
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TECHNICAL MANUAL MT103 DISASSEMBLING GROUP PILOT 46) Disconnet the connectors between the pilot 204/A/FO and the preregulator R14/A/FO, unscrewing the tapered seal connectors. DISASSEMBLING THE PILOT 204/A/FO (Fig. 27) 47) Slacken the lock nut 48) Slacken the adjustment screw for its complete stroke by turning it anticlockwise. 49) Removethe pilot plug 50) From the pilot, remove the spring support , the spring...
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TECHNICAL MANUAL MT103 REASSEMBLING THE PRE-REGULATOR R14/A/FO 75) Reassemble the shaft-filter guide assembly. 76) Screw in the pre-regulator plug 77) Reassemble the diaphragm-obturator assembly. 78) Reassemble the spring and the diaphragm-obturator assembly and fix the cover , securing the screws REASSEMBLING THE PILOT ASSEMBLY 79) Reconnect the connectors between the pilot 204/A/FO and the pre-regulator R14/A/FO screwing in the tapered seal connectors.
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TECHNICAL MANUAL MT103 204/A + R14/A PILOT DOWNSTREAM PRESSURE INLET R 14/A PILOT FEED Fig. 30 | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 PM/819 MONITOR (FIG. 29) Disconnect the connection pipes between the regulator and monitor and the respective pilot units, and between the latter and the downstream pressure take-offs. Remove the screws which secure the reduction assembly of the monitor to the body, making sure that the weight of the reduction assembly itself can be sustained.
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TECHNICAL MANUAL MT103 DISASSEMBLING THE 204/A PILOT (FIG. 30) Slacken the lock nut Slacken the adjustment screw for its complete stroke by turning it anticlockwise. Remove the pilot plug Remove the spring support , the spring and the spring support from the pilot.
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TECHNICAL MANUAL MT103 27) From the pre-regulator body , remove the pre-regulator plug , the reinforced gasket the filter , the obturator guide and the guide ring 28) Clean and carefully check that the obturator is in a good state. 29) Replace all the components which are part of the spare parts kit.
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TECHNICAL MANUAL MT103 DB/819 SILENCER (FIG. 31) Slacken and remove the screws, pos. , and detach the motorization head from the main body. Unscrew the eyebolts und nuts, pos. , and raise the flange, pos. From the sleeve, pos. , remove the complete grill, pos. , the reinforced gasket, pos.
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TECHNICAL MANUAL MT103 SB/82 SLAM-SHUT (FIG. 31 and 32) Check that the slam-shut is in the closed position. Disconnect the pipe between the downstream pressure take-off and the head of the slam-shut pressure switch. Slacken the fixing screws, pos. , so as to partially slacken the spring, pos. ;...
TECHNICAL MANUAL MT103 FINAL OPERATIONS TIGHTNESS AND SETTING CHECK Very slowly open the on/off valve upstream from the regulator and, using a foam solution or the like, check: • the tightness of the external surfaces of the regulator and of the pilot; •...
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TECHNICAL MANUAL MT103 Tab. 13 MAINTENANCE WRENCHES FOR REFLUX 819/FO PRESSURE REGULATORS WITH 204/A/FO AND R14/FO PILOT Combination spanner Adjustable spanner Compass pin wrench Box spanner Hexagon or allen key Hexagonal T key Hexagonal socket T wrench Phillips screwdriver Flat head screwdriver...
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TECHNICAL MANUAL MT103 Tab. 14 MAINTENANCE WRENCHES FOR REFLUX 819/FO PRESSURE REGULATORS WITH 204/A/FO AND R14A/FO PILOT Combination spanner Adjustable spanner Compas pin wrench Box spanner Hexagon or allen key Hexagonal tee key Hexagonal socket T wrench Phillips screwdriver Flat head screwdriver...
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TECHNICAL MANUAL MT103 VERSIONS VERSION DN: 6” - 10” Fig. B VERSION DN: 1” Fig. C VERSION DN: 4” Fig. D VERSION DN: 6” ÷ 10” Fig. E | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 N. OF PIECES 1” ÷ 4” 6” 8” 10” POS. DESCRIPTION Reinforced gasket O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring Diaphragm Guide ring Guide ring Reinforced gasket O.
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TECHNICAL MANUAL MT103 VERSIONS VERSION VERSION DN: 8” DN: 10” Fig. G Fig. H N. OF PIECES 1” ÷ 4” 6” 8” 10” POS. DESCRIPTION Gum gasket Gum gasket O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O.
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TECHNICAL MANUAL MT103 VERSIONS VERSION VERSION DN: 10” DN: 1” VERSION VERSION DN: 3” - 4” DN: 6” ÷ 10” VERSION DN: 6” ÷ 10” | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 N. OF PIECES 1” ÷ 4” 6” - 8” 10” POS. DESCRIPTION O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring Diaphragm Guide ring O. Ring O.
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TECHNICAL MANUAL MT103 N. OF PIECES 1” 2” ÷ 3” 4” ÷ 8” 10” POS. DESCRIPTION Reinforced gasket Guide ring Guide ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring MOD. 102-103-104-105-106-107-108-109 N. OF PIECES POS. DESCRIPTION O.
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TECHNICAL MANUAL MT103 VARIANTE DN: 6” - 8” - 10” N. OF PIECES 4” 6” 8” 10” POS. DESCRIPTION Reinforced gasket O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring Guide ring O. Ring GACO ring Guide ring O.
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TECHNICAL MANUAL MT103 LINE OFF DEVICE PART. A Three-ways valve PART. B Filter PART. C Pressure regulator PART. D Relief valve PART. E Slide valve PART. F Control device | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 PART. B FILTER PART. B POS. DESCRIPTION N. OF PIECES Filter cartridge O. Ring O. Ring PART. D RELIEF VALVE PART. D POS. DESCRIPTION N. OF PIECES Plug | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 CONTROL HEAD Mod.: 103 MOD. 103 N. OF PIECES POS. DESCRIPTION Diaphgram Mod.: 104-105 MOD. 103-105 N. OF PIECES POS. DESCRIPTION O. Ring | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 PILOTS MOD. 204/A/FO-204/A/2CS/FO-205/A/FO 204/A/2CS/FO 204/A/FO-205/A/FO POS. DESCRIPTION N. OF PIECES 204/A/FO 205/A/FO 204/A/2CS/FO O. Ring Diaphragm Plug O. Ring O. Ring O. Ring O. Ring O. Ring | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 PRE-REGULATOR R14/A/FO DOWNSTREAM PRESSURE PILOT FEED INLET POS. DESCRIPTION N. OF PIECES Guide ring Reinforced gasket Diaphragm Filter O. Ring O. Ring O. Ring O. Ring | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 204/A PILOT POS. DESCRIPTION N. OF PIECES 204/A 205/A 204/A/2/CS 204/A/1/CS 204/A/MO O. Ring Diaphragm Obturator O. Ring O. Ring O. Ring O. Ring O. Ring O. Ring | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 R14/A PRE-REGULATOR INLET DOWNSTREAM PRESSURE PILOT FEED POS. DESCRIPTION N. OF PIECES Guide ring Reinforced gasket Diaphragm Filter O. Ring O. Ring O. Ring O. Ring | sales@mvandc.com | Phone: 877.566.3837 | Fax: 925.407.2903 www.mvandc.com...
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TECHNICAL MANUAL MT103 WHEN ORDERING SPARE PARTS, PLEASE SPECIFY: FOR REGULATORS Type of regulator Dne (nominal input diameter) Pe (inlet pressure) Pa (outlet pressure) Works no. (Serial no.) Year of manufacture Type of fluid used Slam-shut (if assembled) Type of control head The no.
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TECHNICAL MANUAL MT103 The data are not binding. We reserve the right to make modifications without prior notice. Pietro Fiorentini S.p.A. OFFICES: I-20124 MILANO Italy - Via Rosellini, 1 - Phone +39.02.6961421 (10 linee a.r.) - Fax +39.02.6880457 E-mail: sales@fiorentini.com I-36057 ARCUGNANO (VI) Italy - Via E.
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