Page 5
TECHNICAL MANUAL MT050 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).
Page 6
(gas/air) inside the piping must be considered. CONFORMITY TO DIRECTIVE 2014/68/EU Pressure regulators series Reflux 819 are classified as fail close regulator according to the standard EN 334 therefore they are categorized as safety accessories acording to directive 2014/68/EU.
MAIN FEATURES The Reflux 819 pressure regulator is a regulator of the piloted type for medium and high pressures. The Reflux 819 is a fail close type regulator and therefore closes in the event of: - rupture of the main diaphragm;...
Page 10
TECHNICAL MANUAL MT050 Connections to be made by the customer Ref. No. for the connections Fig. 1 The set-point can be changed by turning the adjustment screw 10; clockwise rotation increases Pm and therefore the regulated pressure, Pa; the opposite occurs when the ring is turned anticlockwise. If, for example, the downstream 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.
Page 11
TECHNICAL MANUAL MT050 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 between the chambers E and D through the orifice 21, and the force exerted by the spring 54 causes the downward dis- placement of the obturator 5, to restore the regulated pressure to the set-point.
TECHNICAL MANUAL MT050 SETTING SPRINGS The Reflux 819 regulator uses the 204/A, 205/A, and 207/A pilots. The regulation range of the different pilots is given in the tables below. Tab. 1 Pilot 204/A, 204/A/1 Code Colour Setting range in bar...
TECHNICAL MANUAL MT050 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;...
Page 14
TECHNICAL MANUAL MT050 TAB. 4 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 Control pressure gauge Regulator Downstream connection Bleed clock On/Off valve INSTALLATION AT RIGHT ANGELS...
TECHNICAL MANUAL MT050 TAB. 5 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 MT050 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.
Fig. 6 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 2014/68/EU).
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 regulator, it is possible to have the SB/82 slam-shut incorporated both with the service regu- lator and on the one functioning as in-line monitor.
TECHNICAL MANUAL MT050 4.2.1 SB/82 SLAM-SHUT OPERATION (FIG. 9) 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 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 MT050 4.3.1 HB/97 SLAM-SHUT 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.
The monitor is an emergency regulator which comes into operation to replace the service regulator if for any reason the latter permits the down-line pressure to rise up to the value set for its intervention. When pressure regulator Reflux 819 or incorporated monitor PM/819 are used as monitor, to increase response time an accelerato is installed.
TECHNICAL MANUAL MT050 4.4.2 IN-LINE MONITOR With this kind of application, the emergency regulator is installed up-line from the service one (fig.17 and 18). Fig. 17 Heating system for pilot system Connection to be made by the customer Connection without heat exchanger in the pilot supply Fig.
TECHNICAL MANUAL MT050 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 MT050 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 MT050 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 9 and 10.
TECHNICAL MANUAL MT050 COMMISSIONING THE REGULATOR WITH INCORPORATED SB/82 SLAM-SHUT (FIG. 22) If there is also a relief valve in the line, refer to par. 3.1 to check it. Fig. 22 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.
Page 32
TECHNICAL MANUAL MT050 Rest position (A e B in communication) Controll position (A e C in communication) Chamber with controlled pressure Safety device Room with pressure to be checked Fig. 23 B) On devices without the "push" valve (fig. 24) we recommend separately connecting the control head to a controlled auxiliary pressure and repeat the operations described above.
Page 33
10) It is recommended check that the flow of the line stops when the slam-shut is tripped manually. Setting ofon-line apparatuses consistings Tab. 9 of regulator REFLUX 819 + Slam-shut + relief valve Regulator set-point Set-point Set-point...
TECHNICAL MANUAL MT050 COMMISSIONING THE REGULATOR WITH INCORPORATED PM/819 MONITOR AND ACCELERATING VALVE (FIG. 25) If there is also a relief valve in the line, refer to par. 3.1 to check it. Fig. 25/A Fig. 25 1) Partially open the bleed cock 6. 2) Very slowly open the inlet on/off valve V1.
TECHNICAL MANUAL MT050 COMMISSIONING THE REGULATOR PLUS REFLUX 819 IN-LINE MONITOR WITH SB/82 SLAM-SHUT VALVE (FIG. 26) If there is also a relief valve in the line, refer to par. 3.1 to check it. Fig. 26 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.
Page 36
7) Reduce the setting of the pilot 3 to the selected working value for the service regulator. 8) Check that the REFLUX 819 monitor is fully open by controlling the position of the stroke indicator through the window.
TECHNICAL MANUAL MT050 TROUBLE-SHOOTING The problems of various kinds which could arise over time are highlighted below. They derive from phenomena associated with the conditions of the gas as well, of course, as the natural ageing and wear of the materials. It must be remembered that all operations on the apparatuses must be carried out by highly qualified personnel with appropriate knowledge of the subject.
Page 38
TECHNICAL MANUAL MT050 PROBLEM POSSIBLE CAUSES APPARATUS REMEDY Reinforced gasket [7] damaged Replace Replace Obturator guide ring [35] damaged Tightness failure Q=0 REGULATOR (Fig. 27) Ice formation between the seat and the plug Increase the gas inlet tem. to the regulator Diaphragm [20] ruptured R14/A...
TECHNICAL MANUAL MT050 TAB. 12 SB/82 SLAM-SHUT (FIG. 35) PROBLEM POSSIBLE CAUSES REMEDY Slam-shut obturator does not close Diaphragm [4] in sensing device broken Change diaphragm Seal of obturator [40] deteriorated Change seal Leakage from slam-shut obturator Seat of obturator deteriorated Change the seat Seal by-pass [19] deteriorated Change seal...
TECHNICAL MANUAL MT050 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.
Page 42
TECHNICAL MANUAL MT050 204/A + R14/A PILOT DOWNSTREAM INLET PRESSURE PILOT FEED Fig. 28...
Page 43
TECHNICAL MANUAL MT050 Procedure for disassembing, completely changing the spare parts, and reassembling of REFLUX 819 pressure regulator with 204/A + R14/A pilot (PREVENTATIVE PROGRAMMED MAINTENANCE) PRELIMINARY OPERATIONS Put the regulator into conditions of safety; Ensure that the upstream and downstream pressures are 0.
Page 44
TECHNICAL MANUAL MT050 REASSEMBLING THE REGULATOR SERVOMOTOR UNIT Remember that the O-rings and the sliding mech-anical parts (rods, etc.) must be lightly lubricated, before reassembly, with a fine layer of silicone grease, while static parts require grease to make them softer but mainly to hold them in their slots: 19) Reassemble the guide rod, pos.
Page 45
TECHNICAL MANUAL MT050 REASSEMBLING THE REGULATOR REGULATION UNIT Remember that the O-rings and the sliding mechanical parts (rods, etc.) must be lightly lubricated, before reassembly, with a fine layer of silicone grease, while static parts require grease to make them softer but mainly to hold them in their slots: 42) Reassemble the reinforced gaskets, pos.
Page 46
TECHNICAL MANUAL MT050 REASSEMBLING THE PILOT 204/A 59) On the pilot body , reassemble the shaft of the valve seat , putting the diaphragm support between them. 60) Screw the lock unit 61) Reassemble the bottom diaphragm , the protection disc and screw in the pilot lock nut 62) Insert the pilot obturator , the spring...
Page 49
TECHNICAL MANUAL MT050 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.
Page 51
TECHNICAL MANUAL MT050 DB/819 SILENCER (FIG. 30) 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.
Page 53
TECHNICAL MANUAL MT050 MOD. 102 -106 MOD. 103 -106 MOD. 104 -107 MOD. 105-108 - 109 Fig. 32 SB/82 SLAM-SHUT (FIG. 31) Check that the slam-shut is in the closed position. Disconnect the pipe between the downstream sensing line take-off and the head of the slam-shut pressure switch.
TECHNICAL MANUAL MT050 RE-ASSEMBLY 12) Fit the cover, pos. , and fix the screws, pos. on the pressure switch device. 13) Put back the shaft guide, pos. and fix with the retaining ring, pos. 14) Put back the spring, pos. and the ring, pos.
Page 55
TECHNICAL MANUAL MT050 Tab. 13 MAINTENANCE WRECHES FOR REFLUX 819 PRESSURE REGULATORS WITH 204/A AND R14/A 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...
Page 56
TECHNICAL MANUAL MT050 Tab. 14 MAINTENANCE WRENCHES FOR REFLUX 819 PRESSURE REGULATORS WITH 204/A AND R14/A 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...
Page 60
TECHNICAL MANUAL MT050 VERSIONS VERSION VERSION DN: 10” DN: 6” ÷ 10” VERSION VERSION DN: 3” - 4”- 10” DN: 6” - 8” VERSION VERSION DN: 3” - 4” DN: 6” ÷ 10”...
Page 61
TECHNICAL MANUAL MT050 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 O. Ring Diaphragm Guide ring Guide ring...
Page 63
TECHNICAL MANUAL MT050 VERSIONS VERSION VERSION DN: 10” DN: 8” 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. Ring O. Ring Metal gasket DB 819 N.
Page 65
TECHNICAL MANUAL MT050 VERSIONS VERSION VERSION DN: 1” DN: 10” VERSION VERSION DN: 3” - 4” DN: 6” ÷ 10” VERSION DN: 6” ÷ 10”...
Page 66
TECHNICAL MANUAL MT050 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.
Page 68
TECHNICAL MANUAL MT050 VERSIONS VERSION DN: 4” - 6” - 8” VERSION DN: 10”...
Page 69
TECHNICAL MANUAL MT050 VERSIONS SECTION A - A VERSION VERSION DN: 1”÷ 4” DN: 1” ÷ 4” SECTION B - B VERSION VERSION DN: 6” - 8” - 10” DN: 6” - 8” - 10”...
Page 72
TECHNICAL MANUAL MT050 N. OF PIECES 1” ” ÷ 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.
Page 74
TECHNICAL MANUAL MT050 VERSION 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.
Page 75
TECHNICAL MANUAL MT050 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...
Page 76
TECHNICAL MANUAL MT050 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...
Page 77
TECHNICAL MANUAL MT050 Part. F CONTROL DEVICE Mod.: 103-104-105 Mod.: 105/92...
Page 78
TECHNICAL MANUAL MT050 Mod.: 103 N. OF PIECES POS. DESCRIPTION Diaphgram Mod.: 104-105 N. OF PIECES POS. DESCRIPTION O. Ring...
Page 79
TECHNICAL MANUAL MT050 204/A PILOT N. OF PIECES POS. DESCRIPTION 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...
Page 80
TECHNICAL MANUAL MT050 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...
Page 81
TECHNICAL MANUAL MT050 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.
Page 83
TECHNICAL MANUAL MT050 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.
Need help?
Do you have a question about the Reflux 819 and is the answer not in the manual?
Questions and answers