Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 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 –...
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 6.5 PROCEDURE FOR ASSEMBLY REGULATOR URANO SO (FO) ...................... 50 6.6 PROCEDURE FOR REMOVAL THE PILOT G-40 / 42 ........................50 6.7 PROCEDURE FOR ASSEMBLY THE PILOT G-40 / 42 ........................53 6.8 PROCEDURE FOR REMOVAL BOOSTER (PRE-EGULATOR) G-43 ....................
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.
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...
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...
4” 6” 8” 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 WORKING PRESSURE 150# 300# 600# 900# PN 25...
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 2.3.8 ACCURACY AND LOCK 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).
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano FIGURE 1 - URANO FAIL CLOSED Elaborate Verified / Approved Date Review Page Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/14 04 9 de 61...
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 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).
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano FIGURE 2 - URANO FAIL OPEN Elaborate Verified / Approved Date Review Page Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/14 04 11 de 61...
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 3.3 BOOSTER (G-43 & G-44) The Booster is nothing more than a pre regulator that automatically adjusts the process conditions depending on input pressure and output, and aims to reduce the pilot inlet pressure, causing it to operate in a milder condition, thus eliminating any chance of interference on the regulator pilot by the input pressure variation.
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 3.4 PILOTS (G-40 & G-42) The number of drivers G-40 and G-42 is comprised of dual diaphragm pilot that can achieve much higher precision adjustment to other drivers due to their constructional characteristics. Pilots are responsible for sending the exact loading pressure for pressure regulating valves open or close under normal process conditions by the balance between the force of the regulating spring and the outlet pressure received by the sensor outlet.
Pressure Regulating Valve – Model Urano 3.5 FILTERS The GASCAT called pilot blocks consisting of pilot regulator and pre always possess a mechanical barrier against solid impurities, the barrier comprises filter elements polypropylene filtration degree of 10 microns. This barrier aims to prevent solid contaminants in the pipe can clog or damage the internal pre regulator and the pilot,...
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano The URANO regulators operating in the active monitor system exactly as described 3.1 and 3.2 of this manual, but as can be seen in the previous scheme the sensor making the SC controller (FF) is downstream controller active OS (FA) and its set-point must be adjusted to a slightly higher pressure to the set-point controller active (5% - 10% depending on the application).
1) The equipment is in perfect condition or has function in damaged evidence in the handling during transport, if you have a fault not proceed with the installation and contact the GASCAT. 2) The area in which access and installation of the equipment is suitable, including for future maintenance.
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 4.4 SENSE The correct positioning of making impulse in the pipeline is essential for the proper functioning of the throttle valve, therefore install the pilot impulse outlet regulator downstream at a minimum distance of 5 times the nominal pipe diameter and stretch obstruction-free pipe with a pipe diameter where the gas flow rate does not exceed the maximum speed of 25 m / s (considering the lower output pressure and the maximum flow).
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Each throttle model URANO OS (FA) requires two connections to the process: one directly below the pilot and a second that will serve as unloading the actuator under the diaphragm. UNLOADING LINE SENSING LINE PILOT FRONT VIEW REAR VIEW IMAGE URANO FA Elaborate Verified / Approved Date Review Page Raphael Pereira Vanízio Lizo...
4 – Automatic shut-off valve for over pressure (SSV) 9- Output block valve 5 – Pressure regulator valve model URANO GASCAT Note: The position indicated for the sensor outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT.
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2) Pneumatic signal of better quality (stable). 3) Reduction of damage to tubbings during maintenance and transport. Note: The position indicated for lung outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Elaborate Verified / Approved...
11 – Output block valve 6 – Intermediate gauge manifold 2 ways Note: The position indicated for the sensor outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Elaborate Verified / Approved...
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2) Pneumatic signal of better quality (stable). 3) Reduction of damage to tubbings during maintenance and transportation. Note: The position indicated for lung outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Elaborate Verified / Approved...
5 – Automatic shut-off valve for over pressure (SSV) 10 – Output block valve Note: The position indicated for the sensor outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Elaborate Verified / Approved...
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2) Pneumatic signal of better quality (stable). 3) 3) Reduction of damage to tubbings during maintenance and transportation. Note: The position indicated for lung outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Elaborate Verified / Approved...
7) Make sure the SSV is in the closed position. ATTENTION: The SSV GASCAT are sent to the already calibrated field, however due to the conditions of carriage and operation of any equipment the valve may have its set-point change.
URANO model regulator commissioning a simple adjustment line, considering that the recommendations made in section 4.6.1 of this manual have been properly observed. The procedure in question considers the use of GIPS-FC GASCAT model valves as a safety device. 1) Fec Close the vent valve.
PS x 1,250 Note: The values in this table are recommendations based on best practices, but it is not prohibited the use of set- points in different groups of informed upon review and approval of GASCAT. Elaborate Verified / Approved...
URANO model in a stretch where the monitor active configuration is being adopted, considering that the recommendations made in section 4.6.1 of this manual now were noted.. The procedure in question considers the use of valves GIPS-FC GASCAT model and throttle model URANO SC (FF) GASCAT as safety devices.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 7) Once the actuator SSV is already pressurized, release the by-pass valve and proceed with the disengagement of the actuator of the SSV. 8) Reset the shutter GIPS-FC block valve, through the reset lever. 9) Open the vent valve at 20%, make sure the pressure will continue in pre-set value.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano POSITION INDICATOR 17) After that we will now have the active valve operation and monitors wide open waiting for a possible failure on the part of the active valve for operation as shown below: 18) If the pressure is oscillating perform a fine adjustment by opening or closing the discharge valve.
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 22) Note that in an active monitor the line closing pressure system will be given by always monitor regulator, because as we can see in the above scheme taking monitor regulator unloading will be taken downstream coupled to the active valve, so the pilot valve monitors will remain open, until it receives the corresponding pneumatic signal to close, this pneumatic signal is equivalent to valve closing pressure monitors.
GASCAT. 4.6.6 LIST OF RECOMMENDED TOOLS To perform the adjustment set-point commissioning and start-up of regulatory URANO GASCAT the model is required only the use of a combination wrench 7/8 "to adjust the regulation of pilots springs.
(impurities), natural wear and failures during operation of the equipment. It is important to keep in mind that the operation and maintenance of GASCAT equipment must be only carried out by highly qualified and trained personnel, preferably by staff trained by GASCAT instructors.
Before starting maintenance pressure regulators in GASCAT always make sure to have a replacement kit with original parts GASCAT as well as this instruction manual for reference and how to safely and efficiently while maintaining the equipment.
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 6.2 PROCEDURE FOR REGULATOR DESMONATAGEM URANO SC (FF) 1) Before proceeding with the disassembly of the equipment check if all the conditions set out in item 4.6.1 of this manual were observed.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano Note: Note that the diaphragm of the main valve of URANO model controller is shaped and the convex surface tends to face up this assembly, because the more pressure will be in the lower chamber of the actuator. 8) Release the screws (pos 10) of the lower diaphragm plate (item 37), thus releasing the diafragma (pos 2).
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 11) Remove the intermediate screws (pos 12) and release the intermediate (pos 32). 12) Remove the closing spring (pos 1) 13) Remove the piston (item 47) releasing the piston bushing (pos 49) 14) To remove the seat start releasing the lower body cover (pos 45) by removing the screws (pos 12).
Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 2) Remember to lubricate the o-rings with a thin layer of grease during the valve assembly process and the rod, the piston and the static parts to reduce friction between these components. 3) During assembly screws (pos 13) on the diaphragm plate using chemical latch on the threads in order to improve the fixation of parts.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 7.3) Remove the diaphragm assembly. Note: Note that the diaphragm of the main valve of URANO model controller is shaped and the convex surface tends to be turned down in this assembly, because the more pressure will be in the upper chamber of the actuator.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 12) Remove the intermediate screws (pos 15) and release the intermediate (pos 36). 13) Remove the piston locks (pos 16, 14 e 57) 14) Remove the piston or shutter (pos 55), as you can observe the obturator is fully collected in the middle (item 36) and therefore to facilitate removal without damaging the piston is important to proceed as follows: 14.1) Using needle-nosed pliers position the same in the piston holes (pos 55) and pull it at the same time making a turning movement.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 16) To assist in the removal of the spring (item 1) that is tensioned by the pusher (item 50), perform the following procedure: 16.1) position the two locks the shutter (pos 57) upside down on the shaft (item 53) as illustrated below: 16.2) Place the nut (pos 14) on the shaft on the latches (Item 57) and press the opening spring (item 1) until the stop (pos 50) is free spring action.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano To remove the seat start releasing the lower body cover (pos 49) by removing the screws (pos 15 20) Remove the screws (pos 18) and release the shutter (pos 42/43). Note: The regulatory model URANO class 150 #, 300 # and 600 # are factory with two shutters, one gets the trim facing the piston (in use) and the other is kept back-up with the side trim to the other party as evidenced in the illustration below:...
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano The disassembly procedure below references the positions of the components shown in the diagram available in section 6.0 of this manual. 3) Download the pilot regulating spring by turning the set screw (pos 33/30) counter clockwise. 4) Remove the guide adjusting screw (pos 43/38) 5) Remove the regulating spring (pos 50/52) 6) Remove the screws (pos 17/16) and release the sup cover (pos 37/36)
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 11) Remove the diaphragm plate and the lower diaphragm (pos 9/11), turn the steering block to the starting position and proceed with the removal of the plug (pos 35/32). 12) Remove the diaphragm plate (item 36/35) and the upper diaphragm (pos 9/11), 13) Remove the nut (pos 48/50), release the seat (pos 46/48) and the block (pos 44/46) Elaborate...
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 6.7 PROCEDURE FOR PILOT ASSEMBLY G-40/42 To perform the assembly of the G-42 pilot just follow the steps reported in the back disassembly procedure forward starting with the assembly's headquarters, but would like to make two observations on two specific points that must be evaluated thoroughly during the pilot reassembly.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano Marking the body counterclockwise Diaphragm marking between the two Marking the body clockwise 3) diaphragms (pos 9/11) G-42 are shaped pilot therefore have a correct mounting position and it should be observed during the assembly of the pilot, as follows: Mounting position diaphragm lower...
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 1) Remove the cover (pos 39) and the diaphragm assembly (item 28). 2) Lock the shaft (pos 28), release the nut (pos 11), remove the disc springs (pos 12) and the lower diaphragm plate (item 27) to release the diaphragm (pos 10).
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 3) Now let's move to dismantle the bottom of the booster, so the ideal is that it is rotated so that the bottom is face up, made it proceed with the removal of the door trim (pos 45). 4) Remove the filter element (pos 26) and release the trim (item 8) of the door trim (item 45) and their respective o'ring (pos 21).
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 5) Remove the shaft guide (item 40) and the thrust bushing (item 41) 6.9 PROCEDURE FOR BOOSTER ASSEMBLY (PRE REGULATOR) G-43 To perform the assembly of the booster G-43 just follow the steps reported in the back disassembly procedure forward starting with the assembly's headquarters, but would like to make some observations on some specific points that must be evaluated thoroughly during reassembly of the booster.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 6.10 PROCEDURE FOR BOOSTER OF REMOVAL (PRE REGULATOR) G-44 1) Before proceeding with the disassembly of the equipment check if all the conditions set out in item 4.6.1 of this manual have been observed.
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 2) Remove the shaft booster (Item 34)) 3) Release the diaphragm (Item 10) by releasing the lower diaphragm plate (item 43). 4) Now let's move to dismantle the bottom of the booster, so the ideal is that it is rotated so that the bottom is face up, made it proceed with the removal of the door trim (pos 47).
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This internal relief is adjusted by compressing the spring (pos 4) during assembly of the diaphragm assembly axis (Pos 34), in that during assembly it is important to pay attention to the adjustment of this spring, the GASCAT recommends an expulsion 14.4 14.5 mm from the lower diaphragm plate (item 43), but if the operator does not...
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Installation Manual, Maintenance and Operation MI-31 Pressure Regulating Valve – Model Urano 2) After installation of all internal booster, when be performed at its closure, by placing the cover and screws (pos 12), we recommend that during tightening of the diaphragm assembly screws being pushed through with a key allen the upper plug (pos 8) so that the diaphragm can be adequately clamped between the lid and the body of the booster.
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