If there are any questions or ambiguities that affect the proper procedures ask Gascat Ind. e Com. Ltda., who will be pleased to advise or provide the relevant service or instruction. TAKE NO RISKS. Our phone, fax and e-mail numbers are the following: Gascat Indústria e Comércio Ltda.
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve All regulators, shutoff valves, relief valves, etc., must be installed with the correct flow direction. Impulse lines are important components of any control system, and their proper installation is essential, with no isolation valves.
100 bar) and PED 68/2014/EU, the DVGW certificates and reports are available for consultation at GASCAT. If any of these documents is required for your application, please contact our Head office in Indaiatuba and request the necessary copies.
1) Approximate weights given in kilograms (Kg) 2) Consider the body in carbon steel SA-216 WCB 3) For exact weight contact GASCAT for weight confirmation of the chosen model. 4) For models with integrate SSV, to add 12Kg in the weight.
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 2.3.6 MAXIMUM WORK PRESSURE 150# 300# 600# 900# PN 25 PN 40 19 bar 51 bar 100 bar 150 bar 25 bar 40 bar The pressure limits given in this manual or in any applicable standard shall not be exceeded under any circumstances, under risk of damage to the equipment, to the installation safety, and to people involved in the operation.
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve Pressure Regulator: AC up to 1% / SG up to 5%. SSV: AG up to 5% 2.3.10 PRESSURE REGULATOR DIMENSIONS DIMENSIONS (mm) A (RF) 300# / 150# / PN25, 600# 900# PN16 CLASS...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 3.1 REGULATOR SPRING TO CLOSE (FAIL CLOSE) During pressure absence, shutter (A) is kept in closed position by the shutting spring (B), which keeps it pressed against the soft seat (C). It stands out that even when subject to pressure, upstream pressure variations have no influence on the shutter position, due to the balancing of the forces acting on the same, as well as on the actuator shaft (D) that is also balanced.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve FIGURE 1 - URANO FAIL CLOSE Elaborado Verificado / Aprovado Data Revisão Página 05/07/21 10 de 74...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 3.2 REGULATOR SPRING TO OPEN (FAIL OPEN) During pressure absence, shutter (A) is kept in the open position by the main regulator (B) spring, which keeps it away from the gasket (C). It stands out that even when subject to pressure, upstream pressure variations have no influence on the shutter position, due to the balancing of the forces acting on the same, as well as on the actuator shaft (D) that is also balanced.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve FIGURE 2 - URANO FAIL OPEN Elaborado Verificado / Aprovado Data Revisão Página 05/07/21 12 de 74...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 3.3 BOOSTER (G-43 & G-44) The Booster is nothing more than a pre-regulator that automatically adjusts the process conditions as a function of the input pressure and output pressure with the purpose of reducing the pilot inlet pressure, allowing the pilot to operate in a milder condition, thus eliminating any chance of interference on the regulator piloting by the input pressure variation.
3.5 FILTERS The GASCAT pilot blocks, consisting of a pilot and pre-regulator always have a mechanical barrier against solid impurities; this barrier comprises a polypropylene filter element of 10-micra filtration grade. This barrier is intended to prevent that solid contaminants contained within the pipework can clog or damage the internal parts of pre-regulator and of the pilot.
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve The Urano pressure regulators can be provided with an F-10 filter mounted in separate from the pilot unit, or in a compact version, with the filter element already coupled to the pre-regulator. 3.6 SECURITY SHUT-OFF VALVE 3.6.1 ACTUATOR PH &...
Reset Lever Figure 1 Figure 2 The SSV is supplied in the closed position and with the actuator of under pressure blocking disarmed. The springs for over and under pressure blocking are adjusted in Gascat. Elaborado Verificado / Aprovado Data Revisão...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 3.7 ACTIVE MONITOR ASSEMBLY The so-called active monitor installation configuration is largely used in natural gas distribution and transmission. This configuration is usually adopted when the difference between the inlet pressure and the outlet pressure is greater than 16 bar and the downstream piping stress test pressure, and the stress pressure of the other components downstream of the regulator is smaller than the specified inlet pressure, for example, as given in DIN EN 12186.
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1) The equipment is in perfect conditions, or it has evidence of damage during transportation. If so, do not proceed with the installation and contact GASCAT. 2) The space provided for access and installation of the equipment is adequate for future maintenance.
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 4.4 IMPULSE PICK-UP The correct positioning of the impulse pick-up in the pipeline is essential for proper operation of the pressure regulator valve. Therefore, install the pilot impulse pick-up downstream of the regulator at a minimum distance of 5 times the nominal pipe diameter, in a pipe span free of obstruction with a pipe diameter where the gas outflow does not exceed the maximum speed of 25 m/s (considering the smallest outlet pressure and the maximum flow rate).
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Each pressure regulator model URANO SO (FA) requires two connections to the process: one directly below the pilot and a second that will serve for unloading the actuator under the diaphragm. DISCHARGE OUTLET PILOT SENSOR OUTLET FRONT VIEW FRONT VIEW IMAGE OF URANO FA Elaborado Verificado / Aprovado Data Revisão Página 05/07/21 21 de 74...
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Urano - Pressure Regulating Valve Note: The position indicated for the sensor pick-up may be less than 5D if the installation project is analyzed and approved by GASCAT’s engineering. 5 x ND Another recommended installation option is to use a pneumatic lung to connect sensor pick-ups taken near the equipment.
MI-31 Urano - Pressure Regulating Valve Note: The position indicated for the lung pick-up may be less than 5D if the installation project is analyzed and approved by GASCAT’s engineering. 4.5.2 ACTIVE MONITOR SYSTEM 5xND 1 - Inlet blocking valve.
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Urano - Pressure Regulating Valve Note: The position indicated for the sensor pick-up may be less than 5D if the installation project is analyzed and approved by GASCAT’s engineering. 5xND Another recommended installation option is to use a pneumatic lung to connect sensor pick-ups taken near the equipment.
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Urano - Pressure Regulating Valve 3) Reduced damage to tubing during maintenance and transportation. Note: The position indicated for the sensor pick-up may be less than 5D if the installation project is analyzed and approved by GASCAT’s engineering. Elaborado Verificado / Aprovado Data Revisão...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 4.5.3 TWO SSV AND ONE FF REGULATOR 5xND 1 - Inlet blocking valve. 6 - Pressure regulating valve URANO 2 - Cartridge type filter of 5 micra filtration degree 7 - Partial relief valve 3 - Inlet pressure gauge + 2-way manifold 8 - Outlet pressure gauge + 2-way manifold 4 - Automatic overpressure Slam Shut Valve (SSV)
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Urano - Pressure Regulating Valve Note: The position indicated for the sensor pick-up may be less than 5D if the installation project is analyzed and approved by GASCAT’s engineering. 5xND Another recommended installation option is to use a lung to connect sensor pick-ups taken near the equipment.
MI-31 Urano - Pressure Regulating Valve Note: The position indicated for the lung pick-up may be less than 5D if the installation project is analyzed and approved by GASCAT’s engineering. 4.6 COMMISSIONING AND START-UP 4.6.1 GENERAL RECOMMENDATIONS Always, before proceeding with the equipment commissioning it is important to: 1) Check if the equipment is properly installed according to the recommendations of item 4.3 of this...
URANO for a simple regulation span, considering that the recommendations made in section 4.6.1 of this manual have been properly observed. The referred to procedure considers the use of valves model GIPS-FC GASCAT as safety device. 1) Shut-off the vent valve.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve DISCHARGE VALVE 4) SLOW AND GRADUALLY open the inlet shut-off valve, or when the station is provided with a by- pass of the shut-off valve use the same to perform pressurization. 5) Since there is no pressure downstream of the regulator, the blocking valve model GIPS-FC will be in the closed position, hence keep the bypass valve located at the side of the SSV pressed to pressurize the span between the same and the pressure regulator.
PS x 1.150 PS x 1.250 Note: The values given in this table are recommended as the best practices, but it is not forbidden the use different set point ranges upon review and approval by GASCAT. Elaborado Verificado / Aprovado Data Revisão...
4.6.1 of this manual have been properly observed. The referred to procedure considers the use of valves model GIPS-FC GASCAT and pressure regulator model URANO SC (FF) GASCAT as safety devices. 1) Shut-off the vent valve.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 5) Since there is no pressure downstream of the regulator, the blocking valve model GIPS-FC will be in the closed position, hence keep the bypass valve located on the side of the SSV pressed to pressurize the span between the same and the pressure regulator.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 11) If the pressure is oscillating, perform a fine adjustment by opening or closing the discharge valve. 12) Once the pressure has stabilized, open the vent valve by one-half turn and check the adjustment accuracy.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 18) If the pressure is oscillating, perform a fine adjustment by opening or closing the discharge valve. 19) Once the pressure has stabilized, open the vent valve by one-half turn and check the adjustment accuracy.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 22) It is important to note that in an active monitor system the span closing pressure will be always given by the monitor regulator, because as we can see in the diagram above monitor regulator unloading outlet will be coupled to the outlet downstream of the active valve.
GASCAT. 4.6.6 LIST OF RECOMMENDED TOOLS To carry out commissioning set point adjustments and start-up of the GASCAT’s regulators model URANO it is required only the use of a 7/8" combination spanner for setting up the pilot’s adjustment springs.
(impurities), natural wear, and fault during the equipment operation. It is important to keep in mind that the operation and maintenance of GASCAT equipment should only be performed by highly skilled and trained personnel, preferably by teams trained by GASCAT’s instructors.
GASCAT has standard repair kits for each component of the pressure regulator model URANO containing the most likely items to wear with time; this list of components is given in this manual for users guiding.
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Before starting maintenance of GASCAT’s pressure regulators, you shall always assure yourself to have a replacement kit with original GASCAT parts, as well as this instruction manual for reference of how to work safely and efficiently during the equipment maintenance.
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 6.2 PROCEDURE FOR URANO SC (FF) REGULATOR DISASSEMBLY 1) Before proceeding with the equipment disassembly, check if all the conditions set out in item 4.6.1 of this manual have been observed. 2) Under no circumstances start the equipment disassembly if it is pressurized.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 7.3) Remove the diaphragm assembly. Note: Notice that the main valve diaphragm of the regulator model URANO is molded, and the convex surface tends to remain with its face upwards in this assembly, because the higher pressure is applied in the lower chamber of the actuator.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 9) Release the screws (pos 4) and remove the bottom cover of the actuator (pos 31). 10) Pull the actuator guide bushing (pos 42). In order to facilitate this activity use a fine sandpaper as illustrated below: Elaborado Verificado / Aprovado...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 11) Remove the screws of the intermediate (pos 12) and release the intermediate (pos 32). 12) Remove the closing spring (pos 1) 13) Remove the piston (pos 47) releasing the piston sleeve (pos 49) 14) To remove the seat start by releasing the body bottom cover (pos 45) removing its screws (pos 12).
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve Remember to lubricate the O-rings with a thin layer of grease during the valve assembly process, as well as the rod, the piston and the static parts to reduce friction between these components. During screws (pos 13) bolting on the diaphragm plate, use a chemical thread locker in order to improve parts fixing.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 7.2) With a combination spanner remove the upper guide sleeve (pos 45) as illustrated below: 7.3) Remove the diaphragm assembly. Note: Notice that the main valve diaphragm of the regulator model URANO is molded, and the convex surface tends to remain with its face downwards in this assembly, because the higher pressure is applied in the upper chamber of the actuator.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 9) Release the screws (pos 5) and remove the bottom cover of the actuator (pos 35). 10) Pull the actuator guide bushing (pos 46). In order to facilitate this activity use a fine sandpaper as illustrated below: 11) Now we will proceed by releasing of the shutter assembly and the seat.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve the piston, which might be convenient during the process disassembly: The pistons of URANO regulator models of ND 2" to 8" have two threaded holes that allow fixing screws or threaded eyelets, as given in the table below: URANO PISTON THREAD...
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 16.2) Install the nut (pos 14) in the shaft over the locks (pos 57) and press the opening spring (pos 1) until the stop (pos 50) becomes free from the spring action. 17) Proceed with the disassembly of the spring stop (pos 50) by releasing the screws (pos 7).
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve BODY TOP VIEW BODY BOTTOM VIEW 6.5 PROCEDURE FOR URANO SO (FO) REGULATOR ASSEMBLY To perform the assembly of the URANO SO (FO) regulator, follow the steps informed in the disassembly procedure in inverse order, starting with the seat assembly.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 7) Turn the pilot block so that the bottom of the pilot faces up, release the screws (pos 16/15 ) and remove the bottom cover (pos 47/49) 8) Remove the spring and the base (pos 38/37) 9) Remove the bushing (pos 34/31) and the shutter spring.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 11) Remove the diaphragm plate and the lower diaphragm (pos 9/11), turn the pilot block to the initial position and proceed by dismantling the bushing (pos 35/32). 12) Remove the diaphragm plate (pos 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) Elaborado Verificado / Aprovado...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 6.7 PROCEDURE FOR THE PILOT G-40/42 ASSEMBLY To perform the assembly of the G-42 pilot, just follow the steps of the disassembly procedure in inverse order starting with the seat assembly, but we shall make two observations on two specific points that must be examined closely during the pilot reassembly.
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve the marking already made on the diaphragm (pos 9.11); position the marking made on the diaphragm between the two markings on the body, thus we can assume that the seat is centralized. Counterclockwise marking on the body Diaphragm marking...
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 4) Remove the cover (pos 39) and the diaphragm assembly (pos 28). 5) Lock the shaft (pos 28), release the nut (pos 11), remove the disc springs (pos 12) and the lower diaphragm plate (pos 27) to release the diaphragm (pos 10).
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 6) Now we will dismantle the bottom part of the booster. To do this, it is ideal to rotate the same so that the bottom faces upwards, proceed by removing the gasket holder (pos 45). Elaborado Verificado / Aprovado Data...
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 7) Remove the filter element (pos 26) and release the gasket (pos 8) of the gasket holder (pos 45) and its respective O-ring (pos 21). Elaborado Verificado / Aprovado Data Revisão Página 05/07/21...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 8) Remove the shaft guide (pos 40) and the thrust bushing (pos 41) 6.9 PROCEDURE FOR THE G-43 BOOSTER (PRE-REGULATOR) ASSEMBLY To perform the assembly of the G-43 booster, just follow the steps of the disassembly procedure in inverse order starting with the seat assembly, but we shall make some observations on specific points that must be examined closely during the booster reassembly: 1) During assembly of the diaphragm assembly to the shaft (pos 28) it is necessary to perform the...
Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 6.10 PROCEDURE FOR THE G-44 BOOSTER (PRE-REGULATOR) DISASSEMBLY 1) Before proceeding with the equipment disassembly, check if all the conditions set out in item 4.6.1 of this manual have been observed. 2) Under no circumstances start the equipment disassembly if it is pressurized.
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 5) Remove the booster shaft (pos 34) 6) Release the diaphragm (item 10) by loosening the plate of the lower diaphragm (pos 43). 7) Now we will dismantle the bottom part of the booster. To do this, it is ideal to rotate the same so that the bottom faces upwards, proceed by removing the gasket holder (pos 47).
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Installation and Operation Manual MI-31 Urano - Pressure Regulating Valve 8) Release the gasket (pos 9) of the gasket holder (pos 47) and its respective O-ring (pos 22). 9) Remove the shaft guide (pos 40) and the thrust bushing (pos 41) Elaborado Verificado / Aprovado Data...
(pos 34), therefore, during assembly it is important to pay attention to this spring adjustment. GASCAT recommends a distance of 14.4 to 14.5 mm from the lower diaphragm plate (pos 43), but if the operator does not have means to carry out this measurement in the field, we recommend a visual...
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