PIETRO FIORENTINI Reflux 819 Use And Maintenance Manual
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PIETRO FIORENTINI Reflux 819 Use And Maintenance Manual

High medium pressure gas regulator
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Reflux 819
High medium pressure gas regulator
Revision B - Edition 01/2023
USE, MAINTENANCE AND
WARNING MANUAL
EN

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Summary of Contents for PIETRO FIORENTINI Reflux 819

  • Page 1 Reflux 819 High medium pressure gas regulator Revision B - Edition 01/2023 USE, MAINTENANCE AND WARNING MANUAL...
  • Page 2 HIGH PRESSURE REGULATOR INTRODUCTION REV. B Use, maintenance and warning manual Use, maintenance and warning manual...

  • Page 3: Introduction

    It is of particular importance that the personnel responsible for the equipment be trained in its use, maintenance and ap- plication of the safety instructions and procedures indicated in this manual. Revision: B COPYRIGHT 2023 © PIETRO FIORENTINI S.P.A. HIGH PRESSURE REGULATOR INTRODUCTION REV. B...
  • Page 4 HIGH PRESSURE REGULATOR INTRODUCTION REV. B Use, maintenance and warning manual...

  • Page 5: Revision History

    1.1 - REVISION HISTORY Revision Date Revision contents index 10/2022 First issue • Chapter 4: Fig. 4.11 updated 01/2023 • Chapter 6, par. 6.5.2: limits of velocity of the pressurised fluid updated • Chapter 8, par. 8.8.1: Fig. 8.33 updated Tab.

  • Page 6: Table Of Contents

    INDICE 1 - INTRODUCTION ........................3 1.1 - REVISION HISTORY ..........................5 2 - GENERAL INFORMATION ....................13 2.1 - MANUFACTURER IDENTIFICATION ......................13 2.2 - IDENTIFICATION OF THE PRODUCT ...................... 13 2.3 - REGULATORY FRAMEWORK ......................... 13 2.4 - WARRANTY ............................13 2.5 - SYMBOLS USED IN THE MANUAL ......................
  • Page 7 5.2.4 - REFLUX 819 + SB/82 ..........................62 5.2.5 - REFLUX 819 + HB/97 ...........................64 5.2.6 - REFLUX 819 + DB/819 + PM/819 ......................66 5.2.7 - REFLUX 819 + DB/819 + SB/82 ......................68 5.2.8 - REFLUX 819 + DB/819 + HB/97 ......................70 5.3 - EQUIPMENT ANCHORING AND LIFTING METHOD................
  • Page 8 8.4 - CALIBRATION OF ANY ACCESSORIES ....................95 8.5 - REGULATOR COMMISSIONING PROCEDURE ..................96 8.6 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT-IN MONITOR PM/819 8.7 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT-IN PM/819 MONITOR AND M/A THROTTLE ..........................
  • Page 9 9.4 - ROUTINE MAINTENANCE PROCEDURES .................... 123 9.4.1 - TIGHTENING TORQUES REFLUX 819 ....................124 9.4.2 - REPLACING ELEMENTS SUBJECT TO WEAR AND ABRASION............157 9.4.3 - REGULATOR MAINTENANCE PROCEDURE REFLUX 819 ..............158 9.4.4 - DB/819 SILENCER MAINTENANCE PROCEDURE ................218 9.4.5 - PM/819 BUILT-IN MONITOR MAINTENANCE PROCEDURE ...............226 9.4.6 - PILOT MAINTENANCE PROCEDURE 200/A SERIES + PRE-REGULATOR R14/A ......256...
  • Page 10 11 - UNINSTALLATION AND DISPOSAL ................365 11.1 - GENERAL SAFETY WARNINGS ......................365 11.2 - QUALIFICATION OF THE OPERATORS IN CHARGE ................365 11.3 - UNINSTALLATION ..........................365 11.4 - INFORMATION REQUIRED IN CASE OF RE-INSTALLATION ..............365 11.5 - DISPOSAL INFORMATION ........................366 12 - RECOMMENDED SPARE PARTS ...................
  • Page 11 HIGH PRESSURE REGULATOR INTRODUCTION REV. B Use, maintenance and warning manual...
  • Page 12 HIGH PRESSURE REGULATOR INTRODUCTION REV. B Use, maintenance and warning manual...

  • Page 13: General Information

    PIETRO FIORENTINI S.P.A. guarantees that the equipment was manufactured using the best materials, with high quality workmanship, and complies with the quality requirements, specifications and performance set out in the order. The warranty shall be considered null and void and PIETRO FIORENTINI S.P.A. shall not be liable for any damage and/or malfunctions: •...

  • Page 14: Symbols Used In The Manual

    2.5 - SYMBOLS USED IN THE MANUAL Symbol Definition Symbol used to identify important warnings for the safety of the operator and/or equipment. Symbol used to identify information of particular importance in the instruction manual. The information may also concern the safety of the personnel involved in using the equipment. Obligation to consult the instruction manual/booklet.

  • Page 15: Addressees, Supply And Storage Of The Instruction Manual

    Keep the instruction manual near the equipment, in an accessible place known by all qualified technicians involved in using and running it. PIETRO FIORENTINI S.p.A. shall not be held liable for any damage to people, animals and property caused by failure to adhere to the warnings and operating procedures described in this instruction manual.

  • Page 16: Nameplates Applied

    Removing nameplates and/or replacing them with other plates is strictly not allowed. Should the plates be unintentionally damaged or removed, the customer must notify PIETRO FIORENTINI S.p.A. The equipment and its accessories are provided with nameplates (from Id.1 to Id.8).
  • Page 17 Type Image NAMEPLATE MONITOR NAMEPLATE SLAM-SHUT VALVE NAMEPLATE PRESSURE SWITCH NAMEPLATE ACCELERATING VALVE Tab. 2.5 HIGH PRESSURE REGULATOR GENERAL INFORMATION REV. B Use, maintenance and warning manual...

  • Page 18: Glossary For Nameplates

    2.8.1 - GLOSSARY FOR NAMEPLATES The terms and abbreviations used on nameplates are described in Tab. 2.6: Term Description Accuracy class. Accuracy class of pressure boosting slam-shut valves. AG max “OPSO” (Over pressure shut off). Accuracy class of safety devices for pressure drop. AG min ”UPSO”(Under pressure shut off).
  • Page 19 Term Description Full setpoint range with regard to tripping caused by decreased pressure in the pressure switch incorporated in the slam-shut valve. This range can be obtained by adjusting and/or replacing the components (for example, spring or sensitive element). Full setpoint range with regard to tripping caused by decreased pressure in the pressure switch Wdsu incorporated in the slam-shut valve.

  • Page 20: Glossary Of Units Of Measurement

    2.9 - GLOSSARY OF UNITS OF MEASUREMENT Type of measurement Unit of measurement Description Sm³/h Standard cubic metres per hour Volumetric flow rate Scfh Standard cubic feet per hour Unit of measurement in the CGS system Pounds per square inch Pressure “wc inch of water column...

  • Page 21: Qualified Professional Figures

    2.10 - QUALIFIED PROFESSIONAL FIGURES Qualified operators in charge of using and managing the equipment throughout its technical service life: Professional figure Definition Qualified technician able to: • perform preventive/corrective maintenance operations on all mechanical parts of the Mechanical equipment subject to maintenance or repair; maintenance techni- •...
  • Page 22 HIGH PRESSURE REGULATOR GENERAL INFORMATION REV. B Use, maintenance and warning manual...

  • Page 23: Safety

    3 - SAFETY 3.1 - GENERAL SAFETY WARNINGS WARNING! The equipment described in this instruction manual is: • a device subjected to pressure in pressurised systems; • normally installed in systems carrying flammable gases (for example: natural gas). WARNING! If the gas used is a combustible gas, the installation area of the equipment is defined as a “danger zone” as there are residual risks that potentially explosive atmospheres may be generated.

  • Page 24: Personal Protective Equipment

    3.2 - PERSONAL PROTECTIVE EQUIPMENT Tab. 3.9 shows the personal protective equipment (PPE) and its description. An obligation is associated with each symbol. Personal protective equipment means any equipment intended to be worn by the worker in order to protect them against one or several risks that are likely to threaten their safety or health during work.

  • Page 25: Residual Risks

    3.3 - RESIDUAL RISKS In accordance with the requirements of PED 2014/68/EU, point 1.2 of Annex I, below is an assessment of the risks as- sociated with the equipment and an indication of the principles adopted for their prevention, according to the following classification: a) Elimination and/or reduction of the risk.
  • Page 26 3.3.1 - TABLE SHOWING RESIDUAL RISKS DUE TO PRESSURE Effect and Risk and Hazard Event and Cause Solution and Prevention Consequence Pressurised gas a. Handling and installation with appropri- leakage. • Violent impact; • Deformation; ate devices to avoid localised stress. Projection of me- •...
  • Page 27 Effect and Risk and Hazard Event and Cause Solution and Prevention Consequence Pressurised gas • Deformation; leakage. a. With the exclusion of what is set out in • Cracking and slot Projection of • External loads bear- the project, the user must verify that no formation;...

  • Page 28: Table Of Residual Risks For Potentially Explosive Atmospheres

    3.3.2 - TABLE OF RESIDUAL RISKS FOR POTENTIALLY EXPLOSIVE ATMOSPHERES Tab. 3.11 shows the conditions that can lead to the generation of a potentially explosive atmosphere respectively for: • REFLUX 819 pressure regulator; • PM/819 monitor; • SB/82 or HB/97 slam shut valves.
  • Page 29 Potentially Management measures in- Operating explosive Regulatory references cluded in the instructions for conditions atmosphere use and warning This event must be considered a rare malfunction. Breakage of the All atmospheric pressure chambers The instructions for use indicate control head dia- delimited on at least one side by a the need to meet the requirements phragm...

  • Page 30: Obligations And Prohibitions

    3.4 - OBLIGATIONS AND PROHIBITIONS The following is a list of obligations and prohibitions to be observed for the safety of the operator. It is mandatory to: • carefully read and understand the instructions for use and warning; • check whether the downstream equipment is suitably sized according to the performance required of the regulator in the actual operating condition;...

  • Page 31: Safety Pictograms

    Depending on the operating conditions, use and configuration required, the equipment may generate noise other than that permitted by current legislation in the country of installation. For the value of the noise generated by the equipment and further information, contact PIETRO FIORENTINI S.p.A. ATTENTION!
  • Page 32 HIGH PRESSURE REGULATOR SAFETY REV. B Use, maintenance and warning manual...

  • Page 33: Description And Operation

    4 - DESCRIPTION AND OPERATION 4.1 - GENERAL DESCRIPTION The equipment REFLUX 819 is a piloted pressure regulator for medium and high pressure which reduces the inlet gas pressure, keeping the downstream value stable even when the following varies: •...

  • Page 34: Regulator Reaction Modes

    4.1.1 - REGULATOR REACTION MODES The REFLUX 819 equipment is a regulator controlled with a “fail close” reaction (on-closure reaction), that is, it closes in the event of: • breakage of main diaphragm • breakage of the pilot diaphragm(s); •...
  • Page 35 In depressurised conditions, the regulator plug (5) is kept in a shut-off position by the spring (8) and rests on the reinforced gasket (6). The upstream pressure, although variable, does not change this position since the regulator plug (5) is fully balanced.

  • Page 36: Intended Use

    If no written approval is provided, use shall be considered improper. In the event of “improper use”, PIETRO FIORENTINI S.p.A. shall not be held liable for any damage caused to people or property, and any type of warranty on the equipment shall be deemed void.

  • Page 37: Technical Features/Performance

    TECHNICAL FEATURES/PERFORMANCE The REFLUX 819 equipment is a medium and high pressure regulator. REFLUX 819 is a “top entry” type regulator that can be easily serviced and equipped with on-site accessories. The main specifications for this regulator are: Technical features...

  • Page 38: Possible Configurations

    4.5 - POSSIBLE CONFIGURATIONS The REFLUX 819 equipment can have different configurations through the installation of the following accessories: • Built-in silencer DB/819 • Built-in silencer LDB/171 • Incorporated monitor PM/819 (up to 10”) • Incorporated slam-shut valve SB/82 (up to 10”) •...

  • Page 39: Built-In Silencer

    4.5.1 - BUILT-IN SILENCER 4.5.1.1 - BUILT-IN SILENCER DB/819 The DB/819 silencer (1) is incorporated in the regulator (2). The DB/819 silencer (1) attenuates the noise generated by the equipment during the rolling process. Noise is absorbed precisely where it is generated, which prevents it from propagating. pstream pressUre ownstream pressUre oaDing pressUre...

  • Page 40: Built-In Silencer Ldb/171

    4.5.1.2 - BUILT-IN SILENCER LDB/171 The LDB/171 silencer (1) is incorporated in the regulator (2). The LDB/171 silencer (1) reduces the noise generated by the equipment during the lamination process. Noise is absorbed precisely where it is generated, which prevents it from propagating. pstream pressUre ownstream pressUre Fig.

  • Page 41: Pm/819 Monitor

    • they work on independent valve seats. pstream pressUre ownstream pressUre oaDing pressUre regULator pressUre Fig. 4.5. REFLUX 819 with PM/819 monitor HIGH PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. B Use, maintenance and warning manual...
  • Page 42 BUILT-IN MONITOR OPERATION NOTICE! To check the position of the plug (3), look at the position of the stroke indicator rod (9) referring to the glass cover (10): • open 100%; • closed 0%. In depressurised conditions, the plug (3) is kept in a shut-off position by the spring (4) and rests on the reinforced gasket (5). The upstream pressure (Up), even if variable, does not change this position as the plug (3) is completely balanced, just like the stem (6), as a result of the upstream pressure (Up), through the hole (16), in the chamber (B).
  • Page 43 OPERATION OF THE BUILT-IN MONITOR IN STAND-BY CONDITIONS: The PM/819 built-in monitor (1) is normally open during standard operation as pilot (3) calibration is higher than that of the main regulator’s (2) pilot. The passage of the pre-regulator pressure (Pup) generated by the R14/A pre-regulator (4) through the fully open pilot (3) keeps the built-in monitor PM/819 (1) fully open.
  • Page 44 BUILT-IN MONITOR OPERATION IN THE EVENT OF FAILURE OF THE MAIN REGULATOR: pstream pressUre ownstream pressUre oaDing pressUre regULator pressUre Fig. 4.8. Built-in monitor operation in the event of failure of the main regulator Should the main regulator (2) fail, the PM/819 monitor (1) will trip until balanced adjustment is achieved. Therefore, should the following occur during operation: Operating conditions Operating consequences...

  • Page 45: M/A Accelerating Valve

    4.5.2.1 - M/A ACCELERATING VALVE NOTICE! For the monitor to be used as a safety accessory according to “PED” Directive 2014/68/EU, installing the M/A accelerating valve is recommended. In the event of a malfunction of the main regulator (1), the M/A accelerating valve (3) is to be installed in order to facilitate the intervention of the built-in monitor PM/819 (2).

  • Page 46: Slam-Shut Valve

    4.5.3 - SLAM-SHUT VALVE The slam-shut valve is a safety device is used to shut off the gas flow if the pressure value at the control point exceeds the calibration value of the valve itself. The slam-shut valve is incorporated into the main body of the equipment and consists of: •...
  • Page 47 Fig. 4.10. REFLUX 819 with SB/82 incorporated slam-shut valve pstream pressUre ownstream pressUre oaDing pressUre Fig. 4.11. HP2/2 by-pass detail applicable to SB/82 10” only HIGH PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. B Use, maintenance and warning manual...

  • Page 48: Hb/97 Built-In Slam-Shut Valve

    4.5.3.2 - HB/97 BUILT-IN SLAM-SHUT VALVE The built-in HB/97 incorporated slam-shut valve can be operated: • by the pressure switch; • manually; • with remote control. The main features of the HB/97 built-in slam-shut valve are: • balanced valve plug; •...
  • Page 49 Fig. 4.12. REFLUX 819 with HB/97 incorporated slam-shut valve OPERATION: At no pressure, the valve plug (1) is kept in the shut-off position by the spring (10) and rests on the reinforced gasket (11). The upstream pressure (Up) reaches the HP2/2 bypass device (3) and the upper head (12) of the R44/SS regulator (4) to prevent inappropriate resetting of the valve.

  • Page 50: Slam-Shut Valve Pressure Switches

    4.5.4 - SLAM-SHUT VALVE PRESSURE SWITCHES The pressure switch is a control device consisting of (see Fig. 4.12): Pos. Description Control element. NOTICE! The control element can be a diaphragm or a piston. Stem. Adjustment feeler gauges. Spring for maximum pressure tripping. Spring for minimum pressure tripping.
  • Page 51 Tab. 4.28 lists the models of possible pressure switches for this regulator: Model pressure Max [bar] Min [bar] switch 102M 0.2 - 5.5 0.05 - 2.8 102MH 0.2 - 5.5 2.8 - 5.5 103M 2 - 22 0.2 - 8 103MH 2 - 22 8 - 19...
  • Page 52 HIGH PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. B Use, maintenance and warning manual...

  • Page 53: Transport And Handling

    5 - TRANSPORT AND HANDLING 5.1 - SPECIFIC WARNINGS FOR TRANSPORT AND HANDLING NOTICE! Transport and handling must be carried out by personnel: • qualified (specially trained); • who are familiar with accident prevention and workplace safety regulations; • authorised to use lifting equipment; •...

  • Page 54: Packaging And Fasteners Used For Transport

    PIETRO FIORENTINI S.p.A.. NOTICE! PIETRO FIORENTINI S.p.A. shall not be liable for any damage to people or property caused by accidents due to failure to comply with the instructions provided in this manual. Tab. 5.30 shows the types of packaging used: Ref.
  • Page 55 HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...

  • Page 56: Physical Characteristics Of The Equipment

    5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT 5.2.1 - REFLUX 819 (+LDB/171) Fig. 5.14. Physical characteristics REFLUX 819 (+LDB/171) HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 57 Overall dimensions REFLUX 819 (+LDB/171) Nominal diameter [mm] Size [inches] 1” 2” 3” 4” 6” 8” 10” 12” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1195 1015 1140 1322 Pneumatic connec- eØ 10mm x Øi 8mm tions Tab.

  • Page 58: Reflux 819 + Db/819

    5.2.2 - REFLUX 819 + DB/819 Fig. 5.15. REFLUX 819 + DB/819 physical characteristics HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 59 REFLUX 819 + DB/819 overall dimensions Nominal diameter [mm] Size [inches] 1” 2” 3” 4” 6” 8” 10” 12” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1085 1300 1505 1120 1250 1500 1771...

  • Page 60: Reflux 819 + Pm/819

    5.2.3 - REFLUX 819 + PM/819 Fig. 5.16. REFLUX 819 + PM/819 physical characteristics HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 61 REFLUX 819 + PM/819 overall dimensions Nominal diameter [mm] Size [inches] 1” 2” 3” 4” 6” 8” 10” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1300 1500 1600 Pneumatic connec- eØ 10mm x Øi 8mm tions Tab.

  • Page 62: Reflux 819 + Sb/82

    5.2.4 - REFLUX 819 + SB/82 Fig. 5.17. Physical characteristics REFLUX 819 + SB/82 HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 63 Overall dimensions REFLUX 819 + SB/82 Nominal diameter [mm] Size [inches] 1” 2” 3” 4” 6” 8” 10” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1025 1200 1330 Pneumatic connec- eØ 10mm x Øi 8mm tions Tab.

  • Page 64: Reflux 819 + Hb/97

    5.2.5 - REFLUX 819 + HB/97 Ø Fig. 5.18. Physical characteristics REFLUX 819 + HB/97 HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 65 Overall dimensions REFLUX 819 + HB/97 Nominal diameter [mm] Size [inches] 4” 6” 8” 10” 12” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1135 1060 1250 1008 1295 1437 1596 1890 Pneumatic connec- tions Tab.

  • Page 66: Reflux 819 + Db/819 + Pm/819

    5.2.6 - REFLUX 819 + DB/819 + PM/819 Fig. 5.19. REFLUX 819 + DB/819 + PM/819 physical characteristics HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 67 REFLUX 819 + DB/819 + PM/819 overall dimensions Nominal diameter [mm] Size [inches] 1” 2” 3” 4” 6” 8” 10” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1085 1300 1120 1250 1500 1100...

  • Page 68: Reflux 819 + Db/819 + Hb/97

    5.2.7 - REFLUX 819 + DB/819 + SB/82 Fig. 5.20. Physical characteristics REFLUX 819 + DB/819 + SB/82 HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 69 Overall dimensions REFLUX 819 + DB/819 + SB/82 Nominal diameter [mm] Size [inches] 1” 2” 3” 4” 6” 8” 10” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1085 1300 1120 1250 1500 1100...
  • Page 70 5.2.8 - REFLUX 819 + DB/819 + HB/97 Ø Fig. 5.21. Physical characteristics REFLUX 819 + DB/819 + HB/97 HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...
  • Page 71 Overall dimensions REFLUX 819 + DB/819 + HB/97 Nominal diameter [mm] Size [inches] 4” 6” 8” 10” 12” S - Ansi 150/PN 16 S - Ansi 300 S - Ansi 600 Ø 1505 1771 1060 1250 1220 1318 1580 1772...

  • Page 72: Equipment Anchoring And Lifting Method

    5.3 - EQUIPMENT ANCHORING AND LIFTING METHOD HAZARD! Before moving the equipment, make sure that the capacity of the lifting equipment is suitable for the load. WARNING! Unloading, transport and handling activities must be carried out by operators qualified and specially trained: •...

  • Page 73: Forklift Handling Method

    5.3.1 - FORKLIFT HANDLING METHOD HAZARD! It is forbidden to: • Do not transit under suspended loads; • Do not move the load over the personnel operating in the site/plant area. WARNING! The following is not allowed on forklifts: • carrying passengers;...
  • Page 74 Step Action Image Sollevare lentamente il carico di qualche decina di centimetri e veri carne la stabilità facendo attenzio- Inclinare il montante all’indietro (verso il posto guida) per avvantaggiare il momento ribaltante e Adeguare la velocità d ne che il baricentro del carico sia posizionato al centro delle forche di sollevamento. garantire una maggiore stabilità...

  • Page 75: Crane Handling Method

    5.3.2 - CRANE HANDLING METHOD WARNING! CE-marked chains, ropes and eyebolts must be used. Do not use chains connected to each other by bolts. Always check that: • the safety catch of the hook returns to the initial position; • the ropes are in excellent condition and have adequate sections.

  • Page 76: Packaging Removal

    • do not install the equipment; • contact PIETRO FIORENTINI S.p.A. and specify the details provided on the equipment nameplate. 5.4.1 - PACKAGING DISPOSAL NOTICE! Sort the various materials making up the packaging and dispose of them in compliance with the regula- tions in force in the country of installation.

  • Page 77: Storage And Environmental Conditions

    For the replacement of the rubber parts of the equipment, please refer to “9 - Maintenance and functional checks”. NOTICE! PIETRO FIORENTINI S.p.A. recommends checking the condition of rubber parts in case of downtime or storage longer than 3 years.
  • Page 78 HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. B Use, maintenance and warning manual...

  • Page 79: Installation

    6 - INSTALLATION 6.1 - INSTALLATION PRE-REQUISITES 6.1.1 - ALLOWED ENVIRONMENTAL CONDITIONS WARNING! To safely use the equipment, in full respect of the allowed environmental conditions, follow the data shown on the regulator plate and on any accessories (refer to paragraph “2.8 - Nameplates applied”). The installation site must be suitable for the safe use of the equipment.

  • Page 80: Checks Before Installation

    6.1.2 - CHECKS BEFORE INSTALLATION The equipment does not require any further upstream safety device for protection against any overpressure with respect to its PS admissible pressure when, for the upstream reduction station, the maximum incidental downstream pressure MIPd ≤ 1.1 PS MIPd = Maximum incidental downstream pressure value (for further information, see UNI EN 12186:2014).

  • Page 81: Specific Safety Instructions For The Installation Step

    6.2 - SPECIFIC SAFETY INSTRUCTIONS FOR THE INSTALLATION STEP WARNING! Before proceeding with installation, make sure that the upstream and downstream valves installed on the line are shut off. WARNING! Installation may also take place in areas where there is a risk of explosion, which implies that all necessary prevention and protection measures have to be taken.

  • Page 82: General Information On Connections

    6.3 - GENERAL INFORMATION ON CONNECTIONS The equipment must be installed in-line with an arrow on the body pointing to the gas flow direction. In line installation as well as in square installation, they must be present (see Fig. 6.22 and Fig. 6.23): Pos.

  • Page 83: Regulator Installation Positions

    NOTICE! When used in gas pressure reduction stations, the device must be installed at least according to the re- quirements of standards UNI EN 12186:2014 or UNI EN 12279:2007. Equipment vents must be ducted in accordance with UNI EN 12186:2014 or UNI EN 12279:2007 or the standards in force at the place of installation of the equipment.

  • Page 84: Installation Procedures

    6.5 - INSTALLATION PROCEDURES 6.5.1 - EQUIPMENT INSTALLATION PROCEDURE Step Action Place the equipment in the section of the line designated for it. Place the gaskets between the line flange and the regulator flange. Insert the bolts into the appropriate holes of the connecting flanges. Screw the bolts following the technical rules for tightening flanges.
  • Page 85 To calculate the flow rate, use the following formula: 1 − 0,002 = 345,92 V = gas velocity in m/sec Q = gas flow rate Stm³/h DN = nominal pipe diameter in mm Pd = regulator outlet pressure in barg NOTICE! All on-site pneumatic connections must have pipes with a minimum internal diameter of 8 mm.

  • Page 86: Post-Installation And Pre-Commissioning Checks

    If there is a sensing line, provide equipment connections as shown below: • 1 and 2 to the discharge outlet of the control head of the PM/819 monitor, if any; • 3 and 4 to the pilot sensing lines; • 5 and 6 to the sensing lines of the block accelerating valve, when present.

  • Page 87: Commissioning/Maintenance Equipment

    7 - COMMISSIONING/MAINTENANCE EQUIPMENT 7.1 - LIST OF EQUIPMENT Use of commissioning/maintenance equipment • Mechanical maintenance technician; • Electrical maintenance technician; Operator qualification • Installer; • Name of the user. WARNING! The PPE listed in this table is related to the risk associated with the equipment. PPE required For the PPE required to protect against risks associated with the workplace, installation or operating conditions, please refer to:...
  • Page 88 Ref. Equipment type Image T-handle hex socket wrench Phillips screwdriver Slotted screwdriver O-ring extraction tool Circlip pliers Fiorentini special key Fiorentini special key Fiorentini special tool Tab. 7.56 HIGH PRESSURE REGULATOR REV. B COMMISSIONING AND MAINTENANCE EQUIPMENT Use, maintenance and warning manual...

  • Page 89: Equipment Needed For The Different Configurations

    5-6-17 5-6-17 5-6-17 17-20 17-20 17-19-22 17-19-22 Code 7999099 Tab. 7.58 REFLUX 819 + DB/819 Equipment Size [inches] | DN [mm] Ref. Type 25 | 1” 50 | 2” 80 | 3” 100 | 4” 150 | 6” 200 | 8”...
  • Page 90 REFLUX 819 + PM/819 Equipment Size [inches] | DN [mm] Ref. Type 25 | 1” 50 | 2” 80 | 3” 100 | 4” 150 | 6” 200 | 8” 250 | 10” 13-15-17- 13-15-17- 13-15-17- 13-15-17- 13-15-17- 13-15-17- 13-15-17-...
  • Page 91 REFLUX 819 + HB/97 Equipment Ref. Type 100 | 4” 150 | 6” 200 | 8” 250 | 10” 300 | 12” 8-13-14-15-17- 8-13-14-15-17- 8-13-14-15-17- 8-13-14-15-17- 8-13-14-15-17- 19-24-27-30- 19-24-27-30- 19-24-27-32- 19-24-27-32- 19-24-27-30-32 32-41 32-41 46-50 46-50 Ø 9-10-15-24-27- 9-10-15-24-27- 9-10-15-24-30-...
  • Page 92 HIGH PRESSURE REGULATOR REV. B COMMISSIONING AND MAINTENANCE EQUIPMENT Use, maintenance and warning manual...

  • Page 93: Commissioning

    8 - COMMISSIONING 8.1 - GENERAL WARNINGS 8.1.1 - SAFETY REQUIREMENTS FOR COMMISSIONING HAZARD! During commissioning the risks associated with any discharges to the atmosphere of flammable or nox- ious gases must be evaluated. HAZARD! In case of installation on distribution networks for natural gas, consider the risk associated with explosive mixtures (gas/air) being formed inside the piping, if the line is not subjected to inerting.

  • Page 94: Preliminary Procedures For Commissioning

    8.2 - PRELIMINARY PROCEDURES FOR COMMISSIONING HAZARD! Before commissioning the equipment, it must be ensured that any source of explosion has been eliminated if there is such a danger. WARNING! Before commissioning, you need to make sure that the characteristics of the equipment are suitable for the conditions of use.

  • Page 95: Proper Commissioning Check

    8.3 - PROPER COMMISSIONING CHECK Completely sprinkle the equipment with a foaming solution (or equivalent control system) in order to check the tightness of the external surfaces of the regulator and the connections made during the installation. 8.4 - CALIBRATION OF ANY ACCESSORIES NOTICE! To properly calibrate the equipment and accessories present, refer to the accuracy class indicated on the nameplates (see “2.8 - Nameplates applied”).

  • Page 96: Regulator Commissioning Procedure

    8.5 - REGULATOR COMMISSIONING PROCEDURE In the application consisting of two pressure adjusting lines, it is advisable to commission one line at a time, starting with the line with the lowest set point. The set point value is mentioned on the test certificate enclosed with each piece of equipment. Fig.
  • Page 97 Step Action Partially open the bleed cock (6). Completely unscrew the fixing nut and adjusting screw (fig. 8.43) of the pilot (3) to relieve the spring. Open the inlet shut-off valve (V1) very slowly. NOTICE! Check the pressure referring to the upstream pressure gauge (4). Turn the pilot adjustment screw (3) clockwise to load the calibration spring until the regulator (1) trips.

  • Page 98: Commissioning Procedure For The Reflux 819 Regulator With Built-In Monitor

    8.6 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT- IN MONITOR PM/819 Fig. 8.30. Procedure for commissioning the regulator with PM/819 built-in monitor Step Action Partially open the bleed cock (6). Completely unscrew the fixing nuts of the adjusting screws (Fig. 8.36, ref. 10) of the pilots (3, 10).
  • Page 99 Step Action Check that the calibration pressure is at the set value by referring to the upstream pressure gauge (5). NOTICE! • To reduce the pressure (to the required value): turn the pilot adjustment screw (3) an- ti-clockwise; • To increase the pressure (to the required value): turn the pilot adjustment screw (3) clock- wise.

  • Page 100: Commissioning Procedure For The Reflux 819 Regulator With Built-In Pm/819 Monitor And M/A Throttle

    8.7 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT- IN PM/819 MONITOR AND M/A THROTTLE Fig. 8.31. Commissioning of the regulator with built-in PM/819 monitor and M/A accelerating valve Step Action Partially open the bleed cock (6). Completely unscrew the fixing nut of the pilot adjustment screw (3, 10) and the M/A accelerating valve (11).
  • Page 101 Step Action Turn the adjusting screw (Fig. 8.36 ref. 10) on the monitor pilot (10) anti-clockwise to decrease the downstream pressure value to the selected monitor operating value. NOTICE! • Ensure that the accelerating valve (11) has cut off the gas discharge; •...

  • Page 102: Commissioning Procedure For The Reflux 819 Regulator With Built-In Slam-Shut Val

    8.8 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT- IN SLAM-SHUT VALVE SB/82 8.8.1 - CHECKING THE SLAM-SHUT VALVE FOR PROPER SEALING WHEN SB/82 CLOSING Fig. 8.32. Sealing of the SB/82 slam-shut valve when closing Step Action Check that the slam-shut valve (3) is in the closed position.

  • Page 103: Commissioning Of The Regulator Reflux 819 With Slam-Shut Valve Sb/82

    8.8.2 - COMMISSIONING OF THE REGULATOR REFLUX 819 WITH SLAM-SHUT VALVE SB/82 For the following procedure, please refer to Fig. 8.32 at “8.8.1 - Checking the SB/82 slam-shut valve for proper sealing when closing”: Step Action Make sure that the bleed cock (6) is partially open.
  • Page 104 Fig. 8.38. Sealing of the SB/82 slam-shut valve when closing Fig. 8.39. HP2/2 by-pass detail applicable to SB/82 10” only HIGH PRESSURE REGULATOR COMMISSIONING REV. B Use, maintenance and warning manual...
  • Page 105 Check that the downstream pressure (Pd), after an increment phase, does not exceed the closing pressure value (refer to the SG value displayed on the plate, see par. 2.8). NOTICE! If the pressure in the pipe section between the regulator and the downstream shut-off valve (V2) exceeds the closing pressure value, consult chapter 10 “Troubleshooting”...

  • Page 106: Pressure Switches Calibration Procedure 102M/102Mh - 105M/105Mh

    8.8.3 - PRESSURE SWITCHES CALIBRATION PROCEDURE 102M/102MH - 105M/105MH Fig. 8.33. Pressure switches calibration Models 102M/102MH - 105M/105MH SPRING CALIBRATION FOR MAXIMUM PRESSURE TRIP Step Action Increase the downstream pressure to the slam-shut valve by turning the adjustment screw (10) on the pilot (2) of the main regulator (1) to check the correct calibration.
  • Page 107 SPRING CALIBRATION FOR MINIMUM PRESSURE TRIP (IF PRESENT) Step Action Partially open the bleed cock (Fig. 8.29, ref. 6) to the atmosphere and keep it open for the next steps. Decrease the downstream pressure to the minimum required slam-shut device pressure by turning the main regulator's pilot adjustment screw.

  • Page 108: Commissioning Procedure For The Reflux 819 Regulator With Incorporated Slam

    8.9 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH INCOR- PORATED SLAM-SHUT VALVE SB/97 8.9.1 - CHECKING THE INCORPORATED SLAM-SHUT VALVE FOR SEALING HB/97 WHEN CLOSING Fig. 8.34. Sealing of the HB/97 slam-shut valve when closing Step Action Check that the slam-shut valve (3) is in the closed position.

  • Page 109: Commissioning Of The Reflux 819 Regulator With Hb/97 Slam-Shut Valve

    8.9.2 - COMMISSIONING OF THE REFLUX 819 REGULATOR WITH HB/97 SLAM-SHUT VALVE For the following procedure, please refer to Fig. 8.34 at “8.9.1 - Checking the HB/97 incorporated slam-shut valve for sealing when closing”: Step Action Make sure that the bleed cock (6) is partially open.
  • Page 110 Step Action If external leaks are noticed, eliminate the leak points and repeat the procedure from step 7. Open downstream shut-off valve (V2) very slowly until the pipeline fills completely. NOTICE! If the pressure of the downstream pipeline is lower than the calibration pressure, partially open the downstream shut-off valve (V2) so as to not to exceed the maximum flow rate value of the installation.
  • Page 111 HIGH PRESSURE REGULATOR COMMISSIONING REV. B Use, maintenance and warning manual...

  • Page 112: Line Off 2.0 Commissioning And Calibration Procedure For Hb/97 Built-In Slam-Shut Valve

    8.9.3 - LINE OFF 2.0 COMMISSIONING AND CALIBRATION PROCEDURE FOR HB/97 BUILT-IN SLAM-SHUT VALVE Fig. 8.35. LINE OFF 2.0 commissioning and calibration for the HB/97 built-in slam-shut valve HIGH PRESSURE REGULATOR COMMISSIONING REV. B Use, maintenance and warning manual...

  • Page 113: Calibration Of The Pressure Switch For Line Off 2.0

    Step Action Press and hold the button of the bypass valve HP2/2 (7.1) to: • bring the upstream pressure to the power supply unit of the LINE-OFF 2.0 device; • balance the pressure of the HB/97 built-in slam-shut valve plug. Release the button of bypass valve HP2/2 (7.1) after checking that the upstream and downstream pressure of the slam-shut valve is balanced.

  • Page 114: Device Calibration

    8.11 - DEVICE CALIBRATION 8.11.1 - 200/A SERIES PILOTS Fig. 8.36. 200/A series pilots Turn the adjusting screw (10): • anti-clockwise to decrease the adjusted pressure; • clockwise to increase the adjusted pressure. 8.11.2 - PRESSURE SWITCHES MODELS 102M/102MH - 105M/105MH Fig.
  • Page 115 HIGH PRESSURE REGULATOR COMMISSIONING REV. B Use, maintenance and warning manual...
  • Page 116 HIGH PRESSURE REGULATOR COMMISSIONING REV. B Use, maintenance and warning manual...

  • Page 117: Maintenance And Functional Checks

    WARNING! In case of doubt, do not perform any work. Contact PIETRO FIORENTINI S.p.A. for the necessary clarifica- tions. The management and/or use of the equipment includes interventions that are necessary as a result of normal use such as: •...
  • Page 118 Before beginning disassembly of the equipment, make sure that: • the spare parts and parts used in replacements have adequate requirements to ensure the original performance of the equipment. Use recommended original spare parts; • the operator must have the necessary equipment (see chapter “7 - Commissioning/maintenance equipment”). NOTICE! The recommended spare parts are unambiguously identified with tags indicating: •...

  • Page 119: Periodically Checking And Inspecting The Equipment For Proper Operation

    9.2 - PERIODICALLY CHECKING AND INSPECTING THE EQUIPMENT FOR PROPER OPERATION Periodic checks and inspections Operator qualification Mechanical maintenance technician WARNING! The PPE listed in this table is related to the risk associated with the equipment. PPE required For the PPE required to protect against risks associated with the workplace, installation or operating conditions, please refer to: •...

  • Page 120: Routine Maintenance

    9.3 - ROUTINE MAINTENANCE 9.3.1 - GENERAL SAFETY WARNINGS HAZARD! • Put the equipment in a safe condition (close the downstream and then the upstream shut-off valve, drain the equipment completely and lastly drain the line); • Ensure that the pressure upstream and downstream of the equipment is “0”. NOTICE! Before installing new sealing elements (o-rings, diaphragm, etc.), they must be checked for integrity.

  • Page 121: Replacement Frequency For Components Subject To Wear

    9.3.2 - REPLACEMENT FREQUENCY FOR COMPONENTS SUBJECT TO WEAR NOTICE! The following provisions shall apply to equipment components only. The non-metallic parts of the equipment concerned are divided into the following two categories: Preventive maintenance work Covers parts subject to wear and/or abrasion, where: •...
  • Page 122 Minimum Category Part description Evaluation criterion replacement frequency Non-metallic parts with a static sealing If there are Various equipment function only proven leaks Shut-off valves Yearly Lubricating parts Other equipment Yearly Filter elements Filters needed Tab. 9.79 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.

  • Page 123: Routine Maintenance Procedures

    9.4 - ROUTINE MAINTENANCE PROCEDURES Routine maintenance Operator qualification Mechanical maintenance technician WARNING! The PPE listed in this table is related to the risk associated with the equipment. PPE required For the PPE required to protect against risks associated with the workplace, installation or operating conditions, please refer to: •...

  • Page 124: Tightening Torques Reflux 819

    9.4.1 - TIGHTENING TORQUES REFLUX 819 Fig. 9.40. Tightening torques REFLUX 819 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 125 REFLUX 819 (+LDB/171) 1” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M12 M12 piston guide Screw M16X70 UNI 5737 Screw M10X35 UNI 5739 Screw M6X14 UNI 5931 Screw M6X16 UNI 5931 30.1 Screw M6X30 UNI 5931 Screw M10X30 UNI 5739...
  • Page 126 Tightening torques REFLUX 819 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 127 REFLUX 819 (+LDB/171) 3” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M12 M12 piston guide Screw M18X90 UNI 5737 Screw M10X35 UNI 5737 Screw M6X14 UNI 5931 Screw M6X16 UNI 5931 30.1 Screw M6X60 UNI 5931 Screw M12X40 UNI 5739...
  • Page 128 Tightening torques REFLUX 819 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 129 REFLUX 819 (+LDB/171) 6” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M24 Piston guide M18 Screw M22X120 UNI 5737 Screw M14X50 UNI 5931 Screw M6X16 UNI 5931 Screw M6X16 UNI 5931 30.1 Screw M6X85 UNI 5931 Screw M20X70 UNI 5737...
  • Page 130 Tightening torques REFLUX 819 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 131 REFLUX 819 (+LDB/171) 10” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M30 M22 piston guide Screw M27X150 UNI 5737 Screw M20X80 UNI 5737 Screw M6X16 UNI 5931 Screw M6X16 UNI 5931 Screw M22X70 UNI 5737 Nut M20 UNI 5589...
  • Page 132 9.4.1.1 - TIGHTENING TORQUES REFLUX 819 + SILENCER DB/819 Fig. 9.41. Tightening torques REFLUX 819 + Silencer DB/819 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 133 REFLUX 819 + DB/819 1” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M12 M12 piston guide Screw M16X70 UNI 5737 Screw M10X35 UNI 5739 Screw M6X14 UNI 5931 Screw M6X16 UNI 5931 Screw M10X30 UNI 5739 Screw M10X35 UNI 5931...
  • Page 134 Tightening torques REFLUX 819 + Silencer DB/819 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 135 REFLUX 819 + DB/819 4” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M12 M12 piston guide Screw M16X70 UNI 5737 Screw M10X40 UNI 5739 Screw M6X14 UNI 5931 Screw M6X16 UNI 5931 Screw M16X50 UNI 5737 Nut M12 UNI 5589...
  • Page 136 Tightening torques REFLUX 819 + Silencer DB/819 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 137 REFLUX 819 + DB/819 10” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M30 M22 piston guide Screw M27X150 UNI 5737 Screw M20X80 UNI 5737 Screw M6X16 UNI 5931 Screw M6X16 UNI 5931 Screw M22X70 UNI 5737 Nut M20 UNI 5589...
  • Page 138 9.4.1.2 - TIGHTENING TORQUES FOR PM/819 BUILT-IN MONITOR Fig. 9.42. Tightening torques for PM/819 built-in monitor PM/819 1” Pos. Description Torque (nm) Torque (ft - lb) Nut M12 M12 balancing piston guide Screw M16X70 UNI 5737 Screw M10X35 5739 Screw M6X14 UNI 5931 Screw M6X12 UNI 5931 Screw M10X30 UNI 5739 Tab.
  • Page 139 PM/819 2” Pos. Description Torque (nm) Torque (ft - lb) Nut M12 M12 balancing piston guide Screw M16X70 UNI 5737 Screw M10X35 5739 Screw M6X14 UNI 5931 Screw M6X12 UNI 5931 Screw M12X35 UNI 5739 Tab. 9.98 PM/819 3” Pos. Description Torque (nm) Torque (ft - lb)
  • Page 140 Tightening torques for PM/819 built-in monitor HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 141 PM/819 6” Pos. Description Torque (nm) Torque (ft - lb) Nut M24 M18 balancing piston guide Screw M22X120 UNI 5737 Screw M14X50 UNI 5737 Screw M6X16 UNI 5931 Screw M6X16 UNI 5931 Screw M20X60 UNI 5737 Nut M18 UNI 5589 Tab.
  • Page 142 9.4.1.3 - TIGHTENING TORQUES FOR PILOTS SERIES 200 204/A-205/A 207/A Fig. 9.43. Tightening torques for 204/A-205/A-207/A pilots PILOTS 204/A-205/A Pos. Description Torque (nm) Torque (ft - lb) Nut M16X1 Screw M8X30 UNI 5931 AISI Nut M16X1.5 Nut M18X1.5 Tab. 9.104 PILOT 207/A Pos.
  • Page 143 9.4.1.4 - TIGHTENING TORQUES FOR PRE-REGULATORS R14/A Fig. 9.44. Tightening torques for pre-regulator R14/A PRE-REGULATOR R14/A Pos. Description Torque (nm) Torque (ft - lb) Nut M8X30 UNI 5931 AISI Nut M8 UNI 5588 Tab. 9.106 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
  • Page 144 9.4.1.5 - TIGHTENING TORQUES FOR SB/82 BUILT-IN SLAM-SHUT VALVE Fig. 9.45. Tightening torques for SB/82 1” incorporated slam-shut valve SB/82 1” Pos. Description Torque (nm) Torque (ft - lb) Safety valve screw M10 Screw M6X12 UNI 5931 Screw M6X20 UNI 5931 Screw M6X20 UNI 5931 Screw M12X45 UNI 5931 Screw M10X25 UNI 5931...
  • Page 145 Fig. 9.46. Tightening torques for SB/82 2” incorporated slam-shut valve SB/82 2” Pos. Description Torque (nm) Torque (ft - lb) Safety valve screw M10 Screw M6X12 UNI 5931 Screw M6X20 UNI 5931 Screw M6X20 UNI 5931 Screw M6X20 UNI 5931 Screw M12X45 UNI 5931 Tab.
  • Page 146 Fig. 9.47. Tightening torques for SB/82 3”-4” incorporated slam-shut valve SB/82 3” Pos. Description Torque (nm) Torque (ft - lb) Safety valve screw M10 Screw M12X40 UNI 5739 Screw M6X12 UNI 5931 Screw M6X20 UNI 5931 Screw M6X20 UNI 5931 Screw M6X20 UNI 5931 Nut M12 UNI 5588 Tab.
  • Page 147 Fig. 9.48. Tightening torques for SB/82 6”-8” incorporated slam-shut valve SB/82 6” Pos. Description Torque (nm) Torque (ft - lb) Safety valve screw Screw M14X50 UNI 5737 Screw M6X16 UNI 5931 Screw M6X10 UNI 5931 Screw M8X25 UNI 5931 Screw M6X40 UNI 5931 Screw M6X20 UNI 5931 Nut M14 UNI 5588 Tab.
  • Page 148 Fig. 9.49. Tightening torques for SB/82 10” incorporated slam-shut valve SB/82 10” Pos. Description Torque (nm) Torque (ft - lb) Screw M16X90 UNI 5737 Screw M6X16 UNI 5931 Nut M20 UNI 5589 Screw M6X20 UNI 5931 Screw M8X25 UNI 5931 Screw M6X35 UNI 5931 Screw M6X20 UNI 5931 Tab.
  • Page 149 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 150 9.4.1.6 - TIGHTENING TORQUES FOR PRESSURE SWITCHES MODELS 102M/102MH - 105M/105MH MOD. 102M/102MH MOD. 104M/104MH MOD. 103M/103MH MOD. 105M/105MH Fig. 9.50. Tightening torques for pressure switches models 102M/102MH - 105M/105MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 151 MOD. 102M/102MH Pos. Description Torque (nm) Torque (ft - lb) Screw M4X10 UNI 5931 2.21 Screw M5X10 UNI 5933 3.68 Screw M6X16 UNI 5931 7.37 Nut M6 UNI 5588 7.37 Screw M5X15 UNI 8112 3.68 Screw M6X25 UNI 5931 11.80 Nut M20X1 5.90 Screw M5X16 UNI 5931...
  • Page 152 9.4.1.7 - TIGHTENING TORQUES FOR HB/97 BUILT-IN SLAM-SHUT VALVE WITH LINE-OFF 4” 6” - 10” 4” 6”÷10” Fig. 9.51. Tightening torques for HB/97 built-in slam-shut valve with LINE OFF HB/97 4” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M12X1.25 M12X1.25 balancing piston guide Screw M10X40 UNI 5737 Nut M12X1.25 UNI 5589...
  • Page 153 HB/97 8” Pos. Description Torque (nm) Torque (ft - lb) Locking nut M24X1.5 M18X1.5 balancing piston guide Screw M14X50 UNI 5737 Nut M18X1.5 UNI 5589 Nut M16 UNI 5588 Screw M8X20 UNI 5931 Screw M6X25 UNI 5931 Screw M6X16 UNI 5931 Tab.
  • Page 154 9.4.1.8 - TIGHTENING TORQUES FOR HP2/2 BYPASS DEVICE Fig. 9.52. Tightening torques for HP2/2 bypass device HP/22 Pos. Description Torque (nm) Torque (ft - lb) Screw M8X20 UNI 5931 Screw M8X45 UNI 5931 Tab. 9.122 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
  • Page 155 9.4.1.9 - TIGHTENING TORQUES FOR LAMINATION VALVE AR100 Fig. 9.53. Tightening torques for lamination valve AR100 LAMINATION VALVE AR100 Pos. Description Torque (nm) Torque (ft - lb) Cap M20X1.5 Screw M8 AISI Tab. 9.123 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
  • Page 156 9.4.1.10 - TIGHTENING TORQUES FOR R44/SS REGULATOR 24.1 Fig. 9.54. Tightening torques for R44/SS regulator R44/SS Pos. Description Torque (nm) Torque (ft - lb) Nut M16X1 Screw M8X110 UNI 5931 24.1 Screw M8X70 UNI 5931 Nut M16X1.5 Nut M18X1.5 Tab. 9.124 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.

  • Page 157: Replacing Elements Subject To Wear And Abrasion

    9.4.2 - REPLACING ELEMENTS SUBJECT TO WEAR AND ABRASION 9.4.2.1 - INITIAL OPERATIONS ATTENTION! Before carrying out any work, it is important to ensure that the line on which the regulator is installed has been shut off upstream and downstream, and discharged. ATTENTION! During assembly, make sure to tighten the screws as per the tables (tightening torques), according to the size for which maintenance is being carried out.

  • Page 158: Regulator Maintenance Procedure Reflux 819

    9.4.3 - REGULATOR MAINTENANCE PROCEDURE REFLUX 819 9.4.3.1 - REGULATOR REFLUX 819 1" - 2 " Fig. 9.56. Regulator REFLUX 819 1" - 2 " HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 159 Step Action Unscrew and remove the screws (31) securing the control head to the regulator body (1). NOTICE! Support the head assembly during this step to avoid falls. Remove the control head and place it on its side on a plane with an impact-resistant surface. NOTICE! Take care not to damage the plug profile (5).
  • Page 160 Regulator REFLUX 819 1" - 2 " HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 161 Step Action Place the rod guide (17) in the eyebolt flange (14). Assemble the eyebolt flange (14) with the upper lid (3). Insert and fix the screws (27) according to the following tightening torque: • 1”: Tab. 9.81 • 2”: Tab. 9.82 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2.
  • Page 162 Regulator REFLUX 819 1" - 2 " HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 163 Step Action Position the diaphragm (50). NOTICE! The concave part of the diaphragm must face the drive chamber (pos. B, fig. 4.2). Put the diaphragm protection disc (12) and the lower diaphragm support (10) in place. NOTICE! Check that the transfer hole (21) on the upper diaphragm support (13) is aligned with the hole on the lower diaphragm support (10).
  • Page 164 Regulator REFLUX 819 1" - 2 " HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 165 Step Action Remove the stem guide (20), the stem (6) and the key (28). NOTICE! • Lubricate the stem surface (6) with silicone grease. • The key (28) must be in the correct position in the stem (6) Place the lower cover (3) on the plug guide (2). NOTICE! The hole for the passage of the loading pressure must match the similar one on the plug guide.
  • Page 166 Regulator REFLUX 819 1" - 2 " HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 167 Step Action Insert the locking nut (9) according to the tightening torque: • 1”: Tab. 9.81 • 2”: Tab. 9.82 NOTICE! Before fixing the lock nut (9), check that the spring (54) is well seated in the appropriate centring stop on the plug guide (2). Unscrew and remove the screws (31) from the blind flange (4).
  • Page 168 Regulator REFLUX 819 1" - 2 " HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 169 Step Action Insert and fasten the screws (31) in the blind flange (4) according to the tightening torque: • 1”: Tab. 9.81 • 2”: Tab. 9.82 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Position the control head inside the regulator body (1) with the indicator slide (16) visible and perpendicular to the gas flow NOTICE! Take care not to damage the plug profile (5).
  • Page 170 9.4.3.2 - REGULATOR REFLUX 819 3” - 4” Fig. 9.57. Regulator REFLUX 819 3” - 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 171 Step Action Unscrew and remove the screws (31) securing the control head to the regulator body (1). NOTICE! Support the head assembly during this step to avoid falls. Remove the control head and place it on its side in a plane with an impact-resistant surface. NOTICE! Take care not to damage the plug profile (5).
  • Page 172 Regulator REFLUX 819 3” - 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 173 Step Action Remove the O-ring (44) from the rod guide (17) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Place the rod guide (17) in the eyebolt flange (14). Assemble the eyebolt flange (14) with the upper lid (3).
  • Page 174 Regulator REFLUX 819 3” - 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 175 Step Action Position the diaphragm (50). NOTICE! The concave part of the diaphragm must face the drive chamber (pos. B, fig. 4.2). Put the lower diaphragm protection disc (12) and the lower diaphragm support (10) in place. NOTICE! Check that the nozzle hole on the upper diaphragm support (13) is aligned with the hole on the lower diaphragm support (10).
  • Page 176 Regulator REFLUX 819 3” - 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 177 Step Action Remove the stem guide (20), the stem (6) and the key (28). NOTICE! • Lubricate the stem surface (6) with silicone grease. • The key (28) must be in the correct position in the stem (6) Position the spacer (19). Place the lower cover (3) on the plug guide (2).
  • Page 178 Regulator REFLUX 819 3” - 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 179 Step Action Insert and secure the locking nuts (33), applying threadlocking glue, according to the tightening torque: • 3”: Tab. 9.83 • 4”: Tab. 9.84 NOTICE! During this phase, manually compress the spring (54). Undo and remove the screws (64). NOTICE! During this step, take care to support the blind flange (4).
  • Page 180 Regulator REFLUX 819 3” - 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 181 Step Action Insert and fasten the screws (64) in the blind flange (4) according to the tightening torque: • 3”: Tab. 9.83 • 4”: Tab. 9.84 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Position the control head inside the regulator body (1) with the indicator slide (16) visible and on axis with the gas flow direction.
  • Page 182 9.4.3.3 - REGULATOR REFLUX 819 6” - 8” Fig. 9.58. Regulator REFLUX 819 6” - 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 183 Step Action Unscrew and remove the screws (31) securing the control head to the regulator body (1). NOTICE! Support the head assembly during this step to avoid falls. Unscrew the screws (57) from the eyebolt flange (14). Remove the indicator slide (16) Remove the pawl (163).
  • Page 184 Regulator REFLUX 819 6” - 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 185 Step Action Remove the O-rings (39, 47) from the eyebolt flange (14) and replace them, taking care to lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Remove the O-ring (44) from the rod guide (17) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 186 Regulator REFLUX 819 6” - 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 187 Step Action Remove and replace the O-ring (45) from the upper diaphragm support (13), lubricating it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Place the upper diaphragm protection disc (12) in the upper diaphragm holder (13). NOTICE! Check that the transfer hole (21) is free of dirt or foreign bodies.
  • Page 188 Regulator REFLUX 819 6” - 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 189 Step Action Remove the O-rings (40, 41) from the stem guide (20) and replace them, taking care to lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-rings, clean the retaining slots with a cleaning solution. Remove the O-ring (42) from the stem (6) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 190 Regulator REFLUX 819 6” - 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 191 Step Action Put the spring (54) and spring support (34) in place. NOTICE! Check that the spring (54) is properly seated in the centring stop on the plug guide (2). Insert slewing ring (131) and radial bearing (130). Insert the locking nut (9) according to the tightening torque: •...
  • Page 192 Regulator REFLUX 819 6” - 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 193 Step Action Insert and fix the screws (30) according to the following tightening torque: • 6”: Tab. 9.85 • 8”: Tab. 9.86 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Fit the blind flange (4). NOTICE! During this step, support the blind flange (4).
  • Page 194 9.4.3.4 - REGULATOR REFLUX 819 10” Fig. 9.59. Regulator REFLUX 819 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 195 Step Action Unscrew and remove the screws (31) securing the control head to the regulator body (1). NOTICE! Support the head assembly during this step to avoid falls. Unscrew the screws (57) from the eyebolt flange (14). Remove the indicator slide (16) Remove the pawl (163).
  • Page 196 Regulator REFLUX 819 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 197 Step Action Remove the O-rings (39, 47) from the eyebolt flange (14) and replace them, taking care to lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Remove the O-ring (44) from the rod guide (17) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 198 Regulator REFLUX 819 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 199 Step Action Remove the diaphragm holder (10). Remove and replace the diaphragm (50). Check that the transfer hole (21) is free of dirt or foreign bodies. Position the diaphragm (50). NOTICE! The concave part of the diaphragm must face the drive chamber (pos. B, fig. 4.2). Apply thread locking glue to insert and fix the screws (29) according to the following tightening torque: •...
  • Page 200 Regulator REFLUX 819 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 201 Step Action Remove the stem guide (20), the stem (6) and the key (28). NOTICE! • Lubricate the stem surface (6) with silicone grease. • The key (28) must be in the correct position in the stem (6) Put the lower cover (3) in place and fix it on the plug guide (2). NOTICE! The hole for the passage of the loading pressure must match the similar one on the plug guide.
  • Page 202 Regulator REFLUX 819 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 203 Step Action Insert the washer (23). Insert and secure the locking nuts (33), applying threadlocking glue, according to the tightening torque: • 10”: Tab. 9.87 Unscrew and remove the screws (64) from the blind flange (4). NOTICE! During this step, take care to support the flange (4) or any accessory. Remove the blind flange (4), taking care to support it.
  • Page 204 Regulator REFLUX 819 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 205 Step Action Insert and fasten the screws (31) that secure the control head to the regulator body (1), according to the tight- ening torque: • 10”: Tab. 9.87 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Insert the pawl (163) into the rod (18).
  • Page 206 9.4.3.5 - REGULATOR REFLUX 819 12” 27.1 Fig. 9.60. Regulator REFLUX 819 12” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 207 Step Action Unscrew and remove the screws (57) from the eyebolt flange (14). Remove the indicator slide (16) Remove the pawl (163). Unscrew and remove the screws (31) securing the control head to the regulator body (1). NOTICE! Support the head assembly during this step to avoid falls. Remove the control head and place it on its side in a plane with an impact-resistant surface.
  • Page 208 27.1 Regulator REFLUX 819 12” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 209 Step Action Remove and replace the O-rings (44, 47) from the rod guide (17), lubricating them with synthetic grease. NOTICE! Before inserting the replacement O-rings, clean the retaining slots with a cleaning solution. Remove and replace the O-ring (44) from the pawl (163), lubricating it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 210 27.1 Regulator REFLUX 819 12” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 211 Step Action Remove and replace the diaphragm (50). Check that the transfer hole (21) is free of dirt or foreign bodies. Remove and replace the O-ring (116) from the lower diaphragm support (10), lubricating it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Position the diaphragm (50).
  • Page 212 27.1 Regulator REFLUX 819 12” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 213 Step Action Remove the stem guide (20), the stem (6) and the key (28). NOTICE! • Lubricate the stem surface (6) with silicone grease. • The key (28) must be in the correct position in the stem (6) Put the lower cover (3) in place and fix it on the plug guide (2). NOTICE! The hole for the passage of the loading pressure must match the similar one on the plug guide.
  • Page 214 27.1 Regulator REFLUX 819 12” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 215 Step Action Insert the plug (5). Insert the washer (23). Insert and secure the locking nuts (33), applying threadlocking glue, according to the tightening torque: • 12”: Tab. 9.88 Unscrew and remove the screws (64) from the blind flange (4). NOTICE! During this step, take care to support the flange (4) or any accessory.
  • Page 216 27.1 Regulator REFLUX 819 12” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 217 Step Action Insert and fasten the screws (31) that secure the control head to the regulator body (1), according to the tight- ening torque: • 12”: Tab. 9.88 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Insert the pawl (163) into the rod (18).

  • Page 218: Db/819 Silencer Maintenance Procedure

    9.4.4 - DB/819 SILENCER MAINTENANCE PROCEDURE DETAIL 10” DETAIL 12” Fig. 9.61. DB/819 silencer HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 219 Step Action Unscrew and remove the screws (31) that secure the control head to the upper flange (72) of the silencer. NOTICE! Support the head assembly during this step to avoid falls. Remove the control head and place it on its side in a plane with an impact-resistant surface. NOTICE! Take care not to damage the plug profile (5).
  • Page 220 DETAIL 10” DETAIL 12” DB/819 silencer HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 221 Step Action a- ONLY VALID FOR 1”- 8” Remove the O-ring (94) from the lower flange (82) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. b - APPLICABLE TO 10”...
  • Page 222 DETAIL 10” DETAIL 12” DB/819 silencer HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 223 Step Action Remove the O-ring (93) from the valve seat (63) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Clean the upper and lower bearing surfaces of the body (1) and the flanges (72, 82), the contact surfaces be- tween the sleeve (79), conical seat (63) and the body.
  • Page 224 DETAIL 10” DETAIL 12” DB/819 silencer HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 225 Step Action Position the replacement lower oil seal (80). Fit the plating (83). Fit the external basket (78). Fit the internal basket (77). Position the replacement upper oil seal (73). Fit the upper flange (72). Insert and fix the nuts (87) according to the following tightening torques: •...

  • Page 226: Pm/819 Built-In Monitor Maintenance Procedure

    9.4.5 - PM/819 BUILT-IN MONITOR MAINTENANCE PROCEDURE 9.4.5.1 - BUILT-IN MONITOR PM/819 1”- 2” Fig. 9.62. Built-in monitor PM/819 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 227 Step Action Undo and remove the screws (31). NOTICE! Support the head assembly during this step to avoid falls. Remove the reduction unit and place it on its side, on an anti-shock surface. NOTICE! Take care not to damage the plug profile (71). Remove the O-ring (37) from the plug (70) and replace it, taking care to lubricate it with synthetic grease.
  • Page 228 Built-in monitor PM/819 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 229 Step Action Remove the upper lid (3). Remove the indicator rod (18) from the rod guide (17). Undo and remove the screws of the upper section (27). Separate the upper lid (3) from the eyebolt flange (14). Take out the rod guide (17). Remove the O-rings (39, 47) from the eyebolt flange (14) and replace them, taking care to lubricate them with synthetic grease.
  • Page 230 Built-in monitor PM/819 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 231 Step Action Put the upper diaphragm support (13) back in place into the upper diaphragm protection disc (12). NOTICE! Check that the transfer hole (21) is free of dirt or foreign bodies. Fit the new diaphragm (50). NOTICE! Fit the diaphragm so that its convulsion is oriented towards the loading chamber. Put the diaphragm protection disc (12) and the lower diaphragm support (10) in place.
  • Page 232 Built-in monitor PM/819 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 233 Step Action Remove the stem guide (20), the stem (6) and the key (28). NOTICE! Lubricate the rod surface with silicone grease; make sure that the key (28) is in the correct posi- tion in the stem (6). Put the lower lid (3) in place and fix it on the plug guide (70). NOTICE! Match the hole for the passage of the loading pressure to the similar one on the plug guide.
  • Page 234 Built-in monitor PM/819 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 235 Step Action Position the reduction unit, supporting it carefully. NOTICE! Lubricate the rod surface with silicone grease; make sure that the key (28) is in the correct posi- tion in the stem (6). Fit and fix the screws (31) according to the following tightening torques: •...
  • Page 236 9.4.5.2 - BUILT-IN MONITOR PM/819 3”- 4” Fig. 9.63. Built-in monitor PM/819 3”- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 237 Step Action Undo and remove the screws (31). NOTICE! Support the head assembly during this step to avoid falls. Remove the reduction unit and place it on its side, on an anti-shock surface. NOTICE! Take care not to damage the plug profile (71). Remove the O-ring (37) from the plug (70) and replace it, taking care to lubricate it with synthetic grease.
  • Page 238 Built-in monitor PM/819 3”- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 239 Step Action Remove the indicator rod (18) from the rod guide (17). Undo and remove the upper screws (27). Separate the upper lid (3) from the eyebolt flange (14). Take out the rod guide (17). Remove the O-rings (39, 47) from the eyebolt flange (14) and replace them, taking care to lubricate them with synthetic grease.
  • Page 240 Built-in monitor PM/819 3”- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 241 Step Action Put the upper diaphragm support (13) back in place into the upper diaphragm protection disc (12). NOTICE! Check that the transfer hole (21) is free of dirt or foreign bodies. Fit the new diaphragm (50). NOTICE! Fit the diaphragm so that its convulsion is oriented towards the loading chamber. Put the lower diaphragm protection disc (12) and the lower diaphragm support (10) in place.
  • Page 242 Built-in monitor PM/819 3”- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 243 Step Action Remove the O-ring (42) from the stem (6) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Remove the stem guide (20), the stem (6) the spacer (19) and the key (28). NOTICE! •...
  • Page 244 Built-in monitor PM/819 3”- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 245 Step Action Insert the lock nut (9) together with the radial bearing (30) according to the tightening torques: • 3”: Tab. 9.99 • 4”: Tab. 9.100. NOTICE! Before fixing the lock nut (9), check that the spring (80) is well seated in the appropriate centring stop on the plug guide (70).
  • Page 246 9.4.5.3 - BUILT-IN MONITOR PM/819 6”- 10” Fig. 9.64. Built-in monitor PM/819 6”- 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 247 Step Action Undo and remove the screws (31). NOTICE! Support the head assembly during this step to avoid falls. Remove the reduction unit and place it on its side and on an anti-shock surface. NOTICE! Take care not to damage the plug profile (71). Remove the O-ring (37) from the plug (70) and replace it, taking care to lubricate it with synthetic grease.
  • Page 248 Built-in monitor PM/819 6”- 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 249 Step Action Remove the O-ring (87) from the plug guide (72) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Put the plug guide (72) back in place. Insert and fix the screws (86).
  • Page 250 Built-in monitor PM/819 6”- 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 251 Step Action Remove the O-rings (36, 43) from the eyebolt flange (11) and replace them, taking care to lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-rings, clean the retaining slots with a cleaning solution. Place the balancing piston (15) in the piston guide (11). Take out the diaphragm unit.
  • Page 252 Built-in monitor PM/819 6”- 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 253 Step Action Remove the O-ring (41) from the plug guide (70) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Remove the O-ring (40) from the stem guide (20) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 254 Built-in monitor PM/819 6”- 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 255 Step Action Insert and fix the piston guide (11) according to the following tightening torques: • 6”: Tab. 9.101 • 8”: Tab. 9.102 • 10”: Tab. 9.103. NOTICE! In this step, keep the diaphragm unit still, fitting the compass wrench into the holes in the upper diaphragm support (13).

  • Page 256: Pilot Maintenance Procedure 200/A Series + Pre-Regulator R14/A

    9.4.6 - PILOT MAINTENANCE PROCEDURE 200/A SERIES + PRE-REGULATOR R14/A 9.4.6.1 - 200/A SERIES PILOT DISCONNECTION IMPULSO DOWNSTREAM SENSING ELEMENT A VALLE MOTORIZZAZIONE LOADING UPSTREAM IMPULSO SENSING DI MONTE ELEMENT SFIATO VENT VENT Fig. 9.65. Pilot 200/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
  • Page 257 To reconnect the pilot, proceed as indicated at Tab. 9.135 (see Fig. 9.65): Step Action Disconnect the sensing lines between the 200/A pilot and the regulator by adjusting the fittings (1, 2, 3). Unscrew and remove the fixing screw to remove the pilot from the regulator. Remove the pipe (20) by adjusting the fittings (4, 5).
  • Page 258 9.4.6.2 - PILOT 204/A - 205/A A ASSEMBLY (PLUG) B ASSEMBLY (VALVE) Fig. 9.66. Pilot 204/A - 205/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 259 Step Action Loosen the nut (9). Completely release the spring (22) by turning the adjusting screw (10). Remove the adjusting screw (10) together with the cap (9). Remove the cap (8). Remove the O-ring (38) from the cap (8) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 260 A ASSEMBLY (PLUG) B ASSEMBLY (VALVE) Pilot 204/A - 205/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 261 Step Action Remove and replace the lower diaphragm (16), taking care to lubricate the lanyards with synthetic grease. NOTICE! Before inserting the replacement diaphragm, clean the retaining slots with a cleaning solution. Fit the lower protection disc (15). Fix the nut (25) according to the following tightening torque: •...
  • Page 262 9.4.6.3 - PILOT 207/A A ASSEMBLY (PLUG) B ASSEMBLY (VALVE) Fig. 9.67. Pilot 207/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 263 Step Action Loosen the nut (9). Completely release the spring (22) by turning the adjusting screw (10). Remove the adjusting screw (10) together with the cap (9). Remove the cap (8). Remove the O-ring (38) from the cap (8) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 264 A ASSEMBLY (PLUG) B ASSEMBLY (VALVE) Pilot 207/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 265 Step Action Insert assembly “A” (plug) the bottom upwards into the valve body (4). NOTICE! • Take care not to damage the diaphragms (16) during this step. • Make sure the marking on the lower section of the headframe is parallel to the axis of the hole for inserting the seat (3) into the valve body (4).
  • Page 266 9.4.6.4 - PRE-REGULATOR R14/A A ASSEMBLY (PLUG) B ASSEMBLY (CAP) Fig. 9.68. Pre-regulator R14/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 267 Step Action Undo and remove the screws (15). Remove the cover (2) Remove assembly “A” (plug). Remove the spring (12). Unscrew and remove the nut (16). Insert the diaphragm protection disc (6) and the diaphragm (10). Remove and replace the O-ring (17) from the diaphragm protection disc (7), lubricating it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 268 A ASSEMBLY (PLUG) B ASSEMBLY (CAP) Pre-regulator R14/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 269 Step Action Fit the ring (8). Position and secure the assembly " B " (cap). NOTICE! Take care not to damage the O-rings (18, 19) during this step. Fit the spring (12). Insert assembly “A” (plug) into the body (1). NOTICE! Before inserting the plug unit, lubricate the plug surface with silicone grease.
  • Page 270 9.4.6.5 - 200/A SERIES PILOT RECONNECTION IMPULSO A VALLE MOTORIZZAZIONE IMPULSO DI MONTE SFIATO VENT Fig. 9.69. Pilot 200/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 271 To reconnect the pilot, proceed as indicated at Tab. 9.139 (see Fig. 9.69): Step Action Insert and fix the screw (7) to the 200/A pilot. Insert and fix the screw (6) to connect the R14/A pre-regulator to the 200/A pilot. Connect the pipe (20) by adjusting the fittings (4, 5).

  • Page 272: M/A Accelerator Valve Maintenance Procedure

    9.4.7 - M/A ACCELERATOR VALVE MAINTENANCE PROCEDURE Fig. 9.70. M/A accelerating valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 273 Step Action Loosen the nut (27). Completely release the spring (22) by turning the adjusting screw (28). Remove the adjusting screw (28) together with the nut (27). Remove the cap (17). Remove the O-ring (40) from the cap (17) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 274 Accelerating valve M/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 275 Step Action Remove the O-ring (43) from the plug guide (9) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Fit the plug guide (9) together with the reinforced gasket (7). Place the gasket support (1) in the body (10).

  • Page 276: Sb/82 Incorporated Slam-Shut Valve Maintenance Procedure

    9.4.8 - SB/82 INCORPORATED SLAM-SHUT VALVE MAINTENANCE PROCEDURE 9.4.8.1 - INCORPORATED SLAM-SHUT VALVE SB/82 1” Fig. 9.71. Incorporated slam-shut valve SB/82 1” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 277 Step Action WARNING! In this step, support the built-in SB/82 slam-shut valve. Undo and remove the screws (36). Remove the built-in SB/82 slam-shut valve and place it on an anti-shock surface. Undo the screws (137). Remove the flange (8). Remove the O-ring (43) from the flange (8) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 278 Incorporated slam-shut valve SB/82 1” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 279 Step Action Take out the pressure switch unit. NOTICE! For the maintenance procedure of the pressure switch unit, refer to the relative table. Remove the cup (15). Remove the O-ring (42) from the cup (15) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 280 Incorporated slam-shut valve SB/82 1” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 281 Step Action Fit the washer (26) NOTICE! Before inserting the screw (5), apply thread locking glue. Fix the plug screw (5). Fit the spring (47). Fit the plug unit. Insert the serrated washers (60). NOTICE! Before inserting the screw (3), apply thread locking glue. Insert and fix the screws (3) according to the following tightening torque •...
  • Page 282 9.4.8.2 - INCORPORATED SLAM-SHUT VALVE SB/82 2”- 3” Fig. 9.72. Incorporated slam-shut valve SB/82 2”- 3” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 283 Step Action Undo and remove the screws (64). NOTICE! In this step, support the built-in SB/82 slam-shut valve. Remove the O-ring (37) from the flange (9) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Undo the screws (3) together with the toothed washers (60).
  • Page 284 Incorporated slam-shut valve SB/82 2”- 3” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 285 Step Action Extract the stem (6) taking care not to damage it. Remove the seeger ring (28) from the flange (9). Remove the bush (10). Remove the O-ring (41) from the flange (9) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 286 Incorporated slam-shut valve SB/82 2”- 3” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 287 Step Action Fit the spring (47). Fit the plug unit. Insert the screws (3) together with the toothed washers (60). NOTICE! Before inserting the screw (3), apply thread locking glue. Fasten the screws (3), holding down the plug unit to compress the spring (47) in the plug guide (4). Put the SB/82 built-in slam-shut valve in place.
  • Page 288 9.4.8.3 - INCORPORATED SLAM-SHUT VALVE SB/82 4”- 8” Fig. 9.73. Incorporated slam-shut valve SB/82 4”- 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 289 Step Action WARNING! In this step, support the built-in SB/82 slam-shut valve. Undo and remove the screws (31). Remove the O-ring (37) from the flange (9) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Undo the screws (3) together with the toothed washers (32).
  • Page 290 Incorporated slam-shut valve SB/82 4”- 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 291 Step Action Remove the washer (26). Remove the spring (48) and the spring support (4). Unscrew and remove the nut (131). Undo and remove the screws (22) of the pressure switch. Remove the cover (119) and the gasket (29). Undo the side screws (36) inside the control pressure switch. Undo the screws (35).
  • Page 292 Incorporated slam-shut valve SB/82 4”- 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 293 Step Action Remove the I/DWR ring (25) from the bush (10) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before fitting the replacement I/DWR ring, clean the retaining slots using a cleaning solution. Fit the valve seat (10), taking care not to damage the O-ring (41). Place the seeger ring (28) in the flange (9).
  • Page 294 Incorporated slam-shut valve SB/82 4”- 8” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 295 Step Action Apply thread locking glue to insert and fix the plug screws (5) according to the following tightening torque: • 4”: Tab. 9.110 • 6”: Tab. 9.111 • 8”: Tab. 9.112. NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Fit the spring (47).
  • Page 296 9.4.8.4 - INCORPORATED SLAM-SHUT VALVE SB/82 10” Fig. 9.74. Incorporated slam-shut valve SB/82 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 297 Step Action WARNING! In this step, support the built-in SB/82 slam-shut valve. Undo and remove the screws (31). Remove the SB/82 built-in slam-shut valve and place it on a shock-proof surface. Remove the O-ring (37) from the flange (9) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution.
  • Page 298 Incorporated slam-shut valve SB/82 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 299 Step Action Remove the I/DWR ring (25) from the cup (15) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before fitting the replacement I/DWR ring, clean the retaining slots using a cleaning solution. Place the seeger ring (58) in the cup (15). Take out the pressure switch unit.
  • Page 300 Incorporated slam-shut valve SB/82 10” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...

  • Page 301: Hp2/2 Bypass Device Maintenance Procedure

    Step Action Insert and fix the screws (36) according to the following tightening torque: • 10”: Tab. 9.113. NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Fit and secure the cap (30). Fit the gasket (29) and the cover (19).

  • Page 302: Maintenance Procedure For Pressure Switches Mod. 100

    9.4.10 - MAINTENANCE PROCEDURE FOR PRESSURE SWITCHES MOD. 100 9.4.10.1 - PRESSURE SWITCH MOD. 102M/102MH Mod. 102 Fig. 9.75. Pressure switch Mod. 102M/102MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 303 Step Action Unscrew and remove the cap (18). Remove the O-ring (16) from the cover (18) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Completely release the spring (11) by adjusting the ring nut (13).
  • Page 304 Mod. 102 Pressure switch Mod. 102M/102MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 305 Step Action Remove the U-shaped ring (4) from the bush (35) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement U-ring, clean the retaining slots with a cleaning solution. Position the bush (35) together with the O-ring (27). NOTICE! Before inserting the bush (35), lubricate the inner surface with silicone grease.
  • Page 306 9.4.10.2 - PRESSURE SWITCH MOD. 103M/103MH Mod. 103/103MH Fig. 9.76. Pressure switch Mod. 103M/103MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 307 Step Action Unscrew and remove the cap (18). Remove the O-ring (16) from the cover (18) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Completely release the spring (11) by adjusting the ring nut (13).
  • Page 308 Mod. 103/103MH Pressure switch Mod. 103M/103MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 309 Step Action Remove the lower lid (41) Insert and fix the screws (48) according to the following tightening torque: • Mod. 103: Tab. 9.115. NOTICE! • Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”;...
  • Page 310 9.4.10.3 - PRESSURE SWITCH MOD. 104M/104MH - 105M/105MH Mod. 104M/104MH Mod. 105M/105MH Fig. 9.77. Pressure switch Mod. 104M/104MH - 105M/105MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 311 Step Action Unscrew and remove the cap (18). ¹ Remove the O-ring (16) from the cover (18) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Completely release the spring (11) by adjusting the ring nut (13).
  • Page 312 Mod. 104M/104MH Mod. 105M/105MH Pressure switch Mod. 104M/104MH - 105M/105MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 313 Step Action Insert and fix the screws (48) according to the following tightening torques: • Mod. 104-105: Tab. 9.116. NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Fit the upper cover (40). Insert and fix the screws (42) according to the following tightening torques: •...

  • Page 314: Hb/97 Built-In Slam-Shut Valve Maintenance Procedure

    9.4.11 - HB/97 BUILT-IN SLAM-SHUT VALVE MAINTENANCE PROCEDURE 4” Fig. 9.78. HB/97 built-in slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 315 Step Action NOTICE! To disconnect the LINE OFF 2.0 device, refer to paragraph “9.4.10.1 - Pressure switch Mod. 102M/102MH” Undo and remove the screws (81). Remove the bracket (82). Unscrew and remove the nut (59) together with the indicator disc (60). Unscrew and remove the nut (17).
  • Page 316 4” HB/97 built-in slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 317 Step Action ONLY VALID FOR 4” Remove the I/DWR rings (76) from the plug guide (70) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the I/DWR rings, clean the retaining slots with a cleaning solution. Remove the O-ring (88) from the plug (71) and replace it, taking care to lubricate it with synthetic grease.
  • Page 318 4” HB/97 built-in slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 319 Step Action Remove the stem (6) from the stem guide (20). Remove the I/DWR ring (51) from the stem guide (20) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement I/DWR ring, clean the retaining slots with a cleaning solution. Remove the O-rings (36) from the stem guide (20) and replace them, taking care to lubricate them with syn- thetic grease.
  • Page 320 4” HB/97 built-in slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 321 Step Action Insert the stem (6) together with the key (28) in the stem guide (20). NOTICE! Clean and lubricate the stem surface with silicone grease; make sure that the key (28) is in the correct position in the stem (6). Insert the stem guide (20) together with the stem (6) into the plug guide (70).
  • Page 322 4” HB/97 built-in slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 323 Step Action Fit the plating (75). NOTICE! Before refitting the plating (75), clean and lubricate the internal surface with silicone grease. Fit the upper flange (74). NOTICE! The stroke indicator hole must be perpendicular to the flow and visible in the in-line installation. Insert and fix the nuts (67) according to the following tightening torques: •...

  • Page 324: Line Off 2.0 Maintenance Procedure

    9.4.12 - LINE OFF 2.0 MAINTENANCE PROCEDURE 9.4.12.1 - LINE OFF 2.0 DISCONNECTION UPSTREAM SENS- IMPULSO DI MONTE ING ELEMENT IMPULSO A VALLE DOWNSTREAM SENSING ELEMENT BY-PASS BYPASS PRESSIONE DI COMANDO CONTROL PRESSURE Fig. 9.79. LINE OFF 2.0 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
  • Page 325 To disconnect, proceed as follows: Step Action Disconnect the pipes from the fittings (1, 2, 3, 4). Å1 Unscrew and remove the fixing screw to disconnect the LINE OFF 2.0. Disconnect the pipe (20) from the fittings (5, 6). Disconnect the pipe (21) from the fittings (7, 8). Remove assembly “A”...
  • Page 326 9.4.12.2 - HP2/2 BYPASS DEVICE Fig. 9.80. HP2/2 bypass device HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 327 Step Action Remove the knob (9). Undo and remove the screws (15). Remove the cover (2) together with the bush (4), spring (13), plug (12) and stem (8). Remove the bush (4), together with the spring (13), plug (12), stem (8) from the cover (2). Remove the O-ring (22) from the cover (2) and replace it, taking care to lubricate it with synthetic grease.
  • Page 328 HP2/2 bypass device HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 329 Step Action Fit and fix the seat (6) in the body (1). NOTICE! Care must be taken not to ruin the seat profile during this step. Fit the bush (4) in the cover (2). Screw the stem (8) into the plug (12). NOTICE! Before fitting the stem (8), apply thread locking glue.
  • Page 330 9.4.12.3 - AR100 LAMINATION VALVE SEZ. A-A Fig. 9.81. AR100 lamination valve Step Action Undo and remove the locking screw (97). Remove the O-rings (96) from the AR100 lamination valve body (1) and replace them, taking care to lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-rings, clean the retaining slots with a cleaning solution.
  • Page 331 Step Action Unscrew and remove the cap (2). Remove the O-rings (6, 7) from the cap (2) and replace them, taking care to lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-rings, clean the retaining slots with a cleaning solution. Remove and replace the filter (5).
  • Page 332 9.4.12.4 - PRESSURE REGULATOR R44/SS 24.1 24.1 A ASSEMBLY (PLUG) 26.1 26.1 B ASSEMBLY (VALVE) Fig. 9.82. Pressure regulator R44/SS HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 333 Step Action Remove the seeger ring (54). Unscrew the nut (9). Completely release the spring (23) by turning the adjusting screw (10) Unscrew and remove the cap (8). Remove the spring (23) and the spring supports (7). Remove the screw (10) from the cap (8) clockwise, from the inside to the outside. Remove the O-ring (11) from the cap (8) and replace it, taking care to lubricate it with synthetic grease.
  • Page 334 24.1 24.1 A ASSEMBLY (PLUG) 26.1 26.1 B ASSEMBLY (VALVE) Pressure regulator R44/SS HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 335 Step Action Remove the O-ring (56) from the cover (1) and replace it, taking care to lubricate it with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Remove the O-rings (53, 62) from the cover (1) and replace it, taking care to lubricate them with synthetic grease.
  • Page 336 24.1 24.1 A ASSEMBLY (PLUG) 26.1 26.1 B ASSEMBLY (VALVE) Pressure regulator R44/SS HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 337 Step Action Insert and fix the valve seat (38). NOTICE! Take care not to damage the valve seat profile (38) and the O-ring (50). Remove assembly “A” (plug) from the valve body (4). Unscrew and remove the pilot nut (2). Remove the spring (21).
  • Page 338 24.1 24.1 A ASSEMBLY (PLUG) 26.1 26.1 B ASSEMBLY (VALVE) Pressure regulator R44/SS HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 339 Step Action Insert and fix the screws (24.1) according to the following tightening torque: • R44/SS: Tab. 9.124. NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Fit the gaskets (19) and the filter (68). Fit and secure the nut (13) Fit the piston (59) into the spacer (4).
  • Page 340 9.4.12.5 - SAFETY VALVE VS/FI FOR LINE OFF 2.0 Fig. 9.83. Safety valve VS/FI for LINE OFF 2.0 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 341 Step Action Pull out the locking screw (1). Remove the O-rings (8) from the body (2) and replace them, taking care to lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Remove the vent plug (7) and make sure that it is not obstructed by any dirt.
  • Page 342 9.4.12.7 - VALVE 3/2 46.1 46.2 46.3 Fig. 9.84. Valve 3/2 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 343 Step Action NOTICE! Make sure the slam-shut device is set to “OFF”. Undo and remove the screws (122) of the pressure switch cover (119). Remove the pressure switch cover (119) together with the gasket (139). Turn the device upside down. Undo and remove the screw (19) and the lever (18).
  • Page 344 46.1 46.2 46.3 Valve 3/2 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...
  • Page 345 Step Action Remove the O-ring (46.2) and the bush (9). Take out the O-ring (46.1). Replace the O-rings (46.1, 46.2 and 46.3) and lubricate them with synthetic grease. NOTICE! Before inserting the replacement O-rings, clean the retaining slots with a cleaning solution. Remove the O-ring (46.1) and the perforated bush (9).
  • Page 346 46.1 46.2 46.3 Valve 3/2 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...

  • Page 347: Procedure For Recommissioning After Maintenance

    Step Action Insert the valve cover (4) so that the spring (12) rests on the lever of the pressure switch. NOTICE! Keep the valve cover (4) tilted for easier assembly. Push and tilt the valve cover upwards (4). Insert the valve body (3) together with the stem assembly (5, 6, 7, 8, 9, 10) into the valve cover (4). NOTICE! The valve body (3) must be centred with the centring pin (2).
  • Page 348 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. B Use, maintenance and warning manual...

  • Page 349: Troubleshooting

    • qualified and authorised to carry out activities related to the equipment. WARNING! PIETRO FIORENTINI S.p.A. shall not be held liable for any damage to people and property due to services: • other than those described; • performed according to methods other than those specified;...

  • Page 350: Operator Qualification Specification

    10.2 - OPERATOR QUALIFICATION SPECIFICATION Commissioning • Mechanical maintenance technician; • Electrical maintenance technician; Operator qualification • Installer; • Name of the user. WARNING! The PPE listed in this table is related to the risk associated with the equipment. PPE required For the PPE required to protect against risks associated with the workplace, installation or operating conditions, please refer to: •...

  • Page 351: Troubleshooting Tables

    10.4 - TROUBLESHOOTING TABLES NOTICE! See chapter “9 - Maintenance and functional checks” for pictures of the regulator REFLUX 819 and its accessories. 10.4.1 - TROUBLESHOOTING REFLUX 819 REGULATOR Failure Device Possible causes Intervention Dirty or worn reinforced gasket Clean and replace if needed...
  • Page 352 Failure Device Possible causes Intervention Reinforced gasket (8) dirty or Clean and replace if needed damaged O-ring (35) not sealing Clean and replace if needed Balancing piston O-ring (36) not REGULATOR Clean and replace if needed sealing O-ring seal (42) not sealing Clean and replace if needed O-ring (43) not sealing Clean and replace if needed...
  • Page 353 Failure Device Possible causes Intervention Check line filter cartridges for No upstream pressure clogging Clean and check the move- Plug (5) locked ments Dirty O-ring (35) Clean and replace if needed Stem guide (20) O-ring frictions Lubricate and replace if neces- (36) sary Lubricate and replace if neces-...

  • Page 354: Db/819 Silencer Troubleshooting

    10.4.2 - DB/819 SILENCER TROUBLESHOOTING Failure Device Possible causes Intervention Breakage of the external Increase in noise DB/819 SILENCER Replace basket (64) O-ring (39) Clean and replace if needed No sealing not sealing DB/819 SILENCER Zero flow rate O-ring (84) Clean and replace if needed not sealing Tab.

  • Page 355: Apm/819 Built-In Monitor Troubleshooting

    10.4.3 - APM/819 BUILT-IN MONITOR TROUBLESHOOTING Failure Device Possible causes Intervention Dirty or worn plug (9) Clean and replace if needed PRE-REGULATOR R14/A Guide ring (8) worn Replace Dirty or worn plug (17) Clean and replace if needed Diaphragm Centre the hole, assembly holder (16) friction and shaft movement Worn diaphragms (16)
  • Page 356 Failure Device Possible causes Intervention O-ring (17) Clean and replace if needed not sealing O-ring (18) Clean and replace if needed not sealing PRE-REGULATOR R14/A O-ring (20) Clean and replace if needed not sealing Diaphragm (10) worn Replace Diaphragm (16 upper) worn Replace 200/A SERIES PILOTS Dirty or worn plug (17) Clean and replace if needed...
  • Page 357 Failure Device Possible causes Intervention Filter clogging (13) Replace Plug (9) deformation Replace Diaphragm (10) Replace PRE-REGULATOR R14/A damaged Stem (5) locked in closing Clean and lubricate position Stem (5) clogged Clean Plug (17) locked in shut-off Clean and lubricate position Diaphragms (16) Replace...

  • Page 358: Sb/82 Built-In Slam-Shut Valve Troubleshooting

    10.4.4 - SB/82 BUILT-IN SLAM-SHUT VALVE TROUBLESHOOTING WARNING! If the built-in slam-shut valve tripped, close the inlet and outlet valves (V1 and V2) of the line before any other operation and discharge pressure. Failure Device Possible causes Intervention Max. and min. pressure Carry out the calibration spring incorrect calibration again by adjusting the ring...
  • Page 359 Failure Device Possible causes Intervention O-ring (40) Clean and replace if needed not sealing SLAM-SHUT VALVE Plug pad (19) not sealing Clean and replace if needed SB/82 BUILT-IN SLAM- Conical seat (8) SHUT VALVE Replace damaged DN 1” – 3” O-ring (39) Clean and replace if needed not sealing...

  • Page 360: Hb/97 Built-In Slam-Shut Valve Troubleshooting

    10.4.5 - HB/97 BUILT-IN SLAM-SHUT VALVE TROUBLESHOOTING WARNING! If the built-in slam-shut valve tripped, close the inlet and outlet valves (V1 and V2) of the line before any other operation and discharge pressure. Failure Device Possible causes Intervention Max. and/or min. pressure Repeat calibration by ad- spring incorrect calibration.
  • Page 361 Failure Device Possible causes Intervention LAMINATION VALVE Filter (5) clogged Replace AR100 Lower diaphragm (16) Replace breakage Upper diaphragm (16) Replace breakage No sealing Clean and replace if needed dell’O-ring (53) superiore Lower O-ring (53) Clean and replace if needed PRESSURE REGULATOR not sealing R44/SS...
  • Page 362 Failure Device Possible causes Intervention Stem (6) Clean and lubricate locked in opening position Plug (71) Clean and lubricate HB/97 BUILT-IN locked in opening position SLAM-SHUT VALVE O-ring (36) not sealing Clean and replace if needed I/DWR ring (64) replace damaged Breakage of the Diaphragm (43) if...
  • Page 363 Failure Device Possible causes Intervention O-ring (40) Clean and replace if needed not sealing O-ring (36) Clean and replace if needed not sealing O-ring (39) Clean and replace if needed not sealing HB/97 BUILT-IN No sealing Clean and replace if needed SLAM-SHUT VALVE of the "U"...
  • Page 364 HIGH PRESSURE REGULATOR TROUBLESHOOTING REV. B Use, maintenance and warning manual...

  • Page 365: Uninstallation And Disposal

    11 - UNINSTALLATION AND DISPOSAL 11.1 - GENERAL SAFETY WARNINGS HAZARD! Make sure that there are no potentially explosive ignition sources in the work area set up to uninstall and/ or dispose of the equipment. WARNING! Before proceeding with uninstallation and disposal, make the equipment safe by disconnecting it from any power supply.

  • Page 366: Disposal Information

    11.5 - DISPOSAL INFORMATION NOTICE! Bear in mind that the laws in force in the country of installation must be complied with. Illegal or improper disposal involves the application of the penalties provided for by the legislation in force in the country of installation. NOTICE! Proper disposal prevents damage to humans and the environment and promotes the reuse of precious raw materials.

  • Page 367: Recommended Spare Parts

    If spare parts not marked are used,PIETRO FIORENTINI S.p.A. their declared performance cannot be guar- anteed. It is recommended to use original spare partsPIETRO FIORENTINI S.p.A. PIETRO FIORENTINI S.p.A. shall not be held liable for any damage caused by using non-original parts. 12.2 - HOW TO REQUEST SPARE PARTS NOTICE! For specific information, please refer to the sales network of PIETRO FIORENTINI S.p.A.
  • Page 368 HIGH PRESSURE REGULATOR RECOMMENDED SPARE PARTS REV. B Use, maintenance and warning manual...

  • Page 369: Calibration Tables

    13 - CALIBRATION TABLES 13.1 - 200 SERIES PILOT CALIBRATION TABLES The PM/819 monitor uses pilots 204/A, 205/A and 207/A. The adjustment ranges of the different pilots are shown in the following tables: Pilot 204/A Pos. Spring item code Spring colour Min.

  • Page 370: Pressure Switch Calibration Tables Mod. 100

    13.2 - PRESSURE SWITCH CALIBRATION TABLES MOD. 100 Below are the calibration tables for the pressure switches that may be installed in the built-in slam-shut valves: Mod. 102M/102MH - Max pressure Pos. Spring item code Spring colour Min. 2701260 White 2701530 Yellow 0.801...
  • Page 371 Mod. 103M - Min pressure Pos. Spring item code Spring colour Min. 2700464 Orange 2700513 0.501 2700713 Green 0.801 2700750 Black 1.701 2700985 Brown 4.001 d = Wire Diameter (mm) Lo = Spring Length (mm) De = External Diameter (mm) Tab.
  • Page 372 Mod. 105M/105MH - Max pressure Pos. Spring item code Spring colour Min. 2702280 White/Red 2702450 65.001 d = Wire Diameter (mm) Lo = Spring Length (mm) De = External Diameter (mm) Tab. 13.176 Mod. 105M - Min pressure Pos. Spring item code Spring colour Min.
  • Page 373 HIGH PRESSURE REGULATOR CALIBRATION TABLES REV. B Use, maintenance and warning manual...
  • Page 374 TM005ENG...

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