PIETRO FIORENTINI Aperval 101 Use And Maintenance Manual
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PIETRO FIORENTINI Aperval 101 Use And Maintenance Manual

Medium-low pressure gas regulator
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Aperval 101
Medium-low pressure gas regulator
Revision A - Edition 02/2023
USE, MAINTENANCE
AND WARNING
MANUAL
EN

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Summary of Contents for PIETRO FIORENTINI Aperval 101

  • Page 1 Aperval 101 Medium-low pressure gas regulator Revision A - Edition 02/2023 USE, MAINTENANCE AND WARNING MANUAL...
  • Page 2 MEDIUM PRESSURE REGULATOR INTRODUCTION REV. A 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: A COPYRIGHT 2023 © PIETRO FIORENTINI S.P.A. MEDIUM PRESSURE REGULATOR INTRODUCTION REV. A...
  • Page 4 MEDIUM PRESSURE REGULATOR INTRODUCTION REV. A Use, maintenance and warning manual...

  • Page 5: Revision History

    1.1 - REVISION HISTORY Revision Date Revision contents index 02/2023 First issue Tab. 1.1. MEDIUM PRESSURE REGULATOR INTRODUCTION REV. A Use, maintenance and warning manual...

  • Page 6: Table Of Contents

    INDEX 1 - INTRODUCTION ........................3 1.1 - REVISION HISTORY ..........................5 2 - GENERAL INFORMATION ....................11 2.1 - MANUFACTURER IDENTIFICATION ......................11 2.2 - IDENTIFICATION OF THE PRODUCT ...................... 11 2.3 - REGULATORY FRAMEWORK ......................... 11 2.4 - WARRANTY ............................11 2.5 - SYMBOLS USED IN THE MANUAL ......................
  • Page 7 5.1 - SPECIFIC WARNINGS FOR TRANSPORT AND HANDLING ..............35 5.1.1 - PACKAGING AND FASTENERS USED FOR TRANSPORT ..............36 5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT ................37 5.2.1 - APERVAL 101 ............................37 5.3 - EQUIPMENT ANCHORING AND LIFTING METHOD................38 5.3.1 - FORKLIFT HANDLING METHOD ......................39 5.3.2 - CRANE HANDLING METHOD .......................41...
  • Page 8 9.4.1 - TIGHTENING TORQUES APERVAL 101 ....................70 9.4.2 - REPLACING ELEMENTS SUBJECT TO WEAR AND ABRASION............75 9.4.3 - REGULATOR MAINTENANCE PROCEDURE APERVAL 101 ..............76 9.4.4 - MAINTENANCE OF THE 300 SERIES PILOT + AR100 LAMINATION VALVE .........82 MEDIUM PRESSURE REGULATOR INTRODUCTION REV.
  • Page 9 10.2 - OPERATOR QUALIFICATION SPECIFICATION ..................106 10.3 - TROUBLESHOOTING PROCEDURES ....................106 10.4 - TROUBLESHOOTING TABLES ......................107 10.4.1 - TROUBLESHOOTING APERVAL 101 REGULATOR ................107 11 - UNINSTALLATION AND DISPOSAL ................109 11.1 - GENERAL SAFETY WARNINGS ......................109 11.2 - QUALIFICATION OF THE OPERATORS IN CHARGE ................
  • Page 10 MEDIUM PRESSURE REGULATOR INTRODUCTION REV. A Use, maintenance and warning manual...

  • Page 11: 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 12: 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 13: 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 14: Applied Rating Plates

    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 (Id.1 and Id.2). The nameplates specify identification details of the equipment and its accessories to be mentioned in case of need to PIETRO FIORENTINI S.p.A.

  • Page 15: 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 16 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 17: Glossary Of Measurement Units

    2.9 - GLOSSARY OF MEASUREMENT UNITS 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 Pascal...

  • Page 18: 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 19: 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 20: 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 21: 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 22 3.3.1 - TABLE SHOWING RESIDUAL RISKS DUE TO PRESSURE Effect and Risk and Hazard Event and Cause Solution and Prevention Consequence a. Handling and installation with appropri- Pressurised gas • deformation; ate devices to avoid localised stress. • violent impact; leakage.
  • Page 23 Effect and Risk and Hazard Event and Cause Solution and Prevention Consequence a. The user must perform any mainte- • device maintenance • inappropriate open- nance with the equipment not in opera- Pressurised gas with the system ing of pressurised tion.

  • Page 24: 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 the APERVAL 101 pressure regulators to generate a potentially explosive atmosphere. Considering that the silencer does not have active functional parts, in this analysis it is considered an integral part of the APERVAL 101 regulator.
  • Page 25 Atmosphere Management measures in- Operating potentially Regulatory references cluded in the instructions for conditions explosive use and warning This type of malfunction is not rea- Breakage of other sonably expected as it involves stat- non-metallic parts ic seals (to the outside) that cannot (malfunction) generate any external leakage.

  • Page 26: 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 27: 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 28 MEDIUM PRESSURE REGULATOR SAFETY REV. A Use, maintenance and warning manual...

  • Page 29: Description And Operation

    4 - DESCRIPTION AND OPERATION 4.1 - GENERAL DESCRIPTION The equipment APERVAL 101 is a piloted pressure regulator for low and medium pressure which reduces the inlet gas pressure, keeping the downstream value stable even when the following varies: •...

  • Page 30: Regulator Reaction Modes

    4.1.1 - REGULATOR REACTION MODES The APERVAL 101 equipment is a regulator piloted with a “fail open” reaction (on-opening reaction), that is, it opens in the event of: • breakage of the pilot diaphragm(s); • breakage of the pilot plug;...
  • Page 31 In the control head (7), the pressure control element (6), if not pressurised, is kept in the closed position by the spring (8). Under normal operating conditions, the following forces act on the pressure control element (6): • on the upper side: spring load (8), thrust resulting from the control pressure (Cp) in the control chamber (9) and weight of the mobile unit;...

  • Page 32: 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 33: Technical Features/Performance

    The APERVAL 101 equipment is a medium pressure regulator. APERVAL 101 is a “top entry” type regulator that can be easily serviced and equipped with on-site accessories. The reg- ulation system is balanced and guarantees a stable outlet pressure even when the inlet pressure varies.
  • Page 34 MEDIUM PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. A Use, maintenance and warning manual...

  • Page 35: 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 36: 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. 5.19 shows the types of packaging used: Ref.

  • Page 37: Physical Characteristics Of The Equipment

    5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT 5.2.1 - APERVAL 101 Fig. 5.3. APERVAL 101 physical characteristics APERVAL 101 overall dimensions Nominal diameter [mm] Size [inches] 2” 3” 4” S - Ansi 150/PN 16 Connecting pneumatic Øe 10 x Øi 8 pipes Tab.

  • Page 38: 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 39: 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 40 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 41: 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 42: 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 43: 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 44 MEDIUM PRESSURE REGULATOR TRANSPORT AND HANDLING REV. A Use, maintenance and warning manual...

  • Page 45: 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 - Applied rating plates”). The installation site must be suitable for the safe use of the equipment.

  • Page 46: 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 47: 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 48: 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. 6.4 and Fig. 6.5): Pos.

  • Page 49: 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 50: 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 51 To calculate the flow rate, use the following formula: 1 − 0,002 = 345,92 V = gas velocity in m/sec Q = gas flow rate Sm³/h DN = nominal diameter of the regulator in mm Dp = regulator outlet pressure in barg NOTICE! All on-site pneumatic connections must have pipes with a minimum internal diameter of 8 mm To prevent the sensing line pipes from collecting impurities and condensation, it is necessary that:...

  • Page 52: Post-Installation And Pre-Commissioning Checks

    If there is a sensing line, provide equipment connections as shown below: • 1 and 2 free sockets; • 3 and 4 pilot sensing lines; • 5 and 6 free sockets. NOTICE! If there is a multiple sensing line, it is not recommended to place shut-off valves on sensing lines. In any case, follow the regulations in force in the place of installation and use of the equipment.

  • Page 53: 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 54 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. 7.31. MEDIUM PRESSURE REGULATOR REV. A COMMISSIONING AND MAINTENANCE EQUIPMENT Use, maintenance and warning manual...

  • Page 55: Equipment Needed For The Different Configurations

    Code, referring to the equipment. Indicates the Nominal Diameter of the reference configuration. Length, referred to the equipment. Ref. Reference to the equipment. Type Type (size) or code of the equipment. Tab. 7.32. APERVAL 101 Equipment Size [inches] Ref. Type 2” 3” 4”...
  • Page 56 MEDIUM PRESSURE REGULATOR REV. A COMMISSIONING AND MAINTENANCE EQUIPMENT Use, maintenance and warning manual...

  • Page 57: 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 58: 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 eliminat- ed 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 59: Proper Commissioning Check

    8.3 - PROPER COMMISSIONING CHECK Completely sprinkle the equipment with a foaming solution in order to check the tightness of the regulator’s external sur- faces and of the connections made during installation (or equivalent control system). 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 section “2.8 - Applied rating plates”).

  • Page 60: 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 61 Step Action Partially open the bleed cock (6). Completely unscrew the fixing nut and adjusting screw (Fig. 8.12, ref. 10) of the pilot (3) to relieve the spring. Check that the value of the AR100 lamination valve (2) is between 3 and 5. NOTICE! If necessary, turn the screw of the AR100 lamination valve (2) to the required value.

  • Page 62: Device Calibration

    8.5.1 - DEVICE CALIBRATION 8.5.1.1 - 300 SERIES PILOT CALIBRATION Fig. 8.12. 300 series pilot calibration Turn the adjusting screw (10): • anti-clockwise to decrease the adjusted pressure; • clockwise to increase the adjusted pressure. MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...

  • Page 63: 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 64 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 65: 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 66: 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 67: 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 68 Minimum Category Part description Evaluation criterion replacement frequency Relief valves 6 years Non-metallic parts of equipment with an in- ternal sealing function: under normal oper- If there are Regulation lines disconnection equipment ating conditions during maintenance proven leaks Non-metallic parts with a static sealing If there are Various equipment function only...

  • Page 69: 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 70: Tightening Torques Aperval 101

    9.4.1 - TIGHTENING TORQUES APERVAL 101 Fig. 9.13. Tightening torques APERVAL 101 MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 71 APERVAL 101 2” Pos. Description Torque (nm) Torque (ft - lb) Screw M12X35 UNI 5739 Nut M12X1.25 UNI 5588 Tab. 9.43. APERVAL 101 3” Pos. Description Torque (nm) Torque (ft - lb) Screw M12X40 UNI 5739 Nut M12 UNI 5588 Nut M12X1.25 UNI 5588...
  • Page 72 9.4.1.1 - TIGHTENING TORQUES FOR PILOTS SERIES 300 VALID FOR 301/A/TR 24.1 Fig. 9.14. Tightening torques for pilot 301/A and 301/A/TR PILOT 301/A; 301/A/TR Pos. Description Torque (nm) Torque (ft - lb) Nut M16X1 Screw M6X25 UNI 5931 AISI Screw M8X30 UNI 5931 AISI 24.1 Screw M8X40 UNI 5931 AISI Nut M16X1.5...
  • Page 73 24.1 Fig. 9.15. Tightening torques for pilots 302/A PILOT 302/A Pos. Description Torque (nm) Torque (ft - lb) Nut M16X1 Screw M8X30 UNI 5931 AISI Screw M8X25 UNI 5931 AISI 24.1 Screw M8X30 UNI 5931 AISI Nut M16X1.5 Nut M18X1.5 Nut M20X1 Tab.
  • Page 74 9.4.1.2 - TIGHTENING TORQUES FOR LAMINATION VALVE AR100 Fig. 9.16. Tightening torques for lamination valve AR100 LAMINATION VALVE AR100 Pos. Description Torque (nm) Torque (ft - lb) Cap M20X1.5 Screw M8 AISI Tab. 9.48 MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.

  • Page 75: Replacing Elements Subject To Wear And Abrasion

    AR100 lamination valve. NOTICE! For procedures for replacing pilot unit parts, please refer to paragraphs “9.4.3 - Regulator Main- tenance Procedure APERVAL 101” Tab. 9.49 9.4.2.2 - CROSS DIAGRAM FOR TIGHTENING SCREWS When indicated by the maintenance procedure, refer to the following diagram to tighten the screws: Fig.

  • Page 76: Regulator Maintenance Procedure Aperval 101

    9.4.3 - REGULATOR MAINTENANCE PROCEDURE APERVAL 101 9.4.3.1 - APERVAL 101 2” - 3” EYEBOLT DETAIL 3” Fig. 9.18. Regulator APERVAL 101 2” - 3” MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 77 Step Action ONLY VALID FOR 3” Unscrew and remove the nuts (48). ONLY VALID FOR 3” Unscrew and remove the nut (29). Unscrew and remove the fixing screws (24). Remove the upper lid (4). Remove the spring (45). Take out the diaphragm unit (14, 15, 20, 30). Unscrew and remove the nut (30).
  • Page 78 EYEBOLT DETAIL 3” Regulator APERVAL 101 2” - 3” MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 79 Step Action ONLY VALID FOR 3” Insert and fix the nut (29) according to the following tightening torques: • 3”: Tab. 9.44 ONLY VALID FOR 3” Insert the eyebolts (48). Tab. 9.50 WARNING! Ensure that all parts have been fitted correctly. MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
  • Page 80 9.4.3.2 - APERVAL 101 4” Fig. 9.19. Regulator APERVAL 101 4” MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 81 Step Action Unscrew and remove the nuts (48). Unscrew and remove the nuts (29). Undo and remove the screws (24). Remove the upper lid (4). Remove the spring (45). Take out the diaphragm unit (14, 15, 20, 30). Unscrew and remove the nut (30). Remove the diaphragm protection disc (15).

  • Page 82: Maintenance Of The 300 Series Pilot + Ar100 Lamination Valve

    9.4.4 - MAINTENANCE OF THE 300 SERIES PILOT + AR100 LAMINATION VALVE 9.4.4.1 - 300 SERIES PILOT DISCONNECTION DOWNSTREAM SENS- ING LINE TO THE GEAR BOX GAS LEAK UPSTREAM SENSING LINE VENT Fig. 9.20. 300/A series pilot MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
  • Page 83 To disconnect the pilot, proceed as in Tab. 9.52 (Fig. 9.20): Step Action Disconnect the sensing lines between the 300/A pilot and the regulator by adjusting the fittings (2, 3, 4). Unscrew and remove the union (1) to remove the pilot from the regulator. Unscrew and remove the screw (5) to separate the AR100 lamination valve from the pilot.
  • Page 84 9.4.4.2 - PILOT 301/A AND 301/A/TR A ASSEMBLY (DIAPHRAGM) HEAD 301/A/TR B ASSEMBLY (VALVE) C ASSEMBLY (PLUG) Fig. 9.21. Pilot 301/A and 301/A/TR MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 85 Step Action Unscrew the nut (9). Completely relieve the spring (22) by turning the adjusting screw (10) anticlockwise. 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 86 A ASSEMBLY (DIAPHRAGM) HEAD 301/A/TR B ASSEMBLY (VALVE) C ASSEMBLY (PLUG) Pilot 301/A and 301/A/TR MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 87 Step Action Remove the O-ring (55) from the piston guide (62) 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 (56) from the valve seat (3) 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 88 A ASSEMBLY (DIAPHRAGM) HEAD 301/A/TR B ASSEMBLY (VALVE) C ASSEMBLY (PLUG) Pilot 301/A and 301/A/TR MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 89 Step Action Remove and replace the upper 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. Unscrew and remove the nut (25). Remove the lower protection disc (15). Remove and replace the lower diaphragm (16), taking care to lubricate the lanyards with synthetic grease.
  • Page 90 A ASSEMBLY (DIAPHRAGM) HEAD 301/A/TR B ASSEMBLY (VALVE) C ASSEMBLY (PLUG) Pilot 301/A and 301/A/TR MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 91 Step Action Insert assembly “B” (valve) into the valve body (4). NOTICE! Take care not to damage the O-rings (28, 29) and the valve seat (3). Fix the nut (26) according to the following tightening torque: • Pilot 301 and 301/A/TR: Tab. 9.46 a- VALID FOR 301/A Insert the flange (12).
  • Page 92 9.4.4.3 - PILOT 302/A A ASSEMBLY (DIA- PHRAGM) B ASSEMBLY (VALVE) 26.1 24.1 C ASSEMBLY (PLUG) Fig. 9.22. Pilot 302/A MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 93 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 (35) 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 94 A ASSEMBLY (DIA- PHRAGM) B ASSEMBLY (VALVE) 26.1 24.1 C ASSEMBLY (PLUG) Pilot 302/A MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 95 Step Action Remove the O-ring (50) from the valve seat (38) 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 bush (41) Remove the balancing piston (42).
  • Page 96 A ASSEMBLY (DIA- PHRAGM) B ASSEMBLY (VALVE) 26.1 24.1 C ASSEMBLY (PLUG) Pilot 302/A MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 97 Step Action Remove the protective disc (48). Remove and replace the upper 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. Unscrew and remove the nut (25). Remove the protective disc (15).
  • Page 98 A ASSEMBLY (DIA- PHRAGM) B ASSEMBLY (VALVE) 26.1 24.1 C ASSEMBLY (PLUG) Pilot 302/A MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 99 Step Action Insert and fix the screws (24.1) according to the following tightening torque: • Pilot 302: Tab. 9.47 Fit the spring (22) and the spring supports (7). Unscrew the cap (8). Remove the O-ring (11) from the nut (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 100 9.4.4.4 - AR100 LAMINATION VALVE SEZ. A-A Fig. 9.23. 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 101 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 102 9.4.4.5 - 300/A SERIES PILOT RECONNECTION Fig. 9.24. 300/A series pilot MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
  • Page 103 To reconnect the pilot, proceed as indicated in Tab. 9.56 (Fig. 9.24): Step Action Insert and secure the screw (5) into the AR100 lamination valve to connect it to the pilot. Attach the fitting (1) to connect the pilot to the regulator. Connect the sensing lines between the 300/A pilot and the regulator by adjusting the fittings (2, 3, 4).
  • Page 104 MEDIUM PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...

  • Page 105: 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 106: 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 107: Troubleshooting Tables

    10.4 - TROUBLESHOOTING TABLES NOTICE! Refer to chapter 9 “Maintenance and functional checks” for the pictures of the APERVAL 101 regulator and its accessories. 10.4.1 - TROUBLESHOOTING APERVAL 101 REGULATOR Failure Device Possible causes Service Adjust the flow rate LAMINATION VALVE...
  • Page 108 Failure Device Possible causes Service LAMINATION VALVE Filter cartridge (11) Replace AR100 clogging Plug (17) worn Replace Diaphragm (49) worn (for SERIE 300 PILOTS Replace 302/A pilot only) Downstream pressure increases Worn diaphragms (16) Replace REGULATOR Diaphragm (20) worn Replace Adjust the flow rate LAMINATION VALVE Incorrect adjustment...

  • Page 109: 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 110: 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 111: 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 112 MEDIUM PRESSURE REGULATOR RECOMMENDED SPARE PARTS REV. A Use, maintenance and warning manual...

  • Page 113: Calibration Tables

    13 - TABELLE DI TARATURA 13.1 - TABELLE DI TARATURA PILOTI SERIE 300 301/A Pos. Codice articolo molla Colore molla Min. 2700680 Marrone 0,005 0,019 2700830 Rosso/Nero 0,02 0,045 2700920 Bianco/Giallo 0,046 0,078 2701040 Bianco/Arancio 0,079 d = Diametro Filo (mm) Lo = Lunghezza Molla (mm) De = Diametro Esterno (mm) Tab.
  • Page 114 TM0027ENG...

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