Page 1 Aperval 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 5.2.2 - APERVAL + DB .............................50 5.2.3 - APERVAL + PM/182..........................51 5.2.4 - APERVAL + SA .............................52 5.2.5 - APERVAL + DB + PM/182 ........................54 5.2.6 - APERVAL + DB + SA ..........................56 5.3 - EQUIPMENT ANCHORING AND LIFTING METHOD................58 5.3.1 - FORKLIFT HANDLING METHOD ......................59...
Page 8 8.4 - CALIBRATION OF ANY ACCESSORIES ....................79 8.5 - REGULATOR COMMISSIONING PROCEDURE ..................80 8.6 - PROCEDURE FOR COMMISSIONING THE APERVAL REGULATOR WITH PM/182 BUILT-IN MONITOR 82 8.7 - START-UP PROCEDURE FOR APERVAL REGULATOR WITH INCORPORATED MONITOR PM/182 AND ACCELERATOR VALVE V/25 ........................
Page 9 9.4.1 - TIGHTENING TORQUES APERVAL .....................110 9.4.2 - REPLACING ELEMENTS SUBJECT TO WEAR AND ABRASION............131 9.4.3 - REGULATOR MAINTENANCE PROCEDURE APERVAL ..............132 9.4.4 - MAINTENANCE OF THE 300/A SERIES PILOT + AR100 LAMINATION VALVE ........144 9.4.5 - DB APERVAL SILENCER MAINTENANCE ...................164 9.4.6 - PM/182 BUILT-IN MONITOR MAINTENANCE ..................172...
Page 10 11 - UNINSTALLATION AND DISPOSAL ................249 11.1 - GENERAL SAFETY WARNINGS ......................249 11.2 - QUALIFICATION OF THE OPERATORS IN CHARGE ................249 11.3 - UNINSTALLATION ..........................249 11.4 - INFORMATION REQUIRED IN CASE OF RE-INSTALLATION ..............249 11.5 - DISPOSAL INFORMATION ........................250 12 - RECOMMENDED SPARE PARTS ...................
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 (from Id.1 to Id.8).
Page 15 Type Image NAMEPLATE MONITOR NAMEPLATE SLAM-SHUT VALVE NAMEPLATE PRESSURE SWITCH NAMEPLATE ACCELERATOR VALVE Tab. 2.5. MEDIUM PRESSURE REGULATOR GENERAL INFORMATION REV. A Use, maintenance and warning manual...
Page 16: 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 17 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). Term Description Full setpoint range with regard to tripping caused by decreased pressure in the pressure switch Wdsu...
Page 18: 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 19: 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 20 MEDIUM PRESSURE REGULATOR GENERAL INFORMATION REV. A Use, maintenance and warning manual...
Page 21: 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 22: 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 23: 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 24 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 25 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 26: 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: • APERVAL pressure regulator; • the PM/182 monitor; • slam-shut valves SA.
Page 27 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 28: 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 29: 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 30 MEDIUM PRESSURE REGULATOR SAFETY REV. A Use, maintenance and warning manual...
Page 31: Description And Operation
4 - DESCRIPTION AND OPERATION 4.1 - GENERAL DESCRIPTION The equipment APERVAL is a piloted pressure regulator for low and medium pressure which reduces the inlet gas pres- sure, keeping the downstream value stable even when the following varies: •...
Page 32: Regulator Reaction Modes
4.1.1 - REGULATOR REACTION MODES The APERVAL 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 33 In the control head (7), the pressure control element (6), if not pressurised, is kept in the closed position by the spring (8). In normal operating conditions, the following forces act on the 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 34: 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 35: Technical Features/Performance
The APERVAL equipment is a medium pressure regulator. APERVAL is a “top entry” type regulator that can be easily serviced and equipped with on-site accessories. The regulation system is balanced and guarantees a stable outlet pressure even when the inlet pressure varies.
Page 36: Possible Configurations
4.5 - POSSIBLE CONFIGURATIONS The APERVAL equipment can have different configurations through the installation of the following accessories: • DB Aperval silencer • Monitor PM/182 • Built-in slam-shut valve SA The possible configurations are listed in Tab. 4.18: Silencer Monitor...
Page 37: Built-In Silencer
4.5.1 - BUILT-IN SILENCER The DB Aperval silencer (1) is incorporated between the control head (2) and the main body of the equipment (3). The DB Aperval silencer (1) reduces the noise generated by the equipment during the lamination process. Noise is ab- sorbed precisely where it is generated, which prevents it from propagating.
Page 38: Monitor
• they work on independent valve seats. pstream pressUre ownstream pressUre regUlator pressUre oaDing pressUre Fig. 4.4. APERVAL with PM/182 monitor MEDIUM PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. A Use, maintenance and warning manual...
Page 39 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) on the flange of the monitor: • open 100%; • closed 0%. In depressurised conditions, the plug (3) is kept in a closed position by the spring (4) and rests on the reinforced gasket (5).
Page 40 OPERATION OF THE BUILT-IN MONITOR IN STAND-BY CONDITIONS: The PM/182 built-in monitor (1) is normally open during standard operation as pilot (3) calibration is higher than that of the main regulator’s (4) pilot. The passage of the pre-regulator pressure (Pep) generated by the pre-regulator R31/A (4) through the fully open pilot (3) keeps the built-in monitor PM/182 (1) fully open.
Page 41 BUILT-IN MONITOR OPERATION IN THE EVENT OF FAILURE OF THE MAIN REGULATOR: pstream pressUre ownstream pressUre regUlator pressUre oaDing pressUre Fig. 4.7. Built-in monitor operation in the event of failure of the main regulator Should the main regulator (2) fail, the PM/182 monitor (1) will trip until balanced adjustment is achieved. If, during operation, the following should occur: Operating conditions Operating consequences...
Page 42: V/25 And M/A Accelerator Valves
4.5.2.1 - V/25 AND M/A ACCELERATOR VALVES NOTICE! To use the monitor as a safety accessory according to Directive 2014/68/EU 'PED', installing V/25 or M/A accelerator valves is recommended. In the event of malfunctions of the main regulator (2), to speed up tripping of built-in monitor PM/182 (1), accelerator valves will be installed •...
Page 43 pstream pressUre ownstream pressUre regUlator pressUre oaDing pressUre Fig. 4.9. M/A accelerator valve MEDIUM PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. A Use, maintenance and warning manual...
Page 44: 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 45 pstream pressUre ownstream pressUre ontrol pressUre Fig. 4.10. Built-in slam-shut valve SA OPERATION In the control head (C), the downstream pressure (Dp) acts on the diaphragm (6) of the control pressure switch (2), which, integral with the control shaft (8), receives an antagonistic force through the springs (4, 5), which causes the plug (1) on the reinforced gasket (9) to disengage.
Page 46 MEDIUM PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. A Use, maintenance and warning manual...
Page 47: 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 48: 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. 5.24 shows the types of packaging used: Ref.
Page 49: Physical Characteristics Of The Equipment
5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT 5.2.1 - APERVAL Fig. 5.11. APERVAL physical characteristics APERVAL overall dimensions Nominal diameter [mm] Size [inches] 1” 2” 2” 1/2 3” 4” S - Ansi 150/PN 16 Connecting pneumatic Øe 10mm x Øi 8mm pipes Tab.
Page 50: Aperval + Db
5.2.2 - APERVAL + DB Fig. 5.12. Physical characteristics APERVAL + DB Aperval Overall dimensions APERVAL + DB Nominal diameter [mm] Size [inches] 1” 2” 2” 1/2 3” 4” S - Ansi 150/PN 16 Connecting pneumatic Øe 10mm x Øi 8mm pipes Tab.
Page 51: Aperval + Pm/182
5.2.3 - APERVAL + PM/182 Ø Fig. 5.13. APERVAL + PM/182 physical characteristics APERVAL + PM/182 overall dimensions Nominal diameter [mm] Size [inches] 1” 2” 2” 1/2 3” 4” S - Ansi 150/PN 16 Ø Connecting pneumatic Øe 10mm x Øi 8mm pipes Tab.
Page 52: Aperval + Sa
5.2.4 - APERVAL + SA Fig. 5.14. Physical characteristics APERVAL + SA Overall dimensions APERVAL + SA Nominal diameter [mm] Size [inches] 1” 2” 2” 1/2 3” 4” S - Ansi 150/PN 16 Connecting pneumatic Øe 10mm x Øi 8mm pipes Tab.
Page 53 MEDIUM PRESSURE REGULATOR TRANSPORT AND HANDLING REV. A Use, maintenance and warning manual...
Page 54: Aperval + Db + Pm/182
5.2.5 - APERVAL + DB + PM/182 Ø Fig. 5.15. Physical characteristics APERVAL + DB + PM/182 MEDIUM PRESSURE REGULATOR TRANSPORT AND HANDLING REV. A Use, maintenance and warning manual...
Page 55 Overall dimensions APERVAL + DB + PM/182 Nominal diameter [mm] Size [inches] 1” 2” 2” 1/2 3” 4” S - Ansi 150/PN 16 Ø 1174 Connecting pneumatic Øe 10mm x Øi 8mm pipes Tab. 5.33. Weight [kgf] Ansi 150/PN 16 Tab.
Page 56: Aperval + Db + Sa
5.2.6 - APERVAL + DB + SA Fig. 5.16. Physical characteristics APERVAL + DB + SA MEDIUM PRESSURE REGULATOR TRANSPORT AND HANDLING REV. A Use, maintenance and warning manual...
Page 57 Overall dimensions APERVAL + DB + SA Nominal diameter [mm] Size [inches] 1” 2” 2” 1/2 3” 4” S - Ansi 150/PN 16 1164 Connecting pneumatic Øe 10mm x Øi 8mm pipes Tab. 5.35. Weight [kgf] Ansi 150/PN 16 Tab. 5.36.
Page 58: 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 59: 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 60 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 61: 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 62: 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 63: Storage And Environmental Conditions
For the replacement of the rubber parts of the equipment, please refer to “9.4.2.2 - Cross diagram for tightening screws”. NOTICE! PIETRO FIORENTINI S.p.A. recommends checking the condition of rubber parts in case of downtime or storage longer than 3 years.
Page 64 MEDIUM PRESSURE REGULATOR TRANSPORT AND HANDLING REV. A Use, maintenance and warning manual...
Page 65: 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 66: 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 67: 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 68: 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. 6.17 and Fig. 6.18): Pos.
Page 69: 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 70: 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 71 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 72: 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/182 monitor, if any; • 3 and 4 to the pilot sensing lines; • 5 and 6 to the sensing lines of the accelerator of the slam-shut device, if any.
Page 73: 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 74 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. 7.46. MEDIUM PRESSURE REGULATOR REV. A COMMISSIONING AND MAINTENANCE EQUIPMENT Use, maintenance and warning manual...
Page 75: Equipment Needed For The Different Configurations
2.5-8 2.5-8 K./Wr. 4-5-8 4-5-8 4-5-8 4-5-8 4-5-8 K./Wr. 8-10-17-20 8-10-17-20 10-17-19-22 10-17-19-22 65 x 100 Code 7999099 Tab. 7.48. APERVAL + DB Equipment Ref. Type 1” 2” 2” 1/2 3” 4” 10-16-17-18-19- 10-16-17-18-19- 10-16-17-18-19- 10-16-17-18-19- 10-16-17-18-19- K./Wr. 22-24-27-30 22-24-27-30...
Page 76 APERVAL + PM/182 Equipment Ref. Type 1” 2” 2” 1/2 3” 4” 10-16-17-18-19- 10-16-17-18-19- 10-16-17-18-19- 10-16-17-18-19- 10-16-17-18-19- K./Wr. 22-27-30 22-24-27-30 22-24-27-30 22-24-27-30 22-24-27-41 Ø K./Wr. 2.5-8 2.5-8 2.5-8 2.5-8 2.5-8 K./Wr. 4-5-8 4-5-8 4-5-8 4-5-8 4-5-8 K./Wr. 8-10-17-20 8-10-17-20 8-10-19-22...
Page 77: 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 78: 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 79: 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).
Page 80: 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 81 Step Action Partially open the bleed cock (6). Completely unscrew the fixing nut and adjusting screw (Fig. 8.32, 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 82: Procedure For Commissioning The Aperval Regulator With Pm/182 Built-In Monitor
8.6 - PROCEDURE FOR COMMISSIONING THE APERVAL REGULATOR WITH PM/182 BUILT-IN MONITOR Fig. 8.25. Procedure for commissioning the regulator with PM/182 built-in monitor Step Action Partially open the bleed cock (6). Completely unscrew the nut securing the adjusting screws (Fig. 8.32, ref. 10) of the pilots (3, 7).
Page 83 Step Action Check that the calibration pressure is at the set value by referring to the downstream pressure gauge (5). NOTICE! • To reduce the pressure (to the required value): turn the pilot adjustment screw (7) an- ti-clockwise; • To increase the pressure (to the required value): turn the pilot adjustment screw (7) clock- wise.
Page 84: Start-Up Procedure For Aperval Regulator With Incorporated Monitor Pm/182 And
8.7 - START-UP PROCEDURE FOR APERVAL REGULATOR WITH INCORPORATED MONITOR PM/182 AND ACCELERATOR VALVE V/25 Fig. 8.26. Procedure for commissioning the regulator with PM/182 built-in monitor and V/25 accelerator MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
Page 85 Step Action Partially open the bleed cock (6). Completely unscrew the fixing nut of the pilot adjustment screw (3, 7). Unscrew and remove the cap of the V/25 accelerator valve (12). Completely compress the pilot spring (3) by turning the adjusting screw (Fig. 8.32, ref. 10) clockwise. Completely relieve the pilot spring (7) by turning the adjusting screw (Fig.
Page 86 Procedure for commissioning the regulator with PM/182 built-in monitor and V/25 accelerator MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
Page 87 Step Action Check that the downstream pressure, after an increase phase, does not exceed the closing pressure value (refer to the SG value of the built-in monitor on the rating plate, see 2.8). NOTICE! • If the downstream pressure exceeds the shut-off pressure value, refer to chapter 10 “Fault search and troubleshooting”...
Page 88: Start-Up Procedure For Aperval Regulator With Incorporated Monitor Pm/182 And Accelerator Valve M/A
8.8 - START-UP PROCEDURE FOR APERVAL REGULATOR WITH INCORPORATED MONITOR PM/182 AND ACCELERATOR VALVE M/A Fig. 8.27. Procedure for commissioning the regulator with PM/182 built-in monitor and M/A accelerator MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
Page 89 Step Action Partially open the bleed cock (6). Completely unscrew the fixing nut of the adjusting screw (Fig. 8.32, ref. 10) of the pilots (3, 7) and the M/A accelerator valve (12). Completely compress the pilot spring (3) by turning the adjusting screw (Fig. 8.32, ref. 10) clockwise. Completely relieve the pilot spring (7) by turning the adjusting screw (Fig.
Page 90 Procedure for commissioning the regulator with PM/182 built-in monitor and M/A accelerator MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
Page 91 Step Action Check that the downstream pressure, after an increase phase, does not exceed the closing pressure value (refer to the SG value of the built-in monitor on the rating plate, see 2.8). NOTICE! • If the downstream pressure exceeds the shut-off pressure value, refer to chapter 10 “Fault search and troubleshooting”...
Page 92: Commissioning Procedure For The Aperval Regulator With Integrated Sa Block Valve
8.9 - COMMISSIONING PROCEDURE FOR THE APERVAL REGULATOR WITH INTE- GRATED SA BLOCK VALVE SA BUILT-IN SLAM-SHUT VALVE 8.9.1 - CHECKING THE CLOSING TIGHTNESS OF THE Fig. 8.28. Sealing of the SA slam-shut valve when closing Step Action Check that the slam-shut valve (11) is in the closed position.
Page 93: Commissioning Of The Regulator Aperval With Sa Slam-Shut Valve
8.9.2 - COMMISSIONING OF THE REGULATOR APERVAL WITH SA SLAM-SHUT VALVE For the following procedure, please refer to paragraph “8.9.1 - Checking the closing tightness of the SA built-in slam- shut valve”: Step Action Make sure that the bleed cock (6) is partially open.
Page 94 Sealing of the SA slam-shut valve when closing Check that the downstream pressure (Dp), 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 95: Pressurising With External Source
8.9.5 - PRESSURISING WITH EXTERNAL SOURCE It is possible to pressurise the chamber (A) of the pressure switch control head (1) using an external source. Pressurisation can take place via an external pressure source and is controlled using pressure gauges or transducers. To correctly discharge the introduced pressure, make sure there is an additional bleed cock (2).
Page 96: Calibration Procedure For Pressure Switches Mod. Sa
8.9.3 - CALIBRATION PROCEDURE FOR PRESSURE SWITCHES MOD. SA Fig. 8.29. Calibration of pressure switches models SA-91, SA-92, SA-93 Fig. 8.30. APERVAL with built-in SA shut-off valve and external pressure source MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
Page 97 SPRING CALIBRATION FOR MAXIMUM PRESSURE TRIP Step Action Increase the downstream pressure to the start value by turning the adjustment screw (Fig. 8.32, ref. 10) on the pilot clockwise. NOTICE! Check the tripping pressure value of the slam-shut valve indicated on the downstream pressure gauge (Fig.
Page 98 Fig. 8.29 Calibration of pressure switches models SA-91, SA-92, SA-93 MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
Page 99 SPRING CALIBRATION FOR MINIMUM PRESSURE TRIP (IF APPLICABLE) Step Action Partially open the drain cock (Fig. 8.24, ref. 6) to the atmosphere and keep it open for the next steps. Turn the adjustment screw (Fig. 8.32, ref. 10) of the pilot anti-clockwise to decrease the downstream pressure (Dp) to the minimum pressure required for the slam-shut valve to operate.
Page 100: Device Calibration
8.9.4 - DEVICE CALIBRATION 8.9.4.1 - V/25 ACCELERATOR VALVE CALIBRATION Fig. 8.31. V/25 Accelerator valve calibration Adjust the adjustment ring nut (23): • anticlockwise to decrease the adjusted pressure; • clockwise to increase the adjusted pressure. 8.9.4.2 - CALIBRATION OF 300, 200 SERIES PILOTS AND M/A ACCELERATOR VALVE Fig.
Page 101: Calibration Of Pressure Switches Mod. Sa
8.9.4.3 - CALIBRATION OF PRESSURE SWITCHES MOD. SA Fig. 8.33. Calibration of pressure switches mod. SA-91, SA-92, SA-93 Adjust the maximum pressure (11) ring nut (13): • anti-clockwise to decrease the slim-shut device tripping pressure; • clockwise to increase the slim-shut device tripping pressure. Turn the minimum pressure (17) ring nut (15): •...
Page 102 MEDIUM PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
Page 103: 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 104 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 105: 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 106: 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 107: 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 108 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 109: 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 110: Tightening Torques Aperval
9.4.1 - TIGHTENING TORQUES APERVAL VALID FOR APERVAL + DB VALID FOR VALID FOR 4” 1” ÷-3” Fig. 9.34. Tightening torques APERVAL HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 111 Nut M12 UNI 5588 Nut M12X2.5 UNI 5588 Nut M16 UNI 5588 Screw M12X35 UNI 5931 Screw M12X35 UNI 5739 Tab. 9.73. APERVAL 2” 1/2 (+DB APERVAL) Pos. Description Torque (nm) Torque (ft - lb) Screw M12X50 UNI 5737 Screw M12X35 UNI 5739...
Page 112 VALID FOR APERVAL + DB VALID FOR VALID FOR 4” 1” ÷-3” Fig. 9.35. Tightening torques APERVAL HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 113 APERVAL 3” (+DB APERVAL) Pos. Description Torque (nm) Torque (ft - lb) Screw M12X60 UNI 5737 Screw M12X40 UNI 5739 Screw M6X16 UNI 5931 Nut M12 UNI 5588 Nut M12X2.5 UNI 5588 Nut M18 UNI 5587 Screw M12X40 UNI 5931 Screw M12X35 UNI 5739 Tab.
Page 114 9.4.1.1 - TIGHTENING TORQUES FOR PILOTS SERIES 300 VALID FOR 301/A/TR 24.1 Fig. 9.36. 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 115 24.1 Fig. 9.37. 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 116 9.4.1.2 - TIGHTENING TORQUES FOR LAMINATION VALVE AR100 Fig. 9.38. Tightening torques for lamination valve AR100 LAMINATION VALVE AR100 Pos. Description Torque (nm) Torque (ft - lb) Cap M20X1.5 Screw M8 AISI Tab. 9.79 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
Page 117 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 118 9.4.1.3 - TIGHTENING TORQUES FOR PM/182 BUILT-IN MONITOR VALID FOR 1” - 2” Fig. 9.39. Tightening torques for PM/182 built-in monitor HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 119 PM/182 DN 1” Pos. Description Torque (Nm) Torque (ft - lb) Nut M12 M12 piston guide Screw M10X25 UNI 5739 Screw M10X20 UNI 5739 Screw M6X14 UNI 5931 Screw M6X12 UNI 5931 Screw M10X30 UNI 5739 Tab. 9.80. PM/182 DN 2” Pos.
Page 120 VALID FOR 1” - 2” Tightening torques for PM/182 built-in monitor HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 121 PM/182 DN 3” Pos. Description Torque (Nm) Torque (ft - lb) M12 piston guide Screw M10X25 UNI 5739 Screw M10X20 UNI 5739 Screw M6X14 UNI 5931 Screw M6X12 UNI 5931 Screw M12X40 UNI 5739 Tab. 9.83. PM/182 DN 4” Pos. Description Torque (Nm) Torque (ft - lb)
Page 122 9.4.1.4 - TIGHTENING TORQUES FOR PILOTS SERIES 200 Fig. 9.40. Tightening torques for 201/A pilot PILOTS 201/A Pos. Description Torque (Nm) Torque (ft - lb) Nut M16X1 Screw M6X25 UNI 5931 Screw M8X30 UNI 5931 Nut M16x1.5 Nut M16x1.5 Nut M20x1 Tab.
Page 123 Fig. 9.41. Tightening torques for pilots 204 PILOTS 204/A Pos. Description Torque (nm) Torque (ft - lb) Nut M16X1 Screw M8X30 UNI 5931 AISI Nut M16X1.5 Nut M18X1.5 Tab. 9.86 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 124 9.4.1.5 - TIGHTENING TORQUES FOR PRE-REGULATORS Fig. 9.42. Pre-regulator R31/A tightening torques PRE-REGULATOR R31/A Pos. Description Torque (Nm) Torque (ft - lb) Nut M6x25 UNI 5931 Nut M8 UNI 5588 Tab. 9.87. HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 125 Fig. 9.43. Pre-regulator R14/A tightening torques PRE-REGULATOR R14/A Pos. Description Torque (Nm) Torque (ft - lb) Nut M8x30 UNI 5931 Nut M8 UNI 5588 Tab. 9.88. HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 126 9.4.1.6 - TIGHTENING TORQUE SA SLAM-SHUT VALVE Fig. 9.44. SA slam-shut valve tightening torques HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 127 SA 1” Pos. Description Torque (Nm) Torque (ft - lb) Screw M6X12 UNI 5931 Screw M5X16 UNI 5931 Screw M6X12 UNI 5931 Tab. 9.89. SA 2” Pos. Description Torque (Nm) Torque (ft - lb) Screw M6X12 UNI 5931 Screw M5X16 UNI 5931 Screw M6X12 UNI 5931 Tab.
Page 128 9.4.1.7 - TIGHTENING TORQUE CONTROL PRESSURE SWITCH SA-91, SA-92, SA-93 Fig. 9.45. Tightening torques locking mechanism SA-91, SA-92, SA-93 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 129 SA/91 Pos. Description Torque (Nm) Torque (ft - lb) Slam-shut device guide Screw M5X10 UNI 5931 Screw M5X20 UNI 5931 Screw M5X10 UNI 5933 Tab. 9.94. SA/92 Pos. Description Torque (Nm) Torque (ft - lb) Slam-shut device guide Screw M5X10 UNI 5931 Screw M5X20 UNI 5931 Screw M5X10 UNI 5933 Tab.
Page 130 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 131: Replacing Elements Subject To Wear And Abrasion
AR100 lamination valve. NOTICE! To replace the components of the piloting unit, refer to paragraphs “9.4.3 - Regulator Mainte- nance Procedure APERVAL” and “9.4.6 - PM/182 built-in monitor maintenance”. Tab. 9.97 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 132: Regulator Maintenance Procedure Aperval
9.4.3 - REGULATOR MAINTENANCE PROCEDURE APERVAL 9.4.3.1 - APERVAL 1” - 3” Fig. 9.47. Regulator APERVAL 1” - 3” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 133 Step Action Unscrew and remove the fixing screws (24). Unscrew and remove the nuts (48). Unscrew and remove the nuts (29). Remove the upper lid (4). Remove the spring (45). Take out the diaphragm unit (14, 15, 20, 30). Unscrew and remove the nut (30). NOTICE! During this phase, keep the screw (14) still.
Page 134 Regulator APERVAL 1” - 3” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 135 Step Action Remove the O-ring (37) from the blind flange (5) 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. WARNING! Support the sleeve (9) during the next steps to prevent it from falling. Undo and remove the screws (27).
Page 136 Regulator APERVAL 1” - 3” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 137 Step Action Insert and fix the screws (25) according to the following tightening torques: • 1”: Tab. 9.72 • 2”: Tab. 9.73 • 2” 1/2: Tab. 9.74 • 3”: Tab. 9.75 NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Fit the intermediate flange (3).
Page 138 9.4.3.2 - REGULATOR APERVAL 4” Fig. 9.48. Regulator APERVAL 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 139 Step Action Unscrew and remove the nuts (29). Unscrew and remove the nuts (48). 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 140 Regulator APERVAL 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 141 Step Action Remove the sleeve (9) from the top downwards. Remove the O-ring (42) from the sleeve (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. Clean the upper and lower bearing surfaces of the body (1) and the flanges (2, 5), the contact surfaces between the sleeve (9), conical seat (8) and the body (1).
Page 142 Regulator APERVAL 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 143 Step Action Insert and fix the screws (24) according to the following tightening torques: • 4”: Tab. 9.76 NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Insert and fix the nuts (29). Insert the eyebolts (48).
Page 144: Maintenance Of The 300/A Series Pilot + Ar100 Lamination Valve
9.4.4 - MAINTENANCE OF THE 300/A SERIES PILOT + AR100 LAMINATION VALVE 9.4.4.1 - 300/A SERIES PILOT DISCONNECTION DOWNSTREAM SENSING LINE TO THE GEAR BOX GAS LEAK UPSTREAM SENSING LINE VENT Fig. 9.49. 300/A series pilot HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
Page 145 To disconnect the pilot, proceed as in Tab. 9.100 (Fig. 9.49): 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 146 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. 9.50. Pilot 301/A and 301/A/TR HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 147 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 148 A ASSEMBLY (DIAPHRAGM) HEAD 301/A/TR B ASSEMBLY (VALVE) C ASSEMBLY (PLUG) Pilot 301/A and 301/A/TR HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 149 Step Action 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. Remove the O-rings (28, 29) from the valve seat (3) and replace them, taking care to lubricate them with syn- thetic grease.
Page 150 A ASSEMBLY (DIAPHRAGM) HEAD 301/A/TR B ASSEMBLY (VALVE) C ASSEMBLY (PLUG) Pilot 301/A and 301/A/TR HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 151 Step Action Fix the nut (25) according to the following tightening torque: • Pilot 301 and 301/A/TR: Tab. 9.77 Fit the plug (17) and the spring (21). Fit the upper protection disc (15). Fix the nut (2) according to the following tightening torque: •...
Page 152 A ASSEMBLY (DIAPHRAGM) HEAD 301/A/TR B ASSEMBLY (VALVE) C ASSEMBLY (PLUG) Pilot 301/A and 301/A/TR HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 153 Step Action Position the spring (20) together with the shock absorber nozzle (36). NOTICE! The smallest bore of the shock absorber nozzle (36) must point upwards. Fit the lid (1). Insert and fix the screws (23) according to the following tightening torque: •...
Page 154 9.4.4.3 - PILOT 302/A A ASSEMBLY (DIA- PHRAGM) B ASSEMBLY (VALVE) 26.1 24.1 C ASSEMBLY (PLUG) Fig. 9.51. Pilot 302/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 155 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 156 A ASSEMBLY (DIA- PHRAGM) B ASSEMBLY (VALVE) 26.1 24.1 C ASSEMBLY (PLUG) Pilot 302/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 157 Step Action Remove the O-ring (51) from the piston guide (40) 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 (52) 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 158 A ASSEMBLY (DIA- PHRAGM) B ASSEMBLY (VALVE) 26.1 24.1 C ASSEMBLY (PLUG) Pilot 302/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 159 Step Action Fit the protection disc (48). Fix the nut (2) according to the following tightening torque: • Pilot 302: Tab. 9.78 Insert assembly “C” (plug) from the top downwards into the valve body (4). NOTICE! • Take care not to damage the diaphragms (16) during this step •...
Page 160 9.4.4.4 - AR100 LAMINATION VALVE SEZ. A-A Fig. 9.52. 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 161 Step Action 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). Fit and fix the cap (2) according to the following tightening torque: •...
Page 162 9.4.4.5 - 300/A SERIES PILOT DISCONNECTION Fig. 9.53. 300/A series pilot HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 163 To reconnect the pilot, proceed as indicated in Tab. 9.104 (Fig. 9.53): 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 164: Db Aperval Silencer Maintenance
9.4.5 - DB APERVAL SILENCER MAINTENANCE 9.4.5.1 - SILENCER DB APERVAL 1”- 4” Fig. 9.54. Silencer DB Aperval 1”- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 165 Step Action Unscrew and remove the fixing screw (71). Remove the upper lid (4). Remove the spring (45). Take out the diaphragm unit (14, 15, 20, 30). Unscrew and remove the nut (30). NOTICE! During this phase, keep the screw (14) still. Remove the diaphragm protection disc (15).
Page 166 Silencer DB Aperval 1"- 4" HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 167 Step Action Remove and replace the lower anti-oil gasket (88). Undo the screws (69) together with the washers (70). Remove the lower flange (59) together with the tie rods (67). Remove the O-ring (37) from the lower flange (59) 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 168 Silencer DB Aperval 1"- 4" HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 169 Step Action Insert and fix the screws (27) according to the following tightening torques: • 1”: Tab. 9.72 • 2”: Tab. 9.73 • 2” 1/2: Tab. 9.74 • 3”: Tab. 9.75 • 4”: Tab. 9.76 NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Fit the blind flange (5) or any accessory.
Page 170 Silencer DB Aperval 1"- 4" HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 171 Step Action Fit and fix the nuts (68) according to the following tightening torques: • 1”: Tab. 9.72 • 2”: Tab. 9.73 • 2” 1/2: Tab. 9.74 • 3”: Tab. 9.75 • 4”: Tab. 9.76 NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”. Put the eyebolt (79) back in place.
Page 172: Pm/182 Built-In Monitor Maintenance
9.4.6 - PM/182 BUILT-IN MONITOR MAINTENANCE 9.4.6.1 - BUILT-IN MONITOR PM/182 1”- 2” Fig. 9.55. Built-in monitor PM/182 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 173 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 174 Built-in monitor PM/182 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 175 Step Action Insert and fix the screws of the upper section (27) according to the following tightening torque: • 1”: Tab. 9.80 • 2”: Tab. 9.81 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Insert the indicator rod (18) into the rod guide (17). Unscrew and remove the balancing stem guide (11).
Page 176 Built-in monitor PM/182 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 177 Step Action Remove the O-ring (93) from the plug guide (2) 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) and the key (28). Remove and replace the I/DWR ring (51) from the stem guide (20).
Page 178 Built-in monitor PM/182 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 179 Step Action Position the upper cover (3), taking care to position the indicator stem (18) in the space between the upper diaphragm support (13) and the balance stem guide (11). NOTICE! • The indicator rod (18) must not obstruct the pouring hole (21) on the upper diaphragm sup- port (13);...
Page 180 Built-in monitor PM/182 1”- 2” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 181 Step Action Insert and fix the screws (31) according to the following tightening torque: • 1”: Tab. 9.80 • 2”: Tab. 9.81 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Connect the pneumatic connections between the regulator and the respective control unit, including down- stream pressure ports.
Page 182 9.4.6.2 - BUILT-IN MONITOR PM/182 2” 1/2- 4” Fig. 9.56. Built-in monitor PM/182 2” 1/2- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A 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. 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 184 Built-in monitor PM/182 2” 1/2- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 185 Step Action Assemble the eyebolt flange (14) with the upper cover (3). Insert and fasten the screws of the upper part (27) in the upper cover (3) according to the tightening torque: • 2” 1/2: Tab. 9.82 • 3”: Tab. 9.83 •...
Page 186 Built-in monitor PM/182 2” 1/2- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 187 Step Action Apply thread locking glue to insert and fix the screws (29) according to the following tightening torque: • 2” 1/2: Tab. 9.82 • 3”: Tab. 9.83 • 4”: Tab. 9.84 NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Unscrew and remove the screws of the lower part (27) in the lower cover (3).
Page 188 Built-in monitor PM/182 2” 1/2- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 189 Step Action Insert and secure the balancing stem guide (11) according to the tightening torque: • 2” 1/2: Tab. 9.82 • 3”: Tab. 9.83 • 4”: Tab. 9.84 NOTICE! Hold the diaphragm assembly in place by positioning the spanner in the holes in the upper dia- phragm support (13).
Page 190 Built-in monitor PM/182 2” 1/2- 4” HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 191 Step Action Position the control head inside the regulator body (1) with the indicator slide (16) visible and on axis with the gas flow direction. NOTICE! Take care not to damage the plug profile (5). Insert and fix the screws (31) according to the following tightening torque: •...
Page 192: 200/A Series Pilot + Pre-Regulators R31/A And R14/A Maintenance
9.4.7 - 200/A SERIES PILOT + PRE-REGULATORS R31/A AND R14/A MAINTENANCE 9.4.7.1 - PILOT DISCONNECTION SERIES 201/A AND PRE-REGULATOR R31/A Fig. 9.57. 201/A + R31/A series pilot To disconnect pilot 201/A, proceed as shown in Tab. 9.107 (Fig. 9.57): Step Action Disconnect the sensing lines between the 201/A pilot and the regulator by adjusting the fittings (1, 2, 3).
Page 193 9.4.7.2 - 204/A SERIES PILOT DISCONNECTION AND R14/A PRE-REGULATOR IMPULSO A VALLE MOTORIZZAZIONE IMPULSO DI MONTE SFIATO VENT Fig. 9.58. 204/A + R14/A series pilot To disconnect pilot 204/A, proceed as shown in Tab. 9.108 (Fig. 9.58): Step Action Disconnect the sensing lines between the 204/A pilot and the regulator by adjusting the fittings (1, 2, 3). Unscrew and remove the fixing screw to remove the pilot 204/A from the regulator.
Page 194 9.4.7.3 - PILOT 201/A Fig. 9.59. Pilot 201/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 195 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 196 Pilot 201/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 197 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 198 Pilot 201/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 199 Step Action Insert the spring (22). Insert the lower spring guide (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. Place the nut (9) in the adjusting screw (10).
Page 200 9.4.7.4 - PILOT 204/A A ASSEMBLY (PLUG) B ASSEMBLY (VALVE) Fig. 9.60. Pilot 204/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 201 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 202 A ASSEMBLY (PLUG) B ASSEMBLY (VALVE) Pilot 204/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 203 Step Action Fix the nut (25) according to the following tightening torque: • Pilot 204/A: Tab. 9.86 Fit the plug (17) and then the spring (21). Fit the upper protection disc (15). Fix the pilot nut (2) according to the following tightening torque: •...
Page 204 9.4.7.5 - PRE-REGULATOR R31/A Fig. 9.61. Pre-regulator R31/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 205 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). NOTICE! During this step, hold the plug (5) still. Insert the diaphragm protection disc (6) and the diaphragm (10). Remove and replace the gasket (10).
Page 206 Fig. 9.62. Pre-regulator R31/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 207 Step Action Secure the 'B' (cap) assembly by adjusting the cap (4) according to the tightening torque: • R31/A: Tab. 9.87 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. Fit the cover (2).
Page 208 9.4.7.6 - PRE-REGULATOR R14/A A ASSEMBLY (PLUG) B ASSEMBLY (CAP) Fig. 9.63. Pre-regulator R14/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 209 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 210 A ASSEMBLY (PLUG) B ASSEMBLY (CAP) Pre-regulator R14/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 211 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 212 9.4.7.7 - PILOT RECONNECTION SERIES 201/A AND PRE-REGULATOR R31/A Fig. 9.64. Pilot 201/A and pre-regulator R31/A To reconnect pilot 201/A, proceed as shown in Tab. 9.113 (Fig. 9.64): Step Action Insert and fix the screw (7) to the 201/A pilot. Insert and fasten the screw (6) to connect the pre-regulator R31/A to the pilot 201/A.
Page 213 9.4.7.8 - PILOT RECONNECTION SERIES 204/A AND PRE-REGULATOR R14/A IMPULSO A VALLE MOTORIZZAZIONE IMPULSO DI MONTE SFIATO VENT Fig. 9.65. Series 204/A pilot and R14/A pre-regulator To reconnect pilot 204/A, proceed as shown in Tab. 9.114 (Fig. 9.65): Step Action Insert and fix the screw (7) to the 204/A pilot.
Page 214: V/25 Accelerator Valve Maintenance
9.4.8 - V/25 ACCELERATOR VALVE MAINTENANCE Fig. 9.66. V/25 accelerator valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 215 Step Action Unscrew and remove the cap (26). Unscrew and remove the calibration ring nut (23) together with the sliding disc (24). Remove the calibration spring (25). Unscrew and remove the screw (19) together with the nut (18). Remove the cover (3). NOTICE! Check that the vent (22, 27) is free of impurities.
Page 216 V/25 accelerator valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 217 Step Action Replace the reinforced gasket (7). Insert the seeger ring (11). Place the diaphragm (21) in the diaphragm holder (5). Position the diaphragm disc (16). Position the nut (10), holding the stem (9) in place. Insert the diaphragm assembly together with the intermediate flange (2) into the body (1). Fit the cover (3).
Page 218: M/A Accelerator Valve Maintenance
9.4.9 - M/A ACCELERATOR VALVE MAINTENANCE Fig. 9.67. M/A accelerator valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 219 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 220 Accelerator valve M/A HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 221 Step Action Take out the diaphragm/plug unit (8, 11, 12, 25, 29, 31). NOTICE! Before inserting the diaphragm/plug unit, lubricate the plug (8) surface with silicone grease. Fit the sleeve (15) and the bracket (53). Insert and fix the screws (33). NOTICE! Tighten the screws as shown in the diagram at “9.4.2.2 - Cross diagram for tightening screws”.
Page 222: Sealing Of The Sa Built-In Slam-Shut Valve
9.4.10 - SEALING OF THE SA BUILT-IN SLAM-SHUT VALVE Fig. 9.68. Slam-shut valve SA HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 223 Step Action Remove the seeger ring (135). Unscrew and remove the screws (131). Remove the flange (119). Pull the sleeve (112) out of the regulator body (1). Remove the O-rings (115, 142) from the bush (112) and replace them, taking care to lubricate them with syn- thetic grease.
Page 224 Fig. 9.69. Slam-shut valve SA HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 225 Step Action Insert and fix the screws (130) according to the following tightening torque: • 1”: Tab. 9.89 • 2”: Tab. 9.90 • 2” 1/2: Tab. 9.91 • 3”: Tab. 9.92 • 4”: Tab. 9.9³ NOTICE! Tighten the screws according to the cross diagram in paragraph 9.4.2.2. Insert the spring (124) into the plug (104).
Page 226: Maintenance Of Pressure Switch Mod. Sa
9.4.11 - MAINTENANCE OF PRESSURE SWITCH MOD. SA 9.4.11.1 - PRESSURE SWITCH DISCONNECTION MOD. SA Fig. 9.70. Pressure switch mod. SA HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 227 To disconnect the pressure switches mod. SA, proceed as indicated in Tab. 9.118 (Fig. 9.70): Step Action Remove the lever (116). Remove the seeger ring (135). Remove the position indicator (120). Remove the screws (41). Tab. 9.118. HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV.
Page 228 9.4.11.2 - PRESSURE SWITCH SA-91, SA-92 Fig. 9.71. Pressure switch SA-91, SA-92 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 229 Step Action Unscrew and remove the cap (24). Remove the O-ring (60) from the cap (24) 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. Unscrew and remove the screws (42) together with the nuts (46).
Page 230 Fig. 9.72. Pressure switch SA-91, SA-92 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 231 Step Action Insert and fix the cap (24). WARNING! Ensure that all parts have been fitted correctly. HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 232 9.4.11.3 - PRESSURE SWITCH SA-93 Fig. 9.73. Pressure switch SA-93 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 233 Step Action Unscrew and remove the cap (24). Remove the O-ring (60) from the cap (24) 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 and remove the screws (42).
Page 234 Pressure switch SA-93 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 235 Step Action Insert and fix the cap (24). Tab. 9.119. WARNING! Ensure that all parts have been fitted correctly. HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 236 9.4.11.4 - PRESSURE SWITCH RECONNECTION MOD. SA Fig. 9.74. Pressure switch mod. SA HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 237: Procedure For Recommissioning After Maintenance
To connect pressure switches mod. SA proceed as shown in Tab. 9.120 (Fig. 9.74): Step Action Insert and fix the screws (41) according to the following tightening torques: • Pressure switch SA-91: Tab. 9.94 • Pressure switch SA-92: Tab. 9.95 •...
Page 238 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL CHECKS REV. A Use, maintenance and warning manual...
Page 239: 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 240: 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 241: Troubleshooting Tables
10.4 - TROUBLESHOOTING TABLES NOTICE! Refer to chapter 9 “Maintenance and functional checks” for the pictures of the APERVAL regulator and its accessories. 10.4.1 - TROUBLESHOOTING APERVAL REGULATOR Failure Device Possible causes Service Adjust the flow rate LAMINATION VALVE Unsuitable feed pressure to...
Page 242 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 243: Db Silencer Troubleshooting
10.4.2 - DB SILENCER TROUBLESHOOTING Failure Device Possible causes Service Breakage of the external Increase in noise DB SILENCER Replace basket (64) Clean and replace if needed No sealing O-ring (39) not sealing DB SILENCER Zero flow rate Clean and replace if needed O-ring (84) not sealing Tab.
Page 244: Pm/182 Built-In Monitor Troubleshooting
10.4.3 - PM/182 BUILT-IN MONITOR TROUBLESHOOTING Failure Device Possible causes Service Dirty or worn plug (5) Clean and replace if needed PRE-REGULATOR R14/A Plug guide ring (8) worn Replace Dirty or worn plug (17) Clean and replace if needed Align the bore of the dia- Diaphragm phragm holder (16) friction...
Page 245 Failure Device Possible causes Service Clean and replace if needed O-ring (17) not sealing Clean and replace if needed O-ring (18) not sealing PRE-REGULATOR R14/A Clean and replace if needed O-ring (20) not sealing Diaphragm (10) worn Replace Upper diaphragm (16) worn Replace 204/A SERIES PILOTS Dirty or worn plug (17) Clean and replace if needed...
Page 246 Failure Device Possible causes Service PRE-REGULATOR R14/A Plug (5) damaged Replace Plug (17) damaged Replace Diaphragm holder (16) and Check and clean if neces- plug (17) assembly locked sary 204/A SERIES PILOTS in open position Plug spring (21) collapsed Replace Downstream sensing line Clean obstructed...
Page 247 Failure Device Possible causes Service Filter (13) clogged Replace Reinforced gasket (9) dam- Replace aged PRE-REGULATOR R14/A Diaphragm (10) damaged Replace Plug (5) locked during Clean and lubricate shut-off Plug (5) obstructed Clean Plug (17) locked in shut-off Clean and lubricate position Diaphragms (16) Replace...
Page 248: Troubleshooting Of The Sa Slam-Shut Valve
10.4.4 - TROUBLESHOOTING OF THE SA SLAM-SHUT VALVE Failure Device Possible causes Service Carry out the calibration Incorrect maximum (32) and/or again by adjusting the ring minimum (31) spring setting nuts Clean and lubricate the Incorrect tripping PRESSURE SWITCHES Levers with friction linkage and replace the pressure MOD.
Page 249: 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 250: 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 251: 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 252 MEDIUM PRESSURE REGULATOR RECOMMENDED SPARE PARTS REV. A Use, maintenance and warning manual...
Page 253: Calibration Tables
13 - CALIBRATION TABLES 13.1 - 300 SERIES PILOT CALIBRATION TABLES 301 A Pos. Spring item code Spring colour Min. 2700680 Brown 0.005 0.019 2700830 Red/Black 0.02 0.045 2700920 White/yellow 0.046 0.078 2701040 White/orange d = Wire Diameter (mm) Lo = Spring Length (mm) De = External Diameter (mm) Tab.
Page 254: 200 Series Pilot Calibration Tables
13.2 - 200 SERIES PILOT CALIBRATION TABLES The PM/182 monitor uses pilots 201/A and 204/A. The adjustment ranges of the different pilots are shown in the following tables: Pilot 201/A Pos. Spring item code Spring colour Min. 2702820 Blue 2703045 Brown 30.001 2703224...
Page 255: Pressure Switch Calibration Tables Mod. Sa
13.3 - PRESSURE SWITCH CALIBRATION TABLES MOD. SA Listed below are the calibration tables of possible pressure switches in the SA built-in slam-shut valve: Mod. SA-91 - Max. pressure Pos. Spring item code Spring colour Min. Max. 2700680 Brown 0.025 0.045 2700830 Red/black...
Page 256 Mod. SA-92 - Min pressure Pos. Spring item code Spring colour Min. Max. 2700513 0.25 2700713 Green 0.401 0.62 2700750 Black 0.621 1.55 2700985 Brown 1.551 3.01 d = Wire Diameter (mm) Lo = Spring Length (mm) De = External Diameter (mm) Min./Max. = pressure (bar) Tab.
Page 257 HIGH PRESSURE REGULATOR CALIBRATION TABLES REV. B Use, maintenance and warning manual...

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