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PIETRO FIORENTINI Norflux Use & Maintenance

High pressure gas regulator
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Norflux
High pressure gas regulator
Revision A - Edition 04/2024
USE, MAINTENANCE AND
WARNING MANUAL
EN

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  • Page 1 Norflux High pressure gas regulator Revision A - Edition 04/2024 USE, MAINTENANCE AND WARNING MANUAL...
  • Page 2 HIGH PRESSURE REGULATOR REV. A Use, maintenance and warning manual...

  • Page 3: Introduction

    Training of the personnel responsible for the equipment both in its use, as well as in its maintenance and application of the safety directions and procedures given in this manual is of particular importance. COPYRIGHT 2024 © PIETRO FIORENTINI S.P.A. HIGH PRESSURE REGULATOR REV. A...
  • Page 4 HIGH PRESSURE REGULATOR REV. A Use, maintenance and warning manual...

  • Page 5: Revision History

    1.1 - REVISION HISTORY Revision index Date 04/2024 Tab. 1.1. HIGH PRESSURE REGULATOR 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 - PRODUCT IDENTIFICATION ........................11 2.3 - REGULATORY FRAMEWORK ......................... 11 2.4 - WARRANTY ............................11 2.5 - SYMBOLS USED IN THE MANUAL ......................
  • Page 7 5.1.1 - PACKAGING AND FASTENING SYSTEMS USED FOR TRANSPORT ............42 5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT ................44 5.2.1 - NORFLUX .............................44 5.2.2 - NORFLUX + SB.............................46 5.3 - METHOD FOR ANCHORING AND LIFTING THE EQUIPMENT ..............48 5.3.1 - FORKLIFT HANDLING METHOD ......................49 5.3.2 - CRANE HANDLING METHOD .......................51...
  • Page 8 8.6 - REGULATION LINE COMMISSIONING PROCEDURE: REGULATOR AND REGULATOR WITH IN-LINE MONI- TOR FUNCTION ............................72 8.7 - COMMISSIONING PROCEDURE OF THE NORFLUX REGULATOR WITH SLAM-SHUT VALVE....78 8.7.1 - CHECK FOR LEAKAGE OF THE SLAM-SHUT VALVE ................78 8.7.2 - COMMISSIONING OF THE REGULATOR NORFLUX WITH SLAM-SHUT VALVE ........79 8.7.3 - CALIBRATION PROCEDURE OF PRESSURE SWITCHES MOD.
  • Page 9 9.4.1 - TIGHTENING TORQUES ........................96 9.4.2 - REPLACEMENT OF ELEMENTS SUBJECT TO WEAR AND ABRASION ..........103 9.4.3 - MAINTENANCE OF THE NORFLUX REGULATOR WITH SB SLAM-SHUT VALVE .......114 9.4.4 - MAINTENANCE PROCEDURE FOR PRESSURE SWITCHES MOD. 100 ..........120 9.9.1 - RE-COMMISSIONING PROCEDURE FOLLOWING MAINTENANCE ...........127 10 - FAULT FINDING AND TROUBLESHOOTING ..............
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  • Page 11: General Information

    PIETRO FIORENTINI S.P.A. guarantees that the equipment has been made with the best materials, with fine workmanship and complies with the quality requirements, specifications and performance envisaged in the order. The warranty will be considered null and void and PIETRO FIORENTINI S.P.A. will not be responsible 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 operator and/or equipment safety. Symbol used to identify particularly important information in the manual. The information may also concern the safety of personnel involved in using the equipment. Mandatory to consult the instruction manual/booklet.

  • Page 13: Recipients, Supply And Conservation Of The Manual

    Keep the manual near the equipment, in an accessible place known to all qualified technicians involved in its use and management. PIETRO FIORENTINI S.p.A. disclaims all liability for any damage to people, animals and things caused by fail- ure to observe the warnings and operating methods described in this manual.

  • Page 14: Identification Plates Applied

    It is absolutely forbidden to remove the identification plates and/or replace them with others. If, for accidental reasons, the plates are damaged or removed, the customer must inform PIETRO FIORENTINI S.p.A. The equipment and its accessories are equipped with identification plates (Id.1 and Id.2).

  • Page 15: Identification Plates Glossary

    2.8.1 - IDENTIFICATION PLATES GLOSSARY The terms and abbreviations used on the identification plates are described below: Term Description Accuracy class. Pressure increase slam-shut valve accuracy class. AG max “OPSO” (Over pressure shut off). Pressure decrease slam-shut valve accuracy class. AG min ”UPSO”(Under pressure shut off).

  • Page 16: Unit Of Measurement Glossary

    Term Description Full range of set points for tripping caused by pressure increase of the pressure switch incorporat- Wdso ed in the slam-shut valve. This range can be achieved by adjustment but without component replacement. Full range of set points for tripping caused by pressure drop of the pressure switch incorporated in the slam-shut valve.

  • Page 17: Qualified Professionals

    2.10 - QUALIFIED PROFESSIONALS Qualified operators in charge of using and managing the equipment in all its phases of its service life: Professional Definition Qualified technician able to: • carry out preventive/corrective maintenance activities on all mechanical parts of the equip- Mechanical mainte- ment subject to maintenance or repair;...
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  • Page 19: Safety

    3 - SAFETY 3.1 - GENERAL SAFETY WARNINGS The equipment described in this manual is: • a device subject to pressure in pressurized systems; • normally included in systems transporting flammable gases (for example: natural gas). If the gas used is a combustible gas, the area where the equipment is installed is called a "danger zone" be- cause there are residual risks of the formation of potentially explosive atmospheres.

  • Page 20: Personal Protective Equipment

    3.2 - PERSONAL PROTECTIVE EQUIPMENT In Table “Tab. 3.9”, Personal Protective Equipment (PPE) and its description are shown. An obligation is attached to each symbol. Personal protective equipment means any equipment intended to be worn by the worker for the purpose of protecting him/ her against one or more hazards likely to threaten his/her safety or health while at work.

  • Page 21: Residual Risks

    3.3 - RESIDUAL RISKS The risks associated with the equipment and the principles adopted for their prevention are evaluated below, according to the following classification: (a) Elimination and/or reduction of risk. (b) Application of appropriate protective measures. (c) Information to users about residual risks. HIGH PRESSURE REGULATOR SAFETY REV.

  • Page 22: Table Of Residual Risks Due To Pressure

    3.3.1 - TABLE OF RESIDUAL RISKS DUE TO PRESSURE Effect and Risk and hazard Event and cause Solution and prevention consequence a. Handling and installation by appropriate Pressurized gas means to avoid localized stresses. outlet. • Violent impact; • Deformation; b.
  • Page 23 Effect and Risk and hazard Event and cause Solution and prevention consequence a. The user shall perform any maintenance • Maintenance of the • Inappropriate open- Pressurized gas with the equipment not in operation. device with the sys- ing of pressurized leakage.

  • Page 24: Residual Risks Table For Potentially Explosive Atmospheres

    3.3.2 - RESIDUAL RISKS TABLE FOR POTENTIALLY EXPLOSIVE ATMOSPHERES Table “Tab. 3.11” shows the conditions that can lead to the generation of potentially explosive atmosphere by respectively: • the pressure regulator NORFLUX; • the SB slam-shut valve. The table is valid for use with natural gas with a density not exceeding 0.8; for different densities, installation conditions and environmental conditions will also need to be evaluated.
  • Page 25 Potentially Operating explosive Management measures conditions atmosphere Normative references included in the operating and warning instructions Breakage of other This type of malfunction is not reason- non-metallic parts ably expected since it involves static (malfunction)(mal- (outward) seals. function) • Pressure reduction of the section of the system where the equip- ment is installed must be accom- In the instructions for use, the need...

  • Page 26: Obligations And Prohibitions

    For the generated noise value of the equipment and further information, please contact PIETRO FIORENTINI S.p.A. The requirement to use ear muffs or earplugs to protect the operator's hearing remains if noise in the equip- ment installation environment (depending on specific operating conditions) exceeds 85 dBA.

  • Page 27: Description And Operation

    4 - DESCRIPTION AND OPERATION 4.1 - GENERAL DESCRIPTION The NORFLUX equipment is a direct-operated pressure regulator for high pressure that reduces the pressure of the incoming gas while keeping its downstream value stable even when the following change: •...

  • Page 28: Regulator Reaction Modes

    4.1.1 - REGULATOR REACTION MODES The NORFLUX equipment is a direct-operated regulator with a "fail open" reaction, i.e. it opens in case of: • rupture of the main diaphragm; • lack of downstream pressure signal. 4.2 - OPERATION pstream pressUre ownstream pressUre Fig.
  • Page 29 In the absence of pressure, the plug (5) is held in open position by the spring (2). The regulation of the downstream pressure value (Pd) takes place through the comparison between: • the calibration spring load (2); • the thrust on the main diaphragm (3) deriving from the downstream pressure (Pd). The main diaphragm (3) moves the stem (4) integral with the plug (5).

  • Page 30: Intended Use

    "Intended use". Any other use of the equipment than that envisaged must be authorized in advance in writing by PIETRO FIORENTINI S.p.A. In the absence of written permission, the use is considered improper.

  • Page 31: Technical Characteristics/Performance

    4.4 - TECHNICAL CHARACTERISTICS/PERFORMANCE The NORFLUX equipment is a regulator for medium and low pressure. The control system is balanced and guarantees a sta- ble outlet pressure even when the inlet pressure and required flow rate varies. The main specifications of this regulator are:...

  • Page 32: Possible Configurations

    4.5 - POSSIBLE CONFIGURATIONS 4.5.1 - REGULATOR WITH MONITOR FUNCTION The regulator with monitor function (1) has the task of keeping the value of the downstream pressure (Pd) within the predeter- mined limits in case of failure of the main regulator. The regulator with monitor function (1) is installed upstream of the main pressure regulator.

  • Page 33: Regulator With In-Line Monitor Function

    4.5.1.1 - REGULATOR WITH IN-LINE MONITOR FUNCTION The regulator with monitor function (1) is mounted in series on the same line as the main regulator (2). The two regulators are functionally independent and are controlled by independent sensing lines. STANDBY OPERATION The regulator with monitor function (1), during normal operation, is open due to its higher calibration of the main regulator calibration (2).
  • Page 34 FAULT OPERATION OF THE MAIN REGULATOR pstream pressUre ownstream pressUre Fig. 4.5. Regulator-monitor operation in main regulator failure conditions In case of failure of the main regulator (2), the regulator with monitor function (1) will trip keeping the downstream pressure value (Pd) within the value established for the calibration of the latter.
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  • Page 36: Slam-Shut Valve

    The slam-shut valve incorporated into the main regulator consists of: • a control system; • the slam-shut mechanism. 4.5.2.1 - BUILT-IN SB SLAM-SHUT VALVE pstream pressUre ownstream pressUre Fig. 4.6. NORFLUX with SB slam-shut valve HIGH PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. A Use, maintenance and warning manual...
  • Page 37 OPERATION The built-in SB slam-shut valve can be operated: • from the pressure switch; • manually; • with remote control (optional). The main features of the built-in SB slam-shut valve are: • tripping due to increase and / or decrease of the downstream pressure; •...

  • Page 38: Slam-Shut Valve Pressure Switches

    OPSO maximum spring adjustment ring nuts (5). UPSO minimum spring adjustment ring nuts (6). Manual release button. Tab. 4.21 . ownstream pressUre Fig. 4.7. NORFLUX with SB slam-shut valve HIGH PRESSURE REGULATOR DESCRIPTION AND OPERATION REV. A Use, maintenance and warning manual...
  • Page 39 Models of possible pressure switches for this regulator are listed in Tab. 4.22: Pressure switch model Max [psi] Min [psi] 103M 29.01 - 319.09 2.90 - 116.03 103MH 29.01 - 319.09 116.03 - 275.58 104M 217.56 - 652.68 23.21 - 261.07 104MH 217.56 - 652.68 261.07 - 594.66...
  • Page 40 PAGE INTENTIONALLY LEFT BLANK HIGH PRESSURE REGULATOR HIGH PRESSURE REGULATOR DESCRIPTION AND OPERATION DESCRIPTION AND OPERATION REV. A REV. A Use, maintenance and warning manual Use, maintenance and warning manual...

  • Page 41: Transport And Handling

    5 - TRANSPORT AND HANDLING 5.1 - SPECIFIC WARNINGS FOR TRANSPORT AND HANDLING The transport and handling activities, in compliance with the regulations in force in the country of destination of the equipment, must be carried out by personnel: • qualified (specially trained);...

  • Page 42: Packaging And Fastening Systems Used For Transport

    • immediately report to PIETRO FIORENTINI S.p.A. any damage found. PIETRO FIORENTINI S.p.A. is not liable for damage to property or persons caused by accidents due to failure to comply with the instructions given in this manual. Table “Tab. 5.24.” shows the types of packaging used: Ref.
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  • Page 44: Physical Characteristics Of The Equipment

    5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT 5.2.1 - NORFLUX Ø Fig. 5.8. Physical characteristics NORFLUX HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. A Use, maintenance and warning manual...
  • Page 45 Clearances and dimensions NORFLUX [inches] Nominal diameter [mm] Size [inches] 2” S - Class 300 S - Class 600 Ø Pipe 3/8 connection pneumatic piping Tab. 5.25. Weights [kg] S - Class 300 S - Class 600 78.4 Tab. 5.26.

  • Page 46: Norflux + Sb

    5.2.2 - NORFLUX + SB Ø Fig. 5.9. Physical characteristics NORFLUX + SB HIGH PRESSURE REGULATOR TRANSPORT AND HANDLING REV. A Use, maintenance and warning manual...
  • Page 47 Clearances and dimensions NORFLUX + SB [inches] Nominal diameter [mm] Size [inches] 2” S - Class 300 S - Class 600 Ø Pipe 3/8 connection pneumatic piping Tab. 5.27. Weights [kg] S - Class 300 S - Class 600 Tab. 5.28.

  • Page 48: Method For Anchoring And Lifting The Equipment

    5.3 - METHOD FOR ANCHORING AND LIFTING THE EQUIPMENT Before moving a load, make sure that its weight does not exceed the load capacity of the lifting means (and any other equipment) indicated on the specific plate. The unloading, transport and handling activities must be carried out by operators qualified for such opera- tions and specially trained: •...

  • Page 49: Forklift Handling Method

    5.3.1 - FORKLIFT HANDLING METHOD It is forbidden to: • pass under suspended loads; • move the load over the personnel working in the site/plant area. On forklift trucks it is forbidden to: • transport passengers; • lift people. The packaging must always be handled in an upright position. Proceed as follows: Step Operation...
  • Page 50 Image Step Operation 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 di traspor ne che il baricentro del carico sia posizionato al centro delle forche di sollevamento. garantire una maggiore stabilità...

  • Page 51: Crane Handling Method

    5.3.2 - CRANE HANDLING METHOD It is compulsory to use chains, cables and eyebolts marked CE or marked with marks/conformity mark- ings in accordance with the provisions in force in the place of installation. Do not use chains connected to each other by bolts.

  • Page 52: Unpacking

    • do not perform the installation operations; • contact PIETRO FIORENTINI S.p.A. communicating the data shown on the identification plate of the equipment. 5.4.1 - PACKAGING DISPOSAL Separate 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 53: Storage And Environmental Conditions

    To replace the rubber parts of the equipment, refer to chapter “9 - Maintenance and functional testing”. PIETRO FIORENTINI S.p.A. recommends checking the state of conservation of the rubber parts for periods of inactivity or storage exceeding 3 years.
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  • Page 55: Installation

    6 - INSTALLATION 6.1 - INSTALLATION PRE-REQUISITES 6.1.1 - ENVIRONMENTAL CONDITIONS For the safe use of the equipment, respecting the permitted environmental conditions, follow the data on the plate of the regulator and any accessories (refer to paragraph “2.8 - Identification plates applied”). The place of installation must be suitable for safe use of the equipment.

  • Page 56: Checks Before Installation

    6.1.2 - CHECKS BEFORE INSTALLATION In relation to its permissible pressure PS, the equipment does not require any additional upstream safety device to protect against possible overpressure when, for the upstream reduction station, the maximum downstream incidental pressure is: MIPd ≤ 1,1 PS MIPd = maximum value of downstream incidental pressure (for more information see UNI EN 12186:2014).

  • Page 57: Installation-Specific Safety Warnings

    6.2 - INSTALLATION-SPECIFIC SAFETY WARNINGS Before proceeding with the installation phase, make sure that the upstream and downstream valves installed on the line are closed. The installation could also take place in environments at risk of explosion and this implies the adoption of all the necessary prevention and protection measures.

  • Page 58: General Information About Connections

    6.3 - GENERAL INFORMATION ABOUT CONNECTIONS The equipment must be installed in the line with the arrow on the body facing in the direction of gas flow. The online installation must include: Pos. Description 1 shut-off valve upstream of the equipment. 2 vent valves placed one upstream and one downstream of the equipment.

  • Page 59: Installation Locations Of The Regulator

    When the device is used in gas pressure reduction stations, it must be installed at least according to the re- quirements of UNI EN 12186:2014 or UNI EN 12279:2007. The vents of the equipment must be channeled according to UNI EN 12186: 2014 or UNI EN 12279: 2007 or the standards in force at the place of installation of the equipment.

  • Page 60: Installation Procedures

    6.5 - INSTALLATION PROCEDURES 6.5.1 - INSTALLATION PROCEDURES OF EQUIPMENT Step Operation Place the equipment in the section of the line used for it. Place gaskets between the line flanges and the regulator flanges. Insert the bolts into the appropriate holes in the connecting flanges. Screw the bolts following the technical rules for tightening the flanges.
  • Page 61 To calculate the flow rate use the following formula: 14.504 − 0,002 = 0.0498 14.504 V = gas speed in ft/sec Q = Scfh gas flow rate DN = nominal pipe diameter in inches Pd = outlet pressure of the regulator in psi All pneumatic connections to be made in the field must have pipes with a minimum internal diameter of 8 mm.

  • Page 62: Post-Installation And Pre-Commissioning Verification

    In case there is a multiple sensing line, connect the connections of the equipment as follows: • 1 and 2 to the sensing line of the control head of the main regulator and the regulator with built-in monitor or monitor function;...

  • Page 63: Commissioning/Maintenance Equipment

    7 - COMMISSIONING/MAINTENANCE EQUIPMENT 7.1 - EQUIPMENT LIST Commissioning/maintenance equipment use • Mechanical maintenance technician; • Electrical maintenance technician; Operator qualification • Installer; • User technician. The PPE listed in this chart relates to the risk associated with the equipment. For PPE required the PPE required to protect against risks associated with the workplace, installa- tion or operating conditions, refer to:...
  • Page 64 Ref. Type of equipment Image Hexagonal male "T" wrench Hexagonal socket "T" wrench Phillips screwdriver Slotted screwdriver O-ring extraction tool Ring pliers Fiorentini special key Fiorentini special key Tab. 7.38. HIGH PRESSURE REGULATOR COMMISSIONING/MAINTENANCE EQUIPMENT REV. A Use, maintenance and warning manual...

  • Page 65: Equipment Needed For The Different Configurations

    7 - 17 - 18 - 19 - 21 - 27 - 32 - 36 - 46 - 55 4 - 5 - 8 65 x 100 7999099 19 - 60 Tab. 7.40. NORFLUX + SB Equipment Size [inches] Ref. Type 2”...
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  • Page 67: Commissioning

    8 - COMMISSIONING 8.1 - GENERAL WARNINGS 8.1.1 - SAFETY REQUIREMENTS FOR COMMISSIONING During commissioning, the risks posed by possible discharges of flammable or noxious gases into the atmo- sphere must be assessed. In the case of installation on distribution networks for natural gas, the risk of explosive mixture (gas/air) for- mation inside the pipes should be considered if an inerting procedure of the line is not adopted.

  • Page 68: Preliminary Procedures For Commissioning

    Commissioning • Installer; Operator qualification • Licensed technician. The PPE listed in this chart relates to the risk associated with the equipment. For PPE required the PPE required to protect against risks associated with the workplace, installa- tion or operating conditions, refer to: •...

  • Page 69: Verification Of External Tightness

    8.3 - VERIFICATION OF EXTERNAL TIGHTNESS Completely sprinkle the equipment with a foaming solution (or equivalent control system) in order to verify the tightness of the external surfaces of the regulator and connections made during installation. 8.4 - CALIBRATION OF THE EQUIPMENT AND ACCESSORIES PRESENT To perform proper calibration of the equipment and the accessories present, refer to the accuracy class shown on the identification plates (see section “2.8 - Identification plates applied”).

  • Page 70: Regulator Commissioning Procedure

    In the application consisting of several pressure control lines, it is recommended to commission one line at a time starting with the one with the lowest set-point. The set-point value is recalled on the test certificate attached to each piece of equipment. Fig. 8.17. Commissioning of the regulator NORFLUX HIGH PRESSURE REGULATOR COMMISSIONING REV.
  • Page 71 Step Operation Partially open the drain cock (6). Slowly open the upstream shut-off valve (V1), checking that the downstream pressure (Pd) indicated by the down- stream pressure gauge (5) does not exceed the required setting value by more than 50%. In the first pressurization phase of the line, the downstream pressure (Pd) of the downstream pres- sure gauge (5) may exceed the required calibration value, depending on the response time of the regulator.

  • Page 72: Regulation Line Commissioning Procedure: Regulator And Regulator With In-Line Monitor Function

    8.6 - REGULATION LINE COMMISSIONING PROCEDURE: REGULATOR AND REGULATOR WITH IN-LINE MONITOR FUNCTION 41.2 41.1 Fig. 8.18. Commissioning of regulator + regulator with in-line monitor function HIGH PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
  • Page 73 Step Operation Partially open the drain cock (6). Slowly open the upstream shut-off valve (V1), checking that the downstream pressure (Pd) indicated by the down- stream pressure gauge (5) does not exceed the required setting value by more than 50%. In the first pressurization phase of the line, the downstream pressure (Pd) of the downstream pres- sure gauge (5) may exceed the required calibration value, depending on the response time of the main regulator (1).
  • Page 74 41.2 41.1 Commissioning of regulator + regulator with in-line monitor function HIGH PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
  • Page 75 Step Operation Check that the downstream pressure, after an increment phase, does not exceed the closing pressure value of the regulator with in-line monitor function (2) (refer to the rating plate SG value, see paragraph “2.8 - Identification plates applied”). •...
  • Page 76 41.2 41.1 Commissioning of regulator + regulator with in-line monitor function HIGH PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
  • Page 77 Step Operation Very slowly open the downstream shut-off valve (V2) until the pipeline is completely flooded. • If the pressure of the downstream pipeline is lower than the calibration pressure, partialize the opening of the downstream shut-off valve (V2) so as not to exceed the value of the maximum flow rate of the system.

  • Page 78: Commissioning Procedure Of The Norflux Regulator With Slam-Shut Valve

    COMMISSIONING PROCEDURE OF THE NORFLUX REGULATOR WITH SLAM-SHUT VALVE 8.7.1 - CHECK FOR LEAKAGE OF THE SLAM-SHUT VALVE Fig. 8.19. Commissioning of the regulator NORFLUX with slam-shut valve Step Operation Check that the slam-shut valve is in the closed position.

  • Page 79: Commissioning Of The Regulator Norflux With Slam-Shut Valve

    8.7.2 - COMMISSIONING OF THE REGULATOR NORFLUX WITH SLAM-SHUT VALVE For the following procedure, refer to Fig. 8.19 of paragraph “8.7.1 - Check for leakage of the slam-shut valve”: Step Operation Check that the drain cock (6) is partially open.
  • Page 80 Commissioning of the regulator NORFLUX with SB slam-shut valve HIGH PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
  • Page 81 Step Operation Check that the downstream pressure (Pd), after an increment phase, does not exceed the closing pressure value (refer to the rating plate SG value, see “2.8 - Identification plates applied”). If the pressure in the section of pipeline between the regulator and the downstream shut-off valve (V2) exceeds the shut-off pressure value, refer to chapter “10 - Fault finding and troubleshooting”...

  • Page 82: Calibration Procedure Of Pressure Switches Mod. 100

    8.7.3 - CALIBRATION PROCEDURE OF PRESSURE SWITCHES MOD. 100 Fig. 8.20. Calibration of model 100 pressure switches Calibration of spring for maximum pressure trip Step Operation Increase the downstream pressure to the slam-shut valve trip value by turning the set screw (10) of the pilot (2) of the main regulator (1) to check the correct setting.
  • Page 83 CALIBRATION OF SPRING FOR TRIPPING BY MINIMUM PRESSURE (IF ANY) Step Operation Partially open the drain cock (Fig. 8.17, ref. 6) in the atmosphere and keep it open for the next steps. Decrease the downstream pressure to the minimum required slam-shut trip pressure by acting on the set screw of the pilot of the main regulator.

  • Page 84: Regulation Line Commissioning Procedure: Regulator, Regulator With In-Line Monitor Function And Slam-Shut Valve

    8.8 - REGULATION LINE COMMISSIONING PROCEDURE: REGULATOR, REGULATOR WITH IN-LINE MONITOR FUNCTION AND SLAM-SHUT VALVE 41.2 41.1 Fig. 8.21. Commissioning of the regulator, regulator with in-line monitor function and slam-shut valve HIGH PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
  • Page 85 Step Operation Check that the drain cock (6) is partially open. Check that the slam-shut valve is in the closed position. If the slam-shut valve is in open position, close it via the manual button (Fig. 8.20, ref. 10). Slowly open the upstream shut-off valve (V1), checking the pressure value indicated by the upstream pressure gauge (4).
  • Page 86 41.2 41.1 Commissioning of NORFLUX regulator + regulator with in-line monitor function HIGH PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
  • Page 87 Step Operation FOR INITIAL COMMISSIONING OF THE CONTROL LINE If the downstream pressure (Pd) is not at the required calibration value for the regulator with in-line monitor function (2), proceed as follows: • value of downstream pressure (Pd) less than the required calibration value: load the calibration spring by turn- ing the set screw (9) clockwise •...
  • Page 88 41.2 41.1 Commissioning of NORFLUX regulator + regulator with in-line monitor function HIGH PRESSURE REGULATOR COMMISSIONING REV. A Use, maintenance and warning manual...
  • Page 89 Step Operation Check that the downstream pressure, after an increment phase, does not exceed the closing pressure value of the main regulator (1) (refer to the rating plate SG value, see paragraph “2.8 - Identification plates applied”). • If the downstream pressure exceeds the shutdown pressure value, refer to chapter “10 - Fault finding and troubleshooting”...

  • Page 90: Calibration Of Devices

    8.9 - CALIBRATION OF DEVICES 8.9.1 - CALIBRATION OF PRESSURE SWITCH MOD. 100 Fig. 8.22. Calibration of model 100 pressure switches Act on the ring nut (13) for maximum tripping (spring ref. 11): • counterclockwise to decrease the slam-shut trip pressure; •...

  • Page 91: Maintenance And Functional Testing

    Repair or maintenance work not provided for in this manual may be carried out only with prior approval from PIETRO FIORENTINI S.p.A.. No liability related to damage to persons or property can be attributed to PIETRO FIORENTINI S.p.A. for interventions other than those described or performed in a manner other than those indicated.
  • Page 92 Before beginning equipment disassembly operations, it should be ensured that: • spare parts and parts used in replacements have appropriate requirements in order to ensure the original performance of the equipment. Use genuine compliant spare parts; • the operator has the necessary equipment (refer to chapter "7 - Commissioning/maintenance equipment"). Recommended replacement parts are unambiguously identified with tags indicating: •...

  • Page 93: Periodic Checks And Verifications Of Proper Operation

    9.2 - PERIODIC CHECKS AND VERIFICATIONS OF PROPER OPERATION Periodic checks and inspections Operator qualification Mechanical maintenance technician The PPE listed in this chart relates to the risk associated with the equipment. For the PPE required PPE required to protect against risks associated with the workplace, installation or operating conditions, refer to: •...

  • Page 94: Routine Maintenance

    9.3 - ROUTINE MAINTENANCE 9.3.1 - GENERAL SAFETY WARNINGS Put the equipment in a safe condition (close the downstream and then upstream shut-off valve, drain the line completely); Make sure the pressure upstream and downstream of the equipment is "0". After releasing pressure from the line, trip the slam-shut valve.

  • Page 95: Routine Maintenance Procedures

    Minimum Category Part description Evaluation criterion replacement frequency Pressure regulators Nonmetallic parts with a sealing function be- tween parts of which, at least one, is in motion Gas flow block type safety devices 6 years under ordinary working conditions/operation Relief devices with discharge to atmosphere Nonmetallic parts with sealing function in- volved in disassembly operations during main- Equipment subject to maintenance...

  • Page 96: Tightening Torques

    9.4.1 - TIGHTENING TORQUES 9.4.1.1 - TIGHTENING TORQUESNORFLUX Fig. 9.23. Tightening torques NORFLUX HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 97 NORFLUX 2” Pos. Description Torque (Nm) Torque (ft-lb) Nut M24X2 Screw M12X 35 UNI 5739 Screw M18X60 UNI 5737 Screw M5X12 UNI 5931 Nut M12X1, 25 UNI 5588 Nut M12X1, 25 UNI 5588 Screw M6X20 UNI 5931 Tab. 9.57. HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV.
  • Page 98 9.4.1.2 - SB SLAM-SHUT VALVE TIGHTENING TORQUES Fig. 9.24. SB slam-shut valve tightening torques HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 99 SB 2” Pos. Description Torque (nm) Torque (ft - lb) M10 safety valve screw Screw M6X12 UNI 5931 Screw M6X20 UNI 5931 Screw M6X20 UNI 5931 Screw M6X20 UNI 5931 Screw M12X45 UNI 5931 Tab. 9.58 . HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV.
  • Page 100 9.4.1.3 - TIGHTENING TORQUES PRESSURE SWITCH MOD. 100 MOD. 103M/103MH MOD. 104M/104MH - 105M/105MH Fig. 9.25. Tightening torques pressure switch mod. 100 HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 101 MOD. 103M/103MH Pos. Description Torque (nm) Torque (ft - lb) Screw M4X10 UNI 5931 2.21 Screw M5X10 UNI 5933 3.68 Screw M6X16 UNI 5931 7.37 Nut M6 UNI 5588 7.37 Screw M5X15 UNI 8112 3.68 Screw M8X30 UNI 5931 11.80 Screw M5X18 UNI 5931 5.90 Screw M5X20 UNI 5931...
  • Page 102 PAGE INTENTIONALLY LEFT BLANK HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...

  • Page 103: Replacement Of Elements Subject To Wear And Abrasion

    9.4.2 - REPLACEMENT OF ELEMENTS SUBJECT TO WEAR AND ABRASION 9.4.2.1 - INITIAL OPERATIONS After releasing pressure from the line, trip the slam-shut valve. Before carrying out any work, it is important to make sure that the line on which the regulator is installed has been shut-off upstream and downstream that it has been discharged.
  • Page 104 9.4.2.3 - NORFLUX REGULATOR C (1:2) B (1:2) A (1:2) Fig. 9.27. NORFLUX Regulator HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 105 Step Operation Loosen the nut (81). Unscrew and remove the set screw (80) together with the disk (86), nut (81) and O-ring (82). Replace the O-ring (82), lubricating it with synthetic grease. Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Unscrew and remove the plug (73) together with the O-ring (83).
  • Page 106 C (1:2) B (1:2) A (1:2) NORFLUX Regulator HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 107 Step Operation Remove the diaphragm assembly (A) [nut (20), spring guide (61), belleville washer (60), upper diaphragm protec- tion disk (18), lower diaphragm protection disk (17), diaphragm (23), diaphragm support (19), O-rings (52, 49, 53), stroke indicator (14)] from the stem (8). Unscrew and remove the nut (20).
  • Page 108 C (1:2) B (1:2) A (1:2) NORFLUX Regulator HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 109 Step Operation Remove and replace the I/DWR ring (46) from the stem guide (15), lubricating it with synthetic grease. Before inserting the replacement I/DWR, clean the retaining slots with a cleaning solution. Unscrew the screws (31) from the reinforced gasket support (3). Lift the reinforced gasket support (3) together with the O-rings (58, 51, lower 50, 56, 37), screws (33), lower rod guide (9), lower I/DWR (46), reinforced gasket (25), locking ring (7).
  • Page 110 C (1:2) B (1:2) A (1:2) NORFLUX Regulator HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 111 Step Operation Remove and replace the O-ring (55) from the plug guide (6), lubricating it with synthetic grease. Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Remove and replace the I/DWR ring (47) from the plug guide (6), lubricating it with synthetic grease. Before inserting the replacement I/DWR, clean the retaining slots with a cleaning solution.
  • Page 112 C (1:2) B (1:2) A (1:2) NORFLUX Regulator HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 113 Step Operation Place the cover (22) on the lower flange (16). Insert and fasten the screws (32) in the cover (22) according to the tightening torques: • "Tab. 9.57." Tighten the screws as shown in the diagram at paragraph "9.4.2.2 - Cross pattern for tightening screws".

  • Page 114: Maintenance Of The Norflux Regulator With Sb Slam-Shut Valve

    9.4.3 - MAINTENANCE OF THE NORFLUX REGULATOR WITH SB SLAM-SHUT VALVE 9.4.3.1 - BUILT-IN SB 2” SLAM-SHUT VALVE Fig. 9.28. Built-in SB 2” slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 115 Step Operation Check that the built-in slam-shut valve is in the closed position. Unscrew the minimum spring (Fig. 8.20, ref. 17). Check that the minimum spring is present. Arm the slam-shut valve by moving the reset lever (16) to the open position. Hold the built-in slam-shut valve during the next steps.
  • Page 116 Built-in SB 2” slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 117 Step Operation Unscrew the plug screw (5). Remove the washer (26). Remove the spring holder (4) and spring (48). Unscrew and remove the screws (22) of the pressure switch. Remove the cover (119) together with the gasket (29). Unscrew the side screws (36) located inside the control pressure switch. Unscrew the outer screws (35).
  • Page 118 Built-in SB 2” slam-shut valve HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 119 Step Operation Place the pressure switch unit. Insert and fasten the screws (35), according to the tightening torque: • "Tab. 9.58 ." Tighten the screws as shown in the diagram at paragraph "9.4.2.2 - Cross pattern for tightening screws". Insert and fasten the side screws (36), according to the tightening torque: •...

  • Page 120: Maintenance Procedure For Pressure Switches Mod. 100

    9.4.4 - MAINTENANCE PROCEDURE FOR PRESSURE SWITCHES MOD. 100 9.4.4.1 - PRESSURE SWITCH MOD. 103M/103MH Mod. 103/103MH Fig. 9.29. Pressure switch Mod. 103M/103MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 121 Step Operation Unscrew and remove the cap (18). Remove and replace the O-ring (16) from the cover (18), lubricating it with synthetic grease. Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Fully unload the maximum spring (11) via the ring nut (13). Fully unload the minimum spring (17) via the ring nut (15).
  • Page 122 Mod. 103/103MH Pressure switch Mod. 103M/103MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 123 Step Operation Put the lower cover (41) in place. Insert and fasten the screws (48), according to the tightening torque: • Mod. 103: Tab. 9.59. • Tighten the screws as shown in the diagram at paragraph "9.4.2.2 - Cross pattern for tightening screws";...
  • Page 124 9.4.4.2 - PRESSURE SWITCH MOD. 104M/104MH, 105M/105MH Mod. 104M/104MH Mod. 105M/105MH Fig. 9.30. Pressure switch Mod. 104M/104MH, 105M/105MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...
  • Page 125 Step Operation Unscrew and remove the cap (18). ¹ Remove and replace the O-ring (16) from the cover (18), lubricating it with synthetic grease. Before inserting the replacement O-ring, clean the retaining slots with a cleaning solution. Fully unload the maximum spring (11) via the ring nut (13). Fully unload the minimum spring (17) via the ring nut (15).
  • Page 126 Mod. 104M/104MH Mod. 105M/105MH Pressure switch Mod. 104M/104MH, 105M/105MH HIGH PRESSURE REGULATOR MAINTENANCE AND FUNCTIONAL TESTING REV. A Use, maintenance and warning manual...

  • Page 127: Re-Commissioning Procedure Following Maintenance

    Step Operation Put the lower cover (41) in place. Ensure there is a gasket between the lower cover and the pressure switch body. Insert and fasten the screws (48) according to the tightening torques: • Mod. 104-105: Tab. 9.60. Tighten the screws as shown in the diagram at paragraph "9.4.2.2 - Cross pattern for tightening screws".
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  • Page 129: Fault Finding And Troubleshooting

    • qualified and authorized for the activities inherent to the equipment. No liability related to personal injury or property damage can be attributed to PIETRO FIORENTINI S.p.A. for interventions: • other than those described;...

  • Page 130: Specific Qualification Of The Operator

    10.2 - SPECIFIC QUALIFICATION OF THE OPERATOR Commissioning • Mechanical maintenance technician; • Electrical maintenance technician; Operator qualification • Installer; • User technician. The PPE listed in this chart relates 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, refer to: •...

  • Page 131: Troubleshooting Tables

    10.4 - TROUBLESHOOTING TABLES Refer to chapter “9 - Maintenance and functional testing” for pictures of the regulator NORFLUX and its ac- cessories. 10.4.1 - NORFLUX REGULATOR TROUBLESHOOTING If the built-in slam-shut valve has tripped, close the upstream and downstream shut-off valves (V1 and V2) of the line and relieve the pressure before any operation.
  • Page 132 Fault Equipment Possible causes Intervention Diaphragm (20) worn or damaged Replace I/DWR (46) dirty or damaged Clean and if necessary replace Stem (8) locked in opening Clean Downstream pressure Reinforced gasket (4) dirty or worn increases REGULATOR Clean and if necessary replace during delivery Valve seat (5) with damaged profile Replace...

  • Page 133: Built-In Slam-Shut Valve Troubleshooting

    10.4.2 - BUILT-IN SLAM-SHUT VALVE TROUBLESHOOTING If the built-in slam-shut valve has tripped, close the inlet and outlet valves (V1 and V2) of the line and relieve the pressure before any operation. Fault Equipment Possible causes Intervention Perform calibration again by acting on the ring nuts.
  • Page 134 Fault Equipment Possible causes Intervention Lack of O-ring seal (40) Clean and if necessary replace No plug pad seal (19) Clean and if necessary replace BUILT-IN Conical seat (8) SLAM-SHUT VALVE Replace damaged Lack of O-ring seal (39) Downstream pressure Clean and if necessary replace increase with slam-shut Lack of pad O-ring seal (5)

  • Page 135: Uninstallation And Disposal

    11 - UNINSTALLATION AND DISPOSAL 11.1 - GENERAL SAFETY WARNINGS Ensure that there are no effective ignition sources in the work area set up for equipment de-installation and/or disposal. Before proceeding with uninstallation and disposal operations, ensure that the equipment is secured by dis- connecting it from all power supplies.

  • Page 136: Information Needed In Case Of Re-Installation

    11.4 - INFORMATION NEEDED IN CASE OF RE-INSTALLATION In case the equipment after uninstallation is to be reused, refer to chapters: • “6 - Installation”; • “8 - Commissioning”. 11.5 - DISPOSAL INFORMATION Please remember to comply with the laws in force in the country where the equipment is installed. Illegal or improper disposal will result in the application of the penalties provided for in the regulations in force in the country of installation.

  • Page 137: Recommended Spare Parts

    By using non-original replacement parts PIETRO FIORENTINI S.p.A. the stated performance cannot be guar- anteed. It is recommended to use the original PIETRO FIORENTINI S.p.A. replacement parts PIETRO FIORENTINI S.p.A. is not responsible for damage caused by the use of non-original spare parts or components. 12.2 - HOW TO REQUEST SPARE PARTS For specific information, consult the PIETRO FIORENTINI S.p.A.
  • Page 138 PAGE INTENTIONALLY LEFT BLANK HIGH PRESSURE REGULATOR RECOMMENDED SPARE PARTS REV. A Use, maintenance and warning manual...

  • Page 139: Calibration Tables

    13 - CALIBRATION TABLES 13.1 - REGULATOR CALIBRATION TABLES NORFLUX Pos. Spring article code Spring color 2703735 White 12.5 2704390 Green 12.501 2704820 Purple 22.001 2705010 Light blue 36.201 d = Wire Diameter (mm) Lo = Spring Length (mm) De = External Diameter (mm) Tab.
  • Page 140 Mod. 104M/104MH - Max Pressure Pos. Spring article code Spring color 2702280 White/Red 217.56 435.10 2702450 435.11 652.65 d = Wire Diameter (mm) Lo = Spring Length (mm) De = External Diameter (mm) Tab. 13.76. Mod. 104M - Min Pressure Pos.

  • Page 141: Regulator Flow Rate Tables

    Brown d = Wire Diameter (mm) Lo = Spring Length (mm) De = External Diameter (mm) Tab. 13.81. 13.3 - REGULATOR FLOW RATE TABLES NORFLUX 2" (maximum recommended flow rate for optimal performance) Outlet pressure Inlet pressure 10 psi 20 psi...
  • Page 142 TM0096USA...

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