PIETRO FIORENTINI REFLUX 819 Owner's manual

Type
Owner's manual
Reux 819
High medium pressure gas regulator
EN
Revision B - Edition 01/2023
USE, MAINTENANCE AND
WARNING MANUAL
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HIGH PRESSURE REGULATOR | INTRODUCTION | REV. B
Use, maintenance and warning manual
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1 - INTRODUCTION
FOREWORD
All rights reserved. No part of this publication may be reproduced, distributed, translated into other languages or trans-
mitted by any electronic or mechanical media, including photocopies, recording or any other storage and retrieval system,
for any other purposes that are not exclusively the personal use of the buyer, without the express written permission of
the Manufacturer.
The manufacturer is in no way responsible for the consequences of operations carried out in a manner not in accordance
with the manual.
GENERAL REMARKS
All operating, maintenance instructions and recommendations described in this manual must be observed. In order to
obtain the best performance and to keep the equipment in efcient condition, the manufacturer recommends that main-
tenance operations be carried out regularly.
It is of particular importance that the personnel responsible for the equipment be trained in its use, maintenance and ap-
plication of the safety instructions and procedures indicated in this manual.
Revision: B
COPYRIGHT 2023
© PIETRO FIORENTINI S.P.A.
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1.1 - REVISION HISTORY
Revision
index Date Revision contents
A10/2022 First issue
B01/2023
Chapter 4: Fig. 4.11 updated
Chapter 6, par. 6.5.2: limits of velocity of the pressurised uid updated
Chapter 8, par. 8.8.1: Fig. 8.33 updated
Tab. 1.1
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INDICE
1 - INTRODUCTION .................................................................................................................. 3
1.1 - REVISION HISTORY .................................................................................................................................. 5
2 - GENERAL INFORMATION ................................................................................................ 13
2.1 - MANUFACTURER IDENTIFICATION ........................................................................................................ 13
2.2 - IDENTIFICATION OF THE PRODUCT ...................................................................................................... 13
2.3 - REGULATORY FRAMEWORK ................................................................................................................. 13
2.4 - WARRANTY ............................................................................................................................................ 13
2.5 - SYMBOLS USED IN THE MANUAL ......................................................................................................... 14
2.6 - ADDRESSEES, SUPPLY AND STORAGE OF THE INSTRUCTION MANUAL ........................................... 15
2.7 - LANGUAGE ............................................................................................................................................ 15
2.8 - NAMEPLATES APPLIED ......................................................................................................................... 16
2.8.1 - GLOSSARY FOR NAMEPLATES ...........................................................................................................18
2.9 - GLOSSARY OF UNITS OF MEASUREMENT ........................................................................................... 20
2.10 - QUALIFIED PROFESSIONAL FIGURES ................................................................................................... 21
3 - SAFETY .............................................................................................................................. 23
3.1 - GENERAL SAFETY WARNINGS .............................................................................................................. 23
3.2 - PERSONAL PROTECTIVE EQUIPMENT .................................................................................................. 24
3.3 - RESIDUAL RISKS ................................................................................................................................... 25
3.3.1 - TABLE SHOWING RESIDUAL RISKS DUE TO PRESSURE ...................................................................26
3.3.2 - TABLE OF RESIDUAL RISKS FOR POTENTIALLY EXPLOSIVE ATMOSPHERES ...................................28
3.4 - OBLIGATIONS AND PROHIBITIONS ....................................................................................................... 30
3.5 - SAFETY PICTOGRAMS .......................................................................................................................... 31
3.6 - RISK LEVEL ............................................................................................................................................ 31
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4 - DESCRIPTION AND OPERATION .................................................................................... 33
4.1 - GENERAL DESCRIPTION ....................................................................................................................... 33
4.1.1 - REGULATOR REACTION MODES ......................................................................................................... 34
4.2 - OPERATION ............................................................................................................................................ 34
4.3 - INTENDED USE ...................................................................................................................................... 36
4.3.1 - ENVISAGED USE ..................................................................................................................................36
4.3.2 - REASONABLY FORESEEABLE MISUSE ...............................................................................................36
4.3.3 - TYPES OF FLUIDS ................................................................................................................................36
4.4 - TECHNICAL FEATURES/PERFORMANCE .............................................................................................. 37
4.5 - POSSIBLE CONFIGURATIONS ............................................................................................................... 38
4.5.1 - BUILT-IN SILENCER ..............................................................................................................................39
4.5.1.1 - BUILT-IN SILENCER DB/819.........................................................................................................39
4.5.1.2 - BUILT-IN SILENCER LDB/171 .......................................................................................................40
4.5.2 - PM/819 MONITOR ................................................................................................................................ 41
4.5.2.1 - M/A ACCELERATING VALVE ........................................................................................................45
4.5.3 - SLAM-SHUT VALVE ..............................................................................................................................46
4.5.3.1 - INCORPORATED SB/82 SLAM-SHUT VALVE ............................................................................... 46
4.5.3.2 - HB/97 BUILT-IN SLAM-SHUT VALVE ............................................................................................48
4.5.4 - SLAM-SHUT VALVE PRESSURE SWITCHES ........................................................................................50
5 - TRANSPORT AND HANDLING ......................................................................................... 53
5.1 - SPECIFIC WARNINGS FOR TRANSPORT AND HANDLING ................................................................... 53
5.1.1 - PACKAGING AND FASTENERS USED FOR TRANSPORT ....................................................................54
5.2 - PHYSICAL CHARACTERISTICS OF THE EQUIPMENT ........................................................................... 56
5.2.1 - REFLUX 819 (+LDB/171).......................................................................................................................56
5.2.2 - REFLUX 819 + DB/819 .........................................................................................................................58
5.2.3 - REFLUX 819 + PM/819 ......................................................................................................................... 60
5.2.4 - REFLUX 819 + SB/82 ..........................................................................................................................62
5.2.5 - REFLUX 819 + HB/97 ...........................................................................................................................64
5.2.6 - REFLUX 819 + DB/819 + PM/819 .........................................................................................................66
5.2.7 - REFLUX 819 + DB/819 + SB/82 ..........................................................................................................68
5.2.8 - REFLUX 819 + DB/819 + HB/97 ...........................................................................................................70
5.3 - EQUIPMENT ANCHORING AND LIFTING METHOD................................................................................ 72
5.3.1 - FORKLIFT HANDLING METHOD ........................................................................................................... 73
5.3.2 - CRANE HANDLING METHOD ...............................................................................................................75
5.4 - PACKAGING REMOVAL .......................................................................................................................... 76
5.4.1 - PACKAGING DISPOSAL .......................................................................................................................76
5.5 - STORAGE AND ENVIRONMENTAL CONDITIONS .................................................................................. 77
5.5.1 - PRE-INSTALLATION WARNINGS AFTER PROLONGED STORAGE ......................................................77
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6 - INSTALLATION .................................................................................................................. 79
6.1 - INSTALLATION PRE-REQUISITES ........................................................................................................... 79
6.1.1 - ALLOWED ENVIRONMENTAL CONDITIONS .........................................................................................79
6.1.2 - CHECKS BEFORE INSTALLATION ........................................................................................................ 80
6.2 - SPECIFIC SAFETY INSTRUCTIONS FOR THE INSTALLATION STEP ...................................................... 81
6.3 - GENERAL INFORMATION ON CONNECTIONS ...................................................................................... 82
6.4 - REGULATOR INSTALLATION POSITIONS ............................................................................................... 83
6.5 - INSTALLATION PROCEDURES ............................................................................................................... 84
6.5.1 - EQUIPMENT INSTALLATION PROCEDURE ..........................................................................................84
6.5.2 - CONNECTION OF THE SENSING LINES TO THE DOWNSTREAM PIPING ...........................................84
6.6 - POST-INSTALLATION AND PRE-COMMISSIONING CHECKS ................................................................ 86
7 - COMMISSIONING/MAINTENANCE EQUIPMENT........................................................... 87
7.1 - LIST OF EQUIPMENT .............................................................................................................................. 87
7.2 - EQUIPMENT NEEDED FOR THE DIFFERENT CONFIGURATIONS .......................................................... 89
8 - COMMISSIONING ............................................................................................................. 93
8.1 - GENERAL WARNINGS ........................................................................................................................... 93
8.1.1 - SAFETY REQUIREMENTS FOR COMMISSIONING ...............................................................................93
8.2 - PRELIMINARY PROCEDURES FOR COMMISSIONING .......................................................................... 94
8.3 - PROPER COMMISSIONING CHECK ...................................................................................................... 95
8.4 - CALIBRATION OF ANY ACCESSORIES .................................................................................................. 95
8.5 - REGULATOR COMMISSIONING PROCEDURE ...................................................................................... 96
8.6 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT-IN MONITOR PM/819
98
8.7 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT-IN PM/819 MONITOR
AND M/A THROTTLE ............................................................................................................................ 100
8.8 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH BUILT-IN SLAM-SHUT VAL-
VE SB/82 .............................................................................................................................................. 102
8.8.1 -CHECKING THE SB/82 SLAM-SHUT VALVE FOR PROPER SEALING WHEN CLOSING .............. 102
8.8.2 - COMMISSIONING OF THE REGULATOR REFLUX 819 WITH SLAM-SHUT VALVE SB/82 ..................103
8.8.3 - PRESSURE SWITCHES CALIBRATION PROCEDURE 102M/102MH - 105M/105MH .........................106
8.9 - COMMISSIONING PROCEDURE FOR THE REFLUX 819 REGULATOR WITH INCORPORATED SLAM-
SHUT VALVE SB/97 .............................................................................................................................. 108
8.9.1 -CHECKING THE HB/97 INCORPORATED SLAM-SHUT VALVE FOR SEALING WHEN CLOSING ... 108
8.9.2 - COMMISSIONING OF THE REFLUX 819 REGULATOR WITH HB/97 SLAM-SHUT VALVE ..................109
8.9.3 - LINE OFF 2.0 COMMISSIONING AND CALIBRATION PROCEDURE FOR HB/97 BUILT-IN SLAM-SHUT
VALVE .................................................................................................................................................112
8.10 - CALIBRATION OF THE PRESSURE SWITCH FOR LINE OFF 2.0 .......................................................... 113
8.11 - DEVICE CALIBRATION .......................................................................................................................... 114
8.11.1 - 200/A SERIES PILOTS ........................................................................................................................114
8.11.2 - PRESSURE SWITCHES MODELS 102M/102MH - 105M/105MH .......................................................114
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9 - MAINTENANCE AND FUNCTIONAL CHECKS .............................................................. 117
9.1 - GENERAL WARNINGS ......................................................................................................................... 117
9.2 - PERIODICALLY CHECKING AND INSPECTING THE EQUIPMENT FOR PROPER OPERATION ............ 119
9.3 - ROUTINE MAINTENANCE .................................................................................................................... 120
9.3.1 - GENERAL SAFETY WARNINGS .......................................................................................................... 120
9.3.2 - REPLACEMENT FREQUENCY FOR COMPONENTS SUBJECT TO WEAR .........................................121
9.4 - ROUTINE MAINTENANCE PROCEDURES ............................................................................................ 123
9.4.1 - TIGHTENING TORQUES REFLUX 819 ................................................................................................124
9.4.2 - REPLACING ELEMENTS SUBJECT TO WEAR AND ABRASION.........................................................157
9.4.3 - REGULATOR MAINTENANCE PROCEDURE REFLUX 819 ..................................................................158
9.4.4 - DB/819 SILENCER MAINTENANCE PROCEDURE .............................................................................218
9.4.5 - PM/819 BUILT-IN MONITOR MAINTENANCE PROCEDURE ...............................................................226
9.4.6 - PILOT MAINTENANCE PROCEDURE 200/A SERIES + PRE-REGULATOR R14/A ..............................256
9.4.7 - M/A ACCELERATOR VALVE MAINTENANCE PROCEDURE ................................................................272
9.4.8 - SB/82 INCORPORATED SLAM-SHUT VALVE MAINTENANCE PROCEDURE .....................................276
9.4.9 - HP2/2 BYPASS DEVICE MAINTENANCE PROCEDURE ......................................................................301
9.4.10 - MAINTENANCE PROCEDURE FOR PRESSURE SWITCHES MOD. 100 .............................................302
9.4.11 - HB/97 BUILT-IN SLAM-SHUT VALVE MAINTENANCE PROCEDURE ..................................................314
9.4.12 - LINE OFF 2.0 MAINTENANCE PROCEDURE ......................................................................................324
9.4.13 - PROCEDURE FOR RECOMMISSIONING AFTER MAINTENANCE ......................................................347
10 - TROUBLESHOOTING...................................................................................................... 349
10.1 - GENERAL WARNINGS ......................................................................................................................... 349
10.2 - OPERATOR QUALIFICATION SPECIFICATION ...................................................................................... 350
10.3 - TROUBLESHOOTING PROCEDURES .................................................................................................. 350
10.4 - TROUBLESHOOTING TABLES ............................................................................................................. 351
10.4.1 - TROUBLESHOOTING REFLUX 819 REGULATOR ...............................................................................351
10.4.2 - DB/819 SILENCER TROUBLESHOOTING ..........................................................................................354
10.4.3 - APM/819 BUILT-IN MONITOR TROUBLESHOOTING ..........................................................................355
10.4.4 - SB/82 BUILT-IN SLAM-SHUT VALVE TROUBLESHOOTING ................................................................358
10.4.5 - HB/97 BUILT-IN SLAM-SHUT VALVE TROUBLESHOOTING................................................................360
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11 - UNINSTALLATION AND DISPOSAL ............................................................................... 365
11.1 - GENERAL SAFETY WARNINGS ............................................................................................................ 365
11.2 - QUALIFICATION OF THE OPERATORS IN CHARGE ............................................................................. 365
11.3 - UNINSTALLATION ................................................................................................................................. 365
11.4 - INFORMATION REQUIRED IN CASE OF RE-INSTALLATION ................................................................. 365
11.5 - DISPOSAL INFORMATION .................................................................................................................... 366
12 - RECOMMENDED SPARE PARTS ................................................................................... 367
12.1 - GENERAL WARNINGS ......................................................................................................................... 367
12.2 - HOW TO REQUEST SPARE PARTS ...................................................................................................... 367
13 - CALIBRATION TABLES ................................................................................................... 369
13.1 - 200 SERIES PILOT CALIBRATION TABLES .......................................................................................... 369
13.2 - PRESSURE SWITCH CALIBRATION TABLES MOD. 100 ...................................................................... 370
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2 - GENERAL INFORMATION
2.1 - MANUFACTURER IDENTIFICATION
Manufacturer PIETRO FIORENTINI S.P.A.
Address
Via Enrico Fermi, 8/10
36057 Arcugnano (VI) - ITALY
Tel. +39 0444 968511 Fax +39 0444 960468
www.orentini.com arcugnano@orentini.com
Tab. 2.2
2.2 - IDENTIFICATION OF THE PRODUCT
Equipment HIGH PRESSURE REGULATOR
Model REFLUX 819
Tab. 2.3
2.3 - REGULATORY FRAMEWORK
PIETRO FIORENTINI S.P.A., with registered ofces in Arcugnano (Italy) - Via E. Fermi, 8/10, declares under its sole re-
sponsibility that the equipment of the REFLUX 819 series described in this manual is designed, manufactured, tested and
checked in compliance with the requirements of EN 334 standard on gas pressure regulators.
The equipment complies with the requirements of Directive 2014/68/EU ("Pressure Equipment Directive" PED). The as-
sessment procedure adopted is in accordance with module H1 as per Annex III of the Directive.
NOTICE!
The declaration of conformity in its original version is delivered together with the equipment and this oper-
ating and warning manual.
2.4 - WARRANTY
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, specications 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:
due to any acts or omissions of the purchaser or end-user, or any of their carriers, employees, agents, or any third
party or entity;
in the event that the purchaser, or a third party, makes changes to the equipment supplied by PIETRO FIORENTINI S.P.A.
without the prior written approval of the latter;
in the event of failure by the purchaser to comply with the instructions contained in this manual, as provided by
PIETRO FIORENTINI S.P.A.
NOTICE!
The warranty conditions are specied in the commercial contract.
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2.5 - SYMBOLS USED IN THE MANUAL
Symbol Denition
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.
Indicates a requirement for the personnel to refer to (and understand) the operating and warning
instructions of the machine before working with or on it.
Tab. 2.4
HAZARD!
Alerts to a hazard with a high level of risk, an imminent hazardous situation which, if not prevented, will
result in death or severe damage.
WARNING!
Alerts to a hazard with a medium level of risk, a potentially hazardous situation which, if not prevented,
may result in death or severe damage.
ATTENTION!
Alerts to a hazard with a low level of risk, a potentially hazardous situation which, if not prevented, could
result in minor or moderate damage.
NOTICE!
Alerts to specic warnings, directions or notes of particular concern, that are not related to physical injury,
as well as practices for which physical injury is not likely to occur.
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2.6 - ADDRESSEES, SUPPLY AND STORAGE OF THE INSTRUCTION MANUAL
The instruction manual is intended for qualied technicians responsible for operating and managing the equipment
throughout its service life.
It contains the necessary information to properly use the equipment and keep its functional and qualitative characteristics
unchanged over time. All information and warnings for safe, correct use are also provided.
The instruction manual, as well as the declaration of conformity and/or test certicate, is an integral part of the equipment
and must always accompany it whenever it is moved or resold. It is up to the user to keep this documentation intact for
reference throughout the lifespan of the equipment.
WARNING!
Removing, rewriting or editing the pages of the manual and their contents is not allowed.
Keep the instruction manual near the equipment, in an accessible place known by all qualied 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.
2.7 - LANGUAGE
The original instruction manual was drawn up in Italian.
Any translations into additional languages are to be made from the original instruction manual.
HAZARD!
The Manufacturer is not responsible for any incomplete translations. If any inconsistency is found, please
refer to the text of the original manual.
If inconsistencies are found or the text does not make sense:
stop any actions;
immediately contact the relevant ofces of PIETRO FIORENTINI S.p.A.
WARNING!
PIETRO FIORENTINI S.p.A. shall be held liable for the information provided in the original manual only.
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2.8 - NAMEPLATES APPLIED
WARNING!
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).
The nameplates specify identication details of the equipment and its accessories to be provided, if necessary, to
PIETRO FIORENTINI S.p.A.
Tab. 2.5 shows the nameplates applied:
Id. Type Image
1NAMEPLATE
REGULATOR (EC version)
2NAMEPLATE
PILOT
3NAMEPLATE
PRE-REGULATOR
4NAMEPLATE
DB SILENCER
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Id. Type Image
5NAMEPLATE
MONITOR
6NAMEPLATE
SLAM-SHUT VALVE
7NAMEPLATE
PRESSURE SWITCH
8NAMEPLATE
ACCELERATING VALVE
Tab. 2.5
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2.8.1 - GLOSSARY FOR NAMEPLATES
The terms and abbreviations used on nameplates are described in Tab. 2.6:
Term Description
AC Accuracy class.
AG max Accuracy class of pressure boosting slam-shut valves.
“OPSO” (Over pressure shut off).
AG min Accuracy class of safety devices for pressure drop.
”UPSO”(Under pressure shut off).
bpu Range of inlet pressure for which the regulator ensures a given accuracy class.
CE Marking certifying compliance with applicable European directives.
Cg Flow rate coefcient.
Class
Alphanumeric designation used for reference purposes related to a combination of mechanical
and dimensional characteristics for anges, in accordance with the relevant parts of EN 1759
series, which includes the word Class followed by a dimensionless whole number.
DN Nominal size of connections.
Fail safe mode Regulator reaction mode (Fail open or Fail close).
Flange Type of anged connections or type of connection thread.
Fluid Type of uid compatible with the equipment.
ID no. Number of the Notied Body participating in the conformity assessment of the equipment.
Pilot Pilot family.
PS Maximum permissible pressure for which the equipment was designed.
Pumax Maximum inlet pressure at which the regulator can operate continuously under specic condi-
tions.
REGULATOR Equipment family.
SG Shut-off pressure class.
Slam-shut device Slam-shut valve family.
S.n. Equipment serial number.
Strength type Strength class: Integral strength or differential strength (DS).
TPermissible temperature range (min. and max.) for which the equipment was designed.
Tripping unit Pressure switch family.
Type Accessory type and family.
Wd Full setpoint range that can be obtained from the regulator by adjusting and/or replacing certain
components (e.g. replacement of valve seat or control element, e.g. spring).
Wdo
Full setpoint range with regard to tripping caused by increased 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).
Wds Full setpoint range that can be obtained from the regulator by adjusting but not replacing the
components.
Wdso
Full setpoint range with regard to tripping caused by increased pressure in the pressure switch
incorporated in the slam-shut valve.
This range can be obtained by adjusting but not replacing the components.
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Term Description
Wdu
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).
Wdsu
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 but not replacing the components.
Tab. 2.6
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2.9 - GLOSSARY OF UNITS OF MEASUREMENT
Type of measurement Unit of measurement Description
Volumetric ow rate Sm³/h Standard cubic metres per hour
Scfh Standard cubic feet per hour
Pressure
bar Unit of measurement in the CGS system
psi Pounds per square inch
“wc inch of water column
Pa Pascal
Temperature
°C Degree centigrade
°F Fahrenheit degree
K Kelvin
Tightening torque Nm Newton-metre
ft-lbs Foot per pound
Sound pressure dB Decibel
Other measures
V Volt
W Watt
Ohm
Tab. 2.7
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PIETRO FIORENTINI REFLUX 819 Owner's manual

Type
Owner's manual

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