Installation Manual, Maintenance and Operation Pressure Regulating Valve Model URANO FA/FF

Transcription

1 Pressure Regulating Valve Model URANO FA/FF

2 INDEX GENERAL WARNINGS INSTRUCTIONS FOR COMMISSIONING HEALTH AND SAFETY NOISE INSTALLATION OPERATION MAINTENANCE INTRODUCTION SCOPE OF MANUAL DESCRIPTION SPECIFICATIONS AVAILABLE SETTINGS AVAILABLE CONNECTIONS TEMPERATURE LIMITS COEFFICIENTS FLOW APPROXIMATE WEIGHT MAXIMUM WORKING PRESSURE SETTING PRESSURES (SET-POINT) ACCURACY AND LOCK UP PRINCIPLE OF OPERATION REGULATOR SPRING TO CLOSE (FAIL CLOSE) REGULATOR SPRING TO OPEN (FAIL OPEN) BOOSTER (G-43 & G-44) PILOTS (G-40 & G-42) FILTERS MOUNT MONITOR AND ACTIVE INSTALLATION FILTER CLEANING DIRECTION OF FLOW AND SYSTEM INTEGRITY SENSE SCHEME RECOMMENDED INSTALLATION SINGLE REGULATOR SISTEM MONITOR AND ACTIVE TWO SSV AND A REGULATOR FF START-UP GENERAL RECOMMENDATIONS COMMISSIONING (SINGLE REGULATOR) ADJUSTING THE LINE BOOKING COMMISSIONING (SISTEM MONITOR AND ACTIVE) ADJUSTING THE LINE BOOKING (MONITOR - ACTIVE) LIST OF RECOMMENDED TOOLS TROUBLE SHOOTING MAINTENANCE RECOMMENDED REPAIR PARTS AND KITS PROCEDURE FOR REMOVAL THE REGULATOR URANO SC (FF) PROCEDURE FOR ASSEMBLY REGULATOR URANO SC (FF) PROCEDURE FOR REMOVAL THE REGULATOR URANO SO (FO) Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

3 6.5 PROCEDURE FOR ASSEMBLY REGULATOR URANO SO (FO) PROCEDURE FOR REMOVAL THE PILOT G-40 / PROCEDURE FOR ASSEMBLY THE PILOT G-40 / PROCEDURE FOR REMOVAL BOOSTER (PRE-EGULATOR) G PROCEDURE FOR ASSEMBLY BOOSTER (PRÉ REGULATOR) G PROCEDURE FOR REMOVAL BOOSTER (PRE-REGULADOR) G ERRO! INDICADOR NÃO DEFINIDO PROCEDURE FOR ASSEMBLY BOOSTER (PRE-REGULADOR) G LIST OF RECOMMENDED TOOLS FOR MAINTENANCE... ERRO! INDICADOR NÃO DEFINIDO. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

4 1.0 - GENERAL WARNINGS 1.1 INSTRUCTIONS FOR PRE COMMISSIONING It should be clearly understood that with the information presented in Commissioning Instructions that follow, it is not intended to repeal or replace the instructions determined by any other competent body and should be reference to the relevant standards and / or existing recommendations on this subject. Before any commissioning, is implied the performance of the appropriate "Cleaning and Purification Procedures" that must be observed and all the instructions on "Pressurization" and "Work Standards for Health and Safety", must be strictly met. The recommendations of valves suppliers, such as "open slowly" or "open very slowly" should be strictly observed. 1.2 HEALTH AND SAFETY Regulators, valves, and other pressurized components that contain toxic gases, flammable or other hazardous products, are potentially dangerous if not operated and maintained properly. It is imperative that all users of this equipment are adequately educated and guided to the potential hazards and make sure that staff responsible for the installation, testing, commissioning, operation and plant maintenance are competent to do this. Instruction manuals are provided for the guidance of operators, but it is assumed that they have a basic level of knowledge. If any doubts or ambiguities that affect the proper procedures ask Gascat Ind e Com. Ltda. who will be happy to advise or provide the relevant service or instruction. NO RISK. Our phone number, fax number and are described below: Gascat Indústria e Comércio Ltda. Rodovia SP 73, 1141 Indaiatuba / São Paulo. CEP Telefone: Fax: sales@gascat.com.br The comments that follow, while not exhaustive, provide guidance possible sources of danger to health and safety NOISE Regulators, valves and pressure reducers can produce high noise levels, which may be harmful to persons exposed to them for long periods of time. Users should ensure that adequate precautions are taken in order to provide security to the health of employees and / or third parties as the standards and recommendations in force INSTALLATION All equipment, piping and vessels are designed to withstand mechanical stress, for example, torque and moments of "bending" in addition to internal pressure. However, care must be taken during installation to not impose excessive strain, which may cause cracks that may result in a more serious break when the regulator is put into operation. Excessive stress can also be caused due to not supporting the length of the pipe, which must be adequately supported. All regulators, valves shut off, relief valves, etc., should be installed with the correct flow. Impulse lines are important components of any control system and it is essential that they are properly installed and without isolation valves. Impulse lines should be adequately supported to reduce excessive vibration which may cause disruption due to fatigue. They should also be positioned so that they can not serve as a footrest or hands. Impulse lines should be slightly inclined so that condensed liquids and to flow into the main pipe. When necessary (in underground facilities or indoor area) should be installed a pipe ventilation from Ø threaded ¼ "NPT, positioned in the bell or diaphragm housing, which should be extended and positioned in a safe place and ventilated, with the departure of protected vent to prevent water entering the rain and insects that may cause obstruction of ventilation. Auxiliary systems should not be altered or modified without the knowledge of operating conditions and permission of the people responsible. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

5 1.2.3 OPERATION Depending on the type of regulator, the valve may even be positioned fully open. Consequently, when a regulator put in operation, the shutoff valves should be opened slowly so that the regulator valve can assume its regulating position. If the valves are quickly opened the upstream pressure can pass downstream through the regulator and over-pressurize downstream the main line. All regulators, etc., should operate with the spring adjustment specified by the manufacturer. This is especially important when operating relief valve or shutoff valves, since incorrect springs may prevent the relief valve to open and close the shutoff valve. Precautions should be taken to prevent water from entering through the openings for breathing and ventilation MAINTENANCE Regulators and valves contain gases at pressures that are sometimes greater than atmospheric pressure. Before trying to investigate any problem or perform maintenance work on equipment, they must be safely depressurised. Furthermore, as most gases may be flammable, toxic, corrosive, or hazardous, it may be necessary to purge the system with an inert gas such as nitrogen. Special precautions are necessary for operation with gases such as oxygen or hydrochloric gas and the user must be sure that the appropriate procedures are in place. Eventually it is not enough to isolate the high pressure device, since high pressures can be retained downstream of isolation valves. Do not try to remove covers, plugs, etc., before this device is properly released. Still, it is wise to consider that the high pressure gas may be present when removing covers and plugs. Most regulators use spiral springs as a charging device. It is important to reduce the burden these springs away your presser as possible. In some cases, there may be some cargo residue, even when the spring is relaxed within the limits of their house. 2.0 INTRODUCTION 2.1 SCOPE OF MANUAL This manual aims to provide operational information, installation and maintenance of the pressure regulators URANO model manufactured by GASCAT. 2.2 DESCRIPTION The pilot operated pressure regulator model URANO was developed by the Engineering GASCAT, to meet the most varied applications and can operate in various operating conditions, however, it is particularly applicable in situations where requires high flow rates associated with high pressures, typically found in natural gas transportation and custody transfer in natural gas delivery point and can operate with a maximum inlet pressure of 150 kgf/cm² and outlet pressures from 1.0 to 80.0 kgf/cm². The pressure regulator of URANO GASCAT model has CE mark (product identification Number: CE-0085BU0263) and certified tests performed in the laboratory DVGW attesting its efficiency and compliance with DIN EN 334 (Gas pressure regulators for inlet pressures up to 100 bar) and 97/23 / EG (PED), the DVGW certificates and reports are available for inspection at GASCAT if some of the documents necessary for your application, please contact our Headquarters in Indaiatuba and request copies of these documents. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

6 2.3 SPECIFICATIONS AVAILABLE SETTINGS URANO FA: Pilot operated pressure regulator fail open URANO FF: Pilot operated pressure regulator failure close The URANO pressure regulators are classified as FA and FF according to the guidelines reported in DIN EN 334, for fault condition AVAILABLE CONNECTIONS DN FLANGE ASME B16.5 FLANGE DIN 2634 / #RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN #RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN #RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN #RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN #RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN #RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN TEMPERATURE LIMITS Operating temperature: -20 C a 60 C Ambient temperature: -20 C a 60 C Temperature limits reported in this manual or any standard should not be exceeded under any circumstances, at the risk of damage to the equipment, installation and security of the people involved in the operation COEFFICIENTS FLOW DN CV KG Note: 1) We suggest that is considered a 20% safety factor on the calculated value. 2) When scaled active-monitor system finds 25% restriction on the CV / KG of both valves. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

7 2.3.5 APPROXIMATE WEIGHT DN 150# 300# 600# 900# Note: 1) Weights reported in kilograms (Kg) 2) Considered body in carbon steel SA-216 WCB 3) For the exact weights contact the GASCAT for verification of the model MAXIMUM WORKING PRESSURE 150# 300# 600# 900# PN 25 PN bar 51 bar 100 bar 150 bar 25 bar 40 bar Pressure limits reported in this manual or any standard should not be exceeded under any circumstances, at the risk of damage to the equipment, installation and security of the people involved in the operation SET-POINT Pressure regulators, model URANO using two models of pilots for pressure control called G-40 and G-42, here are the adjustment ranges available for each model: PILOT G-40 SPRING COLOR CODE ADJUSTMENT RANGE RED A 25,0 50,0 bar YELLOW ,0 80,0 bar PILOT G-42 SPRING COLOR CODE ADJUSTMENT RANGE GREEN ,0 4,5 bar GRAY ,5 12,0 bar BLUE ,0 17,0 bar RED A 16,0 30,0 bar YELLOW ,0 55,0 bar Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

8 2.3.8 ACCURACY AND LOCK UP Accuracy; Closing: AC até 1; SG até 2,5 3.0 PRINCIPLE OF OPERATION 3.1 REGULATOR SPRING TO CLOSE (FF) In the absence of pressure, the obturator (A) is kept in closing position by the closing spring (B) which keeps the gasket pressed against (C). Importantly, even when subjected to pressure the variation of pressure upstream will have no influence on the setting of the valve due to the balancing of the forces acting on it, as well as the actuator shaft (D) which is also balanced. By pressurizing the leg, the gas passes through a filter element (E) reaches a pre controller (booster) (F) reduces to a near value of the output pressure and delivering the pilot (G) as compared to the output pressure sensed by the pilot diaphragm (M), which controls the flow is injected under the main regulator diaphragm (L). If a decrease in the downstream pressure (for consumption or increasing the amount of pressure drop) occurs an imbalance between the force of the spring (R) on the pilot diaphragm (M) and the force generated by the outlet pressure under the same diaphragm, causing the shutter driver (K) to a larger aperture, causing an increase in pressure under the main regulator diaphragm (L), which combined with downstream pressure drop which acts on the main regulator diaphragm and opposite the pilot pressure acting on it, determine the displacement of the shutter (A) up, thereby increasing the passage restoring the pressure (set point). When the pressure begins to increase, causes the shutter driver (K) to reduce the opening. The increased pressure which operated under the regulator diaphragm (L) flows through the restriction of Bleed (M) (adjustable) that discharges into downstream. The strength of the main regulator of the closing spring (B) plus the reduction in pilot pressure causes displacement of the main shutter (A) down, thus making the pressure back to the preset value. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

9 G I H K E F L B D A M C FIGURE 1 - URANO FAIL CLOSED Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

10 3.2 REGULATOR SPRING TO OPEN (FA) In the absence of pressure, the obturator (A) is in the open position by the main regulator spring (B) which keeps away from the sleeve (C). Importantly, even when subjected to pressure the variation of pressure upstream will have no influence on the setting of the valve due to the balancing of the forces acting on it, as well as the actuator shaft (D) which is also balanced. To pressurize the leg, the gas passes through a filter element and reaches the pre regulator (booster) (F) that reduces to a value near the outlet pressure, and delivery to the pilot (G), it is important to note that unlike what happens in URANO artifact closes regulator, the pressure provided by the booster is also injected directly into the upper chamber of the diaphragm, it is necessary for the regulator to close at normal operating conditions, since the main regulator spring pressing this the shutter so that it is in the open position. The pilot compares the output pressure sensed by the diaphragm (M) and controls the flow that is injected under the main regulator diaphragm (G) to open the valve. If a decrease in the downstream pressure (for consumption or increasing the amount of pressure drop) occurs an imbalance between the force of the spring (R) on the pilot diaphragm (M) and the force generated by the outlet pressure under the same diaphragm, causing the shutter driver (K) to a larger aperture, causing an increase in pressure under the main regulator diaphragm (L), determining the displacement of the shutter (A) up, thereby increasing the pressure restoring passage (Sept -point). When the pressure begins to increase, causes the shutter driver (K) to reduce the opening. Most operated under pressure regulator diaphragm (L) flows through the restriction of Bleed (M) (variable) discharges into the downstream, thereby causing the pressure acting on the diaphragm is greater than the driving force and the strength of the combined spring, moving the shutter down and closing the main valve. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

11 G I H K F L B D A M C FIGURE 2 - URANO FAIL OPEN Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

12 3.3 BOOSTER (G-43 & G-44) The Booster is nothing more than a pre regulator that automatically adjusts the process conditions depending on input pressure and output, and aims to reduce the pilot inlet pressure, causing it to operate in a milder condition, thus eliminating any chance of interference on the regulator pilot by the input pressure variation. The use of pre regulators or booster is recommended only for applications where the differential pressure exceeds 4.0 bar. The boosters G-43 and G-44 model are designed to keep the inlet pressure of the pilots always adjusted to 1-2 bar above the set-point desired, eg if we are adjusting the throttle to 20 bar the booster will be sending for the rider a bar pressure. The boosters G-43 and G-44 model have similar principle of operation, although they have constructive differences, such as different internal, this differentiation is necessary for one to be able to operate with regulatory pressure valve FA and the other regulators for use with FF, where the pressure regulator valve model G URANO pre-regulators are used in model 43 assemblies with valves and FF G-44 in FA valve assemblies. B A C The boosters G-43 and G-44 normally have three connections to the process, represented in red line in the figure above is from the regulator inlet and is loaded with the inlet pressure, the yellow line is the output pressure of the main regulator also sensing called socket and is responsible for acting on the diaphragm (A) of the booster, moving the axis (B) causing it to move away from the sleeve (C), thus allowing the passage of gas from the regulator input pressure 1 to 2 kgf/cm² above the set point pressure of the main regulator, which in turn is represented by the color green and is taken to proceed to the Pilot. Please note: In some assemblies the booster can be integrated into the pilot, this amendment is merely to reduce ergonomic spaces, number of components and ease of operation, however it is important to note that the operating principle is exactly the same as noted above. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

13 3.4 PILOTS (G-40 & G-42) The number of drivers G-40 and G-42 is comprised of dual diaphragm pilot that can achieve much higher precision adjustment to other drivers due to their constructional characteristics. Pilots are responsible for sending the exact loading pressure for pressure regulating valves open or close under normal process conditions by the balance between the force of the regulating spring and the outlet pressure received by the sensor outlet. C A B The green line represents the pressure from the booster or pre regulator, the yellow line is the regulator output pressure (sensor outlet) and this is responsible for moving the diaphragm assembly (A) upward or downward, causing the driver shutter (B) Move it headquarters (C) thus permitting the reduction in inlet pressure and sending the appropriate gas pressure to perform charging of the main valve causing the valve to open or close according to the process conditions. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

14 3.5 FILTERS The GASCAT called pilot blocks consisting of pilot regulator and pre always possess a mechanical barrier against solid impurities, the barrier comprises filter elements polypropylene filtration degree of 10 microns. This barrier aims to prevent solid contaminants in the pipe can clog or damage the internal pre regulator and the pilot, but it is important to note that this filter does not replace the filtration system that should be provided in the previous steps to pressure regulating so as to leave the clean fluid and correct operating conditions, the filter is designed to serve as a barrier to the last solid contaminants. The URANO pressure regulators are available with F-10 filter, mounted separate from the pilot block or compact version with the filter element already attached to the pre regulator. 3.6 ACTIVE MONITOR MOUNT The so-called active monitor mounting configuration is much used in the distribution and natural gas transmission this setting is usually adopted when the difference between the inlet pressure and the outlet pressure is greater than 16 bar and the stress test pressure pipe and other components downstream the setting is less than the inlet pressure as specified, for example DIN EN 12186, in this case the goal of the monitor regulator is use to increase the station's security level. But it is valid to remember that this is the recommendation of DIN EN 12186, there are other standards that specify different conditions for the use of the active monitor system. The active monitor system is the use of two pressure regulators in series one being called which will be in active operation (adjusting) process under normal conditions and should be of the open type failure SO (FA), and closes the failure monitor type SC (FF) which shall remain fully open under normal operating conditions and only take the adjustment in the case of active regulator failure. As previously disclosed in this manual is important to remember that the classification of AF or FF is given by the failure of the diaphragm only the main valve and the lack of power to shutter operation according to DIN EN 334, however it is quite possible that the regulator FA eg fail closed due to some other unforeseen condition in the process, see below some regulators failed positions SC URANO and URANO SO due to possible situations in the field: SITUATION URANO SC (FF) URANO SO (FA) FAIL OPEN FAIL CLOSE FAIL OPEN FAIL CLOSE FAILURE VALVE DIAPHRAGM MAIN X X FAULT PILOT DIAPHRAGM X X DIRT BETWEEN THE PLUG AND VALVE SEAT MAIN X X DIRT BETWEEN THE PLUG AND THE PILOT SEAT X X AXIS MAIN CAUGHT X X X X TAKE BREAK SENSING X X OBSTRUCTION OF PILOT SEAT X X FAILURE DIAPHRAGM BOOSTER X X Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

15 The URANO regulators operating in the active monitor system exactly as described 3.1 and 3.2 of this manual, but as can be seen in the previous scheme the sensor making the SC controller (FF) is downstream controller active OS (FA) and its set-point must be adjusted to a slightly higher pressure to the set-point controller active (5% - 10% depending on the application). Thus during normal operation the monitor regulator will be completely open while the active regulator is in operation and if there is any failure in the active regulator and the pressure begins to rise the monitor regulator will come into operation. 4.0 INSTALLATION 4.1 FILTER We recommend installing a filter type "cartridge", with grade 5 Micra filtration, as close to the regulator inlet, without being united flange to flange, therefore, the filter installed immediately upstream of the regulator may cause turbulence causing disturbance in the regulator pressure control. Care for the filter installation is essential to the smooth operation of Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

16 the instrument as any existing particles in the pipe can become lodged between the seat and the shutter, damaging them and causing feedthrough. 4.2 CLEANING Check the pipe cleaning before valve installation. We recommend a complete purge of the line with nitrogen or compressed air. 4.3 DIRECTION OF FLOW AND SYSTEM INTEGRITY Before proceeding with the installation of the equipment you must ensure that: 1) The equipment is in perfect condition or has function in damaged evidence in the handling during transport, if you have a fault not proceed with the installation and contact the GASCAT. 2) The area in which access and installation of the equipment is suitable, including for future maintenance. 3) The facility was designed to support the load imposed by equipment. 4) The input and output connections where the pressure regulator is installed are perfectly aligned. 5) All outlets of necessary pressure in the pipeline downstream equipment for sensing, were provided and are respecting the dimensions recommended by the manufacturer. 6) It was predicted gauge or any other equipment upstream pressure indicator and downstream equipment to allow the correct fit for the start-up. 7) was provided a line of vent between the regulator and the first output block valve to assist the operator during start-up. 8) Check the direction of flow of the body marked throttle valve and pay attention to the time of installation so that it is properly positioned. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

17 4.4 SENSE The correct positioning of making impulse in the pipeline is essential for the proper functioning of the throttle valve, therefore install the pilot impulse outlet regulator downstream at a minimum distance of 5 times the nominal pipe diameter and stretch obstruction-free pipe with a pipe diameter where the gas flow rate does not exceed the maximum speed of 25 m / s (considering the lower output pressure and the maximum flow). To obtain a better pneumatic signal, use ½ OF tubbings "stainless steel AISI 316 to connect the regulator to the process. In order to avoid the accumulation of impurities and condensate in the impulse taken recommend that they be installed with a slope of 5% to 10% towards the connector on the pipe. Pay attention to the connections welded pipe for it to be totally clear, without any welding residue that could interfere with pneumatic signal. They should be installed block valves of any kind into the pressure regulators pulse taken. Each throttle model URANO SC (FF) needs three process connections: one directly to the actuator on the diaphragm, one that will be connected directly below the pilot and a third for the purpose of discharging the actuator under the diaphragm. SENSING LINE VALVE UNLOADING LINE SENSING LINE PILOT FRONT VIEW REAR VIEW IMAGE URANO FF Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

18 For valves model URANO SC (FF) mounted to operate in active monitor systems the booster is shipped with a connector more on this socket is connected to the input of the booster control valve active pressure, thus serving as food for the booster active valve. When URANO SC (FF) valve is mounted to operate in a system where it will be the only pressure reduction stage this jack is provided sealed by a plug and should not be used. MOUNTING SYSTEM ONLY IN ACTIVE MONITOR Each throttle model URANO OS (FA) requires two connections to the process: one directly below the pilot and a second that will serve as unloading the actuator under the diaphragm. UNLOADING LINE SENSING LINE PILOT FRONT VIEW REAR VIEW IMAGE URANO FA Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

19 4.5 SCHEME RECOMMENDED INSTALLATION SINGLE REGULATOR ND 1 Inlet shut-off valve. 6 Partial relief valve 2 Filter cartridge type degree of filtration 5 micra 7 Output pressure gauge + manifold 2 way 3 Entry gauge + manifold 2 way 8 Valve vent 4 Automatic shut-off valve for over pressure (SSV) 9- Output block valve 5 Pressure regulator valve model URANO GASCAT Note: The position indicated for the sensor outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

20 5 ND Another recommended installation option is the use of a lung to connect the sensor taken near the equipment, among the advantages of adopting this configuration include: 1) Greater convenience during maintenance. 2) Pneumatic signal of better quality (stable). 3) Reduction of damage to tubbings during maintenance and transport. Note: The position indicated for lung outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

21 4.5.2 ACTIVE MONITOR SYSTEM ND 1 Inlet shut-off valve. 7 Pressure regulator valve URANO ACTIVE 2 Filter cartridge type degree of filtration 5 micra 8 Partial relief valve 3 Entry gauge + manifold 2 ways 9 Output pressure gauge + manifold 2 ways 4 Automatic shut-off valve for pressure (SSV) 10 Valve vent 5 Pressure regulator valve model URANO MONITOR 11 Output block valve 6 Intermediate gauge manifold 2 ways Note: The position indicated for the sensor outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

22 5 ND Another recommended installation option is the use of a lung to connect the sensor taken near the equipment, among the advantages of adopting this configuration include: 1) Greater convenience during maintenance. 2) Pneumatic signal of better quality (stable). 3) Reduction of damage to tubbings during maintenance and transportation. Note: The position indicated for lung outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

23 4.5.3 TWO SSV AND A REGULATOR FF ND 1 Inlet shut-off valve. 6 Pressure regulator valve URANO 2 Filter cartridge type degree of filtration 5 micra 7 Partial relief valve 3 Entry gauge + manifold 2 ways 8 Output pressure gauge + manifold 2 ways 4 Automatic shut-off valve for over pressure (SSV) 9 Valve vent 5 Automatic shut-off valve for over pressure (SSV) 10 Output block valve Note: The position indicated for the sensor outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

24 5 ND Another preferred installation option is to use a buffer to connect the sensor to the equipment taken next, among the advantages of adoption of this configuration can cite: 1) Greater convenience during maintenance. 2) Pneumatic signal of better quality (stable). 3) 3) Reduction of damage to tubbings during maintenance and transportation. Note: The position indicated for lung outlet may be less than 5D from the installation project to be reviewed and approved by engineering GASCAT. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

25 4.6 START-UP GENERAL RECOMMENDATIONS Before proceeding with the commissioning of the equipment is important to always: 1) Check that the equipment is properly installed according to the recommendations set out in item 4.3 of this manual. 2) Close the input block valves, output and bypass (if applicable) of the leg. 3) Open the vent valve downstream of the last pressure regulator installed on leg. 4) Make sure that the depressurized this station. ATTENTION: * Under no circumstances do with the line pressurization where the equipment is installed by the posterior valve equipment. * Under any circumstances perform depressurization line where equipment is installed by the valve located at the entrance of the equipment, such as filters drain. 5) Make sure all connectors are properly secured the station before proceeding with the pressurization of the line. 6) Check that the installed equipment is suitable operating conditions through the information available on the nameplate attached to the equipment. 7) Make sure the SSV is in the closed position. ATTENTION: The SSV GASCAT are sent to the already calibrated field, however due to the conditions of carriage and operation of any equipment the valve may have its set-point change. Therefore we recommend that you checked the set-point of the SSV with the help of a connected external air supply directly to the actuator, before proceeding with the pressurization of the line. The model URANO valves are not sent to field set on their set-point, this measure tends to preserve the life of the product's internal therefore to receive a control valve URANO model pressure, keep in mind that you need to perform the adjustment set-point before putting the equipment into operation. The setting of the pressure reducing station should be in accordance with DIN EN / NBR and all other applicable regulations in the region where it will operate. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

26 4.6.2 COMMISSIONING (SINGLE REGULATOR LINE) Using as reference the assembly scheme presented in section we will proceed with the description indicated for URANO model regulator commissioning a simple adjustment line, considering that the recommendations made in section of this manual have been properly observed. The procedure in question considers the use of GIPS-FC GASCAT model valves as a safety device. 1) Fec Close the vent valve. As the line shut-off valves are closed we will use the vent valve to simulate a small flow and do so with the regulator adjustment before aligning the line. 2) Check that the pilot of the regulating spring is properly relieved (discharged). Relieving regulating spring we are ensuring that the valve will remain in the closed position when pressurized. 3) Make sure the unloading valve (needle valve) is open in 1/8 turn. DISCHARGE VALVE 4) SLOWLY AND GRADUALLY open the shut-off valve, or when the station is provided with a by-pass valve block uses the same to carry out pressurization. 5) Since there is no regulator downstream pressure shut-off valve GIPS-FC model will be in the closed position, so keep the bypass valve located on the side of the SSV pressed to pressurize the space between it and the regulator pressure. 6) While still holding the valve bypass the SSV, proceed with placing a light load on the pilot's regulating spring in order to admit a small downstream pressure control valve, use a pressure gauge to monitor the increase of this pressure and let the pressure adjusted to a value at least 20% above the set-point of low pressure SSV. 7) Once the actuator SSV is already pressurized, release the by-pass valve and proceed with the disengagement of the actuator of the SSV. 8) Reset the shutter GIPS-FC block valve, through the reset lever. 9) Open the vent valve at 20%, make sure the pressure will continue in pre-set value. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

27 10) Using a combination wrench 7/8 "turn the adjustment screw clockwise to increase the output pressure to the value of set-point desired. 11) If the pressure is oscillating perform a fine adjustment by opening or closing the discharge valve. 12) If the pressure is oscillating perform the fine adjustment by opening or closing the discharge valve. 13) Being set pressure according to the desired value, close the vent valve and check valve lock up. 14) Check for leakage in connectors and other throttle connections to the line. 15) Open SLOWLY AND GRADUALLY the output shut-off valve to put the line into operation. 16) If necessary to perform fine-tune the set pressure through the pilot regulating spring ADJUSTING THE LINE BOOKING When the regulator is installed in a reserve line recommend that you performed the same procedure reported in 4.6.2, but the set-point pressure regulator should be adjusted for a 15% pressure - 20% less than the valve setpoint that is in operation. Made it open SLOWLY AND GRADUALLY downstream so that the pressure outlet shut-off valve to the regulator leg reserves equalize with the pressure that is already in operation, the regulator reserves remain closed. To make the regulator that the reservation leg assume the setting, press the regulating spring towards slowly clockwise until the set-point of this regulator reaches a value greater than the set-point of the line is in operation, this the way regulatory reserve will open slowly and take the operation. It is important that the two regulators remain with a difference of set-point at least 5% - 10%, so there is not a setpoint of overlap causing a competition between the two lines, ie a minute regulator opens in governor opens another booking, promoting an inaccuracy in regulating. SET POINT MAIN REGULATOR (PS) TABLE SET POINTS RECOMMENDED SET POINT REGULATOR RESERVE SET POINT PSV SET POINT SSV 2,5 5,0 bar PS x 1,150 PS x 1,400 PS x 1,500 5,0 12,0 bar PS x 1,050 PS x 1,200 PS x 1,300 12,0 20,0 bar PS x 1,025 PS x 1,200 PS x 1,300 20,0 80,0 bar PS x 1,025 PS x 1,150 PS x 1,250 Note: The values in this table are recommendations based on best practices, but it is not prohibited the use of setpoints in different groups of informed upon review and approval of GASCAT. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

28 4.6.4 COMMISSIONING (ACTIVE MONITOR SYSTEM) Using as reference the assembly scheme presented in section we will proceed with the description indicated for commissioning of regulators URANO model in a stretch where the monitor active configuration is being adopted, considering that the recommendations made in section of this manual now were noted.. The procedure in question considers the use of valves GIPS-FC GASCAT model and throttle model URANO SC (FF) GASCAT as safety devices. 1) Close the vent valve. As the line shut-off valves are closed we will use the vent valve to simulate a small flow and do so with the regulator adjustment before we put in operation. 2) With the still depressurized line press the pilot spring throttle valve Active and completely relieve the pilot spring regulating valve in the line monitor function. Relieving the regulating spring are ensuring that the valve monitor will remain in the closed position and compressing the spring of the pilot control valve active role in ensuring that are the same shall be open when pressurized. 3) Make sure the unloading valve (needle valve) of active valves and monitors are open in 1/8 turn. DISCHARGE VALVE 4) SLOWLY AND GRADUALLY open the shut-off valve, or when the station is provided with a by-pass valve block uses the same to carry out pressurization. 5) Since there is no regulator downstream pressure shut-off valve GIPS-FC model will be in the closed position, so keep the bypass valve located on the side of the SSV pressed to pressurize the space between it and the regulator pressure. 6) While still holding the bypass of the SSV valve, proceed with placing a light load on the valve pilot regulating spring monitors in order to admit a small downstream pressure the two control valves, use the gauge to handle the lifting this pressure and let the pressure adjusted to a value at least 20% above the set-point of low pressure SSV. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

29 7) Once the actuator SSV is already pressurized, release the by-pass valve and proceed with the disengagement of the actuator of the SSV. 8) Reset the shutter GIPS-FC block valve, through the reset lever. 9) Open the vent valve at 20%, make sure the pressure will continue in pre-set value. 10) Using a combination wrench 7/8 "turn the valve adjustment screw monitors clockwise to increase the output pressure to the value of set-point desired, so only the regulator monitor is in operation and the system will be behaving as outline below: 11) If the pressure is oscillating perform a fine adjustment by opening or closing the discharge valve. 12) Once the pressure has stabilized, open the vent valve in ½ "back and check the accuracy of adjustment. 13) Being set pressure according to the desired value, close the vent valve and check the lock-up valve monitors. 14) Once the set-point valve monitors has been reached, start to unload (release) slowly pilot spring active valve by turning the adjustment screw counter-clockwise, so we will be reducing the set-point of this regulatory. 15) Adjust the set point controller active at a pressure of at least 0.5 kgf / cm² below the monitor setpoint valve to allow the valve remains fully open monitors the line and only the active valve remains in operation. 16) You can see that the valve is fully open and monitors the active will be regulating through local position indicator at the top of the actuator. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

30 POSITION INDICATOR 17) After that we will now have the active valve operation and monitors wide open waiting for a possible failure on the part of the active valve for operation as shown below: 18) If the pressure is oscillating perform a fine adjustment by opening or closing the discharge valve. 19) Once the pressure has stabilized, open the vent valve in ½ "back and check the accuracy of regulation. 20) Being set pressure according to the desired value, close the vent valve and check the lock up of the active valve. 21) While we are testing the lock up of the active valve are recreating a similar scenario to a consumer stopped by the end customer, which is a normal process condition and in this case the two valves should be closed as shown below: Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

31 22) Note that in an active monitor the line closing pressure system will be given by always monitor regulator, because as we can see in the above scheme taking monitor regulator unloading will be taken downstream coupled to the active valve, so the pilot valve monitors will remain open, until it receives the corresponding pneumatic signal to close, this pneumatic signal is equivalent to valve closing pressure monitors. 23) Check for leaks in the connectors and other throttle connections with the line. 24) Open SLOWLY AND GRADUALLY the output shut-off valve to place the leg in charge. 25) If necessary to perform fine-tune the set pressure through the pilot regulating spring RESERVATION LINE ADJUSTMENT (ACTIVE MONITOR) When the regulator is installed in a reserve line with the ACTIVE-MONITOR configuration we recommend that you performed the same procedure reported in 4.6.4, but the set-point of the active throttle reservation leg should be adjusted for a 15% pressure - 20% less than the valve set-point that is in operation. Made it open SLOWLY AND GRADUALLY downstream so that the pressure outlet shut-off valve to the regulator leg reserves equalize with the pressure that is already in operation, the regulator reserves remain closed. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

32 To make the regulator that the reservation leg assume the setting, press the spring adjustment of the active control valve on slowly clockwise until the set-point of this regulator reaches a value greater than the set-point of the line is in operation in this way the regulator booking will open slowly and take the operation. It is important that the two regulators remain with a difference of set-point at least 5% - 10%, so there is not a setpoint of overlap causing a competition between the two lines, ie a minute regulator opens in regulator opens another booking, promoting an inaccuracy in regulating. SET POINT ACTIVE MAIN REGULATOR (PS) SET POINT REGULATOR RESERVE ACTIVE TABLE SET POINTS RECOMMENDED SET POINT REGULATOR MONITOR SET POINT PSV SET POINT SSV 2,5 5,0 bar PS x 0,9 PS x 1,150 PS x 1,400 PS x 1,500 5,0 12,0 bar PS x 0,95 PS x 1,050 PS x 1,200 PS x 1,300 12,0 20,0 bar PS x 0,95 PS x 1,025 PS x 1,200 PS x 1,300 20,0 80,0 bar PS x 0,97 PS x 1,025 PS x 1,150 PS x 1,250 Note: The values in this table are recommendations based on best practices, but it is not prohibited the use of setpoints in different groups of informed upon review and approval of GASCAT LIST OF RECOMMENDED TOOLS To perform the adjustment set-point commissioning and start-up of regulatory URANO GASCAT the model is required only the use of a combination wrench 7/8 "to adjust the regulation of pilots springs. 1 2 The valves are URANO model fornecdias with connectors for tubbing DN ½ "in the sensor plugs, so we still recommend the use of combination wrenches 19 mm and 13/16" for fixing the sensor taken the process line. DN 1 2 1,2,3,4,6, e 8 19 mm, 7/8 e 13/16 1 Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

33 5.0 TROUBLE SHOOTING This section of the manual aims to show potential field problems and their causes. The problems listed in this section may be from different situations, but most of them is related to the gas conditions (impurities), natural wear and failures during operation of the equipment. It is important to keep in mind that the operation and maintenance of GASCAT equipment must be only carried out by highly qualified and trained personnel, preferably by staff trained by GASCAT instructors. For training and qualification of operators and technicians contact the GASCAT through the contacts below to check availability. URANO PROBLEM PROBABLE CAUSE CORRECTIVE ACTION Low flow (less than 5% of the maximum flow). Check the operating conditions and restore the flow conditions for the standards to which the equipment has been designed. Malfunction, outlet pressure oscillation Making poorly localized impulse. Adjust the position of the pulse taken as reported in this manual, or contact the GASCAT for analysis of engineering. Response speed of the regulator incompatible with the system. Adjust the unloading valve (needle). Shutter (pos 48 SC; pos 57 SO) of the locked main regulator Adjust the unloading valve (needle).check state shutter and anti-friction rings proceeding replacement or cleaning if necessary (minimum of grease should be applied to assembly of these items, preferably using bimolybdenum sulfide). Feedthrough or regulator locked in the open position Broken or damaged impulse line Headquarters (pos 44 SO; pos 38 SC) damaged or particulate matter between the shutter and the seat. Check status of impulse line and proceed to replace it if necessary. Make cleaning and check state headquarters, if it has no apparent marks of damage proceed to the assembly and check the lock up, replace if damaged. Disruption of the main diaphragm (pos 3) of the FA valve (Spring to open) Replace the main diaphragm Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

34 Output pressure decrease and or insufficient flow Exhaust gas by the pilot cover the breather. Dirt on the filter Power Outage Passage in the main diaphragm (pos 4) Reg. FF (Spring to close) Breaking the diaphragm (pos 19) Provide filter cleaning or replacing the filter element. 1) Check the locking of the booster shutter. (Pos 7 G-43 / G- 44 pos15) 2) Make sure the pilot's seat (item 3) is blocked. Replace the main diaphragm (pos 4) Replace the diaphragm. Gas leak at door trim booster Booster trim disruption (pos 4 G44 / G43 pos 6) Replace the gasket. 6.0 MAINTENANCE Perform preventive maintenance of pressure regulators model URANO is essential for proper operation of the equipment over time and is directly related to the reliability of the pressure control system, preventing the user operating problems. The frequency of maintenance varies considerably according to the installation, operating conditions and the quality of the fluid in question, for example if the machine is subject to a large presence of contaminants such as black powder, yellow powder, oil, condensate, etc. certainly the service interval should be lower. The GASCAT own standards repair kits for each throttle component URANO model composed of the most likely items to wear with time, this list of components that discriminated in this manual for the guidance of users. ATTENTION: The components of the control valves GASCAT pressure are developed, manufactured and tested with GASCAT exclusivity in order to provide the greatest efficiency and safety operation, not using original components makes unsafe operation and compromises the process efficiency. The GASCAT not responsible for the operation of equipment that do not operate with original components. Before starting maintenance pressure regulators in GASCAT always make sure to have a replacement kit with original parts GASCAT as well as this instruction manual for reference and how to safely and efficiently while maintaining the equipment. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

35 6.1 RECOMMENDED REPAIR PARTS AND KITS URANO SC (FF) Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

36 POS. DESCRIPTION URANO SC (FF) DN 1" 2" 3" 4" 6" 8" 2 DIAPHRAGM POSITION INDICATION DISPLAY O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING PARBACK RING O'RING SHUTTER SHUTTER Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

37 URANO SO (FO) Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

38 POS. URANO SO (FA) DN DESCRIPTION 1" 2" 3" 4" 6" 8" 2 DIAFRAGMA POSITION INDICATION DISPLAY O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING O'RING SHUTTER SHUTTER Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

39 BOOSTER G-43 + PILOT G-42/40 Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

40 BOOSTER G-43 POS. DESCRIÇÃO QTY 8 GARRISON 1 10 DIAPHRAGM 1 18 O'RING 1 20 O'RING 1 21 O'RING 1 22 O'RING 1 25 O'RING 1 PILOTO G-40/42 POS. DESCRIÇÃO QTY 9 DIAPHRAGM 2 19 O'RING 2 23 O'RING 1 24 O'RING 1 29 SHUTTER 1 BOOSTER G-43 + PILOTO G-42/40 Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

41 BOOSTER G-44 + PILOT G-42/40 Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

42 BOOSTER G-44 + PILOT G-42/40 BOOSTER G-44 POS. DESCRIÇÃO QTY 9 GARRISON 1 10 DIAPHRAGM 1 17 O'RING 1 18 O'RING 1 20 O'RING 1 21 O'RING 1 22 O'RING 1 23 O'RING 1 PILOTO G-40/42 POS. DESCRIÇÃO QTY 11 DIAPHRAGM 2 19 O'RING 2 24 O'RING 1 25 O'RING 1 26 SHUTTER 1 Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

43 6.2 PROCEDURE FOR REGULATOR DESMONATAGEM URANO SC (FF) 1) Before proceeding with the disassembly of the equipment check if all the conditions set out in item of this manual were observed. 2) Go up any circumstances start the disassembly of equipment if the same is pressurized. The disassembly procedure below references the positions of the components shown in the diagram available in section 6.0 of this manual. 3) Remove the steering block and all connectors connected to the main valve. 4) Proceed with removing the screws (pos 5) 5) Remove the top cover of the actuator (pos 30) 6) Remove the indicator pin (pos 51) 7) Release the diaphragm assembly in order to facilitate this do the following: 7.1) Set a single cap screw (pos 5) in the bottom cover of the actuator (pos 31) and position a compass key to the right of this locking screw the ends into the holes of the upper diaphragm plate, as illustrated below: 7.2) With a combined key remove the upper guide bushing (item 41) as illustrated below: 7.3) Remove the diaphragm assembly. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

44 Note: Note that the diaphragm of the main valve of URANO model controller is shaped and the convex surface tends to face up this assembly, because the more pressure will be in the lower chamber of the actuator. 8) Release the screws (pos 10) of the lower diaphragm plate (item 37), thus releasing the diafragma (pos 2). 9) Release the screws (pos 4) and remove the bottom cover of the actuator (pos 31). 10) Pull the the actuator guide bushing (item 42), in order to facilitate this activity use a fine sandpaper as illustrated below: Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

45 11) Remove the intermediate screws (pos 12) and release the intermediate (pos 32). 12) Remove the closing spring (pos 1) 13) Remove the piston (item 47) releasing the piston bushing (pos 49) 14) To remove the seat start releasing the lower body cover (pos 45) by removing the screws (pos 12). 15) Remove the screws (pos 14) and release the shutter (pos 38). Note: The regulatory model URANO class 150 #, 300 # and 600 # are factory with two shutters, one gets the trim facing the piston (in use) and the other is kept back-up with the side trim to the other party as evidenced in the illustration below: BODY TOP VIEW BODY BOTTOM VIEW 6.3 PROCEDURE FOR REGULATOR ASSEMBLY URANO SC (FF) To proceed to the assembly of Uranus regulator just follow the steps reported in item 6.1 in reverse order, but some observations can assist in task: 1) To mount the indicator pin (item 51) is indicated that it is first positioned in the guide pin (item 6) before closing the top cover as illustrated below: Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

46 2) Remember to lubricate the o-rings with a thin layer of grease during the valve assembly process and the rod, the piston and the static parts to reduce friction between these components. 3) During assembly screws (pos 13) on the diaphragm plate using chemical latch on the threads in order to improve the fixation of parts. 6.4 PROCEDURE FOR REGULATOR DESMONATAGEM URANO SO (FO) 1) Before proceeding with the disassembly of the equipment check if all the conditions set out in item of this manual were observed. 2) 2) Go up any circumstances start the disassembly of equipment if it is pressurized. The disassembly procedure below references the positions of the components shown in the diagram available in section 6.0 of this manual. 3) Remove the steering block and all connectors connected to the main valve. 4) Proceed with removing the screws (pos 6) 5) Remove the top cover of the actuator (pos 34) 6) Remove the indicator pin (pos 58) 7) Release the diaphragm assembly in order to facilitate this do the followin: 7.1) set a single cap screw (pos 3) on the bottom cover of the actuator (pos 29) and place one compass key to the right of this locking screw the ends into the holes of the upper diaphragm plate, as illustrated below : 7.2) With a combined key remove the upper guide bushing (item 45) as illustrated below: Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

47 7.3) Remove the diaphragm assembly. Note: Note that the diaphragm of the main valve of URANO model controller is shaped and the convex surface tends to be turned down in this assembly, because the more pressure will be in the upper chamber of the actuator. 8) Release the screws (pos 12) of the lower diaphragm plate (item 41), thus freeing the diaphragm (pos 2). 9) Release the screws (pos 5) and remove the bottom cover of the actuator (pos 35). 10) Pull the the actuator guide bushing (item 46), in order to facilitate this activity use a fine sandpaper as illustrated below:: 11) Now let us proceed with the release of the plug assembly and thirst, for this we recommend that the valve body is rotated so that the bottom cover (Item 49) is facing up to facilitate the process, but if the valve is in line and for some reason can not be removed informed procedure is the same, but with the facing lower lid down. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

48 12) Remove the intermediate screws (pos 15) and release the intermediate (pos 36). 13) Remove the piston locks (pos 16, 14 e 57) 14) Remove the piston or shutter (pos 55), as you can observe the obturator is fully collected in the middle (item 36) and therefore to facilitate removal without damaging the piston is important to proceed as follows: 14.1) Using needle-nosed pliers position the same in the piston holes (pos 55) and pull it at the same time making a turning movement. 14.2) With the action of time and accumulation of contaminants that may occur in the region of the piston, reducing lubrication and in turn the piston stroke (item 55), we suggest another way of removing the piston which might be desirable during the process disassembly: pistons regulators URANO model (DN 2 "to 8") have two threaded holes that allow the fixing screws or eyebolts as shown below: DN URANO SCREW PISTON 2 M8 x 1,25 3 M10 x 1,5 4 M14 x 2,0 6 M18 x 2,0 8 M22 x 2,25 Place the 2 screws and a combined or Allen key, pull and rotate the piston simultaneously to remove the same. 15) Remove the lock (item 57) and the stop (pos 54) Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

49 16) To assist in the removal of the spring (item 1) that is tensioned by the pusher (item 50), perform the following procedure: 16.1) position the two locks the shutter (pos 57) upside down on the shaft (item 53) as illustrated below: 16.2) Place the nut (pos 14) on the shaft on the latches (Item 57) and press the opening spring (item 1) until the stop (pos 50) is free spring action. 17) Proceed with the disassembly of the spring stop (pos 50) releasing the screws (pos 7). 18) Release the entire assembly and remove the opening spring (pos 1) Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

50 19) To remove the seat start releasing the lower body cover (pos 49) by removing the screws (pos 15). 20) Remove the screws (pos 18) and release the shutter (pos 42/43). Note: The regulatory model URANO class 150 #, 300 # and 600 # are factory with two shutters, one gets the trim facing the piston (in use) and the other is kept back-up with the side trim to the other party as evidenced in the illustration below: BODY TOP VIEW BODY BOTTOM VIEW 6.5 PROCEDURE FOR REGULATOR ASSEMBLY URANO SO (FO) To perform the assembly of URANO SO regulator (FO) just follow the steps reported in the back disassembly procedure forward starting with the assembly headquarters. 6.6 PROCEDURE FOR PILOT REMOVAL G-40/42 1) Before proceeding with the disassembly of the equipment check if all the conditions set out in item of this manual have been observed. 2) Go up any circumstances start the disassembly of equipment if it is pressurized. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

51 The disassembly procedure below references the positions of the components shown in the diagram available in section 6.0 of this manual. 3) Download the pilot regulating spring by turning the set screw (pos 33/30) counter clockwise. 4) Remove the guide adjusting screw (pos 43/38) 5) Remove the regulating spring (pos 50/52) 6) Remove the screws (pos 17/16) and release the sup cover (pos 37/36) 7) Turn the steering block so that the bottom of the pilot is facing up and release the screws (pos 16/15) and remove the bottom cover (pos 47/49) 8) Remove the spring and the base (pos 38/37) 9) Remove the bushing (item 34/31) shutter spring. 10) Remove the obturator (pos 29/26) Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

52 11) Remove the diaphragm plate and the lower diaphragm (pos 9/11), turn the steering block to the starting position and proceed with the removal of the plug (pos 35/32). 12) Remove the diaphragm plate (item 36/35) and the upper diaphragm (pos 9/11), 13) Remove the nut (pos 48/50), release the seat (pos 46/48) and the block (pos 44/46) Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

53 6.7 PROCEDURE FOR PILOT ASSEMBLY G-40/42 To perform the assembly of the G-42 pilot just follow the steps reported in the back disassembly procedure forward starting with the assembly's headquarters, but would like to make two observations on two specific points that must be evaluated thoroughly during the pilot reassembly. 1) Pay attention to mount the seat (pos 46/48) and mobile (Pos 44/46), the seat of the hole should always be installed in the opposite position to stud the mobile base, as illustrated below, otherwise the seat will not match the shutter (pos 29/26). Top of the mobile base SEAT 2) After mounting the seat (pos 46/48) in the mobile (Pos 44/46) is necessary to leave the perfectly aligned to the mobile base of the hole headquarters in order to prevent the same into contact with the walls of the mobile base during operation, adequate to accomplish this alignment procedure is: 2.1) After mounting the seat (pos 46/48) in the body (post 49/51) mount the lower and upper diaphragm assembly and lock with nut (pos 35/32) and diaphragm support (pos 36/35). 2.2) With the assembled unit, turn the mobile base (pos 44/46) clockwise until it stops at the headquarters (item 46/48), with a pen make a mark on the diaphragm and body, turn again towards the mobile base anti-clockwise until it stops again at headquarters (post 46/48), make a mark on the body following the marking already performed in the diaphragm (pos 9/11), position the marking performed in the diaphragm between the two markings done in the body, so we can assume that this centralized headquarters. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

54 Marking the body counterclockwise Diaphragm marking between the two Marking the body clockwise 3) diaphragms (pos 9/11) G-42 are shaped pilot therefore have a correct mounting position and it should be observed during the assembly of the pilot, as follows: Mounting position diaphragm lower Mounting position upper diaphragm The Model G-40 pilots use diaphragms plans, so the mounting position is indifferent to the operation. 6.8 PROCEDURE FOR BOOSTER OF REMOVAL (PRE REGULATOR) G-43 1) Before proceeding with the disassembly of the equipment check if all the conditions set out in item of this manual have been observed. 2) Go up any circumstances start the disassembly of equipment if the same is pressurized. The disassembly procedure below references the positions of the components shown in the diagram available in section 6.0 of this manual. 3) Release the cover screws (pos 13), use an allen wrench to push the diaphragm assembly down simultaneously through the upper outlet of the booster, in order to facilitate the operation and prevent damage to the diaphragm. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

55 1) Remove the cover (pos 39) and the diaphragm assembly (item 28). 2) Lock the shaft (pos 28), release the nut (pos 11), remove the disc springs (pos 12) and the lower diaphragm plate (item 27) to release the diaphragm (pos 10). Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

56 3) Now let's move to dismantle the bottom of the booster, so the ideal is that it is rotated so that the bottom is face up, made it proceed with the removal of the door trim (pos 45). 4) Remove the filter element (pos 26) and release the trim (item 8) of the door trim (item 45) and their respective o'ring (pos 21). Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

57 5) Remove the shaft guide (item 40) and the thrust bushing (item 41) 6.9 PROCEDURE FOR BOOSTER ASSEMBLY (PRE REGULATOR) G-43 To perform the assembly of the booster G-43 just follow the steps reported in the back disassembly procedure forward starting with the assembly's headquarters, but would like to make some observations on some specific points that must be evaluated thoroughly during reassembly of the booster. 1) When installing the axis diaphragm assembly (item 28) is necessary to perform the assembly of disc springs (pos 12) are in total 6 pieces and the arrangement thereof must be given as shown below: 1) After assembly of all the internal booster, when be performed at its closure, by placing the cover and screws (pos 13), we recommend that during tightening of the diaphragm assembly screws being pushed through with a key allen the upper plug (Pos 7) so that the diaphragm can be adequately clamped between the lid and the body of the booster. Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

58 6.10 PROCEDURE FOR BOOSTER OF REMOVAL (PRE REGULATOR) G-44 1) Before proceeding with the disassembly of the equipment check if all the conditions set out in item of this manual have been observed. 2) Go up any circumstances start the disassembly of equipment if the same is pressurized. The disassembly procedure below references the positions of the components shown in the diagram available in section 6.0 of this manual. 3) Release the cover screws (pos 12), use an allen wrench to push the diaphragm assembly down simultaneously through the upper outlet of the booster, in order to facilitate the operation and prevent damage to the diaphragm. 1) Remove the diaphragm assembly + shaft (pos 34), release the latch relief spring (Item 45), and remove the relief spring (pos 4). Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

59 2) Remove the shaft booster (Item 34)) 3) Release the diaphragm (Item 10) by releasing the lower diaphragm plate (item 43). 4) Now let's move to dismantle the bottom of the booster, so the ideal is that it is rotated so that the bottom is face up, made it proceed with the removal of the door trim (pos 47). 5) Release the trim (item 9) of the door trim (item 47) and their respective o'ring (Item 22). Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

60 Remove the shaft guide (item 40) and the thrust bushing (item 41) 6.11 PROCEDURE FOR BOOSTER ASSEMBLY (PRE REGULATOR) G-44 To perform the assembly of the booster G-44 just follow the steps reported in the back disassembly procedure forward starting with the assembly's headquarters, but would like to make some observations on some specific points that must be evaluated thoroughly during reassembly of the booster. 3) Booster Model G-44 is only used in assemblies Uranus OS (FO) and the differential has a main valve circuit diagram for this reason it is necessary to use an internal relief device to prevent the diaphragm, both the booster as the main valve break in operation due to a high pressure differential. This internal relief is adjusted by compressing the spring (pos 4) during assembly of the diaphragm assembly axis (Pos 34), in that during assembly it is important to pay attention to the adjustment of this spring, the GASCAT recommends an expulsion mm from the lower diaphragm plate (item 43), but if the operator does not have the means to perform this measurement in the field recommend that it be made a visual setting so that only half of the shaft holes (pos 34) are visible by pressing the diaphragm assembly, as shown in the image below: Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61

61 2) After installation of all internal booster, when be performed at its closure, by placing the cover and screws (pos 12), we recommend that during tightening of the diaphragm assembly screws being pushed through with a key allen the upper plug (pos 8) so that the diaphragm can be adequately clamped between the lid and the body of the booster LIST OF RECOMMENDED TOOLS FOR MAINTENANCE TOOLS DIMENSIONS KEY COMBINED 5/8,3/4, 1, 1-1/8, 2, 13mm ALLEN KEY 6mm, 1/4" KEY COMPASS --- Raphael Pereira Vanízio Lizo Gustavo Nieto 05/06/ de 61