Gascat HORUS Manuel utilisateur

Installation Manual, Maintenance and Operation

Pressure Regulating Valve

Model HORUS Spring to Close

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 2 de 32

INDEX

1.0 - GENERAL WARNINGS .......................................................................................................................................................... 3

1.1 – INSTRUCTIONS FOR COMMISSIONING .................................................................................................................................... 3

1.2 – HEALTH AND SAFETY ............................................................................................................................................................... 3

1.2.1 – NOISE ............................................................................................................................................................................... 3

1.2.2 – INSTALLATION ................................................................................................................................................................. 3

1.2.3 – OPERATION ...................................................................................................................................................................... 3

1.2.4 – MAINTENANCE ................................................................................................................................................................ 4

2.0 – INTRODUCTION ................................................................................................................................................................... 4

2.1 SCOPE OF MANUAL .................................................................................................................................................................... 4

2.2 DESCRIPTION .............................................................................................................................................................................. 4

2.3 SPECIFICATIONS ......................................................................................................................................................................... 5

2.3.1 AVAILABLE SETTINGS .......................................................................................................................................................... 5

2.3.2 AVAILABLE CONNECTIONS.................................................................................................................................................. 5

2.3.3 TEMPERATURE LIMITS ........................................................................................................................................................ 5

2.3.4 COEFFICIENTS FLOW ........................................................................................................................................................... 5

2.3.5 APPROXIMATE WEIGHT ...................................................................................................................................................... 6

2.3.6 MAXIMUM WORKING PRESSURE ...................................................................................................................................... 6

2.3.7 SETTING PRESSURES (SET-POINT) ....................................................................................................................................... 6

2.3.8 ACCURACY AND LOCK UP ................................................................................................................................................... 7

3.0 – PRINCIPLE OF OPERATION ................................................................................................................................................... 7

3.1 REGULATOR SPRING TO CLOSE (FAIL CLOSE) .............................................................................................................................. 7

3.2 BOOSTER (G-43) ......................................................................................................................................................................... 9

3.3 PILOTS (G-40 & G-42) ............................................................................................................................................................... 10

3.4 FILTERS ..................................................................................................................................................................................... 11

4.0 – INSTALLATION ................................................................................................................................................................... 11

4.1 FILTER ....................................................................................................................................................................................... 11

4.2 CLEANING ................................................................................................................................................................................. 11

4.3 DIRECTION OF FLOW AND SYSTEM INTEGRITY ......................................................................................................................... 11

4.4 SENSE ....................................................................................................................................................................................... 12

4.5 SCHEME RECOMMENDED INSTALLATION ................................................................................................................................ 13

4.5.1 SINGLE REGULATOR ......................................................................................................................................................... 13

4.6 START-UP ................................................................................................................................................................................. 14

4.6.1 GENERAL RECOMMENDATIONS ....................................................................................................................................... 14

4.6.2 COMMISSIONING (SINGLE REGULATOR) ......................................................................................................................... 15

4.6.3 ADJUSTING THE LINE BOOKING ........................................................................................................................................ 16

4.6.4 LIST OF RECOMMENDED TOOLS ....................................................................................................................................... 17

5.0 TROUBLE SHOOTING ............................................................................................................................................................ 17

6.0 MAINTENANCE .................................................................................................................................................................... 19

6.1 RECOMMENDED REPAIR PARTS AND KITS ............................................................................................................................... 20

6.2 PROCEDURE FOR REMOVAL THE PILOT G-40 / 42 .................................................................................................................... 25

6.3 PROCEDURE FOR ASSEMBLY THE PILOT G-40 / 42 .................................................................................................................... 27

6.4 PROCEDURE FOR REMOVAL BOOSTER (PRE-REGULATOR) G-43 .............................................................................................. 28

6.5 PROCEDURE FOR ASSEMBLY BOOSTER (PRÉ REGULATOR) G-43 .............................................................................................. 31

6.6

LIST OF RECOMMENDED TOOLS FOR MAINTENANCE .............................................................................................................. 32

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 3 de 32

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 e-mail are described below:

Gascat Indústria e Comércio Ltda.

Rodovia SP 73, 1141 – Indaiatuba / São Paulo.

CEP 13347-990

Telefone: +55 19 3936-9300

Fax: +55 19 3935-6009

Email:

[email protected]

The comments that follow, while not exhaustive, provide guidance possible sources of danger to health and safety.

1.2.1 – 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.

1.2.2 – 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 cannot 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.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 4 de 32

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.

1.2.4 – 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 model

HORUS manufactured by GASCAT.

2.2 DESCRIPTION

The pressure regulator model HORUS was designed to meet varied applications and to work with several process

service conditions. It has outstanding applications with high differential pressure combined with high process flow and high

pressure. It are typical installations with these characteristics the natural gas transportation and delivery points where

occurs custody transference. It is also common to utilize with distributor stations of natural gas and other gases non-

corrosive.

The pressure regulator HORUS is pilot operated and has axial flow what result in low noise level as well high flow

capacity. Beyond this, the double diaphragm pilots supplied with the valve allow accuracy in set pressure up to 1%.

It’s construction design meets the active (fail open) monitor (fail close) configuration.

The set of piston and seat was designed to proportionate high flow rangeability to the pressure regulator, can operate

with a maximum inlet pressure of 150 kgf/cm² and outlet pressures from 1.0 to 80.0 kgf/cm².

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 5 de 32

2.3 SPECIFICATIONS

2.3.1 AVAILABLE SETTINGS

HORUS FC: Pilot operated pressure regulator fail close position

2.3.2 AVAILABLE CONNECTIONS

DN FLANGE ASME B16.5 FLANGE DIN 2634 / 2635

2” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

3” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

4” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

6” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

8” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

10” 150#RF / 300#RF / 600#RF ou RTJ / 900#RF ou RTJ PN 25 / PN 40

2.3.3 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.

2.3.4 COEFFICIENTS FLOW

DN CV KG

2” 80 2481

3” 161 5024

4” 320 9924

6” 610 18920

8” 1119 34735

10” 1750 54275

Note:

1) We suggest that is considered a 20% safety factor on the calculated value.

2) When assembled in an active-monitor system consider 25% restriction on the CV / KG of both valves.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 6 de 32

2.3.5 APPROXIMATE WEIGHT

DN 150# 300# 600#

2” 64 65.5 67.5

3” 93 97 99

4” 147 150 157

6” 280 300 340

8” 580 610 650

10” 812 854 905

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.

2.3.6 MAXIMUM WORKING PRESSURE

150# 300# 600# 900# PN 25 PN 40

19 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.

2.3.7 SET-POINT

Pressure regulators, model HORUS use two models of pilots for pressure control called G-40 and G-42, here are the

adjustment ranges available for each model:

G-80 PILOT

SPRING COLOR PART NUMBER RANGE

YELLOW / GREY 01.50.09 20 – 50 mbar

BLUE 01.50.10 45 – 100 mbar

WHITE / GREY 01.50.21G 90 – 250 mbar

SILVER 01.50.21P 150– 430 mbar

GREY 01.50.24 340 – 1100 mbar

PILOT G-40

SPRING COLOR CODE ADJUSTMENT RANGE

RED 01.51.94A 25,0 – 50,0 bar

YELLOW 01.51.94 47,0 – 80,0 bar

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 7 de 32

PILOT G-42

SPRING COLOR CODE ADJUSTMENT RANGE

GREEN 01.49.65 1,0 – 4,5 bar

GRAY 01.49.64 4,5 – 12,0 bar

BLUE 01.49.33 11,0 – 17,0 bar

RED 01.51.94A 16,0 – 30,0 bar

YELLOW 01.51.94 27,0 – 55,0 bar

2.3.8 ACCURACY AND LOCK UP

Accuracy; Closing: AC up to 1; SG up to 2,5

3.0 – PRINCIPLE OF OPERATION

3.1 REGULATOR SPRING TO CLOSE (FC)

During pressure absence, shutter (A) is kept in closed position by the shutting spring (B), which keeps it pressed

against the gasket (C). It stands out that even when subject to pressure, upstream pressure variations have no influence

on the shutter position, due to the balancing of the forces acting on the same, as well as on the actuator shaft (D) that is

also balanced.

When the inlet piping is pressurized, gas reaches the booster (F), which reduces the pressure to a convenient value

near to the outlet pressure and delivers the same to pilot (G). The pilot compares the gas feeding pressure with the outlet

pressure, sensed by the pilot diaphragm (H), and controls the flow to be injected under the main regulator diaphragm (L).

If a decrease in downstream pressure occurs (due to an increased consumption or a drop of the upstream pressure)

an imbalance between the spring (I) force on the pilot (H) diaphragm and the force generated by the outlet pressure under

this same diaphragm, drives the pilot (K) shutter to a larger aperture, therefore, causing a pressure increase under the

main regulator (L) diaphragm, which combined with downstream pressure drop, which actuates on the main regulator

diaphragm and in the opposite side of the pilot pressure thereon, will determines the displacement of the shutter (A)

upwards, thereby increasing the passage and restoring the set point.

When the pre-regulated pressure begins to increase, it makes the pilot (K) shutter to reduce the aperture. The

increased pressure, which actuated under the regulator (L) diaphragm, flows through the Bleed (M) restriction (adjustable)

that discharges the same downstream. The strength of the closing spring of the main regulator (B) plus the decrease of the

pilot pressure cause a downward displacement of the main shutter (A), making the pressure to return to the preset value.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 8 de 32

FIGURE 1 - HORUS FAIL CLOSED

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 9 de 32

3.2 BOOSTER (G-43)

The Booster is nothing more than a pre-regulator that automatically adjusts the process conditions as a function of the

input pressure and output pressure with the purpose of reducing the pilot inlet pressure, allowing the pilot to operate in a

milder condition, thus eliminating any chance of interference on the regulator piloting by the input pressure variation.

The use of a pre-regulator, or booster, is recommended only for applications where the pressure differential exceeds

10.0 bar.

Booster models G-43 and G-44 are designed to keep the pilot input pressure set 1 to 2 bar above the desired set point,

e.g.: if we are adjusting the pressure regulator to 20 bar, the booster will be applying to the pilot a pressure of 21 to 22 bar.

Typically, the booster G-43 have three connections to the process. These are represented by the red line in the figure

above, from the regulator inlet and loaded with the inlet pressure; the yellow line is the output pressure of the main

regulator, also called sensor pick-up, and is responsible for actuating on the booster diaphragm (A), moving the shaft (B)

away from the gasket (C), thus allowing the passage of gas from the regulator input at a pressure 1 to 2 Kgf/cm² above the

set point pressure of the main regulator, which by its turn is represented by the green color and is the pick-up that will

follow to the Pilot.

Attention: In some assemblies, the booster can be integrated into the pilot; this change is merely ergonomic to reduce

space, component count and ease of operation. However, it is important to note that the operating principle is exactly the

same as given above.

Installation Manual, Maintenance and Operation

Pressure Regulating Valve – Model Horus

MI-18

Elaborate

Verified / Approved

CSQ

Date

Review

Page

J.Junior Celso Nieto JM 25/11/16

04 10 de 32

3.3 PILOTS (G-40 & G-42)

The pilots series G-40 and G-42 are composed by dual diaphragm pilot that can achieve much higher accuracy than

other pilots 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.

The green line represents the pressure from the booster or pre regulator, the yellow line is the regulator outlet

pressure (sensor outlet) and this is responsible for moving the diaphragm assembly (A) upward or downward, causing the

driver shutter (B) move it away from the seat (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.

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