Installation, Maintenance and Operating Manual

Pressure Regulator Valve

Model ATHOS
 MI-02 – Rev.04

INDEX

1.0 - GENERAL ADVERTSIMENT ................................................................................................................................................... 3

1.1 – INSTRUCTIONS PRIOR 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 ................................................................................................................................................................ 3
2.0 – INTRODUCTION ................................................................................................................................................................... 4
2.1 MANUAL SCOPE ......................................................................................................................................................................... 4
2.2 DESCRIPTION.............................................................................................................................................................................. 4
2.3 SPECIFICATIONS ......................................................................................................................................................................... 4
2.3.1 AVAILABLE CONFIGURATIONS ............................................................................................................................................ 4
2.3.2 AVAILABLE CONNECTIONS.................................................................................................................................................. 4
2.3.3 TEMPERATURE LIMITS ........................................................................................................................................................ 4
2.3.4 MAXIMUM WORKING PRESSURE ....................................................................................................................................... 4
2.3.5 ESTIMATE WEIGHTS (kg) .................................................................................................................................................... 4
2.3.6 PRESSURE REGULATOR SPRING RANGE ............................................................................................................................. 4
2.3.7 SLAM SHUT VALVE SPRING RANGE .................................................................................................................................... 4
2.3.8 PRE-REGULADOR SPRING RANGE ....................................................................................................................................... 5
2.3.9 ACCURACY AND LOCK UP ................................................................................................................................................... 5
3.0 – WORKING PRINCIPLE .......................................................................................................................................................... 5
3.1 REGULATOR ............................................................................................................................................................................... 5
3.2 PILOT (G-50) ............................................................................................................................................................................... 6
3.3 REGULATOR – ACTIVE / MONITOR SYSTEM ................................................................................................................................ 6
4.0 – INSTALLATION ..................................................................................................................................................................... 8
4.1 FILTER ......................................................................................................................................................................................... 8
4.2 CLEANING................................................................................................................................................................................... 8
4.3 FLOW DIRECTION AND SYSTEM INTEGRITY ................................................................................................................................ 8
4.4 SENSING LINE ............................................................................................................................................................................. 8
4.5 RECOMMENDED INSTALLATION SCHEME .................................................................................................................................. 9
4.5.1 REGULATOR (ACTIVE ONLY) ............................................................................................................................................... 9
4.5.2 WORKING MONITOR SYSTEM ............................................................................................................................................ 9
4.6 COMMISSIONING AND START-UP ............................................................................................................................................. 9
4.6.1 GENERAL RECOMMENDATIONS ......................................................................................................................................... 9
4.6.2 COMMISSIONING (UNIQUE REGULATOR STREAM) ......................................................................................................... 10
4.6.3 RESERVE (STAND BY) STREAM .......................................................................................................................................... 11
4.6.4 COMMISSIONING (ACTIVE / MONITOR SYSTEM) ............................................................................................................. 11
4.6.5 ADJUSTE OF RESERVE STREAM (ACTIVE / MONITOR SYSTEM)......................................................................................... 11
4.6.6 LIST OF RECOMMENDED TOOLS ....................................................................................................................................... 12
5.0 TROUBLE SHOOTING ............................................................................................................................................................ 13
6.0 MAINTENANCE .................................................................................................................................................................... 14
7.0 DRAWINGS / PARTS LIST ...................................................................................................................................................... 15
7.1 MAIN VALVE ........................................................................................................................................................................ 15
7.2 PILOT G50 ............................................................................................................................................................................ 16
7.3 SLAM SHUT VALVE – G-10 ................................................................................................................................................... 17
7.4 SLAM SHUT VALVE – G-10 HP.............................................................................................................................................. 18

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1.2.2 – INSTALLATION
1.0 - GENERAL ADVERTSIMENT
All the equipment, pipe and vessels are designed to
support mechanical efforts as, for example, torch and
1.1 – INSTRUCTIONS PRIOR COMMISSIONING bending moment, in addition to the internal pressure.
It should be clearly understood that with these However, all care shall be taken during the installation to
information hereby presented in the instructions for avoid excess of charge that can cause damage when the
commissioning that follows, there is no intention to system in operation. Excessive tensions can also be
revenue or replace the instructions determined by any caused due of not support the pipe length that can be
other organ or institute and should be done reference to adequate supported by base frame.
the relevant Standards and/or recommendations All the pressure regulators, slam shut valves, relief
existents over this subject. valves etc, shall be installed with correct flow direction.
Before any commissioning, it is understood that the Sensing lines are important components of all control
execution of proper purification and cleanness systems and it is essential that are correctly installed
procedures that shall be observed and all instructions without insulating valves.
about pressurization and standard of safety and health, Sensing line shall be adequate support to reduce
should be strictly observed. excessive vibration that can cause its rupture. It shall be
The valve suppliers recommendation, as for example, positioned in order to avoid be used as foot or hand
open slowly and open very slowly should be strictly support. It shall be lightly inclined to allow liquid and
observed. condensate flow to the main pipe.
When necessary (in underground or buried
1.2 – HEALTH AND SAFETY installation) it shall be installed venting pipe with Ø ¼”
NPT, positioned in the housing (spring or diaphragm)
Regulators, valves and other pressurized components which shall be extended and positioned in a safety and
that contain toxic, flammable gases, or other dangerous ventilated place, with protected vent to avoid water and
products, are potentially dangerous if not operated and incepts block the way.
kept correctly. It is imperative that all users of such Auxiliary systems shall not be changed or modified
equipment had been adequately educated and oriented without knowledge of process service conditions and
for the potential hazards and certified that the permission of responsible staff.
responsible personnel for the installation, test,
commissioning, operation and maintenance of factory are
1.2.3 – OPERATION
competent to do this job. The instruction manuals are
provide for orientation of users, but presume that they Depending on regulator type, the valve can be
have a basic knowledge level. In case of any doubt or positioned totally open. Consequently, when in operation,
ambiguity that affect the correct procedure, GASCAT the slam shut valve shall be opened slowly in order to the
must be contacted in order to inform or offer the service regulator assume its regulating position. If the valves are
and instruction. DO NOT TAKE THE RISK. The phone opened quickly, the upstream pressure can pass to
numbers and email for contact are described below: downstream through the pressure regulator over
pressurizing the main downstream pipe.
Gascat Indústria e Comércio Ltda. All the regulators shall operate with regulating spring
Rodovia SP 73, 1141 – Indaiatuba / São Paulo. specified by manufacture. It is specially important when
CEP 13347-990 operating relief and slam shut valve, since non correct
Phone: +55 19 3936-9300 spring can avoid the relief to open and slam shut to close.
Fax: +55 19 3935-6009
Email: [email protected] It shall take precautions to avoid water in the venting
ways.
The following commentaries, while not exaustive,
provide orientation of possible hazard sources against 1.2.4 – MAINTENANCE
the heath and safety. Regulators and valves contain gases with pressure
sometimes over than the atmospheric pressure. Before
1.2.1 – NOISE trying to investigate the problem or execute the
Regulators, valves and other pressure regulators can maintenance service in the equipment it shall be safely
generate high noise level, which can be prejudicial for depressurized. Beyond this, as the gases can be
people exposed for long period. The users should assure flammable, toxic, corrosive, it means, dangerous, it can
that adequate precautions was take in order to foresee be necessary to purge the installation using inert gas.
security for the health of employees, according to the Special precautions are necessary for operation with
standards and recommendations. gases as oxygen or hydrochloric gas and the user shall
be protected and the safety procedures implemented.

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Eventually it is not enough to isolate the device of 2.3.4 MAXIMUM WORKING PRESSURE
high pressure, since the high pressure can be retained in
the isolating valves. Do not try to remove cover, plugs MAXIMUM
and similar, before device properly released. It is still INLET SEAT
prudent to consider that the gas in high pressure can be PRESSURE
present during cover and plug removal. 145 psi (10 bar) 1/4”, 3/8”, 1/2”
Practically, all regulators use spiral springs. It is
important to reduce the charge of spring. In some case it 130 psi (9 bar) 3/4”
can contain some charge due of spring housing of device.
87 psig (6 bar) 1”
2.0 – INTRODUCTION 29 psi (2 bar) 11/4” *
* Only for version without internal relief.
2.1 MANUAL SCOPE
This manual has the objective to provide information The pressure limits hereby informed or in any
of operation, installation and maintenance about the applicable standard shall not exceed under any
hypotheses, under risk of equipment damage, installation
pressure regulator model ATHOS manufactured by
security or of people involved.
GASCAT.

2.2 DESCRIPTION 2.3.5 ESTIMATE WEIGHTS (kg)

The pressure regulator pilot operated model ATHOS 150# /
ND NPT
was designed by Gascat Engineering, to assist different PN16
applications and process service conditions. It has large 11/2” 15 -
utilization in gas distribution.
Main characteristic is the operating simplicity and easy 2” 16 18
handling, quick maintenance and relation cost-benefit.

2.3 SPECIFICATIONS
2.3.6 PRESSURE REGULATOR SPRING RANGE
2.3.1 AVAILABLE CONFIGURATIONS The pressure regulator model ATHOS uses the pilog
G-50 for pressure control.
• Active / Monitor System
• Working / Monitor System
• Pressure Regulator with SSV for both PILOT G-50
configurations above
SPRING COLOR P/N RANGE
2.3.2 AVAILABLE CONNECTIONS Red 01.50.08 7.5 – 16.5 mbar

ND CONNECTIONS Blue 01.50.09 12.5 – 21 mbar

11/2” Thread NPT / 150# RF / PN16 Green 01.50.10 15 – 35 mbar

Orange 01.50.11 30 – 70 mbar

2” Thread NPT / 150# RF / PN16
Black 01.50.67 55 – 140 mbar
Note: for other diameter / connection consult Gascat White 01.50.21 70 – 350 mbar
Sales Department.
Grey 01.50.24 200 – 1000 mbar
2.3.3 TEMPERATURE LIMITS
Brown 01.50.12 700 – 2400 mbar
Operating Temperature: -4°F to 140°F (-20°C to
60°C).
Environment Temperature: -4°F to 140°F (-20°C to 2.3.7 SLAM SHUT VALVE SPRING RANGE
60°C). The pressure regulator model ATHOS can be
The temperature limits hereby informed or in any supplied with slam shut valve incorporated in the
applicable standard shall not exceed under any regulator body. These models are G-10 or G-10 HP.
hypotheses, under risk of equipment damage, installation
security or of people involved.

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SSV – MODEL G10 the obturator set against the pilot set, closing the gas
passage of the pilot.
SPRING COLOR P/N RANGE In case of gas consumption, the pressure in the pilot
sensing line will decrease, opening the pilot because the
Grey 01.51.77P 10 – 40 mbar pilot regulating spring force is higher than the obturator
spring added to the pressure under its diaphragm. In
Yellow 01.51.78P 25 – 70 mbar parallel, the pressure under the diaphragm of main valve
decrease. In this condition, the regulator open and start
Brown 01.51.88P 50 – 120 mbar
regulating the pressure of the system.
Blue 01.51.89P 80 – 280 mbar

White 01.51.90P 220 – 600 mbar

SSV – MODEL G10 HP

Sensing
SPRING COLOR P/N RANGE Line

Rede 01.51.91P 500 – 1000 mbar

Feeding
Purple 01.51.92P 800 – 2500 mbar

Orange 01.52.14_50 2200 – 3500 mbar

2.3.8 PRE-REGULADOR SPRING RANGE

The pressure regulator model ATHOS when applied
under process service conditions with outlet pressure less
than 700 mmwc and inlet pressure over than 43.5 psi (3
bar), simultaneously, utilize pre-regulador.

Loading
PRE-REGULADOR

SPRING COLOR RANGE

Silver 0 – 2.4 bar

2.3.9 ACCURACY AND LOCK UP Sensing

Accuracy Class - AC up to 1%; Feeding Line

Lock Up – SG: up to 5%.

3.0 – WORKING PRINCIPLE

3.1 REGULATOR
The pressure regulator model Athos works by
principle of drop pressure in the diaphragm lower
chamber of main valve.
In case of flow absence the regulator remain closed, INLET PRESSURE
because the pressure in the diaphragm upper chamber
(feed by the pilot) is the same pressure of lower OUTLET PRESSURE
chamber, prevailing only the force of main spring that will
LOADING PRESSURE
close the regulator.
The pilot, in this condition of flow absence, remain
closed, because the pressure under the diaphragm
added to the obturator spring are higher than the
regulating spring force (over the diaphragm), and move

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3.2 PILOT (G-50) lower than the pressure over the diaphragm, allowing the
main valve open to feed the process gas demand.
The pilot series G-50 has simple diaphragm design, In case of damage in the obturator set and pilot seat
actuated by lever, for low pressure. can occur small passage of gas resulting in outlet
It is responsible to feed with exact loading pressure pressure increasing. Then, in case of relief of pressure
the main valve for open or close it, under normal process during flow absence or shutting down of slam shut valve,
service conditions, assisted by the equilibrium that there the obturator seat of the seat can be damaged.
is between the regulating spring force and the pressure The pilot diaphragm rupture result in pressure
of sensing line. equalization over and under the diaphragm, resulting in
possible pilot opening, once the regulating spring force
Inlet moves the diaphragm set downward opening the pilot.
Pressure
Sensing 3.3 REGULATOR – ACTIVE / MONITOR SYSTEM
Line In the active / monitor system, the working principle
of active pressure regulator is similar than the explained
in item 3.1.
The upstream regulator (monitor) remain opened,
because the pilot sensing line monitors the outlet
pressure of active regulator and, as its set point is lightly
higher, the pilot remain opened. The reason that this pilot
remain opened is due of the pressure under the pilot
diaphragm added to the obturator spring force that are
Loading
lower than the pilot regulating spring force that moves the
Pressure
obturator set downward opening the pilot.
With this, the pressure in the diaphragm upper
chamber of monitor regulator remain lightly higher than
The pressure under the pilot diaphragm, outlet the outlet pressure allowing the regulator remain in the
pressure, moves the pilot diaphragm set upward. In this opened position during under normal process service
condition, the obturator shaft moves to the left and conditions.
assisted by the obturator spring contact the pilot seat, In case of active regulator failure that result in
closing the gas passage. increase in outlet pressure, the pilot of monitor regulator
When there is gas consumption, the pressure under that is opened starts closing until achieve its set point to
the diaphragm decrease and the regulating spring has allow the monitor pressure assuming the regulating
enough force to move the shaft downward to open the control of the system. From this moment, the working
pilot. In this condition, the pressure in the diaphragm principle of this valve is the same of active regulator.
upper chamber of main valve (feeding pressure / loading)
is the same, while the pressure under the diaphragm is
discharged through the sensing line assuming a value

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The assembling configuration active / monitor system is largely applied in transmission and gas distribution. This
configuration is usually applied when the difference between inlet and outlet pressure is over than 232 psi (16 bar) and the
pipe pressure effort test and other components downstream the regulator is lower than the inlet as specified. For example,
DIN EN 12186, in this case the objective to use a monitor regulator is to increase the system safety level.
However, this is a specific recommendation of DIN EN 12186 and there other standards that specifies the use of this
configuration for different process service conditions.
The active / monitor system consists of utilization of two pressure regulators assembled in series where one is the
active (work regulating the pressure) and other is the monitor that remain totally open and will assume the pressure
regulating in case of active regulator failure.

Sensing Sensing
Line Line

Loading Loading

Feeding Feeding

SSV Sensing
Line

Pilot G-50 Pilot G-50

Main Valve Main Valve

INLET PRESSURE SSV model

G-10/G-10HP
OUTLET PRESSURE

LOADING PRESSURE

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4.0 – INSTALLATION where the gas velocity is not higher 25 m/s

(considering the lowest pressure and maximum
flow).
4.1 FILTER To obtain better pneumatic signal utilize tubings
It is recommended the cartridge filter installation with D.E ½” in AISI 316 to connect the sensing lines of
filtration degree of 5 micra, as close as possible of the regulator to the process.
regulator, without install flange to flange, because, the In order to avoid accumulate particles and
filter installed immediately upstream the regulator can condensates in the sensing line it is recommended
cause turbulence disturbing the pressure regulating. The that the sensing lines have inclination of 5%~10% in
care with the filter installation is essential to the perfect direction to the connector located in the pipe.
operation of equipment, because eventual particles in the Atentar para as conexões soldadas a tubulação
pipe can achieve the seat and obturator, damaging it para que as mesmas estejam totalmente
causing direct gas passage. desobstruídas, sem qualquer resíduo de solda que
possa interferir no sinal pneumático.
4.2 CLEANING
Do not install block valve in the sensing line
Verify the cleaning of pipe before the valve of pressure regulator or slam shut valves.
installation. It is recommended to purge completely the
line with nitrogen or air. The pressure regulator model ATHOS needs only
one connection to the process, per regulator, that is
4.3 FLOW DIRECTION AND SYSTEM INTEGRITY the pilot sensing line, independently if it is configured
Before proceeding with equipment installation, it as active or active / monitor system. The loading and
is necessary to verify if: discharging lines are connected directly in the valve
body.
1) The equipment is in perfect conditions or
have evidences of damages in function of
transport; in case of some damages with
installation contact GASCAT.
2) The space foresee for the access and
installation of equipment is adequate; also for
future maintenance.
3) The installation was designed to support the
charge of equipment.
4) The connection of inlet and outlet where the
regulator will be installed are perfectly
aligned.
5) All sensing line necessary in the pipe
downstream the equipment for were properly Sensing lines
installed respecting the distance
recommended.
6) It was foresee gauge manometer or other
equipment to indicate pressure upstream and ATHOS + G-10
downstream to allow the adjustment of
operation. The SSV model G-10 incorporated is supplied with
7) There is a vent line between the regulator standard version of internal sensing line, however,
and the first outlet ball valve to assist the for ATHOS MONITOR it is supplied with external
technician during start-up. sensing line. In this case, two connections to the
8) Verify the flow direction in the body valve and process is needed; one for the regulator + one for
check during the installation and attempt if is the SSV.
in the correct position.

4.4 SENSING LINE

The correct position of sensing line in the pipe is
essential for a good working of the pressure
regulator, because of this, install the pilot sensing
line downstream the regulator with distance
minimum of 5 times of nominal diamter of pipe in a
stretch free of obstruction, with diameter of the pipe

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a. Maintenance;
Regulator
b. Stable pneumatic signal;
Sensing Line c. Reduction of damages to the sensing lines
during transport and maintenance.

4.5.2 WORKING MONITOR SYSTEM

SSV G-10
Sensing Line 1 2 3 4 6 7 8 10 11

ATHOS MONITOR + G-10

5 9
4.5 RECOMMENDED INSTALLATION SCHEME

4.5.1 REGULATOR (ACTIVE ONLY)

1 – Inlet pressure gauge

2 – On-off manual ball valve
3 – Cartridge filter model Metrius – 5 micra
4 – Monitor pressure regulator model ATHOS + G10
5 – Incorporated SSV model G10
1 2 3 4 6 8 9 6 – Manometer connection point
7 – Active pressure regulator model ATHOS
8 – Outlet pressure gauge
9 – Vent
10 – Colector 5 ways.
11 – Partial pressure relief valve series JR CH / LP

5 7 Notes:
1) The position indicate for the sensing line can be
less than 5D if the project of installation had been
analyzed and approved by GASCAT.
2) Other option of installation recommended is the
utilization of a slug pipe parallel to the main one to
1 – Inlet pressure gauge connect all sensing lines close to the equipment, with the
2 – On-off manual ball valve following advantages:
3 – Cartridge filter model Metrius – 5 micra a. Maintenance;
4 – Pressure regulator valve model ATHOS b. Stable pneumatic signal;
5 – Incorporated SSV model G10 c. Reduction of damages to the sensing lines
6 – Outlet pressure gauge during transport and maintenance.
7 – Vent
8 – Colector 5 ways 4.6 COMMISSIONING AND START-UP
9 – Partial pressure relief valve series JR CH / LP

Notes:
4.6.1 GENERAL RECOMMENDATIONS
1) The position indicate for the sensing line can be Before proceeding with commissioning of
less than 5D if the project of installation had been equipment it is important:
analyzed and approved by GASCAT.
2) Other option of installation recommended is the 1) Verify if the equipment is properly installed
utilization of a slug pipe parallel to the main one to according to the recommendations hereby
connect all sensing lines close to the equipment, with described.
the following advantages:

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2) Close the blocking valves of inlet, outlet and The procedure considers utilization of ATHOS
by-pass, when application, of each stream. pressure regulator with slam shut valve
3) Open the vent valve downstrem the last incorporated model G-10 GASCAT.
regulator in the respective stream.
4) Certify that the Skid is NOT pressurizeda. 1) Close the vent valve.
As the blocking valves are closed use the
ATENTION: vent valve to simulate a low flow and then
adjust the regulator set point.
* Under none hypotheses proceed with 2) Verify if the regulating spring of pre-regulator
the stream pressurization where the and pilot is released (with no charge).
equipment is installed by the valve Releasing the regulating spring assure that
downstream the equipment. the regulator will remain closed when
* Under none hypotheses proceed with pressurized.
the stream pressurization where the 3) In the regulator has pre-regulator its spring
equipment is installed by the valve shall be with no charge to assure that the
upstream the equipment, as drain filer, regulator will remain closed during
for example. pressurization of respective stream.
4) Reset the SSV model G-10, pulling the
5) Verify if all connectors are properly tight obturator using the SSV cover.
before proceed with stream pressurization. 5) Open SLOW AND GRADUALLY the inlet
6) Verify if all equipment installed are adequate blocking valve, or when the Skid has by-
to the operating conditions, based on pass for these valves, use it for
nameplate data attached in each equipment. pressurization.
7) Verify if SSV (slam shut valve) is in the 6) For ATHOS without pre-regulator, at this
closed position. stage, occur a small counter-pressure
around 5~10 mbar necessary to close the
GASCAT SSV are supplied already pilot G50.
adjusted, however, due of transport 7) In the version of ATHOS with pre-regulator,
conditions and equipment handling it can turning clockwise the regulating spring,
be changed. assisted by the pressure gauge, adjust it
So that, it is recommended to verify the around 7.25~14.5 psi (0.5 – 1 bar) above the
set-point of SSV using (for example) desired set point.
external pneumatic source directly in the In this stage the same counter-pressure
actuator before proceed with stream informed in item 6 occur.
pressurization. 8) Adjust the pilot G-50 turning clockwise its
regulating spring screw, slowly, to admit a
low pressure downstream the regulator;
ATHOS is not supplied adjusted in utilize the pressure gauge to achieve the
order to preserve internal parts life desired set point.
time, so that, it is necessary to 9) Open the vent valve around 20%, and verify
adjust the set point of ATHOS before if the pressure remain in the value adjusted.
operation. 10) Since the pressure is adjusted, open the
vent valve ½” turn and verify the pressure
The Skid configuration shall be according to regulating.
DIN EN 12186 / NBR 12712 and all-active 11) If the pressure is according to the desired
standards of region where it will work. set pint, close the vent valve slowly to check
the regulator lock up. Make this procedure 3
4.6.2 COMMISSIONING (UNIQUE REGULATOR times before proceeding to the next step.
12) With the line pressurized and the blocking
STREAM) valves closed verify if there is leak in the
Utilizing as reference the assembly scheme connectors and other fittings of the
presented in the item 4.5.1 proceed with the respective stream.
descriptive indicate for commissioning of 13) Open SLOW AND GRADUALLY the outlet
regulator model ATHOS in a single stream, blocking valve to release the stream for
considering that all recommendations of item item operation.
4.6.1 were fully observed.

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4.6.3 RESERVE (STAND BY) STREAM completely the spring of pre-regulator and
pilot of monitor regulator.
When the regulator is installed in a reserve (by- The springs are released to assure that the
pass) line it is recommended to realize the same monitor pressure regulator will remain
procedure informed in the item 4.6.2, however closed; turning totally the spring of active
the set point of pressure regulator shall be regulator it will remain in the open position
adjusted 10% – 20% less than the set point of during the pressurization procedure.
regulator of working stream. 3) Reset the SSV model G-10, using the spring
housing cover to pull up the shaft.
After this, open SLOW AND GRADUALLY the 4) Open SLOW AND GRADUALLY the inlet
outlet blocking valve then the downstream blocking valve, or when the Skid has by-
pressure of regulator equalize the reserve (by- pass for such valve utilize it to pressurize the
pass) stream with the pressure of working stream.
stream; the by-pass regulator will remain closed. 5) Adjust the pre-regulator of monitor regulator
turning clockwise the regulating spring,
To make the regulator in the reserve (by-pass) using the pressure gauge to achieve a value
line assumes the regulating pressure of the of 7.25~14.5 psi (0.5 – 1) over than the
system, turn clockwise the regulating spring, desired set point.
slowly, until the set point of this regulator 6) Adjust the pilot G-50 of monitor pressure
achieve a value superior than the set point of regulator turning clockwise the regulating
regulator of working stream; in this case, the spring, slowly, to admit a low flow
regulator in the reserve line will open slowly and downstream the pressure regulator; utilize
assume the pressure regulating. the pressure gauge to achieve the desired
set point.
It is important that both regulators keep with As the pilot spring of active regulator is
difference in set point of at least 5% - 10%, totally tight this valve will remain opened
avoiding over position in set point, resulting in during this procedure.
looping between the two streams where while 7) Open the vent valve around 20%; check if
one regulator is working the other is trying and the pressure remain adjusted.
vice-versa. 8) Once adjusted the monitor regulator the next
is the active regulator. Still with the vent
Note: the values hereby informed are basic valve opened release slow and gradually the
recommendations based on good practices, pilot regulating spring of active regulator until
however the set points can be changed with achieve its set point that shall be lower than
previous consult and approval of GASCAT. the monitor regulator.
Gradually is possible to verify that the active
4.6.4 COMMISSIONING (ACTIVE / MONITOR regulator is assuming the outlet pressure
SYSTEM) regulating of main line.
9) Once the pressure is stable, open the vent
Utilizing as reference the installation scheme of
valve ½” turn and check the accuracy.
item 4.5.2 the description below is about the
10) With the set point adjusted, close the vent
commissioning of pressure regulator ATHOS in a
valve to check the lock up of the system.
stream where the configuration active / monitor
The lock up in the active / monitor system is
system is utilized, considering that all
done by the monitor pressure regulator.
recommendations of item 4.6.1 were fully
11) While verifying the lock up of the system a
observed.
simulating of stop in gas consumption is
The procedure considers the utilization of slam
done what is a normal condition of operating
shut valve incorporated model G-10 da GASCAT
and in this case both valves shall remain
and the pressure regulator model ATHOS
closed.
MONITOR.
12) Check if there is any leak in the connectors
and other fittings of this stream.
1) Close the vent valve.
13) Open SLOW AND GRADUALLY the outlet
As the blocking valves of the stream are
ball valve for normal operation.
closed utilize the vent valve to simulate a
low flow and proceed with regulator
adjusting before regulating the stream.
4.6.5 ADJUSTE OF RESERVE STREAM (ACTIVE /
2) With the stream non pressurized yet turn MONITOR SYSTEM)
clockwise the pre-regulator and pilot spring When the pressure regulator is installed in a
of active pressure regulator and release reserve (stand-by) stream with the configuration

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of active / monitor system it is recommended to For set point adjustment, commissioning and
do the same procedure informed in the item start-up the pressure regulators model ATHOS is
4.6.4, however, the set point of active pressure necessary a combined tool of 3/8” and 8 mm to
regulator of this stream shall be adjusted adjust the regulating spring of pilot and pre-
between 15%~20% lower than the set point of regulator.
the regulator in the working stream.
After this, open SLOW AND GRADUALLY the
outlet blocking valve in order that the outlet 1
pressure downstream the pressure regulator of
reserve stream equalizes with the pressure of
the working one; the pressure regulator of
reserve stream will remain closed.
To make the pressure regulator of reserve 2
stream assume the pressure regulating turn
clockwise the regulating spring of active
pressure regulator slowly until achieve a set
point higher than the working stream; in this The pressure regulator model ATHOS is supplied with
case the pressure regulator of reserve stream connectors for tubing of DN 10 mm in the sensing
will assume the operation. lines, so that, it is recommended the utilization of
It is important that both regulators keep with combined tools of 18mm and 19mm for the sensing
difference in set point of at least 5% - 10%, lines.
avoiding over position in set point, resulting in
looping between the two streams where while
one regulator is working the other is trying and ND 1 2
vice-versa. 3/8”, 8mm, 18mm,
11/2” & 2” 1”
19mm
Note: the values hereby informed are basic
recommendations based on good practices,
For set point adjustment of slam shut valve
however the set points can be changed with
previous consult and approval of GASCAT. incorporated it is recommended only a screwdriver.

4.6.6 LIST OF RECOMMENDED TOOLS

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5.0 TROUBLE SHOOTING

In this section of this manual the objective is to clarify possible problems at field and respective causes.

The problems listed in this section can come from different situations, however, part of them is related to the
gas conditions (particles), natural waste and fails during equipment operations.

It is important to keep in mind that the operation as well the maintenance of GASCAT equipment shall be
realized by trained technicians, preferentially by ones trained by GASCAT instructors.

For training and qualification of operators and technicians, contact GASCAT to check details about it.

E-mails:
[email protected]
[email protected]
Phone: +55-19-3936-9301.

PROBLEM PROBABLE CAUSE CORRECTION

Low Flow (lower than 5% of Check the operating conditions

maximum flow capacity). related to the sizing of regulator.

Poor performance, Outlet pressure

variation Change the sensing line position
Sensing line wrongly installed. according to this manual or
contact GASCAT for analyzes.

Obturator or seat of pilot Check obturator and seat

damaged conditions and replace or clean it.
Direct passage
Linha de impulso rompida ou Check the condition of sensing
danificada line and replacing it if necessary.

Filter element clogged Clean or replace it.

Lack of feeding Check the pilot seat.
Outlet pressure decreasing
and/or flow insufficient
Main diaphragm rupture Replace it.

Vent of gas by pilot venting Pilot diaphragm rupture Replace it.

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6.0 MAINTENANCE

The preventive maintenance of pressure regulators model DOMUS is essential for a good performance of equipment
as well as has direct relation with the reliability of the system, avoiding problems of different origins.

The periodicity of these maintenances changes according to each installation, process service conditions and quality
of gas; for example if the equipment is working with presence of contaminants as black powder, yellow powder, oil,
condensates etc, certainly the period between maintenance will be lower.

GASCAT has spare part kits composed of for most important parts of DOMUS pressure regulator. This list of
components is in this manual for orientation.

The components of GASCAT pressure regulators are designed, manufactured and test with exclusivity by
GASCAT in order to provide the best efficiency and security to the operation. The use of NON-GENUINE
parts become the operation non-safety and can affect the process efficiency.
GASCAT is not responsible for equipment that work with NON-GENUINE components.

Before start the maintenance of GASCAT pressure regulator certify to have the correct spare part kit with original
parts only provided by GASCAT, as well as this manual for instruction and reference to how proceed with safety and
eficiente procedure during equipment maintenance.

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7.0 DRAWINGS / PARTS LIST

7.1 MAIN VALVE

Quantity
Position Description per valve
1.1/2’’ & 2”
1 Diaphragm – Buna N 1
2 O’ring – Buna N 1
3 O’ring – Buna N 1
4 O’ring – Buna N 1
5 O’ring – Buna N 1
6 Obturator 1
7 Diaphragm Plate 2

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7.2 PILOT G50

Position Description Quantity

13 Obturator 1
16 O’ring – Buna-N 1
21 O’ring – Buna-N 1
26 O’ring – Buna-N 1
28 Diaphragm 1

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7.3 SLAM SHUT VALVE – G-10

Position Description Quantity

3 Diaphragm – Buna-N 1
7 Spheres 4
9 O’ring – Buna-N 1
10 O’ring – Buna-N 1
11 O’ring – Buna-N 1
12 O’ring – Buna-N 1
14 Diaphragm Plate 1
18 Actuator Cover 1
22 Obturator 1

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7.4 SLAM SHUT VALVE – G-10 HP

Position Description Quantity

3 Diaphragm – Buna-N 1
7 Spheres 4
9 O’ring – Buna-N 1
10 O’ring – Buna-N 1
11 O’ring – Buna-N 1
14 Diaphragm Plate 1
16 Obturator 1

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