Instruction Manual
TM
D103677X012
January 2015 - Rev. 00
Type RP
RP Series Spring Loaded Pressure Regulators
SUMMARY
Introduction ........................................................................ 1
P.E.D. Categories and Fluid Group ................................... 2
Characteristics ................................................................... 2
Labelling ............................................................................ 2
Overpressure Protection .................................................... 3
Transport and Handling ..................................................... 3
Atex Requirements ............................................................ 3
Slam-Shut Controller ......................................................... 3
Dimensions and Weights ................................................... 4
Operation ........................................................................... 5
Installation ......................................................................... 6
Startup ............................................................................... 6
Adjustment ......................................................................... 7
Shutdown ........................................................................... 7
Periodical Checks .............................................................. 7
Maintenance ...................................................................... 7
Spare Parts ........................................................................ 8
Troubleshooting ................................................................. 8
Parts List ............................................................................ 9
This product has been designed to be used with fuel gases of
1st and 2nd family according to EN 437, and with other non
aggressive and non fuel gases. For any other gases, other
than natural gas, please contact your local sales agent.
The following versions are available:
RP/011 • RP/022 • RP/033: Regulator
Figure 1. Regulator Type RP/011/66
INTRODUCTION
Scope of Manual
This manual provides instructions for installation, startup,
maintenance and spare parts ordering for the RP series
spring loaded regulators.
Product Description
The RP Series regulators are direct-operated with
non-balanced trim.
They are usually supplied with built in lter and can be also
provided with slam-shut controller for minimum pressure,
maximum pressure or minimum and maximum downstream
pressure.
The regulators of the RP series due to their operating
specications are mainly used in those system where
sudden capacity variations are required, or else, where the
cut-off of the gas distribution is controlled by solenoid valve,
such as for the feeding of burners.
RP/011/66 • RP/022/66 • RP/033/66:
The standard gas pressure devices (regulators and safety
shut-off devices) are those used in the assemblies dealt with
into EN 12186 and EN 12279 and their use has to be under
the provisions into ENs 12186 & 12279.
Fail open stand-alone regulators cannot be used as a safety
accessory according PED 97/23/EC to protect downstream
pressure equipment.
In the pressure regulators (with or without built-in safety
shut-off devices) manufactured by Emerson Process
Management shall be used additional pressure accessories
(e.g. pilots or lters) manufactured and labeled by Emerson
Process Management.
Emerson Process Management will be not responsible for any
possible inefciency due to installation of not own production
additional pressure accessories (e.g. pilots or lters).
When pressure containing parts of possible built-in safety
shut-off device (SSD) valve and pilot have different
maximum allowable pressures, the SSD is differential
strength type.
Regulator with slam-shut
Type RP
P.E.D. CATEGORIES AND FLUID GROUP
According to EN 14382, only in integral strength type and
Class A conguration (when both over and under pressure
protections are set up), the possible built-in safety shut-off
device can be classied like a safety accessory according
to PED.
The minimum PS between SSD valve and pilot shall be the
PS of the safety accessory to comply the provisions of EN
14382 about integral strength type.
Downstream equipments, protected by possible built-in
safety shut-off device (in its Class A and integral strength
conguration) of this product, shall have technical features
such as to be category per table below according Directive
97/23/EC “PED”.
Table 1. P.E.D. Category for RP Series Regulators
PRODUCT SIZE CATEGORY
RP/011
WITH OR WITHOUT SLAM-SHUT
RP/022 E RP/033
WITH OR WITHOUT SLAM-SHUT
SEP
I
FLUID
GROUP
1
Minimum/Maximum Allowable Temperature (TS)
See label
Functional Features
Accuracy Class AC : up to ± 5%
Lock-up Pressure Class SG : up to + 10%
Slam-Shut Controller
Accuracy Class AG : ± 5%
Response Time t
: ≤ 1 second
a
Orice
12.7 - 16 - 20 mm
Temperature
Standard Version: Working -10° to 60°C
Low Temperature Version: Working -20° to 60°C
The RP/011 and possible built-in pressure accessories (e.g.
slam-shut controller OS/66) installed in all the available
sizes of RP series regulators, are conform to Pressure
Equipment Directive (PED) 97/23/EC Article 3 section 3 and
were designed and manufactured in accordance with sound
engineering practice (SEP). Per Article 3 section 3, these
“SEP” products must not bear the CE marking.
CHARACTERISTICS
Body Sizes and End Connection Styles
Threaded Connections
RP/011: 1 x 1-1/4” BSP
RP/022: 1-1/4 x 2” BSP
RP/033: 2 x 3” BSP
Flanged Connections
RP/011-FS: DN 25 x 32 PN 16, 25, 40 / CL150, CL300
RP/022-FS: DN 32 x 50 PN 16, 25, 40 / CL150, CL300
RP/033-FS: DN 50 x 80 PN 16, 25, 40 / CL150, CL300
WARNING
!
The pressure/temperature limits indicated
in this instruction manual or any applicable
standard or code limitation should not be
exceeded.
Maximum Operating Inlet Pressure
19.6 bar
Materials
Covers: Aluminium
Body RP/011/022/033: Ductile iron
Body RP/022/033: Steel
Diaphragm: Fabric Nitrile (NBR)
LABELLING
Notified
APPARECCHIO TIPO / DEVICE TYPE
BOLOGNA ITALY
TARTARINI
MATRICOLA / ANNO
SERIAL Nr. / YEAR
REAZIONE
FAIL SAFE MODE
NORME ARMONIZ.
HARMONIZED STD.
CLASSE DI PERDITA
LEAKAGE CLASS
CLASSE FUNZIONALE
FUNCTIONAL CLASS
FLUIDO GRUPPO
FLUID GROUP
TS °C
TM
FAIL OPEN
EN
Note 3Note 4
Figure 2. Label for rp Series Regulators
Nota 1: See “Characteristics”
Nota 2: Year of manufacture
Nota 3: Class 1: -10/+60 °C
Class 2: -20/+60 °C
Nota 4: PN 16 PS = 16 bar
PN 25 PS = 20 bar
PN 40 PS = 20 bar
CL150 PS = 19.3 bar
CL300 PS = 20 bar
body
xxxx
DN1
Note 2
/
FAIL CLOSE
X
TIPO
TYPE
Cg
pmax
1
PS
DN2
Wds
Wdso
Wdsu
bar
bar x PS barPSD PT=Bar
DN seat
DN sede
Note 1
pdo
bar
bar
bar
bar
1.5
2
Type RP
OVERPRESSURE PROTECTION
The recommended maximum allowable pressures are
stamped on the regulator nameplate.
If actual version hasn’t a built-in safety shut-off device, some
type of overpressure protection is needed if the actual outlet
pressure exceeds the actual maximum operating outlet
pressure rating.
Overpressure protection should also be provided if the
regulator inlet pressure is greater than the maximum
operating inlet pressure. Downstream side pressure after
possible built-in SSD’s intervention shall stay within the
actual maximum operating set-up range to avoid anomalous
back pressures that can damage the SSD’s pilot.
Downstream overpressure protection shall be also provided
if the SSD outlet pressure can be greater than the PS of the
SSD pilot (differential strength type).
Regulator operation below the maximum pressure limitations
does not preclude the possibility of damage from external
sources or debris in the line.
The regulator should be inspected for damage after any
overpressure condition.
TRANSPORT AND HANDLING
Established transport and handling procedures shall be
followed to avoid any damage on the pressure containing
parts by shocks or anomalous stresses.
Built-up sensing lines and pressure accessories shall to be
protected by shocks or anomalous stresses.
(e.g. : lling/exhausting of fuel gas of internal volume
of the isolated part/entire installation with vent lines
to safe area - 7.5.2 of EN 12186 & 7.4 of EN 12279 ;
monitoring of settings with further exhaust of fuel gas to
safe area ; connection of isolated part/entire installation to
downstream pipeline; ….)
• provision in 9.3 of EN 12186 & 12279 shall be enforced by
pressure regulating/measuring station/installation’s end user
• external tightness test shall be carried out after each
reassembly at installation site using testing pressure in
accordance with national rules
• in case of selfop regulators diaphragm’s incidental failure
the amount of maximum ow to be vented can be calculated using the universal gas sizing equation, assuming
inlet pressure = regulator’s set-point, outlet pressure =
atmospheric pressure and venting hole DN on the regulator’s upper cover = 16 mm (Cg = 280).
• periodical check/maintenance for surveillance shall be
carried out complying with national regulations, if any, and
specic manufacturer recommendations.
SLAM-SHUT CONTROLLER
The following controllers are used with RP series regulator
with built-in slam-shut:
• OS/66 Series spring loaded controllers
ATEX REQUIREMENTS
If the provisions of EN 12186 & EN 12279, national regula-
tions, if any, and specic manufacturer recommendations are
not put into practice before installation and if purge by inert
gas is not carried out before equipment’s start-up and shutdown operations, a potential external and internal explosive
atmosphere can be present in equipment & gas pressure
regulating/measuring stations/installations.
If a presence of foreign material in the pipelines is foreseen
and purge by inert gas is not carried out, the following
procedure is recommended to avoid any possible external
ignition source inside the equipment due to mechanical
generated sparks :
• drainage to safe area via drain lines of foreign materials, if
any, by inow of fuel gas with low velocity in the pipe-work
( 5m/sec)
In any case,
• provisions of Directive 1999/92/EC and 89/655/EC shall
be enforced by gas pressure regulating/measuring station/
installation’s end user
• with a view to preventing and providing protection against
explosions, technical and/or organizational measures
appropriate to the nature of the operation shall be taken
Figure 3. OS/66 Slam-Shut Controller
Table 2. OS/66 Characteristics
MODEL
OS/66 6 0.022 0.6 0.007 0.45
OS/66-AP 6 0.2 5 0.1 2.5
BODY
RESISTANCE
bar
OVERPRESSURE
SET RANGE
bar
W
do
Min. Max. Min. Max.
UNDERPRESSURE
SET RANGE
W
bar
du
Materials
Body: Aluminium
Cover: Steel
Diaphragm: NBR rubber
For further informations please
D103657X012.
see the Instruction Manual
3
Type RP
BB
DIMENSIONS AND WEIGHTS
RP/011 · RP/022 · RP/033
Without Shut-off Device
Ø C Ø C
I
B1A
B
D
RP/011/66 · RP/022/66 · RP/033/66
With Shut-off Device
Ø 125
I
160
1
D
H
75
I1 - I2*
I1 - I2*
Figure 4. RP Series Dimensions (mm)
Type
DN
A B B1 C D I I1* I2* H
Inlet Outlet
Weight
Kg
RP/011 1" 1 1/4" 50 280 120 206 102 135 185 195 - 6.5
RP/011/66 1" 1 1/4" - 280 120 206 102 135 185 195 125 7.7
RP/022 1 1/4" 2" 50 300 120 266 106 135 185 200 - 10.5
RP/022/66 1 1/4" 2" - 300 120 266 106 135 185 200 125 11.7
RP/033 2" 3" 70 300 120 266 120 160 230 270 - 13
RP/033/66 2" 3" - 300 120 266 120 160 230 270 142 14.2
* I1 Flanged connections PN 16-25-40 • I2 Flanged connections CL 300
4
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