Tartarini OS/80X Pilots for Shutoff Valves - Manuals & Guides

Instruction Manual

TM

D103650X012

January 2015 - Rev. 00

OS/80X Series

Type OS/80X, OS/84X and OS/88X Slam-Shut Controller

SUMMARY

Introduction ........................................................................ 1

Characteristics .................................................................... 1

Labelling ............................................................................. 2

Dimensions and Weight ...................................................... 2

Installation .......................................................................... 3

Startup ................................................................................ 3

Periodical Checks ............................................................... 3

SEP Statement .................................................................. 3

ATEX Requirements .......................................................... 3

Maintenance .......................................................................

Troubleshooting .................................................................. 5

Parts Lists ........................................................................... 6

Schematic Assemblies........................................................ 7

INTRODUCTION

Scope of Manual

This manual provides installation, startup, maintenance,
troubleshooting, and spare parts for the slam-shut
controller series OS/80X.

Product Description

Designed for pressure regulators and slam-shut valves
control, the following types are available:

• OS/80X

Diaphragm actuator for minimum and/or maximum pressure.

Version: BP, BPA-D, MPA-D and APA-D.

• OS/84X - OS/88X

Piston actuator for minimum and/or maximum pressure.

• OS/80X-PN

Diaphragm actuator for minimum and/or maximum
pressure, controlled by PRX-PN series pilots.

• OS/84X-PN

Piston actuator for minimum and/or maximum pressure,
controlled by PRX-PN series pilots.

4

Figure 1. Type OS/80X-BP

Reinforced version available to be used with BM6X Series
slam-shut valves, and on BM5 DN 150 slam shut valve (e.g.
OS/80X-BP-R).

The full range of OS/80X slam-shut controllers can be
installed in the following equipments:

BFL Series - Cronos Series - BM5 Series - BM6X Series

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.

CHARACTERISTICS

Table 1. Technical Features

SERVOMOTOR

MODEL

OS/80X-BP 5

OS/80X-BPA-D 20

OS/80X-MPA-D

OS/80X-APA-D 2 10

OS/84X 5 41

OS/88X 18 80

OS/80X-PN 0.5 40

OS/84X-PN 30 80

BODY

RESISTANCE

(bar)

100

OVERPRESSURE

SET RANGE

Wdo (bar)

MIN. MAX. MIN. MAX.

0.03 2 0.01 0.60 Aluminium

0.50 5

1/4-inch NPT female threaded connections.

UNDERPRESSURE

SET RANGE

Wdu (bar)

4

8

4

7

16

70

40 Steel

80 Brass

0.25

0.30

0.5

30

BODY

MATERIAL

Steel

Brass

OS/80X Series

=x

LABELLING

BOLOGNAITALY

O.M.T.

MATRICOLA
SERIALNr.
ANNO
YEAR
NORMEARMONIZ.
HARMONIZEDSTD.
CLASSE DI PERDITA
LEAKAGE CLASS
CLASSE FUNZIONALE
FUNCTIONAL CLASS
FLUIDO GRUPPO
FLUIDGROUP

TS

Note 3

Note 2

EN

Cg

pmax

1

PS

°C

body

APPARECCHIO TIPO/DEVICE TYPE

Note 1

DN1

DN2

Wa

Note 4

Wao

Note 5

Wau

Note 5

bar

PS

bar

covers

-

Figure 2. Label for OS/80X Series

Note 1: See “Characteristics”

Note 2: Year of Manufacture

Note 3: Class 1: -10° to 60°C

Class 2: -20° to 60°C

Note 4: Specicset-pointaccordingtoorder

Note 5: See “Characteristics”

DIMENSIONS AND WEIGHT

pao

bar PT

1.5

bar

bar

bar

bar

PS bar

205

OFF

ON

R

M

A

I

O

T

E

E

S

OS/80X

G

E

R

N

E

Z

M

A

E

E

M

C

E

N

R

E

G

270

Y

R

R

80

155

OS/08X SERIES FULL RANGE WEIGHT: UP TO 7.5 kg

Figure 3. OS/80X Series Dimensions (mm)

2

OS/80X Series

INSTALLATION

a. Install the actuator in a covered area and protect it

against weather agents.

b. Check that data on the plate are compatible with actual

working conditions.

c. Make sure actuator is installed upright, i.e. screw

(key 49) on top.

CAUTION

Mounting in any other way will jeopardize
actuator’s performance.

d. Carry out the connection of gas outlet (A). It must be

derived from the pressure control piping, in a straight
tract, possibly far away from restrictions, curves or
derivations, in order to avoid turbulence that can alter the
trip pressure setpoints.

STARTUP

a. Using lever, activate slam-shut by turning reset pin (key 6)

in the direction shown by the arrow.

b. Wait until the pressure being controlled stabilizes and

then slowly release lever.

c. Now repeat this procedure, make sure that levers

keep actuator properly set and that lever (key 33) is in
horizontal position.

PERIODICAL CHECKS

Itisrecommendedthatactuatorbeefciencycheckedperiodically.

Cut-off Test

a. Cutoff the circuit by means of inlet and outlet valves and

disconnect the pressure control pipe (A). The Actuator
should cutoff at minimum pressure (only if so set).

b. Through the pressure control connection, use a small

pump or other appropriate means, to raise the pressure to
normal operating level. Reset actuator after cutoff in step a.

c. Simulate pressure increase until maximum pressure cutoff

value is reached.

d. Connect the pressure control actuator (A) and set the

circuit back to operating conditions by following the
instructions described in the Startup section.

Valve-seal Check

a. Slowly close the valve located downstream.

b. Press the “EMERGENCY” button. This will cause the

immediate closing of slam-shut device.

c. Loosen a connector in the downstream line of the

slam-shut device or of the regulator. Check the
connector with soap and water, making sure there are
no leaks; make any necessary repairs otherwise.

SEP STATEMENT

Emerson Process declares this product conforms to
Pressure Equipment Directive (PED) 97/23/EC.

Article 3 section 3 and was designed and manufactured in
accordance with sound engineering practice (SEP).

Per Article 3 section 3, this “SEP” product must not bear the
CE marking.

ATEX REQUIREMENTS

WARNING

!

If the provisions of EN 12186 & EN 12279,

nationalregulations,ifany,andspecic

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 shut-down
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inow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

(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

• periodical check/maintenance for surveillance shall be
carried out complying with national regulations, if any, and

specicmanufacturerrecommendations.

3

OS/80X Series

MAINTENANCE

Routine actuator maintenance entails simply periodic
checking of the diaphragm on the Type OS/80X (the piston
lip seal on the Type OS/84X) and the movement of the
levers, i.e. they should move freely with a minimum of
friction. If necessary, lubricate pins with “Molykote 55 M”.

WARNING

!

For a successful job it is indispensable to use

qualiedpersonnel,possiblycallingonour

Technical Support Representatives. Before starting
maintenance, disconnect impulse connection (A)
to make sure there is no gas under pressure in the

pilot.Whenmaintenanceoperationsarenished

check the tightness with suds.

Replacing Diaphragm (OS/80X Series only)

a. Remove screws (key 27) and cover (key 61).

b. Replace diaphragm (key 62).

c. To remount diaphragm, coat it with grease, set it in place

around the edge of cover (key 61) and evenly tighten
screws (key 27) to ensure proper sealing.

Replacing O-ring (Type OS/84X and OS/88X only)

a. Remove plug (key 61) and extract piston (key 68) from body

(key 60).

b. Replace O-ring (key 67) and lip seal (key 66).

c. Reassemble by reversing the above procedures.

General Maintenance

a. Remove screws (key 40) and casing (key 47).

b. Remove dowels (key 12) and bushing (key 13).

c. Slide off pin (key 6), lever assembly (key 17 and 2), balls

(key 10) and shim ring (key 15). Wash parts, replace any
if worn.

d. Remove nuts (key 18), levers (key 20 and 36) and springs

(key 37 and 21).

e. Remove nut (key 30), screw (key 29) and lever (key 33).

f. Remove minimum register screw (key 49), maximum

register ring (key 50) and springs (key 53 and 54).

g. Remove cover (key 61) on OS/80X Series, or body

(key 60) on Types OS/84X and OS/88X, and proceed as
directed in replacing diaphragm/O-ring section.

h. Remove nut (key 70) and locknut (key 69), then slide off

stem assembly (key 57).

i. Loosen dowel (key 3), unscrew ring (key 9), remove ball

holder (key 5) and check seals (key 4 and 8) for wear.

l. Clean all parts with petrol, replace any if worn.

Reassembly

Reassemble all parts by reversing the steps in the general
maintenance section. As you proceed, make sure all parts
move freely without friction. If necessary, lubricate them with
Molykote 55 M. Make sure to:

a. Narrow the gap between nuts (key 30 and 18) so that levers

(key 33, 36, and 20) have minimum play yet move freely
without friction.

b. Before mounting minimum spring (key 54), register

position of lever (key 33) by means of nut (key 70),
locking it into place with locknut (key 69).

Note

The lever (key 33) is in proper position when
it is exactly horizontal and in the center of
the groove of lever (key 36).

c. Now remount lever assembly (key 17 and 2), balls

(key 10), keeping them in their seat with grease, and
stem (key 6), which is to be turned so the balls enter
their seats. The stem and lever assembly should now
be tightly fitted together.

d. Remount bushing (key 13), make sure that the dowels are

rmlysetinthegroovesofthestem(key6).

e. Repeatedly check if pilot resets properly and, lastly,

remount minimum spring (key 54).

f. Always check pilot setting.

Minimum and Maximum Setting

a. Make sure that the lever (key 33) is in horizontal position

when pilot is reset. If necessary, use nut and locknut
(key 69 and 70) to adjust (see step b, Reassembly
section).

b. Use ring nut (key 50) to completely load maximum

pressure spring (key 53). Loosen screw (key 49) to
completely relieve minimum pressure spring (key 54).

c. Disconnect pressure control pipe (A).

d. Through the pressure control connection, use a small

pump or other appropriate means to raise the pressure to
normal operating level.

e. Reset pilot and reduce the pressure until it reaches

minimum cutoff level.

f. Use register (key 49) to load spring (key 54) slowly until pilot is

triggered.

g. Repeat procedures (d) and (e) above, making any

necessary adjustment in the setting.

h. Bring pressure back to normal values.

i. Reset pilot and raise the pressure until it reaches

maximum cutoff level.

4