Gascat BRISE PLUS Manuale utente
INSTALLATION & OPERATION MANUAL
PRESSURE REGULATOR VALVE
MODEL BRISE PLUS
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 2 de 45
INDEX
1 – INSTRUCTIONS PRIOR TO COMMISSIONING ......................................................................................................... 3
1.1 – SAFETY AND HEALTH ......................................................................................................................................... 3
1.1.1 – NOISE ............................................................................................................................................................ 3
1.1.2 – INSTALLATION .............................................................................................................................................. 4
1.1.3 – OPERATION .................................................................................................................................................. 4
1.1.4 – MAINTENANCE ............................................................................................................................................. 4
2 – INTRODUCTION .......................................................................................................................................................... 5
2.1 – SCOPE OF MANUAL ............................................................................................................................................ 5
2.2 – DESCRIPTION ...................................................................................................................................................... 5
2.3 – SPECIFICATIONS ................................................................................................................................................. 5
2.3.1 – AVAILABLE CONFIGURATIONS .................................................................................................................. 5
2.3.2 – AVAILABLE CONNECTIONS ........................................................................................................................ 6
2.3.3 – TEMPERATURE LIMITS ................................................................................................................................ 6
2.3.4 – FLOW COEFICIENT ...................................................................................................................................... 6
2.3.5 – VALVE WEIGHT ............................................................................................................................................. 6
2.3.6 – MAXIMUM WORKING PRESSURE ............................................................................................................... 6
2.3.7 – PRESSURE REGULATOR SPRING RANGE (SET-POINT) ......................................................................... 7
2.3.8 – SLAM SHUT VALVE SPRING RANGE (SET-POINT) ................................................................................... 8
2.3.9 – ACCURACY AND LOCK UP .......................................................................................................................... 9
2.3.10 – PRESSURE REGULATOR DIMENSIONS .................................................................................................. 9
3 – OPERATING PRINCIPLE .......................................................................................................................................... 10
3.1 – PRE PILOT AND INTERNAL FILTER ................................................................................................................. 12
3.2 – PILOT .................................................................................................................................................................. 13
3.3 – SLAM SHUT VALVE BUILT-IN ........................................................................................................................... 13
3.3.1 – L ACTUATOR ............................................................................................................................................... 15
3.3.2 – H ACTUATOR .............................................................................................................................................. 16
4 – INSTALLATION .......................................................................................................................................................... 15
4.1 – CHECKING SYSTEM INTEGRITY ..................................................................................................................... 15
4.2 – PRESSURE REGULATOR NAMEPLATE .......................................................................................................... 15
4.3 – FILTER ................................................................................................................................................................ 16
4.4 – CLEANING .......................................................................................................................................................... 16
4.5 – FLOW DIRECTION ............................................................................................................................................. 16
4.6 – SENSE LINE ....................................................................................................................................................... 17
4.7 – RECOMMENDED INSTALLATION SCHEME .................................................................................................... 18
4.8 – OTHER IMPORTANT DEVICES FOR A SAFETY INSTALLATION ................................................................... 19
5 – OPERATION (START UP) ......................................................................................................................................... 20
5.1 – PRESSURE REGULATOR ADJUSTMENT ........................................................................................................ 21
5.2 – RECOMMENDED TOOLS FOR START-UP ...................................................................................................... 21
6 – TROUBLESHOOTING ............................................................................................................................................... 22
7 – WARRANTY ............................................................................................................................................................... 23
8 – STORAGE .................................................................................................................................................................. 23
9 – GENERAL RECOMMENDATION .............................................................................................................................. 23
10 – COMPONENTS & SPARE PARTS .......................................................................................................................... 23
11 – PROCEDURE FOR BRISE PLUS REGULATOR DISASSEMBLY ......................................................................... 36
11.1 – MAIN REGULATOR VALVE ............................................................................................................................. 36
11.2 – SLAM SHUT VALVE (ACTUATOR L & H) ........................................................................................................ 39
11.3 – G-80 PILOT ....................................................................................................................................................... 40
12 – PROCEDURE FOR BRISE PLUS REGULATOR ASSEMBLY ............................................................................... 42
11.1 – MAIN REGULATOR VALVE ............................................................................................................................. 42
13.3 – G-80 PILOT ....................................................................................................................................................... 44
13 – RECOMMENDED TORQUES .................................................................................................................................. 45
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 3 de 45
1 – INSTRUCTIONS PRIOR TO COMMISSIONING
It should be clearly understood that the information given under the Commissioning Instructions below do not intend to
revoke or substitute instructions laid by any relevant entity and reference should be made to the relevant Standards and/or
existent recommendations on this subject.
It is implied that before Commissioning the performance of the appropriate "Cleaning and Purification Procedures" will
be observed and all the instructions contained in "Pressurization" and "Labor Safety and Health Standards" shall be strictly
attended.
The recommendations of valves' suppliers, as for instance, "open slowly" or "open very slowly" should be strictly
observed.
1.1 – SAFETY AND HEALTH
Regulators, valves, and other pressurized components that contain toxic or flammable gases, or other hazardous
products, are potentially dangerous if not correctly operated and maintained. It is mandatory that all users of these
equipments are properly instructed and warned on their potential danger, and certify yourself that the personnel
responsible for installation, test, commissioning, operation, and maintenance of the plant are skilled enough to perform
their duties. Instruction manuals are provided for orientation of the operators, but it is supposed that they have a basic
knowledge level. If any doubts or ambiguities remain that could affect the proper procedures ask Gascat, which will be
pleased to instruct, or to provide the suitable service or instruction. NOT TO TAKE ANY RISK. Our telephone, fax
numbers, and e-mail are the following:
Gascat Indústria e Comércio Ltda.
Rodovia SP 73, 1141 – Indaiatuba / São Paulo.
CEP 13347-390 – Brazil
Phone: 55 19 3936-9300
Fax: 55 19 3935-6009
E-mail sales@gascat.com.br
The comments below, while not completely inclusive, provide guidance on possible sources of risk to safety and health.
1.1.1 – NOISE
Regulators, valves, and other pressure reducers can produce high noise levels, which can be harmful to persons
exposed to them for long periods of time. Users should assure themselves that appropriate provisions will be taken, in
order to foresee health safety of employees and/or third parties, according to valid standards and recommendations.
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 4 de 45
1.1.2 – INSTALLATION
All equipment, piping, and vessels are designed to support mechanical efforts, as, for instance, torque and bending
momentum, in addition to internal pressure. However, careful shall be exercised during installation not to develop
excessive efforts, which can cause cracks that may result in serious breakage when the regulator is put into operation.
Excessive tensions can also be caused if the equipment is overburden by piping, which should be otherwise appropriately
supported.
All regulators, shutoff valves, relief valves, etc., shall be installed taking into account the correct flow sense.
Impulse lines are important components of any control system and it is essential for them to be correctly installed
according to instructions.
Impulse lines should be appropriately supported to reduce excessive vibration, which can provoke fatigue breaks. They
should also be positioned so that they cannot serve as feet or hands supports. Impulse lines should be slightly sloping so
that liquids and condensates drain towards the main piping.
Auxiliary systems should not be changed, or modified, without knowledge of the operation conditions and permission of
the responsible in charge.
1.1.3 – OPERATION
Depending on the regulator type, its valve can be positioned fully open. Consequently, when a regulator is put into
operation, the shutoff valves should be open 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 regulating spring specified by the manufacturer. This provision is particularly
important when operating relief or shutoff valves, since incorrect springs can hinder a relief valve to open and a shutoff
valve to close at the proper time.
Provisions should be taken to avoid water input through breathing and ventilation openings.
1.1.4 – MAINTENANCE
Regulators and valves contain gases at pressures that sometimes are higher than the atmospheric pressure. Before
trying to investigate any problem or to perform service maintenance of the equipment, they should be safely de-
pressurized. Besides, as most gases can be flammable, poisonous, corrosive, or somehow, dangerous, it may be
necessary to purge the installation with an inert gas, as nitrogen. Special precautions are necessary for operation with
oxygen or hydrochloric gas and the user should be reassured that appropriate procedures are implemented.
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 these parts are properly freed-up. Even so, it is advisable
to consider if high-pressure gas can be present at the time of removal of covers and plugs.
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 5 de 45
Most regulators use spiral springs as the loading device. It is important to reduce the load of these springs relieving
their loaders as much as possible. In some cases, some residual load may last, even though the spring is relaxed to the
limits of its housing.
There is not a recommendation about the frequency to change the repair kit due several different variables in the
process that changes installation by installation as, for example, process gas quality, service conditions etc. The repair kit
should be changed when the regulator has problems during operation, as leakage, increase in set pressure and also
others that become the quality and regulator performance different.
However, Gascat recommends that after all regulators opening during maintenance service the repair kit must be
changed. It is also indicated to change a complete repair kit and not only specific part (example o’ring, obturator), to have
the all spare parts with same life time.
Gascat already inform to avoid all non original and genuine parts.
2 – INTRODUCTION
2.1 – SCOPE OF MANUAL
This Instruction manual has as objective supply information about operation, installation and maintenance about BRISE
PLUS pressure regulator manufactured by GASCAT.
2.2 – DESCRIPTION
Brise Plus pressure regulating valve was designed by Gascat’s Engineering to assist many different applications and
service conditions according to valve configuration. Brise Plus series is a pilot pressure regulating valve and it can be
utilized with all non-corrosive gas group and for corrosive gases when built in special versions.
Due “top entry” characteristics it is not necessary to remove the valve of the pipe for maintenance service or clean up
the regulator. Brise Plus also is recognized by robust construction, high performance, with accuracy of + 2.5% (or better
depending on the configuration - 1%), with high flow capacity.
Brise Plus Series was designed specially for gas distribution in low pressure or any other application where is necessary
an excellent regulation and low lock-up.
2.3 – SPECIFICATIONS
2.3.1 – AVAILABLE CONFIGURATIONS
BRISE PLUS SC: Pilot operated pressure regulator spring to close (fail close).
BRISE PLUS pressure regulators are classified as SC in accordance with standard DIN EN 334 directives, for fail
condition.
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 6 de 45
2.3.2 – AVAILABLE CONNECTIONS
ND FLANGE ASME
B16.5
FLANGE DIN
2633 THREAD
1” 150#RF PN 16 NPT-F
2” 150#RF PN 16 NPT-F
3” 150#RF PN 16 -
2.3.3 – TEMPERATURE LIMITS
Operating temperature: -20°C a 60°C
Ambient temperature: -20°C a 60°C
The temperature limits informed at this manual or in any applicable standard must not be exceeded under any
circumstances, at risk of damage the equipment, safety of installation and safety of people involved in the operation.
2.3.4 – FLOW COEFICIENT
DN KG
1” 496
2” 1600
3” 3000
2.3.5 – VALVE WEIGHT
DN 150# / PN16 / NPT-F
1” 28 Kg
2” 38 Kg
3” 48 Kg
2.3.6 – MAXIMUM WORKING PRESSURE
150# / PN 16 / NPT-F
10 bar
The pressure limit informed at this manual or in any applicable standard must not be exceeded under any
circumstances, at risk of damage the equipment, safety of installation and safety of people involved in the operation.
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 7 de 45
2.3.7 – PRESSURE REGULATOR SPRING RANGE (SET-POINT)
G-50 PILOT (old model)
SPRING COLOR PART NUMBER RANGE
RED 01.50.08 7,5 – 16,5 mbar
BLUE 01.50.09 12,5 – 21,0 mbar
GREEN 01.50.10 15,0 – 35,0 mbar
ORANGE 01.50.11 30,0 – 70,0 mbar
BLACK 01.50.67 55,0 – 140,0 mbar
WHITE 01.50.21 70,0 – 350,0 mbar
GREY 01.50.24 200,0 – 1000,0 mbar
BROWN 01.50.12 700,0 – 2400,0 mbar
G-80 PILOT (old model, with plane diaphragm)
SPRING COLOR PART NUMBER RANGE
YELLOW 01.53.33 20 – 60 mbar
BLUE 01.50.09 45 – 85 mbar
WHITE 01.50.21G 60 – 220 mbar
BLACK 01.50.67 170 – 320 mbar
SILVER 01.50.21P 230 – 400 mbar
GREY 01.50.24 350 – 1100 mbar
BROWN 01.50.12 1050 – 2500 mbar
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 8 de 45
G-80 PILOT
SPRING COLOR PART NUMBER RANGE
YELLOW / GREY 01.50.09P 20 – 50 mbar
BLUE 01.53.35 40 – 130 mbar
WHITE / GREY 01.50.21A 90 – 250 mbar
SILVER 01.50.21P 230– 400 mbar
GREY 01.50.24 350 – 1100 mbar
BROWN 01.50.12 1050 – 2500 mbar
G-31 PILOT
SPRING COLOR PART NUMBER RANGE
GREEN 01.49.65 2,0 – 4,0 bar
2.3.8 – SLAM SHUT VALVE SPRING RANGE (SET-POINT)
SSV – ACTUADOR L
SPRING COLOR PART NUMBER RANGE
GREEN 01.53.46* 25 – 70 mbar
BLACK 01.53.47 50 – 150 mbar
SSV – ACTUATOR H
SPRING COLOR PART NUMBER RANGE
BLACK 01.51.98A 80 – 280 mbar
BLUE 01.53.35 200 – 340 mbar
WHITE 01.53.36 300 – 680 mbar
RED 01.53.37 650 – 1070 mbar
PURPLE 01.53.38 780 – 1200 mbar
ORANGE 01.53.51 1000 – 2100 mbar
GRAY 01.53.38H 2000 – 3600 mbar
*Note: To the ND 3” when to use the green adjusting spring, part number 01.53.46, the grey / orange color closing
spring with part number 01.52.10 must be used. To every others applications, the yellow closing spring, part number
01.50.72 must be used.
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 9 de 45
2.3.9 – ACCURACY AND LOCK UP
Pressure regulator: AC up to 2,5% / SG up to 5%
SSV: AG up to 5
2.3.10 – PRESSURE REGULATOR DIMENSIONS (STANDARD LAYOUT)
DIMENSIONS (mm)
A (RF)
B
C
D
ND 150# / PN16 150# / PN16 150# / PN16 150# / PN16
1” 184 327 538 363
2” 254 463 621 422
3” 298 501 621 422
General Tolerance = ± 2.0
Installation and Operation Manual
Brise Plus - Pressure Regulating Valve MI-23
Elaborado Verificado / Aprovado CSQ Data Revisão Página
JJ
GN JM 10/09/18 06 10 de 45
DIMENSIONS (mm)
A (RF)
B
C
D
ND 150# / PN16 150# / PN16 150# / PN16 150# / PN16
1” 184 327 290 280
2” 254 463 356 340
3” 298 501 356 340
General Tolerance = ±2.0
3 – OPERATING PRINCIPLE
Brise Plus Series works by loading pressure principle by pilot in the upper cover diaphragm of main valve that, through
the pressure differential between loading and inlet, it moves the diaphragm and, consequently, the main stem and
obturador. It increase and/or decrease the valve opening.
The outlet pressure is controlled by a low pressure pilot. An adjustable pre-regulator is usually used to assure a stable
feeding pressure to the low pressure pilot and the accuracy of the system.
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