EMERSON TARTARINI Types PSA/79 and PSA/80 Pilots Instruction Manual

Types PSA/79 and PSA/80 Pilots
Instruction Manual
D104256X012
September 2021

Introduction

Scope of the Manual

This manual provides installation, startup, maintenance, troubleshooting, and spare parts for the pilot series PSA/79 and PSA/80.

Product Description
Designed for pressure regulators control, the following types are available:

• Type PSA/79 – single diaphragm pilot for pilot-controlled gas pressure regulator (active or wide-open monitor)
• Type PSOA/79 – single diaphragm pilot for the setting of the first pressure-reducing step of pilot-controlled gas pressure regulator (working monitor)
• Type REOA/79 – single diaphragm pilot for the setting of downstream pressure reducing step of pilot controlled gas pressure regulator (working monitor) In case of failures, these pilots with single diaphragm will cause a fail open reaction of the regulator.
• Type PSA/80 – double diaphragm pilot for pilot-controlled gas pressure regulator (active or wide-open monitor)
• Type PSOA/80 – double diaphragm pilot for the setting of the first pressure-reducing step of pilot-controlled gas pressure regulator (working monitor)
• Type REOA/80 – double diaphragm pilot for the setting of a downstream pressure-reducing step of pilot-controlled gas pressure regulator (working monitor)

Characteristics

APPLICATION

| ALLOWABLE PRESSURE PS, bar| SET RANGE Wd, bar| BODY AND COVERS MATERIAL
---|---|---|---
Regulator or Monitor| Working Monitor
Regulator| Monitor
Type PSA/79| Type PSOA/79| Type REOA/79| 100| 0.5-40*| Steel
Type PSA/80| Type PSOA/80| Type REOA/80| 1.5-40
() Types PSA/79-AP and PSA/80-AP versions are available on request with a set range up to 65 bar.

All PSA Series pilots are supplied with a filter (5μ filtering degree) and built-in pressure stabilizer, except for pilots Types PSOA/79 and PSOA/80 .

Labeling Figure 2. Label for Types PSA/79 and PSA/80 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: See “Characteristics”
Dimensions and Weights
Table 2. Dimensions (mm) and weights (kg)

| TYPE PSA/79 FULL RANGE| TYPE PSA/80 FULL RANGE
---|---|---
A| 90| 90
B| 265| 290
Weight| 8| 9

In case of failures, these pilots with double diaphragms will cause a failed close reaction of the regulator .
Tightness cover version available on request (e .g . Types PSA/79-P and PSA/80-P).
The full range of PSA pilots can be installed in the following pressure regulators:
FLA Series – Cronos Series – EZH Series – Type 971 This product has been designed to be used with fuel gases of the first and second 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.

Installation

1. Check that data on the pilot’s plate are compatible with actual working conditions.
2. Install in accordance with a regulator instruction manual.

Startup
See the set-up and pilot adjustment instructions applying to the equipment where the pilot is fitted.
Periodic Checks
Slowly close the outlet slam-shut and check the line pressure between it and the regulator.
A slight increase in pressure should be detected: this results from overload due to closing and is followed by pressure stabilization. If the outlet pressure continues to rise, then the seal is defective. Check if the leak is coming from the regulator or pilot, and service.
SEP Statement
Emerson Process Management Regulator Technologies, Inc . declares this product conforms to the Pressure Equipment Directive . Article 3 section 3 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 and EN 12279, national regulations, if any, and specific 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 and gas pressure regulating/measuring stations installations.
If the 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 mechanically generated sparks:

• Drainage to safe area via drain lines of foreign materials, if any, by inflow of fuel gas with low velocity in the pipe-work (5 m/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.: filling/exhausting of fuel gas of internal volume of the isolated part/entire installation with vent lines to a safe area – 7 .5 .2 of
  EN 12186 and 7.4 of EN 12279; monitoring of settings with the further exhaust of fuel gas to a safe area; connection of isolated part/entire installation to the downstream pipeline)

• A provision in 9.3 of EN 12186 and 12279 shall be enforced by pressure regulating/measuring station/ installation’s end user

• External tightness test shall be carried out after each reassembly at the 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 specific manufacturer recommendations . Asia Pacific Only

Maintenance

CAUTION
Servicing should be carried out by qualified, skilled personnel only. For further information, please contact our
Technical Support Representatives or our authorized dealers. Before servicing, cut off the regulator inlet and outlet and release any trapped pressurized gas. Use suds to check that there are no leaks.
Replacing Filter
1 . Remove the screws (key 41), cover (key 59), and replace felt (key 61). Reassemble by reversing the above sequence.
Replacing Stabilizer Diaphragm and Seal Pad

1. Remove screws (key 41), cover (key 64), spring (key 47), and diaphragm assembly (keys 48, 49, 50, 51, 52 and 53) . Replace the diaphragm if necessary.
2. Unscrew the seat (key 54) and replace the pad holder (key 56).
3. Reassemble by reversing the above sequence, make sure not to “pinch” O-rings (key 55).

Replacing Valve Seal Pads

1.  Remove the plug (key 27) and seat (key 30) . Slide out spring (key 32), pad holder unit (key 34), and forked stem (key 35).
2.  Replace the pad holder (key 34) and O-ring (key 37).
3. Reassemble by reversing the above sequence.

General Maintenance

1. Completely release the spring (key 5) by turning the adjusting screw (key 1) counterclockwise.

2. Remove screws (key 7) and cover (key 4) . Keep the plate (key 9 or 75 for the AP version) blocked with a box wrench, and unscrew the nut (key 6).
   This must be done exactly as described to prevent damage to or breaking of the safety valve (key 20).

3. Unscrew the plate (key 9 or 75 for the AP version) from stem (key 13) and remove parts (keys 10, 11, and 12 or 76, 78, 10, 77, and 12 for the AP version).

4. For Type PSA/80 and Type PSA/80-AP versions:
   Unscrew plate (key 9 or 75 for the AP version) from stem (key 13) remove parts (keys 10, 68, 69, 11 and 12 or 76, 78, 68, 69, 10, 77 and 12 for the
   AP version).

5. Slide off split pin (key 40). Remove the locknut (key 16) with an appropriate wrench and slide out parts (keys 17, 18, 19, and 20). Make sure that the surface of the seat (key 26) which is sealed by the pad (key 21) is in proper condition.

6. Replace diaphragms (key 10) and all seals.

7. Proceed as directed in the replacement of the filter, stabilizer diaphragm, seal pad, and valve seal pads.

Reassembly
Lubricate the static O-rings with a thin layer of heavy-duty lubricating paste, and be very careful not to damage the O-rings when reassembling. No other pilot parts are to be lubricated. Reassemble parts by reversing the above steps. As you proceed, make sure that parts move freely and without friction. In addition:

1. Once lever (key 39) and stem (key 13) have been mounted, check that, with stem (key 13) against the body (key 25), clearance between the forked stem (key 35)  and registered (A) of the lever (key 39) is 0 .2 to 0 .3 mm. If not, use the register to correct it.
   CAUTION
   The above clearance can be checked by gently pulling the stem (key 13) upward. Use the proper tool to make sure that the top plate (key 9) is on the same plane as that supporting the diaphragm (key 10) in the body (key 25).

2. Mount the diaphragm (key 10) and screw on a plate (key 9), first by hand then with a box wrench, (always holding the upper diaphragm (key 10) firmly in place) in order to avoid damage to the stem (key 13) and levers below.

3. Holding the plate (key 9) firmly in place with a box wrench, tighten the nut (key 6).

4. Before remounting the cover (key 4), center the diaphragm as follows:
   • Mark a reference point (with pencil) on the diaphragm; turn it to the right without forcing and mark another reference on body.
   • Now turn the diaphragm to the left and mark a further reference.
   • Position the diaphragm mark midway between the two marks on the body.

5. Tighten all screws uniformly to ensure
   proper sealing.

CAUTION
The pilot has a wide range of self-adjustment values. However, given actual operating conditions, it may necessary to assist it at times by finding the best set of register/pin screws (key 29) or the most suitable calibration jet (key 15).

Troubleshooting

Table 3. Troubleshooting for Types PSA/79 and PSA/80 Pilots

SYMPTOMS| CAUSE|

ACTIONS

---|---|---
Desired set point is not reached| The calibration spring (key 5) is too weak| Check the springs catalog and replace it with a stronger one
Leaks from pilot connections| Check pilot feed connections
and proper gas flow feeding
Outlet pressure drops well below set point| Filter (key 61) is clogged preventing
proper through-flow of gas| Clean or replace it
Pad holder (key 56) is swollen
preventing proper feed flow| To be replaced
Pad holder (key 34) is swollen
preventing proper feed flow| To be replaced
Outlet pressure increases over set point| Faulty sealing of pad holder (key 56)| To be replaced
Faulty sealing of pad holder (key 34)| To be replaced
Slow response to changes in gas demand| The insufficient flow rate of valve seat (key 30)| Increase flow by means of register/pin screw (key 29)
Overly large calibration jet (key 15) (only for Types PSA/79 and PSA/80)| To be replaced with a smaller one
Overly rapid response to changes in gas demand, i.e. Hunting| The excessive flow rate of valve seat (key 30)| Reduce flow by means of a pin screw (key 29)
The calibration jet (key15) is too small (only for Types PSA/79 and PSA/80)| To be replaced with a larger one
Not proper internal parts assembly| Check clearance between lever (key 39) and forked stem (key 35)
Gas continually escaping from relief (S)| Defective seal of pad (key 21)| To be replaced
__ The outlet pressure is not within the usual values| Diaphragms (key 10) are damaged| Replace diaphragms (key 10) that show signs of wear
The upper diaphragm (key 10) is damaged| If gas escapes from the silencer (key 45), replace the upper diaphragm (key 10)

Parts List

Type PSA/79 (See Figure 4)
Key Description

Type PSA/80
Key Description

Types REOA/79 and REOA/80 Only
Key Description
15 Plug
Types PSA/79-AP and PSA/80-AP Only
Key Description

Rubber parts marked with (*) are supplied in the “spare parts kit”, recommended as stock.
To order the kit it is necessary to communicate to us the type of pilot and its serial number.

Schematic Assemblies

CODE

|

CONNECTIONS

---|---
M| Upstream of the regulator
R| To the regulator (loading pressure)
S| Downstream or safe area
V| Downstream of the regulator

Figure 4. Types PSA/79 and PSA/80 Series Detailed Pilots Assemblies Figure 4. Types PSA/79 and PSA/80 Series Detailed Pilots Assemblies (continued)

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Emerson Automation Solutions
Americas
McKinney, Texas 75070 USA
T +1 800 558 5853
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Europe
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T +39 051 419 0611
Asia Pacific
Singapore 128461, Singapore
T +65 6777 8211
Middle East and Africa
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T +971 4 811 8100
D104256X012 © 2019, 2021 Emerson Process Management Regulator Technologies, Inc. All rights reserved. 09/21.
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Tartarini™ is a mark owned by O.M.T. Officina Meccanica Tartarini s.r.l., a business of Emerson Automation Solutions.
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they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without notice. Emerson Process Management Regulator Technologies, Inc does not assume responsibility for the selection, use, or maintenance of any product. Responsibility for proper selection, use, and maintenance of any Emerson Process Management Regulator Technologies, Inc. product remains solely with the purchaser.
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