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Reflux 819

Pressure
Regulators
Reflux 819

> Pressure regulators

Introduction

Reflux 819 is a boot style pilot-controlled pressure regulator for medium and high pressure applications.
Reflux 819 is normally a failed closed regulator and specifically will close under the following conditions:
- breakage of main diaphragm;
- lack of feeding to the pilot circuit.
These regulators are suitable for use with previously filtered, non-corrosive gases.

Fig.1

Reflux 819
Main Features

The modular design of Reflux 819 pressure regulators allows retrofitting of an emergency monitor PM/819,
slam shut valve and or silencer on the same body.
The Reflux 819 regulator is Truly a “top entry design” which allows ease of maintenance or retrofitting options
in the field. The unique dynamic balancing system insures an outstanding turn down ratio combined with an
extreme accurate outlet pressure control.

Reflux 819 + PM/819 + DB/819 Reflux 819 + SB/82

Designed - Compact Design - Outstanding Turn Down Ratio


- Easy Maintenance - High Accuracy
With Your - Top Entry - Low Operation cost
Needs In Mind - Low Noise - Extreme Flexibility
Main Features

-Design pressure: up to 100 bar (1450 Psi)


-Design temperature: -20 °C to +60 °C (-4 to + 140°F)
>
-Ambient temperature: -20 °C to +60°C (-4 to + 140°F)
-Range of inlet pressure bpe: 0,5 to 85 bar ( 7 to 841 Psi)
-Range of outlet pressure Wh: 0,3 to 74 bar (5 to 1073 Psig) depending on installed pilot
-Minimum working differential pressure: 0,5 bar (7,25 Psig)
-Accuracy class AC: up to 1
-Closing pressure class SG: from 5 to 1 depending on outlet pressure
-Available size DN: 1” -2” -3” -4” -6” -8” -10”
-Flanging: class 150-300-600 RF or RTJ according to ANSI B16.5 and PN16 according to ISO 7005.

Materials

Body Cast steel ASTM A352 LCC for classes 300 and 600
ASTM A216 WCB for classes 150 and PN16
Head covers ASTM A350 LF2 Forged steel
Stem ISI 416 Stainless steel
Plug AISI 416 for DN ≤3” - AISI 420 for DN 4”. Nickel-plated carbon Steel on
the external surface with seal edge in stainless steel for size >4".
Valve seat Steel + vulcanized rubber
Seals Nitrile rubber
Compression fittings According to DIN 2353 in zinc-plated carbon steel

The characteristics listed above are referred to standard products. Special characteristics and materials for specific
applications may be supplied upon request.
Reflux 819

Choosing the pressure regulator

Sizing of regulators is usually made on the basis of Cg valve and KG sizing coefficients (table 1). Flow rates at fully open position and various
operating conditions are related by the following formulae where:

Q = flow rate in Stm3/h


Pu = inlet pressure in bar (abs)
Pd = outlet pressure in bar (abs).

A > When the Cg and KG values of the regulator are known, as well as Pu and Pd, the flow rate can be calculated as follows:

A-1 in sub critical conditions: (Pu<2xPd)


Pu - Pd
Q = KG x Pd x ( Pu - Pd ) Q = 0 . 526 x Cg x Pu x sen K 1 x ( Pu
(
A-2 in critical conditions: (Pu≥2xPd)
KG
Q = x Pu Q = 0 . 526 x Cg x Pu
2
B > Vice versa, when the values of Pu, Pd and Q are known,the Cg or KG values, and hence the regulator size, may be calculated using:

B-1 in sub-critical conditions: (Pu<2xPd)


Q Q
KG = Cg =
Pu - Pd
Pd x ( Pu - Pd ) 0 . 526 x Pu x sen x K1 x( Pu
(
B-2 in critical conditions (Pu≥2xPd)
2xQ Q
KG = Cg =
Pu 0,526 x Cg x Pu

NOTE: The sin val is understood to be DEG.

Table 1: Cg, KG and K1 coefficient

Nominal diameter (mm) 25 50 80 100 150 200 250


Size (inches) 1" 2" 3" 4" 6" 8" 10"
Cg coefficient 575 2220 4937 8000 16607 25933 36525
KG coefficient 605 2335 5194 8416 17471 27282 38425
K1 coefficient 106,78 106,78 106,78 106,78 106,78 106,78 106,78
Reflux 819

> Pressure regulators

The above formulae are applicable to natural gas having a relative density of 0.61 w.r.t. air and a regulator inlet
temperature of 15 °C. For gases having a different relative density S and temperature t in °C, the value of the flow
rate, calculated as above, must be multiplied by a correction factor, as follows:

175 . 8
Fc =
S x ( 273 . 16 + t )

Table 2 lists the correction factors Fc for a Table 2: Correction factors FC


number of gases at 15 °C. Type of gas Relative density Fc Factor
Air 1.0 0.78
Propane 1.53 0.63
Butane 2.0 0.55
Nitrogen 0.97 0.79
Oxygen 1.14 0.73
Carbon dioxide 1.52 0.63

Caution:
in order to get optimal performance, to avoid premature erosion phenomena and to limit noise emissions,
it is recommended to check gas speed at the outlet flange does not exceed 150 m/sec.
The gas speed at the outlet flange may be calculated by means of the following formula:

Q 1 - 0 . 002 x Pd
V = 345 . 92 x x
2 1 + Pd
DN
Where
V = gas speed in m/sec
Q = gas flow rate in Stm3/h
DN = nominal size of regulator in mm
Pd = outlet pressure in bar g.
Pilots System

Pilots

Reflux 819 regulators are equipped with series 200 pilot as listed below:
- 204/. control range Wh: 1.0 to 33 bar; (14,5 to 478 Psig)
- 205/. control range Wh: 30 to 60 bar; (435 to 870 Psig)
- 207/. control range Wh: 41 to 74 bar; (595 to 1073 Psig)
Pilots may be adjusted manually or remotely as shown in table 3:

Table 3: Pilot adjusting instructions

Pilot type .../A Manual setting


Pilot type .../D Electric remote setting control
Pilot type .../CS Setting increased by pneumatic signal remote point

Preregulators

The pilot loop is completed with a device called preregulator, external to the pilot.
The preregulators listed below are available:
- R14/A: self adjusting preregulator that automatically regulates the feeding pressure to the pilot complete
with integral filter at the inlet.
- R34/A: adiustable preregulator complete with integral filter at the inlet.

Accessories on request

For Regulator
- stroke limiter
- flow-limiting devices
- limit switches
- position transmitters
- stainless steel fittings, single or dual sealing
For Pilot
- supplementary filter CF 14
- dehydrating filter CF 14/D
Reflux 819

> Pressure regulators

Incorporated silencer DB/819


Whenever specific noise limits are required, the silencer allows you to considerably reduce the decibel (dBA) noise emissions during
the gas pressure regulators operation as in example (Fig. 2). The diagram in Fig.3 demonstrates the silencers efficiency at specified
working conditions.
The Reflux 819 pressure regulator can be supplied with an incorporated silencer in either the standard version, with incorporated
slam-shut or incorporated monitor regulator.
With the built-in silencer the Cg and KG valve coefficients are 5% lower than the corresponding version without the silencer. Given
the modular arrangement of the regulator, the silencer may be retrofitted to both standard Reflux 819 version as well as those with
incorporated slam-shut or monitor, without any need to piping modification. Pressure reduction and control operate the same
manner as in standard version.

dBa (A)
120

110

100 Not Silenced

90

80 Silenced

70 Reflux 819 Dn4”


Pu =70 bars
Pd = 5 bars
60

50
0 5 10 15 20 25 30 35
Flow rate Stmc3/h x 1000

Fig.2 Fig.3
Reflux 819 + BB/819
Monitor

The monitor regulator is used for over pressure protection either as a single unit or in conjunction with a relief valve.
It is an emergency regulator that comes into operation when the main control regulators downstream operating
pressure increases until reaching the monitor set-point pressure. The Monitor regulator is then available to take over
the pressure control. The Monitor regulator is available in two versions, incorporated in the same regulator body as the
control regulator or installed as a separate regulator.

PM/819 Incorporated

This emergency regulator (monitor) is directly integrated to the body of the main regulator. Both pressure regulators,
therefore, use the same valve body with the following exceptions:
- are governed by two different independent pilots and by separate regulator valve seats.
- the operational characteristics of the PM/819 monitor are the same as for the Reflux 819 regulator
(refer to specific catalogue).
- the Cg and KG coefficients of regulator having an incorporated monitor are 8% lower than those for standard
version. Another great advantage offered by the incorporated monitor regulator is that it can be installed at any time,
even on an already existing Reflux 819, without piping modifications.
This solution consents the construction of reduction lines with compact dimensions.

Reflux 819 + PM/819

Fig.4
Reflux 819

> Pressure regulators

In-line monitor

The monitor is generally installed upstream of the main regulator (fig.5). Although the function of the monitor regulator is different,
the two regulators are virtually identical from the point of view of their mechanical components. The only difference is that monitor is
set at a higher pressure than the main regulator. The Cg and KG coefficients of the regulator plus in-line monitor system are about
20% lower than those of the regulator alone.

Fig.5

M/A Accelerator

When the monitor is required to take over more rapidly in the event of a main regulator failure, an M/A accelerator pilot is installed
on the monitor (Fig.5). Installation of the accelerator is mandatory when monitor is used on safety accessory according to PED
directive. Depending on a downstream pressure signal, this device discharges the gas enclosed in the motorisation chamber of the
monitor regulator, allowing the monitor to take over faster.
The set point of M/A accelerator may is usually set higher than set point of the monitor by 0.3 to 0.5 bar.
In case of monitor override configuration (two stage cut) the accelerator may not be necessary.
Slam shut

This device immediately stops gas flow (SAV) whenever a failure causes downstream pressure to rise reaching the
set point of the slam-shut itself.
The slam-shut device can also be closed manually.

Incorporated Slam shut

The Reflux 819 pressure regulator offers the possibility of installing an incorporated slum shut valve SB/82 (fig.6)
or HB/97 valve (fig.7), either from the factory or retrofit in the field.
The Cg and KG coefficients of a regulator plus incorporated slam-shut system are 2,5% lower than those for
standard versions.
The incorporated slam shut can also be retrofitted to Reflux 819 regulators without modifying the pressure
regulator assembly.
The main characteristics of this device are:
- overpressure and underpressure pressure shut off;
- manual push-button control;
- option for pneumatic or electromagnetic remote control;
- manual re-setting with internal by-pass activated by the lever mechanism;
- compact dimensions;
- easy maintenance;
- possibility of installing remote signal devices (contact switches or proximity switches).

Fig.6 Fig.7
Reflux 819

> Pressure regulators

Installation

Whenever Reflux 819 pressure regulator is being installed, it is essential to follow a few basic rules in order to ensure the achievement
equipment’s operational and performance characteristics.
These rules may be summarised as follows:
a) filtering: the gas arriving from the main pipeline must be adequately filtered; it is also advisable to make sure that the pipe upstream of
the regulator is perfectly clean and void of residual impurities;
b) pre-heating: whenever the pressure drop at the regulator is considerable, the gas must be pre-heated enough to avoid the formation of
ice during decompression (for reference natural gas the temperature drop is about 0,4°C to 0,5°C for every bar of pressure reduction);
c) condensate collector: natural gas sometimes contain traces of vapour-state hydrocarbons that can interfere with the functioning of the
pilot. It is therefore necessary to install a condensate collector, complete with drainage system, upstream of the pilot circuit;
d) Outlet pipe size must also be sized correctly so the velocity is not to high. High velocity will result in improper pressure control.
e) impulse take-off: for correct operation, the impulse take-off must be located in the right position. Between the regulator and the
downstream take-off there must be a straight lengh of, pipe ≥ 4 times the diameter of the outlet pipe and downstream the take-off,
there must be a further lengh of pipe ≥ 2 times the same diameter (example below).

Possible installation schemes


REFLUX 819 + PM/819

Inlet pressure
Outlet pressure
Motorization monitor
Pre-regulator feed
Feed pilot
Motorization MO
Feed pilot

Motorization regulator
SBC 782 + REFLUX 819

Fig.9

REFLUX 819 + SB/82 + REFLUX 819

Fig.10

REFLUX 819/MO + SB/82 + REFLUX 819

/MO

Fig.11
Reflux 819

> Pressure regulators

Reflux 819

E
C

G A
F
P

DN DN H
B D

Overal dimensions in mm

Size (mm) 25 50 80 100 150 200 250


Inches 1” 2” 3” 4” 6” 8” 10”
S - Ansi 150/PN 16 184 254 298 352 451 543 673
S - Ansi 300 197 267 317 368 473 568 708
S - Ansi 600 210 286 336 394 508 609 752
A 320 350 430 490 650 750 800
B 100 130 150 190 225 265 340
C 278 278 360 360 510 510 610
D 130 160 200 250 275 320 440
E 310 310 320 320 420 420 470
F 260 290 350 380 410 460 560
G 410 430 530 600 735 850 900
H 420 480 580 680 875 1015 1240
P 170 200 260 290 320 370 500
Tubing Connections ∅e10 x ∅i 8

Weights in Kgf

ANSI 150/PN16 44 61 105 146 308 408 900


ANSI 300 45 62 109 156 345 470 950
ANSI 600 46 64 112 165 360 495 1000
Face to face dimensions S according to IEC 534-3 and EN 334
Reflux 819 + SB/82
+ HB/97 E
C

G A
F
E
P

DN DN H

B B
D
D
* *
S

Overal dimensions in mm

Size (mm) 25 50 80 100 150 200 250


Inches 1” 2” 3” 4” 6” 8” 10”
S - Ansi 150/PN 16 184 254 298 352 451 543 673
S - Ansi 300 197 267 317 368 473 568 708
S - Ansi 600 210 286 336 394 508 609 752
A 320 350 430 490 650 750 800
B 215 240 270 300 518* 375 645* 450 687* 530 796*
C 278 278 360 360 510 510 610
D 280 330 380 440 650* 560 835* 625 900* 730 1060*
E 310 310 320 320 358* 420 410* 420 445* 470 510*
F 260 290 350 380 410 460 560
G 410 430 530 600 735 850 900
H 535 590 700 790 1025 1200 1330
P 170 200 260 290 320 370 500
Tubing Connections ∅e10 x ∅i 8
*indicated Dimensions with the MODEL HB/97

Weights in Kgf

ANSI 150/PN16 53 71 115 160 320 460 950


ANSI 300 55 73 122 171 365 525 1000
ANSI 600 56 75 125 180 380 550 1050
Face to face dimensions S according to IEC 534-3 and EN 334
Reflux 819

> Pressure regulators

Reflux 819 + PM/819


E
C

G A
F
P

DN DN H

P
B
D

C
Overal
r dimensions in mm S

Size (mm) 25 50 80 100 150 200 250


Inches 1” 2” 3” 4” 6” 8” 10”
S - Ansi 150/PN 16 184 254 298 352 451 543 673
S - Ansi 300 197 267 317 368 473 568 708
S - Ansi 600 210 286 336 394 508 609 752
A 320 350 430 490 650 750 800
B 320 350 430 490 650 750 800
C 278 278 360 360 510 510 610
D 410 430 530 600 735 850 900
E 310 310 320 320 420 420 470
F 260 290 350 380 410 460 560
G 410 430 530 600 735 850 900
H 640 700 860 980 1300 1500 1600
P 170 200 260 290 320 370 500
Tubing Connections ∅e10 x ∅i 8

Weights in Kgf

ANSI 150/PN16 84 105 180 245 517 670 1400


ANSI 300 85 106 184 255 554 731 1450
ANSI 600 86 108 187 264 569 756 1500
Face to face dimensions S according to IEC 534-3 and EN 334
Reflux 819 + DB/819

E
C

G A
H F
P

DN DN
B D

S
K

Overal dimensions in mm

Size (mm) 25 50 80 100 150 200 250


Inches 1” 2” 3” 4” 6” 8” 10”
S - Ansi 150/PN 16 184 254 298 352 451 543 673
S - Ansi 300 197 267 317 368 473 568 708
S - Ansi 600 210 286 336 394 508 609 752
A 520 575 700 800 935 1085 1300
B 100 130 150 190 225 265 340
C 278 278 360 360 510 510 610
D 130 160 200 250 275 320 440
E 310 310 320 320 420 420 470
F 425 495 615 670 795 895 1100
G 610 640 785 895 1120 1250 1500
H 620 705 850 990 1160 1350 1640
P 370 400 505 585 690 770 1000
K 220 300 330 390 480 595 695
Tubing Connections ∅e10 x ∅i 8

Weights in Kgf

ANSI 150/PN16 70 126 195 260 565 835 1280


ANSI 300 72 128 204 289 608 925 1380
ANSI 600 73 130 207 298 640 950 1430
Face to face dimensions S according to IEC 534-3 and EN 334
Reflux 819

> Pressure regulators

E
Reflux 819 + DB/819 + SB/82 C
+ HB/97

G
A
F
P
H
E

DN DN

B B
D
D
*

*
S
Overal dimensions in mm K

Size (mm) 25 50 80 100 150 200 250


Inches 1” 2” 3” 4” 6” 8” 10”
S - Ansi 150/PN 16 184 254 298 352 451 543 673
S - Ansi 300 197 267 317 368 473 568 708
S - Ansi 600 210 286 336 394 508 609 752
A 520 575 700 800 935 1085 1300
B 215 240 270 300 518* 375 645* 450 687* 530 796*
C 278 278 360 360 510 510 610
D 280 330 380 440 650* 560 835* 625 900* 730 1060*
E 310 310 320 320 358* 420 410* 420 445* 470 510*
F 425 495 615 670 795 865 1100
G 610 640 785 895 1120 1250 1500
H 735 815 970 1100 1310 1535 1830
P 370 400 505 575 690 770 1000
K 220 300 330 390 480 595 695
Tubing Connections ∅e10 x ∅i 8
*indicated Dimensions with the MODEL HB/97

Weights in Kgf

ANSI 150/PN16 79 136 205 274 274 887 1330


ANSI 300 82 139 217 304 304 980 1430
ANSI 600 83 141 220 313 313 1500 1480
Face to face dimensions S according to IEC 534-3 and EN 334
Reflux 819 + DB/819 + PM/819

E
C

G
A
F
P
H

DN DN

L
D B

C
S K

Overal dimensions in mm

Size (mm) 25 50 80 100 150 200 250


Inches 1” 2” 3” 4” 6” 8” 10”
S - Ansi 150/PN 16 184 254 298 352 451 543 673
S - Ansi 300 197 267 317 368 473 568 708
S - Ansi 600 210 286 336 394 508 609 752
A 520 575 700 800 935 1085 1300
B 320 350 430 490 650 750 800
C 278 278 360 360 510 510 610
D 410 430 530 600 735 850 900
E 310 310 320 320 420 420 470
F 425 495 615 670 795 895 1100
G 610 640 785 895 1120 1250 1500
H 840 925 1130 1290 1585 1835 2100
P 370 400 505 575 690 770 1000
K 220 300 330 390 480 595 695
Tubing Connections ∅e10 x ∅i 8

Weights in Kgf

ANSI 150/PN16 110 170 270 359 774 1097 1780


ANSI 300 112 172 267 388 783 1185 1880
ANSI 600 113 174 270 397 815 1210 1930
Face to face dimensions S according to IEC 534-3 and EN 334
Pietro Fiorentini S.p.A.
via E.Fermi 8/10 via Rosellini 1
I-36057 Arcugnano (VI) I-20124 Milano
Italy Italy

Tel. +39 0444 968.511 Tel. +39 02 696.14.21


Fax. +39 0444 960.468 Fax. +39 02 688.04.57
www.fiorentini.com

CT-s502-E-m July 2007