user guide

UG 100
pressure regulator
mod. IPR

Installation
Start-up
Maintenance

STF KEMIM S.r.l.

strada provinciale 33 Km. 0,6
20080 Vernate (MI)
Tel. (39).02.9052621
Fax.(39).02.9052631
E-mail : stfkemim@samgasgroup.it
www.samgasgroup.it

user guide UG 100

Page 2 of 34
Rev.02 - 01/2006

user guide UG 100

INTRODUCTION
1.1
Object
1.2
Specifications
1.3
Operating principle

page 5

AUXILIARY EQUIPMENT
2.1
Slam shut device (OS)
2.2
Emergency regulator (Monitor)
2.3
Relief valve

page 13

INSTALLATION
3.1
General indications
3.2
Preliminary operations
3.3
Connections

page 18

START-UP
4.1
IPR B Regulator
4.2
IPR X Regulator
4.3
IPR XB Regulator

page 20

ADJUSTMENT
5.1
Regulator and Monitor
5.2
Slam shut device (OS)

page 24

TROUBLESHOOTING

page 26

MAINTENANCE
7.1
Periodic controls
7.2
Periodic maintenance
7.3
Checks
7.4
Tools table
7.5
Spares tables

page 27

Page 3 of 34
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user guide UG 100

STF KEMIM SRL. guarantees its customers updates on the evolution of technical specifications
regarding its products. Nonetheless, the specifications reported hereunder shall be considered
exact only following confirmation by a representative of STF KEMIM SRL.

This document constitutes intellectual property belonging to STF KEMIM SRL. and cannot be
reproduced, even partially, without the written consent of STF KEMIM SRL.

This document is distributed as a NON-CONTROLLED copy.

Registration of revision status

Rev.

Variation

Date

00
01
02

first emission
general review
Review

01.01.2002
28.05.2002
01.01.2006

Page 4 of 34
Rev.02 - 01/2006

user guide UG 100

1

INTRODUCTION

1.1
Object
The object of this User Guide is to provide information regarding the installation, start-up, use and
maintenance of the model IPR pressure regulators.
1.2
Specifications
The IPR series regulators are a line of direct action type pressure regulators, normally used in decompression
installations for civil and industrial uses in canalized networks for natural gas, manufactured gas, LPG or other
non corrosive, preliminarily treated stable gases. For use with different fluids we recommend users consult with
our technical department.

Available sizes

IPR 75
IPR 150
IPR 300
IPR 600

1 x 1
1 x 11/2
DN 32 and DN40
DN 40 and DN 50

Connections

threaded
flanged

Rp
PN 16 and PN25
ANSI 150 RF

Maximum inlet pressure

5 and 19

[bar]

Outlet pressure range

10 4000

[mbar]

Design temperature

- 20 60

[ C ]

Operating temperature

- 20 60

[ C ]

( ISO 7/1 )
( UNI 2240-67 )
( B16.5 )

(higher or lower temperatures on request)

Regulating class (RG)

up to 5

(according to EN 334)

Closing pressure class (SG)

up to 10

(according to EN 334)

The mod. IPR pressure regulators are of the fail to open type, which means that in case of malfunction
due to the breaking of the main diaphragm or as a result of a lack of impulse downstream the regulator
will open up completely.

Top entry design allows for maintenance operations without having to remove the body from the pipes.

Modular design allows for variations in its configuration even when already installed in stream. In addition,
the modules can be easily disassembled for eventual controls and in case of malfunctions can be easily
replaced with spare modules and subsequently repaired in the workshop, without having to shut down the
installation.

Counterbalanced regulation device

Stroke indicator for quick identification of the instrument in operation

1.2.1

Standard materials
Body

Covers :
Diaphragms :
Housings :
Springs :

Page 5 of 34
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- spheroidal cast iron GJS 40-18U LT (EN 1593:98)

- steel ASTM A352 LCB
- aluminium (EN AB 46100)
(only for models 75 and 150)
- steel (UNI EN 10028)
synthetic rubber with cloth reinforcement
stainless steel
stainless steel

user guide UG 100

1.2.2
Choosing a regulator
Based on different types of systems and installation requirements, users can choose from the following versions:

IPR regulator

IPR regulator with slam shut

suffix
B

IPR regulator with monitor and slam shut

suffix
X

IPR regulator with double slam shut

suffix
XB
1.2.3
Sizes
The selection of a pressure regulator is based on the use of the valve coefficient Cg. This coefficient
corresponds numerically to the value of the capacity in scf/h under critical conditions with the regulator
completely open at a pressure of 1 psia and a temperature of 15C.
Capacities with maximum opening at different operating conditions can be extrapolated using the following
equations :
a.

under non critical conditions (when Pe < 2 Pa )

(Pe Pa)
Q = 0,526 * Cg * Pe * sin 93,5 *

Pe

b.

where :

Deg

Q = capacity [Stm3/h]
Pe = absolute pressure upstream [bar]
Pa = absolute press. downstream [bar]

under critical conditions (when Pe 2 Pa )

Q = 0,526 * Cg * Pe
Cg values
IPR mod.
75
150
DN 32
300
DN 40
DN 40
600
DN 50

IPR
160
281
459
574
928
1160

IPR B
160
281
459
574
928
1160

IPR -X

IPR -XB

459
574
928
1160

459
574
928
1160

For a gas with relative density (d) other than 0,61 natural gas or absolute temperature (t) other than 273,
multiply the capacity calculated by the correction factor C, given by the equation :

C=

0,61 273
*
d
t

using the following average values for the most common fluids :

Air
Town gas
Butane
Propane
Ethane
Methane
Carbon dioxide

Page 6 of 34
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d= 1
d= 0,44
d= 2,01
d= 1,53
d= 1,05
d= 0,55
d= 1,52

user guide UG 100

1.2.4

Conversion factors

a.

pressure
to obtain :
multiply by :
psi
inch H2O
mm H2O
inch Hg
mm. Hg
bar
Kg/cm2
KPa

psi

inch
H2O

mm.
H2O

inch
Hg

mm.
Hg

bar

Kg/cm2

KPa

1
0,0361
0,0014
0,4911
0,01934
14,5
14,22
0,1450

27,68
1
0,0394
13,6
0,535
401,5
393,7
4.015

703,1
25,4
1
345,4
13,6
10198,1
10000
101,98

2,036
0,07355
0,00289
1
0,03937
29,53
28,96
0,2953

51,7
1,87
0,07355
25,4
1
750,06
735,58
7,501

0,06895
0,0025
0,00098
0,03386
0,001333
1
0,9807
0,01

0,0703
0,0026
0,0001
0,03453
0,00136
1,02
1
0,0102

6,895
0,2491
0,001
3,386
0,1333
100
98,07
1

where :
psi
inch H2O
mm. H2O
inch Hg
mm. Hg
bar = 105 Pa
Kg/cm2
KPa

b.

: Pounds per square inch

: Inches of water column
: Millimetres of water column
: Inches of mercury column
: Millimetres of mercury column
: Kilograms per square centimetre
= 1000 millibars [mbar]
: Kilograms per square centimetre (atm)
: Kilopascal
= 1000 Pa (N/m2)

capacity
scf/h
1
35,71
0,0417
1,4879
41667

Scf/h
Scm/h
Scf/d
Scm/d
MMCFD

Scm/h
0,028
1
0,0012
0,0417
1167

Scf/d
24
857,04
1
35,71
1 *106

Scm/d
0,672
24
0,028
1
28003

MMCFD
2,4 * 10-5
8,57 * 10-4
1 *10-6
3,57 *10-6
1

where :
Scf/h : Standard cubic feet per hour (60F; 14,7 psi)
Scm/h : Standard cubic meters per hour (15C; 1,01325 bar)
Scf/d : Standard cubic feet per day
Scm/h : Standard cubic meters per day
MMCFD : Millions of standard cubic feet per day
c.

various

1 kWh
1 J (=1Nm)
1 Kcal

: Kilowatt hour
: Joule
: Kilocalorie

1Btu

: British thermal unit

Kilocalorie
Millions BTU

Kcal
MMBtu

= 3,6 *106
= 277,8 *10-9
= 1,163 *10-3
= 4186,8
= 293,1 *10-6
= 1055,16

J
kWh
kWh
J
kWh
J

= 0,11*10-3 cubic meters gas (*)

= 27,69 cubic meters gas (*)
(*) assuming a calorific value of 9100 Kcal/m3

Page 7 of 34
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user guide UG 100

1.2.5

Available versions
bpe
[ bar ]

Type

Head diameter
[ mm ]

outlet pressure
range
[ mbar ]

version

189
189
189 TR
189 TR

12 150
150 500
500 4000
500 4000

BP
MP
AP
APS

189
189
189 TR
189 TR

12 150
150 500
500 4000
500 4000

BP
MP
AP
APA

310
310
232
232

12 150
150 500
500 4000
500 4000

BP
MP
AP
APA

310
310
232
232

12 150
150 500
500 4000
500 4000

BP
MP
AP
APA

0,5 5

IPR 75

2 19

0,5 5

IPR 150

2 19

0,5 5

IPR 300

2 19

0,5 5

IPR 600

2 19

1.2.6

Marking

The mod. IPR regulators are pressure devices used in pressurized systems which in some cases can be classified
under marking parameters for regulation 97/23/CE dated May 29, 1997 ( PED ).
Instruments are identified with nameplates listing both manufacturing data and operating parameters.
For models IPR 75 and IPR 150, considered as pressure accessories, since these models present specifications
inferior to the limits stipulated by article 3 at points 1.1,1.2 and 1.3, they fall under the description established by
art. 3 par. 3 and therefore do not require a CE marking as stipulated at art. 15.
A typical example of a nameplate is shown below.
where:

20080 VERNATE (MILANO)

Strada Provinciale 33 Km. 06
DESCRIZIONE

U.M.

CORPO

COPERCHI

Pressione di progetto / esercizio

Ps max
Temperatura di progetto / esercizio Ts min Ts max
Pressione di prova idraulica
PT
Capacit geometrica
Capacit geometrica totale

bar
C
bar

XX

XX

Peso totale a vuoto

Peso totale pieno d'acqua
Diametro nominale della tubazione
Utilizzo previsto
NORME DI PROGETTO

Page 8 of 34
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litri
litri
Kg.
Kg.

XX

XX

XX
XX

XX
XX
XX
XX

XX
DN
XX
Regolatore di pressione
DIN 3840

ISPESL V.S.R.

Pressione di progetto/esercizio
= design/working pressure
Temperatura di progetto/esercizio
= design/working temperature
Pressione di prova idraulica
= Idraulic test pressure
Capacita' geometrica totale
= Total geometric volume
Capacita' geometrica
= Geometric volume
Peso totale a vuoto
= Total tare weight
Peso totale pieno d'acqua
= Total weight full of water
Diametro nominale tubazione
= Nominal diameter of piping
Utilizzo previsto Regolatore di pressione
= Normal use Pressure regulator
Norme di progetto
= Design Norms

user guide UG 100

00062
Regolatore tipo XXXXXXXXXX

Wa

XXXXXXXXXX

bar

DN

XX

Wh

XXXXXXXXXX

bar

Pzul

XX

bpe

XXXXXXXXXX

bar

Pe max
Fluido

PN
bar
XX bar

XXXXX

XX
Cg

XXXX

Matr. XXXXXXX

RG XXX

Anno XXXX

Pa

Dispositivo di blocco

SG XXX
XXXXX

Pso XXX mbar

XXX

mbar

Psu XXX mbar

Who

XXXX

bar

Wao

XXXX

bar

Whu

XXXX

bar

Wau

XXXX

bar

where :

P zul [bar]
maximum pressure sustained by the body under
safety conditions
CG
valve coefficient
Pe max [bar]
maximum operating pressure at which each
component on the instrument can operate with
continuity
Wa [bar]
the instruments calibration field, obtainable
through subsequent calibration, without replacing
any internal parts (e.g. springs, diaphragms, etc.)
Wh [bar]
the instruments calibration field, obtainable
through subsequent calibration, by replacing some
internal parts (e.g. springs, diaphragms, etc.)
bpe [bar]
variability field of input pressure under normal
operating conditions within which precision class is
ensured
RG
precision class. Expresses the field of maximum
oscillation, expressed in percentage, with respect
to the calibration pressure for the capacity field
SG
pressure class in closure. Expresses the maximum
overpressure, expressed in percentage, with
respect to the calibration pressure at the moment
of closing

Page 9 of 34
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Pas [mbar]
calibration pressure
Pso [mbar]
calibration pressure for the maximum pressure
device
Psu [mbar]
calibration pressure for the minimum pressure
device
Wao [bar]
calibration field for the slam shut device for the
maximum pressure obtainable through subsequent
calibration, without replacing any parts (e.g.
springs, diaphragms, etc.)
Wau [bar]
calibration field for the slam shut device for the
minimum pressure obtainable through subsequent
calibration, without replacing any parts (e.g.
springs, diaphragms, etc.)
Who [bar]
calibration field for the slam shut device for the
maximum pressure obtainable through subsequent
calibration, replacing some internal parts (e.g.
springs, diaphragms, etc.)
Whu [bar]
calibration field for the slam shut device for the
minimum pressure obtainable through subsequent
calibration, replacing some internal parts (e.g.
springs, diaphragms, etc.)

user guide UG 100

1.2.7

Weights and dimensions

H
1 x 1

1 x
11/2

DN 32

E
DN 40

DN 50

[ mm. ]
-B 75

100

-B 150

130

220 385

90

135

220 385

90

235

175

-B 300

183

223

400 450 151 240

-X 300

183

223

400 450 151 400 130 175

-XB300

183

223

400 450 151 240 130 175

-B 600

223

254

400 460 165 250

-X 600

223

254

400 460 165 410 170 175

-XB600

223

254

400 460 165 250 170 175

Page 10 of 34
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175

weight

version
189
BP
189
BP
310
BP
310
BP
310
BP
310
BP
310
BP
310
BP

[ mm. ]
189
MP
189
MP
310
MP
310
MP
310
MP
310
MP
310
MP
310
MP

[Kg.]
189 TR
AP APS
189 TR
AP APA
232
AP APA
232
AP - APA
232
AP APA
232
AP APA
232
AP APA
232
AP APA

4,5
4,5
25
36
28
32
44
34

user guide UG 100

1.3
Operating principle (fig. 1)
The operating principle for the IPR regulators is the same as for all models, with the exception of certain
marginal differences, exemplified below.
The mod. IPR pressure regulator is a direct action type instrument with pressure control downstream through
external impulse (A).
The downstream pressure is controlled by comparing the spring load (B) and the thrust deriving from the
downstream pressure on the diaphragm (C). The diaphragms movement is transmitted by the lever system (D)
to the rod (E) and stopper (F). The rubber pad (G) is vulcanized on the stopper and assures hermetic closing
when the required capacity is nil.
If during operation the thrust deriving from the downstream pressure is less than the spring load (B), the
diaphragm (C) lowers itself, and draws the stopper (F) away from the valve housing (H), until the downstream
pressure once again attains the preset calibration value.

Fig. 1
Page 11 of 34
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user guide UG 100

The regulator has two incorporated antipumping devices (L) which operate to reduce the inflow/outflow of
gas to the head during transitory phases, in order to exclude pumping phenomenon.
These models are also equipped with a shock absorber (fig. 2), in order to protect the stopper from damage
due to abrupt increases in the regulated pressure.
This solution, in fact, allows the diaphragm (C) to come up against the upper limit stroke (P) thus relieving the
stopper (F) and rod (E) from the sudden increased pressure load.
In fact, when the stopper comes up against the valve housing, and the regulated pressure exceeds the
normal overload value, the mobile equipment (rods, levers and stoppers) stops, while the plate and
diaphragm, compressing the spring (M), shift over to the upper limit stroke (P).

Fig. 2
1.3.1
IPR 75 e 150
The regulator has just one incorporated antipumping device, on the atmosphere side, which operate to
reduce the inflow/outflow of gas to the head during transitory phases, in order to exclude pumping
phenomenon.
These models are equipped with an incorporated relief device (fig. 3a) which function is to intervene following
short-term events, seeing to discharging externally a certain quantity of gas when the grid pressure exceeds
the calibration pressure, thus avoiding or postponing the intervention of the slam shut devices.
If the regulator is in the closed position the overpressure lifts the plate (P) overcoming the load of the springs
(M) and (B). Through the housing (S) the gas seeps through and is discharged in atmosphere (Q).
The relief device can be transformed into a shock absorber, by changing the position of the O-Ring (T),
inserting it into the duct as shown in fig. 3b, or deactivated, replacing the spring (M) with a spacer. During the
transformation, we recommend to check the integrity of the sealing ring and lubricating it before assembly.

Fig. 3a
Page 12 of 34
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Fig. 3b

user guide UG 100

2

AUXILIARY EQUIPMENT

2.1
Slam shut device (OS)
It is essentially comprised of sensitive organ and stopper set, mechanically separate and independent in its
operation from the main regulator, which acts directly at the valve housing, intercepting the gas upstream
from the regulator.
It is based on a rod hooking system, which is linked to the movement of the stopper.
This system comprises spheres, which, if positioned as shown in fig. 4 maintains the stopper in the opening
position. When the stopper set releases, the systems position is expressed in fig. 4a and 4b as an intervention of
maximum pressure or minimum pressure respectively.
The object of the slam shut device is to preserve the equipment and the section downstream from the
regulator from pressure irregularities, caused by the grid or the equipments non-perfect operation.
Available in versions :

BP
MP
AP TR

- Low pressure
- Medium pressure
- High pressure with reduced head

Main characteristics for this equipment are:

precision class: AG 5 on the calibration value,

exclusively manual rearming,

intervention for maximum and/or minimum pressure downstream,

possibility of calibration within the range foreseen,

possibility of application even on previously installed equipment,

incorporated by-pass for easier rearming,

quick operations time.

Fig. 4a

Fig. 4b

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user guide UG 100

2.1.1
Operating principle (fig. 4)
The operating principle for the slam shut devices, in the different models produced, is based on the same
principles.
The following diagram is referring to model OS3, version BP.
The diagram in fig. 4 shows the device armed.
The downstream pressure keeps the group (A) armed, up against the spring support (B) and surface (P).
The spring support (B) is in turn held up against the tang (C) on the spring (D). This results in a balanced position
such that the tooth (E) maintains the spheres (F) inside the groove on the rod (G).
If the pressure increases beyond the calibration value underneath the diaphragm (H), the diaphragm group
tends to lift upwards, overcoming the counterthrust of the spring for overpressure (D), shifting the tooth (E)
upwards until the spheres are no longer held back, as they can expand and free the rod (G), assuming the
locking position (fig. 4a). With the rod free, the spring (L) brings in the closed position the cut-off (M) on to the
valve housing (N).
In case of a decrease in pressure, the diaphragm group tends to fall below the action of the underpressure
spring (Q), downwards, until the tooth (E) no longer holds back the spheres (F), which can expand and thus
free up the rod (G), assuming the locking position (fig. 4b). With the rod free, the spring (L) brings the cut-off
(M) in the closed position, onto the valve housing (N).

Fig. 4
Page 14 of 34
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user guide UG 100

For the IPR X and XB models, a slam shut device is situated laterally, based in any case on the operating
principle described above, intercepting the flow and controlling a cut-off no longer integral with the sensitive
organ, but operating by means of delays. In this case, it is an indirect stoppage (fig. 5).
The operation of the Sensitive Organ is absolutely similar to the preceding one, while the stopper set operates
as follows:
the cut-off is kept in the open position by a pinion-rackrail system, where the pinion (A) is maintained in the
rearming position by the sphere (B), and by the position of the rod (C).
When the rod (C) is freed up through the action of the spring (E) and hits the shaft (D), causing its shifting and
allowing the sphere (B) to release itself from the shaft (F), integral with the pinion, turning through the action of
the internal spring (G), which pushes the cut-off in the closed position on the valve housing.

Fig. 5

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user guide UG 100

2.2
Emergency regulator or Monitor (fig. 6)
This is a direct action type device, incorporated in the main regulator, that comes into effect in place of the
main regulator should the latter, due to a malfunction, allow the downstream pressure to increase until
reaching the monitor set-point pressure, which under normal conditions is completely open.
The mod. IPR X regulators are equipped with stroke indicators, in order to show the instrument in service easily
identifiable.
The following are the main characteristics of this instrument, whose general operations do not differ from the
main regulator, already described at point 1.3 :

reaction in opening ( fail to open ),

ready response,

counterbalanced piston type regulation device

possibility of application even on previously installed instruments.

Fig. 6
2.2.1
IPR 75 and 150
The IPR 75 and 150 instruments can be transformed to obtain operation as a monitor (fig. 7b).
Simply slide out the internal impulse connection (A) and use a grub screw (B) to close the hole which enables
contact between the regulator head with the downstream part.

Fig. 7a

Page 16 of 34
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Fig. 7b

user guide UG 100

2.3
Relief valve
The relief valve is a device which function is to maintain the pressure in the system or in pressure vessels within
the limit set for the intervention.
These models are equipped with an incorporated relief valve, which function is to intervene following shortterm events, seeing to discharging externally a certain quantity of gas when the grid pressure exceeds the
calibration pressure, thus avoiding or potponing the intervention of the slam shut devices.
2.3.1
Operating principle (fig. 8)
The operating principle of the relief valves, in the different models produced, is based on the same principles.
The following diagram is referring to model VSP301, version BP.
Operation is based on a contrast of forces between the thrust exercised by the gas pressure on the
diaphragm (A) and the contraposition deriving from the calibration spring (B) load. When the pressure below
the diaphragm overcomes the contraposition of the spring load, the cut-off (C) rises from its housing (D),
opening up the valve outlet. The amount of overpressure determines the quantity of gas discharged. When
the overpressure fails, the cut-off returns to its closed position on its housing.

Fig. 8
2.3.2
Installation solutions
Based on the type of installation and operating requirements, the relief valve can be installed according to
the diagrams below.

A = Bleed cock
B = Relief valve
Page 17 of 34
Rev.02 - 01/2006

C = pressure take-off
D = downstream valve

A = Bleed cock
B = Relief valva

C = downstream valve

user guide UG 100

Regulation installations must respect legal directives and norms in force in the country of
installation, with particular attention to the health and safety of persons, domestic animals, and
property.
Pay special attention to norms and restrictions in matters of positioning for installations, with
respect to distance from roads with intense traffic and the geology of the territory, adopting
necessary precautions, or contact our technical department for specific installation solutions.
Furthermore, we recommend to contact our technical department in case of installation in a location
with special characteristics (chemical installations, refineries, or in extreme climactic and
environmental conditions) in order to verify the instruments suitability.

INSTALLATION

3.1
General indications
The following is a list of general aspects which must be taken into consideration in using the instruments in gas
regulation systems:

install, upstream from the regulator, a suitable filter, capable of avoiding damage due to impurities

install instruments and regulation systems in protected environments such as containment kiosks or cement
housings

transport the instruments to the installation site in their original packing and make certain lifting
mechanisms are available which are suited to the weight of the instrument, proceeding with handling
operations using the lifting supports situated on the head

carry out a visual check of the instrument, to make certain there has been no damage to the packing,
such as dents to the heads, cracks on the body, and scratches in the flange sealing areas

verify that the type of installation allows for a connection of the instrument impulse sockets, in accordance
with norms in force

verify that the part of pipes downstream from the instrument up to the impulse sockets presents no stop
valves or other flow disruptors

verify that the tightening of bolts and tie-rods is uniform, in order to avoid tensions, and that, for the
flanged connections, gaskets are applied that are suitable for the type of fluid employed

verify that in case of use with On/Off installations, there must be an adequate volume of gas between the
instrument and the burner, so as to partly absorb pressure swings caused by rapid capacity variations

verify that the speed, downstream the regulator, in the area of the impulse sockets, does not exceed the
values specified below :
V max
V max
V max

= 30 [m/s]
= 25 [m/s]
= 15 [m/s]

for
for
for

Pa < 5
0,5 < Pa < 5
Pa < 0,5

[bar]
[bar]
[bar]

using the formula :

345,92 * Q * (1 0,002 * p)
V=
(1+ p) * D2

where:
V = velocy [m/s]
Q = capacity [ Stm3 /h]
p = relative pressure [bar]
D = internal diameter of pipiline [mm]

3.2
Preliminary operations
Before installing the regulator, check for the following:

the regulator can be inserted in the space foreseen, and is sufficiently reachable for maintenance
operations,

the pipes upstream and downstream are aligned, correctly centred and capable of sustaining the
regulators weight without transmitting flex-torsion stress to the regulator body,

the connection flanges are parallel and clean,

the pipes upstream has been cleaned of any impurities (welding residue and slag), and flushed out of any
residues of paint, water, etc.,
When the installation requirements demand it, the regulator can also be installed upside down. Pay attention
to the fact that for this usage, the spring and calibration range for the device are different from standard
settings. Please remember to specify the type of installation when ordering.
Page 18 of 34
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user guide UG 100

3.3

Connections
be sure the regulator has been assembled so that the direction of gas flow corresponds to the direction of
the arrow on the body of the instrument
connect the regulator to the impulse sockets as indicated in fig. 14,15 and 16, based on the type of
installation used.

Typical installation diagram in horizontal position

Fig. 10
Typical installation diagram in vertical position

Fig. 11

Page 19 of 34
Rev.02 - 01/2006

user guide UG 100

should it be necessary to use several pressure sockets, we recommend the use of multiple pressure sockets
as shown below.

1/4" GAS

1/2" GAS
1/2" GAS CONICO

1/4" GAS
1/4" GAS

16

1/4" GAS

1/2" GAS CONICO

1/2" GAS

16

1/4" GAS

1/2" GAS

1/4" GAS

1/2" GAS
1/4" GAS

1/2" GAS
1/4" GAS

1/2" GAS

1/4" GAS

16
1/2" GAS CONICO

Fig. 12

START-UP

Having preceded with installation, make sure the input and output stop valves, eventual by-pass and blow
cap are closed.
Before start-up, we recommend checking that the instrument specifications conform to operating conditions.
Check the instrument nameplate identification data.
Before proceeding with the instrument start-up, we also recommend verifying that the system is sealed
towards the outside.
Proceed by spreading soapy water or some other foamy product over those areas which can allow the
passage of gas between the inside and outside of the instrument (contact area of covers, screw housings,
surface areas, etc.). If a leak is present, swelling and/or bubbles will be noted.
The instruments are generally supplied already calibrated at our manufacturing plant, based on customer
order specifications.
In any case, we recommend verifying that the calibration values requested for the regulator and its
accessories correspond to the data on the identification nameplate.
For installations comprising 2 or more streams, proceed with the start-up of one stream at a time, beginning
with the one considered as an emergency stream, using the instructions outlined at points 4.1 4.2 4.3
based on the type of installation.
We recommend activating the stop valves very slowly. Manoeuvres too quick, with a consequent waterhammering could damage the instrument.
In order to avoid damage to the gauges, also due to so-called water-hammering, we recommend keeping
the gauge holders closed during the valve opening phase. The gauge holder opening manoeuvre should also
be performed slowly.

Page 20 of 34
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user guide UG 100

4.1

IPR B Regulator (fig. 14)

Proceed with the start-up as follows:

slightly open the stop valve downstream (V) so as to allow the passage of a minimum quantity
of flow
open the stop valve upstream very slowly (M)
remove the cap (A), screw it on to the rod as shown in fig. 2 and pull slowly
keep the rod pulled taut for a few seconds and wait for the pressure downstream to be
stabilized,
unscrew the cap on the rod and screw it back on in its original position
complete the opening of the stop valve downstream very slowly

Fig. 14

Page 21 of 34
Rev.02 - 01/2006

user guide UG 100

4.2
IPR X Regulator (fig. 15)
Proceed with the start-up as follows:
slightly open the stop valve downstream (V) so as to allow the passage of a minimum quantity
of flow
open the stop valve upstream very slowly (M)
remove the cap (A), screw it on to the rod as shown in fig. 2 and pull slowly
keep the rod pulled taut for a few seconds and wait for the pressure downstream to be
stabilized, then slowly turn the shaft (B) counter-clockwise until the connection of the spheres is
perceived, then release
verify, by means of the stroke indicator (C), that the main regulator is in operation,
unscrew the cap on the rod and screw it back on in its original position
complete the opening of the stop valve downstream very slowly

Fig. 15

Page 22 of 34
Rev.02 - 01/2006

user guide UG 100

4.3
IPR XB Regulator (fig. 16)
Generally, in this configuration, the slam shut device (X) is equipped with a safety for maximum and
minimum pressure, while the device (Y) is fitted with a maximum pressure safety.
Proceed with the start-up as follows:
slightly open the stop valve downstream (V) so as to allow the passage of a minimum quantity
of flow
open the stop valve upstream very slowly (M)
remove the caps (A e A1), and screw them on to the rods as shown in fig. 2
pull the rod (A), keeping it taut for a few seconds, then release
pull the rod (A1), and while keeping it taut, slowly turn the shaft (B) counter-clockwise until the
connection of the spheres is perceived, wait for the pressure downstream to stabilize, then
release
unscrew the caps on the rods and screw them back on in their original position
complete the opening of the stop valve downstream very slowly

Fig. 16

Page 23 of 34
Rev.02 - 01/2006

user guide UG 100

5

CALIBRATION

The regulators are generally supplied already calibrated at our manufacturing plant, based on customer order
specifications.
Should a subsequent modification of the calibration value prove necessary, keep in mind that it cannot be
carried out only within the regulation range of the spring installed.
In case of an appreciable variation in the regulated pressure, we recommend varying the intervention
pressure of the slam shut devices
5.1
Main regulator and monitor (fig. 17)
Proceed always first with the calibration of the monitor, since it is calibrated at a greater pressure than the
regulator.
Using the diagram in the figure, proceed as follows :

the calibration must be carried out with the instrument in distribution.

position a gauge (P) downstream from the instrument to check the regulated pressure,

slowly open the drain gauge (W) and the stop valve upstream (M),

turn the ring nut (B) for an approximate regulation, and the register screw (A) for a fine-tuned regulation,
clockwise to increase the pressure and counter-clockwise to reduce it,

To obtain large variations in regulated pressure with respect to the original pressure, it may be necessary to
replace the spring (C), selecting a spring, the most suitable from the table of springs.
In this case:

turn the register screw (A) counter-clockwise until complete deviation,

unscrew the ring nut (B) and spring pressing device (D),

replace the spring (C),

position the spring pressing device and screw the ring nut (B) back on until about 2/3 of the threading,

proceed with the precision regulation using the screw (A)

Fig. 17

Page 24 of 34
Rev.02 - 01/2006

user guide UG 100

5.2
Slam shut device OS (fig. 18)
Using the diagram in the figure, proceed as follows :
5.2.1
Minimum pressure device

cut off the stream by means of the valves upstream (M) and downstream (V),

discharge the pressure by opening the valve (W). The slam shut device will release (if foreseen),

to vary the intervention pressure of the underpressure slam shut device, remove the cap (E) and adjust the
ring nut (G) by turning it clockwise to increase the pressure and counter-clockwise to reduce it

raise the pressure once more, up to the regulator calibration value, then rearm and repeat the discharge
operation until achieving the requested values.
5.2.2
Maximum pressure device

cut off the stream by means of the valves upstream (M) and downstream (V),

connect to the valve (W) a suitable instrument which allows for the pressure variation,

increase the pressure until the maximum pressure stoppage release value, and check the value,

to vary the intervention pressure of the overpressure slam shut device, remove the cap (E) and adjust the
ring nut (G) by turning it clockwise to increase the pressure and counter-clockwise to reduce it

repeat the operation until achieving the requested values.

disconnect the equipment, close the valve (W) and service the stream.

To obtain large variations in intervention pressure of the slam shut devices with respect to the original pressure,
it may be necessary to replace the overpressure springs (A) and/or underpressure springs (B), selecting a
spring, the most suitable from the table of springs. In this case:

unscrew the cap (E),

unscrew the ring nut (F) and replace the overpressure spring,

unscrew the ring nut (G) and replace the underpressure spring,

screw the cap back on (E),

proceed with the calibration.

Fig. 18

Page 25 of 34
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user guide UG 100

SPRING TABLE - REGULATOR (tab. 1)

IPR 75 e 150
Regulation spring
MIN.
[mbar]

MAX
[mbar]

code

ext.
[mm]

wire
[mm]

lenght.
[mm]

coils

version

14
20
28
46
63
81
110

21
28
46
63
81
130
170

002167
002097
002098
002099
002166
002100
002101

38.3
38.5
38.0
38.0
37.8
38.0
38.0

1.8
2.0
2.5
2.5
2.8
3.0
3.5

150
140
120
140
140
140
130

10
10
12
10
11
10
12

189.BP

160
200
300

230
350
550

002168
002179
002180

39.0
39.0
39.0

4.0
4.5
5.0

120
100
100

11
9,5
10

189.MP

320
500
750
1000
1500

560
800
1000
1550
2000

002179
002180
002181
002182
002183

39.0
39.0
39.5
39.0
38.5

4.5
5
5.5
6.0
6.5

100
100
100
100
100

9,5
10
9
10
10

189.AP TR

MIN.
[mbar]

MAX
[mbar]

code

ext.
[mm]

wire
[mm]

lenght.
[mm]

coils

version

17
18
25
30
49
60

25
34
45
63
118
152

001890
001889
001891
002186
002161

62.0
62.0
62.0
62.0
62.0
62.5

3.7
3.7
4.0
4.5
5.0
5.5

180
180
180
180
180
180

11
12
12
12
10
11

310.BP

38
67
190

270
420
600

002005
002123
... 002114

62.5
63.5
63.0

6.5
7.5
8.0

155
155
150

9,5
10
10

310.MP

170
350
300
1500
2500

960
1300
1600
2800
3950

002123
... 002114
002189
002190
002191

63.5
63.0
63.0
63.0
63.0

7.5
8.0
9.0
10.0
10.0

155
150
150
150
150

10
10
10
9
9

232.AP

IPR 300 e 600

Regulation spring

Page 26 of 34
Rev.02 - 01/2006

user guide UG 100

SPRING TABLE SLAM SHUT (tab. 2)
Overpressure setting spring for type OS 4 e OS 5
MIN.
[mbar]

MAX
[mbar]

code

ext.
[mm]

wire
[mm]

lenght.
[mm]

30
45
80
100
150
180
280
490
1000
2300

60
80
100
150
190
290
500
1400
2500
4000

001090
001680
001439
001681
001514
001515
001516
002176
002177
002178

14.8
14.9
14.7
14.8
14.9
15.0
15.1
15.7
16.7
18.0

1.0
1.1
1.3
1.4
1.5
1.6
1.7
2.0
2.5
3.0

21
21
21
21
21
21
21
21
21
21

version

BP

MP
AP TR

Overpressure setting spring for type OS 2 - OS 3 e OS 6

MIN.
[mbar]

MAX
[mbar]

code

ext.
[mm]

wire
[mm]

lenght.
[mm]

30
37
55
90
200
330
430
500
300
700
880
1120
1430
2050
2500
3000
4500

40
60
100
210
350
450
550
650
650
900
1150
1450
2250
2800
3350
4500
5000

002471
001872
002135
002136
002122
002188
002115
002141
002136
002122
002188
002115
002141
002187
002142
002172
002173

26.2
26.2
25.5
24.7
24.8
25.0
25.0
25.5
24.7
24.8
25.0
26.0
26.2
26.2
26.2
26.2
26.5

2.2
2.2
2.5
2.7
2.8
3.0
3.0
2.5
2.7
2.8
3.0
3.5
3.7
3.7
3.7
3.7
4.0

30
30
31
37
37
37
37
31
37
37
37
31
31.5
31.5
31.5
31.5
31

version

BP

MP

AP TR

Underpressure setting spring for type OS 4 e OS 5

MIN.
[mbar]

MAX
[mbar]

code

ext.
[mm]

wire
[mm]

lenght.
[mm]

8
10
30
55
100
200
300
600
1000

13
20
60
110
250
400
700
1300
2000

001092
001698
001442
002385
002385
002485
002485
002486
002487

7.1
7.3
7.6
7.9
7.9
7.9
7.9
7.9
7.8

0.5
0.6
0.8
1.0
1.0
1.3
1.3
1.5
1.7

18.6
18.6
18.6
20.0
20.0
20.0
20.0
20.0
20.0

version

BP

MP
AP TR

Underpressure setting spring for type OS 2 - OS 3 e OS 6

MIN.
[mbar]

MAX
[mbar]

code

ext.
[mm]

wire
[mm]

lenght.
[mm]

8
20
50
100
230
200
400
600

40
110
150
250
400
500
1200
2500

001873
002442
002474
002475
002476
002474
002475
002476

11.0
11.7
11.5
12.0
11.9
11.5
12.0
11.9

1.0
1.1
1.6
2.0
2.4
1.6
2.0
2.4

26.0
27.0
27.0
27.0
27.0
27.0
27.0
27.0

Page 27 of 34
Rev.02 - 01/2006

version

BP
MP

AP TR

user guide UG 100

Setting for auxiliary equipment (Tab. 3)

Regulator
Set-point

Built-in auxiliary equipment

Relief valve

Pa [ mbar ]

Overpressure
slam shut

Underpressure
slam shut

12 <
Pa
15 <
19 <

Pa

15
(Pa) x 1.5
19

10 mbar
(Pa) + 20 mbar

Pa
24

24 <
Pa
30 <

(Pa) x 1.4
30
(Pa) 10 mbar

Pa
60

60 <
Pa
80 <

Pa

(Pa) + 30 mbar
(Pa) x 1.25

80
(Pa) 20 mbar

110

(Pa) + 40 mbar

110 <

(Pa) 40 mbar

Pa
200
200 <

Pa

(Pa) + 100 mbar

(Pa) 60 mbar

(Pa) + 150 mbar

(Pa) - 100 mbar

(Pa) + 300 mbar

(Pa) 200 mbar

400

400 <

Pa

800

800 <

Pa

1000

1000<

Pa

2500

2500<

Pa

Page 28 of 34
Rev.02 - 01/2006

4000

(Pa) x 1.15

(Pa) + 500 mbar

(Pa) 300 mbar
(Pa) + 1000 mbar

user guide UG 100

Setting for auxiliary equipment (Tab. 4)

Regolator
Set-point

Built-in auxiliary equipment

Pa [ mbar ]

Monitor

12 <
Pa
15 <
19 <

Pa

25 mbar

19

Underpressure
slam shut

10 mbar

(Pa) x 1.8

(Pa) + 20 mbar

Pa
24
Pa

(Pa) + 5 mbar

Pa

(Pa) x 1.4
(Pa) + 30 mbar

60 <
Pa
Pa

(Pa) 10 mbar

(Pa) x 1.55
30
60

80 <

Overpressure
slam shut

15

24 <
30 <

Relief

80
(Pa) + 40 mbar

110

(Pa) 20 mbar

110 <

Pa

(Pa) 40 mbar
200

(Pa) x 1.3

200 <

Pa

(Pa) 60 mbar
400

(Pa) x 1.4

400 <

Pa

(Pa) x 1.15

(Pa) 100 mbar

800

800 <

(Pa) 200 mbar

Pa
1000
1000<

(Pa) x 1.3

Pa
2500
2500<

(Pa) 300 mbar

(Pa) x 1.25

Pa
4000

Page 29 of 34
Rev.02 - 01/2006

(Pa) x 1.16

user guide UG 100

6

TROUBLESHOOTING

At times, certain malfunctions can occur in instruments as a result of normal wear of components or because
of particular operating conditions and the type of gas transported, or at start-up.
The following is a list of possible inconveniences more commonly encountered, and a description of the
possible causes and solutions.
This list, far from replacing a specialised fault analysis, should be used as a first reference in seeking a solution
for inconveniences of average importance.
Please contact our technical department or authorised retailers for further clarifications.

PROBLEM

POSSIBLE CAUSE

SOLUTION

Phenomenon : abnormal operation

Pumping

Rearming of slam shut

impossible
Regulation tolerance
ample between max and min
operation
Imperfect seal
Slow response to
variations in capacity
Capacity nil

Dirt
Wrong position of impulse socket
Inadequate downstream conduct
Antipumping valve
Balancing diaphragm broken
Diaphragm broken
Calibration spring
Pressure
downstream
over
calibration
Diaphragm broken
Fastening system deteriorated
Balancing diaphragm broken
Calibration spring
Diaphragm broken
Wrong position of impulse socket
Dirt
Valve housing damaged
Pad
Antipumping valve
Insufficient volume downstream
Wrong position of impulse socket
Shut-off device in closing position
Upstream valve closed
Gas absence

CLEAN
CHECK
CHECK
REGULATE OR REPLACE INTERNAL PARTS
REPLACE
REPLACE
CHECK
CHECK CALIBRATION
REPLACE
CHECK
REPLACE
CHECK
REPLACE
CHECK
CLEAN
REPLACE
REPLACE
CHECK
CHECK
CHECK
REPLACE
CHECK
CHECK

Phenomenon : pressure over calibration

Imperfect seal

Regulator wide open

Seal ring worn out

Pad worn out
Valve housing dented
Dirt in seal area
Imperfect diaphragm fitting
Balancing diaphragm broken
Diaphragm broken
Impulse socket not connected
Impulse socket broken

REPLACE
REPLACE
REPLACE
CLEAN
CHECK
REPLACE
REPLACE
CHECK
REPLACE

Phenomenon : low pressure downstream / weak capacity

Pressure downstream weak

Insufficient capacity

Page 30 of 34
Rev.02 - 01/2006

Filter upstream clogged

Valve upstream not open
Insufficient instrument set-point
Capacity
request
more
instrument capacity
Filter upstream clogged
Upstream valve not open

CLEAN
CHECK
CHECK

than

CHECK
CLEAN
CHECK

user guide UG 100

7

MAINTENANCE

A correct maintenance program is indispensable for the proper operation of the instruments over time.
Remember that all interventions on the equipment must be performed by technically qualified personnel
possessing the necessary know-how.
We therefore urge users to qualify their maintenance personnel, or avail themselves of our technical
department or authorised area retailers.

WARNING:
Interventions on equipment on behalf of inexpert personnel will exempt STF KEMIM from any
responsibilities whatsoever

Maintenance interventions are closely tied to the quality of the gas transported (impurities, humidity and
corrosive substances), as well as the efficiency of filtration.
As such, we recommend preventive maintenance who frequency, if not established by norms, is dependent
on:

the quality of the gas transported,

the state of cleanliness and preservation of the pipes upstream from the regulator,

the level of reliability requested of the reduction installation

Before beginning disassembly operations on the instruments, be sure that you have available:

a series of wrenches,

a series of recommended spare parts.

WARNING:
The use of non original spare parts will exempt STF KEMIM from any responsibilities whatsoever

We recommend affixing indication signs on parts which may present problems of placement or positioning
during the assembly phase.
7.1
Periodic controls
For the proper efficiency of the regulator and its slam shut devices we recommend proceeding with their
periodic verification.
7.1.1
Tightness test
Close the stop valve downstream from the instrument. An increase will be noted in pressure due to the normal
overload in closing, which will stabilize after a few seconds.
If, on the contrary, a pressure increase is noted downstream, even slowly, it is an obvious sign that the stopper
is not providing a perfect seal. In this case, proceed with maintenance.
7.1.2
Trip test for slam shut device
Using the diagram in fig. 18, proceed as follows:

Cut off the stream by means of the valves upstream and downstream,

Discharge the pressure by opening the valve (W). The slam shut device will release (if foreseen),

Connect suitable equipment to the valve (W) to enable a variation in pressure,

Increase the pressure up to the lock tripping value for maximum pressure, and check the value,

continue to raise the pressure up to the trip of the 2nd slam shut (if present) and check the value,

disconnect the test equipment, close the valve (W) and service the stream.
7.2
Periodic maintenance
In order to prevent damage to the instruments and consequent installation shutdowns, we recommend
carrying out the periodic replacement of components which can deteriorate due to normal mechanical
wear, as indicated by the recommended spare parts kit.
In conjunction, we recommend also verifying the accessory equipment on the decompression stream, such
as, for example, filters, valves, etc.

Page 31 of 34
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user guide UG 100

7.3
Checks
After having proceeded with maintenance operations or having intervened on the equipment, we
recommend preceding the installation safety deployment before the instrument start-up.
Carry out the operations described below:
7.3.1
Controls
Very slowly open the stop valve upstream from the regulator and be sure there are no gas leaks towards the
outside of the instrument.
Proceed with the functional control by repeating the points outlined at point 7.1.1 Tightness test and point
7.1.2 Trip test for slam shut device.
Having verified the proper operation of the equipment, proceed with the calibration of the regulator and its
auxiliary devices, following the points described at point 5 Calibration.
7.3.2
Servicing the line
Service the stream only after having carried out all the controls and proceeded with the calibrations, following
the procedures described at point 4 Start-up, and using the most suitable installation diagram.
7.4
Table of tools
Before proceeding with maintenance operations, make certain of the availability of the proper tools, in order
to ensure the successful outcome of disassembly and assembly operations. Check the table for specific tools
required.

IPR 75 e 150
-B
BP
AP
MP
APA
APS
A
B
C
D
E
F
G
H
I
L
M
N
O
P
Q
R
S
T
U

3
8,17,30

3,4
8,17,30

IPR 300
-B
BP
MP

AP
APA

3,5,6
17

3,5,6
17

IPR 600

-X e -XB
BP
AP
MP
APA

3,5,6

-B

3,5,6,7

BP
MP

AP
APA

3,5,6
17

3,5,6
17

-X e -XB
BP
AP
MP
APA

3,5,6,7
17

3,5,6,7
17

10

L.200

22

8,22

9
CH 006
CH 003
CH 005

9
CH 006
CH 003
CH 005

9
CH 006
CH 004

9
CH 006
CH 004
CH 010

CH 001
CH 009
CH 007

Page 32 of 34
Rev.02 - 01/2006

CH 007

CH 008

CH 008

L.200

13,18,24,26,27,30
45
2 x 100
1,5 x 6,5 x 125
10-25
10-25
9
CH 006
CH 006
CH 006
CH 003
CH 003
CH 004
CH 005
CH 005
CH 010
CH 001
CH 002

L.200

CH 007

CH 008

CH 008

CH 008

9
CH 006
CH 004

L.200

10-25

10-25

CH 006
CH 004

CH 006
CH 004

CH 010

CH 010
CH 002
CH 008

CH 008

Ch.
Ch.
Ch.
Ch.
Ch.
Ch.
Ch.
Ch.
Ch.
Ch.
Ch.
Ch.
Cod.
Cod.
Cod.
Cod.
Cod.
Cod.
Cod.

user guide UG 100

Allen key

Polygonal socket wrench

Exagonal bushing spanner

Socket "T" wrench

reversible pawl wrench

Extension

H
Combined spanner

Philips screwdriver

Adjustable spanner

Flat head screwdriver

Pincer for clamping ring

Tapared nose plier for snap ring

O-Ring extraction special tool

Exagonal 38 bushing spanner 3/4" with

special insert

U
Ramp

Page 33 of 34
Rev.02 - 01/2006

Special exagonal bushing

spanner

Special tool

Special tool for valve housing

Special tool for clamping ring

user guide UG 100

7.5
Spares tables
The list of spare parts and recommended spares are indicated in detail on the product spares table referred to
the product, in detail as follows:

Product

Spare table

Product

Spare table

IPR B 75 .BP
IPR B 75 .MP
IPR B 75 .AP
IPR B 75 .APS

TR 101
TR 102
TR 103
TR 104

IPR X 300.BP
IPR X 300.MP
IPR X 300.AP
IPR X 300.APA

TR 117
TR 118
TR 119
TR 120

IPR B 150.BP
IPR B 150.MP
IPR B 150.AP
IPR B 150.APA

TR 105
TR 106
TR 107
TR 108

IPR X 600.BP
IPR X 600.MP
IPR X 600.AP
IPR X 600.APA

TR 121
TR 122
TR 123
TR 124

IPR B 300.BP
IPR B 300.MP
IPR B 300.AP
IPR B 300.APA

TR 109
TR 110
TR 111
TR 112

IPR XB 300.BP
IPR XB 300.MP
IPR XB 300.AP
IPR XB 300.APA

TR 125
TR 126
TR 127
TR 128

IPR B 600.BP
IPR B 600.MP
IPR B 600.AP
IPR B 600.APA

TR 113
TR 114
TR 115
TR 116

IPR XB 600.BP
IPR XB 600.MP
IPR XB 600.AP
IPR XB 600.APA

TR 129
TR 130
TR 131
TR 132

Page 34 of 34
Rev.02 - 01/2006