TESCOM 50-4X Series - Welcome to Emerson Process
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1. 23 25 Brandon Street Hamilton ML3 6DA South Lanarkshire UK T 44 1698 424 254 F 44 1698 459 299 uk tescom emerson com www tescom com TESCOM ASIA PACIFIC 3 F Building 2 No 1277 Xin Jin Qiao Road Jingiao E P Z Pudong Shanghai 201206 China T 862128929970 F 8621 2892 9001 ap tescom emerson com www tescom com MIDDLE EAST amp AFRICA PO Box 17033 Jebel Ali Free Zone South Zone 2 Dubai UAE T 9714811 8443 F 49714886 5465 mea tescom emerson com www tescom com DOPSM2091X012 TESCOM Corporation 2015 All Rights Reserved TESCOM is a business unit of Emerson Proces s Management Regulator Technologies Inc Trademarks are property of divisions of Emerson Process Management The contents of this publication are presented for information purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees the products or services described herein or tl All sales are governed by our terms and condi express or implied regarding heir use or applicability tions which are available on request We reserve the right to modify or improve the designs or specifications of our products at any time witl hout notice A es EMERSON2. Safety Precautions T 2 10 11 12 13 14 15 16 17 18 Inspect the regulator valve and accessories before each use Never connect regulators valves or accessories to a supply source having a pressure greater than the maximum rated pressure of the regulator valve or accessory Refer to product label model specific for maximum inlet pressures If this rated pressure cannot be found contact your local TESCOM representative for the rated pressure prior to installation and use Verify the designed pressure rating of all equipment e g supply lines fittings connections filters valves gauges etc in your system All must be capable of handling the supply and operating pressure Clearly establish flow direction of the fluid before installation of regulators valves and accessories It is the responsibility of the user to install the equipment in the correct direction Remove pressure from the system before tightening fittings gauges or components Never turn regulator or valve body Instead hold regulator or valve body and turn fitting nut If a regulator or valve leaks or malfunctions take it out of service immediately Do not modify equipment or add attachments not approved by the manufacturer Apply pressure to the system gradually avoiding a sudden surge of fluid or pressure shock to the equipment in the system Regulators are not shut off devices Install a pressure relief device do
3. accordance with CGA 4 1 and ASTM G93 Verification Type 1 Test 1 and Test 2 With periodic verification of cleaning process to MIL STD 1330D A WARNING Make sure that the components and materials used in the fluid handling system are compatible with the fluid and have the proper pressure rating Failure to do so can result in death serious injury and or property damage Inspect the regulator valve and accessories for physical damage and contamination Do not connect the regulator valve or accessory if you detect oil grease or damaged parts If the regulator valve or accessory is damaged contact your local TESCOM representative to have the regulator cleaned or repaired Repair Service If a regulator or valve leaks or malfunctions take it out of service immediately You must have instructions before doing any maintenance Do not make any repairs you do not understand Have qualified personnel make repairs Return any equipment in need of service to your equipment supplier for evaluation and prompt service Equipment is restored to the original factory performance specifications if repairable There are flat fee repair charges for each standard model The original equipment warranty applies after a complete overhaul Section 2 Safety Installation and Operations Precautions 50 4X Series DOPSM2091X01 Section 3 Installation 2 July 2015 A CAUTION Proper Component Selection 1 Consider the total system design when selectin
4. power units for production wellhead control panels WHCP and intervention work over control systems IWOCS where start up requires high flow rates at large differentials and operate at high pressures with precise control Specifications Maximum Inlet Pressure 10 000 amp 15 000 psig 690 amp 1034 bar Maximum Outlet Pressure 5500 15 000 3000 10 000 3000 6000 3000 4000 psig 380 1034 207 690 207 414 207 275 bar Operating Temperature 15 F to 165 F 26 C to 73 C Flow Capacity Cy 0 12 Control Regulator C 1 9 Integrated Bypass Weight Approximately 14 lbs 6 4 kg N Section 3 Installation 50 4X Series July 2015 3 3 3 4 DOPSM2091X012 Installation Diagram Letter call outs are referenced in the Installation and Start Up Procedures section of this manual 50 4X SERIES S US INLET gt OUTLET gt VALVE VALVE VENT LINE B E Uu Installation A WARNING Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion fire and or chemical contamination causing property damage and personal injury or death TESCOM regulators must be installed operated and maintained in accordance with federal state and local codes rules and regulations If the regulator vents gas or a leak develops in the
5. rain snow ice vegetation insects birds etc Do not interconnect vent lines use separate lines if more than one vent is needed Section 2 Safety Installation and Operations Precautions 5 Section 2 Safety Installation and Operations Precautions 50 4X Series July 2015 DOPSM2091X012 2 1 2 2 19 Do not locate regulators valves or accessories controlling flammable fluids near open flames or any other source of ignition 20 Some fluids when burning do not exhibit a visible flame Use extreme caution when inspecting and or servicing systems using flammable fluids to avoid death or serious injury to employees Provide a device to warn employees of these dangerous conditions 21 Many gases can cause suffocation Make certain the area is well ventilated Provide a device to warn employees of lack of Oxygen 22 Never use oil or grease on these regulators valves or accessories Oil and grease are easily ignited and may combine violently with some fluids under pressure 23 Have emergency equipment in the area if toxic or flammable fluids are used 24 Upstream filters are recommended for use with all fluids 25 Donot bleed system by loosening fittings 26 Prevent icing of the equipment by removing excess moisture from the gas 27 Always use proper thread lubricants and sealants on tapered pipe threads Installation Do not open packaging until ready for installation or in a clean environment Product is cleaned in
6. Note Refer to the Installation Diagram for additional information 1 Begin with the manual override external hex under the cap E fully engaged 2 Rotate regulator hand knob B counterclockwise until it stops turning This will change the regulator s setpoint to 0 psi 0 bar which will effectively close the regulator 3 Leave the inlet A and outlet C block and bleed valves surrounding the regulator closed and pressurize the supply side or inlet side of the system 4 Slowly open the inlet block valve A to apply pressure to the inlet of the 50 4X regulator B Verify the regulator s inlet pressure F 6 Verify the regulator s outlet pressure G to determine if there is any leakage If there is any leakage remove regulator for inspection and repair If no leakage occurs move on to Step 7 7 Check the vent line D for any sign of leakage If leakage occurs remove regulator for inspection and repair If no leakage occurs move on to step 8 8 Slowly adjust the regulator hand knob B clockwise to increase the outlet pressure G until the pressure is above the bypass valve setpoint and verify pressure is stable not increasing or decreasing 9 Slowly open the bypass valve by adjusting the manual override hex E counterclockwise CCW until a metal stop occurs 10 Verify outlet pressure C It should not change 11 Fully open outlet valve C to fill downstream volume 12 Verify and record flow rate and pressure o
7. Operations amp Service Manual DOPSM2091X012 July 2015 TESCOM 50 4X Series Safety Installation amp Start Up Procedures Do not attempt to select install use or maintain this product until you have read and fully understood this manual 4 ey TESCONM EMERSON Process Management 50 4X Series Table of Contents DOPSM2091X012 July 2015 Contents Section 1 Symbols aaan cece eee ee eect teen een ene 4 Section 2 Safety Installation and Operations Precautions 4 2 1 Installation sses esee PUR ebb dae ou DIE EP IEEr CURE E gd 6 2 2 RepalESGEVICe sesso ca me ER eei RR ae Rene eee eae ERE 6 Section 3 Installation 0 000 000 00 cece cece eee ees 7 3 1 Introductio su useeorebhpACEUU E oes oo ene eres teed bh Oa eae EN 7 3 2 Specifications 25 notes seseded danas ia bootie oads KR E e RETINA DX 7 3 3 Installation Diagram cise aie Ere her ee ERR ae the Uh n ee danas 8 3 4 INS GAN ATION 59 vteseer erbe LLLOL aa acdsee Sd Pes eed rA M ED 8 Section 4 Start up Procedures oossososooseesueseeses 10 4 1 Manual Override Start up Procedure lisse eese 10 4 2 Non Manual Override Start up Procedure ceeceeee eee eee eeeee eee 11 Table of Contents 3 Section 1 Symbols 50 4X Series July 2015 DOPSM2091X012 Section 1 Symbols Paragraphs highlighted by the CAUTION icon contain information that must be followed to maintain a safe and successful operating envir
8. e cap E a Rotate external hex clockwise until a metal stop occurs hand tight Confirm all pipe fittings are torqued to manufacturer s recommended rating A WARNING Personal injury equipment damage or leakage due to escaping accumulated fluid or bursting of pressure containing parts may result if this regulator is Over pressured Used with incompatible process fluid Installed where service conditions could exceed the limits given in the specifications section and on the appropriate nameplate Where conditions exceed any ratings of adjacent piping or piping connections To avoid such injury or damage provide pressure relieving or pressure limiting devices to prevent service conditions from exceeding those limits Section 4 Start up Procedures 50 4X Series July 2015 DOPSM2091X012 Section 4 Start up Procedures 4 1 Manual Override Start up Procedure The manual override option allows operators to manually turn off the bypass valve in the event that their final control pressure would need to be below the bypass valve setpoint A WARNING To avoid possible personal injury equipment damage or leakage due to escaping fluid make certain the regulator is installed as instructed in the Installation section Pressure gauges must always be used to monitor downstream pressure during Start up Note For airload units follow the same process except instead of adjusting the handknob adjust the pressure on the airloader appropriately
9. g a component for use in a system 2 Theuseris responsible for assuring all safety and warning requirements of the application are met through his her own analysis and testing 3 TESCOM may suggest material for use with specific media upon request Suggestions are based on technical compatibility resources through associations and manufacturers TESCOM does NOT guarantee materials to be compatible with specific media THIS IS THE RESPONSIBILITY OF THE USER 4 Component function adequate ratings proper installation operation and maintenance are the responsibilities of the system user A WARNING Do not modify equipment or add attachments not approved by the manufacturer Failure to do so can result in death serious injury and or property damage ASSEMBLY INSTALLATION DRAWINGS amp BILLS OF MATERIAL drawings and parts lists for your product may be obtained by contacting TESCOM TESCOM will provide these by email fax or mail Your local TESCOM representative can provide additional assistance Be sure to have your complete model number ready Section 3 Installation 3 1 3 2 Section 3 Installation Introduction 50 4X Series pressure reducing regulators are specifically designed for extended life operation in high pressure hydraulic applications The 50 4X Series is designed with an integrated bypass valve which controls large variations in flow rates at pressures up to 15 000 psig 1034 bar Applications include hydraulic
10. g at its maximum setpoint to determine if there is any leakage If there is any leakage remove regulator for inspection and repair If no leakage occurs move on to Step 6 Check the vent line D for any sign of leakage If leakage occurs remove regulator for inspection and repair If no leakage occurs move on to Step 7 Turn the hand knob of the regulator B counterclockwise to decrease outlet pressure to below the desired outlet pressure setting Pressure will be vented off through the vent return line D as the pressure setting is adjusted to a lower setpoint but it must be above the bypass valve setpoint Turn the hand knob clockwise to increase outlet pressure to the desired outlet pressure setting that is above the bypass valve setpoint Verify pressure is stable G not increasing or decreasing Fully open outlet valve C to fill downstream volume Verify and record flow rate and pressure over time Note If the desired pressure is below the bypass setpoint the regulator will need the manual override option Section 4 Start up Procedures 11 Emerson Process Management Regulator Technologies Inc TESCOM AMERICAS 12616 Industrial Blvd Elk River MN 55330 USA T 1800 447 1250 1 763 241 3238 F 1 763 241 3224 na tescom emerson com www tescom com EUROPE An der Trave 23 25 23923 Selmsdorf Germany T 49 0 388 23 31 287 F 49 0 3 88 23 31 140 eu tescom emerson com www tescom europe com Brandon House
11. onment A CAUTION Paragraphs highlighted by the WARNING icon contain information about practices or circumstances that can lead to personal injury or death property damage or economic loss Section 2 Safety Installation and Operations Precautions Do not attempt to select install use or maintain this regulator valve or accessory Us until you have read and fully understand these instructions Be sure this information reaches the operator and stays with the product after installation Do not permit untrained persons to install use or maintain this regulator valve or accessory Improper selection improper installation improper maintenance misuse or abuse of regulators valves or related accessories can cause death serious injury and or property damage Oxygen service requires special expertise and knowledge of system design and material compatibility in order to minimize the potential for death serious injury and or property damage Possible consequences include but are not limited to High velocity fluid gas or liquid discharge e Parts ejected at high speed Contact with fluids that may be hot cold toxic or otherwise injurious Explosion or burning of the fluid e Lines hoses whipping dangerously Damage or destruction to other components or equipment in the system 4 Section 1 Symbols 50 4X Series DOPSM2091X012 Section 2 Safety Installation and Operations Precautions July 2015 A CAUTION
12. system service to the unit may be required Failure to correct trouble could result in a hazardous condition Installation operation and maintenance procedures performed by unqualified personnel may result in improper adjustment and unsafe operation Either condition may result in equipment damage or personal injury Call qualified personnel when installing operating and maintaining the 50 4X Series regulator Section 3 Installation 50 4X Series DOPSM2091X012 Section 3 Installation Section 3 Installation July 2015 A WARNING Personal injury equipment damage or leakage due to escaping fluid may result if needle valves are used to isolate the pressure reducing regulator It is strongly recommended that block valves be used to properly isolate the regulator from system Confirm with gauges that there is zero pressure in the system prior to installation Note Refer to the Installation Diagram for additional information 1 5 Confirm both the inlet A and outlet C block and bleed valves are closed prior to installation Install the regulator with inlet port connected to the supply or inlet piping of the system and connect the outlet port to the downstream piping in the system Connect the vent port of the regulator to the vent line D return line to reservoir Note Skip Step 4 if the regulator does not have the manual override external hex E option Forunits with the manual override external hex remov
13. ver time 13 Adjustthe outlet pressure to the desired pressure setting above the bypass valve setpoint Note If the desired control pressure is below the bypass valve setpoint the manual override must be closed using the external hex under the cap E 14 Pressure will be vented off as the pressure setting is adjusted to a lower setpoint 10 Section 4 Start up Procedures 50 4X Series DOPSM2091X012 Section 4 Start up Procedures July 2015 4 2 Non Manual Override Start up Procedure To avoid possible personal injury equipment damage or leakage due to escaping fluid make certain the regulator is installed as instructed in the Installation section Pressure gauges must always be used to monitor downstream pressure during Start up Note For airload units follow the same process except instead of adjusting the handknob adjust the pressure on the airloader appropriately Note Refer to the Installation Diagram for additional information 1 10 11 Prior to opening the supply or inlet block valve A rotate the hand knob of the regulator B clockwise until it stops turning This will verify the regulator B is set at its maximum setpoint Pressurize the system upstream of the closed inlet block and bleed valve A Slowly open the inlet block valve A to apply pressure up to the inlet of the 50 4X regulator B Verify inlet pressure F Verify the regulator s outlet pressure G is stable and not increasin
14. wnstream of the regulator to protect the process equipment from overpressure conditions Shut off the supply pressure when the regulator is not in use Periodic inspection and scheduled maintenance of your equipment is required for continued safe operation The frequency of servicing is the responsibility of the user based on the application Positive seal tied diaphragm regulators require the downstream pressure vented before turning the hand knob counterclockwise to reduce the outlet pressure Damage may occur to the regulator if this procedure is not followed Never allow problems or lack of maintenance to go unreported Read and follow precautions on compressed gas cylinder labels Itis important that you analyze all aspects of your application and review all available information concerning the product or system Obtain read and understand the Material Safety Data Sheet MSDS for each fluid used in your system Never use materials for regulators valves or accessories that are not compatible with the fluids being used Users must test components for material compatibility with the system operating conditions prior to use in the system Vent fluids to a safe environment and in an area away from employees Be sure that venting and disposal methods are in accordance with Federal State and Local requirements Locate and construct vent lines to prevent condensation or gas accumulation Make sure the vent outlet is not obstructed by
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