GIPS - Fail Close Series Shut-Off Valves Installation ... - Gascat

Gascat – Indústria e Comércio Ltda 

GIPS - Fail Close Series Shut-Off Valves 

Installation, Maintenance, and Operation Manual

Gascat Ind Com Ltda 

GIPS Series – Fail Close Shut-Off Valves 

Installation, Maintenance, and Operation Manual 

CONTENTS 

1 – RELEVANT INSTRUCTIONS PRIOR TO COMMISSIONING Page 3 

2 – HEALTH AND SAFETY Page 3 

3 – INTRODUCTION Page 4 

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4 – PRINCIPLE OF OPERATION Page 4 and 5 

5 – CHARACTERISTICS Page 6 

6 – INSTALLATION Page 6 and 7 

7 – OPERATION (START-UP) Page 7 to 19 

8 – STORAGE Page 20 

9 – GENERAL RECOMMENDATIONS Page 20 

10 – MAINTENANCE Page 21 

11 – WARRANTY Page 21 

12 – VALVE DRAWING AND SPARE PART LIST Page 22 to 24 

13 – SET POINT ADJUSTMENT TOOLS Page 25 to 27 

Prepared by Ver. / Approved by Quality Control (CSQ) Date Revision Page 

Gustavo Nieto Vanizio Lizo / C.S. Rubens Ribeiro August August01, 13,2008 

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1 – RELEVANT INSTRUCTIONS PRIOR TO COMMISSIONING 

It shall be clearly understood that the information given in the Commissioning Instructions that follows do not 

intend to revoke or substitute the instructions set by any pertinent entity. References will be made to applicable 

Standards and/or existing recommendations on the subject. 

Before commissioning starts the execution of applicable “Cleaning and Purification Procedures” are implied, 

which are applicable to all instructions on “Pressurization” and the “Standards for Labor Health and Safety”, which 

shall be strictly adhered to. 

Valve suppliers advices, such as: “open slowly”, or “open very slowly”, shall be strictly followed. 

2 – HEALTH AND SAFETY 

Regulators, valves and other pressurized components containing poisonous or flammable gases, or other 

hazardous products, are potentially dangerous if not correctly operated and maintained. It is mandatory that all 

users of such equipment are properly trained and guided on potential dangers, and assurance is necessary that all 

personnel responsible for installation, testing, commissioning, operation, and maintenance of the plant are qualified 

to do their jobs. Instruction manuals are provided to guide operators, but it is supposed that the same already have 

a basic knowledge level. If any doubt remains, or if there is ambiguity on the correct procedures, ask Gascat on the 

correct proceeding. We will be pleased to explain the corresponding instructions or provide the corresponding 

service. TAKE NO RISKS. Our telephone, fax number and e-mail follows: 

Gascat Indústria e Comércio Ltda. 

Rodovia SP 73, 1141 – Indaiatuba, SP, Brazil. 

13347-390 – Brazil 

Phone: 55 19 3936-9300 

Fax: 55 19 3935-6009 

Email: vendas@gascat.com.br 

The comments below, although abridged, provide guidance on possible hazards to health and safety. 

2.1 – NOISE 

Regulators, valves and other pressure reducers can produce high noise levels, which can be harmful to 

person exposed to them for long time periods. Users shall assure themselves that appropriate precautions are 

taken to provide safety to employees’ health and/or third parties, according to applicable standards and 

recommendations in force. 

2.2 – INSTALLATION 

All equipments, piping and vessels are designed to support mechanical stresses, as torque and bending 

moment, in addition to the internal pressure. However, great care shall be exercised during installation not to apply 

excessive strain that could cause cracks that may result in serious break down when the regulator is put into 

operation. Excessive stress can also be caused by unbearable length of piping, which should be appropriately 

supported. 

All regulators, shutoff valves, relief valves, etc., shall be installed with the correct flow direction. 

Impulse lines are important components in any control system and it is essential for them to be correctly 

installed according to instructions. 



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Impulse lines should be appropriately supported to reduce excessive vibration, which can cause fatigue 

breaking. They should also be positioned in such manner that they cannot serve as support to feet or hands. 

Impulse lines shall have a slight slope for liquids and condensates drain towards the main piping. 

Auxiliary systems should not be changed or modified without knowing the operation conditions and after 

permission of the responsible superior. 

2.3 – OPERATION 

Depending on the regulator type, its valve can be positioned as fully open. Consequently, when putting a 

regulator into operation, the shutoff valves shall be opened slowly so that the regulator valve to assume its 

regulating position. If valves are quickly opened, the upstream pressure can pass downstream through the 

regulator and over-pressurize downstream of the main line. 

All regulators, etc., shall operate with the regulating spring specified by the manufacturer. That is particularly 

important in relief or shutoff valves operation, since incorrect springs can hinder a relief valve to open, or a shutoff 

valve to close. 

Precautions should be taken to avoid water from entering through venting and breathing apertures. 

2.4 – MAINTENANCE 

Regulators and valves restrain gases with pressures several times larger than the atmospheric pressure. 

Before trying to investigate any problem or performing maintenance service in the equipment, they should be safely 

depressurized. Furthermore, as most gases can be flammable, poisonous, corrosive, i.e. dangerous, it may be 

necessary to purge the installation with an inert gas, as nitrogen. Special precautions are necessary for operation 

with gases as oxygen or hydrochloric gas and the user shall be sure that appropriate procedures were 

implemented. 

Eventually, it is not enough to isolate high-pressure device, since high pressures can be trapped downstream 

of the insulation valves. Do not try to remove covers, plugs, etc., before the item is properly freed. Even so, it is 

advisable to consider that high-pressure gas can be trapped when removing covers and plugs. 

Most regulators use spiral springs as the loading device. It is important to reduce the load on these springs by 

moving their pressing device backward as much as possible. In some cases, a residual load may be left, even with 

the spring released to the end of its housing. 

3 – INTRODUCTION 

GIPS valves function is to protect gas nets, equipment, and downstream installations, from a pressure 

increase, away from the adjusted set point. Also is a fail close valve, in case the pressure at the sense connection 

(actuator) droops, the GIPS will instantly closes. This set can be adjusted up to 6 bar. This characteristic protects 

the installation from a pressure droop at the line or a damage at the sense connection. 

GIPS valves have instantaneous shut-off, complete tightness, manual reset, low load loss, wide regulation 

range, and easy installation. 

4 – PRINCIPLE OF OPERATION 

The valve mechanism (see detail drawing on page 5, below). Where the porthole lock is not linked to the 

actuator stem, which, in this case, cannot be regulated. This mechanism is independent of the lock and insulated 

from the valve body internal pressure, with its movement being transmitted by the actuator block to the actuator pin 

as a hammer. 



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The security shut-off valves GIPS-FC have an actuator with spheres holder accomplish connected to 

the sensor Setting element the adjustment and this nut oneallows is sensitive precision to the adjustment downstream of the pressure set point and for the reset. following Basic setting cases: is made at the 

a) factory. downstream However, increase in case pressure of maintenance, beyondor thespring set limit, change, it will be necessary to readjust the regulating nut. 

b) in case For initial of diaphragm adjustment, rupture, we suggested the following procedure: 

c) in case of sensing tubings ruptures, 

d) downstream With pressure an assembled bellow the set, setbut limit. without the spring cover, pressing the diaphragm assembly, reset the 

As pervalve. the sense of any above case under the diaphragm/piston the tripping bush moves to the release 

position with the Keeping ball mechanism the diaphragm disengaging assembly the pressed, valve stem turn diaphragm to close thenut control counterclockwise, element. until it becomes 

After normal disarmed. external control pressure has been restored the valve actuator must be manually reset 

and after that, Adjust the valve the must height be of rearmed the regulating to thenut, open turning position diaphragm .To able nut the now reset in the theclockwise upstreamdirection, and downstream by three 

pressures must to be eight equalized turns. by a bypass valve. 

Note: The instruction for adjustment of the regulating nut given above does not apply to the 12” model. 

For valves with Ø3” and 4” there is a retention device used as a limit for the reset lever that during set point 

and repeatability adjustments, may be used to avoid total valve blocking and flow interruption, therefore allowing 

tests performance without suspending gas supply. 



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5 – CHARACTERISTICS 

Self-operated by a spring; 

Manual reset; 

Internal or external bypass (depending on the pressure class and on the valve size); 

Fittings: 1”, 2”, 3”, 4”, 6”, 8” and 12” flanged body for classes 150/300/600# RF or RTJ, according to 

ANSI B.16.5, and 1” NPT – F taped body (BSP or BSPT as option); 

GIPSH – Closes by pressure increase in the range of 0,2 to 16 bar; 

GIPSPH – Closes by pressure increase in the range of 12,2 to 57 bar; 

6 – INSTALLATION 

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6.1 – Filter 

We recommended the installation of a basket type filter of 150 mesh (minimum), as close as possible to the 

inlet of the GIPS blocking valve. A careful filter installation is essential to the perfect operation of the equipment, 

because eventual particles existing in the piping can lodge themselves between the seat and the shutter, damaging 

them and provoking direct flow passage. 

6.2 – Cleaning 

Check pipe cleaning before the regulator installation. We recommended a complete purge of the line with 

nitrogen or compressed air. 

6.3 – Flow direction and recommended installation 

Check the valve flow direction before installation. 

Check in the schematic drawing below, the typical recommended assembly option. 

6.4 – Impulse intake 

Install the GIPS impulse intake downstream of the pressure regulator (Ø 3/8” or ½” tube fitting) at a minimum 

distance of 3 times the nominal pipe diameter, in a piping section free from obstructions, at a pipe diameter position 

where the gas speed does not surpass 20 m/s (considering the minimum output pressure and maximum flow). 

6.5 – Other important devices for a safe installation (see ABNT NBR 12313, DIN EN 12279, DIN EN 

12186) 

A safe installation shall contain, at least (see outline drawing proposed below): 

1. Manual blocking valve (ball type, or similar). 

2. Filter with drain. 

3. Pressure gauge to read the input pressure. 

4. Automatic shut-off valve (GIPS model). 

5. Pressure regulator. 

6. Partial relief valve (Gascat Junior model). 

7. Pressure gauge to read the output pressure. 

8. Purge valve, Ø ½”. 

9. Manual blocking valve (ball type, or similar). 



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7 – OPERATION (START-UP) 



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The GIPS is supplied with the obturator and actuator on the closed position (disarmed). The springs are 

regulated at factory. See Detail drawing 1. 

To set the valve to the armed position or open position (ready to run), connect the sense line on the 

actuator chamber until the pressure reach 1bar above the fail close set point. Pull the stem, M5 thread to 

up until a slight ‘click’ sound. See Detail drawing 2. See picture 1. 

At this position, the top of the stem extremity will be almost parallel to the cover face. See Detail drawing 3. 

Use the handspike supplied with the valve to make the obturator rearm. See Detail drawing 4. 

To make the valve disarm for over pressure, increase the pressure at the sense line until the set point pre 

adjusted at factory, at this moment should occur the obturator disarm, blocking the gas passage. See 

Detail drawing 5. 

To rearm the actuator and the obturator, droop the pressure from 1 to 2 bar bellow the high set point, and 

pull the actuator stem up until a slight ‘click’ sound. Use the lever to rearm turning it ¼ lap. 

Picture 1 and 2. illustrate the adjustment to the armed position. 

Pictures 3 and 4 illustrate the low (fail close) set point adjustment (from 4 to 6 bar) 

Pictures 5 and 6 illustrate the high (over pressure) set point adjustment. 



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IMPORTANT NOTICE: 



Do not try rearm (reset) the obturator, without first rearm the actuator. 

Do not try rearm the actuator if the pressure is bellow 25% from the high pressure set point. 

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For the Ø12" model the reset lever was substituted by a handwheel coupled to a reduction box, in order to 

ease the effort of the reset operation. Before the reset operation, the actuador stem shall be repositioned. 

To do this, with the aid of the upper part of the external cap thread assembled in the threaded end of the 

actuator stem, to pull the assembly until it locks in the upper position. Confirm the stem repositioning by 

forcing the stem down (it should not return to its initial position – the position it had before repositioning). 

It will not be possible to reset the valve if the line is under pressure. In this case, it will be necessary to 

equalize the shutter pressure by opening the bypass valve in its body, which can be of push-button or ball 

type (depending on the valve size and pressure class). 

The valve (GIPS) can be reset if the pressure at the impulse input (control line), is approximately 10% 

below the adjustment pressure or lower. 

Open the gas inlet slowly. 

7.1 – Blocking adjustment and tightness verification 

Press the shut-off valve spring, by approximately 70% of the spring total travel, through the pressing disk, 

which is accessed by the cap located in the upper part of the cover (for low pressure shut-off valves) or by 

the regulating screw in upper part of the cover (for high pressure shut-off valves). 

Reset the shut-off valve (see item 7 procedures) 

With the purge valve closed, adjust the regulator output pressure to trigger at the desired blocking value. 

Slowly release the spring pressing disk of the shut-off valve, until it triggers. This can be noticed by the 

rotation of the reset lever. 

Open the Purge Valve, depressurizing the system downstream of the regulator. 

Close the Purge Valve, await for approximately for 2 minutes, to check tightness of the shut-off valve. 

Under this condition, no pressure increase can occur, and the downstream pressure gauge shall indicate 

zero pressure. 

For GIPS, reduce the regulator adjustment pressure. 

Open the by pass valve, located in the shut-off valve for pressure equalization. 

Reset the shut-off valve with the reset lever. 

Repeat the valve trigger operation, to certify the repeatability of the same and make minor adjustment until 

get ascertained that the valve is operating satisfactorily. 



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Picture 1. 



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Picture 2. 



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Picture 3. 



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Picture 4. 



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Picture 5. 



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Picture 6. 



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8 – STORAGE 

Regulators and valves shall not suffer mechanical shocks, under risk of damaging internal components. 

Regulators and valves shall be stored in a clean and dry place, protected from bad weather. 

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9 – GENERAL RECOMMENDATIONS 

We test all our regulators and valves at the requested operation conditions. 

The criteria and maintenance steps are contained in handbooks, however, in case of any usage, operation 

or maintenance doubt contact Gascat’s technical department that will provide proper guidance. 

Gascat can supply, on request, the complete replacement kit. 

10 – MAINTENANCE 

For the requested supply conditions to be maintained unaffected, the GIPS/GDPS valves should be submitted 

to preventive revisions, whose frequency will be a function of flow, the gas dirt, and the work regime of the 

installation. 

Direct passage (pressure 

increase after the valve 

blocking). 

Defect Probable Cause Solution 

Gas passage through the cover 

vent. 

Gas passage through the 

bypass pressure-equalizing 

valve. 

Gas passage through the seal 

sealing ring. 

Seat O-ring (Item 12) 

Stem obturator O-ring 

(Item 4) 

Gas passage between seat and 

shutter. Obturator (Item 17), 

Seat (Item 16) 

Piston O´rings damage (Items 

5, 7 and 15) 

If the bypass is of the internal push-button type 

substitute the valve o-rings. 

If the bypass is external substitute the bypass ball 

valve. 

Replace the O-ring. 

Clean the seat and shutter. Check for any damage 

signal, or for irregular deformation. 

If confirmed, substitute the damaged part. 

Replace O´ring. (Not necessary remove pressure 

and valve from pipeline) 

11 – WARRANTY 

We warrant our products, for a 12 months period from the date of invoicing, if the products are in operation, 

extending the warrant up to 18 months, in case they are in stock. Such warranty only covers those cases for which 

the occurrence of production defects are evidenced, which remained unnoticed at the time the product delivery. 

To present warranty is not valid if it is found that the defect or mishap was caused by accident, normal wear, 

inadequate installation, improper maneuvering or use, inadequate storage, assembly disregarding technical 

standards or if the buyer undertook repairs or changes in equipment by himself, without the manufacturer's 

previous authorization. 



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The information contained in this manual contains Gascat's supply conditions, independently of the verified 

performance. 

The information herein contained shall not be interpreted or suggest performance warranty in relation to the 

final products, or the system usage purpose, nor should they serve as usage recommendation for any product or 

process mentioned in the specifications. This system should only be operated by qualified technician trained for 

this purpose; and no changes that may affects the system safety can be executed without our previous 

authorization. 

Gascat Ind e Com. Ltda. withholds the right to make changes without notice, introducing improvements in the 

described products drawings or specifications. 



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12 – VALVE DRAWING AND SPARE PART LIST 

GIPS 6” N.D. 

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NOTE: Items of the spare kit 



GIPS 6” N.D. 

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532 



GIPS 6” N.D. – MAIN DIMENSIONS 

505 

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309


13 – SET POINT ADJUSTMENT TOOLS 



REARM TOOL 

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LOW SET POINT ADJUSTMENT TOOL 

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HIGH SET POINT ADJUSTMENT TOOL 

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GIPS - Fail Close Series Shut-Off Valves Installation ... - Gascat

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