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UNDERGROUND GAS REGULATION STATION
Honeywell Process Solutions
Honeywell Bryan Donkin Gas Technologies Ltd.
Enterprise Drive, Holmewood
Chesterfield S42 5UZ, England
Tel: +44 (0)1246 501‐501
Fax: +44 (0)1246 501‐500
www.honeywellprocess.com
Operators manual underground gas pressure reducing station
Operators manual
TYPE: HON COCON 13
Twin stream
Active/Slam – Active/Monitor
OPERATORS‐MANUAL
© 2017 Honeywell International Inc.
Type: COCON 13
Edition : January 2016
Page 1
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Summary of Contents for Honeywell HON COCON 13
- Page 1 Honeywell Process Solutions Honeywell Bryan Donkin Gas Technologies Ltd. Enterprise Drive, Holmewood Chesterfield S42 5UZ, England Tel: +44 (0)1246 501‐501 Fax: +44 (0)1246 501‐500 www.honeywellprocess.com Edition : January 2016 © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 1...
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Page 2: Table Of Contents
4.5 – Troubleshooting 26 4.6 – Shutting down 27 © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 2... - Page 3 30 6 ‐ Additional data 31 6.1 ‐ Adjustment form 31 © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 3...
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Page 4: 1 - Introduction
This gas pressure reducing station is the result of years of development. Development is still in process. We will inform you by mailing about developments concerning this type of gas pressure reducing station. Definitions = Inlet pressure = Reduced pressure p = Differential pressure (p ‐p ) CR = Closing rate MR = Monitoring rate Q = Capacity © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 4... - Page 5 Operators manual The standard Cocon 13 is a twin stream gas reducing system which can be configured in several ways. Example 1 Both lines Active regulator with SSV Example 2 One line Active / Monitor regulator and one line Active / SSV Picture of a twin stream Cocon 13 inclusive manifolds and final coating. The in‐and outlet valves are connected by manifolds creating a twin steam configuration. One of the lines normally is the “stand‐by” line and one is operational. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 5...
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Page 6: 2 - General
: name manufacturer, type specification, serial number, maximum operation pressure, year of construction Unit : name manufacturer, type specification, serial number, maximum operation pressure, minimal reduced pressure, year of construction Pilots : name manufacturer, type specification, spring type, serial number, adjustment data, year of construction, maximum allowed inlet pressure © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 6... -
Page 7: What Is Hon Cocon
The gas regulating station HON COCON 13 consists of two parts: ‐ The body. ‐ The gas regulating and safety unit. (Cartridge) Remark: The "gas regulating and safety unit" will be referred to as the cartridge in the rest of the manual. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 7... -
Page 8: Active/Slam Operation
SSD‐controller 04 Body 05 Regulator 06 SSD‐valve 07 Filter element 08 Stem extension 09 Inlet ball valve* 10 Pit cover 11 Outlet valve* * (Isolating valves) © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 8... - Page 9 ‐ The device consists of a ssd valve (06) and a ssd controller (03). The controller sits on top of the cartridge. If the regulator fails in the open position, the relay will detect an increase in line pressure and release the spring‐loaded valve, cutting off the gas supply. It is also fitted with a manual emergency release button. Gas pressure reduction is achieved by a pilot operated, diaphragm regulator (05). The required outlet pressure is set and controlled with the pilot. A valve (11) is attached to the outlet flange. The valve can be operated without removing the cover of the casing. However, as a safety feature, if this valve is open, then it is not possible to remove this Plexiglas cover. The installation of a relief valve is an option. Transducers can be installed in the protection of the enclosed space, for the remote measurement of pressures. Close indication of the slam shut valve by means of a proximity switch is also available. The station is fitted with two pressure gauges which read the inlet and outlet pressures. These gauges are situated under the protection of the Plexiglas cover but are visible when the pit lid cover is opened. Purge valves for depressurization of the unit are mounted on the cartridge. A handle is attached to the cartridge, so the cartridge can be easily removed from the casing. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 9...
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Page 10: Active/Monitor Operation
Operators manual 2.4.2 – Active/Monitor operation Gas flows from inlet to outlet passing inlet valve, filter, monitor, worker, and outlet valve. Fig. 2.4.2 © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 10... -
Page 11: Pressure Pattern
Operators manual 2.4.3 Pressure Pattern The following functional pressures stages can be distinguished: Fig. 2.4.3 Take note that in the piloting additional auxiliary pressure stages can be found. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 11... -
Page 12: Pressure Control
2.4.4 Pressure Control Two operation modes are possible: active and monitor control. Both modes operate identical and can be reversed during testing and operation. During normal operation the upstream control valve monitors the outlet pressure in wide‐open position, while the downstream valve reduces inlet to outlet pressure in throttling position. Control has been based upon cascaded loops (with master and slave) which have been proven reliable and accurate under most operation conditions. The outlet pressure depends upon the dome‐load (motorization) as set and corrected by the pilot. 2.4.5 Active Control Fig. 3.3.1 Low Pressure If the dome load (active motorization) on the active valve (1) exceeds the outlet pressure, the diaphragm (2) will move upward. This increases the stem travel and allows the active to compensate (directly) for low pressure. High Pressure © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 12... -
Page 13: Monitor Control
Operators manual If the outlet pressure exceeds the dome load, the diaphragm (2) will move downward. This results in decrease of stem travel and allows the active to compensate (directly) for high pressure. 2.4.6 Monitor Control Fig. 3.3.2 Low Pressure If the dome load (monitor motorization) on the active valve (1) exceeds the outlet pressure, the piston (2) will move downward. This increases the stem travel and allows the active to compensate (directly) for low pressure. High Pressure If the outlet pressure exceeds the dome load, the piston (2) will move upward. This results in decrease of stem travel and allows the active to compensate (directly) for high pressure. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 13... -
Page 14: Pilot Control
Fig. 3.3.3 Consideration should be given to the bleed or discharge of the monitor controller @ lock‐up, low flow and testing of the active. Upon activation of the monitor pilot the excess of motorization will be discharged to outlet which results in closing of the monitor. Note that after monitor lock‐up (which equals system lock‐up) no bleeds are present. See also the relevant pilot manual © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 14... - Page 15 When the cause of the rise in outlet pressure has been rectified, the slam shut valve can then be reset by pressing a button on the relay. Illustration 2.2 'Flow scheme HON COCON 13 twin stream active/slam – Active/slam’ Objectives The operational objectives of the gas regulating station are: ‐ No gas leakage. ‐ Accurate control of the outlet pressure by means of the pilot controlled regulator. ‐ Clean filtering of the gas medium. ‐ Watertight protection of the control equipment. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 15...
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Page 16: Automatic Operation
Operators manual 2.5 ‐ Automatic operation The HON Cocon is a completely self‐contained gas regulating station, which operates automatically if correctly installed and set. Should a major malfunction occur, then the cartridge automatically shuts off the gas supply. 2.6 ‐ Maintenance Although the cartridge has relatively few moving parts, regular maintenance is advised. This helps to ensure the long and smooth operation of the cartridge. Due to its ingenious design the cartridge can be replaced quickly and easily with a previously set‐up spare cartridge. Cartridge maintenance can be done in the service shop. Lubrication During normal operations, the moving parts of the station needs no additional lubrication. All moving parts are either self‐lubricating or don't need any. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 16... -
Page 17: 3 - Safety
‐ Ensure that you are sufficiently trained to service the cartridge. ‐ Protect ‐ if necessary ‐ your ears, eyes and hands, when carrying out maintenance work. Wear ear protection, safety glasses and working gloves. ‐ Ensure that the station and the direct surroundings are always well illuminated in dark and twilight, during on‐site maintenance. ‐ Ensure that there is sufficient ventilation surrounding the station, when removing the cartridge. Gas condensate and other additives or contaminations may damage your health. ‐ Use spark free tools for all maintenance work to prevent explosions. ‐ Take care of your back during the installation and removal of the cartridge. Bend your knees and keep your back straight in accordance with proper lifting practices. Do not extend yourself or attempt to lift anything that is too heavy for you. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: COCON 13 Page 17... -
Page 18: 4 - Installation & Operation
Illustration 4.1 'Fully installed station' © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 18... -
Page 19: Soil Condition And Foundation
Depth pit = 980 + d Fill in the thickness of the foundation d in millimeters. The number "980" is the distance from the bottom to the top of the casing. The result ‐ the depth of the, to be dug, pit ‐ is in millimeters. Example: For a foundation plate (d ) that is 100 millimeters thick, the pit depth, for a partially exposed in‐ground station is 906 + 100 = 1006 millimeters. For a foundation plate (d ) that is 100 millimeters thick, the pit depth for a station equal to ground level is 980 + 100 = 1080 millimeters. Dig a funnel shaped hole, so that you can easily attach the supply and discharge pipes to the casing. Fasten the piping ‐ tension free ‐ in the clamps, which are attached to the foundations. Delivery of a complete foundation ‐ supplied with a positioning frame for the casing and fastening clamps for the piping ‐ is possible. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 19... -
Page 20: Placement Of The Body
Support the opened pit cover, by wind force eight and up, with a support to prevent closing. When the casing cover and pit cover are closed and the station is in operation, the area in which the regulator pilot, relief valve and shut off relay are located is kept atmospheric. This is done by a connection between the casing and the vent pipe by means of heavy‐duty flexible hoses. The relief has its own separate connection to atmosphere through the vent pipe with a flame arrestor on top of the vent pipe. ‐ Fill the space between the station and the wall of the hole, until just under the vent connections on the casing with soil. ‐ Place the vent stack at a distance of approximately 0.5 meters from the casing in a depth in accordance with illustration 4.1. The vent stack requires a concrete foundation. Two hoses are supplied with the unit (Three hoses if a relief valve is fitted). One of 2 meters (In case of relief valve two) and one of 3 meters to make it possible to place the vent stack on each side of the HON Cocon. Attach the hoses with the ¾” fitting between the ventilation connections on the casing and the vent stack. The vent stack has three connections the middle one is for the relief valve connection. The other two have to be connected to the casing to keep the area in which the regulator pilot, relief valve and shut off relay are located atmospheric. Be sure that the hoses are connected in such a way that no water can enter the hoses. Close the pit cover. ‐ Fill the space between the station and wall of the hole to ground level with soil. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 20... -
Page 21: Starting Up
Remark: During bad weather conditions (storm and wind), place a shelter above the station. This will prevent water and dirt from getting into the station. It is important that the area under the shelter is well ventilated. Support the opened pit cover, by wind force eight and up, with a support. Illustration 4.2 is a top view of the station with the pit cover open. Use the illustration for locating the various valves and pressure gauges. Illustration 4.2 ' Twin stream station with an open pit cover' Active/Slam – Active/slam/Relief © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 21... -
Page 22: Installation Of Cartridge
Take note: once a lower trip function is installed and set, the outlet pressure should be above the lower trip value (+ relatching difference) to enable reset © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 22... -
Page 23: Operation
Decrease the downstream pressure to the desired lower trip value of the SSV (open the purge valve) by backing out the adjust screw (CW) of the regulator pilot. 10 Slowly increase the trip pressure spring tension of the ssd valve by advancing the adjust screw of the controller (CW) until the trip mechanism is activated. 11 Relatch the ssd controller (take note of the minimal relatching differential) by first advancing the adjust screw of the regulator pilot and then increasing the downstream pressure, close the purge valve. Equalize pressure over the closing member by using the built‐in bypass (push the reset‐button as previously described) Finally relatch the SSV by pushing the button all the way to its stop (push twice) 12 Re‐check the lower trip pressure and fine‐adjust if necessary by repeating actions 9 to 11 13 Increase the downstream pressure to the desired upper trip value of the SSV (do not open the purge valve) by advancing the adjust screw (CW) of the regulator pilot. 14 Slowly decrease the trip pressure spring tension of the ssd valve by backing out the adjust screw of the controller (CCW) until the trip mechanism is activated © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 23... -
Page 24: 2- Relief Valve
Start at 4.3.2.1 (first time only) 1 Decrease the downstream pressure to just below the set point of the regulator. This can be done by opening & closing the hand relief valve.(purge) 1a Then advance the adjusting screw (CW) of the regulator pilot (do not open the purge valve) until the set point of the regulator is reached. 2 Check the downstream pressure for lockup. 4.3.2.4 – Gas Control Module 1 Check the atmospheric upper chamber for leakages with a leak detector before commissioning. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 24... -
Page 25: Commissioning Of The Hon Cocon
Fine tune the regulator if necessary. Notes: Change pressure spring of pilot for next higher in range to increase damping if necessary. Install a flow restrictor in the motorization line of the pilot to increase damping further if required. (Check with manufacturer for advise) To take the unit out of operation, close the upstream block valve first Do not forget to connect all data‐transmitting devices Clean and grease the seal/sealings surfaces before mounting the covers. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 25... -
Page 26: Troubleshooting
Problem 5 : There is water on the cartridge. Cause 5 : The cartridge and the pit cover seals are worn. Solution 5 : Replace the seal rings. Problem 6 : There is dust in the discharge pipe. Cause 6 : The filter is defect. Solution 6 : Replace the defect filter with a new filter. See paragraph 4.8.3.. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 26... -
Page 27: Shutting Down
See paragraph 4.6 for the installation of a spare cartridge. 4.7 ‐ Replacing parts The following paragraphs describe the replacement of a number of parts in the cartridge. The following parts can be replaced on site, by the operator. The upper seal ring between the cartridge and casing (paragraph 4.7.1); The two lower seal rings between the cartridge and casing (paragraph 4.7.2); Dust filter (paragraph 4.7.3). The seal rings have to be replaced in case of a leakage. The dust filter has to be replaced when the pressure loss over the filter is not acceptable. The remaining parts must be replaced by a qualified maintenance engineer in the service workshop. Paragraph 4.6 describes how to remove the cartridge from its casing. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 27... -
Page 28: Upper Seal Rings
4.7.2 ‐ Lower seal rings The two lower seal rings are situated in the grooves directly above the dust filter. The replace the lower seal rings, proceed as follows: Remove both seal rings from the grooves. ‐ Clean both grooves with a solvent, which does not affect the cartridge's material. Remark: Make sure that the seal rings are sufficient greased with a low viscosity, gas resistant gel (We recommend Parker Super‐O‐Lube). Slide both rings from the bottom of the cartridge upwards, until just under both grooves. Press the upper ring in the groove. ‐ Press the lower ring in the groove. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 28... -
Page 29: Dust Filter
Do not expose the cartridges to extreme temperatures. Place the cartridges, in such a way, that they cannot tip. Turn the pilot spindles and the shut off relay to the left. This minimizes the pressure on the spring. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 29... -
Page 30: 5 - Options
A close indication by means of a proximity switch can be mounted on the Plexiglas cover of the slam shut valve. © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 30... -
Page 31: 6 - Additional Data
Monitor Pilot regulator : .... bar/millibar (if applicable) Shut off relay : .... bar/millibar Relief valve : .... bar/millibar (if applicable) Use the space underneath for notes: .................................... .................................... .................................... .................................... .................................... .................................... © 2017 Honeywell International Inc. Operators manual underground gas pressure reducing station Type: HON COCON 13 Page 31...