Honeywell HON COCON 13, Operator'S Manual

Page 1: ... 1 UNDERGROUND GAS REGULATION STATION TYPE HON COCON 13 Twin stream Active Slam Active Monitor OPERATORS MANUAL 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 ...

Page 2: ...ontrol 13 2 4 7 Pilot Control 2 5 Automatic operation 15 2 6 Maintenance 15 3 Safety 17 4 Installation operation 18 4 1 Installation instructions 18 4 1 1 Soil condition and foundation 19 4 1 2 Pit dimensions 19 4 1 3 Placement of the body 20 4 1 4 Installation of vent stack 20 4 2 Starting up 21 4 2 1 Installation of cartridge 22 4 2 2 Emergency stop 22 4 3 Operation 23 4 3 1 Before getting start...

Page 3: ...ucing station Type COCON 13 Page 3 4 7 Replacing parts 27 4 7 1 Upper seal rings 28 4 7 2 Lower seal rings 28 4 7 3 Dust filter 29 4 7 4 Stock 29 4 8 Storage 24 5 Options 30 5 1 Introduction Options 30 5 4 Relief valve 30 5 5 Valve position indicator 30 6 Additional data 31 6 1 Adjustment form 31 ...

Page 4: ... easy access to the required information Chapter 1 Introduction Chapter 2 General information concerning the gas pressure reducing station Chapter 3 Describes how to operate the Cocon 13 safely Chapter 4 Describes installation commissioning and maintenance Chapter 5 Describes the extra options that are possible Chapter 6 Additional data contains various lists to help you find the required informat...

Page 5: ...em 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 ...

Page 6: ...mpulse line connection metric fittings according to DIN 2353 Pressure gauges 2 or 3 for measuring inlet intermediate and outlet pressure Pressure gauge BSP thread Regulator type two path pilot operated spring loaded closed gas pressure regulator Shut off valve type direct acting safety shut off device SSD with integral pressure equalizing Push button type Filter cartridge filter with support cage ...

Page 7: ... that is installed underground into the gas main Above ground is a vent stack which contains vent pipes for atmospheric reference and the relief valve The HON Cocon is supplied pre assembled into a skid package which considerably reduces the on site installation time The station is made of steel aluminum bronze and synthetics The station can be produced in other materials upon request 2 3 Construc...

Page 8: ... station Type COCON 13 Page 8 2 4 1 Active Slam operation figure 2 4 1 Cross section HON Cocon 13 Active Slam Shut Valve 01 Cover 02 Lifting handle 03 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 ...

Page 9: ...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 Plexi...

Page 10: ...l International Inc Operators manual underground gas pressure reducing station Type COCON 13 Page 10 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 ...

Page 11: ...rators manual underground gas pressure reducing station Type COCON 13 Page 11 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 ...

Page 12: ...on 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 motorizati...

Page 13: ...nsate 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 decr...

Page 14: ...on set point deviation the pilot which functions similar to the main line valve will open or close to correct the dome load and indirectly correct the outlet pressure Low Pressure High Pressure 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...

Page 15: ...r than the value set on the regulator pilot 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 th...

Page 16: ...matically 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 norm...

Page 17: ...d pressure are to be prevented by appropriate means Before starting maintenance always close the valves in the upstream supply and downstream discharge pipes first These valves should be situated within a distance of five meters of the station s inlet and outlet flanges Ensure that you are sufficiently trained to install and remove the cartridge Ensure that you are sufficiently trained to service ...

Page 18: ...llation operation 4 1 Installation instructions This chapter describes the installation of the casing and the attachment of the upstream supply and downstream discharge pipes to the body Illustration 4 1 is a drawing of a fully installed station Use this drawing for guidance in the next four paragraphs Illustration 4 1 Fully installed station ...

Page 19: ...the top of foundation plate is levelled 4 1 2 Pit dimensions The pit depth depends on the thickness of the foundation To determine the pit depth of a partially exposed in ground station pit cover above ground level always use the following formula Depth of pit 906 df Fill in the thickness of the foundation df in millimeters The number 906 is the distance from the bottom of the casing to halfway up...

Page 20: ...tation This prevents the station from obstruction e g vehicles 4 2 Installation of the vent stack 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 to prevent clos...

Page 21: ...n 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 ...

Page 22: ... There is an emergency stop control button on the slam shut valve controller which can be used when required to put the cartridge immediately out of operation To use this emergency stop button proceed as follows Open the casing cover The silver coloured button is located on the side of the slam shut valve controller Press the emergency stop control button This causes the valve to close down the ga...

Page 23: ...epressurize the module 4 Fail the regulator open by advancing the adjust screws CW until a little spring tension builds up 5 Check the upstream downstream pressures on the gauges provided for lockup of block valves 6 Crack the upstream block valve and the upstream isolation valve of the HON Cocon 7 Check the downstream pressure for lockup 8 Relatch the ssd controller enable reset by presetting the...

Page 24: ... pressure by opening closing the purge valve 2b by advancing the adjust screw CW of the regulator pilot do not open the hand relief 3 Slowly decrease the opening pressure spring tension 3a by backing out the adjust screw CCW of the relief valve 3b until the relief valve opens use an indicator 4 Close the relief valve mind the minimum closing difference 4a by first backing out the adjust screw of t...

Page 25: ... button at this point until fully open 4 Gradually open downstream block valve 5 Gradually open upstream isolation valve of the HON Cocon 6 Gradually open the upstream block valve 7 Increase the regulator pilot spring tension by adjusting the screw inwards until the required set point is reached in the outlet piping 8 Fine tune the regulator if necessary Notes Change pressure spring of pilot for n...

Page 26: ... Cause 2c The filter is severely polluted Solution 2c Replace the filter with a new one See paragraph 4 10 3 Problem 3 Gas is required but is not passing through Cause 3a The ball valve is closed Solution 3a Open the ball valve Cause 3b The outlet valve is closed Solution 3b Open the outlet valve Cause 3c The valve in the supply pipe located within a distance of 5 meters from the station s inlet h...

Page 27: ...rom the cover To remove the cartridge proceed as follows Open the casing cover Loosen the 4 x M16 M24 nuts Lift the cartridge from the casing by the handles Remark Take care of your back by following proper lifting procedures while installing and removing the cartridge See paragraph 4 6 for the installation of a spare cartridge 4 7 Replacing parts The following paragraphs describe the replacement ...

Page 28: ... greased with a low viscosity gas resistant gel We recommend Parker Super O Lube Press the o ring in the groove 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 M...

Page 29: ...ng plate against the dust filter Attach the fastening plate to the cartridge with a nut M6 4 7 4 Stock We strongly recommend you to keep parts mentioned in this chapter on stock Quantity description article number paragraph 1 Upper seal ring 8401202604369 4 7 1 2 Lower seal rings 8401094902154 4 7 2 1 Dust filter 8301010000005 4 7 3 4 8 Storage Spare units when being stored for long periods should...

Page 30: ...d but which can be supplied as an option The operation of the station is made a lot easier with the use of these optional parts 5 2 Relief valve The relief valve is optional When the pressure in a redundant station is too high due to leakage the relief valve ensures that excess pressure is vented to atmosphere 5 3 Valve position indication SSV A close indication by means of a proximity switch can ...

Page 31: ...everal stations with different adjustments we advise you to keep all the forms together Adjustment form Model HON COCON Type 13 Delivery date station number unit number Name Date Location Place Street Exact location Write down all relevant data for the adjustment of the cartridge below Inlet pressure bar Outlet pressure millibar Settings for pilot and shut off relay Remark The shut off relay must ...