K1000~K3000 Instruction Manual Nov 2003

Technical Manual NTAKBP0310 November 2003

K1000 - K3000

MULTIFUNCTIONALPILOT-OPERATED REGULATOR

SUMMARY INTRODUCTION ................................................................. 1 CHARACTERISTICS ........................................................... 2 LABELLING .......................................................................... 2 DESCRIPTION..................................................................... 3 SPARE PARTS ..................................................................... 3 DIMENSIONS ANDWEIGHTS ............................................. 4 OPERATION......................................................................... 4 INSTALLATION .................................................................... 5 COMMISSIONING................................................................ 6 MAINTENANCE ................................................................... 7

Type K1000

INTRODUCTION The K1000 or the K3000 are pilot-operated regulators, PS 25 bar, single-staged, high speed of responses, and stable pressure control.

The K1000 or the K3000 includes a filter, a regulator and a slam shut valve.

Its design allows a turbine meter to be mounted directly on the

outlet flange, a new slam shut technology, the OS2, and a Francel Piloting System.

A noise attenuation permits theK1000 or the K3000 to be classified in the category of silent or low noise regulators.

As an option is can be equipped with a blockage indicator without a connector.

14/06/2005

The K1000 or theK3000 is in conformity with the PED 97/23/EC and is classified in category IV.

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Technical Manual NTAKBP0310 November 2003

K1000 - K3000

CHARACTERISTICS Operating pressure Body, slam shut Outlet flange BMS associated, according to size Ambient temperature / TS A216 WCB body A352 LCC body Operating temperature / Gas T° Outlet pressure REGULATOR Maximum differential Regulator accuracy

PS

Pa

- 20 / 60 °C - 30 / 60 °C - 20 / 60 °C 0.020 to 16 bar

Max P AC

25 bar 2.5

TS

SLAM SHUT Maximum differential Max P 25 bar Reponse time <1s Accuracy AG 2.5 Set point range Pt 0.010/14 bar Valve plug travel (K1000) 28 mm (K3000) 23 mm Resetting Manually after fault rectification Position indicator On the mechanism box Groups 1 and 2 according to PED 97/23/EC,st 1and 2nd family gas Fluid according to EN 437, or other gases (compressed air, nitrogen). The gas must be non corrosive, clean or moderately loaded (internal filtration) and dry

25 bar 16 bar 5 to 20 bar

Flow Coefficient Regulator K1000 K3000

Qf 550 1340

Cg 1067 2600

Filtration C1 35 35

Polyester or felt cartridge Filtration

qN 1100 2680

5

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MATERIAL Body Connecting parts and bottom Actuator Regulator/Slam shut orifice Regulator valve plug Slam shut valve plug Regulator/Slam shut discplugs

CONNECTIONS Steel Steel Aluminium/Steel Stainless steel Stainless steel Steel Nitrile

Inlet: Outlet: Pilot impulse line: Slam shut impulse line (IS): BM vent: Impulse diameter : Contact :

ISO PN 25 K1000 : ISO PN 16 or PN 25 K3000 : ISO PN 16 1/4’’ NPT tapped 1/4’’ NPT tapped 1/4” NPT tapped Pipe interior Ø 8/10 mm See NTAOS2 manual

LABELLING

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Technical Manual NTAKBP0310 November 2003

K1000 - K3000

DESCRIPTION The K1000 or the K3000 consist of: • A subassembly external body, a subassembly internal body, and a subassembly slam shut valve • A pilot body capable of receiving: - the two pilot blocks - the pre-expansion and pilot safety manometric boxes (see NTAPIL manual) - a manometric gauge

• A release relay type OS2 (see NTAOS2 manual) with: - a mechanism box (BM1) - a safety manometric box (BMS1) to be connected outlet side of the regulator or - a mechanism box (BM2) - two safety manometric boxes (BMS2) to be connected outlet side of the regulator

SPARE PARTS

O19a

O19b

K1000

K3000 Reference

Item Description K1000

K3000

197 353

197 353

1

Packing gland + control stem

2 3

VS support O-ring Filtering cartridge (polyester)

4 5 6

VS orifice O-ring Impulse O-ring Impulse O-ring

400 269 400 266 400 268

400 278 400 275 400 264

7 8

Impulse O-ring (external) Diaphragm

400 267 143 523

143 568

9 10

O-ring Disc plug (regulator orifice)

400 273 400 270

400 283 400 280

Item

400 264 400 071 143 531/4008553 143 565/4008554

K1000

K3000

11 12

Noise attenuation disc O-ring

143 527 400 512

143 579 400 512

13 14

Upper plug O-ring Slam shut O-ring

400 265 400 528

400 276 400 534

15 16 17

Valve pipe O-ring O-ring O-ring

400 087 400 272 400 548

400 278 400 279

18

O-ring Spare parts kit*

400 036 197 477

400 281 197 355

Set of O-rings**

197 478

197 358

* Includes all commissioning spares and O-rings. ** Includes all O-rings.

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Code

Description

O25

Technical Manual NTAKBP0310 November 2003

K1000 - K3000

DIMENSIONS ANDWEIGHTS Inlet DN Outlet DN A (mm) B (mm) C (mm) D (mm) E (mm) Weight (kg)

K1000 50 80 o r 100 488 300 166 133 90 68

K3000 80 150 682 420 220 209 130 148 O26

OPERATION This regulator operates by admitting modulated pressure. Gas enters the regulator by the intlet flange (1), flows through the filter (2) inside which it reaches the slan shut valve (3). The gas then flows through the pilot relay which regulates outlet pressure.

The different functions are carried out by the following: • Pressure regulation The K1000 or K3000 is an axial-flow pilot-operated regulator .

The position of the valve depends on the flow rate and the pilot control of the modulated pressure .

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• Filtration The filter is directly incorporated inside the body of the K1000 or K3000. It is composed of a polyester filtering cartridge which assures, as much as possible, the protection of sensitive mechanical parts (slam shut valve, regulator valve, pilot, etc.).

• Noise attenuation and flow straightening These are achieved by a slotted disc (4), different layers of porous materiels (mineral foam and synthetic fibers) and a flow straightener (5). This technic allows a turbine meter to be connected on the outlet side of the K1000 or the K3000, without using an intermediate straight line of pipe • Slam shut The slam shut is situated on the downstream side of the K1000 or the K3000, where the gas is hot, to avoide the valve from freezing. Once the set pressure level is reached, the mechanism box (6) releases the valve, which then blocks the gas passage. Balancing the pressure and resetting the valve is actioned by the resetting lever (7) (incorporated bypass).

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• Pilot system The K1000 or the K3000 pilot allows the valve-pipe (8) ot be positioned according to the flow required. It consists of three parts: - a pre-pilot relay (9): assures a stable pressure level (Pd) superior to the outlet pressure, - a pilot part (10): using the modulated pressure (Pm) the valve-tube is positioned depending on the outlet pressure,

- a pilot body (11): containing the two pilot blocks (12) and the pre-expansion and pilot manometric boxes.

Different types of manometric boxes exist depending on the outlet pressure.

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Technical Manual NTAKBP0310 November 2003

K1000 - K3000

INSTALLATION

Figure 1 (With one safety manometric box)

Figure 2 (With two safety manometric boxes)

All interventions on the equipment should only be performed by qualified and trained personnel.

!

• • • •

•

•

• •

W A R N IN G

!

The regulator is installed on the bottom left pipe line angle.

Installation according to EN12186 is recommended.

Install according to the direction of the fluid flow (arrow).

When assembling with adjacent elements care must be taken not to create pressure force on the body and the assembling elements (bolts, O-rings, flanges) should be compatible with the geometry and working conditions of the equipment.

Connect the long pilot impulse line (IP) at 4D on the straight run of the outlet pipe. The slam shut impulse lines (IS) and reject pilot (RP) are connected in series.

A turbine meter can be directly connected to the K1000 or the K3000 (Figure 1).

The K1000 or the K3000 contain an internal filtering cartridge, an additional filter on the outlet side in not necessary.

If the remote alert option is chosen, electrically connect the contact (see NTAOS2 manual).

No modification should be made to the structure of the equipment (drilling, grinding, soldering...).

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W A R N IN G

•

It is recommended to install a servicing valve on the outlet pipeline to facilitate adjustments and bleeding off to the atmosphere.

•

Verify that the inlet side is protected by an appropriate device(s) to avoid exceeding the limits of utilization (PS, TS).

•

Verify that the limits of utilization correspond to the appropriate operating conditions.

•

Verify that the safety manometric box (BMS) and spring correspond to the appropriate operating conditions on the outlet side of the regulator.

•

The equipment should not receive any type of shock, especially the release relay.

•

Fire, seismic and lightening are not taken into consideration for standard regulators. If required, a special product selection and/or specific calculations may be supplied according to specific requirements.

•

The user should verify or carry out a protection adapted to the environment.

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Technical Manual NTAKBP0310 November 2003

K1000 - K3000

COMMISSIONING All interventions on equipment should only be performed by qualified personnel.

PRELIMINARY VERIFICATIONS Start-up positions • Inlet and outlet valves  Closed Verify absence of pressure between inlet and outlet valves • Slam shut valve plug  Closed • Slam shut impulse line valve 5  Closed • Atmospheric impulse line valve  Open Set point verification Using the atmospheric valve, inject a pressure equal to the pressure foreseen for the regulator •1 st release relay stage  Set (Stage 1) • Slam shut valve plug  Open (Stage 2)

Stage 1

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• Reject valve 1  Open (2 turns) • Adjustment knobs 2 & 4  Unscrewed The equipment is ready for commissioning COMMISSIONING

Stage 2

C38a

• Inlet valve  Open very slowly • Pilot supply valve 3  Open • Slam shut valve bypass  Open slowly •1 st release relay stage  Set (Stage 1) • Slam shut valve plug  Open (Stage 2) • Operating valve  Slightly open • Pre-expansion relay 4  Turn the handwheel (Pa + 200 to 500 mbar) Possibility to connect an external manometer at 8 (1/4 NPT connection) • Pilot 2  Turn the handwheel (to Pa) • Long impulse line valve 7  Open • Short impulse line valve 6  Closed The equipment is commissioned

C38b

 Progressively increase the pressure to reach tripping  Adjust setting if necessary (NTAOS2) Note the set point value on the equipment or mark it in an commissioning document Positions before commissioning • Pilot supply valve 3  Closed • Long impulse line valve 7  Closed • Short impulse line 6  Open • Impulse isolation valve  Open • Impulse atmospheric valve  Closed • Slam shut valve plug  Closed • Servicing valve  Closed

It is recommended to seal the release relay 6

Technical Manual NTAKBP0310 November 2003

K1000 - K3000

MAINTENANCE SERVICING CHECK

Departure positions

Recommended frequency :

• Inlet valve  Open • Outlet valve  Open • Slam shut valve plug  Open • Regulator  In service Inlet and outlet side of the regulator under pressure

• Twice yearly minimum Verification : • • • •

Verification of the set point Valve plug tightness Tripping and valve plug set point value Slam shut valve plug tightness

If the outlet pressure

Tightshut and tripping verifications • Inlet valve • Outlet valve • Regulator

increases

 Closed  Closed Observe the evolution of the outlet pressure (control regulator)

Internal leak Close the pilot supply valve

Observe the evolution of the outlet pressure (control regulator tightness) If the outlet pressure increases

If the outlet pressure is

stable

If the outlet pressure decreases If the outlet pressure is constant

Regulator tightness fault Control the regulator valve plug Control the regulator orifice Control the tightshut O-rings

or contact after-sales

Pilot tightness fault Control the pilot valve

or contact after-sales

External leak Locale and seal the leak

or contact after-sales

The regulator is tightshut Increase the set point until slam shut tripping occurs (without exceeding the outlet limits)

If the slam shut valve plug will not close

Operating fault Control the release relay Control the slam shut valve plug

If the slam shut valve plug closes Observe the evolution of the outlet pressure (control tightness)

or contact after-sales

Operating correctly

If the outlet pressure is constant Purge the outlet side of the regulator Observe the evolution of the outlet pressure (control tightness) If the outlet pressure

increases

Internal leak Control the slam shut valve plug Control the slam shut orifice Control the bypass

If the outlet pressure is constant

Slam shut valve plug is tightshut

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or contact after-sales

Technical Manual NTAKBP0310 November 2003

K1000 - K3000

MAINTENANCE DISASSEMBLY OF THE REGULATOR AND SLAM SHUT Recommended frequency : • Every year (or less depending on operating conditions) Verification and/or replacement : • Filtering cartridge Recommended frequency : • Every 4 to 6 years (or less depending on operating conditions) Verification : • Condition of O-rings, diaphragms, valve disc plug, lubrication Replacement : • O-rings, diaphragm Tools: • Male spanners for six-sided wrench 4, 5, 6, 8, 10, 12 • Flat spanners 8, 10, 11, 12, 13, 17, 19, 21 REGULATION

Screw Torque (N.m)

• • • • • • • • • • • • • • • • • • • • •

Valve plug closed M8 15 Close inlet and outlet valves M10 30 Bleed off outlet pressure M12 60 O27 Bleed off inlet pressure Unscrew the slam shut impulse connection Unscrew the pilot supply connection Remove the BM cover 1 Unscrew the fixing screws 2 Free the hook head 3 Remove the BM 4 Unscrew screws 5 Remove the VS support 6 Remove the bypass 7 Unscrew screws 8 Remove the upper plug 9 Remove the filtering cartridge 10 Unscrew the modulated pressure connector Unscrew the outlet pressure connector Remove the impulse pins 11 Remove the inner body unit 12 Separate the front inner body 13 from the rear inner body 14 (precaution with the spring force) • Remove carefully the mobile unit without damaging the valvepipe 15

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• Remove the flow straightener 16 • Remove the whisper cage 17 • Remove the phonic casing 18 REASSEMBLY • Preform the above operations in reverse order (respect tightening torques) • Replace the diaphragm every 6 years or less depending on condition • Replace the tightshut disc plug every 12 years or less depending on condition • The valve plug should be held in an upper position using a packing gland and a box to facilitate disassembly • Replace O-rings at each disassembly • Lubricate screws before tightening • Lightly lubricate O-rings (silicone grease) • Lightly lubricate the stem (silicone grease) • Lubricate the release relay mechanism (yoke and bolt) (molybdenum graphite grease) • Lubricate the BMS spring (molybdenum graphite grease)

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