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SERVING THE GAS INDUSTRY WORLDWIDE

Product Manual – Product Information: Installation: Commissioning: Maintenance

mini KRYSALIS 19

TM

Self contained gas pressure reduction station for underground locations: Inlet pressure up to 19 bar : Inlet sizes 50, 80,100,150 mm: Outlet 100 and 150 mm

PM6480 – Rev B – 22.05.08

Bryan Donkin RMG Gas Controls Limited


mini KRYSALIS 19TM Product manual

Revision details Bryan Donkin RMG reserve the right, without notice, to modify the designs or specifications of the product described. Every effort is made to ensure that the information contained herein is accurate, but should not be construed as a guarantee. Revision X Revision A

Revision B

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Details of the Slam/Active configuration added. Detail of the LP pilot added. Minor changes to the spring details. Details of external gauges and valved ICL to ECL connection added.

References: The following standards provide information on pressure reducing installations and the equipment contained within them. BS EN 12186:2000 Gas supply systems. Gas pressure regulating stations for transmission and distribution. Functional requirements IGE/TD13 - Pressure regulating installations for transmission and distribution systems BS EN 334:2005 Gas pressure regulators for inlet pressures up to 100 bar

BS EN 14382:2005 Safety devices for gas pressure regulating stations and installations. Gas safety shut-off devices for operating pressure up to 100 bar

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mini KRYSALIS 19TM Product manual

Contents Features: Performance: Installation: Commissioning: Maintenance:

Dimensions and weights Regulator Pilots Slamshut Relief Valve Section Schematic Site Surface Boxes Connections Vent Stack Control Lines Pre commissioning Commissioning De-commissioning Schedule Cartridge Removal Disassembly Reassembly

Features The Krysalis 19 module contains all the elements of a conventional pressure reduction station. ~ Fabricated steel body suitable for inlet pressures up to 19bar. ~ The working parts are contained in a lightweight removable cartridge. ~ The cartridge chamber is sealed with a watertight cover. ~ Configurations: Slam/Active, Monitor/Active, Slam/Monitor/Active, single or twin stream package. For use on natural gas transmission and distribution systems where above ground space is restricted or minimum levels of environmental or aesthetic intrusion are required. The buried design simplifies planning by limiting mains diversion and eliminating housing costs. In operation the emitted noise levels are minimal and opportunity for vandalism is much reduced. The module body is protected by a high integrity coating and sealed by a watertight cover. An independent load bearing outer cover is required to be fitted at ground level. Above ground is a 'vent stack’, which contains vent pipes for atmospheric reference pressure and a vent from the relief valve, if fitted; alternative vent stacks can contain additional instrumentation

Major Components Item

Material

Specification

Body

Steel

External protection

Glass Flake Epoxy 400 micron Dry Film Thickness High Integrity Oven Baked Anti Corrosion Coating Aluminium

PIPES API 5L PLATES EN 10025:S355J2G3 BDRMG MI 5432

Seal Faces Regulator cartridge

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BDRMG MI 5432 BS EN 755 (BS 1474 HE30)

PM6480 - Rev B - 22.05.2008

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mini KRYSALIS 19TM Product manual

Weights Slam/Monitor/Active Cartridge: Slam/Active Cartridge: Monitor/Active Cartridge: Body complete with A/M/S Cartridge

Kg : 31 23 25 160

Flange connections : Inlet PN16 or ASA #150

:50,80,100, 150 mm dia.

Outlet

:100,150 mm dia.

PN16 or ASA #150

Weld end connections can be supplied

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mini KRYSALIS 19TM Product manual

Performance Regulator Regulator type: Pilot controlled membrane. Maximum Inlet Pressure 19 bar.

5

Minimum operating pressure differential 0.5 bar. Outlet Pressure, accuracy and lock up – See ‘Regulator Pilots’ Operating temperature range

-10 deg C to + 60 deg. C

KG value – Slam/Monitor/Active 1500, Monitor/Active 1600, Slam/Active 2000 Capacity in sm3/hr gas 0.6SG – Type Slam/Monitor/Active. Inlet Pressure 1 2 4 6 bar 0.2 bar outlet 700 2000 4000 5500 0.5 bar outlet 2000 3750 5400 2 bar outlet 3500 5200 4 bar outlet 4700

Inlet 100 mm, Outlet 150mm 8

10

16

19

6700 6700 6700 6700

8200 8200 8200 8200

12700 12700 12700 12700

15000 15000 15000 15000

Connecting pipe capacities based on the gas velocity: Inlet Pipe Capacity Inlet Pressure bar Inlet Pipe Capacity 100 mm 20 m/s Outlet Pipe Capacity Outlet Pressure bar Outlet Pipe capacity 100mm @ 40 m/s Outlet Pipe capacity 150mm @ 40 m/s

1

2

4

6

10

16

19

1175

1759

2926

4100

6429

9930

11682

0.2

0.5

2.0

4.0

1416

1766

3518

5853

3214

4000

7980

13280

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mini KRYSALIS 19TM Product manual

Inlet Filter Filter Element - Stainless steel outer with 5, 50 or 200-micron filter media stainless or polypropylene. Options: Electrical switch on the filter differential pressure gauge:

Body

6

All pressure-containing chambers are hydrostatically tested to a pressure of 28.5 bar Cartridge Chamber - any breathing or venting of the system components will be via the atmospheric reference pipe through the vent stack, the cartridge chamber and lid will withstand an internal pressure in excess of 1 bar.

Regulator Pilots Pilot Type 600LP 600 Note

Outlet pressure mbar 15-200 >200

Accuracy Class AC RG10 AC 5

Lock up Class SG SG15 SG 10

Maximum Inlet 19bar 19bar

Discharge Line Required Not required

a)- the power gas supply to the pilot is filtered through a 50 micron element b)- control accuracy, 1 mbar reduction in outlet pressure for each 1 bar rise in inlet pressure.

Series 600LP Pilot – spring ranges Outlet Pressure mbar Spring Number Colour

15-140

25-200

150-500

1047 Dark Blue

TX002 Self

TX 003 Blue

0.2 - 0.5

0.2 - 2.9

0.2 – 4.4

1047 Dark Blue

TX002 Self

TX003 Light Blue

Series 600 Pilot – spring ranges Outlet Pressure bar Spring Number Colour

Relief Valves

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mini KRYSALIS 19TM Product manual

Slamshut Maximum Working (Functional) pressure Pmax :Maximum allowable inlet pressure PS :Mechanism type :-

10 bar 19 bar Series 309 (Publication SS.309.00.0900)

Spring ranges - Slamshut Set Pressure bar

LP Type 0.028 to 0.100

MP Type 1.5 to 4.0

MP Type 4.0 to 6.0

Spring Number Colour

1158

1192

1192+1135

White

White/Purple

+White/Brown

7

Relief Valve Spring ranges Set Pressure bar Spring Number Colour

0.3 to 3.0

0.5 to 5.0

263

264

Typical capacity when set at 2 bar:At 10% overpressure 2 cu.m/hr At 15% overpressure 9 cu.m/hr

White

Tan At 20% overpressure 16 cu.m/hr

The relief valve will re-seat approximately 10% below set point

Vent Stack The vent stack provides an atmospheric reference pressure point, which is piped back to the atmospheric chamber ( above the cartridge) Components located in the atmospheric chamber must have the external atmospheric pressure as a reference pressure for their correct operation. In the event of leakage from the system components gas would also be vented through this pipe. The vent stack also contains the vent pipe for the relief valve thus enabling it to vent at a high level

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mini KRYSALIS 19TM Product manual

mini Krysalis 19 -General Section Slam/Monitor/Active

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Schematic (For Slam/Monitor/Active)

Note that the pilot ECL’s also act as the discharge line in the above schematic.

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mini KRYSALIS 19TM Product manual

mini Krysalis 19 -General Section Slam/Active

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This arrangement shows the Slam/Active configuration with the low pressure pilot and external gauges. The control lines are shown close coupled to the outlet of the body upstream of the isolating valve. A 3 way valve enables the module to be ‘set’ with the isolating valve closed and turned to ‘run’ when the valve is opened. UThe 3 way valves are to be locked in the ‘set’ position when maintenance is to be carried out.

Schematic (For Slam/Active)

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mini KRYSALIS 19TM Product manual

Installation These recommendations are not intended to over-ride the requirements of the Gas Transmission / Distribution Code or any other National Code. If an operation is covered by an approved code then that code should be followed.

Site Selection

10

Considerations affecting site selection include:- minimum diversions of inlet and outlet mains - suitable location for the vent stack. - ease of access for routine checks of filter and cartridge - security against interference. Twin Stream Installations can be made side by side or with the bodies staggered and located some distance apart. The vent and relief pipes (to the vent stack) may be located adjacent to the body of the Krysalis

Body Installation Site Preparation A concrete slab should be installed minimum 100 mm thick on top of 150 mm well compacted hard-core or solid ground. Backfill material should be free of large stones and sharp objects. A brick or concrete ‘throat’ should be constructed at the top, this will provide a clean environment for working on the Krysalis. A pad should also be prepared for the vent stack. See ‘vent stack installation’.

Light duty installation – An A15 or B125 rated cover is fitted over the module. The valves have standard access covers or can be included under the main cover. A long ‘T’ key operates the valve via access pipes

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mini KRYSALIS 19TM Product manual

Medium/heavy duty installation - the concrete foundation should be sufficiently wide to support a steel structure or brick/ concrete pillars constructed each side of the Krysalis and providing load carrying capacity for the outer cover directly down to the foundation. Again a brick or concrete ‘throat’ should be constructed at the top, which will provide a clean working environment for working on the Krysalis, unless, as shown in the drawing, it is part of a fabricated support structure. Surface boxes and manhole covers should be selected having adequate load bearing capacity, typically D400 rated

Access chamber Incorporating an access chamber during installation can ease future maintenance. The chamber will need to be water tight and resistant to ground forces. Light weight preformed concrete rings are available for this purpose.

Preparation of the Body Check if the body has a cartridge fitted, if one is present then it is suggested that it is removed, placed in a protective cover and stored safely until the body is installed. The inner cover should be fitted to the body prior to the installation process to prevent entry of dirt or other material into the chambers Weld end bodies will normally be supplied with the pipe ends closed by a plate welded in suitable for testing, this will require cutting off and the pipe ends prepared for welding as per specification

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PM6480 - Rev B - 22.05.2008

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mini KRYSALIS 19TM Product manual

Body Connections and Pressure Gauges – Slam/Monitor/Active

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When a slamshut switch and dp gauge switch are fitted the electrical connections from them are routed through ducting to an instrument cabinet above ground. Rubber covered plug/socket connectors are fitted in the chamber for easy disconnection. The outlet pressure gauge measures the pressure in the outlet chamber Connections for the Monitor/Slam/Active Module: ECL Pilot, ECL SSV, SSV switch, DP gauge switch, Internal pressure gauges. Other configurations Slam/Active, Monitor/Active as appropriate. Pilot ECL for monitor and active 10 mm ss. pipe from module to the downstream pipe Slamshut ECL

10 mm ss. pipe from module to the downstream pipe

Relief Valve

20 mm PE pipe – from the Relief Valve outlet to the vent stack

Breather

32 mm PE pipe – from the module pilot chamber to the vent stack

DP gauge switch and slamshut switch

20mm PE pipe duct for cable from the switch to the cabinet

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mini KRYSALIS 19TM Product manual

Body Connections and External Pressure Gauges – Slam/Active – ICL/ECL Selection Valve

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Detail of External Gauges and LP Pilot connections – Slam/Active

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mini KRYSALIS 19TM Product manual

Vent Stack Installation UThese recommendations are not intended to over-ride the requirements of the Gas Transmission /

Distribution Code or any other National Code. If an operation is covered by an approved code then that code should be followed. A vent stack is required to carry relief valve outlet pipes and other breather pipes to an above ground location. The installed height of the stack is specified in the applicable code of practice but is typically 3 meters. Check the inside diameter of the stack will accommodate all necessary pipes. Check the outlet of the stack complies with the requirements of the code. The vent stack may be the only visible above ground part of the pressure reduction installation. Recommendations: Locate away from roadways and possible vehicular traffic, a fenced compound is preferred but not essential. Locate the vent stack away from areas liable to prolonged overhead water drips during winter thaws, this will help prevent icing. Also locate away from any buildings where vented gas may cause a problem. Locate 15 meters maximum but preferably reasonably close to the station to shorten lengths of pipe runs but away from buildings where any vented gas would cause problems. Cast the concrete base approximately 100 mm deep or as the site dictates for stability, foundation bolts can be cast in situ. It is suggested that the internal pipes are at least partly installed in the stack before it is lifted to the upright position and finally bolted down to the base. The type ‘A’ stack is supplied galvanised to BS EN ISO 1461 at 85 min. micron thickness and normally requires no further above ground protection. The buried portion may, if desired, be over coated with bitumastic for additional protection.

Run the vent and breather pipes to the top of the stack cutting the ends at 45 degrees to prevent blocking. Local codes and standards may require the fitting of flame traps to the relief outlet but the free venting and breathing must not be inhibited.

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PM6480 - Rev B - 22.05.2008

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mini KRYSALIS 19TM Product manual

Control Lines Installation Control lines should be 10 or 12 mm O/D stainless steel pipe. The slamshut will be impulsed upstream of any non-return valve, regulator lines can be further downstream as practice dictates. Note that if they are connected downstream of the stream isolating valve then special provision, eg. a valved tee or 3 way valve, will be required for commissioning purposes. It is recommended that the control lines are pressure tested prior to back filling etc.

Telemetry Connections There may be a need for telemetry connections to be made to the body, for example, a cable connection to a slamshut operated micro switch and Âź o/d connections to gauges mounted in an instrument cabinet. These connections are usually contained in 20mm pe pipe as ducting. The cable or pipes should be sealed after installation by the application of silicone sealant to the ends of the duct pipe, this prevents the duct pipe acting as an additional breather pipe.

Corrosion Protection Body The body is protected by a factory applied high specification glass filled epoxy coating, no further protection of this coating is required.

Pipework All sections of pipe and fittings should be protected e.g. by wrapping, to the requirements of the applicable specifications for underground installations.

Cathodic Protection A Cathodic Protection system should be considered and applied if necessary to the module; guidance for these is given in BS 7361 (BS EN 13636:2004) and IGE/SR/25. M12 studs are welded to the side of the steel fabrications to enable a connection to be made to a CP system

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mini KRYSALIS 19TM Product manual

Commissioning Introduction UThese recommendations are not intended to over-ride the requirements of the Gas Transmission /

Distribution Code or any other National or Regional Code of Practice. If an operation is covered by an approved code then that code should be followed.

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Pre - Commissioning It is particularly important to avoid contamination by dust and grit that might come into contact with seals and sealing faces. If the cartridge is fitted with an under pressure / over pressure slam shut (UPCO / OPCO ) the slam shut valve will be closed in the depressurised condition, see combined under pressure / over pressure slam shut. Remove the surface manhole cover (outer cover) over the Krysalis body; also remove any other surface covers to allow access to isolating valves. Remove the inner cover storing it to keep the sealing o ring clean. UWhen a 3 way valve is fitted to give selection of ICL/ECL it must be moved to the ICL ‘Set/Maintain’ position

and locked in that position for cartridge removal and commissioning. Following commissioning it should be moved to and locked in the ECL ‘Run’ position.

Commissioning The inlet and outlet valves should be closed. Check any ICL/ECL selection valve is locked in the ‘Set / Maintain’ position. For Slam/Active configurations disregard references to the monitor. Adjust the set point of the pilots to a low value by turning the spring adjuster anti clockwise. Regulations or local practice may require the provision of a controlled pressure source i.e. nitrogen, to enable the set point of the slamshut and other parts to be checked. Note, additional required pressurising and pressure measuring equipment can be fitted to the vent valve(s). Alternatively if a controlled pressure source is not available very carefully crack open the inlet valve and use the vent valve to control the setting pressure in the module. For combined under pressure / over pressure slam shut. The slam shut actuator will not relatch correctly and therefore gas cannot pass to the outlet until the correct pressure is applied to its measuring diaphragm. Allow the pressure in the outlet to slowly increase until the set outlet pressure is reached, at this point it should be possible to latch up the actuator. Setting of the slamshut can then proceed:

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mini KRYSALIS 19TM Product manual

Increase the spring setting of the slamshut (OPCO) and the relief valve. If an UPCO is fitted it will have a smaller diameter inner spring adjuster. Progressively increase the setting of the monitor and active pilot to the set point for the slamshut. Reduce the slamshut OPCO spring load until the slam-shut valve trips closed. Reduce the outlet pressure to 75% set point, re latch the valve and increase the pressure to repeat the test. Repeat as required adjusting the spring to give the desired setting. For the setting of an UPCO reduce the setting of the inner adjuster to a minimum. Lower the pressure to UPCO set point. Increase the UPCO setting until the valve trips closed. Increase to normal outlet set pressure, relatch the valve and decrease the pressure to repeat the test. Repeat as required adjusting the spring to give the required setting. Once correctly adjusted it is recommended that 3 to5 operations are carried out at both OPCO and UPCO set point to check for good repeatability Relief Valve With the slamshut valve open reduce the outlet pressure to the required relief valve setting. Reduce the spring setting on the relief valve until it just opens, increase the pressure 10% to check further opening, reduce the pressure 20% to check closing. Pilots Ensure the monitor is set low and the active is set high. Very slowly open the inlet valve and allow a small flow of gas through the outlet vent to a safe area. Increase the monitor to its required setting. Reduce the active to its required setting. Close the outlet vent valve, and check the lock up pressure. When checking the lock up remember that because of the small gas flow through each pilot the outlet pressure will rise to the lock up value of the pilot set to the higher pressure. USlowly fully open the inlet valve followed by slowly opening the outlet valve.

Note – initially the outlet pressure can be set a little lower than the downstream pipe system, this will prevent rapid and full opening of the regulator. UMove to and lock any ICL/ECL selection valve into the ‘Run’position.

Final setting of the pilot should be carried out at a sufficiently high level of gas flow to ensure that the main regulator has moved off the lock up condition.

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mini KRYSALIS 19TM Product manual

De-Commissioning For short term shut down: For longer term shut down:

Close the inlet valve. Close the inlet valve and slowly close the outlet valve.

UCheck any ICL/ECL selection valve is moved to and locked in the ‘Set / Maintain’ position.

The regulator may be locked up, to avoid trapping pressure, check that the inlet pressure between the inlet valve and the regulator falls. If not, temporarily open the outlet vent valve. Note that a vent valve is fitted in the active pilot loading pressure, operating this allows the active regulator to open and pass any pressure trapped in the interstage to the outlet. If maintenance is to be carried out then in addition to the above: Continue to vent using the outlet vent valve. Finally open the inlet vent valve to discharge remaining pressure upstream of the monitor. UAlways vent down the outlet before the inlet to ensure that pressure reversal does not take place..

For longer term shut down consider the need to account for any small leakages through the main line valves.

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mini KRYSALIS 19TM Product manual

Maintenance General WARNING UTo prevent personal injury or damage to property caused by unexpected release of pressure, it is essential

that de-commissioning and, if necessary, purging, is thoroughly carried out. Be aware that pressure may become trapped in small isolated chambers, ensure complete venting of sub assemblies prior to commencing work. UBe aware that protective equipment may need to be worn, the gas stream can contain fine dust particles which collect in certain areas and MUST NOT be inhaled or have contact with unprotected skin or eyes. UOnly trained personnel should carry out these maintenance procedures.

Further guidance on Health and Safety and Pre Maintenance Instructions is available on data sheets numbers HS 1854 and OM 1787.The strip down procedures for each sub assembly assume that all necessary venting and pre cleaning has taken place.

Maintenance Schedule Moving parts of the module and seals are subject to normal wear, some static parts in contact with the gas or the erosive action of dust particles may also exhibit some wear after longer periods of service. The frequency of maintenance may be determined by government regulations, codes of practice or specific schedules based on knowledge of equipment and local conditions. In the absence of any pre-set regulations, the table below may be used as a guide and amended as appropriate to suit local conditions only after operating experience is gained. Recommended Maintenance Schedule Duration 1st hour

Cartridge Continuously monitor pressure conditions including dp gauge Monitor 8 hourly

Inlet Filter

1st day

Body Continuously monitor pressure conditions Monitor 8 hourly

1st month

Monitor weekly

Remove cartridge cover and inspect externally

First 6 months

Inspect monthly

Remove cartridge cover and inspect externally

Every 5 years

Inspect

Remove cartridge and inspect sub assemblies

Remove and inspect if dp gauge indicates contamination. Remove and inspect if dp gauge indicates contamination. Remove and inspect

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Pilot Filter

Remove and inspect (at 6 months) Remove and inspect

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mini KRYSALIS 19TM Product manual

Cartridge Removal UWarning - before any maintenance is carried out ensure that all chambers are vented to atmospheric

pressure. Remove the surface manhole cover (outer cover), and inner covers. Purge the stream according to the requirements of the relevant authority Disconnect any cable connections to switches. Place the cable ends where they will not be trapped. Check any ICL/ECL selection valve is moved to and locked in the ‘Set / Maintain’ position.

Cartridge – disassembly. Before attempting to remove the cartridge ensure all vent valves are open and carry out a final check to make absolutely certain that all residual pressures within the chambers, especially the inlet chamber, have been vented to atmospheric pressure. Failure to do this may result in unexpected and sudden lifting of the cartridge through the top of the body when the retaining bolts are removed. Loosen the 6 retaining bolts, it is not necessary to fully remove them. Lift out the cartridge placing it on a clean surface. Ideally invert it and check for the presence of sealing o-rings, check no o-rings have been left in the body.

Filter The filter element will be contaminated with fine dust particles. These must not be inhaled or have contact with unprotected skin or eyes. Appropriate protective equipment should be worn. Invert the cartridge using a suitable support to keep the cartridge level and correctly positioned for working on. Remove the 2 bolts retaining the filter element, remove the element. The element should be placed into a suitable container for cleaning to prescribed procedures in a safe area.

Slamshut. If possible trip the slamshut to close the valve. Uncouple the operating cable at the connector, if the slamshut is latched up then use a piece of wood to support the valve as the cable is disconnected. Remove the 4 – M8 screws and lift off the valve housing. Revert the cartridge, remove the 4 – M6 screws and lift off the slamshut actuator. Gauges.

Gauges can be removed to gain better access if required.

Pilots. Remove the 4 – M6 screws connecting the end blocks to the bulkhead plate and lift off the pilot rail.

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mini KRYSALIS 19TM Product manual

Relief Valve. Wind off the spring loading, remove the 8 - M6 screws and lift off the relief valve.

Regulator cartridge. Invert the cartridge. Remove the 8 – M10 bolts with their sealing copper washers, these washers should be replaced on reassembly. Lightly hold down the monitor inlet during removal of the last bolts as it can lift due to the loading of the closing spring. Remove the monitor inlet, the diaphragm sub assembly and the spring. Note the presence and condition of the sealing o-rings. Lift out the monitor top, remove the 8 – M8 screws and lift off the active inlet. Note the presence and condition of the sealing o-rings. Note the condition of the grid plates and the seat edge, only if required remove the 4 countersunk screws and remove the grid plates

Reassembly Check the condition of all parts, replace as required. Rebuild diaphragm sub assemblies Fit:Grid plates Closing spring. Hold the diaphragm in the active inlet, locate the spring on the diaphragm plate and lower in place in the correct orientation. Fix with the M8 screws, progressively tightening. Monitor top Closing spring. Hold the diaphragm in the monitor inlet, locate the spring on the diaphragm plate and lower in place in the correct orientation. Lightly holding down to compress the spring fix with the M10 screws, use new copper sealing washers under the heads, progressively tightening. Slamshut valve with seat and spacers. Revert the cartridge. Slamshut actuator

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mini KRYSALIS 19TM Product manual

Relief valve Pilots and pressure gauges Invert the cartridge. Connect the slamshut operating cable, if convenient check the function of the slamshut. Allow 1mm of pre-travel with the valve in the closed position. Filter element Rebuild complete, revert the cartridge.

At all stages ensure that all sealing ‘o’ rings are in place in the components prior to re-assembly, check that rings and sealing faces are clean and lightly greased. Covers and pressure transfer passages between the cartridges and the body are sealed with o-rings in dovetail grooves, check these are in place, clean and greased prior to re-fitting the cartridge. Slowly lower the cartridge into the body locating on the dowel. Progressively tighten the retaining bolts. Re-connect any electrics. If appropriate at this stage refit the inner cover with o-ring seal on the body correctly and tighten the retaining bolts to ensure there is no ingress of water.

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mini KRYSALIS 19TM Product manual

Body, Cartridge and Inner Cover – Exploded view

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mini KRYSALIS 19TM Product manual

Cartridge – Exploded view Relief Valve

Slamshut Actuator

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Cartridge Fixing Bolts (6) Pilot Rail

Pilot Filter

Active Regulator

Monitor Regulator

Slamshut Seat

Slamshut spacer (4)

Slamshut Valve

Operating Cable

Filter Element

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mini KRYSALIS 19TM Product manual

Regulator Cartridge – Monitor/Active – Shown Inverted

Retaining bolts

Copper Washer

Monitor Inlet

Grid Plate

Bottom Diaphragm Plate

Diaphragm

Diaphragm Plate

Closing Spring

Monitor Top

Active Inlet

Bulkhead Plate

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mini KRYSALIS 19TM Product manual

Regulator Cartridge – Active Only – Shown Inverted

26

Copper Washer Retaining bolts Adaptor Flange Active Inlet Bottom Diaphragm Plate Diaphragm Closing Spring

Bulkhead Plate

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mini KRYSALIS 19TM Product manual

Slamshut Cartridge Reset knob Top cap Adjuster, spring(s) and the carrier.

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Spring housing

Spring housing fixing screws Latch block and diaphragm sub assembly (The internal spring is not fitted to the LP type ) Rollers and roller retaining plates

Slamshut Actuator Body

Slamshut seat Spacer Upper Operating cable Note the condition of the main seat o-ring in the valve head. Also disassembling the head by removing the circlip enables examination of the condition of the bypass valve and its seat. Check the condition of the slamshut seat and of the sealing o-rings. Valve Body Cable coupling Note- Remove the nut and coupler to allow the cable to pass through the regulator when the slamshut actuator is lifted off. Valve Spindle Lower Operating Cable

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mini KRYSALIS 19TM Product manual

Relief Valve

Spring Adjuster Locknut

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Spring Housing Spring Carrier Spring Diaphragm Plate

Spindle Diaphragm Bottom Diaphragm Plate

Fixing Screws Body Seat (retained in the Bulkhead Plate)

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mini KRYSALIS 19TM Product manual

Series 600 Pilot Regulator

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Plug

Inlet Filter

Monoblock

ITEM

DESCRIPTION

QTY.

NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14-1 14-2 14-3 14-4

PART

MATERIAL

NUMBER O’RING SQUARE HEAD CAP SCREW HEX NUT SPRING ADJUSTER PLATE MAIN SPRING TOP HALF CASING BOTTOM HALF CASING O’RING VALVE RETAINING NUT VALVE SPRING VALVE PHILLIP HEAD SCREWS DIAPHRAGM ASSEMBLY DIAPHRAGM CARRIER DIAPHRAGM DIAPHRAGM PLATE PUSH ON CLIP

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1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1

TF/001 BS/USA 113 TN/005 ¼”-28 TN/004 REFER TO ORDER TC/003 TB/004 BS/USA 013 TN/001 TX/001 TN-003 #8-32x5/8 Lg. TJ-005 TJ/003 TJ/004 TJ/002 5115-12

Aluminum Nitrile Plated Steel Plated Steel Plated Steel Spring Steel Aluminum Aluminum Nitrile Brass Spring Steel Brass / Nitrile Plated Steel Aluminum Nitrile Plated Steel St. Steel

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mini KRYSALIS 19TM Product manual

Series 600LP Pilot Regulator

30

ITEM

DESCRIPTION

QTY.

NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

PART

MATERIAL

NUMBER O’RING SQUARE HEAD CAP SCREW HEX NUT SPRING ADJUSTER PLATE MAIN SPRING TOP HALF CASING BOTTOM HALF CASING O’RING VALVE RETAINING NUT VALVE SPRING VALVE PHILLIP HEAD SCREWS SPRING CARRIER O RING SCREW, HEX HEAD O RING DIAPHRAGM DIAPHRAGM PLATE BOTTOM DIAPHRAGM CASING TOP DIAPHRAGM CASING

Bryan Donkin RMG Gas Controls Limited

1 1 1 1 1 1 1 1 1 1 1 1 6 1 2 8 1 1 1 1 1

TF/001 BS/USA 113 TN/005 ¼”-28 TN/004 REFER TO ORDER TC/003 TB/004 BS/USA 013 TN/001 TX/001 TN-003 #8-32x5/8 Lg. 200/PD/001 BS/USA 035 M8x30 BS/USA 047 201/WJ310 201/XH/310 200/PB/001 200/PC/001

Aluminum Nitrile Plated Steel Plated Steel Plated Steel Spring Steel Aluminum Aluminum Nitrile Brass Spring Steel Brass / Nitrile Plated Steel Aluminum Nitrile Stainless steel Nitrile Nitrile Plated Steel Aluminum Aluminum

PM6480 - Rev B - 22.05.2008


mini KRYSALIS 19TM Product manual

Body There are no regular maintenance tasks required for the body other than to ensure that the sealing faces are kept clean and lightly greased. Note that the top surfaces have an anti-corrosion coating, which should not be damaged by using abrasive cleaners. Always check that the sealing rings are in good condition and lightly greased.

Inspection of Body Wall Thickness The external surfaces of the body are protected with a high integrity coating system, which is designed to prevent corrosion occurring. If so required, the thickness of the body can be measured and recorded using ultrasonic measuring equipment. Initial measurement should be taken when the body is first installed prior to fitting the cartridge and filter. Ensure that internal faces of the body to be inspected are thoroughly cleaned and prepared in accordance with the operating instructions of the measurement equipment. Records should be maintained of the location of measurement of body wall thickness and of the equipment used for measurement. It is suggested that a indelible marker pen is used to mark the body with the location of the inspection to provide continuity for future inspections. Subsequent inspections should not be required at less than 5 yearly intervals

Spares Consult the separately issued spares list for details.

Bryan Donkin RMG Gas Controls Limited

PM6480 - Rev B - 22.05.2008

31

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