Emerson FRANSEL REGAL 3 User manual

REGAL 3

Instruction Manual

NTAREG30406

June 2004 - Rev. 03

www.emersonprocess.com/regulators

SUMMARY

INTRODUCTION ................................................................. 1

CHARACTERISTICS ........................................................... 2

LABELLING .......................................................................... 2

DESCRIPTION..................................................................... 3

SPARE PARTS ..................................................................... 3

DIMENSIONS AND WEIGHTS ............................................. 3

OPERATION ......................................................................... 4

RELIEF VALVE ADJUSTMENT ............................................ 4

INSTALLATION .................................................................... 5

COMMISSIONING ................................................................ 6

MAINTENANCE ................................................................... 7

INTRODUCTION

TheREGAL3 isadirect-operated, spring setpoint pressure regulator,

usedfor supplying industriesand commercial businesses.

As an option, it can be equipped with a slam shut type VSX2 or OS2

which permits the gas flow to be cut off rapidly and totally in the case of

underor over outletregulator pressure.

Asa standard featurefor outletpressure settings inferioror equalto

180 mbar, a relief valve is provided.

On request, this relief valve may be disconnected and replaced by a

dampener.

Upon request, for pressures 180 mbar <Pa <= 1100 mbar, the REGAL 3

can be equipped with a relief valve.

This relief valve can be factory adjusted.

DIRECT-OPERATED REGULATOR

Type Regal 3/VSX2

DECLARATION OF CONFORMITY REGAL 3

Manufacturer: FRANCEL

Address: Z.A. La Croix Saint Mathieu, 28320 GALLARDON

Equipment: REGAL 3 Identification no.:

Conformity Assessment Module: Module A

Theundersigned declarethat thedesign, manufacture andinspection ofthis equipmentare inconformity withthePressure Equipment Directive97/23/EC(PED)

Name: Function: Company stamp:

Date: Signature:

The REGAL 3 is in conformity with the Pressure Equipment Directive

PED 97/23/EC and is classified under category I.

Equipmentand pipelinesituated on theoutlet sideof theregulator are

either;

- not subject to the PED (Pa <= 0.5 bar), or

- subject to (Pa > 0.5 bar) : in which case they should come

under category 1 maximum.

An Non-PED version of the Regal 3 is also available.

Type Regal 3/OS2

Europe, Middle East, and Africa Document Only

REGAL 3

REGULATOR

Accuracy AC 10

Inlet/outlet diameter DN 50

Pe min 0.5 bar

Pe max 10bar

Spring set point (PED version) Pa 0.008 to 1.5 bar

(Non-PED version) 2.0 / 3.0 bar

Groups 1& 2 according to PED 97/23/EC,1st and 2nd family gas

Fluid according to EN437,orother gases (compressed air, nitrogen).

Thegas must be noncorrosive,clean (filtration oninlet side

necessary) and dry.

Operating pression

Body, valve plug, slam shut 10bar

Actuator (Pa <= 1.5 bar PED version) PS 1.5 bar

(Pa <= 3.0 bar Non-PED version) 3.0 bar

BMS* associed, according to size 5bar

Operating temperature TS - 30 / 71 °C

Outlet pressure (PED version) Pa 8 / 1500 mbar

(Non-PED version) 2000/3000mbar

PS Servo/Actuator

Pset max

Date Fab/Test

N°serie/Serial N°

Type

Cat.

Regulateur

Regulator

FRANCE

28320 Gallardon

Groupe fluide 1

(Gaz naturel)

REGAL3 10 ou 20

10 bar - 30 / 71°C I

JJ MM 20AN

1.1 bar

1.5 bar

FRANCEL

Tarage / Set nominal

Plage / Range

Code

Type

AG maxi

Sécurité

Slam shut

10 barVSX2LPC3

196433 10

Min (mbar)

FRANCEL

Max (mbar)

100 / 500

350

400 / 1100

700

FRANCEL

CHARACTERISTICS

LABELLING

RELIEF VALVE

Relief valve set point Pa + 20 mbar up to 90 mbar setting

Pa + 30 mbar up to 140 mbar setting

Pa + 40 mbar up to 180 mbar setting

Pa + 60 mbar up to 340 mbar setting (option)

Pa + 100 mbar up to 550 mbar setting (option)

Pa + 200 mbar up to 1100 mbar setting (option)

MATERIAL

Body Ductileiron

Sittingpart Brass

Actuator Aluminium

Regulator/slamshutorifice Brass

Regulatorvalve plug Aluminium

Slam shut valve plug Aluminium

Regulator/slamshut plug disc Nitrile

C91

C94

Regulator set point spring table

* BMS : Safety manometric box

FRANCEL

Code

FRANCEL

Regulateur

Regulator

FRANCE

28320 Gallardon

FSREG3-31

300 / 550

500

Yes

600

Plage / Range (mbar)

Réglage / Set (mbar)

Soupape / Relief

Tarage / Set (mbar)

FRANCEL

bar

mini maxi

N°

Ressort/Spring

AG maxi

BMS taille

size

serie

serial

FRANCEL

CONNECTIONS

Inlet/ Outlet: ISO PN 10 / 16

ISO PN 20 / ANSI 150

Actuator impulse line ISM : 1/2’’NPT tapped

Actuatorvent: 3/4’’ NPTtapped

Impulseline: Internal pipe Ø >= 15 mm

Slam shutimpulse line (VSX2 / OS2) IS : 1/4” NPT tapped

Impulseline (VSX2) : Internal pipe Ø >= 4 mm

(OS2) : Internal pipe Ø >= 8 mm

Slam shut vent (VSX2 / OS2) : 1/4’’NPT tapped

Contact (OS2) : See NTAOS2

C94

Slam shut set point spring table

(1) For VSX2 (2) For OS2 * Non-PED version

* Non-PED version

Pa (mbar) Spring Spring

Nominal Min. Max. Wire Ø Length code

(mm) (mm)

20 8 25 3.0 171 144 136

35 20 55 4.0 171 122 832

60 40 90 4.5 165 131 919

100 60 140 5.5 165 131 918

160 80 180 6.0 165 142 539

300 100 340 7.5 180 137 054

500 300 550 8.0 170 131 793

1000 400 1100 10.0 170 144 035

1500 750 1500 8.0 170 131 793

2000* 1400 2600 10.0 144 035

3000* 2000 4000

Nominal Spring wire Ø Nominal set point (mbar)

Pa VSX2 OS2 Min Relief valve

(mbar) Min Max Min & Max Max with Max without

20 1.1 1.7 10 50 40

35 217 70 60

60 1.4 35 100 90

100 2.3 3.5 60(1)/70(2) 160 150

160 1.7 2.6 110 235 225

300 2.4 3.1 5200 430 400

500 3.5 350 700 650

1000 3.2 4.1 6.5 700 1400 1300

1500 2.4 3.1 1000 2000

2000* 2.4 3.5 6.5 1400 2600

3000* 3.2 4.1 2000 4000

PED label - Pa <= 100 mbar Regulatorinformation (examplePa 500 mbar)

VSX2 slam shut information (example Pa 500 mbar) OS2 slam shut information (example Pa 300 mbar)

Europe, Middle East, and Africa Document Only

REGAL 3

Item Description LP HP

1 Valve plug assembly 181058

2 O-ring 400506

3 Diaphragm 142033 142980

4 Relief valve/clutch O-ring 400505

5 Spring Tableau

6 Cap O-ring 400080

7 Screw 403030

8 Actuator/bodyO-ring 400029

9 Truarcring 406201

10 Sensingdiaphragm (d2)standard 138 369

Sensingdiaphragm (d4)(1) 144155

11 Washer 461173

12 Orifice 142 017

13 OrificeO-ring 400102

With Slam Shut VSX2 OS2

LP HP BMS 162

14 Circlips 406153

15 Spring 144064

16 Valve plug 142 130

17 Slam shut Pe O-ring 400081

18 Slam shut Pa O-ring 400074

19 Screw 403028

20 Bypass O-ring 400501

21 Stem O-ring 400 505

22 Diaphragm assembly 181017 181 027 181105

23 Slam shut assembly 196433 196 250 196245

Without Slam Shut

24 BottomO-ring 400081

Spareparts kit

(commissioningspares) 197 338 197347

OS2

VSX2

Impulse line

detail

Without

relief valve

With

relief valve

345 6

LP HP

DESCRIPTION

The Regal 3 consists of:

A version without integral slam shut:

•A body, a diaphragm actuator (LP or HP), a bottom

•A diaphragm-balanced valve plug, an orifice

Dependingon setpoint required:

- A Pa set point adjustment spring

A version with integral slam shut VSX2:

•A body, a diaphragm actuator (LP or HP)

•A diaphragm-balanced valve plug, an orifice

•An integral bypass slam shut (LP or HP) in place of the bottom

(see NTAVSX2)

Dependingon setpoint required:

- A Pa set point adjustment spring

- A tripping spring set to max

- A tripping spring set to min

A version with integral slam shut OS2:

•A body, a diaphragm actuator (LP or HP)

•A diaphragm-balanced valve plug, an orifice

•A slam shut connecting part in place of the bottom

•A valve plug with integral bypass

•A release relay type OS2 (see NTAOS2)

- A safety manometric box (BMS) for connection outlet side of the

regulator

- A mechanism box (BM)

Dependingon theset pointrequired:

- A Pa set point adjustment spring

- A max. and min. set point tripping spring

A version with relief valve (set point option 180 to 1100 mbar):

•Replacementof the disconnecterby an internalpartial relief valve

Orientation and regulator impulse line

Theactuator and slamshut can beorientated 360°.

The regulator impulse line is connected directly onto the body, which

makesmaintenance easier (theactuator canbe removed without

disconnectingthe impulsepipeline).

C93

C92

O 270

100 100

365

300

181

177.5

148

O 166

257

253

40*

40* 30*

180*

DIMENSIONSANDWEIGHTS

Weight: With slamshut 18.8 kg VSX2 24 kg OS2

Without slamshut 18 kg

C95

* Disassembly

dimentions

(1) On special request, for low inlet pressure applications (< 1 bar)

SPARE PARTS

Europe, Middle East, and Africa Document Only

REGAL 3

RELIEF VALVEADJUSTMENT

(Pa < 180 mbar)

• Unscrew the cap 6

• Unscrew the adjustment screw 5

• Pressthe adjustment screw

• Turn the sub-assembly 5a 1/4 turn to release it

• Remove the adjustment screw assembly 5

• Remove the set point spring 4

• Screw the relief valve set point nut 3to maximum (without blocking it)

with a box spanner 30

• Loadthe relief pressurevia the actuatorimpulse line

• Thepressure requireddepends onthe spring

• Spring 20 and 35 mbar

Loading pressure = relief setting - Pa + 7 mbar

• Spring 60 and 100 mbar

Loading pressure = relief setting - Pa + 8 mbar

• Spring160 mbar

Loading pressure = relief setting - Pa + 15 mbar

1. With relief valve

123456

OPERATION

The Regal 3 is a pressure regulator with expansion achieved by a

balancedvalve plug andpressure control bya direct-operated actuator.

Thebalanced valve plug/stem assuresaccuracy independent ofinlet and

outletpressures.

Pressurecontrol is achievedthrough the actuatordiaphragm, which

receives, on the one side, the outlet pressure and, on the other side the

spring load, adjusted to the desired value by the set point spring.

Tightshutoff is ensuredby the regulatorplug disc pushingon the orifice.

The regulator can be equipped with a slam shut using a release relay

type VSX2 or OS2.

For the EC standard version and for a Pa <= 180 mbar, an actuator with

an integral partial relief valve avoids slam shut tripping in the case of the

gasflow being abruptlycut off ortemperature increase onthe outlet side

whenthe regulator isnot in operation.

For the version without relief valve, in the case of over pressure, the

diaphragm plate assembly will travel up the actuator and sit into the cap,

withoutany leakor deteriorationof the components(disconnecter).

2. Without relief valve

7856

For example, for a Pa pressure setting = 25 mbar

(20 mbar spring) for a relief pressure setting of 45 mbar, load a

pressure of 45-25+7 = 27 mbar

• Unscrew the nut 3 until the relief valve opens

• Replace the set point spring 4

• Replace the adjustment screw assembly 5

• Replacethe cap 6 (afteradjusting theset point)

C96

Adjustment

screw

Resetting

button

Pe Pa

C97

Assembly with relief valve Assembly without relief valve

Standard assembly Standard assembly

Pa (mbar) Description Item Code Pa (mbar) Description Item Code

Relief valve stem 1 144089 Disconnecterstem 7 144041

<= 140 O-ring 400505 > 180 O-ring 400505

Spring D3 2116006 Spring D4 8 116816

> 180 Spring D4 116816

Assembly possibility Assembly possibility

Pa (mbar) Description Item Code Pa (mbar) Description Item Code

Relief valve stem 1 144089 Disconnecterstem 7 144041

> 180 O-ring 400505 <= 180 O-ring 400505

<1100 Spring D5 Pa <= 550 2 120588 Spring D4 8 116816

Spring D5.5 Pa > 550 2 120904

C102

Europe, Middle East, and Africa Document Only

REGAL 3

IS : lam shut impulseVSX2 s

IS : OS2 slam shut impulse

ISM : Actuator impulse

INSTALLATION

•The regulator is installed on horizontal (recommended) or

vertical pipeline. Version with slam shut, the release relay

can be situated towards the bottom or the top.

•Installation according to EN12186 or EN12279 recom-

mended.

•Install according to direction of 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.

•If the case arises a support must be used to avoid

pressure force on the body (a support can be installed

under the flanges).

•Connect the actuator (ISM) to the impulse at 4D minimum

on a straight run of the outlet pipe.

•Version with integral slam shut, connect the safety

manometric box (IS) to the impulse at 4D on a straight run

of the outlet pipe.

•It is recommended to separate the slam shut impulse line

(IS) from that of the actuator (ISM). Do not connect the

impulses on the lower generator line.

•Version with integral slam shut, it is recommended to

install an isolation valve (R1) and an atmospheric valve

(R2), which are useful for tripping and verifications.

•No modification should be made to the structure of the

equipment (drilling, grinding, soldering...).

•It is recommended to install a servicing valve (R3) on the

outlet pipeline to facilitate adjustments and bleeding off to

theatmosphere.

•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 appro-

priate operating conditions.

•Version without slam shut, verify that a pressure limiting

device on the outlet side of the regulator guarantees a

pressure limit < or equal to the actuator PS.

•Versionwith slam shut,verify thatthe springs (forVSX2), and

the safety manometric box (BMS) and its spring (for OS2)

correspond to the appropriate operating conditions on the

outlet side of the regulator.

•The equipment should not receive any type of shocks.

•Fire, seismic and lightening are not taken into consideration

for standard regulators. If required, a special product selec-

tion and/or specific calculations may be supplied according

to specific requirements.

•The user should verify or carry out a protection adapted to

the environment.

•Versionwith slam shut, ifthe outlet sideis subject tothe PED

and not protected by any other means, verify that no compo-

nent is superior to category 1.

All interventions on the equipment should only be performed by

qualified and trained personnel.

WARNING

C98

CAUTION

Europe, Middle East, and Africa Document Only

REGAL 3

Adjustment

screw

Resetting

button

Pe Pa

COMMISSIONING

All interventions on equipment should only be performed by

qualified personnel.

Operations concerning the integral slam shut version type VSX2 and

OS2 are in italic.

PRELIMINARY VERIFICATIONS

Start-up positions

• Inlet and outlet valves

ÆClosed

Verify the absence of pressure between inlet and outlet valves

• Setpoint adjustment screw

ÆUnscrewed (case 1) or set (case 2)

•Slam shut valve plug

ÆClosed

•Impulse isolating valve (R1)

ÆClosed

Slam shut set point verification

Type VSX2

Using the atmospheric valve (R2), inject a pressure equal to the

pressurerequired for theregulator

•Slam shut valve plug

ÆSet (Unscrew, pull, rescrew the resetting button

(see NTAVSX2))

ÆProgressively increase the pressure to reach tripping

ÆAdjust the setting if necessary (NTAVSX2)

Note the set point value on the equipment

or mark it on a commissioning document

Type OS2

Using the atmospheric valve (R2), inject a pressure

equal to the pressure required for the regulator

•1st release relay stage

ÆSet (Stage 1)

•Slam shut valve plug

ÆSet (Stages 2 and 3)

ÆProgressively increase the pressure to

reachtripping

ÆAdjust the setting if necessary (NTAOS2)

Note the set point value on the equipment

or mark it on a commissioning document

Positions before commissioning

•Impulse isolating valve (R1)

ÆOpen

•Impulseatmospheric valve (R2)

ÆClosed

•Slam shut valve plug

ÆClosed

• Servicing valve

ÆClosed

The equipment is commissioned

COMMISSIONING

• Inlet valve

ÆOpen very slowly

•Slam shut valve plug

Type VSX2

ÆSlowlyunscrew (bypassage)

Verify that the outlet pressure corresponds to the set point required

If not, adjust the regulator set point (adjustment screw)

Pull (set, when the bypassage is completed)

Gently push back and rescrew

Type OS2

•1st release relay stage

ÆSet (Stage 1)

•Slam shut valve plug

ÆBypassage (Stage 2)

ÆOpen (Stage 3)

• Servicing valve

ÆSlightlyopen

• Setpoint adjustment screw

ÆSlowly adjust to required value (adjustment screw)

• Outlet valve

ÆOpen slowly

• Servicing valve

ÆClosed

The equipment is commissioned

It is recommended to seal the release relay

C99

Travel

stop

Travel

stop

Travel

stop

Tripped position

Stage 1

Stages 2 and 3

C112

CAUTION

Europe, Middle East, and Africa Document Only

REGAL 3

MAINTENANCE

Operations concerning the integral slam shut versions are in italic.

SERVICING CHECK

Recommendedfrequency:

• Twice yearly minimum

Verification:

• Verificationof theset point

• Regulatorvalve plug tightness

•Tripping and slam shut valve plug set point value

•Slam shut valve plug tightness

Departure positions

• Inlet valve ÆOpen

• Outlet valve ÆOpen

•Slam shut valve plug ÆOpen

• Regulator ÆInoperation

Inletand outlet side of regulatorunder pressure

Tightshut verification (and tripping verification for integral slam

shut versions)

• Inlet valve ÆClosed

• Outlet valve ÆClosed

• Regulator Observetheevolutionoftheoutletpressure

(controlregulatortightness)

If the outlet pressure increases Internal leak

Controlthe regulator valve plug

Controlthe regulatororifice or contactafter-sales

If the outlet pressure decreases Externalleak

Locateand seal theleak or contactafter-sales

If the outlet pressure is constant The regulator is tightshut

Close the impulse isolation valve

Open the impulse atmospheric valve

Progressively inject pressure

(withoutexceeding outletpressure limits)

If the slam shut valve plug will not close Operatingfault

Control the release relay

Control the slam shut valve plug orcontact after-sales

If the slam shut valve plug closes Operating correctly

Observe the evolution of the outlet pressure (control tightness)

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 internal bypass orcontact after-sales

If the outlet pressure is constant Slam shut valve plug is tightshut

DISASSEMBLY OF THE REGULATOR AND SLAM SHUT

Recommendedfrequency:

Every 4 to 6 years (or less depending on operating conditions)

Verification:

Diaphragms, valve disc plug, lubrication

Replacement:

O-rings,diaphragms (dependingon condition

andlength ofusage),tightshut rings

Tools:

Male spanners for six-sided wrench 2.5, 4 and 6

Flatspanner 10

Box spanner 30 and 46

Spanner Torque

(N.m)

615

10 6

13 15

C101

2flat spannersfor flanges 24

Adjustmentspanner for VSX2 Ref.197 226

REGULATOR

• Valve plug closed (no flow)

• Inlet and outlet valves closed

•Bleed off outlet pressure

•Bleed off inlet pressure

• Unscrew the cap 6

• Unscrew the adjustment screw 5

• Remove the adjustment screw assembly 5

• Unscrew the actuator screws 3

• Remove the cover 4

Europe, Middle East, and Africa Document Only

REGAL 3

REGULATOR (continued)

• Unscrew the main diaphragm assembly 2

Beforedisassembling thediaphragm, note thedimension between

the relief valve setpoint nut and the diaphragm plate assembly 2

• Unscrew screws 7and remove the actuator body 1

• Control the O-ring 8

• Unscrew screws 9

• Remove the valve plug assembly 10

• Unscrew the orifice 11

• Control the O-ring 12

SLAM SHUT

Version with integral slam shut (type VSX2)

• Disconnectthe impulse pipe (IS)

• Unscrew the screws 14 and remove the VSX2 slam shut

• Control the valve plug 13

• Disassembly : see NTAVSX2

Version with integral slam shut (type OS2)

• Disconnectthe impulse pipe (IS)

• Unscrew the screws 14 and remove the OS2 slam shut

• Unscrew screws 17 from the mechanism box 16

• Disconnect the valve axe 15 from the mechanism box yoke 16

• Remove the connecting part 18 and the valve axle 15

• Contrôler le clapet desécurité 13

REASSEMBLY

• Performthe aboveoperations in reverseorder (respecttightening

torques)

• Diaphragms to be changed every 6 years or less depending on

condition

456

LP HP

C100

• Respectthe relief valvesetpoint dimension notedduring disassembly

• Replace O-rings at each disassembly

•Lubricatescrews beforetightening

• Lightlylubricate O-rings (siliconegrease)

• Lightly lubricate the valve plug stem (silicone grease)

• Lightly lubricate the slam shut valve plug stem (silicone grease)

• Lubricatesprings (molybdenumgraphitegrease)

Emerson Process Management

Natural Gas Technologies

Francel S.A.

Z.A. La Croix St. Mathieu

28320 Gallardon

France

Tel. +33 (0)2 37 33 47 00

Fax. +33 (0)2 37 31 46 56

For further information visit www.emersonprocess.com/regulators

The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective owners. Francel is a mark owned by Francel S.A. a business of

Emerson Process Management.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or

guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such

products at any time without notice.

Francel does not assume responsibility for the selection, use or maintenance or any product. Responsibility for proper selection, use and maintenance of any Francel product remains solely with the

purchaser.

CAUTION

Europe, Middle East, and Africa Document Only

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