Emerson REGAL 3F User manual

REGAL 3F

Instruction Manual

D103693X012

July 2018

Direct-Operated Regulator

SUMMARY

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

DESCRIPTION.............................................................. 2

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

LABELLING................................................................... 3

DIMENSIONS AND WEIGHTS...................................... 4

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

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

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

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

SPARE PARTS.............................................................. 10

Type Regal 3F/OS2

Figure 1. Type REGAL 3F Direct-Operated Regulator

DECLARATION OF CONFORMITY REGAL 3F

Manufacturer: FRANCEL

Address: 3 avenue Victor Hugo, 28008 Chartres

Equipment: REGAL 3F Identiﬁcation no.:

Conformity Assessment Module: Module A

The undersigned declare that the design, manufacture and inspection of this equipment are in conformity with the Pressure Equipment

Directive 2014/68/UE (PED)

Name: Function: Company stamp:

Date: Signature:

The type REGAL 3F is in conformity with the Pressure

Equipment Directive PED 2014/68/UE and is classiﬁed

under category I.

Equipment and pipeline situated on the outlet side of

the regulator are either;

• not subject to the PED (Pu <= 0.5 bar), or

• subject to (Pu > 0.5 bar): in this case the type

Regal 3F is classiﬁed under category 1 maximum.

INTRODUCTION

The type REGAL 3F is a direct-operated, spring set point

pressure regulator, used for supplying industries and

commercial businesses.

As an option, it can be equipped with a slam shut types VSX2

or OS2 which permits the gas ﬂow to be cut off rapidly and

totally in the case of under or over outlet regulator pressure.

Type Regal 3F/VSX2

REGAL 3F

CHARACTERISTICS

Material

Body Ductile iron

Sitting part Brass

Actuator Aluminium

Regulator/slam shut oriﬁce Brass

Regulator valve plug Aluminium

Slam shut valve plug Aluminium

Regulator/slam shut plug disc Nitrile

* BMS : Safety Manometric Box

Operating pression

Body, valve plug, slam shut

4 bar

Actuator 1.5 bar

BMS* associed, according to size 5 bar

Operating temperature TS - 20 / 60 °C

Outlet pressure Pd 100/1000 mbar

REGULATOR

Accuracy

AC 5

SG 10

SZ 10

Inlet/Outlet diameter DN 50

Fluid

Groups 1& 2 according to PED 2014/68/UE, 1

and 2

family gas

according to EN 437, or other gases (compressed air, nitrogen). The gas

must be noncorrosive, clean (ﬁltration on inlet side necessary) and dry.

Table 1. General Characteristics for Type Regal 3F Regulator

DESCRIPTION

The Regal 3F consists of:

A Version without Integral Slam Shut

• A body, a diaphragm actuator, a bottom

• A diaphragm-balanced valve plug, an oriﬁce

Depending on set point required:

- A Pd set point adjustment spring

A Version with Integral Slam Shut Type VSX2

• A body, a diaphragm actuator

• A diaphragm-balanced valve plug, an oriﬁce

• An integral bypass slam shut in place of the bottom (see

D103695X012 manual)

Depending on set point required:

- A Pd set point adjustment spring

- A tripping spring set to max

- A tripping spring set to min

A Version with Integral Slam Shut Type OS2

• A body, a diaphragm actuator

• 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 D103683X012 manual)

- A safety manometric box (BMS) for connection outlet

side of the regulator

- A mechanism box (BM)

Depending on the set point required:

- A Pd set point adjustment spring

- A max. and min. set point tripping spring

Orientation and Regulator Impulse Line

The actuator and slam shut can be orientated 360°.

The regulator impulse line is connected directly onto the

body, which makes maintenance easier (the actuator can be

removed without disconnecting the impulse pipeline).

Connections

Inlet/Outlet: ISO PN 10

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

Actuator vent: 3/4’’ NPT tapped

Impulse line: Internal pipe Ø >= 15 mm

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

Impulse line (VSX2) : Internal pipe Ø >= 4 mm

(OS2) : Internal pipe Ø >= 8 mm

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

Contact (OS2) : See D103683X012 manual

REGAL 3F

Pset max

Date Fab/Test

N°serie/Serial N°

Type

Cat.

Regulateur

Regulator

FRANCE

28320 Gallardon

Groupe fluide 1

(Gaz naturel)

REGAL3F 10

4 bar - 20 / 60°C I

JJ MM 20AN

0.320 bar

1.5 bar

FRANCEL

Code

FRANCEL

Regulateur

Regulator

FRANCE

28320 Gallardon

902237

100 / 320

300

Plage / Range (mbar)

Réglage / Set (mbar)

Soupape / Relief

Tarage / Set (mbar)

Tarage / Set nominal

Plage / Range

Code

Type

AG maxi

Sécurité

Slam shut

10 barVSX2LPC3

196433 10

Min (mbar)

FRANCEL

Max (mbar)

100 / 350

200

260 / 600

400

Wdso

BMS

PSD BMS

N°

AG maxi

Taille

Size

Série

Serial

Ressort/Spring Ø

Wdsu

162 5

2.5

bar

Fisher

LABELLING

PED label Regulator label

Type VSX2 slam shut label Type OS2 slam shut label

Table 4. Set Point Spring & Slam Shut Range Table

Figure 2. Type Regal 3F/VSX2 and Type Regal3F/OS2 Labels

Pd (mbar) Pu (bar) Q (m3/h(n)) AC

100 0.7<Pu<1 520 10

100 > 1 520 5

160 0.7<Pu<1 520 10

160 > 1 520 5

300 0.7<Pu<1 520 10

300 > 1 520

500 > 1 500 5

1000 > 2 700

Table 2. Regulator Flow Ranges Table

Pd (mbar) Spring Spring

Nominal Min. Max. Wire Ø Length

(mm) (mm) code

100 60 140 5.5 165 131 918

160 80 180 6.0 142 539

300 100 320 7.0 167 144 300

500 300 550 8.0 170 131 793

1000 400 1100 10.0 144 035

Table 3. Regulator Set Point Spring & Regulator Ranges Table

Wire Ø (mm) Nominal Set Point

Nominal Pd VSX2 Springs OS2 Springs (mbar)

(mbar) Min. Max. Min. & Max. Min. Max.

100 1.4 2.3 3.5 60(1)/70(2) 150

160 1.7 2.6 110 225

300 2.4 3.1 5 200 400

500 3.5 350 650

1000 3.2 4.1 6.5 700 1300

(1) For VSX2 (2) For OS2

Nominal Pd Slam Contact Regulator code

(mbar) Shut

PN10 PN20

OS2 C1 902 463 FSREG3F-19NR

100 VSX2 LP NO 902 464 FSREG3F-20NR

NO 902 465 FSREG3F-21NR

OS2 C1 902 466 FSREG3F-22NR

160 VSX2 LP NO 902 467 FSREG3F-23NR

NO 902 468 FSREG3F-24NR

OS2 C1 902 283 FSREG3F-13NR

300 VSX2 LP NO 902 237 FSREG3F-10NR

NO 902 235 FSREG3F-16NR

OS2 C1 902 454 FSREG3F-14NR

500 VSX2 LP NO 902 453 FSREG3F-11NR

NO 902 456 FSREG3F-17NR

OS2 C1 902 455 FSREG3F-15NR

1000 VSX2 LP NO 902 238 FSREG3F-12NR

NO 902 236 FSREG3F-18NR

Table 5. Regulator Types Table

REGAL 3F

O270

100 100

365

300

181

177.5

148

O166

83 253

40*

40*30

180*

DIMENSIONS AND WEIGHTS

Weight

With slam shut: 18.8 kg VSX2 / 24 kg OS2 Without slam shut: 18 kg

* Disassembly

dimentions

Figure 3. Type Regal 3F/VSX2 and Type Regal3F/OS2 Dimensions (mm)

OPERATION

The type Regal 3F is a pressure regulator with expansion

achieved by a balanced valve plug and pressure control by a

direct-operated actuator.

The balanced valve plug/stem assures accuracy

independent of inlet and outlet pressures.

Pressure control is achieved through the actuator

diaphragm, 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.

Tight shutoff is ensured by the regulator plug disc pushing

on the oriﬁce.

The regulator can be equipped with a slam shut using a

release relay types VSX2 or OS2.

In the case of temporary over pressure, the diaphragm plate

assembly will travel up the actuator and sit into the cap, without any

leak or deterioration of the components (disconnector).

Figure 4. Type Regal 3/VSX2 and Type Regal3/OS2

Operational Schematic

OS2

VSX2

Pu Pd

Adjustment screw

Resetting button

REGAL 3F

INSTALLATION

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 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.

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.

Version with slam shut, verify that the

springs (for VSX2), 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 selection and/

or speciﬁc calculations may be supplied

according to speciﬁc requirements.

CAUTION

All interventions on equipment should

only be performed by qualiﬁed and trained

personnel.

WARNING

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 recommended.

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.

IS : lam shut impulseVSX2 s

IS : OS2 slam shut impulse

ISM : Actuator impulse

Figure 6. Type Regal 3F/VSX2 and Type Regal3F/OS2 Installation Schematic

REGAL 3F

The user should verify or carry out a

protection adapted to the environment.

Version with slam shut, if the outlet side is

subject to the PED and not protected by any

other means, verify that no component is

superior to category 1.

COMMISSIONING (Figure 4)

CAUTION

All interventions on equipment should only

be performed by qualiﬁed personnel.

Operations concerning the integral slam shut version types

VSX2 and OS2 are in italic.

Preliminary Veriﬁcations

Start-up Positions

• Inlet and outlet valves

- Closed

Verify the absence of pressure between inlet and outlet

valves

• Set point adjustment screw

- Unscrewed (case 1) or set (case 2)

• Slam shut valve plug

-Closed

• Impulse isolating valve (R1)

-Closed

SLAM SHUT SET POINT VERIFICATION

Type VSX2

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

the pressure required for the regulator

• Slam shut valve plug

-Set (Unscrew, pull, rescrew the resetting button

(see D103683X012 manual))

-Progressively increase the pressure to reach tripping

-Adjust the setting if necessary (see D103695X012

manual)

Note the set point value on the equipment or mark it on a

commissioning document

Type OS2 (Figure 7)

Using the atmospheric valve (R2), inject a pressure

equal to the pressure required for the regulator

• 1st release relay stage

-Set (Stage 1)

• Slam shut valve plug

-Set (Stages 2 and 3)

-Progressively increase the pressure to reach tripping

-Adjust the setting if necessary (see D103683X012 manual)

Note the set point value on the equipment or mark it on a

commissioning document

Positions before Commissioning

• Impulse isolating valve (R1)

-Open

• Impulse atmospheric valve (R2)

-Closed

• Slam shut valve plug

-Closed

• Servicing valve

- Closed

The equipment is commissioned

Commissioning

• Inlet valve

- Open very slowly

• Slam shut valve plug

Type VSX2

• Slowly unscrew (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 (Figure 7)

• 1st release relay stage

-Set (Stage 1)

Travel

stop

Travel

stop

Travel

stop

Tripped position Stage 1 Stages 2 and 3

Figure 7. Release Relay Activation Stages

REGAL 3F

• Slam shut valve plug

-Bypassage (Stage 2)

-Open (Stage 3)

• Servicing valve

- Slightly open

• Set point adjustment screw

- Slowly adjust to required value (adjustment screw)

• Outlet valve

- Open slowly

• Servicing valve

- Closed

The equipment is commissioned.

It is recommended to seal the release relay.

MAINTENANCE

Operations concerning the integral slam shut versions are in italic.

Servicing Check

Recommended frequency:

Twice yearly minimum

Veriﬁcation:

• Veriﬁcation of the set point

• Regulator valve plug tightness

• Tripping and slam shut valve plug set point value

• Slam shut valve plug tightness

Departure positions

• Inlet valve

- Open

• Outlet valve

- Open

• Slam shut valve plug

-Open

• Regulator

- In operation

Inlet and outlet sides of regulator under pressure

Tightshut veriﬁcation (and tripping veriﬁcation for

versions with integral slam shut)

• Inlet valve

-Closed

• Outlet valve

-Closed

• Regulator

-Observe the evolution of the outlet pressure (control

regulator tightness)

SYMPTOMS CAUSE ACTIONS

If the outlet pressure increases Internal leak

Control the regulator valve plug

Control the regulator oriﬁce

or contact after-sales

If the outlet pressure decreases External leak Locate and seal the leak

or contact after-sales

If the outlet pressure is constant The regulator is tightshut

Close the impulse isolation valve

Open the impulse atmospheric valve

Progressively inject pressure

(without exceeding outlet pressure limits)

If the slam shut valve plug will not close Operating fault

Control the release relay

Control the slam shut valve plug

or contact 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

or contact after-sales

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

Table 6. Troubleshooting for Type Regal 3F/VSX2 and Type Regal 3F/OS2 Regulators

REGAL 3F

Disassembly of Regulator and Slam Shut

Recommended frequency:

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

Veriﬁcation:

Diaphragms, valve disc plug, lubrication

Replacement:

O-rings, diaphragms (depending on condition and usage),

tightshut rings

Figure 8. Type Regal 3F/VSX2 and Type Regal 3F/OS2 detail

Spanner Torque (N.m)

615

10 6

13 15

Table 5. Corresponding Spanner / Torque Information

Tools

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

Flat spanner: 10

Box spanner: 30 and 46

2 ﬂat spanners for ﬂanges: 24

Adjustment spanner 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 (key 6)

• Unscrew the adjustment screw (key 5)

• Remove the adjustment screw assembly (key 5)

• Unscrew the actuator screws (key 3)

• Remove the cover (key 4)

• Unscrew the main diaphragm assembly (key 2)

CAUTION

Before disassembling the diaphragm, not

e the dimension between the relief valve

setpoint nut and the diaphragm plate

assembly (key 2)

• Unscrew screws (key 7) and remove the actuator body

(key 1)

• Control the O-ring (key 8)

• Unscrew screws (key 9)

• Remove the valve plug assembly (key 10)

• Unscrew the oriﬁce (key 11)

• Control the O-ring (key 12)

IS IS

456

REGAL 3F

Slam Shut

Version with Type VSX2 integral slam shut

• Disconnect the impulse pipe (IS)

• Unscrew the screws (key 14) and remove the VSX2 slam shut

• Control the valve plug (key 13)

• Disassembly : see D103683X012 manual

Version with Type OS2 integral slam shut

• Disconnect the impulse pipe (IS)

• Unscrew the screws (key 14) and remove the OS2 slam shut

• Unscrew screws (key 17) from the mechanism box

(key 16)

• Disconnect the valve axe (key 15) from the mechanism

box yoke (key 16)

• Remove the connecting part (key 18) and the valve axle

(key 15)

• Contrôler le clapet de sécurité (key 13)

Reassembly

• Perform the above operations in reverse order (respect

tightening torques)

• Diaphragms to be changed every 6 years or less

depending on condition

• Respect the relief valve setpoint dimension noted during

disassembly

• Replace O-rings at each disassembly

• Lubricate screws before tightening

• Lightly lubricate O-rings (silicone grease)

• Lightly lubricate the valve plug stem (silicone grease)

• Lightly lubricate the slam shut valve plug stem (silicone

grease)

• Lubricate springs (molybdenum graphite grease)

REGAL 3F

SPARE PARTS

Figure 9. Type Regal 3F/VSX2 and Type Regal 3F/OS2 Spare Parts detail

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