Honeywell HON COCON 13 User manual

Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 1

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UNDERGROUNDGASREGULATIONSTATION

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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

Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 2

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CONTENTSPage:

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1‐Introduction4



2‐General5



2.1‐Technicaldata7

2.2‐WhatisHONCocon137

2.3‐Construction7

2.4‐Principleofoperation

2.4.1‐Active/Slamoperation    8

2.4.2‐Active/Monitoroperation    10

2.4.3‐Pressurepattern11 

2.4.4–PressureControl12

2.4.5–ActiveControl12

2.4.6–MonitorControl13

2.4.7–PilotControl

2.5‐Automaticoperation15

2.6‐Maintenance15



3‐Safety17

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4–Installation&operation18

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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started    23

4.3.2–Leakagetestandsetup    23



4.3.2.1–SlamShutValve    23

4.3.2.2–ReliefValve    24

4.3.2.3–Regulator(s)    24

4.3.2.4–GasControlModule   24





4.4–CommissioningoftheHONCocon    25



4.5–Troubleshooting26



4.6–Shuttingdown27

Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 3

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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

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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

Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 4

1.Introduction

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Thismanualhasbeencompiledtohelpyouinstall,adjustandmaintainthegaspressurereducingstation.

Itanswersthemostrecurringquestionsaboutthegaspressurereducingstationanditexplainshowtoreplaceseveral

partseasily.Themanualisforoperatorswhoarequalifiedinassemblingandoperatinggasinstallations.



Thismanualhasbeendividedintosixchapters,inordertogivetheoperators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informationinthis

manual.



Thisgaspressurereducingstationistheresultofyearsofdevelopment.Developmentisstillinprocess.Wewill

informyoubymailingaboutdevelopmentsconcerningthistypeofgaspressurereducingstation.



Definitions



p1=Inletpressure

p2=Reducedpressure

p=Differentialpressure(p1‐p2)

CR=Closingrate

MR=Monitoringrate

Q=Capacity

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Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 5

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ThestandardCocon13isatwinstreamgasreducingsystem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.

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Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 6

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2.General

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2.1Technicaldata

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TechnicaldataHONCOCON13twinstream:

Medium    :alltypesofgasesexceptforSulphur‐containinggases(H2S).

StationsforgaspressurereductionofgasescontainingSulphur

areavailableonrequest.

Inletpressure(p1)  :maximum20bar(ANSI150)

Outletpressure(p2)  :minimum20mbar(2kPa)

MinimalΔp(p1‐p2)  :0.5bar

Temperaturerange(ambient) :‐20°Cto+60°C

Flowcoefficient   :Cgvalue(EN334)435

Regulatingcapacities  :seesizingtables



Totalweight    :about300kg

Cartridgeweight   :about40kg

Packedvolume   :about1.5m3

Length    :maximum1435mm(incl.header)

Width    :maximum860mm

Height    :maximum980mm



Inletconnection   :2”

Outletconnection  :4”

Pressurerating   :accordingtoANSI150



Impulselineconnection  :metricfittingsaccordingtoDIN2353

Pressuregauges   :2or3,formeasuringinlet,(intermediate)andoutletpressure.

Pressuregauge   :¼"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

Filtermaterial   :felt

Filterfineness   :3micron(0,003mm)



Safetydevices

Safetydevice   :SSDvalvewithSSDcontroller



Locationoftypeplates

Casing    :beneathpitcover

Unit    :onmembranecover

Pilots    :onthesideofthepilot



Informationontypeplates

Casing    :namemanufacturer,typespecification,serialnumber,maximum

operationpressure,yearofconstruction

Unit    :namemanufacturer,typespecification,serialnumber,maximum

operationpressure,minimalreducedpressure,yearof

construction

Pilots    :namemanufacturer,typespecification,springtype,serial

number,adjustmentdata,yearofconstruction,maximum

allowedinletpressure

Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 7

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2.2WhatistheHONCOCON13

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TheHONCocon13isacompleteself‐containedundergroundgasregulatingstationforthereductionofgaspressure.

Thestationcanbecompletelyburiedorinstalledabovegroundinanareamuchsmallerthanaconventional

regulatingstation.

Thestationensuresreliablegassupplyataconstantpressureindependentofthegasconsumption.



Thestationhavingallessentialelementsofaconventionalpressurereductionstationisdesignedforuseongas

distributionandindustrialapplications.

Onlyaveryrestrictedareaisrequiredforinstallingthestation.

Theworkingelementsarecontainedinaremovablecartridgeretainedbyasimpleclosingconstruction.

Allbeinghousedinasteelbody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Construction



Remark:Forthelocationofthepartsofthegaspressurereducingstation,mentionedinthetext,wereferto

illustration2.4.1.



Theshortnumbersbetweenthebrackets,whicharementionedinthetext,

arepositionnumbersofthepartsinillustration2.1.



Thetopofthestationislocatedafewcentimetersaboveoratgroundlevel.Dependingonthecompositionofthe

soil,aconcretefoundation(plate)underthestationmaybeneeded.



ThegasregulatingstationHONCOCON13consistsoftwoparts:



‐ Thebody.

‐ Thegasregulatingandsafetyunit.(Cartridge)



Remark:The"gasregulatingandsafetyunit"willbereferredtoasthecartridgeintherestofthe

manual.



Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 8

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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)   

Operators manual

Operators manual underground gas pressure reducing station

Type: COCON 13

Page 9

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Thehingedpitlidcover(10)isfittedwithastainlesslatchthatissecurelypluggedforthepreventionofunauthorized

entry.



Anisolatingballvalve(09)ismountedtotheinletofthecasing.Whenthisballvalveisopen,itshandleprevents

removalofthePlexiglascover.



Adustfilter(07)isconnectedunderthecartridge.



Thegasthenpassesthroughasafetyshut‐offdeviceupstreamoftheregulatorwithinthemodularcartridge:



‐ Thedeviceconsistsofassdvalve(06)andassdcontroller(03).Thecontrollersitsontopofthecartridge.If

theregulatorfailsintheopenposition,therelaywilldetectanincreaseinlinepressureandreleasethe

spring‐loadedvalve,cuttingoffthegassupply.Itis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Plexiglascover.



Theinstallationofareliefvalveisanoption.



Transducerscanbeinstalledintheprotectionoftheenclosedspace,fortheremotemeasurementofpressures.Close

indicationoftheslamshutvalvebymeansofaproximityswitchisalsoavailable.



Thestationisfittedwithtwopressuregaugeswhichreadtheinletandoutletpressures.Thesegaugesaresituated

undertheprotectionofthePlexiglascoverbutarevisiblewhenthepitlidcoverisopened.



Purgevalvesfordepressurizationoftheunitaremountedonthecartridge.



Ahandleisattachedtothecartridge,sothecartridgecanbeeasilyremovedfromthecasing.



Operators manual

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

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