Emerson FRANSEL REGAL 3 User manual

REGAL 3
Instruction Manual
NTAREG30406
June 2004 - Rev. 03
1
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
2
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°
PS
Type
TS
DN
Cat.
PN
Regulateur
Regulator
FRANCE
28320 Gallardon
Groupe fluide 1
(Gaz naturel)
50
REGAL3 10 ou 20
10 bar - 30 / 71°C I
JJ MM 20AN
1.1 bar
1.5 bar
FRANCEL
FRANCEL
Tarage / Set nominal
Plage / Range
Code
Type
AG maxi
PS
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
O
PS
Pt
mm
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
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
14
15
16
17
18
22
20
19
21
23
9
10
7
8
11
12
13
With
relief valve
345 6
LP HP
LP
2
1
24
23
22
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
83
257
253
40*
40* 30*
180*
LP
HP
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
4
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
LP
HP
LP
Adjustment
screw
R1
R2
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
5
Pe
R2
R2
R1
R1
IS : lam shut impulseVSX2 s
IS : OS2 slam shut impulse
D
4D
ISM : Actuator impulse
Pa
R3
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
!
WARNING
C98
CAUTION
Europe, Middle East, and Africa Document Only

REGAL 3
6
LP
HP
LP
Adjustment
screw
R1
R2
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
7
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)
44
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
8
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
3
2
1
456
7
8
9
10
11
12
13
14
IS
IS
13
14
18
17
16
15
LP HP
LP
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)
© Francel S.A. All Rights Reserved
Emerson Process Management
Natural Gas Technologies
Francel S.A.
Z.A. La Croix St. Mathieu
28320 Gallardon
France
Tel. [phone]
Fax. [phone]
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