Honeywell HON COCON 13 User manual

Operators manual
© 2017 Honeywell International Inc.
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
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OPERATORS‐MANUAL
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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
© 2017 Honeywell International Inc.
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
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2‐General5
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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
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3‐Safety17
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4–Installation&operation18
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4.1–Installationinstructions18
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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
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4.2‐Startingup21
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4.2.1‐Installationofcartridge    22
4.2.2‐Emergency‐stop22
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4.3‐Operation23
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4.3.1–Beforegettingstarted    23
4.3.2–Leakagetestandsetup    23
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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
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4.4–CommissioningoftheHONCocon    25
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4.5–Troubleshooting26
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4.6–Shuttingdown27

Operators manual
© 2017 Honeywell International Inc.
Operators manual underground gas pressure reducing station
Type: COCON 13
Page 3
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4.7‐Replacingparts27
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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
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4.8‐Storage24
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5–Options30
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5.1‐Introduction:Options30
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5.4‐Reliefvalve30
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5.5–Valvepositionindicator30
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6‐Additionaldata31
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6.1‐Adjustmentform31

Operators manual
© 2017 Honeywell International Inc.
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.
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Thismanualhasbeendividedintosixchapters,inordertogivetheoperatorseasyaccesstotherequiredinformation.
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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.
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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.
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Definitions
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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
© 2017 Honeywell International Inc.
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.
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Example1
BothlinesActiveregulatorwithSSV
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Example2
OnelineActive/MonitorregulatorandonelineActive/SSV
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PictureofatwinstreamCocon13inclusivemanifoldsandfinalcoating.
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Thein‐andoutletvalvesareconnectedbymanifoldscreatingatwinsteamconfiguration.
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Oneofthelinesnormallyisthe“stand‐by”lineandoneisoperational.
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Operators manual
© 2017 Honeywell International Inc.
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
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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
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Inletconnection   :2”
Outletconnection  :4”
Pressurerating   :accordingtoANSI150
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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
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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)
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Safetydevices
Safetydevice   :SSDvalvewithSSDcontroller
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Locationoftypeplates
Casing    :beneathpitcover
Unit    :onmembranecover
Pilots    :onthesideofthepilot
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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
© 2017 Honeywell International Inc.
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.
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
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Operators manual
© 2017 Honeywell International Inc.
Operators manual underground gas pressure reducing station
Type: COCON 13
Page 8

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
© 2017 Honeywell International Inc.
Operators manual underground gas pressure reducing station
Type: COCON 13
Page 9

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
© 2017 Honeywell International Inc.
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