Honeywell COCON 26 DRA-LP/MP User manual

Honeywell
UNDERGROUND GAS REGULATION STATION
TYPE: COCON 26 DRA-LP/MP
Active - Slam
MAINTENANCE AND ASSEMBLY MANUAL
Assembly and maintenance documentation
Cocon 26 Active – Slam configuration
July 12, 2017
Rev 0

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 2
Contents
Page:
1. Technical Data 3
2. Assembly 4
2.1 General 4
2.2 Gas Regulation Station (G.R.S) 6
2.3 Safety Shut-off Valve (S.S.V.) 8
2.4 Cover of Cartridge 10
2.5 Gas Regulation Station Casing 11
2.6 Assembly of Gas Regulation Station and Cover of Cartridge 13
2.7 Assembly of Safety Unit (S.S.V.) 16
2.8 Assembly of Regulator Pilot, Safety Relief Valve and Measuring Units
such as Vent and Pressure Relief Pipes. 18
2.9AssemblyofDustFilter 23
3.Inspection 25
3.1 Inspection of Gas Regulating Station and Safety Unit 25
3.2TestCasing 26
3.3 Assembly of the Gas Regulating Station and Safety Unit
on the Test Casing 27
3.4LeakageTest 27
3.5 Setting of the Gas Regulating Station
and Safety Unit 27
3.6 Removal of the Gas Regulating Station and Safety Unit from the
Test Casing 28
4. Cleaning of Cartridge 28
5. Problems and Possible Solutions 29
6. Spare Parts 30

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 3
1 Technical Data
Technical Data of Type UGPRS : COCON 26.
Medium : all non-aggressive gases
Temperature : -15°C to +50°C
Inlet Pressure (p1) : max. 16 bar or 19 bar
Outlet Pressure (p2) : min. 20 mbar
Differential Pressure Delta P : min. 0.3 mbar
Weight of Cartridge : + 60 kg
Volume of UGPRS (packed) : + 1 m3
Length : ± 1000 mm
Width : ± 1000 mm
Height : ± 1000 mm
Pressure gauge : for inlet and outlet pressure
Control : Gas regulation station with auxiliary power from the inlet pressure
Safety Shut-off Device : Safety Shut-off Valve with monitor control.
Filter Material : Felt
Separation Rate : 98 % at particle size of 3 micron (0.003 mm)
Shut-off Valves : Inlet : Ball Valve DN 50 ANSI300
Outlet : Butterfly valve DN150 PN 16 or PN25
Mounting of Type Plates : on the membrane cover, under the pit cover, on
the regulator pilot, on the monitor control and on the shut-off relay.
Data on the type plate : Name of manufacturer, classification, serial number,
Max. operating pressure, set outlet pressure, year of construction
Regulator Pilot
Gas Regulation Station (G.P.R.S) : Cartridge
Regulator Pilot : RP-LP/MP
Safety Shut-off Valve (S.S.V.) : 050-LP(D)/MP(D)
Safety Relief Blow-off Valve (S.P.R.V.): AV-LP/MP

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 4
2 Assembly
2.1 General
These guidelines provide information on the assembly of the cartridge.
WARNING: Non-compliance of the instructions shown in these maintenance guidelines
could result in the following problems:
- Malfunctioning of the UGPRS
- Damage to individual components
- Personal injury
Disassembly
Chapter 2 describes the assembly of the cartridge. Disassembly takes place in the opposite manner. Please
pay attention to the following instructions when working:
- Always wear protective goggles when assembling the unit.
- Use the right tools to assemble the individual components.
- Keep the parts mentioned in a chapter together and separate them from other parts mentioned in
other chapters. This way you will have sorted all parts for the assembly of a component part as
described in a specific chapter.
- Disassemble the parts of the station carefully. Please ensure that parts like the pressure spring do
not 'shoot off'.
- Replace damaged or worn down parts with new parts.
Numbering
( 3 ) = Pos. 3
( 02.08 ) = Diagram 02.08
( 02.08 Pos. 3 ) = Pos. 3 of diagram 02.08
Article Numbers
The appropriate article numbers as well as the pos. number, number of items and description are stated in
the respective parts list.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 5
Diagram: 02.01

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 6
2.2 Gas Regulation Station
Assembly
- Place the membrane holder (11) on its raised edge.
- Hold the membrane holder so tightly that the raised edge points to the palm of your hand.
- Slide the membrane (12) over the membrane holder so that the membrane encloses the
membrane holder. The edge of the membrane hole lies on the raised edge of the membrane holder.
The thickened membrane side points to the centre of the membrane holder.
- Slide the membrane disc (44) – with the concave side to the front – against the membrane.
The membrane is now closed between the membrane disc and the membrane holder.
- Secure the membrane disc to the membrane holder with four hex socket head screws (46).
- Put this part aside.
- Slide the guiding holder (47) over the guide valve rod (23).
- Secure the guiding holder to the guide valve rod with a lock ring (52).
The frame on the outer diameter of the control valve (20) separates the control valve into a short and a long
end.
- Slide the largest diameter of the guide valve rod (23) into the long end of the control valve. Press
the guiding holder against the raised edge of the control valve.
- Secure the guiding holder and the guide valve rod in the control valve with a lock ring (51) .
- Put the long end of the control valve through the membrane holder from the convex side.
Ensure that the frame of the control valve lies on the membrane holder. Pay attention not to press
the seal ring in the membrane holder out of the groove when mounting the control valve. .
- Secure the membrane packets to the membrane holder with the disc (65) and four hex socket head
screws (65).

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 7
PARTS LIST: 02.02 No. of Items (belonging to diagram 02.02)
11 (1) Membrane Holder 8104003131980
12 (1) Membrane *8104004106720
20 (1) Control Valve 8104003131970
23 (1) Guide Valve Rod 8104004100520
43 (1) Seal Ring * 8401050502136
44 (1) Membrane Disc 8104003131990
46 (4) Hex Socket Head Screw 8251050060016
47 (1) Guiding Holder 8104004100530
51 (1) Lock Ring 8236050040001
52 (1) Lock Ring 8236000015001
64 (4) Screw 8251110060016
65 (1) Disc 8104004131960
We recommend to have on stock the with * marked parts.
Diagram: 02.02

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 8
2.3 Safety Shut-off Valve
Assembly
- Hold the valve rod (25) so that the screw thread points upwards.
- Slide the two sinus spring rings (27) with the convex side facing downwards over the top of the valve
rod.
- Place the seal ring (31) into the groove of the safety shut-off valve (56).
- Slide the retainer (30) into the safety shut-off valve. The seal ring is pressed between the
safety shut-off valve and retainer.
- Secure the retainer onto the safety shut-off valve with two hex socket head screws (28) and spring
rings (29).
- Slide the retainer over the valve rod and against the sinus spring rings.
- Press the safety shut-off valve against the spring pressure of the sinus springs and place the seal
ring (32) into the groove of the valve rod.
- Screw the guiding (58) onto the valve rod. The seal ring is pressed between the safety shut-off valve
and guiding.
- Take an open lug wrench with a "big jaw" opening (8) in order to tighten the guiding.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 9
PARTS LIST: 02.03 No. of Items (belonging to diagram 02.03)
25 (1) Valve Rod 8104004100230
27 (2) Sinus Spring Rings 8503210653400
28 (2) Hex Socket Head Screw 8207160040012
29 (2) Spring Ring 8237020040001
30 (1) Retainer 8104004150990
31 (1) Seal Ring * 8404037703222
32 (1) Seal Ring * 8404006002108
56 (1) Safety Shut-off Valve 8104004103880
58 (1) Guiding 8104004100550
We recommend keeping the spare parts marked with * ready for maintenance
purposes.
Diagram: 02.03

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 10
2.4 Cover of Cartridge
The cover of the cartridge (40) closes the top of the gas regulating and safety internal component. The
monitor control is mounted later on the cover of the cartridge. The control valve (02.02 Pos. 20) of the gas
regulation station is located in the interior of the cartridge
Assembly
- Fasten the seal ring (39) into the groove on the interior of the valve guide (10).
- Place a seal ring (41) into the groove on the exterior.
- Place the cover of the cartridge (40) with the concave side facing upwards.
- Slide the valve guide onto the edge in the centre of the cartridge cover.
- Close the valve guide with a lock ring (42) cover of the cartridge.
- Turn over the cover of the cartridge.
- Place the seal ring (3) into the groove on the top of the cover of the cartridge.
Put this part aside.
PARTS LIST 02.04 No. of Items (belonging to diagram 02.04)
3 (1) Seal Ring * 8401047302134
10 (1) Valve Guide 8104004117080
39 (1) Seal Ring * 8401050204329
40 (1) Cover of Cartridge 8104001126260
41 (1) Seal Ring * 8401071102149
42 (1) Lock Ring 8236050075001
We recommend to have on stock the with * marked parts.
Diagram: 02.04