Service Manual I-0057 - Emerson Process Management
Contents
1. DIFFERENTIAL PRESSURE PIPELINE PRESSURE ACROSS 4 RATE OF DROP IN PIPELINE PRESSURE lt ez L E Ze Lis 2 uJ ul I ala 5 2 a G n Z o d i zio lt gt a Sr rg n oz B 1 12 0167482 UPDT STDS ADD JEVA 204 1995 REVISE SPRING RANGES REV BY DATE REF Ove FIGURE 7 i 0057 wpd 27 REV 2 0126 00 0 67 EBREAK SYSTEM SG PAE JUL 31 92 DWG NO 50 60 70 8090100 50 60 70 8090100 40 40 JEVA 103H 30 NATURAL GAS 20 C RATE OF DROP RoD PSIG MINUTE RT2 RATE OF DROP LIN NATURAL GAS CALIBRATION CHART TYPE 100416 J1 1 PILOT 0 85 X RoD SPECIFIC GRAVITY 6 7 8910 SHIFT THE LINES TO THE LEFT USING AIR DIFFERENTIAL PRESSURE PIPELINE PRESSURE ACROSS J PIPELINE PRESSURE RATE OF DROP IN RoD o a a 2 lt 2 lt o 2 o a lt o o H FOR AIR 34155384 IWILNIYIIIIG 12 0167482 1 5 MOVIE REV UPDT STDS ADD JEVA 103H REVISE SPRING RANGES vL 1995 1992 08 21 5716 1 REVISE SPRING RANGES FIGURE 7 i 0057 wpd 28 APPENDIX A ALTERNATE PROCEDURES FOR SECTION 1 CALIBRATION AND TESTING AND SECTION2. simultaneously e Record P T T1 and T2 Note whether and when the J 1 switches f After T T2 close the LOW PRESSURE BLOCK VALVE to end the run g To calculate the RoD for the run use RoD P T T1 P T T2 2 To calculate the approximate P L for the run use P L P T T1 J 1 AP setting h If the J 1 switched reduce ie close down metering valve slightly for the next run If the J 1 did not switch increase RoD for the next run J1 RT2 TYPE T1 T2 NO 050416 100416 200416 400416 i 0057 wpd 37 APPENDIX A SECTION FUNCTION CHECK continued This procedure can be used even if the available PIPELINE PRESSURE ie starting pressure for each run is below normal However since all the variables are interdependent the setpoint RoD and P L values will be correspondingly reduced so they cannot be directly compared to spec or previously established baseline values 4 RESTORE THE UNIT TO OPERATING CONDITION Depressurize system and disconnect test equipment Install caps on HIGH PRESSURE and LOW PRESSURE TEST CONNECTIONS CAUTION Ensure that all connections are leak tight especially on the HIGH PRESSURE SIDE ie HIGH PRESSURE TEST CONNECTION plug U TUBE and RATE TANK DRAIN VALVE plug Check with soapy water when system is re pressurized i 0057 wpd 38 orig AG tl 1992 rev6 AG mc 1995 12 19 app dist EF O SM P
3. 171 9128 86 61 009 9 AT 9 LNOAVT SNOISN3WIQ WALSAS 215 17 ad SOR VavNvO 8158 011148 VN3N39 SACHS DNIAVUO NOLLVSISITTM 304 CILLINO 9 1601 f 0477 3 amp 1 11304 11 8817 2 9159 11504 11 8 1192 dH 6 154 OST NOILO3NNOO Adans 9 159 NOILOSNNGD 402 WNOSIS NOILOSNNOD 3NIGdId 1014 1 2 AIENASSY CIOJINVN UYY 1019 4 ONUNnOM 3unso1oN3 NOUGIBOS3U TT TUTTI 9 1 0016480 01 2661 14 NOUO3NNOO 434405 SYM 80S 0002 1 6222 006 0 22 2901 1591 089 FIGURE 3 i 0057 wpd 22 VI 00 966145 4 1 9125 26 21 NA VZN Avid NwodinHs Lv dv AVAX INU Wolvs3go OFINVY Svo XL1VQOVNYO SLLISa 51134 1014 38085184 3450 344 ANYL INWA YNVL YOLILSIY 3AWA uuu INWA NOLLYOSI 3NIi3did AYGO INU ANY INU SATA AANS 4 BATA SAWA 3XOMLS 30 43138 YOLVINESY 38055384 diindaNvH 3AWA 0
4. 6114 dNNOVE 0 1 91 0 V ON DAC 1 6108 TA 88 20 435 5 80601633880 60 1661 08 20255330 33195881 20 2661 52345 00 5015 1040 90 9160 531 5806 21 2661 S 1040 2545 WOS OGY A1gW3ssv AvMvino 1014 38055384 WUN3343lQ 510450 0270 EERSTE vavnvo suas 911199 0184 06 S 39NVN SNISN3S S3HONI NI 119 3SIAN3HI0 031319395 5531 S 9ISd 0061 R 891 441 ST 555 N f 2 05 2 9 1 08 j N 599 YNOS 76 gt SV9 L33AS 331835 f v l 251304 61 0 8 522 15 11921 312345 WAYS ON 1394 LIX 3199349 515 4 1305 A5 310N 1912 39 1104 1342944 066 1261 NZ S 39 WaS 3425 ONILNAOW 961 066 SET IIE 9908 88 6 13 9 88 ONIINAOW 661 066 SET 02 se39i4 061 066 oct 0511 33A02 SNISdS 121 066 ter 0121 6001395 SNINIV13N 021 066 02l CID 0121 X 2 NWa3iS ANOVA 61 066 6 CID S 1 15 4 1 8II 0 6 GED CA OON NAg WSLS 3 0 211 066 SEL 6 6 J X94 N vNn amp 31914 1804405 ONIN D 9II 0 6 133599 ONIS D SII 0 6 E 6 6 6 35
5. IS AVAILABLE PRESSURE TAKE OFF TAP VALVE PIPELINE 1 t 4 SETPOINT FUNCTION CHECK CHECK i GAUGE Gauce 4 MUFFLER 0 600 0 2000 7 Low 4 DKI PRESSURE TIMER T GAUGE FACTAE SELECTOR valve VALVE HIGH PRESSUR CONNECTION gt lt METERING HIGH PRESSURE VALVE BLOCK VALVE PIPELINE CONNECTION FILTER 1 t Law PRESSURE CONNECTION SET UP FOR 41 2 CALIBRATION AND TESTING WITH CALIBRATION KIT i 0057 wpd 9 FIGURE 2 SECTION CALIBRATION AND TESTING continued 4 J 1 AP CALIBRATION a Remove U TUBE and install caps on fittings b Open the LOW PRESSURE SIDE to atmosphere by fully opening the METERING VALVE and the LOW PRESSURE BLOCK VALVE Close the RATE TANK DRAIN VALVE and PANEL NEEDLE VALVE Set the GAUGE SELECTOR VALVE to the SETPOINT CHECK GAUGE c Open the HIGH PRESSURE BLOCK VALVE and slowly increase pressure on the HIGH PRESSURE SIDE using the NEEDLE VALVE Note the reading on the SETPOINT CHECK GAUGE when the J 1 switches ie MICROVALVE toggles Close NEEDLE VALVE after J 1 switches d Repeat test vent the HIGH PRESSURE SIDE by closing the NEEDLE VALVE and opening the RATE TANK DRAIN VALVE and repeat procedure b and c above e Compare the J 1 switch pressure to the required f Adjust the J 1 spring load if required turn adjusting nut FIG 4 item 111 and repeat steps b c and d until switchi
6. refer to Section VI item 3 and 4 Refer to Section item 4 Clean and lubricate parts replace diaphragm refer to Section VI item 8 SECTION V TROUBLESHOOTING continued PROBLEM C NOSIGNAL OUTPUTFROM 1 J 1 MICROVALVE on ESD condition 2 3 4 D SYSTEM ACTIVATES in 1 absence of ESD condition false signal 2 3 i 0057 wpd 18 CAUSE Insufficient lift on valve travel of microvalve Microvalve is clogged by foreign material Supply filters are dirty flow rate is then restricted Regulator setting is incorrect low pressure output only J 1 setpoint too low P L is less than RATE TANK PRESSURE while attempting to reset Low RoD develops high AP due to clogged restrictor REMEDY See J 1 pilot drawing check the bracket bolt tightness and trigger bolt adjustment refer to Section VI item 7 Clean valve passages Clean filter elements Check regulator setpoint adjust if necessary Refer to Section item 4 Allow to stabilize Check and clean restrictor refer to Section VI item 6 SECTION VI MAINTENANCE PROCEDURES 1 DISARM AND DEPRESSURIZE BEFORE REMOVAL DISASSEMBLY The following steps are to be carried out when removing disassembling any part of the linebreak system for reasons of safety Isolate or disarm downstream controls and equipment to prevent inadvertent operation or alarms Close isolation valve at the pipeline ie upst
7. RT2 System is shipped separately customer connections in addition to above include Low pressure supply connection to J 1 pilot valve supply connection C 74 female 150 psig max Low pressure signal connection to J 1 pilot valve signal connection B 74 NPT female i 0057 wpd 5 SECTION INSTALLATION AND START UP continued START UP Refer to FIG 4 1 OPERATION AND FUNCTION OF MANUAL VALVES a PIPELINE ISOLATION VALVE item 101 This valve is normally open Closing this valve isolates the system from the pipeline RATE TANK DRAIN VALVE item 107 This valve is normally closed and plugged Unplug and open to depressurize the J1 RT2 system or drain condensate 2 START UP Check and close all manual control valves Open the main isolation valve on the pipeline customer supplied SLOWLY open PIPELINE ISOLATION VALVE item 101 to pressurize system When flow into the RATE TANK has stopped the signal pressure gauge should indicate if a signal is being applied to or removed from the valve operator control package The Line Valve item 2 should be able to be opened and it should remain open LEAK TEST ALL FITTINGS AND CONNECTIONS WITH SOAPY WATER i 0057 wpd 6 SECTION CALIBRATION AND TESTING THREE REQUIREMENTS FOR CORRECT J1 RT2 OPERATION CORRECT J 1 PILOT CALIBRATION Verify using the J 1 AP CALIBRATION procedure in this section LEAK TIGHT HIGH PRESSURE SIDE
8. Record pressure reading at 90 seconds and close the LOW PRESSURE BLOCK VALVE f Compare this to the appropriate MAXIMUM END PRESSURE value in the table below If the end pressure is above the maximum there is plugging or obstruction of the restrictor or filters refer to Section VI MAINTENANCE PROCEDURES J1 RT2 TYPE NO MAXIMUM END PRESSURE psig NATURAL GAS AIR NITROGEN 050416 172 189 100416 226 237 200416 260 267 400416 280 283 7 Restore the unit to operating condition or proceed to the FUNCTION CHECK procedure Section IV Ensure that all remade connections are leak tight especially on the HIGH PRESSURE SIDE ie cap for HIGH PRESSURE TEST CONNECTION and plug at the RATE TANK DRAIN VALVE Check with soapy water i 0057 wpd 35 APPENDIX A SECTION FUNCTION CHECK The J1 RT2 function and calibration can be checked in the field by doing RoD SIMULATION RUNS Using P L repeat runs at different RoDs to approximate the SETPOINT ie the RoD which generates just enough AP to activate the J 1 pilot at a particular P L This process will give two RoD values The upper value the lowest RoD at which the J 1 switched The lower value the highest RoD at which the J 1 did not switch The closer the two values are the more accurately the SETPOINT RoD is determined Each value of RoD will have a corresponding value of P L which is also recorded NOTE The THREE REQUIREMENTS FOR CORRECT J1 RT2 OPERATION s
9. TEST EQUIPMENT This is the same as Section step 3 except the hose connecting the PIPELINE PRESSURE TAP to the CALIBRATION KIT PANEL PIPELINE CONNECTION is not required and the RATE TANK DRAIN VALVE is closed and plugged Set the GAUGE SELECTOR VALVE to FUNCTION CHECK GAUGE 3 RoD SIMULATION RUNS Each run must have the same starting pressure ie P T 0 00 Use a starting pressure which is equal to or slightly less than typical pipeline operating pressure Using the same starting pressure for future function checks will allow direct comparison of data Use the table below to find the appropriate value for T1 and T2 i 0057 wpd 14 SECTION IV FUNCTION CHECK continued Each RoD SIMULATION RUN consists of the following a Using available PIPELINE PRESSURE charge the system to the starting pressure by opening the PIPELINE ISOLATION VALVE Ensure the LOW PRESSURE BLOCK VALVE is closed b Close the PIPELINE ISOLATION VALVE and set the METERING VALVE The METERING VALVE setting controls RoD and must be determined by trial and error c Stabilize at the starting pressure for at least one minute d Open the LOW PRESSURE BLOCK VALVE and start the TIMER 0 00 simultaneously e Record P T T1 and T2 Note whether and when the J 1 switches f After T T2 close the LOW PRESSURE BLOCK VALVE to end the run 4 To calculate the RoD for the run use RoD P T T1 P T T2 2 To calculate the approximate P L for the run u
10. Verify using the PRESSURE HOLD TEST procedure in this section UNOBSTRUCTED RESTRICTOR AND FILTERS Verify using the PLUGGING TEST procedure in this section CALIBRATION AND TESTING PROCEDURES For routine calibration and testing the following steps 1 to 7 are to be executed in sequence NOTE THESE PROCEDURES REQUIRE BETTIS CALIBRATION KIT PART NO 930 980 REFER TO APPENDIX A FOR AN ALTERNATE PROCEDURE BASED ON SIMPLIFIED EQUIPMENT THIS SIMPLIFIED EQUIPMENT IS SPECIFIED IN THE PROCEDURE AND MAY BE SUPPLIED BY THE USER 1 DISARM SYSTEM Isolate or disarm controls and equipment downstream of the J1 RT2 output signal to prevent inadvertent operation or alarms Follow applicable procedures and operating instructions Depending on where and how this is done selected downstream controls can be left active The function of these controls can then be verified when J1 RT2 output signals are generated during the following procedures 2 CHECK FOR EXTERNAL LEAKS While the J1 RT2 system is still pressurized check for external leaks at all connections using soapy water Fix any leaks before proceeding i 0057 wpd 7 SECTION CALIBRATION AND TESTING continued 3 SETUP TEST EQUIPMENT SEE FIG 2 SETUP FOR J1 RT2 CALIBRATION AND TESTING WITH CALIBRATION KIT CAUTION DISARM AND DEPRESSURIZE BEFORE ATTEMPTING SERVICE Close the PIPELINE TAKE OFF VALVE and de pressurize the system by opening the RATE TANK DRAIN VALVE CAUTI
11. failure of the HIGH PRESSURE HOLD TEST is likely due to leaking tube fittings valves or internal leakage through the J 1 diaphragm or the check valve refer to Section VI MAINTENANCE PROCEDURES Depressurize the system by venting the RATE TANK open the RATE TANK DRAIN VALVE 6 PLUGGING TEST Ensure the PIPELINE ISOLATION VALVE is closed and the system is depressurized ie the RATE TANK DRAIN VALVE is open Re install the U TUBE Ensure that these tube connections are leak tight as they are on the HIGH PRESSURE SIDE Check with soapy water after the system is pressurized CAUTION Use minimal torque when remaking U TUBE connections to extend tube life Close the RATE TANK DRAIN VALVE and LOW PRESSURE BLOCK VALVE Ensure the METERING VALVE is near fully open the HIGH PRESSURE BLOCK VALVE is closed and the GAUGE SELECTOR VALVE is on SETPOINT CHECK GAUGE Pressurize the system to 300 psi by opening the PIPELINE ISOLATION VALVE Stabilize the pressure for one minute If pressure will not stabilize there is a leak in the system which must be fixed before running the test See item 5 PRESSURE HOLD TEST Open the LOW PRESSURE BLOCK VALVE and simultaneously start TIMER Record pressure reading at 90 seconds and close the LOW PRESSURE BLOCK VALVE Compare this to the appropriate MAXIMUM END PRESSURE value in the table below If the end pressure is above the maximum there is plugging or obstruction of the restrictor or filters refer
12. to Section VI MAINTENANCE PROCEDURES i 0057 wpd 12 SECTION CALIBRATION AND TESTING continued J1 RT2 TYPE NO MAXIMUM END PRESSURE psig NATURAL GAS AIR NITROGEN 050416 172 189 100416 226 237 200416 260 267 400416 280 283 7 RESTORE THE UNIT TO OPERATING CONDITION or proceed to the FUNCTION CHECK procedure Section IV CAUTION Ensure that all connections are leak tight especially on the HIGH PRESSURE SIDE ie HIGH PRESSURE TEST CONNECTION plug U TUBE and RATE TANK DRAIN VALVE plug Check with soapy water when the system is re pressurized i 0057 wpd 13 SECTION IV FUNCTION CHECK The J1 RT2 function and calibration can be checked in the field by doing RoD SIMULATION RUNS Using PIPELINE PRESSURE repeat runs at different RoDs to approximate the SETPOINT ie the which generates just enough AP to activate the J 1 pilot at a particular P L This process will give two RoD values The upper value the lowest RoD at which the J 1 switched The lower value the highest RoD at which the J 1 did not switch The closer the two values are the more accurately the SETPOINT RoD is determined Each value of RoD will have a corresponding value of P L which is also recorded NOTE The THREE REQUIREMENTS FOR CORRECT J1 RT2 OPERATION see Section are the first priority and must be met for this function check to be valid PROCEDURE 1 DISARM SYSTEM See Section III step 1 2 SETUP
13. 3345 80123135 10714 INWA TWANYN AVM E 5 3AWA 1 SIN3NOqOO 30 088900000888888868888888888 V 50330 3 IVY TONINOO NOMS 5 INJA Ol SI 1014 38056384 38055389 INN JO OL 51 34055384 SIHL Nouvoriddv NINO V YO 03215 O3X ONI3H 3215 34056344 SNM 30 JO ONY 3216 10141538 3ZIS 1 30 V SI 10114 38055384 34055384 SIHL SOL 101 153 SSOYOV SNM GNY N33MI3S CBLVSND SI 38055384 VUN3HiidI S3sv3HO30 38055384 INN 31 801 NI 38155384 HUM 38066384 INN SIYVdNOD 021 1014 38055384 3833 10 XO3HO 801 xNvl ALVY OL 021 1019 38055384 1 OL G3rlddv 51 34055384 INN 1835344 SVO Y3MOd 35019 N3dO HUM NAOHS 8 434405 SB1336 UO FIGURE 4 i 0057 wpd 23 M 70 3 7921 52 6261 11 6861 04 SU
14. CHART Refer to FIG 6 identified by a TYPE number which corresponds to the TYPE number stamped on the unit name plate The CALIBRATION CHART maps the relationship between AP RoD and P L The J 1 pilot is calibrated to trip at a particular AP by adjusting the spring preload or changing springs The CALIBRATION CHART also indicates the AP ranges of the four J 1 springs which may be used stocked at the factory The selection of restrictor is done at the factory based on the specified RoD range and P L operating range Specific instructions for reading the required AP from the CALIBRATION CHART are given in Section III 4 J 1 AP CALIBRATION The CALIBRATION CHARTS are for natural gas with a specific gravity SG of 67 and temperature of 20 C After correcting for SG and temperature they will normally agree with field data within 20 on RoD The inaccuracy is due to manufacturing tolerances and the fact that the chart P L lines are adjusted from original data using air Considering the above the recommended uses of the CALIBRATION CHARTS are limited to the following Selection of the correct restrictor for an application normally done at the factory Initial J 1 pilot calibration normally done at the factory to be verified at final installation using the FUNCTION CHECK procedure Section IV Illustration of performance characteristics for training calibration or troubleshooting purposes Use of the CALIBRATION CHARTS to verif
15. DATE pee AUG 14 92 ce 1 009771 i 0057 wpd 25 FIGURE 6 40 SO 60 70 8090100 30 100 50 60 70 8090 RATE OF DROP RoD PSIG MINUTE SG 0 67 0 85 X RoD NATURAL GAS SHIFT THE LINES TO THE LEFT USING AIR LI LEGEND RoD uo x e 4 lt 2 Lr x z o lt 2 lt a ac 0 x 22 kK lt o FOR AIR ETTIS CANADA LTD BETTIS J1 PIPELINE PRESSURE JEVA 404H NATURAL GAS 20 C C 0128 DWG RT2 RATE OF DROP LINEBREAK SYSTEM CALIBRATION CHART TYPE 400416 1 PILOT DIFFERENTIAL PRESSURE PIPELINE PRESSURE ACROSS J RATE OF DROP IN He DEC 02 92 C 0198 00 2 CHK KN DWG NO BY SCALE N A 6101 1 DEC 01 95 WO SPECIFIC GRAVITY 12 0187482 1 THERS CORR FOR CAL ERROR 1994 02 0387008 1800 2100 P L LINES ADDED REV BY DATE REF UPDT STDS ADD JEVA 404H amp VL 1995 FIGURE 7 i 0057 wpd 26 92 REV 1 00 12 0127 SG 0 67 50 60 70 8090100 40 50 60 70 8090100 40 CHK 21 DWG NO RoD PSIG MINUTE KN JEVA 204H 30 30 NATURAL GAS 20 C BY GW 1 RT2 RATE OF DROP LINEBREAK SYSTEM CALIBRATION CHART NATURAL GAS TYPE 200416 BETTIS CANADA LTD 5716 ami a Ji 1 PILOT 6 7 8 810 SPECIFIC GRAVITY
16. Edmonton Alberta Canada T6E 5V2 Tel 780 450 3600 EDMONTON Actuators amp Controls Fax 780 450 1400 Service Manual Bettis Canada Ltd 4112 91A Street a ed BETTIS J1 RT2 RATE OF DROP LINEBREAK DETECTION SYSTEM CUSTOMER W O TYPE DATE FACTORY SET psi min RoD psi P L SECTION PAGE GENERAL DESCRIPTION amp INFORMATION 2 Il INSTALLATION AND 5 4 III CALIBRATION AND TESTING 6 IV FUNC HON CHECK dc eoe enc 13 V TROUBLE SHOOUTING ko CR RR 16 VI MAINTENANCE PROCEDURES 18 VII DRAWINGS Outline Drawing FIG 3 FIG 4 J 1 Pilot Assembly FIG 5 Manifold Assembly FIG 6 Rate of Drop vs AP Calibration Charts FIG 7 APPENDIX A ALTERNATE PROCEDURES FOR SECTION III CALIBRATION AND TESTING AND SECTION IV FUNCTION CHECK 29 I 0057 WPD 1 REV 6 1995 12 19 SECTION GENERAL DESCRIPTION 8 INFORMATION The Bettis J1 RT2 system is designed to automatically monitor a gas pipeline and deliver a pneumatic signal if a pre determined rate of pressure drop is exceeded The unit is typically used to detect a pipeline break situation and signal a valve operator The system consists of a rate tank J 1 differential pressure pilot restrictor check
17. IAN 9399191 vii 0 6 rt S S9 1104 399181 60 06 O IT 1 2572 14 2 39 1404 4342954 2 6 2 jr 91 109 TW LAN 11 066 11 Ir NOUN WLS 10Nxon1 Jil w Aazu2 DNAs 060 066 06 jt 1914190919 BADD 45 080 066 08 91 1909 19 31914 1904205 090 066 09 E ee NOSE l3xSv9 WOvsHdvId 060 066 06 sussdMv3 090 0 6 Ov ess X wais 0 0 0 6 oe i f 31 199 d1 020 066 Jt X 2391 190 19 0 4404 010 066 or 1310 13 101 14319 NOILdINOS3I 1594 W311 FIGURE 5 i 0057 wpd 24 FILTER END PLUG O RING FILTER ELEMENT SPRING CHECK VALVE To RETAINER RATE PLUG O RING CHECK VALVE ES AO p E IET 227 N ACA im RESTRICTUR HOUSING CAP LP SIDE RESTRICTOR CAP HP SIDE TEST CONNECTION TEST CONNECTION B PIPELINE ISOLATION VALVE SECTION A A SECTION B B PIPELINE BETTIS semis canada cro Actuators amp Controls MANIFOLD ASSEMBLY 41 2 LINEBREAK SYSTEM UPDATE RESTRICTOR HOUSING DY 1995 12 0829815 3 T EDITORIAL UPDATE AG 1993 03 0209144 1 R 0657 WEIGHT 4 60 LB REV BY DATE REF DEC 08 95 SCALE 1
18. IV FUNCTION CHECK THESE ALTERNATE PROCEDURES ARE BASED ON SIMPLIFIED TEST EQUIPMENT SPECIFIED IN THE PROCEDURE WHICH MAY BE SUPPLIED BY THE USER i 0057 wpd 30 APPENDIX A SECTION CALIBRATION AND TESTING THREE REQUIREMENTS FOR CORRECT J1 RT2 OPERATION CORRECT J 1 PILOT CALIBRATION Verify using the J 1 AP CALIBRATION procedure in this section LEAK TIGHT HIGH PRESSURE SIDE Verify using the PRESSURE HOLD TEST procedure in this section UNOBSTRUCTED RESTRICTOR AND FILTERS Verify using the PLUGGING TEST procedure in this section CALIBRATION AND TESTING PROCEDURES For routine calibration and testing the following steps 1 to 7 are to be executed in sequence 1 DISARM SYSTEM Isolate or disarm controls and equipment downstream of the J1 RT2 output signal to prevent inadvertent operation or alarms Follow applicable procedures and operating instructions Depending on where and how this is done selected downstream controls can be left active The function of these controls can then be verified when J1 RT2 output signals are generated during the following procedures 2 CHECK FOR EXTERNAL LEAKS While the J1 RT2 system is still pressurized check for external leaks at all connections using soapy water Fix any leaks before proceeding i 0057 wpd 31 APPENDIX A SECTION CALIBRATION AND TESTING continued 3 SETUP TEST EQUIPMENT Close the PIPELINE ISOLATION VALVE Depressurize the system by opening th
19. ON Ensure that contaminants eg dust soapy water etc do not enter at the HIGH or LOW PRESSURE TEST CONNECTIONS a Connect HIGH PRESSURE CONNECTION on CALIBRATION KIT PANEL to HIGH PRESSURE TEST CONNECTION on the J1 RT2 MANIFOLD 3 8 tube fitting b Connect LOW PRESSURE CONNECTION on CALIBRATION KIT PANEL to LOW PRESSURE TEST CONNECTION on the J1 RT2 MANIFOLD 1 4 tube fitting c Connect PIPELINE CONNECTION on CALIBRATION KIT PANEL to a PIPELINE PRESSURE TAP or between the PIPELINE TAKE OFF VALVE and the PIPELINE ISOLATION VALVE Ensure 1 All CALIBRATION KIT PANEL valves are closed except the METERING VALVE which should be near fully open 2 GAUGE SELECTOR VALVE is set to FUNCTION CHECK 3 All connections are made leak tight To pressurize system for leak checking connections Open PIPELINE TAKE OFF VALVE and PIPELINE ISOLATION VALVE Open HIGH PRESSURE BLOCK VALVE Slowly open CALIBRATION PANEL NEEDLE VALVE allowing system to fill and stabilize To vent off Close PIPELINE TAKE OFF VALVE Open RATE TANK DRAIN VALVE Open LOW PRESSURE BLOCK VALVE i 0057 wpd 8 HP 4 1 RENS J i RATE NU U TUBE MANIFOLD RESTRICTOR HOUSING HIGH PRESSURE SIDE LOW PRESSURE SIDE HIGH RATE tank V DRAIN VALVE PIPELINE T LD ISOLATION PRESSURE VALVE TEST CONNECT ION CONNECTION ALTERNATE CONNECTION IF HOSES PIPELINE 7 PIPELINE SEPARATE
20. and RATE TANK DRAIN VALVE plug Check with soapy water when system is re pressurized i 0057 wpd 16 SECTION V TROUBLE SHOOTING A B In general the J1 RT2 system will be trouble free as long as the THREE REQUIREMENTS FOR CORRECT OPERATION are met refer to Section Ill In case of trouble the procedures below should help to isolate the problem See also the remainder of this manual for correct operating procedures and detailed description of components Re check assembly and operating procedures if problems arise immediately after shutdown for maintenance or calibration CAUTION Before doing any work on the system refer to SECTION VI MAINTENANCE PROCEDURES item 1 DISARM AND DEPRESSURIZE BEFORE REMOVAL DISASSEMBLY PROBLEM CAUSE J1 RT2 FAILS TO ACTIVATE 1 1 diaphragm cracked or on ESD condition high leaking RoD 2 Externalleakage Confirm by doing PRESSURE HOLD TEST 3 By pass check valve inside MANIFOLD is leaking confirm by doing PRESSURE HOLD TEST 4 Dirty filters J1 PILOT FAILS TO 1 J 1setpoint too high ACTIVATE on ESD condition high RoD high AP 2 J 1 diaphragm stiff or shaft jammed confirm by removing spring and checking for 74 free travel i 0057 wpd 17 REMEDY Replace diaphragm refer to Section VI item 8 Check and correct Check if there is any foreign material at the poppet of the check valve refer to Section VI item 5 Clean or replace filters
21. d cause rapid plugging of the manifold filter elements Inspect and or replace the filter cartridge on the same schedule as the manifold filter elements refer to item 3 Ensure that the filter body is depressurized before opening 5 CHECK VALVE REMOVAL INSPECTION Refer to FIG 6 Remove CHECK VALVE RETAINER PLUG and NPT pipe plug at opposite side of MANIFOLD Push the check valve out using a suitable non metal tool to avoid damage or scratches Check for moisture or debris inside check valve body or between o ring and poppet If present hold the poppet off the seat and clear with compressed air Check for free movement of the poppet Inspect the sealing surface in the manifold bore and condition of the external o ring on the check valve body If the valve still leaks the internal o ring is probably damaged and the valve requires replacement 6 RESTRICTOR MAINTENANCE Refer to FIG 6 To ensure correct operation the RESTRICTOR must be free of obstruction The manifold filters and recommended prefilter are meant to keep the restrictor clean and dry However if plugging is suspected follow the procedure below a Remove RESTRICTOR HOUSING from MANIFOLD The restrictor cannot be removed from the housing without special tools b Soakin solvent for a 24 hour period To remove solvent and provide proper filtering attach the RESTRICTOR HOUSING to the manifold via the U TUBE only ie do not screw housing into manifold then blow air t
22. e RATE TANK DRAIN VALVE Setup test equipment as shown in the diagram below CAUTION Ensure that contaminants eg dust soapy water etc do not enter at the HIGH PRESSURE and LOW PRESSURE SIDE TEST CONNECTIONS All connections must be leak tight CAUTION When PIPELINE PRESSURE is greater than the range of the PRESSURE GAUGE use extreme care when opening valves to avoid over pressurizing i 0057 wpd 32 45 HP SIDE a ee ts MICRO TANK CONNECTION U TUBE RESTRICTOR HOUSING 4 8 0 4 4 PRESSURE t GAUGE 1 i7 ESTO DRAIN M PIPELINE CONNECTION ISOLATION BA VALVE t bt LP BLOCK 1 TU PIPELINE FILTER VALVE t i TAKE OFF ALVE gt lt gt lt METERING HP BLOCK NEEDLE ALVE t VALVE VALVE HOSE PIPELINE PRESSURE TAP PIPELINE TEST EQUIPMENT TEST EQUIPMENT SPECIFICATIONS PRESSURE GAUGE 0 1000 PSI RANGE 2 5 PREFERRED METERING VALVE 037 ORIFICE 1 STEM TAPER VERNIER HANDLE PREFERRED FILTER 0 5 MICRON INLINE 1 4 CONNECTIONS BLOCK VALVES 1 4 NOMINAL 1 4 TURN BUBBLE TIGHT NEEDLE VALVE 1 4 NOMINAL BUBBLE TIGHT HOSE HIGH PRESSURE TIMER STOPWATCH PREFERRED SEI UP FOR J1 RT2 CALIBRATION AND TESTING FIGURE 8 APPENDIX A SECTION CALIBRATION AND TESTING continued 4 J 1 AP CALIBRATION a Open the LOW PRESSURE SIDE to atmosp
23. ee Section III are the first priority and must be met for this function check to be valid PROCEDURE 1 DISARM SYSTEM See Section item 1 2 SETUP TEST EQUIPMENT This is the same as Section item except the HIGH PRESSURE BLOCK VALVE NEEDLE VALVE and HOSE are removed and the RATE TANK DRAIN VALVE is closed and plugged If the normal PIPELINE PRESSURE range exceeds the range of the gauge used in Section III ie 0 1000 psi then install a gauge of suitable range with resolution of no greater than 10 psi div 3 RoD SIMULATION RUNS Each run must have the same starting pressure ie P T 0 00 Use a starting pressure which is equal to or slightly less than typical pipeline operating pressure Using the same starting pressure for future function checks will allow direct comparison of data Use the table below to find the appropriate value for T1 and T2 i 0057 wpd 36 APPENDIX A SECTION IV FUNCTION CHECK continued Each RoD SIMULATION RUN consists of the following a Using available PIPELINE PRESSURE charge the system to the starting pressure by opening the PIPELINE ISOLATION VALVE Ensure the LOW PRESSURE BLOCK VALVE is closed b Close the PIPELINE ISOLATION VALVE and set the METERING VALVE The METERING VALVE setting controls RoD and must be determined by trial and error c Stabilize at the starting pressure for at least one minute d Open the LOW PRESSURE BLOCK VALVE and start the TIMER T 0 00
24. here by fully opening the METERING VALVE and the LOW PRESSURE BLOCK VALVE b Slowly increase pressure on the HIGH PRESSURE SIDE using the NEEDLE VALVE and note the reading on the PRESSURE GAUGE when the J 1 switches ie MICROVALVE toggles When the HIGH PRESSURE SIDE is pressurized there will be a small flow through the restrictor c After the J 1 switches shut the NEEDLE VALVE and vent the HIGH PRESSURE SIDE by opening the HIGH PRESSURE BLOCK VALVE d Compare the J 1 switch pressure to the required e Adjust the J 1 spring load if required turn adjusting nut FIG 4 item 111 and repeat steps b c and d until switching occurs at the required AP If the required AP is outside the range of the J 1 spring contact the factory for an alternate If the required is unknown or not yet established use the CALIBRATION CHART to find the AP corresponding to the specified desired RoD and P L If the pipeline operates over a wide pressure range a typical pressure must be selected Use of CALIBRATION CHART to find AP Find the specified desired RoD along the horizontal axis and trace a line upward to where it intersects the specified desired P L line interpolation between P L lines may be required From this intersection trace a horizontal line to the vertical axis and read the AP value Refer to comments on the CALIBRATION CHART in Section I 5 PRESSURE HOLD TEST a Ensure the PIPELINE ISOLATION VALVE is closed Depressur
25. hrough the RESTRICTOR by pressurizing the RATE TANK side of the system i 0057 wpd 20 SECTION VI MAINTENANCE PROCEDURES continued d e Reinstall RESTRICTOR HOUSING and U TUBE on the MANIFOLD Verify correct installation of the manifold filters refer to item c in this section T J 1 MICROVALVE ALIGNMENT Refer to FIG 5 Remove the spring item 90 Pressurize the HIGH PRESSURE SIDE to 120 psi Adjust the trigger bolt outwards until the microvalve item 130 is triggered Lock in place with locknut The microvalve lever should have approximately 0 010 to 0 032 inches additional over travel Do not use excessive force on the lever Vent the HIGH PRESSURE SIDE and re install the spring PILOT INSPECTION MAINTENANCE Refer to FIG 5 Disconnect the tubes at the HIGH PRESSURE and LOW PRESSURE fittings remove the J 1 spring and check that the diaphragm mechanism travels from stop to stop about total travel without binding or catching Apply about 100 psi at the HIGH PRESSURE fitting and check for leakage at the LOW PRESSURE fitting This can be done by installing a tube cap loosely and checking for bubbles with soapy water Alternatively a 1 4 plastic tube can be connected to the LOW PRESSURE fitting with the free end submerged in c in water In either case there should be no sustained bubbling If any problems are detected obtain a spare parts kit and rebuild i 0057 wpd 21 026140
26. ize the system by venting the RATE TANK open the DRAIN VALVE and HIGH PRESSURE BLOCK VALVE i 0057 wpd 33 APPENDIX A SECTION CALIBRATION AND TESTING continued b Remove the U TUBE and install tubing caps on the fittings the cap on the HIGH PRESSURE SIDE must be installed leak tight to pass the pressure hold tests CAUTION Ensure that contaminants eg dust soapy water etc do not enter at these fittings as they are internal to the manifold filters Close the RATE TANK DRAIN VALVE leaving the HIGH PRESSURE BLOCK VALVE open c LOW PRESSURE HOLD TEST Close the LOW PRESSURE BLOCK VALVE Pressurize the HIGH PRESSURE SIDE TO 20 psi by opening the PIPELINE ISOLATION VALVE the flow through the check valve will require it to open and reseat at low pressure resulting in a worst case test Stabilize the pressure reading for one minute then vent the LOW PRESSURE SIDE by opening the LOW PRESSURE BLOCK VALVE Monitor the PRESSURE GAUGE for 3 minutes The maximum allowable pressure loss is 10 of RoD over 3 minutes eg if RoD 20 psi min then allowable pressure loss over 3 minutes is 2 psi or less d HIGH PRESSURE HOLD TEST Close the LOW PRESSURE BLOCK VALVE Pressurize the HIGH PRESSURE SIDE to 500 psi or to available P L if less by opening the PIPELINE ISOLATION VALVE Stabilize the pressure reading for one minute then vent the LOW PRESSURE SIDE by opening the LOW PRESSURE BLOCK VALVE Monitor the pressure gauge for 3 minute
27. ng occurs at the required AP If the required AP is outside the range of the J 1 spring contact the factory for an alternate If the required AP is unknown or not yet established use the CALIBRATION CHART to find the AP corresponding to the specified desired rate of drop RoD and pipeline pressure P L If the pipeline operates over a wide pressure range a typical pressure must be selected Use of CALIBRATION CHART to find AP Find the specified desired RoD along the horizontal axis and trace a line upward to where it intersects the specified desired P L line interpolation between P L lines may be required From this intersection trace a horizontal line to the vertical axis and read the AP value Refer to comments on the CALIBRATION CHART in Section 1 i 0057 wpd 10 SECTION CALIBRATION AND TESTING continued 5 PRESSURE HOLD TEST a Ensure the PIPELINE ISOLATION VALVE is closed Depressurize the system by venting the RATE TANK open the RATE TANK DRAIN VALVE Disconnect the hose from the PIPELINE PRESSURE TAP and PANEL PIPELINE CONNECTION Re install plugs at both fittings b If not done in step 4a then remove the U TUBE and install tubing caps on the fittings CAUTION Ensure that contaminants eg dust soapy water etc do not enter at these fittings Close the RATE TANK DRAIN VALVE and HIGH PRESSURE BLOCK VALVE CAUTION Ensure that plugs have been installed leak tight Check with soapy water when the system is p
28. pipeline break the AP takes time to reach its maximum value These dependencies are inherent in this type of system The time delay in reaching the maximum AP necessitates the following clarification P L is the pipeline pressure occurring at the time that the maximum AP is developed not the pipeline pressure at the initiation of the RoD refer to FIG 1 This time delay is apparent and accounted for in the FUNCTION CHECK procedure SECTION IV i 0057 wpd 2 SECTION GENERAL DESCRIPTION amp INFORMATION continued FIGURE 1 shows the characteristic pressure versus time relationship of the system If the RoD shown was the SETPOINT then the maximum AP shown would be equal to the 4 1 SETPOINT The 4 1 would switch ie trip and send a pneumatic alarm signal at time Tx If the RoD shown was slightly below the SETPOINT RoD then the maximum AP shown would be less than the 4 1 AP SETPOINT and it would not switch no matter how much time passed If the RoD shown was higher than the SETPOINT RoD the AP would reach the J 1 AP SETPOINT before time Tx PIPELINE PRESSURE AT SENSING POINT d PRESSURE PIPELINE BREAK JI RT2 RATE TANK PRESSURE MAXIMUM AP 1 N CHARACTERISTIC PRESSURE VERSUS TIME RELATIONSHIP FOR J1 RT2 i 0057 wpd 3 FIGURE 1 SECTION GENERAL DESCRIPTION amp INFORMATION continued Each combination of restrictor and rate tank size has a specific CALIBRATION
29. ream of all linebreak system components Depressurize the system by opening the RATE TANK DRAIN VALVE STANDARD PRACTICES FOR MAINTENANCE Clean around any parts to be removed before removal Note or mark piping or parts orientation before removal to facilitate re assembly Clean all parts before assembly particularly sealing surfaces Lubricate all o rings and sliding surfaces Lubricate all threads to prevent galling MAINTENANCE OF MANIFOLD FILTER ELEMENTS Refer to FIG 6 To maintain free flow and prevent false shutdowns the two filter elements in the MANIFOLD should be cleaned or replaced at least every six months until service experience indicates a more suitable interval To do this Remove one of the FILTER END PLUGS on left side of MANIFOLD Remove the spring Tap or pry filter element lightly on side to break loose from the tapered sealing bore Clean the filter element Insert the clean filter element into the bore Tap lightly with smooth faced tool to re seat the element in tapered bore Replace spring and END PLUG Tighten END PLUG securely Repeat 3 through 8 for second filter i 0057 wpd 19 SECTION VI MAINTENANCE PROCEDURES continued 4 MAINTENANCE OF OPTIONAL PREFILTER Refer to FIG 3 An optional prefilter item 170 upstream of MANIFOLD connection Port A is highly recommended in wet or dirty service to entrap foreign particles and moisture which coul
30. ressurized in step c Set the GAUGE SELECTOR VALVE to the SETPOINT CHECK GAUGE c LOW PRESSURE HOLD TEST Close the LOW PRESSURE BLOCK VALVE Pressurize the HIGH PRESSURE SIDE to 20 psi by opening the PIPELINE ISOLATION VALVE the flow through the check valve will require it to open and reseat at low pressure resulting in a worst case test Stabilize the pressure reading for one minute then vent the LOW PRESSURE SIDE by opening the LOW PRESSURE BLOCK VALVE METERING VALVE near fully open Monitor the SETPOINT CHECK GAUGE for 3 minutes The maximum allowable pressure loss is 10 of RoD over 3 minutes eg if RoD 20 psi min then allowable pressure loss over 3 minutes is 2 psi or less d HIGH PRESSURE HOLD TEST Close the LOW PRESSURE BLOCK VALVE Pressurize the HIGH PRESSURE SIDE to 500 psi or to available P L if less by opening the PIPELINE ISOLATION VALVE Stabilize the pressure reading for one minute then vent the LOW PRESSURE SIDE by opening the LOW PRESSURE BLOCK VALVE and metering valve is nearly full open Monitor the SETPOINT CHECK GAUGE for 3 minutes The maximum allowable pressure loss is 1096 of RoD over 3 minutes see example in step c above i 0057 wpd 11 SECTION CALIBRATION AND TESTING continued If the maximum allowable pressure loss rates are exceeded there is a leak in the HIGH PRESSURE SIDE which must be traced and fixed A failure of the LOW PRESSURE HOLD TEST is likely due to a faulty check valve A
31. s The maximum allowable pressure loss is 10 of RoD over 3 minutes see example in step c above e If the maximum allowable pressure loss rates are exceeded there is a leak in the HIGH PRESSURE SIDE which must be traced and fixed A failure of the LOW PRESSURE HOLD TEST is likely due to a faulty check valve A failure of the HIGH PRESSURE HOLD TEST is likely due to leaking tube fittings valves or internal leakage through the 4 1 diaphragm or the check valve refer to Section MAINTENANCE PROCEDURES Depressurize the system by venting the RATE TANK and re install the U TUBE f Ensure that these tube connections are leak tight as they are on the HIGH PRESSURE SIDE Check with soapy water after the system is pressurized i 0057 wpd 34 APPENDIX A SECTION Ill CALIBRATION AND TESTING continued 6 PLUGGING TEST a Ensure the PIPELINE ISOLATION VALVE is closed and the system is depressurized ie the RATE TANK DRAIN VALVE and HIGH PRESSURE BLOCK VALVE are open b Close the RATE TANK DRAIN VALVE and LOW PRESSURE BLOCK VALVE and fully open the METERING VALVE leave the HIGH PRESSURE BLOCK VALVE open c Pressurize the system to 300 psi by opening the PIPELINE ISOLATION VALVE Stabilize the pressure for one minute If pressure will not stabilize there is a leak in the system which must be fixed before running the test See item 5 PRESSURE HOLD TEST d Open the LOW PRESSURE BLOCK VALVE and simultaneously start TIMER e
32. se P L P T T1 J 1 AP setting h If the J 1 switched reduce RoD ie close down metering valve slightly for the next run If the J 1 did not switch increase RoD for the next run J1 RT2 TYPE T1 T2 NO 050416 100416 200416 400416 i 0057 wpd 15 SECTION IV FUNCTION CHECK continued This procedure can be used even if the available PIPELINE PRESSURE ie starting pressure for each run is below normal However since all the variables are interdependent the setpoint RoD and P L values will be correspondingly reduced so they cannot be directly compared to spec or previously established baseline values The METERING VALVE used in the FUNCTION CHECK procedure has a very small annular gap between the orifice and the needle Due to the this and the large pressure drop across it freeze off may occur when the ambient temperature is low or when the pipeline gas dew point is high This will cause difficulty in adjusting and achieving a continuous RoD in the RoD SIMULATION RUNS The remedy is to apply heat to the body of the METERING VALVE either by hand contact or a chemical or electric heating pad or similar device at 80 C 20 C 4 RESTORE THE UNIT TO OPERATING CONDITION Depressurize and disconnect test equipment Install caps on HIGH PRESSURE and LOW PRESSURE TEST CONNECTIONS CAUTION Ensure that all connections are leak tight especially on the HIGH PRESSURE SIDE ie HIGH PRESSURE TEST CONNECTION plug U TUBE
33. valve manifold assembly and associated tube fittings gauges and filters The system works as follows when pipeline pressure is rising gas flows through the check valve and restrictor into the rate tank When pipeline pressure is falling gas flows out of the rate tank back to the pipeline through the restrictor only The restrictor resists the flow creating a pressure drop which is sensed by the J 1 as differential pressure The J 1 will send a pneumatic signal if the differential pressure exceeds its calibrated setting The greater the rate of drop in the pipeline pressure the greater the differential pressure across the J 1 The following abbreviations will be used pipeline pressure P L rate of drop RoD differential pressure AP Normally the pipeline will be operating at a steady or slowly changing pressure When a pipeline break occurs the RoD at the J1 RT2 sensing point will depend on the distance to the break Greater distance to the break will decrease RoD at the sensing point A compromise must be made in adjusting the RoD setpoint It must be as low as possible to detect remote breaks but not so low that normal pipeline pressure fluctuations will cause a false alarm As indicated earlier the J 1 differential pressure pilot does not respond directly to RoD but to AP The AP depends on but also on 1 P L The required to generate a given AP increases with higher P L 2 Time After the initiation of a RoD due to a
34. y FUNCTION CHECK data is not recommended as itis complicated Corrections would generally have to be made for SG and temperature and unnecessary the data from the FUNCTION CHECK procedure stands by itself as proof that the system is operating to specification provided the unit has been calibrated and tested per Section Ill It is recommended that users establish their own baseline calibration records using the procedures in Section Ill IV and keep calibration records i 0057 wpd 4 SECTION INSTALLATION AND START UP GENERAL INFORMATION The unit can be installed remote from or on the valve operator The following preparations are required 1 Ensure the isolation valve on the pipeline is installed with take off to top of pipeline to allow liquids to drain back into the line 2 Ensure that pipe and tube to be used is free of chips and debris 3 Use minimum 1 4 NPT or 3 8 tube with support adequate to prevent vibration and strain on connections An additional pre filter is recommended Refer to Section VI item 4 It should be installed between the PIPELINE ISOLATION VALVE FIG 4 item 101 and the customer supplied isolation valve at the pipeline take off CONNECTIONS Refer to FIG 3 When the J1 RT2 System is shipped pre installed on the valve operator customer connections consist of High pressure pipeline gas connection to PIPELINE ISOLATION VALVE pipeline connection A 74 NPT female When the J1
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