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EI Regulator Station Handbook TDC UK PDF
EI Regulator Station Handbook TDC UK PDF
HANDBOOK
CONTENTS
INTRODUCTION 4
History 5
Present 5
Maximum allowable pressure loss 7
REGULATOR STATIONS 8
Functions 8
Essential design parameters 8
Safety and environmental codes and regulations 9
OPERATIONAL ASPECTS 13
Gas quality 13
Availability and maintenance 13
Electrical safety and hazardous areas 14
Construction 14
Noise 14
Station layout 15
Pipe sizing 17
Valves 18
Regulators 18
Gas filters 23
Monitor regulator 25
Safety shut-off valves 25
Safety relief valves 27
Heat exchangers 27
Setpoints 28
REFERENCES 30
3
INTRODUCTION
This manual is one of a series that Instromet has prepared for the gas
industry. It describes the installations that are used to reduce the gas
pressure to the operating pressure of the downstream system or
appliances.
The next chapter is devoted to the main operational aspects, and this
is followed by a description of the layout of the individual
components and of their function.
Gas regulator stations are often also used for metering. This
handbook concentrates on the regulator aspects. For the metering
system the “Systems Handbook” should be consulted. The
requirements for the installation of the meter vary with the
construction of the particular type of meter. The handbook relating
to the meter type selected for the station, provides information on
this subject.
4
DISTRIBUTION AND TRANSMISSION SYSTEMS
History
In the early days of gas, its distribution was carried out at very low
pressures, traditionally about 2 kPa or 20 cm water column (8” WC)
and often even less. As the gas was locally manufactured at low
pressure, this was the most economic solution. Additionally, the
technology at that time did not permit the economic manufacture of
pipes and fittings capable of withstanding higher pressures.
Present
From the source to the user the pressure is reduced in stages, the
maximum pressure in each stage being determined by the weakest
component in the system subjected to the pressure of that particular
stage. Regulator stations form the connection between the
subsequent stages of the system.
5
An example of a practical system is given in figure 1.
r
ba
Gathering
0+
10
Wells Treatment/
r conditioning
ba
H.P.Transmission
67
r
ba
Compressor
20
H.P.Transmission
Industry
r
ba
67
M.P. Transmission
r
ba
r
ba
40
8
M
r
ba
40
M
r
ba
Distribution
8
M
M
r
r
ba
ba
SHOPPE
r
ba
M
8
r
4
ba
0m
20
Commercial
20
M M M M M
r
ba
m
20
Residential
Figure 1
Example of modern transmission and distribution system
6
Maximum allowable pressure loss
P22 2
qm
+ =1 (1)
P21 q2m max
In this equation the pressures are absolute pressures and qmmax is the
absolute theoretical maximum mass flow rate. This equation, when it
is plotted, is a quarter circle as shown in figure 2.
100
P2 /P1 %
60
80 100
qm/qm max %
Figure 2
Relation between pressure ratio and carrying capacity
It is easy to see that if the flow is at 80 % of its theoretical maximum,
the pressure at the end of the pipe has already reduced to 60 % of
the inlet pressure. Any further increase in the flow rate has a large
influence on the outlet pressure, and most operators would be very
reluctant to operate beyond this limit.
The minimum inlet pressure of a regulator station would therefore
rarely be less than 60 % of the operating pressure of its supply system.
7
REGULATOR STATIONS
Functions
The regulators and other safety devices are normally powered by the
gas itself so that these functions do not have to rely on the presence
of external power.
In some stations the gas is also metered and this function usually
influences the design.
8
In an existing transmission system the maximum inlet pressure is a
given parameter. This determines the rating of the regulator body
and the upstream pipework.
For the most economic design these two last values should be known
accurately. However, in practice the uncertainty of these values is high
and may change in time. Stations will therefore in general be sized
somewhat larger than required to avoid having to change them too
soon.
The quality control and assurance for pressure vessels and piping also
vary considerably among countries.
Environmental concerns are mainly for the noise issuing from the
station. The venting of gas to the atmosphere may also be restricted.
9
Usually this is formulated for one mole of gas as:
Ql = Q • Pb•Z• T (3)
(P•Zb•Tb)
Q
Ql = (4)
P
where P is the outlet pressure in bar.
As a rule of thumb one can assume that for natural gas the
temperature drops by 0.5° C for every bar of pressure reduction.
10
For large pressure drops the temperature can therefore drop to well
below freezing point when the gas has not been preheated before
reduction.
W = 0.5 • Vn • ∆T (5)
Apart from the heating costs, the investment in heaters and heat
exchangers and their maintenance contribute to the cost of
ownership. The advantages, however, are:
11
It is perfectly possible to operate stations with sub-zero outlet
temperatures and save the energy otherwise required for heating.
Advantages are:
For the particular gas it is found from [3] that the values for Z are:
12
P •Z• T 1.013 • 0.9778 • 283
Ql = Q• b = 10,000 •
(P• Zb• Tb) 11.013 • 0.9981 • 288
10,000
The approximate formula gives 11 = 909 m3/h. (8)
OPERATIONAL ASPECTS
Gas quality
13
Electrical safety and hazardous areas.
Construction
Noise
Some regulators have special cages to break down the velocity more
gradually. Some have different valve constructions with the same
objective. All “silent” regulators are bigger and more expensive.
Heavier pipe walls and larger diameters generally help to reduce the
noise as does external insulation, specifically of the downstream
pipework.
14
Burying the installation is a very effective way of insulating it from
Outlet valve
Pipe silencers can be effective. However, in many cases the intense
vibration that the sound absorbing material is subjected to, destroys
ion
Meter
Small relief
at
all
LAYOUT AND COMPONENTS Regulator
t
in s
Station layout
ing
Heat exchanger
t
In figure 3 a general layout of a station and its components is given.
ra e
There are an infinite number of possible variations of which the most
Op
common are given below.
similar valve will be installed in the outlet line. The inlet and outlet of
the station proper are connected to these valves by headers and risers.
ion
Inlet valve
t
the application, and the codes and regulations that apply. In all cases
sta
there will be an inlet valve and a regulator, and in most cases also a
n
yi
present. This relief valve can be small as it only has to blow off the
possible leakage through the regulator. Some regulators can be
equipped with a small built-in relief valve for that purpose. The relief
valve can only be dispensed with when it is absolutely certain that a
no-consumption situation will never occur.
15
Full capacity relief
Outlet valve
tion Small relief
lla Station outlet valve
n sta
yi
d -b Meter
tan
S
Regulator
16
Safety device (Shut-off, monitor)
Figure 3
ion
at
As has been described earlier, it may be desirable to heat the gas before
reduction to prevent condensation of either hydrocarbon condensates
or water from the gas or water vapour on the outside of the station. In
that case a heat exchanger and boiler have to be installed.
The meter and its additional pressure and temperature sensors are
usually installed downstream of the regulator. Guidelines for the
installation of the meter are given in the handbooks for the
respective meter types (Turbine Gasmeter Handbook, Rotary Piston
Gasmeter Handbook and Ultrasonic Gasmeter Handbook). For
further details on the instrumentation and the metering system,
please see the “Systems Handbook”.
Pipe sizing
17
Valves
Ball valves are normally of the same size as the piping, but a ball with
reduced bore may be used. The additional noise generated by this
restriction is small compared with the noise of the regulator, and is
usually outweighed by the cost saving.
Regulators
Gas regulators differ from control valves such as used in the process
industry by the fact that they do not use any external energy source.
Instead they use either a spring or the gas itself to generate the force
to operate the valve. As a result they are faster and more reliable.
The other major difference is that gas regulators are always equipped
with a soft seat making it possible to fully seal the inlet from the
outlet when no gas is used.
18
The space above the diaphragm has to be open to the atmosphere.
The aperture should be small enough to prevent ingress of foreign
matter. A small breathing aperture would limit the closing speed of
the regulator. The Instromet 243 regulator pictured in figure 4 is
equipped with a breather valve that opens for quick closure of the
main valve.
Breather valve
Figure 4
Instromet 243 spring-loaded regulator
The outlet pressure is somewhat dependent on flow rate and inlet
pressure. Typical curves are given in figure 5. These curves are for one
spring and one valve orifice. Other springs and orifices would give
different sets of curves. For zero flow rate the pressure to push the
valve sufficiently strongly onto the soft seat to obtain complete
closure is called “lock-up pressure”.
19
Outlet pressure mbar
20
2.8 bar
1.7 bar
15
.15 bar .35 bar .7 bar 1 bar
Figure 6
Internal relief valve
20
In a pilot-operated regulator, a small, spring-loaded regulator (the
pilot) provides the gas pressure to control the main regulator. There
are several designs of pilot-operated regulators, and a picture of an
axially symmetric design is given as an example in figure 7. In this
design a sleeve valve is connected to a spring-loaded diaphragm.
When the pilot does not deliver any pressure, the spring pushes the
sleeve against its seat. During normal operation the pressure under
the diaphragm is higher than the outlet pressure to balance the force
of the closing spring. When the outlet pressure drops, the pilot
operator increases the pressure below the diaphragm. The outlet
pressure setpoint is determined by the spring of the pilot. The
deviation of the actual outlet pressure from the setpoint is amplified
by the pilot to provide the force to open and close the main valve
against the spring. The supply to the pilot regulator is stabilised by a
special small regulator to a pressure that is a fixed amount above the
outlet pressure.
Figure 7
Pilot-operated regulator
21
Pilot-operated regulators are used for large capacities. They are fast,
and their outlet pressure is, contrary to spring-operated regulators,
practically independent of flow rate and inlet pressure.
qb = Kc• P (10)
For lesser pressure differences, the flow rate can be expressed as:
q =K
b v
√(P - P )
1 2
(11)
22
Inlet Orifice size / valve angle
Max. outlet pressure variation : 14 mbar
pressure 1”/30° 3/4”/30° 3/4”/10° 1/2”/10° 3/8”/10 1/4”/10°
140 mbar 80 53 50 32 26 13
Regulator 243-12, internal control
Gas filters
A filter protects the rest of the station from any debris or dust that
may be carried with the gas stream. Debris may for example consist of
parts accidentally left in the pipe during construction. It could also
result from swarf from drilling holes for taps, or it could be welding
beads and sand from construction or fine iron oxide dust.
Filters are equipped with a cover plate on top that can either be bolted
or secured by a quick closure device. For cover plates weighing more
than 30 kg an optional lifting device (davit) is recommended.
Dust is transported with the gas stream when flow rates are high. If
the velocity remains below a certain level, most of it remains
dormant. If this level is exceeded, all that can move is transported. If
the amount of dust and debris exceeds the capacity of the filter, the
element will be blocked and collapses.
23
dP
Drain
Figure 8
Filter
Minimising the amount of dust and debris is therefore the best
approach and this can be achieved by observing the following:
24
Monitor regulator
25
Figure 9
Safety shut-off valve
Figure 10
Safety shut-off option installed on an Instromet 243 regulator
as from Figure 4
26
Safety relief valves
Large relief valves are used to take the full capacity of the station.
They should be designed for worst case conditions: maximum inlet
pressure and fully open regulator and monitor.
Heat exchangers
Very few instances are known of the heat exchanger tubing failing,
thus pressurising the water circuit. Nevertheless, as a safety measure
a safety device to prevent the boiler from being pressurised can be
mounted in the water circuit. The simplest way is to use a rupture disc
in the water circuit. Alternatively an ordinary relief valve can be
connected to the water circuit. In some countries the regulations call
for special security safety valves to isolate the boiler totally from the
heat exchanger in case of a leak.
27
Setpoints
17.4 bar
Safety shut-off operating install.
17 bar
Relief valve (small) >lock-up pressure
allow for + 2.5%
uncertainty
16 bar
Regulator operating installation
15.5 bar
Regulator by-pass installation
Figure 11
Example of settings of regulator and safety devices
28
The highest pressure in the downstream system is governed by the
setting of the last safety device that will start operating. The setting
of this last device should therefore be higher than the weakest part in
the downstream installation. The actual operating pressure will be a
considerable amount lower, depending on the margins between the
settings. These margins are in turn determined by the tolerance,
uncertainty and drift in the regulators and safety devices, or may be
determined by the local codes of practice.
29
REFERENCES
30
Sales Offices: Products & Services:
In Argentina: ● Ultrasonic gas meters
INSTROMET S.A.
In Brazil:
● Electronic volume correctors
INSTROMET MEDIÇÃO E CONTROLE LTDA.
● Flow computer systems
In Croatia:
INSTROMET CROATIA
● Calorimeters
In France:
INSTROMET S.A.R.L.
● Gas chromatographs
In Germany:
INSTROMET G.M.B.H.
● Supervisory Systems
In Hungary:
INSTROMET HUNGARY SERVEX HUNGARY KFT.
● Gas filters
In India:
SIDDHA GAS INSTROMET INDIA PVT. LTD. ● Gas pressure regulators
In Italy:
INSTROMET ITALIA S.R.L. ● Safety shut-off valves
In Korea:
INSTROMET KOREA LTD. ● Telemetering systems
In Malaysia:
INSTROMET INTERNATIONAL ● Electronic metering and control systems
REGIONAL OFFICE, SOUTH EAST ASIA
In Portugal:
INSTROMET PORTUGAL LDA.
In Spain:
INSTROMET ACUSTER S.L.
In Switzerland:
INSTROMET AG.
In the UK:
INSTROMET UK
In the Ukraine:
INSTROMET UKRAINE LTD.
In the USA:
INSTROMET INC.
INSTROMET has agents and representatives worldwide. For your nearest sales office or
YOUR SALES OFFICE OR REPRESENTATIVE:
representative please contact:
INSTROMET INTERNATIONAL
Rijkmakerlaan 9 - B-2910 ESSEN - BELGIUM
Tel: +32 3 6700 700 - Fax : +32 3 667 6940
E-mail: sales@instromet.be
Web-page: http://www.instromet.com