Technical Manual

NTAKBP0310
November 2003 K1000 - K3000

MULTIFUNCTIONAL PILOT-OPERATED REGULATOR

SUMMARY

INTRODUCTION ................................................................. 1

CHARACTERISTICS ........................................................... 2

LABELLING .......................................................................... 2

DESCRIPTION ..................................................................... 3

SPARE PARTS ..................................................................... 3

DIMENSIONS AND WEIGHTS ............................................. 4

OPERATION ......................................................................... 4

INSTALLATION .................................................................... 5

COMMISSIONING ................................................................ 6

MAINTENANCE ................................................................... 7

Type K1000

INTRODUCTION

The K1000 or the K3000 are pilot-operated regulators,
PS 25 bar, single-staged, high speed of responses, and stable
pressure control.
The K1000 or the K3000 includes a filter, a regulator and a slam
shut valve.
Its design allows a turbine meter to be mounted directly on the
outlet flange, a new slam shut technology, the OS2, and a Francel
Piloting System.
A noise attenuation permits the K1000 or the K3000 to be
classified in the category of silent or low noise regulators.
As an option is can be equipped with a blockage indicator without
a connector.

The K1000 or the K3000 is in conformity with the

PED 97/23/EC and is classified in category IV.
14/06/2005

www.francel.com

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Technical Manual
NTAKBP0310
November 2003 K1000 - K3000

CHARACTERISTICS
Operating pressure SLAM SHUT
Body, slam shut 25 bar Maximum differential Max ∆P 25 bar
Outlet flange PS 16 bar Reponse time <1s
BMS associated, according to size 5 to 20 bar Accuracy AG 2.5
Ambient temperature / TS Set point range Pt 0.010/14 bar
A216 WCB body - 20 / 60 °C Valve plug travel (K1000) 28 mm
TS
A352 LCC body - 30 / 60 °C (K3000) 23 mm
Operating temperature / Gas T° - 20 / 60 °C Resetting Manually after fault rectification
Outlet pressure Pa 0.020 to 16 bar Position indicator On the mechanism box
REGULATOR Groups 1 and 2 according to PED 97/23/EC, 1st and 2nd family gas
Maximum differential Max ∆P 25 bar Fluid according to EN 437, or other gases (compressed air, nitrogen). The gas
Regulator accuracy AC 2.5 must be non corrosive, clean or moderately loaded (internal filtration) and dry

Flow Coefficient Filtration

Regulator Qf Cg C1 qN Polyester or felt cartridge

K1000 550 1067 35 1100
Filtration 5µ
K3000 1340 2600 35 2680
O23

MATERIAL CONNECTIONS
Body Steel Inlet: ISO PN 25
Connecting parts and bottom Steel Outlet: K1000 : ISO PN 16 or PN 25
Actuator Aluminium/Steel K3000 : ISO PN 16
Regulator/Slam shut orifice Stainless steel Pilot impulse line: 1/4’’ NPT tapped
Regulator valve plug Stainless steel Slam shut impulse line (IS): 1/4’’ NPT tapped
Slam shut valve plug Steel BM vent: 1/4” NPT tapped
Regulator/Slam shut disc plugs Nitrile Impulse diameter : Pipe interior Ø 8/10 mm
Contact : See NTAOS2 manual

LABELLING

O24

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Technical Manual
NTAKBP0310
November 2003 K1000 - K3000

DESCRIPTION
The K1000 or the K3000 consist of: • A release relay type OS2 (see NTAOS2 manual) with:
• A subassembly external body, a subassembly internal body, - a mechanism box (BM1)
and a subassembly slam shut valve - a safety manometric box (BMS1) to be connected outlet side
• A pilot body capable of receiving: of the regulator
- the two pilot blocks or
- the pre-expansion and pilot safety manometric boxes - a mechanism box (BM2)
(see NTAPIL manual) - two safety manometric boxes (BMS2) to be connected outlet
- a manometric gauge side of the regulator

SPARE PARTS

O19a O19b

K1000 K3000

Reference Code
Item Description Item Description
K1000 K3000 K1000 K3000
1 Packing gland + control stem 197 353 197 353 11 Noise attenuation disc 143 527 143 579
2 VS support O-ring 400 264 400 071 12 O-ring 400 512 400 512
3 Filtering cartridge (polyester) 143 531/4008553 143 565/4008554 13 Upper plug O-ring 400 265 400 276
4 VS orifice O-ring 400 269 400 278 14 Slam shut O-ring 400 528 400 534
5 Impulse O-ring 400 266 400 275 15 Valve pipe O-ring 400 087 400 278
6 Impulse O-ring 400 268 400 264 16 O-ring 400 272 400 279
7 Impulse O-ring (external) 400 267 17 O-ring 400 548
8 Diaphragm 143 523 143 568 18 O-ring 400 036 400 281
9 O-ring 400 273 400 283 Spare parts kit* 197 477 197 355
10 Disc plug (regulator orifice) 400 270 400 280 Set of O-rings** 197 478 197 358
* Includes all commissioning spares and O-rings. O25
** Includes all O-rings.

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Technical Manual
NTAKBP0310
November 2003 K1000 - K3000

DIMENSIONS AND WEIGHTS

K1000 K3000
Inlet DN 50 80
Outlet DN 80 or 100 150
A (mm) 488 682
B (mm) 300 420
C (mm) 166 220
D (mm) 133 209
E (mm) 90 130
Weight (kg) 68 148
O26

OPERATION
This regulator operates by admitting modulated pressure. Gas
enters the regulator by the intlet flange (1), flows through the
filter (2) inside which it reaches the slan shut valve (3). The gas
O15
then flows through the pilot relay which regulates outlet pressure.
The different functions are carried out by the following:
• Pressure regulation
The K1000 or K3000 is an axial-flow pilot-operated regulator.
The position of the valve depends on the flow rate and the pilot
control of the modulated pressure.
• Filtration
The filter is directly incorporated inside the body of the K1000
or K3000. It is composed of a polyester filtering cartridge which
assures, as much as possible, the protection of sensitive
mechanical parts (slam shut valve, regulator valve, pilot, etc.).
• Noise attenuation and flow straightening
These are achieved by a slotted disc (4), different layers of
porous materiels (mineral foam and synthetic fibers) and a flow
straightener (5). This technic allows a turbine meter to be
connected on the outlet side of the K1000 or the K3000, without
using an intermediate straight line of pipe
• Slam shut
The slam shut is situated on the downstream side of the K1000
or the K3000, where the gas is hot, to avoide the valve from
freezing. Once the set pressure level is reached, the
mechanism box (6) releases the valve, which then blocks the
gas passage. Balancing the pressure and resetting the valve is
actioned by the resetting lever (7) (incorporated bypass).
O16
• Pilot system
The K1000 or the K3000 pilot allows the valve-pipe (8) ot be
positioned according to the flow required. It consists of three parts:
- a pre-pilot relay (9): assures a stable pressure level (Pd) - a pilot body (11): containing the two pilot blocks (12) and the
superior to the outlet pressure, pre-expansion and pilot manometric boxes.
- a pilot part (10): using the modulated pressure (Pm) the Different types of manometric boxes exist depending on the
valve-tube is positioned depending on the outlet pressure, outlet pressure.

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Technical Manual
NTAKBP0310
November 2003
INSTALLATION
Figure 1
(With one safety manometric box)
All interventions on the equipment should only be
performed by qualified and trained personnel.
! WARNING
• The regulator is installed on the bottom left pipe line
angle.
• Installation according to EN12186 is recommended.
• Install according to the direction of the 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 condi-
tions of the equipment.
• Connect the long pilot impulse line (IP) at 4D on the
straight run of the outlet pipe. The slam shut impulse
lines (IS) and reject pilot (RP) are connected in series.
A turbine meter can be directly connected to the K1000
or the K3000 (Figure 1).
• The K1000 or the K3000 contain an internal filtering
cartridge, an additional filter on the outlet side in not
necessary.
• If the remote alert option is chosen, electrically
connect the contact (see NTAOS2 manual).
• No modification should be made to the structure of the
equipment (drilling, grinding, soldering...).
5
K1000 - K3000
O17
Figure 2
(With two safety manometric boxes)
! WARNING
• It is recommended to install a servicing valve on the
outlet pipeline to facilitate adjustments and bleeding
off to the atmosphere.
• 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
appropriate operating conditions.
• Verify that the safety manometric box (BMS) and
spring correspond to the appropriate operating
conditions on the outlet side of the regulator.
• The equipment should not receive any type of shock,
especially the release relay.
• Fire, seismic and lightening are not taken into consid-
eration for standard regulators. If required, a special
product selection and/or specific calculations may be
supplied according to specific requirements.
• The user should verify or carry out a protection
adapted to the environment.
Technical Manual
NTAKBP0310
November 2003 K1000 - K3000

COMMISSIONING
All interventions on equipment should only be performed
by qualified personnel.
PRELIMINARY VERIFICATIONS
Start-up positions
• Inlet and outlet valves
! Closed
Verify absence of pressure between inlet and outlet valves
• Slam shut valve plug
! Closed
• Slam shut impulse line valve 5
! Closed
• Atmospheric impulse line valve
! Open
Set point verification
Using the atmospheric valve, inject a pressure equal to the
pressure foreseen for the regulator
• 1st release relay stage
! Set (Stage 1) O18
• Slam shut valve plug
! Open (Stage 2)
• Reject valve 1
! Open (2 turns)
• Adjustment knobs 2 & 4
! Unscrewed
The equipment is ready for commissioning

Stage 1 Stage 2 COMMISSIONING

• Inlet valve
! Open very slowly
• Pilot supply valve 3
C38a C38b ! Open
• Slam shut valve bypass
! Progressively increase the pressure to reach tripping ! Open slowly
! Adjust setting if necessary (NTAOS2) • 1st release relay stage
Note the set point value on the equipment ! Set (Stage 1)
or mark it in an commissioning document • Slam shut valve plug
! Open (Stage 2)
Positions before commissioning
• Operating valve
• Pilot supply valve 3 ! Slightly open
! Closed • Pre-expansion relay 4
• Long impulse line valve 7 ! Turn the handwheel (Pa + 200 to 500 mbar)
! Closed Possibility to connect an external manometer at 8
• Short impulse line 6 (1/4 NPT connection)
! Open • Pilot 2
• Impulse isolation valve ! Turn the handwheel (to Pa)
! Open • Long impulse line valve 7
• Impulse atmospheric valve ! Open
! Closed • Short impulse line valve 6
• Slam shut valve plug ! Closed
! Closed
The equipment is commissioned
• Servicing valve
! Closed It is recommended to seal the release relay

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Technical Manual
NTAKBP0310
November 2003 K1000 - K3000

MAINTENANCE
SERVICING CHECK Departure positions
Recommended frequency: • Inlet valve ! Open
• Outlet valve ! Open
• Twice yearly minimum • Slam shut valve plug ! Open
Verification: • Regulator ! In service
• Verification of the set point Inlet and outlet side of the regulator under pressure
• Valve plug tightness Tightshut and tripping verifications
• Tripping and valve plug set point value
• Slam shut valve plug tightness • Inlet valve ! Closed
• Outlet valve ! Closed
• Regulator Observe the evolution of the outlet
pressure (control regulator)

If the outlet pressure increases Internal leak

Close the pilot supply valve
Observe the evolution of the outlet pressure (control regulator tightness)

If the outlet pressure increases Regulator tightness fault

Control the regulator valve plug
Control the regulator orifice
Control the tightshut O-rings or contact after-sales

If the outlet pressure is stable Pilot tightness fault

Control the pilot valve or contact after-sales

If the outlet pressure decreases External leak

Locale and seal the leak or contact after-sales

If the outlet pressure is constant The regulator is tightshut

Increase the set point until slam shut tripping occurs
(without exceeding the outlet limits)

If the slam shut valve plug will not close Operating fault
Control the release relay
Control the slam shut valve plug or contact 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 bypass or contact after-sales

If the outlet pressure is constant Slam shut valve plug is tightshut

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Technical Manual
NTAKBP0310
November 2003 K1000 - K3000

MAINTENANCE
DISASSEMBLY OF THE REGULATOR AND SLAM SHUT

Recommended frequency:
• Every year (or less depending on operating conditions)
Verification and/or replacement:
• Filtering cartridge
Recommended frequency:
• Every 4 to 6 years (or less depending on operating conditions)
Verification:
• Condition of O-rings, diaphragms, valve disc plug, lubrication
Replacement:
• O-rings, diaphragm
Tools:
• Male spanners for six-sided wrench 4, 5, 6, 8, 10, 12
• Flat spanners 8, 10, 11, 12, 13, 17, 19, 21

REGULATION Screw Torque (N.m)

• Valve plug closed M8 15
• Close inlet and outlet valves M10 30 O20

• Bleed off outlet pressure M12 60

• Bleed off inlet pressure O27

• Unscrew the slam shut impulse connection • Remove the flow straightener 16
• Unscrew the pilot supply connection • Remove the whisper cage 17
• Remove the BM cover 1 • Remove the phonic casing 18
• Unscrew the fixing screws 2
REASSEMBLY
• Free the hook head 3
• Remove the BM 4 • Preform the above operations in reverse order (respect
• Unscrew screws 5 tightening torques)
• Remove the VS support 6 • Replace the diaphragm every 6 years or less depending on
• Remove the bypass 7 condition
• Unscrew screws 8 • Replace the tightshut disc plug every 12 years or less depend-
• Remove the upper plug 9 ing on condition
• Remove the filtering cartridge 10 • The valve plug should be held in an upper position using a
• Unscrew the modulated pressure connector packing gland and a box to facilitate disassembly
• Unscrew the outlet pressure connector • Replace O-rings at each disassembly
• Remove the impulse pins 11 • Lubricate screws before tightening
• Remove the inner body unit 12 • Lightly lubricate O-rings (silicone grease)
• Separate the front inner body 13 from the rear inner body 14 • Lightly lubricate the stem (silicone grease)
(precaution with the spring force) • Lubricate the release relay mechanism (yoke and bolt)
• Remove carefully the mobile unit without damaging the valve- (molybdenum graphite grease)
pipe 15 • Lubricate the BMS spring (molybdenum graphite grease)

Emerson Process Management

Regulator Division
Francel S.A.
Z.A. La Croix St. Mathieu
28320 Gallardon - France
Tel. +33 (0)2 37 33 47 00
Fax. +33 (0)2 37 31 46 56
www.francel.com
© Francel S.A. 2003, printed in France by MARCOM Francel
Characteristics, dimensions and diagrams only commit Francel
after written confirmation