PRS O&Manual AC Standard

Atlas Copco
Compressed Natural Gas

Pressure Reducing Station (PRS)
Operation and Maintenance Manual

No. 1904999444
Copyright 2017, Atlas Copco (Shanghai) PRS Co., Ltd.

Any unauthorized use or copying of the contents or any part thereof is
prohibited. This applies in particular to trademarks, model denominations, part
numbers and drawings.
Atlas Copco (Shanghai) Compressor Co.,Ltd.

No. 899, Cenglin Road, Lingang New City
Pudong New Area, Shanghai, China, 201306 www.atlascopco.com
No 1904 9994 44 Ed.04

2019-01
Operation & Maintenance Manual
Preface
This set of manuals consists of
• Package Operating & Maintenance Manual

• PRS Parts list
This Manual will acquaint you with the safe operation of your Atlas Copco CNG equipment.
It contains installation and operating instructions for the package and basic maintenance schedules and
fault finding.
For trouble free operation it is necessary to observe all instructions contained in this manual.
We therefore recommend that operating personnel read these instructions as carefully as possible to get
acquainted with the service and function of the PRS and other related equipment before operating the
equipment.
Guarantee according to Atlas Copco terms of delivery and quotation will only be granted if this instruction
manual has been complied with. Atlas Copco may deny any responsibility for damage to the PRS, which
may result from not complying with the stipulations of this manual.
The PRS will operate to full satisfaction if installation, service and operations are carried out according to
procedures laid out in this manual.
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Customer details
Customer:
Company
...................................................................................................................................................
Address
...................................................................................................................................................
City/State
...................................................................................................................................................
Phone
...................................................................................................................................................
Fax
...................................................................................................................................................
Email address
...................................................................................................................................................
Site location
...................................................................................................................................................
Serial no.:...................................................................................................................................
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Table of Contents
1 Warranty Policy and Procedures ........................................................................................................ 9
1.1 General ......................................................................................................................................... 9
1.2 Policy ............................................................................................................................................ 9
1.3 Procedure ..................................................................................................................................... 9
2 Safety Instructions and Emergency Procedures ............................................................................ 13

2.1 General Safety ............................................................................................................................ 13
2.2 Precautions General Safety ........................................................................................................ 14
2.3 Precautions during installation .................................................................................................... 14
2.4 Precautions during operation ...................................................................................................... 15
2.5 Precautions during maintenance ................................................................................................ 16
2.6 Summary .................................................................................................................................... 18
2.7 Product information and safety plates ........................................................................................ 18
2.8 Emergency Procedures .............................................................................................................. 19
2.8.1 PRS Emergency Procedure .................................................................................................. 19
2.8.2 Cascades Emergency Procedure ......................................................................................... 20
2.8.3 Trailer Decant Panel Emergency Procedure ......................................................................... 20
3 General Information ........................................................................................................................... 21

3.1 System Description ..................................................................................................................... 22
3.2 System Major Components ........................................................................................................ 22
3.2.1 Shell and Tube Heat Exchangers ......................................................................................... 22
3.2.2 Pressure Reducing Regulators ............................................................................................ 22
3.2.3 Gas flow Meter ..................................................................................................................... 25
3.2.4 Bypass 1st Stage Reduction ................................................................................................. 26
3.2.5 Protection system.................................................................................................................. 26
3.2.6 Control System...................................................................................................................... 26
3.3 PRS Data .................................................................................................................................... 28
4 Installation and Commissioning ....................................................................................................... 30

4.1 Transportation and shipping ....................................................................................................... 30
4.2 Installation ................................................................................................................................... 32
4.2.1 PRS Skid installation ............................................................................................................. 32
4.2.2 PRS Mechanical installation................................................................................................ 33
4.2.3 PRS Electrical installation ................................................................................................... 34
4.3 Water Heater installation ............................................................................................................ 35
5 Commissioning .................................................................................................................................. 37
5.1 General ....................................................................................................................................... 37
5.2 Purging PRS ............................................................................................................................... 38
5.3 Starting System .......................................................................................................................... 40
5.4 PRS Pressure Adjustment .......................................................................................................... 40
5.5 Control Gas Regulator ................................................................................................................ 42
5.6 PRS Commissioning Sheet .......................................................... Error! Bookmark not defined.
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6 Operation ............................................................................................................................................ 45
6.1 General Operation ...................................................................................................................... 45
6.2 HMI display ................................................................................................................................. 46
6.3 Gas Composition-Variation Effects ................................................................................................ 52
7 Maintenance ....................................................................................................................................... 53
7.1 General Safety ............................................................................................................................ 53
7.2 Individual Average Weights ........................................................................................................ 53
7.3 PRS Torque Settings .................................................................................................................. 55
7.3.1 NPT fittings ........................................................................................................................... 55
7.3.2 Flanges ................................................................................................................................. 55
7.3.3 Tube Connections ................................................................................................................. 56
7.4 Service Checks ........................................................................................................................... 57
8 Troubleshooting ................................................................................................................................. 57
Annexure 1: Piping and instrument diagram ....................................................................................... 60
Annexure 2: General arrangement drawing ......................................................................................... 64
Annexure 3: Electrical wiring diagrams ............................................................................................... 67
Annexure 4: NZ pressure regulating valve Instruction Manual.......................................................... 91
List of Tables
Table 1 Major components of PRS ............................................................................................................. 21

Table 2 PRS Technical Data ...................................................................................................................... 28
Table 3 Communication from PRS to Water Heater ................................................................................... 36
Table 4 PRS part descriptions .................................................................................................................... 39
Table 5 PRS Commissioning checklist ......................................................... Error! Bookmark not defined.
Table 6 Alarms ........................................................................................................................................... 50
Table 7 Faults ............................................................................................................................................. 51
Table 8 Approximate weights ..................................................................................................................... 54
List of Figures
Figure 1 Typical PRS Package Name Plate ............................................................................................... 16

Figure 2 Name Plate Heat Exchanger ........................................................................................................ 18
Figure 3 Name Plate Inlet Filter .................................................................................................................. 19
Figure 4 Typical PRS Major Components .................................................................................................. 21
Figure 5 1st Stage Regulator Configuration ................................................................................................ 23
Figure 6 2ndStage Regulator Configuration................................................................................................. 24
Figure 7 Control Gas Regulator.................................................................................................................. 25
Figure 8 General View (Coriolis Flow Meter) .............................................................................................. 25
Figure 9 PRS Controller ............................................................................................................................. 26
Figure 10 Transportation and Shipping ...................................................................................................... 32
Figure 11 Skid wiring IDs ............................................................................................................................ 34
Figure 12 PRS Inlet Valve and Drain Valve ................................................................................................ 39
Figure 13 1st Pressure Regulator ................................................................................................................ 40
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Figure 14 2nd pressure drop regulator (NZ Fisher) ..................................................................................... 41

Figure 15 Control Gas Regulator ................................................................................................................ 42
Figure 16 HMI Display “Overview” - Operating Parameters ....................................................................... 46
Figure 17 HMI Display “Set Points” – set point values are for illustration only ........................................... 47
Figure 18 HMI display “Set Points” for heater ............................................................................................. 48
Figure 19 HMI display for “Heater” ............................................................................................................. 48
Figure 20 PRS 1000 Manual Operation ...................................................................................................... 49
Figure 21 PRS 1000 Alarm Information ...................................................................................................... 49
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1 Warranty Policy and Procedures

(Operative from commissioning date)
1.1 General
Introduction
All Atlas Copco CNG equipment is carefully inspected and factory test run before shipment and each
new piece of equipment is warranted to be free from defects in material and workmanship.
PRS and Distributors Standards

Ultimately the responsibility for a product that is safe in operation and satisfactory in performance
belongs to the packager, however, compliance with Atlas Copco Operating Procedures is required for
warranty claims to be considered.
Unit Start Up
The PRS should be started up in accordance with the latest version of Atlas Copco’s ‘Commissioning
Check List’. All start-up data should be made available to Atlas Copco upon request.
Long Storage Period

When machines are stored for a long time before commissioning, the storage instructions have to be
followed. Please contact Atlas Copco’s Service department for further instructions.
The warranty conditions will become valid when an Atlas Copco or Atlas Copco Specialist commissions
the unit and confirms in his commissioning report that the storage instructions have been respected.
The maximum limit is 18months starting from the supply date from Atlas Copco factory.
1.2 Policy
Warranty - Non-Atlas Copco Manufactured Parts
Certain items on Atlas Copco’s units are from sources other than Atlas Copco. The warranty on these
items is passed through to the customer, from each manufacturer. In the majority of cases, the
warranty is for parts only, with no allowance for labor.
Warranty - Atlas Copco Manufactured Parts

Atlas Copco liability shall be limited to the repair or replacement (at Atlas Copco (Shanghai)
Compressor Co., Ltd. option) of any goods becoming defective as a result of faulty workmanship and/or
materials, for a period of 18 months from date of shipment or 12 months from the date the goods are
placed into use by the Buyer, whichever is the sooner. Atlas Copco warrants that the products supplied
conform to the drawings and specifications attached to Atlas Copco Limited quotation. If within the
warranty period Atlas Copco (Shanghai) Compressor Co., Ltd. receives written notice from the
purchaser of any alleged defect in or non-conformance of any product, and if in Atlas Copco’s sole
judgment that product does not confirm or is found to be defective in materials or workmanship, then
Atlas Copco (Shanghai) Compressor Co., Ltd. shall be responsible for repair or replacement of same.
1.3 Procedure
Warranty claims will be administered according to the following guidelines.
Warranty Notification Forms

A completed ‘Warranty Notification’ form must be completed by the packager and in Atlas Copco Ltd.
possession before a ‘Request for Warranty’ can be processed. The ‘Warranty Notification’ form must
be forwarded to Atlas Copco upon shipment of the package.
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Notification of Problem
Atlas Copco should be notified as quickly as possible about any problem that might result in a warranty
consideration. This notification may be by telephone or by fax to Atlas Copco. Any major problem
should be reported to Atlas Copco immediately. In such a case, Atlas Copco will probably request that
no disassembly of the damaged components should be done until an Atlas Copco representative visits
the job site.
Request for Warranty Credit

For a warranty claim to be considered, a completed “Request for Warranty” form with detailed
serviceman’s reports is to be submitted no later than 21 days after the date of components failure.
Defective material must be returned within 30 days from issuance of “Return of Materials Instructions”
and “Return Material Number”.
Time Limit for Labour

Payment of labour charges is limited to failure of items of Atlas Copco manufacture that occur during
packaging and within the first 60 days after start-up.
Labour Allowance
Atlas Copco will pay for one mechanic under this policy. Atlas Copco will also not be responsible for
additional manpower requirements that are the result of abnormal job site conditions such as sour gas,
lack of lifting facilities or customer requirement. Atlas Copco will not be responsible for cost of
personnel transporting, replacement of parts or on delays incurred while waiting for parts.
Mileage Allowance
Travel time and mileage will be paid on up to 150 driven miles (240km) on way or actual travel time
from the packager’s closest service location to the unit location. If the unit is at a greater distance, the
additional cost will be at the expense of the customer.
Labour Rates
Atlas Copco will pay in United States Dollars for labour and recognised Public Service rates for mileage
as per the terms & conditions of the contract warranty agreement.
Labour Adjustment
Atlas Copco may adjust the labour on warranty claims so that the labour paid will be in line with a
reasonable amount of time to accomplish the task for which the claim is submitted. The initial
investigation of a warranty item will be at the expense of the customer.
Warranty Credit
Atlas Copco Ltd. will attempt to issue credit within 30 days after acceptance of claim. Atlas Copco Ltd.
will also advise reason for adjustment or rejection of each warranty claim.
Limitation
There are no other warranties, expressed, statutory or implied, including those of merchant ability and
of fitness for purpose; nor any affirmation of fact or representation which extends beyond the
description on the face hereof.
Atlas Copco Ltd. cannot be held responsible for any loss or damage (direct, indirect, consequential,
economic, physical or otherwise) of any nature arising in any way from any defect or failure of the
goods which are sold in good faith.
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The warranties of Atlas Copco Ltd. do not cover and Atlas Copco Ltd. makes no warranty with respect
to:
1.) Installations not commissioned by Atlas Copco authorized personnel.
2.) Failures not reported to Atlas Copco Ltd. within the warranty period specified above.
3.) Failures or damage due to misapplication, abuse, improper installation, abnormal conditions of
temperature, water, dirt or corrosive matter or the like;
4.) Failures due to operation above rated capacities or in an otherwise improper manner.
5.) Installations operated without required complete maintenance checks recorded in a log register.
6.) Products which have in any way been tampered with or had remedial work carried out by
anyone other than an authorized representative of Atlas Copco Ltd.
7.) Products physically damaged in shipment or due to neglect during storage or otherwise without
fault of Atlas Copco Ltd.
8.) Any fires or explosions in the equipment or installation.
9.) Items specifically excluded are valves, seals, bearings and rings, all of which are subject to
normal wear and tear.
The warranty is invalid if the purchaser does not immediately take steps to notify Atlas Copco Ltd. of
any defect or malfunction to prevent the fault from becoming more serious and causing damage.
Failure to maintain the equipment in accordance with procedures stated in the manual, and failure to
keep maintenance records and logs will also invalidate the warranty.
PRS Warranty Notification form follows on the next page for your use for official notification.
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To: Atlas Copco (Shanghai) Compressor Co. ,Ltd Date:

From Phone: +86 (0) 510 6665 5888
PRESSURE REDUCING STATION WARRANTY NOTIFICATION

Coverage Under Atlas Copco’s Warranty Policy Is Based Upon Receipt of
Notification and Complete Information
Documentation and Accessories
Are the following included in the Unit Installation? Customer

Company
1 Operator’s Manual
2 Heater Manual
Address
3 Unit Spare Parts List
st
1 stage regulator Valve
City
Spring Type
Manufacturer Country
Model
2nd stage regulator Valve PRS
Spring Type Model
Manufacturer
Serial Number
Model
Flow Meter Shipment date
Manufacturer Start-up date
Model Unit Location
Water Heater Address
Manufacturer
Model
Country State
Applied KW
Water Flow Directions to location
Contact Person
Contact phone
Operating Conditions
PRS Service . . . . . . . . . . Specific Gravity . . . . . . Capacity . . . . . . . . . . CFM . . . . . . . .

(Gathering, Injection, Recycle, Booster, etc.) Elevation . . . . . . . Ft ASL N' value . . . . . . . .
Gas Compressed (NG, CO2, N2, Air etc.) . .. . . H2S . . . . . . . . . % CO2 . . . . . . . . %
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2 Safety Instructions and Emergency Procedures

2.1 General Safety
Danger for life
Warning
Important note
Use hearing protection
Use Eye protection
Safety shoes required!
Wear head protection
Wear hand protection
Dangerous outlet gases
Hot surface
Read instructions before lifting
Lifting permitted
Lifting not permitted
Opening of valves prohibited
Warning! Part under pressure
No smoking
Do not use mobile phones
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2.2 Precautions General Safety

1.) Personal Protective Equipment (PPE) must be worn during any installation, operation and
maintenance work. Safety protective equipment includes and is not limited to foot protection,
hearing protection, eye protection, head protection and hand protection.
( , , , , ).
Clothing worn during operation and maintenance work or during presence of gases in a system
should be made from static dissipative material to prevent fire or explosions when working with
flammable gases.
2.) Systems must be entirely vented before carrying out any repair or maintenance work. The
equipment must be electrically isolated by pad-locking and the main switch in the “OFF”
position, corresponding warning signs must be fixated in the work area.
3.) Installation, operation, maintenance and repair shall be carried out only by qualified personnel
and in accordance with the corresponding regulations for operation and safety.
4.) The operator must employ safe working practices and observe all related work safety
requirements and regulations.
5.) If any of the following statements does not comply with the applicable legislation, the stricter of
the two shall apply.
6.) Do not store flammable materials e.g. oily rags near the PRS.
7.) Pipe work and other components, which may not be included in scope of supply, must be
suitable for the respective working pressure. If necessary, they have to be tested and protected
by a pressure unloading device.
8.) High-voltage electrical cables used in hazardous area must comply with the local electrical
authority regulations. The entire electrical system must be approved and certified by the local
authority inspector.
Compressed gas is a highly dangerous substance.
No Smoking or EX lights are allowed within 10m of any flammable gas

installation.
Do not adjust, remove or bypass any protective device.
2.3 Precautions during installation

maintenance work. Safety protective equipment includes and not limited to foot protection,
hearing protection, eye protection, head protection and hand protection
( , , , , ).
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2.) Clothing worn during operation and maintenance work or during presence of gases should be
made from static dissipative material to prevent fire or explosions when working with
flammable gases.
3.) The PRS must be lifted with suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly not
allowed to dwell or stay in the risk zone under a lifted load. Lifting acceleration and
deceleration must be kept within safe limits.
4.) Any blanking flanges, plugs and caps must be removed before connecting the pipes.
5.) Natural gas hoses must be of correct size and suitable for the working pressure. Never use
frayed, damaged or worn hoses. Distribution pipes and connections must be of the correct
size and suitable for the working pressure.
6.) No external force may be exerted on the Inlet/outlet valve or any other connections to the
PRS; the connected pipe must be free of strain.
7.) The PRS must bear a clear sign stating: “DANGER: This PRS is remotely controlled and may
start without warning”.
8.) The electrical connections must correspond to the applicable codes. The PRS must be
earthed and protected against short circuits by fuses in all phases.
9.) Never remove or tamper with the safety devices, guards or insulation fitted on the PRS. Every
pressure vessel or auxiliary installed outside the PRS to contain gas or air above atmospheric
pressure must be protected by a pressure relieving device or devices as required.
10.) Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be
accidentally touched by personnel in normal operation must be guarded or insulated. Other
high temperature piping must be clearly marked with this sign. .
2.4 Precautions during operation

hearing protection, eye protection, head protection and hand protection
( , , , , ).
2.) Clothing worn during operation and maintenance work or during presence of gases in a
system should be made from static dissipative material to prevent fire or explosions when
working with flammable gases.
3.) The PRS must be maintained in a safe condition to operate and should be regularly inspected.
Log sheets and maintenance records MUST be kept up-to-date as required by the equipment
supplier.
4.) Before starting the PRS, make sure that no inspection, maintenance or repair work is
happening on the unit.
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5.) The PRS MUST be operated within the parameters outlined in the technical specification.
Make sure no person is in contact with the pipe work or other heated parts of the PRS during
operation.
6.) Keep clear of hot exhaust pipe and manifolds.
7.) Never carry out repair work when the PRS package is in operation.
8.) Parameters given on the name plate should be strictly followed.
Figure 1 Typical PRS Package Name Plate
Compressed gas is a highly dangerous substance.
In case, the customer/s, do not have or follow their own Safety, Health and
Environmental Guidelines, then we, Atlas Copco Ltd. shall follow its own set of
applicable guidelines.
In case of Non-conformity to the Safety, Health And Environmental Standards, Atlas
Copco Ltd. shall not be responsible or liable for any kind of damage or loss (of life or
otherwise).
2.5 Precautions during maintenance

1.) Personal protective equipment (PPE) must be worn during any installation, operation and
hearing protection, eye protection, head protection, and hand protection.
( , , , , ).
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2.) Clothing worn during operation and maintenance work or during presence of gases in a system
should be made from static dissipative material to prevent fire or explosions when working with
flammable gases.
3.) The PRS must be maintained in a safe condition to operate and should be regularly inspected.
4.) Log sheets and maintenance records MUST be kept up-to-date as required by the equipment
supplier.
5.) Maintenance and repair work must be carried out only on an entirely vented System. If
necessary, isolate all storage systems and blow-down all condensate traps and heat
exchanger. Open all manual drain valves.
6.) The PRS fasteners MUST be tightened to torque values outlined in the technical specification.
7.) Make sure no person is in contact with pipe work or other parts of the PRS that heat up during
operation.
8.) Systems must be entirely vented before repair or maintenance work is carried out. The
equipment must be electrically isolated by pad-locking and the main switch in the “OFF”
9.) Only use genuine spare parts and recommended products for maintenance and repair works
on the PRS.
10.) Never do welding on gas systems before venting and purging the compressed gas from the
unit.
11.) During maintenance and repair work, observe strict cleanliness. Keep impurities away by
covering dismounted parts and free openings with clean cloth or plastic covers.
12.) After completion of repair work, make sure that no tools, loose parts or cleaning rags have
been left on or in the PRS.
13.) Do not use flammable agents for cleaning of parts. Remove solvents from cleaned parts with
compressed air.
14.) After modification or repair work on pressure vessels and safety equipment, such as relief
valves, all work must be tested and accepted by the concerned inspection authority.
15.) Only qualified and authorized persons may open the switchboard.
16.) Even if the main switch is set to the "OFF" position, the poles of the switch and feed cables of
the terminal strip are “alive”. Do not carry out remedial work with the mains supply switched
“ON”. Before starting work check that the system is entirely free of power.
17.) Do not touch bare wires and live (current-carrying) parts, when the electrical system is
energized.
18.) During maintenance and repair, weights of disassembled parts must be taken into
consideration for handling. Approximate weight information is detailed in this manual.
Use eye protection when working with compressed gas/air.
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2.6 Summary
Compressed gas contains immense energy, hence is highly dangerous. Only properly trained or qualified
personnel are to be permitted to operate and maintain the CNG equipment.
If in doubt, contact Atlas Copco Service.
In case the customer/s, do not have (or follow) their own Safety, Health and
Environmental Guidelines, then we, Atlas Copco shall follow its own set of applicable
guidelines.
In case of Non-conformity to the Safety, Health And Environmental Standards, Atlas
Copco shall not be responsible or liable for any kind of damage or loss (of life or
otherwise).
2.7 Product information and safety plates
Severe personal injury and property damage can result, if pressure system is not
completely vented before loosening bolts on flanges, heads, valves, and caps. Consult
Atlas Copco technical manual before performing any maintenance.
Figure 2 Name Plate Heat Exchanger
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Figure 3 Name Plate Inlet Filter
2.8 Emergency Procedures

Personal protective equipment (PPE) must be worn during any installation, operation and maintenance
work. Safety protective equipment includes and not limited to foot protection, hearing protection, eye
protection, head protection and hand protection.
( , , , , ).
Clothing worn during operation and maintenance work or during presence of gases in a system should be
made from static dissipative material to prevent fire or explosions when working with flammable gases.
Before any emergency procedure is carried out, the situation must be carefully
appraised at the outset.
Safety is the prime concern. Do not put yourself or anyone else in danger. There are
numerous emergency shutdown switches and shut-off valves within the CNG system.
Use the safety mechanism, which does not put you in any danger while activating it.
The procedures listed below are a guide only. Full CNG system operation and Emergency Procedure
training must be given before the CNG Station becomes fully operational.
It is important to make the CNG Station operators familiar with all locations of emergency shutdown
switches and shut off valves.
2.8.1 PRS Emergency Procedure

Generally, if a fault situation arises while the PRS is in operation, the PLC controller will automatically shut
down the PRS. However, if an emergency arises, the following procedures should be observed.
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Situation Emergency Action
1.) Shutdown PRS, using PRS Emergency Stop (i.e E-Stop) button on
the main control panel or on the PRS Skid.
Major Gas Leak
2.) Isolate all manual shutoff valves on the inlet and discharge of the
PRS, when conditions are safe to operate such valves.
Loud abnormal noise Shutdown PRS using PRS E-Stop button main control panel.
coming from PRS
Shutdown PRS using PRS E-Stop button on the main control panel.
Relief valve venting
2.8.2 Cascades Emergency Procedure

Close relevant Storage Bank Isolation Valve.
Major Gas Leak
Then if necessary, close each of the storage bank cylinder valves.
Blown Cylinder Valve

Determine which cylinder burst disk is venting and close that cylinder valve.
Burst Disk.
2.8.3 Trailer Decant Panel Emergency Procedure

In the event of a vehicle driving away with the Trailer Decant Panel fill hose still connected, the fill hose
will disconnect from the Trailer Decant panel because of the inclusion of a breakaway coupling within the
fill hose assembly. The breakaway coupling also has an excess flow component part, which stops the
flow.
In the event of any other hose failure (i.e. hose burst/rupture), do not attempt to manually secure the
damaged hose during such an event.

Isolate Decant Panel using shut off valves at inlet and outlet of Decant
Panel.
Major Gas Leak
Shut off discharge of gas from Decant Panel using shut off valve on
Decant Panel.
!!! FIRE!!!
In Event of Fire:
1. Shutdown entire CNG system using e-Stop Button.
2. Evacuate all personnel from the CNG station Area.
3. Follow Procedures as laid down in the CNG station safety manual.
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3 General Information
Figure 4 Typical PRS Major Components
Table 1 Major components of PRS
Reference Description
WI Water Inlet
WO Water Outlet
RSI Regulator Stage 1
HX102 Heat exchanger final stage
GV Gas Vent
RFS Regulator final stage
WRV Water Relief Valve
GI Gas Inlet
GR Gas Regulator
FM Flow Meter
HX101 Heat exchanger first stage
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3.1 System Description

The Pressure Reducing Station (PRS) receives Compressed Natural Gas (CNG) from an incoming
high-pressure gas source (250 bar), typically a transportable gas trailer, and reduces the pressure to
a level required by the downstream apparatus.
Atlas Copco PRS achieve the required downstream pressure through two reduction cycles, while
prior to gas expansion, gas is heated to a suitable operating temperature to prevents hydrates
formation in the gas.
As high-pressure gas is reduced through expansion, consequentially gas temperature is reduced,
since methane is the main component (>80%) of natural gas which has a positive Joules Thomson
coefficient.
3.2 System Major Components
The PRS consists of the following major components.
3.2.1 Shell and Tube Heat Exchangers

Shell and tube heat exchangers consist of shell (i.e. pressure vessel) and a bundle of tubes inside of
the shell. Water runs through the tubes bundle and CNG run over the tubes (i.e. through the shell).
The configuration of the tube bundle is straight-tube one pass.
Typical Atlas Copco PRS is supplied with two identical shell and tube heat exchangers suitable for
high pressure (refer to the technical details in chapter 3.3).
3.2.2 Pressure Reducing Regulators

Atlas Copco PRS system consists of three pressure reducing regulators as follows:
1.) 1st Stage Pressure Reduction Regulator, is a dome-loaded regulator type, as high-pressure gas
enters the dome chamber (i.e. Pilot Port in Figure 5) the volume of gas inside the dome chamber
(pilot gas pressure) forces the main valve to lift from the main seat as illustrated in figure 5. The
configuration of this reducing regulator, pilot pressure equal or marginally above the outlet
pressure of the regulator,
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Figure 5 1st Stage Regulator Configuration
Caution: during adjustment thread stripping can happen if an operator attempts to set
an outlet pressure, which exceeds the regulator’s capacity or the available inlet
pressure.
2.) 2nd Stage Pressure Reduction Regulator, a pilot-operated regulator is used to achieve the final
pressure reduction. This type uses the inlet pressure as the operating medium, which is reduced
through pilot operation to load the regulator actuator diaphragm. Outlet pressure opposes
loading pressure in the actuator and opposes the pilot control spring. When the outlet pressure
(Pd) drops below the setting of the pilot control spring, pilot control spring forces the pilot
diaphragm opening the pilot valve plug, providing additional motorization pressure (Pm) to the
actuator diaphragm. This diaphragm motorization pressure opens the main valve plug, supplying
the required flow to the downstream system.
Basic configuration is illustrated in Figure 5. For further details refer to OEM’s datasheets and
specifications.
For more details of NZ Pressure regulating valve refer to Annexure 4: NZ pressure regulating
valve.
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Figure 6 2ndStage Regulator Configuration
The pilot-operated NZ Series (Spring-to-Close version) will fail in close position with a
main valve diaphragm failure or lack of pressure supply to the pilot. Refer to OEM’s
instruction manuals.
3.) Instrumentation Gas Regulator, this type of equator is similar in configuration to the 1st stage
regulator. However, it uses a diaphragm for the sensing element instead of a piston. The
regulator is used to achieve a desired gas pressure to operate the actuated ball valves. When
downstream pressure is at or above set pressure, the disk is held against the seat and there is
no flow through the regulator. When demand increases, downstream pressure decreases,
allowing the regulator spring to extend, moving the yoke and disk assembly down and away from
the seat. This allows flow through the body to the downstream system.
Basic configuration is illustrated in Figure 7. For further details refer to OEM’s datasheets and
specifications.
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Figure 7 Control Gas Regulator
3.2.3 Gas flow Meter
Gas flow meter component is installed downstream the 2nd stage regulator, the type used is Coriolis flow meter (R-
Series) from Emerson. The flow meter is flitted with a transmitter and display to allow connection to a remote display
(Local HMI).
Basic configuration is illustrated in Figure 8 for further details refer to OEM’s datasheets and specifications
Figure 8 General View (Coriolis Flow Meter)
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3.2.4 Bypass 1st Stage Reduction
To achieve the maximum rated flow through the PRS at low inlet pressures (e.g. when supply trailer
is near empty). Actuated ball valve opens (commanded by the PLC program) located upstream the
1st stage regulated causing gas to pass directly to the 2nd stage heat exchanger.
In addition to the bypass actuated ball valve, isolation actuated ball valves are fitted onto the PRS.
The following are a short summary of their functions:
1.) Inlet isolation gas actuated ball valve: Located at the inlet of the PRS and on the outlet of the
1st stage shell and tube heat exchanger, these valves when actuated allows gas flow to pass
through the system.
2.) Bypass isolation gas actuated ball valve: Located at 1st stage shell and tube heat exchanger
inlet, these valves when actuated the gas is flown directly to the 2nd stage shell and tube heat
exchanger.
3.2.5 Protection system

Protection System consists of pressure safety relief valves fitted at each stage of PRS to protect the
equipment from over pressurization. The PRS operation is also protected and controlled via an
intrinsically safe system where signals from transmitters are relayed to the PLC controller to ensure
that the operating parameters within the equipment are at acceptable limits.
3.2.6 Control System

A Programmable Logic Controller (PLC) controls the PRS operation.
Analog and digital input signals from pressure/temperature transmitters and switches are sent to the
PLC via intrinsically safe barriers. Intrinsically safe barriers relays are required for interface between
locally mounted transmitters or switch and PLC to comply with hazardous area regulations.
Each PRS comes complete with an electric control cabinet. Control cabinet components include main
supply isolation switch; PLC controller; LCD display unit; intrinsically safe barriers, control relays; etc.
Termination strips are included for simple field connection to output devices and control equipment.
Below is a typical layout of a PRS control cabinet:
Figure 9 PRS Controller
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Water Heater,
Eelectric hot water heater supply heating medium to gas prior to the reduction in gas pressure. The
heating medium (softened water) is circulated in and out under close-loop principles. Automatic
replenishment valve and expansion tank are equipped at the water supply line to maintain constant
water pressure during heating and cooling (i.e. expansion and contraction). Safety relief as well as
bleeding valves is mounted on the vessel in case of water overheating which leads to increase in
water pressure.
In the addition to the above the water heater is equipped with instrumentation, including pressure and
temperature probes and water level sensor, which signals are relayed to the PLC controller for
monitory and control
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3.3 Performance Data

Table 2 PRS Technical Data
Model; PRS 3000 +

Pressure, Inlet Maximum 3625psig (250bar g)
Pressure, Inlet Minimum 220psig (15bar g)
Pressure, Outlet Range: 41~80psig (2.8~5.5bar g)
Pressure 1st Reduction (HP) 3625 psig (250 bar g) to 870 psig (60 bar g)
Pressure 2nd Reduction (LP) 580 psig (40 bar g) to 58 psig (4 bar g)
MAWP Shell and Tube Heat Exchanger #1 3800 psig (262 bar g)
MAWP Shell and Tube Heat Exchanger #2 3800 psig (262 bar g)
Temperature Outlet Gas 41~140°F （5~60°C）
Temperature Range (tube side) 30º C to 80º C
Temperature Range (shell side) 0º C to 70º C
Flow Rate Gas Maximum 3000 SCMH @ Pressure, Inlet Minimum
Flow Rate Gas Minimum 500 SCMH
Flow Rate Water 5 m3/hr
Heating medium Softened Water H2O
Heater Capacity 120 kW
Pressure Pipework ASTM A106 Gr.B
Pressure Pipe Fittings ASTM A234 WPB / ASTM A105
Stainless Steel Tube work ASTM A269
Relief Valves ASME VIII
Skid dimensions (L x W x H mm) See general arrangement drawings
PRS connections
Gas Inlet: 1” tube Connection
Gas Outlet: Flange SO 3" CLASS 300LB RF
Gas Manifold Vent: 1-1/2” NPT(F)
Hot water Inle/Out: 1-1/2” BSPP(F)
Filter Drain 1/4” Tube Connection
Weight (approximate) 1000 Kg
Reduction pressures may be altered to suitable application.
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Water Heater Performance

Table 3 Technical Data
Model: LDR0.12-0.7/95/70
Pressure Outlet Maximum 5 bar (g)
MAWP (vessel) 7 bar (g)
Pressure Setting Safety Valve 6 bar (g) → Size 15 DN
Temperature outlet (Rated) 95℃
Temperature inlet (Rated) 70℃
Temperature outlet (Setting) 60- 65℃
Temperature inlet (Setting) 45 - 50℃
Temperature Ambient (allowable) ＋5℃～＋40℃（+41°F～+104°F）
Power Max 120kW
Power each electric heating tube 20kW
Current Rated 180 A
Voltage Rated 380 V
Water hardness conditions (recommended) 〈 0.03 mMol/L
Flow rate (WATER) @ Water Heater Outlet 5 m3/hr
Connection Outlet/Inlet Water 1-1/2 Inch BSPP (F)
Connection Drain Water 1 inch BSPP (F)
Connection Supply Water 1/2 inch BSPP (F)
Approximate Weight ~290 Kg
Overall size (L× W ×H) → 1000×900×1600 (mm)
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4 Installation and Commissioning

4.1 Transportation and shipping
Caution while removing the PRS from the shipping container, the PRS is bolted
on a wooden base to allow stability during transportation.
The container must be removed from the truck and placed on level and flat concrete or sealed ground. It is
recommended to transport the equipment to site or designated storage area before its removal from the
shipping container. The PRS package is packaged inside a sealed wooden box with available forklift slots
for safe handling of the equipment while inside the packing. Refer to Figure 10
Figure 10 PRS typical packing

Sea Freight
Gross Weight. 1530 [kg]
Length 390 [cm]
Width 200 [cm]
Height 210 [cm]
Air Freight
Gross Weight 1530 [kg]
Length 310 [cm]
Width 200 [cm]
Height 210 [cm]
Personal protective equipment (PPE) must be worn during lifting, unpacking

and handling of the equipment in general
Actual packing dimensions and package weight varies in accordance to the

method shipping. Packing List details will indicate such information.
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Before the equipment is removed from the wooden box operator (s) should be familiar with the content of
the wooden box, to avoid damage to the equipment during dismantle of the wooden surrounding the
equipment inside, Figure 11 gives a typical arrangement of the equipment inside the wooden box. It is
recommended to dismantle the top wooden piece then the sides. Ones all sides of the wooden box are
removed the foil covering the equipment can be removed. Then straps/bolts should be removed to free
the equipment from the wooden base. Figure 11 illustrates a typical equipment packaging arrangement.
Figure 11 Typical Packaging Arrangement

Ensure all valve are close during lifting until purging or installation to avoid dirt/particles etc. from
contaminating the PRS/WATER Heater pipe work.
CAUTION, Equipment is under pressure over 0.3 bar (g). Handle with caution and care.
CAUTION, PRS discharge pressure gauge must be check during before PRS handling
Figure 12 PRS Contain Nitrogen Pressure
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CAUTION do not lift the equipment by any pipe work, heat exchanger supports
or any other part of the PRS other than that indicated for lifting in this manual.
Ensure that the slings/strops are strong enough to support the weight. We recommend the use of
two 3-meter long slings/strop in this process. Ensure each strop is rated to a minimum of 1000 kg.
Before lifting, remove the eight securing bolts from the wooden base. The same strops can be used
for lifting the control cabinet.
Figure 13 PRS Lifting Points
VERY IMPORTANT:
• For safety, access should be prohibited to area under and around lifted
objects during lifting and handling in general.
• For safety, it is highly recommended the use of adequate individual
protective equipment (e.g. glasses, gloves, shoes…) during lifting and
handling.
• To avoid damage to equipment during lifting, it is prohibited to lift the PRS
from the bottom or any other point not indicated for lifting.
• If any non-compliance from Devanning or Unloading Work Instruction is
observed, Atlas Copco will not be held responsible for any potential damage
to this equipment or personnel involved in process of unloading the PRS.
4.2 Installation
4.2.1 PRS Skid installation
The PRS/Water Heater/Control Cabinet unit must be mounted on standard concrete floor.
The PRS skid must be leveled before fixing in position.
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The PRS/Water Heater/Control Cabinet must be installed under a shed or inside a ventilated room
as equipment is not designed for direct exposure to sun and weather.
The PRS contains flammable gas, therefore keep any source of fire, high temperature, high voltage,
or ignition away at a safe distance of minimum 5 meters.
The PRS/Water Heater/Control Cabinet must be bolted to the concrete. Refer to the general
arrangement drawing attached in the annexure section of this manual for bolt locations.
4.2.2 PRS Mechanical installation

1.) Refer to general arrangement drawing for PRS battery limits (i.e. connection location and sizes).
2.) Inlet connection (i.e. connecting tubes and fittings) to the PRS shall be rated to a minimum of
5% above the safety relief valve fitted on the PRS 1st stage shell and tube heat exchanger.
Emergency shutoff valves must be placed in easily accessible positions in the inlet line(s).
3.) Discharge connection (i.e. connecting pipes and fittings) to PRS shall be rated to a min of 5%
above the safety relief valve relief valve fitted upstream the 2nd stage regulator. Emergency
shutoff valves must be placed in easily accessible positions in the discharge line(s).
4.) All safety relief valves must connect to a common vent line. This must be piped out the PRS
house to a minimum of 3 meter in height, or as applicable local safety regulations.
5.) Gas pipe sizing must be engineered in such way to ensure the minimum pressure drop to the
inlet and from the outlet of the PRS. It is vitally important that such sizing is selected to retain
the maximum allowable pressure in accordance to the applicable local norms and regulation.
6.) Surge volume vessels (0.5 m3) minimum is recommended to be installed at the discharge of the
PRS, especially in cases where the downstream equipment’s are largely distanced from the
PRS.
7.) Gas piping to and from the PRS inlet must be entirely cleaned and free from dirt and scale on
the inside.
Atlas Copco must be consulted regarding pipework cleaning procedures before any
cleaning is carried out. All compressor inlet and discharge pipework must be
pressure tested to a recognized standard.
Piping or other parts with a temperature exceeding 65˚C (150˚F) and which can be
accidentally touched by personnel in normal operation must be guarded or
insulated. Other high temperature piping must be clearly marked with this symbol.
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4.2.3 PRS Electrical installation
Do not connect the PRS to the power supply at this time. All of the preparation
must be completed, and all panels reinstalled before connecting the PRS to the
electric supply.
All electrical work must be carried out by registered electricians and done in
compliance with local Gas and Electrical Authority regulations. This shall include
installation of a readily accessible disconnect device into the fixed wiring power
supply.
All supplied electrical equipment must be grounded in accordance to the local

regulations.
Control cabinet illustrated in section 3.2.6 must be installed in a safety area (i.e. an
area where explosive atmospheres or explosive gases are not present).
1.) For cable requirements, see Cable Schematic Drawing in the annexure of this manual. Cable
specifications should be verified with Atlas Copco before being purchased.
2.) Junction boxes mounted on are the PRS skid shall be wired as illustrated in Figure 11.
3.) PRS Frame must be connected to ground (i.e. earthed) to avoid static electricity build-up when
handling flammable gas or electrostatic-sensitive devices.
4.) All cables/glands must comply with the local electrical regulations and Atlas Copco
requirements.
5.) An electrical checklist must be completed before commissioning is carried out.
Figure 14 Skid wiring IDs
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All cables must comply with local electrical regulations and Atlas Copco
requirements. Local Electrical Wiring regulation must be followed for compliance of
site hazardous area installation.
4.3 Water Heater installation

Water Heater Mechanical installation
1.) Water heater should be installed at a minimum distance of 6 meters in radius from the PRS. It is
equally important not to install the PRS too far from the PRS; this is, to reduce water pipe
frictional losses which in cases of high-water pressure drop would overload the water pump
equipped in the water heater.
2.) Refer to water heater general arrangement drawing battery limits (i.e. connection location and
sizes).
3.) Pipe connection to PRS must be of 1.5-inch galvanized steel, avoid any unnecessary bends,
reducers and pipe elevations to reduce water frictional loss.
4.) Water Heater outlet should be connected to shell and tube heat exchanger 1 (HX101 as in
figure 15) and water heater inlet must be connected to shell and tube heat exchanger 2 (HX102
as in figure 15).
5.) Ensure the water supply is connected to o the inlet of the magnetic valve, non-softened water
such as well water, river water shall not be used.
Figure 15 Water Pipe Connections in PRS
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6.) Water used must meet national standard. It is recommended that water softener to be utilized in
such cases where such standards cannot be met, to avoid scale and impurities that may
negatively affect the efficiency heating exchanged as well as shorting life of the devices.
7.) Do not use low conductivity medium such as distilled water and pure water, which will affect level
controlling and measuring.
Water Heater must be installed in a safety area (i.e. an area where explosive
atmospheres or explosive gases are not present).
If water heater is not supplied by Atlas Copco, user must consult Atlas Copco
regarding the type and size to be used.
In such case of any failures to the PRS due to inappropriate sizing, application,
selection or quality of the water heater, Atlas Copco shall not be responsible or
liable for any kind of damage or loss (of life or otherwise).
Do not connect the PRS control cabinet to the power supply at this time. All of
the preparation must be completed, and all panels reinstalled before connecting
the PRS to the electric supply.
Water Heater Electrical Installation
All electrical work must be carried out by registered electricians and done in
compliance with local Gas and Electrical Authority regulations. This shall include
installation of a readily accessible disconnect device into the fixed wiring power
supply.
All supplied electrical equipment must be grounded in accordance to the local

regulations.
1.) For cable requirements, see Cable Schematic Drawing in the annexure of this manual. Cable
specifications should be verified with Atlas Copco before being purchased.
2.) Junction boxes mounted on are the PRS skid shall be wired as illustrated in Figure 11.
3.) All cables/glands must comply with the local electrical regulations and Atlas Copco
requirements.
4.) An electrical checklist must be completed before commissioning is carried out.
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5 Commissioning
5.1 General
An Atlas Copco approved commissioning engineer must carry out commissioning. Failure to comply
with this requirement will lead to the equipment warranty being made void.
Atlas Copco (Wuxi) Compressor Co.,Ltd.

PRS Commissioning Sheet REF: 4.9, 4.10 PRT-035
Customer:
Customer Site:
Job Reference:
PRS Model:
PRS Serial #:
Manufacturer:
Commissioning Engineer:
Commissioning Checks Date Signed Remarks
Check all installation piping

Check tightness of all PRS tube fittings, pipework, etc
Ensure that PRS supply pipework is clean
Check electrical cable connections are as per electrical drawings.
Purge PRS with process gas
Set PRS 1st stage regulator reference pressure.
Check 1st stage regulator pressure
Set 2nd stage regulator pressure
PRS Performance & Functionality
Check Station supply Voltage
Check overall PRS function
Check Emergency Stop button function
Check PRS Bypass function
Check Interstage overpressure function
Check final discharge overpressure function
Manuals handed to customer?
Operator training completed?
Leak Test Pressure Signed
Tube Fittings
Pipe Fittings
Valves
Commissioned
Verified by
by
Date Date
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5.2 Purging PRS
Before Purging ensure the following: (Refer to PRS commissioning sheet)

1.) Check tightness of all PRS tube fittings, pipework, etc.
2.) Ensure that PRS supply pipework is clean.
3.) Check electrical cable connections are as per electrical drawings.
Before putting the PRS system into operation, the PRS must be purged with
Nitrogen and in extreme cases where Nitrogen is not available, process gas
maybe used, however extra care should be taken when purging with process
gas.
Ensure Nitrogen bottles are connected to the inlet of the PRS! (Notice each
stage maximum pressure, in case of over pressure for the system).
1.) To purge, first open drain valve VV111 connecting to the inlet filter and open the actuated valve
VV150 manually (from the HMI), then slowly partially open inlet isolating valve VV101 until small
flow of nitrogen/gas discharging is observed on all valves.
2.) Continue to allow gas to drain from this valve for approximately 30 seconds then close inlet
isolating valve and drain valves.
3.) Open the actuated valve VV150 and vv151 manually (from the HMI), this will allow gas to flow on
the second stage heat exchanger, open vent valve on the second stage heat exchanger VV114
and NZ pilot drain vent VV115 until small flow of nitrogen/gas discharging. Using the above
procedure purge the bypass tube by opening actuated valve VV152 manually. (All actuated ball
valves can be manually open via the HMI).
4.) Process piping at discharge of the PRS should also be purged with process gas. Open the ball
valve VV103. A drain valve on the installation process piping should be opened, slowly partially
open inlet isolating valve VV101 until there is flow of gas discharging from drain valve. Continue
to allow gas to drain from this valve until all air is purged from process pipe.
5.) Then, close PRS inlet valve and drain valve.
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Figure 16 PRS Inlet Valve and Drain Valve
Table 4 PRS part descriptions
References Description
VV150 Inlet Actuated Ball Valve
VV151 Inter-stage Actuated Bal Valve
VV152 Bypass Actuated Bal Valve
VV122 Pressure Reducing Regulator 1st stage
VV123 Pressure Reducing Regulator 2nd stage
VV101 Inlet Ball Valve
VV103 Discharge Ball Valve
VV161, VV162 Water Gate valves
HX101, HX102 Heat exchangers 1st & 2nd stage respectively
RV101, RV102, RV103 Safety valves
PI101, PI102, PI103, PI104, PI105 Pressure indicators
FF401 Filter
VV111 Filter drain valve
VV112, VV113, VV114, VV115 Bleeding Needle Valve
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5.3 Starting System

1.) Allow hot water to flow through PRS through gate valves VV161 & VV162. Ensure that hot water
temperature is minimum 40 ºC before putting PRS into operation. (PLC will allow a delay for water
to circulate & raise temperature before operation begins).
2.) With PRS discharge isolating valve closed, slowly open PRS inlet isolating valve. Pressure in heat
exchanger # 1 (HX101) will increase as indicated on pressure indicator (PI-101).
3.) Pressure will also increase in heat exchanger # 2 (HX-102) as indicated on PI-102.
4.) Then, ensure control gas regulator is set to 100psi.
5.) When pressure has stabilised at PI-101, ensure that inlet isolating valve is fully open.
6.) Slowly open PRS discharge valve (VV103) to place the PRS into operation. Pressure indication at
PI-103 should read 58psi. Slight adjustments may be required on 1st pressure regulator VV122 and
on 2nd pressure drop regulator VV123. See adjustment section below for procedure.
1.) 1st Stage pressure reduction drops the pressure from 3600psi to approximately 900psi.
2.) 2nd Stage pressure reduction drops the pressure from 900psi to 58psi (or desired output
pressure).
After initial commissioning of the PRS, when the two main gas regulators are set for ideal
performance, automated control of the system is performed by the PLC control unit. This measures -
1.) Gas inlet pressure,
2.) 2nd stage heat exchanger gas pressure,
3.) Outlet gas pressure,
4.) Outlet gas temperature and,
5.) Gas flow rate.
5.4 PRS Pressure Adjustment

1st Pressure Regulator (VAR-02A)
Figure 17 1st Pressure Regulator

To increase or reduce the discharge pressure of the dome loaded regulator (VV122) the pilot
pressure to the regulator needs to be adjusted.
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To Reduce Pressure -
With gas flowing through the PRS, using valve VV112 vent pressure from the reference cylinder
VE101 until the indicator PI104 drops to the desired pressure.
To Increase Pressure -
With gas flowing through the PRS, using valve VV113 add pressure to the reference cylinder VE101
until the indicator PI101 increases to required set pressure (45 bar.g or 652.52 PSI).
In practice opening and closing valves VV112 and VV113 is carried out simultaneously until the
desired pilot pressure is obtained in the reference cylinder. Once this is achieved both valves are
closed sealing the reference cylinder pressure. The pilot pressure should be monitored daily and
maintained by topping up the reference cylinder pressure from the inlet gas supply.
The ratio of regulated pressure to pilot pressure equals 1:1 e.g. PI 104 and
PI102 should read same pressure values within an error of 2-3%.
See PRS Components section for further VAR-02A Regulator details.
2nd Pressure Drop Regulator (NZ Fisher) Adjustment
Figure 18 2nd pressure drop regulator (NZ Fisher)

Control spring
The regulator control spring is factory set at the set point specified in the order. If no set point is
specified, the control spring is set at approximately the midpoint of the spring range. An initial
adjustment may be required to achieve the desired pressure at site. If adjustment of the outlet
pressure is required, close the Outlet Isolation Valve and slightly open the vent valve. Slowly open
the Inlet Isolation Valve.
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Manually turn the adjusting screw on the pilot and monitor the downstream pressure to achieve the
required pressure. If a wide-open monitor is installed, first, set the pilot of working regulator to a
setpoint higher than the desired setpoint for the monitor pilot, second, adjust the monitor pilot to the
desired monitor takeover pressure and then reduce the setpoint of working regulator to the desire
valve.
Restrictor
The restrictor on the pilot controls the regulator’s proportional band droop and speed of response.
The restrictor on the pilot should be adjusted carefully. The restrictor is normally set at the tightest
mode till it can no longer be screwed in the clockwise direction. Observe extreme caution during
unscrewing the restrictor so that it does not come out of the pilot body face.
In the event of hunting of the stable outlet pressure, unscrew the restrictor slowly in increment of 1/4
turn until pressure stabilizes, 2 turns at most.
For more information, refer to Annexure 4: NZ pressure regulating valve.
Control Gas Regulator
Figure 19 Control Gas Regulator

1.) Ensure that all pre-commissioning checks have been carried out as per instructions.
2.) Loosen the pressure adjustment screw fully.
3.) Manually open the Inlet Gas actuator valve. Open the manual discharge valve.
4.) Allow Inlet Gas pressure to equalize in the complete machine.
5.) Close Inlet Gas Actuated valve. Start the machine and allow the discharge pressure to buildup.
6.) Gradually rotate the pressure adjustment screw, clock wise and set the control gas pressure
between 90 to 110 psi (6.2 to 7.5 bar).
7.) After the machine has reached the maximum operating pressure, check and ensure that the
Control Gas pressure does not exceed 110 psi or 7.5 bar. Tighten the lock nut.
If the actuators are sluggish in operation, should increase the control gas pressure
gradually till actuators operate smoothly. (Max pressure 8.5 bar / 125 psi).
To increase control gas pressure, rotate adjustment screw clock-wise.
To decrease control gas pressure, rotate adjustment screw anti-clock-wise.
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Reference Vessel Proportional Relief Valve

Ensure the proportional relief valve is set between 800-900 PSI
Figure 20 Proportional Relief Valve
Static Balance Valve setting

Static balance valve is located at the outlet of the water heater. The standard position of the valve, see
Fig1 and Fig 2.
Fig 1 Fig 2
Presetting
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Fig 3 Valve fully closed Fig 4 Opening control valve 2.3 Fig 5 Valve fully open
Ways of setting balance valve according to a certain pressure drop (Opening control valve 2.3)
as follows:
1. Valve fully Closed (Fig 3).

2. Set the valve at position 2.3 (Fig4).
3. Use a 3 mm Allen key to tighten the inner valve rod clockwise.
4. Valve setting finished.
When the system started pressure at 1.0 bar and running temperature at 80°C, the
reference value of the Opening control valve is as Tab1.
Tab 1
System flow (t/h) Valve opening

5 1.55
4.5 1.25
4 1.00
3.5 0.78
3 0.6
2.5 0.48
The factory set of the balancing valve is locking at 1.00 turns.
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6 Operation
6.1 General Operation
Once the equipment has been commissioned with all operating parameters set, operating the PRS
package is simple. The PRS can be started or stopped by the key switch provided on the control
cabinet. Once the PRS has started, the operation is automatic.
Emergency stop control should only be used in emergency situations. It should not
be used for normally stopping the PRS.
1.) Turn the Power On/Off isolate switch to the on position. The Red lamp will illuminate.
2.) Turn Key Start/Stop/Reset switch to start position. The Green lamp will illuminate.
3.) Emergency stop button is for emergency stop.
To reset the system, turn the switch to stop/reset position.
The water heater will turn on and will circulate hot water through the system. When the water is up
to the set temperature, the actuated valve VV151 will open letting the high-pressure gas pass
through the PRS.
High pressure gas from the trailer enters the PRS through inlet isolating valves (VV101 and VV102).
Gas then passes through 1st pressure reduction heat exchanger (HX101). Gas is heated as it
passes through the heat exchanger.
Gas pressure is then reduced by the high-pressure regulator valve (VV122). Pressure is reduced
from 3600psi (250bar) to 580psi (40 bar). Operating pressure range for (VV122) regulator is 290psi
– 2900psi. 1st regulator outlet pressure reading is indicated on gauge PI-102 mounted on the 2nd
stage heat exchanger (HX102).
Gas then flows through 2nd pressure reduction heat exchanger (HX102). Gas pressure is further
reduced by the low-pressure regulator valve (VV123) from 580psi (40bar) to 58psi (4bar). Second
stage regulator outlet pressure reading is indicated on gauge (PI-103).
When the inlet pressure from the trailer reaches the set point the actuated by-pass valve is opened.
The gas will flow from by-pass and inlet valve to the 1st stage Heat Exchanger and 1st stage
Regulator.
When the inlet pressure drops to 15bar (217psi) the PRS automatically shuts down.
It is imperative that hot water supply to the PRS is maintained during operation
of the PRS. If hot water supply is terminated while PRS is in operation, freezing
may occur resulting in damage to the PRS.
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6.2 HMI display

HMI display on the remote-control panel (i.e. cubical) is available with several tap buttons, the
contained of each tap button can be displayed by a simple touch on the screen.
Figure 21 HMI Display “Overview” - Operating Parameters
In the overview tap button users may find the operating parameters of the PRS and the status of the water
heater as indicated in the bottom right corner of Figure 17.
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Figure 22 HMI Display “Set Points” – set point values are for illustration only
PRS set points tab button are displayed in Figure 17, these values are set by the factory and cannot be
edited, and such information are used only for information.
The I/O tap button display is used to check the communication status of a list of devices. A simple touch
on the corresponding button will give the status such as green color for ‘communicating’ and grey color
indicates no communication.
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Figure 23 HMI display “Set Points” for heater
Figure 24 HMI display for “Heater”
To view the status of the water heater, click on the Heater tap. The screen displayed will be as in Figure
19.
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Figure 25 PRS 1000 Manual Operation
The devices Listed in the manual tap button of the HMI can be used during commissioning and
maintenance, such devices cannot be operated when the PRS is running. It is highly recommended that
before changing the status of a device that can be listed in the alarm screen as in Figure 21 to ensure that
safety precautions listed in this manual are strictly followed by the operator.
Figure 26 PRS 1000 Alarm Information

In case of PRS fault, user can find fault message in this tap for troubleshooting. The alarm tap button flash
in green color in the instance of PRS fault.
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Table 5 Alarms
Inlet pressure low (WARNING) 10 bar(g) 145psi
Inlet pressure high (TRIP) 255 bar(g) 3700 psi
Inter-stage pressure low (WARNING) 2 bar(g) 29 psi
Inter-stage pressure high (WARNING) 70 bar(g) 1015.26 psi
Inter-stage pressure high (TRIP) 95 bar(g) 1380 psi
Discharge pressure low (WARNING) 1.2 bar(g) 18 psi
Discharge pressure low (TRIP) 1.0 bar(g) 14.6 psi
Discharge pressure high (TRIP) 7 bar(g) 101.5 psi
Discharge low temperature (TRIP) 5 °C 41 °F
Discharge high temperature (TRIP) 65 °C 140 °F
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50 1904999444
Table 6 Faults
(A) PRS on field devices

Unit Setting Fault Outcome
Emergency stop button Local (ON PRS) [-] TRIP
Emergency stop button Local (ON Control Panel) [-] TRIP
Gas Detector Low Level [-] N/A
Gas Detector High Level [-] N/A
Gas Detector Fault [-] N/A
Inlet Temp High °C TRIP
Inlet Temp Low °C TRIP
Discharge Temp High °C 60 TRIP
Discharge Temp Low °C 5 TRIP
Inlet Pressure Low bar.g 10 Warning
Inlet Pressure High bar.g 255 TRIP
Discharge Pressure High bar.g 7 TRIP
Discharge Pressure Low bar.g 1.2 Warning
Discharge Pressure Low bar.g 1.0 TRIP
Inter-stage Pressure Low bar.g 2 Warning
Inter-stage Pressure High bar.g 70 Warning
Inter-stage Pressure High bar.g 95 TRIP
Inlet Pressure transmitter Fault [-] TRIP
Inter-stage Pressure Transmitter Fault [-] TRIP
Discharge Temperature transmitter Fault [-] TRIP
Inlet Temperature Transmitter Fault [-] TRIP
Discharge Temperature Transmitter Fault [-] TRIP
By-Pass Set Pressure bar.g 40 [-]
By-Pass Valve Fault [-] TRIP
(B) Water heater on field devices

Unit Setting Fault Outcome
Heating Element 1 Run fail Warning
Heating Element Fault 1 Warning
Atlas Copco 2019-01

1904999444 51

Heating Element Temp High 1 TRIP
Water Level Low TRIP
Water Temperature High °C 70 Warning
Water Over heating °C 80 TRIP
Water Pressure High TRIP
6.3 Gas Composition-Variation Effects

Gas composition variations can have important effects on the performance and life cycle of the PRS.
Hence the following paragraphs indicates some effects and recommended values that ensures a safe and
satisfactory operation.
Water Content
The use of natural gas with high water content can result in the formation of liquid water, ice particles or
hydrates at low operating temperatures and high pressure. Such formations can cause:
Partial blocking to the PRS inlet filter element causing it to fail.
Reduce the life of or damage to the regulators especially during ice formation.
Heavier Hydrocarbons
Propane has a low vapor pressure and if present in significant quantities, it will form a liquid phase at
elevated pressures and low temperatures. The significant presence of the heavier hydrocarbons in the
gas mixture will cause large amount of liquid to be carried over to the delivery line.
Carbon dioxide
Provided that the corrosive environment is controlled via the limited water concentration and Sulphur, no
limits are required on the concentration of CO2 for this purpose. Rather, a limit of 3.0% CO2 by volume is
recommended to help maintain stoichiometry.
Sulphur content
Sulphur compounds in natural gas are in the form of mercaptans, hydrogen sulphide, and odorants. The
first two are naturally occurring at source (gas fields) and have already been reduced by treatment at the
gas processing plant to avoid oxidation The sulphur-based odorants (tetrahydrothiophene, THT, and
tertiary butylmercaptan(TBM)) at concentrations as low as 10-15 mg sulphur/m3 of natural gas can have a
very damaging effect, if oxidized. Therefore, it is highly recommended to ensure that the percentage of
H2S in Natural Gas is not in access of 10 ppm(V).
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52 1904999444
7 Maintenance
7.1 General Safety
During any maintenance work on the PRS, ensure that all fasteners are tightened to
the recommended torques.
To keep your CNG equipment in good running order, regular maintenance must be
carried out and periodic service checks done.
Failure to carry out maintenance and log-keeping in accordance with the
procedures herein could void the equipment warranty.
A copy of the Atlas Copco Compressor Log Sheets is included in this manual. A
log sheet booklet is also included with this manual.
Take PRS readings as outlined on LOG SHEETS before and after carrying out any
maintenance work.
1.) Before carrying out maintenance of PRS, the system must be isolated and all gas vented.
2.) Close PRS inlet isolation valves (VV101).
3.) Close PRS discharge isolation valve (VV103).
4.) Drain system using drain valve in order from the lowest pressure (VV112, VV113, VV114,
VV115).
5.) Maintenance and repair work must be carried out only on an entirely vented System. If
necessary, isolate all storage systems and blow-down all condensate traps and heat
exchanger. Open all manual drain valves.
6.) Make sure no person is in contact with pipe work or other parts of the PRS that heat up during
operation.
7.) The equipment must be electrically isolated by pad-locking and the main switch in the “OFF”
7.2 Individual Average Weights

Before removing or handling any part of the PRS, during maintenance, beware of its weight to avoid
any injury or incident. Below given are the approximate weights of some heavy parts.
Note: Weights are approximate, such information is provided to allow correct handling of heavy parts
during maintenance, repair and lifting, in general.
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1904999444 53
Table 7 Approximate weights
S. No. Description Weight (kg)

1 Shell and tube Head exchanger 110
2 Skid Frame 110
3 1st Stage Regulator >5
4 2nd stage Regulator (Fisher NZ) 35
5 Metering sensor (Micro Motion) 10
6 Inlet filter (Screwed Vessel) 20
7 Discharge Pipe Spool 25
8 Control System (Cubical) 100
Severe personal injury and property damage can result if pressure system is not
completely vented before loosening bolts on flanges, heads, valves, and caps.
Consult Atlas Copco technical manual before performing any maintenance.
Inlet filter vessel must be drained manually, at least two times a week, however
periodic draining is recommended as the amount of contaminate is mostly
dependent on quality of gas delivered and amount of gas discharged per day.
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54 1904999444
ATLAS COPCO PRS LOG SHEET

PRS MODEL :
PACKAGE SERIAL # :
NZ SERIAL # :
Date:
Time:
PRS Hours:
PRS Capacity
Inlet Pressure
1st Stage Pressure (after 1st stage reduction)
Final Stage pressure (delivery line)
Ambient Temperature
Gas Inlet temperature (inlet to PRS)
Final Stage Temperature (delivery line)
Water Heater Temperature (inlet to shell and tube)

Water Heater Temperature (outlet from shell and tube)
Water Balance Valve Setting
Water Heater Amps (i.e. Current)
Water Pump Amps (i.e. Current)
Voltage
7.3 PRS Torque Settings

7.3.1 NPT fittings
1.) Assembly turns from finger tight For NPT Fittings Smaller Than And Equal To 1" To Be 2~3 Turns
2.) Assembly turns from finger tight For NPT Fitting 1" and larger to be 1.5 and 2.5 turns.
7.3.2 Flanges
1.) After flange assembly and all nuts have been run down by hand, start wrench tightening following
the star sequence fashion.
2.) Keep even gap between flanges around the circumference during wrench tightening.
3.) Apply the recommended torque in three round of tightening (25%, 75% and then 100%).
4.) Re-torque after 24 hours. Most of bolt preload loss occurs within 24.
Atlas Copco 2019-01

1904999444 55
Nominal Pipe Size Torque Torque

Class
(inch) (ft. lbs) (Nm)
1.0 150 60 82
1.5 150 80 110
2.0 150 120 162
3.0 150 160 217
1.0 300 120 162
1.5 300 200 270
2.0 300 90 125
3.0 300 160 217
For Use with ASTM A193 B7 Bolting or equal yield strength bolt material.
7.3.3 Tube Connections

Mostly consists of Ferulok assembly, during assembly and disassembly ensure the following steps are
strictly followed.
Fitting is shown in the disconnected position.
Insert tubing with pre-swaged ferrules into the fitting body until front ferrule seats.
Tighten the nut by hand. Rotate nut to the original position with a wrench. An increase in resistance will be
encountered at the original position. Tighten slightly with the wrench.
Smaller tube sizes will require less tightening to reach the original position, while larger tube sizes will
require more tightening. The wall thickness will also influence tightening.
The Swagelok gap inspection gage is not intended to be used when the fitting is retightened.
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56 1904999444
7.4 Service Checks

1.) Replace Inlet Filter element every 6 months or earlier depending on quality of inlet gas.
2.) Replace the 1st and 2nd Stage regulator minor service repair kit every 6 months.
3.) Replace all the ball valves and actuated ball valves service kit every year.
4.) Replace the 1st, 2nd and control gas regulator valves major service kit every year.
8 Troubleshooting
The following faults will be indicated on the HMI on the control cabinet
Fault Possible Cause
Follow OEMs troubleshooting instruction, specific fault description will be

Water Heater Alarm
shown on the Control Cabinet HMI display.
1.) Inlet pressure source to the PRS is higher than the allowable
Inlet Pressure High maximum pressure.
2.) Faulty or wrong pressure transmitter.
1.) Inlet pressure source has depleted to the minimum allowable pressure
by the PRS.
2.) Inlet actuated ball valve failed to open (Check further troubleshooting
for this failure).
Inlet pressure Low
3.) Manual shutoff ball valve at the inlet of the PRS is on the close
position
4.) Inlet train to the PRS is clogged
5.) Faulty or wrong pressure transmitter
1.) 1st stage regulator fault (e.g. valve seat failure, Spring failure, sensing
piston failure)
2.) Regulator outlet pressure or reference vessel pressure set too high.
Inter Stage Pressure High 3.) Bypass actuated ball valve (if provided) fail to close or too slow to
close when inlet pressure switch from low to high (Check further
troubleshooting for this failure).
4.) Faulty or wrong pressure transmitter
1.) 1st stage regulator fault (e.g. valve seat failure, Spring failure, sensing
piston failure).
Inter Stage Pressure Low 2.) Regulator outlet pressure or reference vessel pressure set too low.
3.) Actuated ball valve fails to open or is not opening fully
Atlas Copco 2019-01

1904999444 57
1.) 2nd stage regulator fault (e.g. valve seat failure, Spring failure, sensing
piston failure). Pilot seat of the 2nd stage regulator damage
2.) Regulator outlet pressure / pilot pressure set too high.
3.) Pilot regulator damper setting incorrect
Final Stage Pressure High
5.) Surge in gas flow, install buffer vessel downstream of PRS. (surging
may happen if downstream equipment’s from the PRS is largely
distanced from the PRS or piping is of incorrect size).
1.) 2nd stage regulator fault (e.g. valve seat failure, spring failure, sensing
piston failure). Pilot seat of the 2nd stage regulator damage
2.) Regulator outlet pressure / pilot pressure set too low.
3.) Pilot regulator damper setting incorrect.
Final Stage Pressure Low
5.) Surge in gas flow, install buffer vessel downstream of PRS. (surging
may happen if downstream equipment’s from the PRS is largely
distanced from the PRS or piping is of incorrect size).
1.) insufficient gas heating
2.) Shell and tube heat exchanger failure.

Final Stage Temperature 3.) Inadequate regulation of the 1st or and the 2nd stage regulators.
Low
4.) 1st stage regulator outlet pressure set too low.
5.) Micro Motion core processor fault.
6.) Ambient Temperature or inlet gas temperature is below the allowable
limit of the PRS.
1.) Excessive gas heating, Follow OEMs troubleshooting instruction.

Follow OEMs troubleshooting instruction.
Final Stage Temperature 2.) Inadequate regulation of the 1st or and the 2nd stage regulators.
High 3.) Micro Motion core processor fault.
4.) Ambient Temperature or inlet gas temperature is higher than the
allowable limit of the PRS.
Gas Detector low or High

Gas leak from the PRS or the surrounding.
Level
Flame Detector Alarm Fire detected from the PRS or the surrounding.
1.) Transmitter failed.

Transmitter Fault 2.) Transmitter wiring loose.
3.) Transmitter sensing port clogged.
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58 1904999444
1.) Actuator assembly on valve obstructed or damaged.

2.) Solenoid valve fault / stuck / jammed.
3.) Solenoid coils burnt or not powered.
Actuated ball valve not
opening or closing 4.) Control gas regulator is faulty.
5.) Insufficient gas supply to the Solenoid valve (i.e. control regulator
pressure setting is incorrect).
6.) No gas supply to the Solenoid valve.
PLC power supply lost PLC power supply fuse blown.
1.) Main switch off.

No HMI display visible at
2.) Blown fuse or circuit breaker tripped.
switchboard
3.) HMI power supply failure.
1.) Relevant stage pressure too high.

2.) Relevant transmitter not shutting PRS down before safety valve blows
Inter-stage safety valve off.
blow off
3.) Safety valve fault.
4.) Gas outlet restriction.
1.) Relevant transmitter not shutting PRS down before safety valve blows
Discharge pressure off.
safety valve
2.) Restriction.
blow off
3.) Faulty safety valve.
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1904999444 59
Annexure 1: Piping and instrument diagram
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60 1904999444
Annexure 2: General arrangement drawing
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1904999444 64
1 2 3 4 5 6 7 8 9 10
C
Water Heater
Water Outlet
Water Heater Outlet
Customer Supply
Two Water Pipes
(1 1/2" Galv. Pipes) D
Water Heater Notes:

PRS Technical Data Drain Outlet 1) Water Heater and Control Cubicle, NOT rated for Hazardous Area. Must be positioned within
Model PRS-060-2 a safe Outside the designated hazardous area.
Medium Natural Gas Water Heater 2) All Actuated Ball valves are gas operated.
Number of Stages 2 3) Inlet and Outlet Connections Such as Fittings and Pipes etc. to the PRS Must be Selected
copied, used for manufacturing or communicated to any other person or company.
Water Supply Inlet

to Recognized International Standards Such as ASME to the Ratings Descripted to the Table.
This document is our properety and shall not without our permission be altered,
Max Inlet Pressure 250 Bar.g

Discharge Pressure 2.8~5.5 Bar.g 4) ApproximateTotal Weight of the PRS = 810 Kg.
Water Heater Inlet F
5) Total Weight of the Water Heater = 230 Kg.
Gas Inlet Temperature 0~60° C
Allowable Ambient Temperature 0~40° C Tolerances, if not indicated, according to:
Outlet Temperature 5~60° C TOLERANCES UNLESS ATLAS COPCO STANDARD CLASS
1.6
Capacity 3000 SCMH ± 5% OTHERWISE STATED
Water Heater Rated Power 120KW Name PRS 3000 + GENERAL ARRANGEMENT Confidentiality Class
acc. to 1102 K
Water Heater Flow Rate 5 m^3/h WHOLE No's  5mm [0.040"]
1 DEC. PLACES 0.0  0.5mm [0.020"]
Material As Spec. 2
Water Heater Inlet 1-1/2" BSPP(F)
2 DEC PLACES 0.00  0.1mm [0.004"] Treatment See Drawing
Water Heater Outlet 1-1/2" BSPP(F) INV
CONFIDENTIAL:
ANGULAR  2.0°
Water Heater Safety Valve Outlet 1/2" BSPP(F) Scale 1 : 25 Family A3 Compare Drawing owner
Water Heater Water Supply Inlet 1/2" BSPP(F) All materials supplied are in compliance with the
requirements of the List of Prohibited Substances Drawn by GECIA Blank nr. Replaces COF G
Water Heater Drain Outlet 1-1/2" BSPP(F)
00 Version Drwg / 2
00 STATUS 00.00 Blank wt. 0 Kg Fini wt. 0 Kg Designation Sheet 1
Ed Posi-
tion
Modified from Date Intr./Appd. Parent 3D model Ed . Version 3D Preliminary
Des checked. Prod checked. Approved. Date
2017-06-07 3394043587
1 2 3 4 5 6 7 8 9 10
703 1520
Overall Width LIFTING POINT
A
Water Safety Valve

Outlet 1/2" BSPT(F)
Water Outlet
1 1/2" BSPT(F)
Overall Height
682
1867
Water Inlet
1 1/2" BSPT(F)
1381
Outlet Connection
964
700
700
A A C
Gas Inlet
1" Tube Connection 300
598 1770 482
Water Connection
225 745 Filter Drain
Inlet Connection Inlet Connection 1/4" NPT (F)
282 1196
Outlet Connection Outlet Connection D
150
19
4 Places
E
300
Outlet Connection
376
800 1000
3612
Water Heater Overall Length
Outlet 1-1/2" BSPP
Section A-A
1 : 10
This document is our properety and shall not without our permission be altered,
1490
1065
F
140
Tolerances, if not indicated, according to:
TOLERANCES UNLESS 1.6 ATLAS COPCO STANDARD CLASS

OTHERWISE STATED
555 160 Name PRS 3000+ GENERAL ARRANGEMENT Confidentiality Class
acc. to 1102 K
WHOLE No's  5mm [0.040"]
Water Heater
1 DEC. PLACES 0.0  0.5mm [0.020"]
Material As Spec. 2
Inlet 1-1/2" BSPP  0.1mm [0.004"]
2 DEC PLACES 0.00 Treatment See Drawing INV
CONFIDENTIAL:
ANGULAR  2.0°
Note: Scale 1 : 20 Family A3 Compare Drawing owner
Water Heater NOT rated for Hazardous Area. Must Be Positioned All materials supplied are in compliance with the
within a safe Outside the Designated Hazardous Area. requirements of the List of Prohibited Substances Drawn by GECIA Blank nr. Replaces COF G
00 Version Drwg / 2
00 STATUS 00.00 Blank wt. 0 Kg Fini wt. 0 Kg Designation Sheet 2
Ed Posi-
tion
Modified from Date Intr./Appd. Parent 3D model Ed . Version 3D Preliminary
2017-06-07 3394043587
Annexure 3: Electrical wiring diagrams
2019-01 Atlas Copco

67 1904999444
1 2 3 4 5 6 7 8 9 10
PRESSURE REDUCTION STATION WITH HEATER

CONTROL PANEL WIRING
B
F
This document is our property and shall not without our permission be altered,
Name PRESSURE REDUCTION STATION WITH HEATER CONTROL PANEL Secrecy Class
Material NOT APPLICABLE 1102 K/ 03
Treatment Not Applicable ACD

Scale -:- Family A3 Compare
Drawing owner
Drawn by Ji Zhen Rong Blank nr. Replaces GAP G
g
on
R
Version Drwg
en
03 2018.1.25 Blank wt. Designation Sheet 1 (23)

0 Kg Fini wt. 0 Kg
Zh
STATUS 01
Ji
Note
Posi-
tion
Modified from Date Intr./Appd. Parent 3D Model Ed.Version 3D Approved
2017.09.11 3394 0428 73
1 2 3 4 5 6 7 8 9 10
2 2
5 6 7 8
STOP START
STOP START
9 10 11 12
ER
GEN START - STOP 6 8
EM
CY
STOP
13
D
STOP/RESET-START
12
R GEN
E E
EM
CY
3 3
STOP
F
10
LEFT VIEW FRONT VIEW RIGHT VIEW Material: Steel

Enclosure Painting: RAL7035
Plinth Painting: RAL7022
G
Designation Sheet 2 (23)
ACD Name PRESSURE REDUCTION STATION WITH HEATER CONTROL PANEL STATUS Ed. Date Prev. Page Next Page A3
Drawing owner
GAP Approved 03 2018.1.25
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F
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F
Ethernet Switch
3
5
1
4
7760048001 IES10-SW5
G
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TT107 TT108 PS1 PT301 PT302 PT303 TT201
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What sets Atlas Copco apart as a company is our
conviction that we can only excel in what we do if we
provide the best possible know-how and technology to
really help our customers produce, grow and succeed.
There is a unique way of achieving that - we simply call
it the Atlas Copco way. It builds on interaction, on long-term
relationships and involvement in the customers’ process,
needs and objectives. It means having the flexibility to
adapt to the diverse demands of the people we cater for.
It’s the commitment to our customers’ business that
drives our effort towards increasing their productivity
through better solutions. It starts with fully supporting
existing products and continuously doing things better, but
it goes much further, creating advances in technology
through innovation. Not for the sake of technology, but for
the sake of our customer’s bottom line and peace-of-mind.
That is how Atlas Copco will strive to remain the first
choice, to succeed in attracting new business and to
maintain our position as the industry leader.
No. 1904999444/ 2019-01 Printed in China

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Atlas Copco

Compressed Natural Gas

Operation and Maintenance Manual

Copyright 2017, Atlas Copco (Shanghai) PRS Co., Ltd.

Atlas Copco (Shanghai) Compressor Co.,Ltd.

No 1904 9994 44 Ed.04

• Package Operating & Maintenance Manual

Atlas Copco 2019-01

2019-01 Atlas Copco

2 Safety Instructions and Emergency Procedures ............................................................................ 13

3 General Information ........................................................................................................................... 21

4 Installation and Commissioning ....................................................................................................... 30

Atlas Copco 2019-01

Annexure 1: Piping and instrument diagram ....................................................................................... 60

Annexure 2: General arrangement drawing ......................................................................................... 64

Annexure 3: Electrical wiring diagrams ............................................................................................... 67

Annexure 4: NZ pressure regulating valve Instruction Manual.......................................................... 91

Table 1 Major components of PRS ............................................................................................................. 21

Figure 1 Typical PRS Package Name Plate ............................................................................................... 16

2019-01 Atlas Copco

Figure 14 2nd pressure drop regulator (NZ Fisher) ..................................................................................... 41

Atlas Copco 2019-01

2019-01 Atlas Copco

1 Warranty Policy and Procedures

PRS and Distributors Standards

Long Storage Period

Warranty - Atlas Copco Manufactured Parts

Warranty Notification Forms

Atlas Copco 2019-01

Request for Warranty Credit

Time Limit for Labour

2019-01 Atlas Copco

1.) Installations not commissioned by Atlas Copco authorized personnel.

8.) Any fires or explosions in the equipment or installation.

Atlas Copco 2019-01

To: Atlas Copco (Shanghai) Compressor Co. ,Ltd Date:

PRESSURE REDUCING STATION WARRANTY NOTIFICATION

Documentation and Accessories

Are the following included in the Unit Installation? Customer

PRS Service . . . . . . . . . . Specific Gravity . . . . . . Capacity . . . . . . . . . . CFM . . . . . . . .

2019-01 Atlas Copco

2 Safety Instructions and Emergency Procedures

Danger for life

Use hearing protection

Use Eye protection

Safety shoes required!

Wear head protection

Wear hand protection

Dangerous outlet gases

Read instructions before lifting

Lifting not permitted

Opening of valves prohibited

Warning! Part under pressure

Do not use mobile phones

Atlas Copco 2019-01

2.2 Precautions General Safety

Compressed gas is a highly dangerous substance.

No Smoking or EX lights are allowed within 10m of any flammable gas

2.3 Precautions during installation

2019-01 Atlas Copco

high temperature piping must be clearly marked with this sign. .

2.4 Precautions during operation

Atlas Copco 2019-01