Gas Pressure Regulator HON

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1 Gas Pressure Regulator HON OPERATING AND MAINTENANCE INSTRUCTIONS/ SPARE PARTS EDITION 0/07 Serving the Gas Industry Worldwide

2 Contents page. General Remarks 3. Safety Instructions 3. Special Operating Instructions. Start-up. Shut-down 3. Special Maintenance Instructions 3. Main Valve 3. Screw Torque Figures 3.3 Lubricants. Spare Parts. Spare Parts Drawings.. DN /0 and DN 0/00.. DN 80/0, DN 00/00, DN 0/300 and DN 00/ Spare Parts Lists DN /0 and DN 0/00 DN 80/0 and DN 00/00 DN 00/00 and DN 00/300 Spare Parts for Maintenance p.

3 . General Remarks Every person engaged with installation, supervision, or maintenance of the gas pressure regulator type HON 0 is requested to read the following leaflets and brochures beforehand: - Technical Description contains technical data, measurements, and describes function and design. - General Operating Instructions for Gas Pressure Regulators and Safety Devices - this Honeywell brochure describes installation and operation, and includes general hints on fault finding and repair. - Operation and Maintenance, Spare Parts contains further details on installation and operation of the gas pressure regulator HON 0. Maintenance instructions and the spare part drawings and -lists of the main valve are also included. - The integrated functional elements are described in the corresponding individual leaflets Operation and Maintenance, Spare Parts pilot filter i.e. HON 630 or HON 60 HON Additionally, the relevant national rules and laws have to be strictly observed. (In Germany please refer to the DVGW worksheets G 600, G 9/II, G 9 und G 9). The frequency of periodical maintenance of the gas pressure regulator HON should be determined according to the prevailing conditions and the type and composition of the gaseous medium. Therefore, no fixed maintenance intervals can be prescribed. For Germany: At the beginning we recommend to use the maintenance intervals stated in the DVGW worksheet G 9. Then individual maintenance intervals should be determined for every station. For maintenance all parts are to be cleaned and subjected to a thorough visual inspection. A visual inspection should also occur when the course of operation or functional tests have shown lack of regulating accuracy. Particular care should be given to the checking of sealings and diaphragms, as well as carrying and moving parts. Damaged parts should be replaced by new ones. The item numbers referred to in the maintenance instructions are identical with those of spare parts drawings and spare parts lists. We recommend to keep all parts that are specially marked "W" in the spare parts lists in stock for prompt maintenance availibility. These parts are listed separately on page. Safety symbols Safety symbols include the following key words in these operating instructions symbols explanation! Caution! risk of damaging equipment or environment Note additional information or requirements 0.0 p.3

4 . Special Operating Instructions. Start-up: Close the outlet gate valve. Pressure release in the outlet via the discharge line. When putting the regulator into operation the first time we recommend to turn completely the setpoint springs of both, the pilot HON 630, 60 and the load limiting stage (only valid for the Honeywell pilot HON 630) counter-clockwise. Note!! Caution! Note! Open the start-up valve. The starting valve assures a pressure compensation at the throttling diaphragm. Pressurize slowly. It is important to close the start-up valve again. Adjust the setpoint of the load limiting unit of pilot HON 630 to approximately 0 bar above the outlet pressure value (p a ). Set the outlet pressure to the required value by turning the setpoint adjusting screw clockwise in small steps. The load limiting pressure of the HON 630 increases automatically. Open the outlet gate valve slowly.. Shut-down: Turn the setpoint adjusting screw counter-clockwise in small steps until the gas pressure regulator closes. Close the outlet gate valve slowly. 3. Special Maintenance Instructions 3. Main Valve Because of its easy maintenance construction, only the throttling diaphragm and the noise reducing elements (version with noise reduction) have to be controlled and necessarily replaced by new ones. Prior to dismantling all gas supplied chambers must be depressurised.! Caution! The released throttling diaphragm (6) has to be put into the corresponding seat of the main valve. It is necessary to replace the foam elements (9, from size DN 80/0) for each maintenance. 3. Screw Torque Figures MA in Nm screw size DN item no. /0 0/00 80/0 00/00 0/300 00/ Lubricants element (grease slightly) lubricant HON-part-no. all o-rings, mounting swelling of throttling silicone grease (Tube 0. kg) diaphragm all fixing screws and tube fitting mounting grease p.

5 . Spare Parts Drawings.. DN /0 and DN 0/00 Version without noise reduction Version with noise reduction 3 6 rotation of /9 W 7 E0 M A W 6 3 W 3 A A B B B - B A - A 7 W W W 8/9 E0 E 6/7 M A See screw torque figures stated in table on page! W Parts are to be kept in stock for maintenance 0.0 p.

6 .. DN 80/0, DN 00/00, DN 0/300 and DN 00/300 Version without noise reduction Version with noise reduction 3 W 6 rotation of /9 W 7 W 6 E0 "X" M A 8 9 W 3 M A 0 8 W 3 A A B B "X" Version without noise reduction DN 0/300 and DN 00/300 B - B A - A 7 W W 7 7 W 0 8/9 E0 M A See screw torque figures stated in table on page! W Parts are to be kept in stock for maintenance. E 6/7 0.0 p.6

7 . Spare Parts List.. DN /0 and DN 0/00 item no. description quant. body: PN 0 GS ANSI 300 RF GS ANSI 300 RJ GS ANSI 600 RF GS ANSI 600 RJ GS PN 0 / ANSI 600 RF GS ANSI 300 RF / ANSI 600 RF GS lower diaphragm plate LM O-ring W insert NSt drilled expansion piece LM diaphragm W sealing ring W LM cap nut St compression joint St nozzle St pressure spring NFSt diaphragm cover St/LM ring bolt St cylinder screw St diaphragm plate LM cylinder screw 0 St cylinder screw St drilled expansion piece LM metal foam ring St supporting ring LM closing screw St nozzle St cap nut St compression joint St safety washer St W material HON part number DN /0 DN 0/00 W Parts are to be kept in stock for maintenance material key St... steel NSt... stainless steel FSt... spring steel NFSt... stainless spring steel GS... steel cast GGG... spher. graphite cast iron GZn... zink cast GBz... brass cast LM... light metal Ms... brass Cu... copper Bz... bronze GLM... light metal cast GMs... brass cast AlBz... aluminium bronze SSt... K FP... FPM... FP... PGL... foam material plastic material rubber like plastic material rubber like plastic material with special coating rubber like plastic material special plastic material plexiglass 0.0 p.7

8 .. DN 80/0 and DN 00/00 item HON part number no. description quant. W material DN 80/0 DN 00/00 body: PN 0 GS ANSI 300 RF GS ANSI 300 RJ GS ANSI 600 RF GS ANSI 600 RJ GS PN 0 / ANSI 600 RF GS ANSI 300 RF / ANSI 600 RF GS lower diaphragm plate LM O-ring W insert NSt drilled expansion piece LM diaphragm W sealing ring W LM cap nut St compression joint St nozzle St pressure spring NFSt diaphragm cover St/LM ring bolt St foam plate W SSt cylinder screw St diaphragm plate LM cylinder screw St foam ring W SSt cylinder screw St drilled expansion piece LM metal foam ring St supporting ring LM closing ring St nozzle St cap nut St compression joint St safety washer St p.8

9 ..3 DN 0/300 and DN 00/300 pos.- HON part number no. description quant. W material DN 0/300 DN 00/300 body PN 0 GS ANSI 300 RF GS ANSI 300 RJ GS ANSI 600 RF GS ANSI 600 RJ GS PN 0 / ANSI 600 RF GS ANSI 300 RF / ANSI 600 RF GS lower diaphragm plate LM O-ring W insert NSt drilled expansion piece St diaphragm W sealing ring W LM cap nut St compression joint St nozzle St pressure spring NFSt diaphragm cover St/LM ring bolt St foam plate W SSt cylinder screw St diaphragm plate LM cylinder screw 30 St foam ring W SSt cylinder screw St drilled expansion piece St metal foam ring St supporting ring LM closing screw St nozzle St cap nut St compression joint St safety washer St p.9

10 .3 Spare Parts for Maintenance item no. description quant. material DN /0 HON part number DN 0/00 3 O-ring diaphragm sealing ring LM item no. description quant. material DN 80/0 DN 00/00 3 O-ring diaphragm sealing ring LM foam plate SSt foam ring SSt item no. description quant. material DN 0/300 DN 00/300 3 O-Ring diaphragm sealing ring LM foam plate SSt foam ring SSt p.0

11 For More Information To learn more about Honeywell s Advanced Gas Solutions, visit or contact your Honeywell account manager GERMANY Honeywell Process Solutions Honeywell Gas Technologies GmbH Osterholzstrasse 33 Kassel, Germany Tel: +9 (0) Fax: +9 (0) HON Honeywell International Inc.

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