Honeywell HON P095NG Series User And Maintenance Manual Download

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General considerations

User manual for HON R100 gas pressure regulator with HON P095NG pilot

Honeywell Process Solutions

Honeywell Gas Technologies GmbH

Osterholzstraße 45

34123 Kassel

GERMANY

Tel: +49 561 5007‐0

Phone number for service: +49 561 5007‐180

Fax: +49 561 5007‐107

Fax number for service: +49 561 5007‐108

E‐mail: gas‐[email protected]

Website:

www.honeywellprocess.com

www.hongastec.de

Printed in Germany

The manufacturer is not liable for damages and malfunctions arising from non‐observance of
this user manual and the other applicable documents.

The written approval from Honeywell Gas Technologies GmbH, Kassel, is required for any
modifications and additions to the product. Any violation will void the legal liability for con‐
sequences arising thereof.

1.2

About the safety notices

The information contained in the safety notices is intended to prevent personal injury. Safety
notices contain the following information:



Nature and source of the danger



Possible consequences associated with the non‐observance of the notice



Procedures for the prevention of personal injury

This document contains the following types of safety notices:

Type of safety notice

Description

Sign

Basic safety notices

Superordinate safety notices not relating to a
specific task:



They contain a summarized description of
hazards, risks and safety procedures associ‐
ated with the handling of the device.



Their purpose is to inform and educate the
user about an existing danger and about
practicing behavioral safety.



They are suitable as safety instruction for all
employees handling the device.

Recognizable by the heading
of the chapter

Instruction‐related
safety notices

Safety notices containing specific instructions
relating to the entire manual or a group of
manuals

Copyright

Details about the manu‐
facturer’s liability

Constructive changes

Meaning

Types of safety notices

Summary of Contents for HON P095NG Series

Page 1: ...HON R100NG Gas pressure regulator with HON P095NG pilot User and maintenance manual Maintenance parts ...

Page 2: ...cation example Active monitor regulator 30 5 Transport installation and start up 32 5 1 Transporting the gas pressure regulator 32 5 2 Installing the gas pressure regulator 34 5 3 Installing the device connections 35 5 4 Checking the system for leaks 36 5 5 Starting up the gas pressure regulator 38 6 Adjusting the settings of the device 40 6 1 Setting the target pressure 40 7 Malfunctions 42 7 1 M...

Page 3: ...78 9 1 Disassembling the device 78 9 2 Storing the device 78 9 3 Putting the gas pressure regulator back into operation 79 9 4 Disposing of the device 80 10 Appendix 81 10 1 Additional information regarding spare parts 81 10 2 Spare parts for HON R100NG 82 10 3 Spare parts for HON P095NG pilot 85 10 4 Lubricants and threadlockers 89 ...

Page 4: ...tions in a number of different sizes For this reason we are unable to guarantee that illustrations in this user manual coincide with the dimensions of your product In these cases the illustrations should be viewed as a concept sketch Failing to observe the information provided in this document may lead to injuries including death and material damages To ensure the safety any persons handling the p...

Page 5: ...the safety notices is intended to prevent personal injury Safety notices contain the following information Nature and source of the danger Possible consequences associated with the non observance of the notice Procedures for the prevention of personal injury This document contains the following types of safety notices Type of safety notice Description Sign Basic safety notices Superordinate safety...

Page 6: ...dangers risks and specific instructions for safety procedures can be found The safety notices containing specific instructions are identified with a signal word The signal word represents a certain danger level Danger level If you fail to follow the instruction then And the consequence is DANGER an accident will happen serious bodily injury or death WARNING an accident may happen possible serious ...

Page 7: ...095NG pilot are suitable for use with natural gas or dry non aggressive industrial gases Note The utilization limits of the device with regard to the medium operating pressure and operating temperature can be gathered from the type plate attached on the device or the technical specifications The use under different operating conditions must be coordinated in consultation with the manufacturer Plea...

Page 8: ... bar 2 25 to 217 psi HON P095NG HP High pressure model high pressure 10 to 60 bar 145 to 860 psi The only structural difference between the two versions is the upper diaphragm unit s design meaning that you can switch between the versions by changing the diaphragm unit The technical specifications see page 17 and the Maintenance see page 44 section as well as the spare parts lists and spare parts ...

Page 9: ... follow required operating instructions This will pose a risk of injury Make sure to always keep all relevant labels in good condition so that they will be easily legible Immediately replace damaged and missing labels The following labels markings can be found on the front of the actuator assembly Figure No Meaning 1 Name of the device 2 Nominal size and pressure rating 3 Body section materials 4 ...

Page 10: ...dentifying the device Make sure you have the right manual for your gas pressure regulator Use the nameplates to identify the actuator assembly and the pilot Make sure that the on site conditions match the information on the nameplates and the technical specifications Technical specifications see page 17 The type plate of the actuator assembly can be found here Figure No Description 1 Actuator asse...

Page 11: ...7 Manufacturing date 8 Directive 9 Fluid group 10 CE marking 11 In conformity with standard e g DIN EN 334 12 Customer revision No 13 Manufacturing date year 14 Pressure rating 15 Installation length 16 Serial number of the device 17 Default position open closed 18 Type of pilot The nameplate can be found in the location shown below Figure No Description 1 Front of the pilot Interpreting the type ...

Page 12: ...ilot can be used to maintain the outlet pressure of a gas con stant within set limits within a regulating line regardless of the influence of disturbance variables such as inlet pressure changes and or discharge changes The outlet pressure that needs to be regulated is fed to the pilot The diaphragm system in the pilot determines the pressure process value as a force on the measuring dia phragm an...

Page 13: ...ation Figure No Description 1 Dome 2 Diaphragm unit 3 Moving parts 4 Valve housing 5 Bottom cover The parts 3 that move with the diaphragm unit 2 are shown in dark gray Figure Color Meaning Inlet pressure Outlet pressure Motorization pressure Actuator assembly con figuration Actuator assembly pres sure sections ...

Page 14: ...an the compression spring and outlet pressure acting from below the valve plate will be pushed downward This will open a corresponding gap between the inlet pressure and outlet pressure areas In a depressurized state the compression spring will push the diaphragm downward causing the valve plate to be pushed downward and opening a gap between the inlet pressure and outlet pressure areas fail open ...

Page 15: ... 2 Upper diaphragm unit 3 Control stage housing 4 Lower diaphragm unit 5 Upstream pressure stage housing The HON P095NG pilot features the following fittings Figure No Connection 1 Outlet pressure measuring line 2 Outlet pressure discharging 3 Pressure gauge loading pressure 4 Inlet pressure 5 Motorization pressure actuator assembly 6 Vent line ambient pressure compensation Pilot components Pilot ...

Page 16: ...lower chamber of the upstream pressure stage This pressure is conveyed into the chamber above the lower diaphragm through the valve The pressure reduced by the valve is the loading pressure which produces a force component that acts on the lower diaphragm from above The outlet pressure is conveyed into the pilot from the other side This pressure is con veyed into the chamber below the lower diaphr...

Page 17: ...ass NBR FKM There are various flange facings for the nominal diameters of 1 DN 25 2 DN 50 3 DN 80 4 DN 100 6 DN 150 and 8 DN 200 as specified in the following stand ards ASME B16 5 Pressure rating as per Class 150 300 600 Class 150 20 bar Class 300 51 bar Class 600 102 bar Flange facing Raised face ring joint DIN EN 1759 1 Pressure rating as per Class 150 300 600 Class 150 20 bar Class 300 51 bar ...

Page 18: ...DN 50 600 137 62 3 DN 80 300 20 04 509 13 78 350 4 88 124 14 02 356 247 112 3 DN 80 600 249 113 4 DN 100 300 25 16 639 16 69 424 6 65 169 17 01 432 408 185 4 DN 100 600 428 194 6 DN 150 300 36 10 917 24 80 630 9 57 243 22 01 559 1100 499 6 DN 150 600 1127 511 8 DN 200 300 39 69 1008 24 80 630 10 35 263 25 98 660 1420 644 8 DN 200 600 1486 674 The HON P095NG pilot used in this example weighs 17 6 l...

Page 19: ... up pressure class SG Lock up pressure zone SZ pd 14 5 14 5 psi 1 bar to 3 bar 2 5 10 2 5 pd 43 5 psi 3 bar 1 2 5 2 5 Design Specific set range Wds Pilot spring No Color MP 7 25 36 25 psi 0 5 2 5 bar 850523ST12660 Green 21 75 72 52 psi 1 5 5 0 bar 850523ST12670 blue 43 51 159 54 psi 3 0 11 0 bar 850523ST12680 red 87 02 217 56 psi 6 0 15 0 bar 850523ST12690 Yellow HP 145 04 507 63 psi 10 0 35 0 bar...

Page 20: ...HON P095NG MP HON P095NG HP Pressure gauge loading pressure G1 4 10 HON P095NG MP HON P095NG HP Inlet pressure G1 4 10 HON P095NG MP HON P095NG HP Outlet pressure measuring line G1 4 10 HON P095NG MP HON P095NG HP Outlet pressure feedback G1 4 10 HON P095NG MP HON P095NG HP Motorization pressure actua tor assembly G1 4 10 The properties of the gas conveyed through the devices must meet the require...

Page 21: ... if you are giving the device away Observe the following rules Only individuals who meet the requirements set forth in this user manual have permis sion to handle the device The device s intended use includes its use in hazardous locations All work with and on the device must be carried out only after the presence of an explosive atmosphere has been fully ruled out Only use the device for the inte...

Page 22: ...ances Always consult the directives of your company concerning the protection of the workforce 3 2 Requirements concerning the workforce personal protective gear workplaces Individuals tasked with handling the device must meet the following requirements Personnel Responsibilities Required qualification Skilled person or expert Any work on and with the device Professional training and experience op...

Page 23: ...he installa tion Set up Professional training and experience operating pressure equipment and systems Knowledge of the relevant standards and regulations Ability to identify and avoid dangers autonomously Mechanical maintenance personnel Involving mechanical parts Fault finding Maintenance Repairs Professional training and experience operating pressure equipment and systems Knowledge of the releva...

Page 24: ...tective clothing Safety harness Ear protection Safety boots with protection for electrostatic dis charge ESD Safety goggles Safety gloves To ensure the safe handling of the device the personnel must remain at the workplaces intended for performing their tasks The workplaces for performing the various tasks are at the following locations Task Workplaces Installation Start up Set up Maintenance repa...

Page 25: ...monitor regulator 29 4 1 Installation examples Configuration Direct acting gas pressure regulator non piloted With expander without noise reduction element downstream of the gas pressure regu lator Configuration Indirect acting gas pressure regulator pilot operated With expander without noise reduction element downstream of the gas pressure regu lator Outlet pressure gauge with protection against ...

Page 26: ...lot operated Indirect acting slam shut device pilot operated two With expander without noise reduction element downstream of the gas pressure regu lator The numbers have the following meaning No Meaning 1 Safety Shut Off Valve 2 Gas pressure regulator 3 Pilot 4 Safety relief valve 5 Outlet stop valve armature 6 Sensing point for connection lines gray area 7 Feedback line 8 Discharging line 9 Gas p...

Page 27: ...steady flow pattern must be selected for the sensing point There must not be any components that disturb the flow directly upstream and downstream of the sensing point e g orifice plates expanders bends junctions shut off devices etc The flow rate at the sensing point should not exceed approx 25 m s depending on the system conditions In the case of specific system circuits such as gas regulating l...

Page 28: ...n the LuR lengths of the undisturbed pipes down stream of the sensing point must be 1 5 to 4 x DN of the pipe Undisturbed length of pipe for LuR min 1 5 x DN Thermowells LuR min 1 5 x DN Reducers and expanders depending on the specific system conditions LuR min 3 x DN Shut off devices gate valves check valves and reduced bore ball valves LuR min 4 x DN Tees Shut off devices with an undisturbed flo...

Page 29: ...e If the measuring unit becomes damaged e g diaphragm rupture it can start conveying gas Under certain operating conditions and following consultation with the manufacturer vent lines can be omitted if vent valves HON 915 or safety diaphragm configurations can be used instead Blowdown line The blowdown line in a safety relief valve is used to divert gas leaking gas for example into the atmosphere ...

Page 30: ...le Active monitor regulator The arrows on the pipes show the direction of flow Front Back Sectional view The numbers have the following meaning No Meaning 1 HON R100NG actuator assembly with HON P095NG pilot monitor regulator unit 2 HON R100NG FO actuator assembly with HON P095NG pilot active regulator unit 3 Outlet pressure measuring line Overview ...

Page 31: ... connected to the regulating line s inlet and outlet pressures Together the actuator assembly and the pilot make up the monitor regulator unit Downstream of this setup a fail open actuator assembly is installed with a HON P095NG pilot as well Together with the HON P095NG pilot this second actuator assembly makes up the active regulator unit The outlet pressure is monitored by the upstream monitor ...

Page 32: ...ious injury in the event that load handling attachments break while holding a suspended load Heavy loads picked up or transported with hoisting and slinging gear may result in serious impact and crush injuries if the load handling attachments fail Only fasten the device at the positions intended for the transport The load bearing capacity of the appropriate hoisting equipment must correspond at le...

Page 33: ... packed device and the handling equipment Make sure to measure all of the package s dimensions The transport route will be able to handle the load exerted by the total weight of the handling equipment and the load being transported There is enough space for unpacking and installing the device at the installation loca tion Proceed as follows Figure Step Description 1 Leave the transport panels 1 on...

Page 34: ...ctive plates from the flange 2 Transport the device to the location where it will be installed The device needs to be installed in the piping in a horizontal and level position If you want to use a different installation position consult with the manufacturer first Pay attention to the direction of flow for the gaseous fluid as marked on the body 3 Secure and support the device s position in such ...

Page 35: ...talled 4 Inlet pressure line Operating line needs to be installed 5 Outlet pressure feedback line Operating line needs to be installed 6 Outlet pressure line Operating line needs to be installed Prepare the following materials Pipes connecting pieces and fittings as per the specifications in the Technical specifica tions see page 17 Shut off devices for the operating and measuring lines as well as...

Page 36: ...e system must undergo a leak test at the set up location in ac cordance with applicable international and national standards Risk of serious injury posed by pressurized components moving in an uncontrolled manner when handled improperly If not handled properly or in the event of a defect gas can escape from pressurized compo nents under high pressure and cause serious injuries and even death Befor...

Page 37: ...let stop valve armature 2 Apply the test medium to all detachable pipe joints 3 Observe the test medium on all detachable pipe joints for several minutes If then no foam or bubbles are formed the system is leak proof the system may be put into operation Foam or bubbles are formed the affected pipe joint is leaking the system may not be put into operation Proceed with step 4 Step Description 4 Slow...

Page 38: ...een the individual steps until the desired state is reached The numbers have the following meaning No Meaning 1 Inlet stop valve armature 2 Inlet pressure gauge 3 Gas pressure regulator 4 Loading pressure gauge 5 Blowdown line shut off device 6 Outlet pressure gauge 7 Outlet stop valve armature Make sure that the following requirements are met The system has been checked is fully functional and ha...

Page 39: ... setpoint 3 Open the blowdown line s shut off device 4 Slowly screw in the pilot s set screw further until the outlet pressure matches the setpoint exactly 5 Now secure the set screw s position by tightening the hex nut Important Make sure that the set screw does not turn as you tighten the hex nut 6 Screw the cap back on 7 The regulating system has now been adjusted Now slowly open the outlet shu...

Page 40: ...ts during commissioning please refer to Starting up the gas pressure regulator see page 37 The system is pressurized with the operating pressure A pressure gauge is connected in front of the outlet valve Proceed as follows Figure Step Description 1 Unscrew the cap 1 2 Loosen the lock nut of the set screw 1 Important Make sure that the set screw does not turn as you loosen the nut 3a To raise the o...

Page 41: ...tep Description 3b To lower the operating pressure unscrew the set screw Adjust the screw position until the operating pressure you want is reached 4 Now secure the set screw s position by tightening the hex nut 1 Important Make sure that the set screw does not turn as you tighten the hex nut 5 Screw the cap 1 back on ...

Page 42: ...d The active regulator has failed and the monitor regulator is operating Determine what the problem with the active regulator is Only in case of a very low ambient operating temperature The pilot heater has failed Restore the heating function Outlet pressure too low The setting for the active regulator s pilot is too low Screw in the pilot s pilot spring a bit until the desired pressure is reached...

Page 43: ...Recognized as Outlet pressure fluctu ation 0 2 sec Interaction between the process and the regulator Solution 1 Check the regulator settings Solution 2 If solution 1 does not fix the prob lem you can try to replace the pilot spring with a stiffer one so that you can set a higher outlet pressure The maintenance intervals are too long Solution 3 Another possible reason for the fluctuations is increa...

Page 44: ...ied below are recommendations only Since the intervals for maintenance work depend heavily on the system s operating conditions and on the gas properties the maintenance intervals specified below may have to be adjusted as necessary Gas property specifications Technical specifications see page 17 Perform the following maintenance and repairs within the specified time intervals Interval Task See se...

Page 45: ...heavy soiling that cannot be removed contact the manufacturer in order to clarify the situation before putting the device back into opera tion After clarifying the situation you can order the relevant servicing parts from the manufacturer 2 Have the required lubricants and thread lockers ready For specifications concerning the lubricants that must be used please refer to Lubricants and threadlocke...

Page 46: ...Outlet stop valve armature Proceed as follows Step Description 1 Close the inlet valve 1 2 Close the outlet valve 7 3 Depressurize the pilot Turn the set screw on the pilot clockwise until the pressure in the regulator is equalized 4 Open the blowdown line s 5 shut off device to discharge the pressure between the inlet and the outlet All the gas pressure regulator s lines must be purged with nitro...

Page 47: ...ther the actuator assembly can be left in the gas regulating line during maintenance please refer to the following table You want to perform maintenance on both the actuator assembly and the pilot The discharging line and the vent line on the pilot need to be uninstalled The motorization line between the pilot and the actuator assembly needs to be uninstalled The pilot needs to be removed from the...

Page 48: ...ot and the actuator assembly Before you can remove the actuator assembly you must first remove the pilot Proceed as follows Figure Step Description 1 Remove the actuator assembly s outlet pressure line 1 and outlet pressure feedback line 2 2 If there is one disconnect the electrical connection for the remote control indica tor 3 Stabilize the actuator assembly in its installation position without ...

Page 49: ...49 Figure Step Description 5 Unscrew the threaded joints on the connection flange Make sure to follow a criss cross sequence when doing so 5 Remove the actuator assembly from the regulating line and remove the flange gaskets 1 2 6 Slowly and carefully transport the actuator assembly ...

Page 50: ...n injury especially in the torso area Make sure to always have enough people lifting heavy device components guideline using metric units 15 max 55 kg guideline using imperial units 30 max 120 lbs de pending on age and gender Comply with all the occupational health and safety regula tions and instructions that apply at the installation location Use suitable hoisting equipment and slings in order t...

Page 51: ...ure Step Description 1 Remove the visual position indicator s retaining ring 1 2 Remove the cover ring 1 and the sight glass 2 3 Remove the magnetic ring 1 4 Use an open end wrench to unscrew the position indicator s housing 1 5 Remove the indicator pin including the spring 1 Removing the position indicator ...

Page 52: ...bs 2 38 UNC 1 2 13 x 2 4 80 Nm 59 ft lbs 39 UNC 1 2 13 x 2 16 120 Nm 89 ft lbs 3 38 UNC 5 8 11 x 3 6 120 Nm 89 ft lbs 39 UNC 5 8 11 x 3 16 230 Nm 170 ft lbs 4 38 UNC 3 4 10 x 4 6 160 Nm 118 ft lbs 39 UNC 3 4 10 x 3 16 400 Nm 295 ft lbs 6 38 UNC 3 4 10 x 4 8 160 Nm 118 ft lbs 39 UN 1 8 x 5 16 1400 Nm 295 ft lbs 8 38 UNC 3 4 10 x 4 10 160 Nm 118 ft lbs 39 UN 1 8 x 5 16 1400 Nm 295 ft lbs Proceed as ...

Page 53: ...over s nuts 1 Remove the cover Caution Parts from the inside may fall out 4 Unscrew the securing rode used to secure the diaphragm 1 While doing so secure the valve shank from below 5 Remove the upper diaphragm plate 1 and the diaphragm 2 6 Remove the lower diaphragm plate 1 7 Remove the compression spring 1 and the spring plate 2 ...

Page 54: ... cage 3 Important Both components feature sealing edges that must not be damaged 10 Pull out the valve shank including the compensating plate upward 11 Hold the guide bush 2 in place from below Unscrew the hold screw 1 Re move the guide bush Use a rubber mallet if necessary Important Make sure not to damage the guide bush especially the sealing edges 12 Check the guide bush s sealing face for dama...

Page 55: ...let side Make sure not to damage the O rings when inserting the sliding bushing 15 Secure the guide bush 2 with the hold screw 1 The hold screw needs to be screwed in all the way without fail If you are unable to screw the hold screw in all the way correct the guide bush s position until you are able to screw the hold screw in all the way 16 Take the valve shank Remove the retaining ring 1 below t...

Page 56: ... damage the O ring 1 or change its position Make sure that the compensating plate is positioned correctly The sliding ring 2 should be on top and the O ring 3 underneath it 21 Secure the compensating plate with a new retaining ring 1 22 Insert the valve shank 1 back into the actuator assembly from above The compensating plate should sit tightly inside the upper part of the guide bush 2 23 Take the...

Page 57: ...Make sure not to damage the O ring on the valve shank or change its position 26 Screw the locknut 1 all the way onto the valve shank While doing so secure the valve shank from above 27 Take the support cage Check the support cage for damage The upper sealing edge must not have any scratches or dents If necessary replace the support cage with a new one 28 Check the lower sealing lip for damage The ...

Page 58: ...ssary 30 Insert the support cage 1 including the metal foam insert back into the body from below 31 Insert the spring plate 2 back into the guide bush from above making sure that the plate opens upwards Insert the compression spring 1 32 Insert the lower diaphragm plate 1 33 Insert a new diaphragm Glue the surfaces to the diaphragm plate and to the body s contact surfaces Make sure that the bulge ...

Page 59: ...ricated O rings 36 Secure the diaphragm unit by screwing in the securing rode used to secure the diaphragm 1 all the way into the valve shank While doing so secure the valve shank from below 37 Take the bottom cover Replace the O ring 1 with a new greased O ring Skip this step for devices with a nominal diameter of 1 38 Put the bottom cover back in place Tighten the nuts 1 in a criss cross se quen...

Page 60: ...escription 1 Replace the O ring 1 in the body hole intended for the position indicator with a new greased O ring 2 Insert the inner pin including the spring 1 back into the hole 2 for the position indicator 3 Use an open end wrench to screw the position indicator s housing 1 back in place 4 Pull the magnetic ring 1 over the position indicator s housing The magnetic ring position shown in the figur...

Page 61: ...r position proceed with step 5 Figure Step Description 5 Remove the magnetic ring from the position indicator s housing turn it 180 and place it back over the housing 6 Place the sight glass 2 and the cover ring 1 back on the position indicator s hous ing Make sure that the magnetic ring stays in the required position 7 Install the retaining ring 1 Depending on what you will be doing next proceed ...

Page 62: ...pacity If necessary secure removed components so that they will not fall or topple over Wear the required personal protective equipment Exercise caution when performing the relevant tasks Observe the following cleaning instructions Before assembly all parts must be cleaned in order to remove any foreign particles swarf and soiling If screws bolts or washers are replaced with identical new parts an...

Page 63: ...095NG pilot 63 Figure Step Description 35 Remove the washer 1 and the reduction ring 2 36 Remove the lower diaphragm plate 1 37 Replace the diaphragm with a new one 38 Put the lower diaphragm plate 1 back in place 39 Put the washer 1 and the reduction ring 2 back in place ...

Page 64: ...in the appendix 41 Insert the diaphragm unit 1 back into the second pressure stage s housing 42 Put the spring housing back in place Tighten the screws 1 including the washers in a criss cross sequence Refer to the additional tightening torque infor mation at the beginning of this topic 43 Insert the compression spring 2 and the spring plate 1 back in 44 Take the lock nut Replace the O rings 1 2 w...

Page 65: ...ing the HON P095NG MP pilot Crush and impact hazard posed by components falling or toppling over accidentally When working with heavy components that have been removed or are yet to be installed injury may result if the components start moving in an uncontrolled manner e g fall down from the working surface or topple over Place removed components exclusively on level horizontal working surfaces wi...

Page 66: ...cal new parts any oil on these new parts must first be removed Observe the tightening torques below when following the instructions in this section Part Tightening torque Step Screws 24 Nm 26 Screws 47 Nm 40 Proceed as follows Figure Step Description 1 Unscrew the cap 1 2 Unscrew the set screw including the hex nut 3 Unscrew the lock nut 1 Remove the lock nut 4 Remove the spring plate 1 and the co...

Page 67: ...ew the spring housing s screws 1 in a criss cross sequence Remove the spring housing 6 Remove the diaphragm unit 1 7 Turn the pilot over Important The valve rod and the valve rod s compression spring may fall out Set them aside if they do Unscrew the cap 1 8 Remove the retaining ring 1 9 Unscrew the stabilizer seat 1 ...

Page 68: ...tom of the pilot Remove the upstream pressure stage housing 11 Remove the lower diaphragm unit 1 including the compression spring from the upstream pressure stage housing 12 Loosen the guide 1 Remove the guide 13 Remove the filter 1 Replace the filter with a new one 14 Take the guide Replace the guide s O rings 1 2 with new lubricated O rings ...

Page 69: ...emove the spring plate 2 17 Replace the diaphragm 1 with a new one Make sure that the bulge points upwards Re assemble the diaphragm unit Use threadlocker as specified in the list in the appendix 18 Put the compression spring 1 back on the diaphragm unit 19 Insert the lower diaphragm unit 1 including the compression spring back into the upstream pressure stage housing Make sure that the holes and ...

Page 70: ...rod 1 and the valve rod compression spring underneath it provided you have not already set them aside in a previous step 21 Unscrew the guide 1 from the housing 22 Remove the valve 1 Replace the valve including the O ring with a new one Insert the new valve into the housing 23 Take the guide Replace the O rings 1 2 and 3 with new lubricated O rings 24 Screw the guide 1 back into the housing ...

Page 71: ...g back on the second pressure stage s housing Make sure that the diaphragm unit does not fall out Tighten the screws 1 including the washers in a criss cross sequence Observe the tightening torque information provided in the table before this section 27 Replace the stabilizer seat with a new one Unscrew the nut 1 28 Insert new greased O rings 1 2 Screw the nut back on 29 Screw the stabilizer seat ...

Page 72: ... 1 back in place 31 Screw the grommet nut 1 back on 32 Turn the housing over Insert the valve rod s compression spring and the valve rod 1 back into the guide 33 Replace the O ring 1 with a new greased O ring 34 Take the diaphragm unit for the second pressure stage Unscrew the upper dia phragm plate 1 and the hex nut 2 from the pin 3 ...

Page 73: ...e lower diaphragm plate 2 36 Replace the diaphragm with a new one 37 Put the lower diaphragm plate 2 and the washer 1 back in place 38 Screw the hex nut 2 and the upper diaphragm plate 1 back on the pin 3 Use threadlocker as specified in the list in the appendix 39 Insert the diaphragm unit 1 back into the second pressure stage s housing ...

Page 74: ...cluding the washers in a criss cross sequence Ob serve the tightening torque information provided in the table before this section 41 Insert the compression spring 2 and the spring plate 1 back in 42 Take the lock nut Replace the O rings 1 2 with new lubricated O rings 43 Screw the locknut 1 back in place all the way 44 Screw the set screw 1 including the hex nut back in ...

Page 75: ...ge 78 8 5 3 Maintaining the P095 pilot s adjustable restrictor Observe the following cleaning instructions Before assembly all parts must be cleaned in order to remove any foreign particles swarf and soiling If screws bolts or washers are replaced with identical new parts any oil on these new parts must first be removed Proceed as follows Figure Step Description 1 Unscrew the adjustable restrictor...

Page 76: ...ghten it Install the adjustable restrictor back on the pilot Proceed as follows Completing the maintenance see page 76 Maintaining the actuator assembly see page 50 Storing the device see page 78 8 6 Completing the maintenance When conducting work involving the pipework please always observe the following Figure Description Do not twist the pipe connections in the assemblies Use a second spanner w...

Page 77: ...he pilot 3 Reinstall all the lines you removed previ ously on the actuator assembly and the pipes Result The pilot is now installed on the actuator assembly and in the gas regulating line To install follow the same steps for removal but in opposite order Please refer to Starting maintenance see page 45 for information on how to remove the pilot and the actuator assembly Proceed as follows Checking...

Page 78: ...to 25 C 32 F to 77 F Relative humidity 55 Avoid mechanical vibrations Storage periods When storing the device for up to one year Store the device in its original packaging and in the same condition it was de livered All protective caps of the device must remain in place When storing the device for more than one year e g as a backup device Store the device in its original packaging and in the same ...

Page 79: ...n to the storage time 9 3 Putting the gas pressure regulator back into operation Risk of injury posed by bursting parts in the event that they are subjected to pressure in the wrong direction The device has been designed for a specific direction of flow which is labeled on the device Subjecting the device to pressure in the wrong direction may result in serious injury caused by bursting parts Pres...

Page 80: ...ns see page 17 The system is depressurized between the inlet shut off device and the outlet shut off device Proceed as follows Step Description 1 Slowly open the inlet shut off device to pressurize the inlet pressure area 2 The outlet pressure will slowly increase Once this pressure matches the pilot s setpoint slowly open the outlet shut off device If problems occur when putting the device back i...

Page 81: ... number of spare parts is indicated under the part number in the Part No column If no quantity is specified this means that only one unit is required The spare parts always required for maintenance are grouped together into spare parts kits appropriate for the device in question Each spare parts kit has its own part number Individu al spare parts can be ordered by using the corresponding part numb...

Page 82: ...Appendix User manual for HON R100 gas pressure regulator with HON P095NG pilot 82 10 2 Spare parts for HON R100NG Spare part drawing ...

Page 83: ...sure regulator with HON P095NG pilot 83 Name Part no HON R100NG 1 kit KR100NG 001 HON R100NG 2 kit KR100NG 002 HON R100NG 3 kit KR100NG 003 HON R100NG 4 kit KR100NG 004 HON R100NG 6 kit KR100NG 006 HON R100NG 8 kit KR100NG 008 Spare parts kits ...

Page 84: ...8401020401019 2 units 34 O ring 20419 20419 20419 41 O ring 8401025102120 8409043804327 8401075604337 No Name 4 Part no 6 Part no 8 Part no 8 Diaphragm 8304000215430 8304000215440 8304000215440 13 Sliding ring 8312020121410 21 O ring 8401136103253 3 units 8401183703263 3 units 8401240903272 3 units 22 Sliding ring 8312020123230 2 units 8312020121330 2 units 8312020121400 23 Locknut 8212300270001 8...

Page 85: ...manual for HON R100 gas pressure regulator with HON P095NG pilot 85 10 3 Spare parts for HON P095NG pilot Name Part no Spare parts HON P095NG HPS MPS V20 00 C1 939401S216040 Spare parts kits drawing Spare parts kits ...

Page 86: ...lot 86 No Name Part no 1 Set screw 8303010000031 2 Hex nut 8201340120125 3 Locknut 8103004114690 4 Spring plate 8103004135980 5 Compression spring Please refer to the Pilot springs section in Technical specifications 6 Hex nut 8251080080001 Spare part drawing Bill of materials ...

Page 87: ...phragm 8103004151780 22 Filter 8103004112130 23 O ring 8401006801000 24 Washer 8238093080001 25 Screw 8207160080070 26 Upstream pressure stage housing 8611189018000 27 Control stage housing 8103200215950 28 Compression spring 8501210109700 29 Control valve 1 0mm hole 9303504109910 Control valve 2mm hole 9303504139250 Control valve 3 5mm hole 9303504141450 30 Control valve compression spring 850122...

Page 88: ... O ring 8401031501026 63 O ring 8401039402129 64 Washer 8251930080001 88 Washer 8207670063001 89 Blind plug 8250302130018 103 Bearing shell 8302010000006 104 Axial bearing 8302010000004 109 O ring 8401004501008 120 Locknut 8103004142700 121 O ring 8405003701007 122 O ring 8401059903229 140 Protective cap 8103000161670 No Name Part no 3 Dummy plug with Ø10 threaded hole 8106000211640 4 Ø10 dosing n...

Page 89: ...ing parts in SAV controlgear and switchgear High temperature model Switch jacks and locking sleeves PFPE grease 102389 Control balls and control rollers Ball bearing Valve sleeves and valve sleeve gaskets in gas pressure regulators Silicone grease 27052 Setpoint set screws Power screws Assembly paste 27091 Thread material combination Al Al Screw in fittings and fastening screws Spring plate depres...

Page 90: ...Appendix User manual for HON R100 gas pressure regulator with HON P095NG pilot 90 HON P095NG pilot threadlocker drawing ...

Page 91: ...arkway South Houston TX 77042 Phone 1 602 293 1866 Option 4 Honeywell Gas Technologies GmbH Osterholzstrasse 45 23123 Kassel Germany Phone 49 0 561 5007000 Emaar Business Park Building 2 Sheikh Zayed Road PO Box 232362 Dubai United Arab Emirates Phone 97144505800 Honeywell Engineering Sdn Bhd 1st Floor Block B No 10 Jalan Bersaru 13 4 46200 Petailing Jaya Selangor DE Malaysia Phone 603 7626 57000 ...

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