Honeywell HON HSV086 Manual

© 2017 Honeywell International Inc
Operation and maintenance manual HON HSV086 1
Safety Shut-off Valves
HON HSV086
Operation & Maintenance Manual
Honeywell Process Solutions
HoneywellGasTechnologiesGmbH
Osterholzstr.45,34123Kassel,Germany
+49(0)5615007‐0(General)
www.honeywellprocess.comDocumentnumber; 8098060403010
Documentname;HONHSV086manual
Revision; 01

© 2017 Honeywell International Inc
Operation and maintenance manual HON HSV086 2
Contents
1 Technical specifications.....................................................................................................3
1.1 General .............................................................................................................4
1.2 Materials............................................................................................................4
1.3 Dimensions and weights 1” – 12”.............................................................................5
1.4 Dimensions and weights 16”- 24” ............................................................................6
1.5 Determination of the capacity...................................................................................7
1.6 Pressure converter and setpoint springs.................................................................8
1.6.1 Pressure converter: setpoint range .............................................................8
1.6.2 Pressure converter: setpoint springs...........................................................8
1.6.3 Choice of pressure converter and setpoint springs.....................................9
1.7 Type indication..........................................................................................................9
2 Operation ........................................................................................................................10
2.1 General ...........................................................................................................10
2.2 Switch and reset mechanism................................................................................ 11
2.2.1 Overpressure protection ........................................................................... 12
2.2.2 Underpressure protection ......................................................................... 12
2.2.3 Operation of the emergency button.......................................................... 12
2.3 Releasing and opening ......................................................................................... 13
3 Installation instructions....................................................................................................15
3.1 Connection of the signal lines.........................................................................15
3.2 Some remarks.................................................................................................15
4 Operational guidelines......................................................................................................16
4.1 Replacing the setpoint springs..........................................................................16
4.2 Setting the lower threshold value....................................................................16
4.3 Setting the higher threshold value...................................................................... 17
4.4 Operational test................................................................................................17
4.5 Commissioning................................................................................................19
4.6 Taking out of operation........................................................................................ 19

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Operation and maintenance manual HON HSV086 3
5 Maintenance.......................................................................................................................20
5.1 General ...........................................................................................................20
5.2 Lubricants.............................................................................................................. 20
5.3 Pressure converters SM........................................................................................ 21
5.4 Valve and body HON HSV................................................................................... 24
5.5 Valve and body HON HSVS ................................................................................ 28
5.6 Spare-part sets...................................................................................................... 29
5.7 Parts list shut-off device ........................................................................................ 32
5.8 Parts list valve and body ....................................................................................... 33
5.9 Parts list switch and reset mechanism SVC086 ..............................................35
5.10 Parts list pressure converters SM...................................................................37
6 Failure solutions................................................................................................................39
7 Accessories.......................................................................................................................41
7.1 Accessories, general......................................................................................41
7.2 By-pass pipeline..............................................................................................42
Appendix
HSV086 safety manual rev 01..................................................................................page 1 to 6
Revision Description Date Revised by
01 Update lubrication 09-07-2018 J.Tong
While great care has been taken in composing the text and illustrations, Honeywell does not accept liability for any
inaccuracies.

© 2017 Honeywell International Inc
Operation and maintenance manual HON HSV086 4
1 Technical Specifications
1.1 General
Type : HON HSV086 / HON HSVS086
Nominal diameter : 1” – 20”
Pressure categories : ANSI 300 and 600 under EN certification
: ANSI 900 and 1500 just PED certification
Design : PED, EN 14382, EN 12516, EN 13445, ANSI B16.10
Operating pressure : up to 250 bar
Threshold value:
against high pressure : 1.23 to 49.5 bar ANSI 300 / 1.23 to 95 bar ANSI 600
60 to 130 bar ANSI 900/1500
against low pressure : 0 up to 15 bar
Reproducibility
high pressure : AG 1 between 20 - 95 bar
: AG 2.5 between 1.23 – 17 bar
low pressure : AG 10 between 0 - 15 bar
Temperature range : -20 up to +60°C,
Closing time : < 1 sec.
Building-in position : horizontally with switch and reset mechanism up
PIN-DVGW No. HON HSV(S) : CE-0085BS0202
1.2 Materials
Valve body / Cover : A352 Gr.LCC, A350, S355NL, P355N or equal
Valve rod : X17CrNi16-2
Guides : X17CrNi 16-2 + QT800 or X2CrNiMoN 22-5-3
Valve stem : C35 or equivalent
O-rings : Viton and NBR or equivalent
Diaphragm : NBR with nylon
SVC086 (operational parts) : stainless steel
Dual tripping device : brass and steel
When corrosive gasses are used, other materials may be necessary. We would advise always to
describe the composition of the gas exactly when placing the order.

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Operation and maintenance manual HON HSV086 5
1.3 Dimensions and weights 1”- 12”
DN ANSI 300 (RF) ANSI 600 (RF) ANSI 900 * ANSI 1500 *
size L H W L H W L H W L H W
1”
2”
3”
4”
6”
8”
10”
12”
203
267
318
356
445
559
787
838
555
615
655
665
715
867
965
960
30
45
65
105
195
295
455
600
216
292
356
432
559
660
787
838
555
615
655
665
715
867
965
960
33
45
70
115
210
320
550
660
381
546
711
841
1000
968
668
853
961
913
1083
958
132
480
660
1050
1240
1325
254
371
473
546
711
841
1000
1146
642
668
668
853
961
913
965
958
37
78
tbd
580
780
1260
1340
1900
Table I: Dimensions L and H (mm) and weight W (kg), (* RF or RTJ to be requested)
For dimensional drawing see figure 1a (barring alterations)
Figure 1a: Dimensional drawing

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Operation and maintenance manual HON HSV086 6
1.4 Dimensions and weights 16”- 24”
DN ANSI 300(RF) ANSI 600(RF) ANSI 900/1500(RTJ)
Size L H W L H W L H W
16”
20”
24”
990
1397
1397
990
1397
1397
1375
1340
1500
1290
1540
1820
1375
1340
1500
1240
1500
1780
990
1375
1290
Table II: Dimensions L and H (mm) and weight W (kg)
For dimensional drawing see figure 1b (barring alterations)
Figure 1b: Dimensional drawing.

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Operation and maintenance manual HON HSV086 7
1.5 Determination of the capacity
To determine the pressure loss of a safety device with fully open valve, you may use this
formula:
 

piCg
TudQn
p..57,13
273.. 2
2


For natural gas with qn = 0.831 kg/m³
d = 0.643
When using other gasses
d= qngas / 1.29
with Qn= flow rate in mn3/h
p
i= inlet pressure in bar (abs)
Cg = capacity rate
d = relative density (air = 1)
Tu = inlet temperature of the gas (oC)
q
n= gas density (Tu = 273 K = 0oC)
DN 1" 2" 3" 4" 6" 8" 10" 12" 16" 20" 24"
Cg480 1950 4300 7050 15100 26060 40800 60050 104150 166640 287953
Table II: Capacity rates Cg(up to 600#, high pressures on request)
To limit the flow forces we would advise not to exceed the following flow rate. You
have to use the formula below for this purpose.
in which D1= nominal diameter in mm
pimin = minimum inlet pressure in bar (abs)
Q
max = maximum flow in mn3/h
K= 100 for DN = 1” up to 6”
K= 200 for DN = 8” up to 12”
K= 300 for DN =16” up to 24”
p
D
Qmini
1
max K

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Operation and maintenance manual HON HSV086 8
1.6 Pressure converter and setpoint springs
1.6.1 Pressure converter: setpoint range
SETPOINT RANGE IN BAR
pressure
converter Wdu
bar AG Wdo bar
AG
SM1.9-A 0.7 - 2.5 10 1.4 - 21.0 2.5
SM1.4-
A
1.0 - 5.0 10 17.0 - 46.0 1
SM1.2-A 2.0 - 10.0 10 31.0 - 81.0 1
SM2/2500 2 - 15 10 60 - 130 1
SM90 0.0 - 0.8 10 1.23 - 2.53 2.5
Table III: Setpoint range of the pressure converters
1.6.2 Pressure converter: setpoint springs
Springs sensing element type SM
Color / Code nr. 1.9A 1.4A 1.2A 2/2500 90
bar bar bar bar mbar
Green
8501114120470 0 to 0.8 0 to 1.8 0 to 3 0 to 7 0 to 90
Yellow
8501114120480 0.6 to 1.5 1.3 to 3.2 2 to 5.5 5 to 12 70 to 170
Black
8501114120490 1.4 to 3.8 3 to 8.2 5 to 14 10 to 40 230 to 450
White
8501114120500 3.7 to 7.1 7.8 to 15 *
13 to 25* 30 to 60 430 to 830
Orange
8501114120510 6.2 to 9.6 13.5 to 20
22 to 35* 50 to 80 730 to 1130
Grey
8501114120520 7.9 to 11.3 17 to 24 28 to 41* 70 to 90 930 to 1330
Purple
8501114120530 10.5 to 16.5
23 to 35 38 to 60 80 to 140 1230 to 1930
Brown
8501114120540 15.5 to 21.5
33 to 46 56 to 78 130 to 180 1830 to 2530
Table IV: setpoint springs, the grey marked are most preferred spring choices.

© 2017 Honeywell International Inc
Operation and maintenance manual HON HSV086 9
1.6.3 Choice of pressure converter and setpoint springs
In order to choose the correct pressure converter and setpoint springs for a required
threshold value, proceed as follows:
The lower threshold value is only determined by the force of the minimum spring;
Choose the pressure converter for the required threshold value from table III;
When you have a choice of 2 pressure converters, choose the pressure converter
with the largest sensing surface (SM2 is the smallest, SM90 is the largest);
Now select from table IV the relevant setpoint spring for the minimum threshold value
of the pressure converter you have just decided on;
The maximum threshold value is determined by means of the force of the minimum
and maximum spring. In order to determine the maximum threshold value, the
minimum threshold value should be deducted from the maximum. The pressure
difference determines the selection of the maximum spring;
Using the calculated pressure difference, you select from table IV the setpoint spring
of the maximum threshold value.
Example of selection of the setpoint springs for the minimum and maximum
threshold value
Given: Minimum threshold value 2 bar
Maximum threshold value 22 bar
Calculate the pressure difference between maximum and minimum threshold value:
Result: 22 bar - 2 bar = 20 bar.
Choosing the pressure converter and setpoint springs:
acc. table III, pressure converters SM1.4-A and SM1.9-A are suitable. The SM1.9-A
has the larger diaphragm surface and is to be chosen;
in table IV we find for a lower threshold value of 2 bar the black setpoint spring with a
pressure range of 1.4 to 3.8 bar;
for the maximum threshold value of 20 bar we find the brown setpoint spring with a
pressure range of 15.5 to 21.5 bar.
1.7 Type indication (example)
HON HSV086 - .." - ANSI 600 -
Type
Nominal diameter (in inch or DN)
Pressure stage (ANSI)

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Operation and maintenance manual HON HSV086 10
2 Operation
2.1 General
The HON HSV086 is a mechanical safety shut-off device of the slam shut type.
The safety shut-off device is not self-acting. Having solved the failure, the valve has
to be opened by someone locally (i.e. at the device). The valve can only be opened
when the failure has been solved and the switch mechanism (the SVC086) has
already been released.
The safety shut-off device functions very precisely and has a limited switching
trajectory, so that the threshold value may be relatively close to the set pressure of
the regulator.
At an undesired failure in the pressure converter or an impulse line the valve shuts
automatically.
Owing to the application of two pressure converters and two minimum/maximum
springs, a "one of the two" redundancy is possible for each shut-off valve. Standard,
the safety shut-off device has been equipped with an emergency button. In addition,
several accessories are available.
The working of the shut-off valve rests on three main elements:
The switch and reset mechanism SVC086 functions as a sensor and forces a
switching-on;
Subsequently the locking of the valve is released;
The valve then blocks the flow to be protected.

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Operation and maintenance manual HON HSV086 11
2.2 The switch and reset mechanism
The switch and reset mechanism SVC086 is used standard on all HON HSV safety
shut-off devices. When the stroke of the HON HSV is smaller than 110 mm, the
SVC086 may be mounted directly onto the body.
Figure 2: Working principle of the switch and reset mechanism SVC086

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Operation and maintenance manual HON HSV086 12
2.2.1 Overpressure protection
(see figure 2 / figure 3)
When the pressure Pa in pressure converter D is higher than the threshold value set
by compression springs V1 and V2, diaphragm C is pressed down and handle H turns
around pivoting point O1. Pin N is pushed upwards, so that balance jaw P turns to the
right past pivoting point O2. Because of this, the balance jaw will no longer support
the downward pointing switch rod M of the switch handle, so that it rotates around its
axle. This axle partly has a crescent-shaped section. This is the point of support of
the valve, and for HON HSVS the point of support of rod L, which releases the
"second-stage handle" H2. When the switch handle (K) has made a quarter-turn,
valve (S) closes by means of handle arm (R) fitted in the valve body. Because of the
pressure exchange at the outlet side of the installation, a pressure difference usually
occurs at valve (S), so that it is pushed further into the valve seat.
Continued for 16” and larger.
When switch handle K has made a quarter-turn, handle H2 can move downwards
(due to the force executed by the valve). This will switch on the valve or the second
stage. Switching on the second stage: see chapter 4.1.
The safety device is now locked. Even when pressure Pa drops below the threshold
value, valve (S) remains shut.
2.2.2 Underpressure protection
When pressure Pa of pressure converter D is lower than the set threshold value of
spring V1, diaphragm C moves upwards. The top of V2, by means of the spring seat,
now presses against the housing of the control and switch mechanism and no longer
against the diaphragm disc of the pressure converter. Because of this, the threshold
value is determined by spring V1 only. Handle H is now going to push down pin Q, so
that balance jaw P (just as with overpressure) turns to the right.
The working principle of switch handle K, valve (S) and valve shaft L, which releases
the valve or the "second-stage handle" H2, is identical to the one of overpressure.
2.2.3 Operation of the emergency button
When the emergency button (red button) is pressed (not indicated in figure 2),
balance jaw P turns to the right. This will make switch handle K turn at least a quarter.
For 16” and larger, shaft L of the "second-stage handle" H2 touches on the crescent-
shaped point of support and the second stage is switched on. The position of handle
H, diaphragm C and the minimum and maximum springs is not changed. The valve
shaft passes the crescent-shaped point of support and the valve is shut.

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Operation and maintenance manual HON HSV086 13
Figure 3: Working principle second stage HON HSVS
2.3 Releasing and opening HON HSV / HON HSVS
(see figures 2 and 3)
After having solved the failure, the pressure to be protected returns to a value
between the lower and higher threshold value. Handle H returns to its initial position.
Due to gravity, balance jaw P follows this movement.
In order to make the HON HSV ready-for-operation again, the switch and reset
mechanism must first be reset and then the second stage (if 16” and larger).
Here follows a short description of the actions for releasing and opening the
HON HSV.
Solve the failure;
Bring the pressure to be protected to a normal value between the higher and lower
threshold values;
Ensure that no gas is taken off at the outlet side and that the pressure above and
below the valve is in equilibrium, using a bypass;
First press and then turn clockwise handle arm R of the lifting component of the
SVC086;

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Operation and maintenance manual HON HSV086 14
Press reset button A when valve shaft L is kept in its highest position. This makes
that switch rod M falls into balance jaw P;
Again slightly turn handle arm R back. Switch rod M is now locked by the balance
jaw. Let go of handle arm R. This can turn freely again;
The following steps for an HON HSVS
Handle arm H2 has now moved upwards. This moved support D3 against the force
of the two draw springs F2 into groove R4;
Push in hand wheel H3 and turn anti-clockwise;
When hand wheel H3 has been turned sufficiently a notch in valve rod S2
automatically snaps shut into support D3 (clearly audible);
Let go of hand wheel H3, so that it is disconnected from valve rod S2;
Check the open position of the valve (valve position indication K1), the closed
position of the bypass valve and the free turning of hand wheel H3, handle arm R
of the lifting component.
Figure 4: SVC 086 (HON HSV)

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Operation and maintenance manual HON HSV086 15
3 Installation Instructions
3.1 Connection of signal lines
Connect the signal lines of the pressure converters of the safety shut-off valve as
shown in figure 5.
See figure 2 (chapter 2.2), connection B, for connection to the pressure converter.
The signal lines of the pressure converters should have a minimum diameter of
10 mm. Sometimes it is desirable (and in certain countries obligatory) that the vent
opening (see figure 2 (chapter 2.2), connection D) of the diaphragm of the pressure
converter is installed to outside. In this way no gas can get into the installation space
when a diaphragm fractures. The vent pipeline should be no longer than 40 m.
3.2 Some remarks
Mind the following when mounting the HON HSV:
When there is a possibility that filth detach from the pipeline between dust filter and
safety valve, it is advisable to fit a simple wire-mesh filter right before the
HON HSV during the first operational period. This filter may be removed later;
Mount the safety shut-off device in such a way that the arrow on the valve body
points into the flow direction.
Figure 5: Example with two safety shut-off valves
Figure 6: Example of a safety shut-off valve in dual execution ("one-of-the-two" redundancy).

© 2017 Honeywell International Inc
Operation and maintenance manual HON HSV086 16
4 Operational guidelines
4.1 Replacing the setpoint springs
(see figure 2 chapter 2.2)
a) Completely release the maximum and minimum springs (V2 and V1) by turning the
spring seats (G and I) of the springs all the way down.
b) Remove pressure converter after loosening the corresponding screw connection U
(top and bottom of the pressure converter need not be disconnected).
c) Replace setpoint springs.
d) Re-mount pressure converter.
e) Set the pressure as described in chapters 4.4 and 4.5.
4.2 Setting the lower threshold value
a) Screw the minimum spring seat I all the way down (minimum spring is fully
released).
b) Screw maximum spring seat G all the way up (maximum spring is fully
compressed, don’t block).
c) Set the pressure in the pressure converter between lower and higher threshold
value, at approx. half the value of the higher threshold value.
d) Screw in set screw S until the balance handle H is horizontal. The balance handle
should not have any play now at the points of support N and Q and at the balance
jaw P. Fix the set screw with lock nut T.
e) Lift valve shaft L with handle arm R and lock switch pin M with balance jaw P.
f) Lift the valve by pushing in hand wheel H3 and turning it anti-clockwise.
g) Now set the lower threshold value of the pressure converter.
h) Turn the minimum spring seat I up until the SVC086 disconnects.
i) Place balance handle H horizontally again by adjusting the pressure in the
pressure converter as described in point c).
j) Repeat steps e) to j), resp. steps e), h), i), and j) a number of times and adjust
minimum spring seat I if necessary.
Check that the SVC086 disconnects at the right threshold value.

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Operation and maintenance manual HON HSV086 17
4.3 Setting the higher threshold value
a) The lower threshold value has already been set.
b) If not, turn maximum spring seat G all the way up (maximum spring is completely
compressed, don’t block).
c) Set the pressure in pressure converter D between the lower and higher threshold
value, at approx. half the value of the higher threshold value.
d) Screw in set screw S until the balance handle H is horizontal. The balance handle
should not have any play now at the points of support N and Q and at the balance
jaw P. Fix the set screw with lock nut T.
e) Lift the valve shaft L with handle arm R and lock switch pin M with balance jaw P.
The following steps for an HON HSVS
f) Lift the valve by pushing in hand wheel H3 and turning it anti-clockwise (this may
already have been done when setting the lower threshold value).
g) If necessary, fit accessory A9 in SVC086 to prevent complete disconnection.
h) Set the higher threshold value of the pressure converter.
i) Turn maximum spring seat G down until SVC086 disconnects.
j) Place balance handle H horizontally again by adjusting the pressure in the
pressure converter as described in point c).
k) Repeat steps e) to j), resp. steps e), h), i), and j) when accessory A9 is used, a
number of times and adjust maximum spring seat G if necessary.
Check that the SVC086 disconnects at the right higher threshold value.
Remark
When the lower threshold value is altered, the higher threshold value also has to be
reset (because of the lever action in the SVC086).
4.4 Operational test
At the works, the device was equipped with the correct springs for the threshold value
as specified in the order. In principle, a normal operational test should therefore
suffice.
However, when this test shows that the set pressure is not set correctly, you’ll have to
alter it. Consult chapters 4.4 and 4.5 for this.
As a safety valve is seldom activated in normal operation, it is advisable to carry out
an operational test regularly. Don’t forget to test the emergency button, either. This
operational test should be carried out with a complete system. Because of the forces
exercised and carried over at the current pressure, it is advisable and useful for the
system to be pressurised during the operational test.

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Operation and maintenance manual HON HSV086 18
Checking the lower threshold value
The setting for underpressure, resp. diaphragm fracture protection, has to be checked
as follows.
Pressurise the pressure converter. Choose a pressure value between the lower
and higher threshold values.
Let the pressure in the pressure converter decrease slowly.
When the lower threshold value has been reached, the system has to switch.
Bring the pressure in the pressure converter back to a value between the lower
and the higher threshold values.
Bring the pressure above and below the valve in equilibrium, by means of the
bypass.
Lock the HON HSV (see chapter 4.4).
Run this check several times.
Checking the higher threshold value
Bring the pressure in the pressure converter to a value between the lower and
higher threshold values.
Let the pressure in the pressure converter increase slowly.
When the higher threshold value has been reached, the system has to switch.
Bring the pressure in the pressure converter back to a value between the lower
and the higher threshold values.
Bring the pressure above and below the valve in equilibrium, by means of the
bypass.
Lock the HON HSV (see chapter 4.4).
Run this check several times.
Checking the emergency button
Build up the normal initial pressure in the pressure converter.
Press the emergency button of the SVC086 (red button at the top of the SVC086)
The system should now switch.
Bring the pressure above and below the valve in equilibrium, by means of the
bypass.
Release the HON HSV (see chapter 4.4).
Run this check several times.

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Operation and maintenance manual HON HSV086 19
4.5 Commissioning
Before commissioning the HON HSV is de-pressurised. The valve is closed.
The threshold values should be correctly set and checked.
Slowly open the inlet valve of the installation.
When the full inlet pressure has built up before the still closed safety shut-off
device, the bypass valve may be opened. This enables equilibration of the
pressure above and below the valve.
The pressure has now also built up before the gas pressure regulator, so that it
can be taken into operation.
When the gas pressure regulator produces an outlet pressure higher than the set
minimum threshold value of the HON HSV, the control and switch mechanism can
be locked and the safety shut-off device can be opened using the lifting
component.
Close the bypass valve if it doesn’t close automatically.
We would advise to use a self-closing bypass valve, so that you can’t fail to close
the valve (an automatic bypass valve is supplied standard).
When the required outlet pressure has been reached, the outlet valve can slowly
be opened
The installation is now operational.
When commissioning the installation, the bypass valve of the
HON HSV bypass must be closed.
Remark
Before first commissioning an installation, the threshold values of the HON HSVs
should be checked.
4.6 Taking out of operation
Slowly close the inlet valve of the regulating line.
Then slowly close the outlet valve. When gas still has to be transported, the stand-
by line or a second installation takes over regulating.
Unpressurise the line at the outlet side using the manual blow-off.
Close the HON HSV when the minimum threshold value has been reached.
In order to unpressurise the chamber before the HON HSV also, the bypass valve
of the bypass has to be opened. The gas now flows via the bypass to the outlet of
the regulating line and can be blown off there.
After the line has been completely unpressurised, you can (if required) carry out
maintenance work.
Consult chapter 4.1 when you wish to take the installation back in operation.

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Operation and maintenance manual HON HSV086 20
5 Maintenance
5.1 General
Maintenance work is limited to replacing the O-rings and diaphragms.
To all dynamic O-rings (seals between the moving parts) and the diaphragms applies,
for optimal working, a recommended maximum life of 4 years. For static O-rings
(seals between fixed, non-moving parts) Honeywell advises a useful life of 6 to 7
years.
You can find all required parts for maintenance work in the parts list added.
5.2 Lubricants
Mind the following during all maintenance work:
Unless otherwise indicated, all screw connections are to be greased with a suitable
grease (Honeywell advises weicon anti-seize).
All O-rings are to be greased with a suitable grease (Honeywell advises krytox
GPL 309 or Klueber unisilikon TK44 N2).
All guiding surfaces are to be greased with a suitable grease (Honeywell advises
Krytox GPL 309 or Klueber unisilikon TK44 N2).
CAUTION !!!
De-pressurise the line before starting
maintenance work!