Honeywell HON R100NG Series Operating instructions

HONR100NG
Gaspressureregulator
withHON P095NG pilot
Userandmaintenancemanual
Maintenanceparts

Contents
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  2
Contents
1Generalconsiderations 4
1.1Aboutthisusermanual 4
1.2Aboutthesafetynotices 5
2Description 7
2.1Intendeduse 7
2.2Devicemodels 8
2.3Labels/Markings 9
2.4Identifyingthedevice 10
2.5Layoutandoperation 12
2.6Technicalspecifications 17
3Safety 21
3.1Basicsafetyrules 21
3.2Requirementsconcerningtheworkforce,personalprotectivegear,workplaces 22
4Basicsforinstallingthedeviceinapipe 25
4.1Installationexamples 25
4.2Meterruncharacteristics 27
4.3Operatingandmeasuringlines 29
4.4Alternativeapplication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Malfunctions 42
8Maintenance 44
8.1Maintenanceschedule 44
8.2Preparingforthemaintenance 45
8.3Startingmaintenance 45
8.4Maintainingtheactuatorassembly 50
8.4.1MaintainingtheHONR100NGactuatorassembly 50
8.5Maintainingthepilot 62
8.5.1MaintainingtheHONP095NG‐HPpilot 62
8.5.2MaintainingtheHONP095NG‐MPpilot 65
8.5.3MaintainingtheP095pilot’sadjustablerestrictor 75
8.6Completingthemaintenance 76


Contents
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  3
9Decommissioning,storage,renewedstart‐up,disposal 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

Generalconsiderations
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  4
1 Generalconsiderations

Topic Page
Aboutthisusermanual 4
Aboutthesafetynotices 5

1.1 Aboutthisusermanual
ThisusermanualappliestoHON R100NGgaspressureregulatorsfeaturinganHON P095NG
pilot.
Thisusermanualprovidesallindividualswiththeinformationrequiredforthesafehandling
inconnectionwiththefollowingtasks:
 Transport
 Installation
 Start‐up
 Set‐up
 Maintenance
 Decommissioning,disassembly,renewedstart‐up,storageanddisposal

Thisusermanualisintendedforanyoneworkingwiththeproduct:
 Transportationpersonnel
 Installationpersonnel
 Set‐upandoperatingpersonnel
 Maintenanceandservicepersonnel

Honeywelloffersproductswithidenticalfunctions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productmusthavereadandunderstoodthe
followingpartsofthisdocumentbeforetheystartwithanyworkinvolvingit:
 thechapterentitledSafety
 thechaptersthatdescribetheworktobedone

Unlessexplicitlypermitted,thedisclosureaswellasduplicationofthisdocument,theexploi‐
tationandcommunicationofitscontentsareprohibited.Anybreachorinfringementwill
resultinliabilityfordamages.Allrightsreservedintheeventofpatent,utilitymodelor
registereddesignregistration.

Contents
Validityandpurpose
Targetgroup
Illustration
Safety
Copyrightnotice

Generalconsiderations
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  5
©Copyright2018by
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‐k[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

Generalconsiderations
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  6
Typeofsafetynotice Description Sign
Step‐relatedsafety
notices
Safetynoticescontainingspecificinstructions
relatingonlytothestep
DANGER
WARNING
CAUTION
Additionalsafety
notice
Instructiontoobservecertainsafetynotices
withreferencetoalocationinthedocument
wheresafetynoticescontainingspecific
informationabout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bodily
injuryordeath.
CAUTION anaccidentmayorwillhappen. minorormoderatebodily
injury.

WarningsaboutpossiblematerialdamagesareidentifiedwiththewordAttentioninthis
document.

Dangerlevels
Warningsaboutmaterial
damages

Description
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  7
2 Description

Topic Page
Intendeduse 7
Devicemodels 7
Labels/Markings 8
Identifyingthedevice 10
Layoutandoperation 12
Technicalspecifications 17

2.1 Intendeduse
HON R100NGgaspressureregulatorsfeaturinganHON P095NGpilotcanbeusedtomain‐
taintheoutletpressureofagasconstantwithinaregulatinglineregardlessoftheinfluence
ofdisturbancevariablessuchasinletpressurechangesand/ordischargechanges.Inaddition,
thesegaspressureregulatorscanbeusedtoimplementanactive‐monitorregulatorconfigu‐
ration.Itcanbeusedintransferstationsofgastransportationnetworks,inpowerplantsand
industrialplants.HON R100NGgaspressureregulatorsfeaturinganHON P095NG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.

Pleaseobservethefollowinglimitationsofuse:
 Donotusethedeviceforanymediaotherthanthosementionedintheintendeduseor
thosediscussedwithandapprovedbythemanufacturer.
 Donotusethedeviceinanyinstallationpositionotherthantheonedocumentedin
thisusermanual.
 Donotusethedeviceagainstthedirectionofflowspecifiedonthedeviceandinthe
usermanual.
 Whenreplacingdefectiveparts,onlyuseoriginalsparepartsormanufacturer‐approved
standardparts.
 Donotattempttomodifyorremodelthedeviceonyourown.



Contents
Intendeduse
Limitationsofuse

Description
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  8
2.2 Devicemodels
GaspressureregulatorsconsistingofanHON R100NGregulatorunitcombinedwithan
HON P095NGpilotareavailableinanumberofversions.Theseversionsarederivedfromthe
variouspossiblecombinationsbetweenthevariouspilotandactuatorassemblyversions.

TheHON R100NGactuatorassemblyisavailableintwodesigns.Inadditiontothetwobasic
configurations–thestandardversionandthefail‐openversion–anactivemonitorregulator
circuitcanbesetupaswell.Thetablebelowshowsthedifferentcharacteristicsofthese
designs:
HON R100NG HON R100NG‐FO
Standardversion 
fail‐closed fail‐open
1",2",3",4",6",8"
nominalinletsizes
1",2",3",4",6",8"
nominalinletsizes
ANSIclass150toclass600pressureratings ANSIclass150toclass600pressureratings

Thefollowingtableshowswhichmodelsareavailable:
Description Design Setpointrange
HON P095NG‐MP Medium‐pressuremodel
(mediumpressure)
0.5to15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drawingsintheappendix(seepage81),describeall
thegaspressureregulatorversionsandallthemodelscorrespondingtothestandardforthis
devicetype.Special‐purposeversionsareidentifiedwith“SO”intheinspectioncertificate,
whichisincludedwiththegaspressureregulator.
TheremainingsectionsinthisusermanualmostlyusetheversionwiththeHON P095NG
pilotasareference.However,otherversionsandmodelswillbecoveredspecificallyaswell
whenthereareimportantdifferencesthatneedtobepointedout. 
Ifyouhavetroubleunderstandingtheinformationinthisdocumentation,contactthemanu‐
facturerwithoutfailbeforestartinganyworkonthedevice.



Gaspressureregulator
versions
HON R100NGactuator
assemblymodels
HON P095NGpilotmod‐
els
Versionsanddesignsin
thisusermanual

Description
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  9
2.3 Labels/Markings

Illegibleinformationonthedeviceposesariskofinjuryduetoresultingerroneousopera‐
tion,use,orinstallation.
Labels,aswellasinscriptionsandstampingonthedevice,caneventuallybecomesoiledor
otherwiseunrecognizabletosuchanextentthatuserswillnotbewarnedeffectivelyof
hazardsandmaybeunableto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 Arrowindicatingthedirectionofflow

Thefollowinglabels/markingscanbefoundatthetopoftheactuatorassembly:
Figure No. Meaning
1 ANSIpressurerating
2 Material

Illegiblelabels
Labelsonthe
HON R100NGactuator
assembly

Description
UsermanualforHONR100gaspressureregulatorwithHONP095NGpilot  10
Foradetailedlistoftheinformationonthenameplateandwhatitmeans:
Identifyingthedevice(seepage10)

Smalllabelsmustbeusedtocolor‐codeandexplicitlynametheactuatorassembly’sconnec‐
tionlinesbasedonwhatthelinesareintendedforandtheirminimumnominalsize.


2.4 Identifying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assemblyside

Nameplate
Labelsonconnection
lines
Identifyingthegaspres‐
sureregulator
Verifyingthetechnical
specifications
Locatingthetypeplateof
theactuatorassembly