Honeywell HON 380 Instruction Manual

HON 380 gas pressure

regulator with

HON 673/674 controller

User and maintenance instructions

Spare parts

Contents

HON 380 gas pressure regulator with HON 673/674 controller 2

Contents

1General considerations 4

1.1 About this user manual 4

1.2 About the safety notices 5

2Description 7

2.1 Intended use 7

2.2 Device models 8

2.3 Labels/Markings 9

2.4 Identifying the device 10

2.5 Physical design and operation 11

2.6 Technical specifications 15

3Safety 19

3.1 Basic safety rules 19

3.2 Requirements concerning the workforce, personal protective gear, workplaces 20

4Basics for installing the device in a pipe 23

4.1 Installation example 23

4.2 Meter run characteristics 24

4.3 Operating and measuring lines 26

5Transport and installation 27

5.1 Transporting the gas pressure regulator 27

5.2 Installing the gas pressure regulator 28

5.3 Installing the device connections 30

5.4 Checking the system for leaks 31

6Adjusting the settings of the device 33

6.1 Adjusting the regulator unit setpoint 33

6.2 Adjusting the throttle valve on the measuring line of the regulator unit 36

7Malfunctions 37

7.1 Malfunctions 37

8Maintenance 39

8.1 Maintenance schedule 39

8.2 Preparing for the maintenance 40

8.3 Starting maintenance 41

8.4 Removing the regulator unit 43

8.5 Dismounting the controller 45

8.6 Performing maintenance on regulator unit 47

8.6.1 Performing maintenance on regulator unit RE1 47

8.6.2 Performing maintenance on regulator unit RE2 52

8.6.3 Performing maintenance on regulator unit RE0 57

8.7 Installing the regulator unit 61

8.8 Maintaining the monitoring device 62

8.9Installing the controller 62

8.10 Completing the maintenance 63

Contents

HON 380 gas pressure regulator with HON 673/674 controller 3

9Storage, removal, and disposal 64

9.1 Storing the device 64

9.2 Disassembling the device 65

9.3 Disposing of the device 66

10 Appendix 67

10.1 Additional information regarding spare parts 67

10.2 Spare parts kit for HON 380 with RE1 69

10.3 Spare parts kit for HON 380 with RE2 71

10.4 Spare parts kit for HON 380 with RE0 75

10.5 Lubricants 78

General considerations

HON 380 gas pressure regulator with HON 673/674 controller 4

1General considerations

Topic Page

About this user manual 4

About the safety notices 5

1.1 About this user manual

This user manual applies for gas pressure regulator HON 380 in combination with

controller HON 673/674.

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

Note: Detailed information on the HON 673/674 controller can be found in the

component documentation included in delivery.

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 un-

derstood the following parts of this document before they start with any work in-

volving 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 exploitation and communication of its contents are prohibited. Any breach or

patent, utility model or registered design registration.

Contents

Validity and purpose

Target group

Illustration

Safety

General considerations

HON 380 gas pressure regulator with HON 673/674 controller 5

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-ks@honeywell.com

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 consequences 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 no-

tice

Description Sign

Basic safety notices Superordinate safety notices not relating

to a specific task:

They contain a summarized descrip-

tion of hazards, risks and safety proce-

dures associated 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 in-

structions relating to the entire manual

or a group of manuals

Details about the

manufacturer’s

liability

Constructive changes

Meaning

Types of safety

notices

General considerations

HON 380 gas pressure regulator with HON 673/674 controller 6

Type of safety no-

tice

Description Sign

Step-related safety

notices

Safety notices containing specific in-

structions relating only to the step

DANGER

WARNING

CAUTION

Additional safety

notice

Instruction to observe certain safety no-

tices with reference to a location in the

document where safety notices contain-

ing 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 bod-

ily injury.

Warnings about possible material damages are identified with the word Attention

in this document.

Danger levels

Warnings about

material damages

Description

HON 380 gas pressure regulator with HON 673/674 controller 7

2Description

Topic Page

Intended use 7

Device models 8

Labels/Markings 9

Identifying the device 10

Physical design and operation 11

Technical specifications 15

2.1 Intended use

The HON 380 direct-acting gas pressure regulator must be used and operated

exclusively with a compatible controller made by Honeywell. The gas pressure reg-

ulator is to be used in combination with a controller to provide a safety-shut off

function in a regulating line.

Depending on the type, the gas pressure regulator can be used to maintain the

outlet pressure of a gas constant within the regulating line, regardless of the influ-

ence of disturbance variables such as pressure changes and/or changes in con-

sumption.

As a gas pressure regulator, it can be used in transfer stations used in gas trans-

portation networks, as well as in power plants and industrial facilities. Gas pres-

sure regulator HON 380 with controller HON 673/HON674 is 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 at-

tached 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 in-

tended use or those discussed with and approved by the manufacturer.

Do not use the device in any installation position other than the one docu-

mented 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 manufac-

turer-approved standard parts.

Do not attempt to modify or remodel the device on your own.

Contents

Intended use

Limitations of use

Description

HON 380 gas pressure regulator with HON 673/674 controller 8

2.2 Device models

The gas pressure regulator HON 380 in combination with a HON 673/HON 674

controller is available in a number of versions. There are different versions of the

controller and of the regulator.

The following table shows which models are available:

Nominal diameters of 1" (DN25), 2" (DN50), 3" (DN80), and 4" (DN100)

each with

Flange facing as

defined by standard

Pressure rating Maximum opera-

ting pressure

[bar]

Flange facing

ASME B16.5 Class 150 20 Raised face

DIN EN 1092-1 PN 16 16 B flange

The following table shows which models are available:

Regulator unit (RE): Setpoint range

Body

DN 25 DN 50 DN 80 DN 100

RE1 20 mbar to

1000 mbar

X X

RE2 20 mbar to

1000 mbar

X X X

RE0 1000 mbar to

2000 mbar

X X X X

The comparator stage as an individual component is executed in four models with

different designs in dependence on the control range (Wd) of the controller:

Control range Wdso Design for upper response pressure

25 to 2300 mbar K1a: Diaphragm measuring unit

400 to 5200 mbar K2b: Diaphragm measuring unit

Control range Wdsu Design for lower response pressure

10 to 300 mbar K1a: Diaphragm measuring unit

60 to 400 mbar K2b: Diaphragm measuring unit

The comparator stage as an individual component is executed in three models

with different designs in dependence on the control range (Wd) of the controller:

Control range Wdso Design for upper response pressure

40 to 500 mbar K4: Diaphragm measuring unit

200 to 1500 mbar K5: Diaphragm measuring unit

600 to 4500 mbar K6: Diaphragm measuring unit

Gas pressure regula-

tor versions

HON

380 gas pres-

sure regulator

versions

Regulator unit

versions

HON 673 controller

models

HON 674 controller

models

Description

HON 380 gas pressure regulator with HON 673/674 controller 9

Control range Wdsu Design for lower response pressure

5 to 60 mbar K4: Diaphragm measuring unit

15 to 120 mbar K5: Diaphragm measuring unit

40 to 300 mbar K6: Diaphragm measuring unit

The technical specifications and the Maintenance section, as well as the spare

parts lists and spare parts drawings in the appendix, describe all the gas pressure

regulator versions and all the models corresponding to the standard for this de-

vice type. Special-purpose versions are identified with “SO” in the inspection cer-

tificate, which is included with the gas pressure regulator.

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 manufacturer without fail before starting any work on the device.

2.3 Labels/Markings

Illegible information on the device poses a risk of injury due to resulting erro-

neous operation, use, or installation.

Labels, as well as inscriptions and stamping on the device, can eventually be-

come 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 in-

structions. 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 labels and markings of the gas pressure regulator can be found here:

Figure No. Description

1 Regulator type plate

2 Gas pressure regulator type plate

3 Arrow indicating direction of flow on

controller type plate

4 Body nominal size

5 Arrow indicating the direction of flow

For the location of the nameplates, as well as a detailed list of the information on

them and what it means, please refer to:

Identifying the device (see page 10)

Small labels must be used to color-code and explicitly name the gas pressure reg-

ulator’s connection lines (measuring lines and operating lines) based on what the

lines are intended for and their minimum nominal size.

Versions and designs

in this user manual

Illegible labels

Gas pressure regula-

tor HON 380 labels

and markings

Nameplates

Labels on connection

lines

Description

HON 380 gas pressure regulator with HON 673/674 controller 10

2.4 Identifying the device

Make sure you have the right manual for your gas pressure regulator.

Use the nameplates to identify the gas pressure regulator.

Make sure that the on-site conditions match the information on the nameplates

and the technical specifications.

Technical specifications

The gas pressure regulator HON 380 type plate locations are as follows:

Figure No. Meaning

1 Front of the body

2 On the side of the regulator unit

3 On the side of the controller

The details on the type plate have the following meaning:

Figure No. Meaning

1 Manufacturer

2 Model name

3 CE - PIN

4 Device version

5 Nominal size

6 PS = Maximum allowable pressure

7 Serial number of the device

8 Year built

9 Temperature range

10 Connection

11 Standard (EN 334)

Identifying the gas

pressure regulator

Verifying the tech-

nical specifications

Locating the gas pres-

sure regulator’s

nameplates

Interpreting the type

plate of the gas pres-

sure regulator

This manual suits for next models

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