Honeywell HON 5020 Operating instructions

HON 5020

gas pressure regulator

with HON 640a /

HON 642a pilot

User and maintenance manual

Spare parts

Contents 
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 2 
 
Contents 
1General considerations 4 
1 About this user manual 4 
2 About the safety notices 5 
2Description 7 
1 Intended use 7 
2 Device models 8 
3 Labels/Markings 9 
4 Identifying the device 10 
5 Layout and operation 12 
6 Technical specifications 17 
3Safety 24 
1 Basic safety rules 24 
2 Requirements concerning the workforce, personal protective gear, workplaces 25 
4Basics for installing the device in a pipe 28 
1 Installation examples 28 
2 Alternative application example: Active monitor regulator 30 
3 Meter run characteristics 31 
4 Operating and measuring lines 32 
5Transport and installation 34 
1 Transporting the gas pressure regulator 34 
2 Installing the gas pressure regulator 36 
3 Installing the device connections 37 
4 Checking the system for leaks 39 
6Adjusting the settings of the device 41 
1 Setting the target pressure 41 
2Adjusting the amplifying valve 43 
7Malfunctions 44 
1 Malfunctions 44 
8Maintenance 45 
1 Maintenance schedule 45 
2 Preparing for the maintenance 46 
3 Starting maintenance 47 
4 Maintaining the actuator assembly 49 
4.1 Maintaining the actuator assembly 49 
5 Maintaining the pilot 52 
5.1 Maintenance for imperial HON 640a / metric HON 640a with diaphragm measuring unit 52 
5.2 Maintenance for imperial HON 640a with metal bellows measuring unit 60 
5.3 Maintenance for imperial HON 642a with diaphragm measuring unit 70 
6 Completing the maintenance 79 

Contents 
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 3 
 
9Storage, removal, and disposal 80 
1 Storing the device 80 
2 Disassembling the device 81 
3 Disposing of the device 82 
Appendix 83 
1 Additional information regarding spare parts 83 
2 Spare parts drawing for HON 5020 actuator assembly 84 
3 Maintenance and servicing parts for the actuator assemblies 85 
4 Spare parts drawing for imperial HON640a pilot with diaphragm measuring unit 89 
5 Spare parts drawing for imperial HON640a pilot with metal bellow measuring unit 90 
6 Spare parts drawing for metric HON640a with diaphragm measuring unit 91 
7 Spare parts drawing for imperial HON642a pilot with diaphragm measuring unit 92 
8 Bill of materials and spare parts for pilots 93 
9 Spare parts for travel indication option 95 
10 Lubricants, threadlockers, and special tools 96 
 

General considerations

HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 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 to HON 5020 gas pressure regulators featuring a pilot from the

HON 640a / HON 642a series.

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

registered design registration.

Contents

Validity and purpose

Target group

Illustration

Safety

General considerations

HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 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 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

Details about the manu-

facturer’s liability

Constructive changes

Meaning

Types of safety

notices

General considerations

HON 5020 gas pressure regulator with HON 640a / HON 642a 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

HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 7

2Description

Topic Page

Intended use 7

Device models 8

Labels/Markings 9

Identifying the device 10

Layout and operation 12

Technical specifications 17

2.1 Intended use

HON 5020 gas pressure regulators featuring an HON 640a / HON 642a pilot can be used to

maintain the outlet or inlet pressure of a gas constant within a regulating line regardless of

the influence of disturbance variables such as pressure changes and/or discharge changes. In

addition, these gas pressure regulators can be used to implement an active-monitor regulator

configuration. It can be used in transfer stations of gas transportation networks, in power

plants and industrial plants. HON 5020 gas pressure regulators featuring an HON 640a /

HON 642a 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

HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 8

2.2 Device models

Gas pressure regulators consisting of an HON 5020 regulator unit combined with a pilot from

the HON 640a or HON 642a series 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 following table shows which models are available:

Nominal diameters of 1" (DN 25); 2" (DN 50); 3" (DN 80); 4" (DN 100), and 6" (DN 150) with

Flange facing as de-

fined by standard

Pressure rating

Maximum operating

pressure

[bar]

Flange facing

ASME B16.5

Class 150

Raised face;

ring joint

Class 300

Class 600

102

DIN EN 1759-1

Class 150

Bflange;

Jflange

Class 300

Class 600

102

DIN EN 1092-1

PN 16

Bflange

PN 25

PN 40

The following table shows which designs and versions are available:

Series

Design

System of

measu-

rement

Setpoint range

[bar]

Standard com-

ponents

Versions /

optional com-

ponents

640a

Diaphragm

measuring unit

Imperial

1-40

Integrated filter

None

Metal bellows

measuring unit

Imperial

20 -90

Integrated filter

None

Diaphragm

measuring unit

Metric

1-40

Integrated

filter

Inlet pressure

gauge

Outlet pres-

sure gauge

Protection

against over-

pressure

642a

Diaphragm

measuring unit

Imperial

1-40

Integrated filter

None

The designs that use the imperial system of measurement feature ports that conform to

Anglo-American thread standards and use inches as a unit.

The designs that use the metric system of measurement feature ports that conform to Euro-

pean thread standards and use metric units.

Gas pressure regulator

versions

HON 5020 actuator

assembly models

Designs and versions in

the HON 640a and

HON 642a pilot series

Description

HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 9

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 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 640a impe-

rial pilot with a diaphragm assembly 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.

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 actuator assembly’s casing:

Figure

No.

Meaning

Nameplate

Body part number

Batch number

Foundry code

CE PIN

(only if the unit has been granted a CE type

approval)

Body nominal size

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 regulator’s

connection lines (measuring impulse 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

Labels on the HON 5020

actuator assembly

Nameplates

Labels on connection

lines

Description

HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 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 (see page 17)

The type plate of the actuator assembly can be found here:

Figure

No.

Meaning

Front of the actuator assembly

For actuator assembly models that use the metric system, the information on the name-

plate will be as follows:

Figure

No.

Meaning

Model name

Manufacturer

Nominal size

Serial number of the device

Valve seat diameter

Device version

(IS = version with integral overpressure

protection)

Standard (EN 334)

Manufacturing date (month/year)

Connection

Temperature range

Failure function (fail-open)

Maximum allowable pressure

Maximum allowable inlet pressure

Identifying the gas pres-

sure regulator

Verifying the technical

specifications

Locating the type plate of

the actuator assembly

Interpreting the type

plate of the actuator

assembly

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