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

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



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

This manual suits for next models

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