Honeywell HON 512 Betriebsanleitung

Connected Industrial

HON 512

gas pressure regulator

with HON 650 pilot

User and maintenance manual

Spare parts

Contents

HON 512 with HON 650 pilot user manual 2

Contents

1General considerations 4

1.1 About this user manual 5

1.2About the safety notices 7

2Description 8

2.1 Intended use 9

2.2 Device models 10

2.3 Labels/Markings 12

2.4 Identifying the device 13

2.5Layout and operation 15

2.6 Assemblies and their function 17

2.7 Technical specifications 22

3Safety 31

3.1 Basic safety rules 32

3.2 Requirements concerning the workforce, personal protective gear, workplaces 34

4Basics for installing the device in a pipe 36

4.1 Installation examples 37

4.2 Meter run characteristics 40

4.3 Operating and measuring impulse lines 42

5Transport, installation and start-up 43

5.1 Transporting the gas pressure regulator 44

5.2 Installing the gas pressure regulator 46

5.3 Installing the device connections 48

5.4 Checking the system for leaks 50

5.5 Starting up the gas pressure regulator 53

6Adjusting the settings of the device 55

6.1 Adjusting the loading pressure 56

6.2 Adjusting the control stage setpoint 57

6.3 Adjusting the amplifying valve 59

7Malfunctions 61

7.1 Malfunctions 62

8Maintenance 65

8.1 Maintenance schedule 66

8.2 Preparing for the maintenance 67

8.3 Maintaining the actuator assembly 69

8.3.1 Maintaining the actuator assembly - Design 1, example with expander 70

8.3.2 Maintaining the actuator assembly - Design 2, example without expander 83

8.3.3 Maintaining the actuator assembly - Design 3 93

8.4 Maintaining the pilot 102

8.4.1 Disassembling the pilot and maintaining the base plate 103

8.4.2 Maintaining the control stage with a diaphragm assembly 106

8.4.3 Maintaining the control stage with a larger diaphragm assembly 114

Contents

HON 512 with HON 650 pilot user manual 3

8.4.4 Maintaining the control stage with a metal bellows assembly 125

8.4.5 Maintaining the load limiting stage 134

8.4.6 Maintaining the fine mesh filter 137

8.4.7 Reassembling the pilot 139

8.5 Completing the maintenance 141

9Decommissioning, storage, renewed start-up, disposal 144

9.1 Preparing for disassembly 145

9.2 Disassembling the device 147

9.3 Storing the gas pressure regulator 149

9.4 Putting the gas pressure regulator back into operation 150

9.5 Disposing of the gas pressure regulator 151

10 Appendix 152

10.1 Additional information regarding spare parts 153

10.2 Spare parts for HON 512 actuator assembly, design 1, DN 25 –DN 100 155

10.3 Spare parts for HON 512 actuator assembly, design 2, DN 150 –DN 250 162

10.4 Spare parts for HON 512 actuator assembly, design 3, DN 25 –DN 250 170

10.5 Spare parts for two-stage HON 650 pilot 183

10.6 Spare parts for single-stage HON 650-1 pilot 198

10.7 Lubricants, threadlockers, and tools 202

10.8 Technical specifications for HON 970a electrical displacement transducer 204

General considerations

HON 512 with HON 650 pilot user manual 4

1General considerations

Topic Page

About this user manual 5

About the safety notices 7

Contents

General considerations

HON 512 with HON 650 pilot user manual 5

1.1 About this user manual

This user manual applies to gas pressure regulators consisting of an HON 512 actuator as-

sembly combined with an HON 650 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

▪Troubleshooting

▪Converting

▪Maintenance

▪Putting the valve back into operation

▪Decommissioning, disassembly, 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.

Validity and purpose

Target group

Illustration

Safety

General considerations

HON 512 with HON 650 pilot user manual 6

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

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.

Details about the manu-

facturer’s

liability

Constructive changes

General considerations

HON 512 with HON 650 pilot user manual 7

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

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.

Meaning

Types of safety

notices

Danger levels

Warnings about material

damages

Description

HON 512 with HON 650 pilot user manual 8

2Description

Topic Page

Intended use 9

Device models 10

Labels/Markings 12

Identifying the device 13

Layout and operation 15

Assemblies and their function 17

Technical specifications 22

Contents

Description

HON 512 with HON 650 pilot user manual 9

2.1 Intended use

Gas pressure regulators consisting of an HON 512 actuator assembly combined with an HON

650 pilot can be used to maintain the outlet pressure constant within set limits within a gas

regulating line regardless of gas discharge changes and inlet pressure changes. These gas

pressure regulators work on a purely pneumatic basis. Typical applications include gas regu-

lating lines in transfer stations, transmission networks, power stations, and industrial facilities.

Due to their control dynamics, the gas pressure regulators are used especially for gas turbine

circuits. The gas pressure regulators are suitable for use with natural gas or dry,

non-aggressive industrial gases.

Note: The gas pressure regulator’s operating limits concerning the gas, the operating pres-

sure, and the operating temperature can be found either on the nameplates affixed to the

device or in the device’s 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.

Intended use

Limitations of use

Description

HON 512 with HON 650 pilot user manual 10

2.2 Device models

Gas pressure regulators consisting of an HON 512 regulator unit combined with an HON 650

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 650 pilot features a number of individual expansion options.

The following individual components are always part of the device:

▪HON 905 fine mesh filter

▪Inlet pressure gauge

▪Amplifying valve

▪Control stage, including spring adjuster and base plate

The following individual components are optional expansions:

▪Load limiting stage, including spring adjuster and loading pressure gauge

▪Outlet pressure gauge

▪With HON 925 protection against overpressure for setpoint ranges Wdof 0.3

to 20 bar

▪Without protection against overpressure for setpoint ranges Wdof 10 to 40

bar

▪HON 915 vent valve

▪Electrical remote setpoint adjustment for control stage and/or load limiting stage

The standard HON 650 pilot version features two stages, i.e., it includes both a load limiting

stage and a control stage.

The manufacturer uses designation HON 650-1 for the single-stage pilot version featuring a

control stage but no load limiting stage.

There are three different versions of the individual control stage component installed in the

HON 650 pilot, with the specific version used depending on the control stage’s setpoint range

(Wd):

Setpoint range Wd

Design

0.3 to 1 bar

With larger diaphragm assembly

0.5 to 40 bar

With diaphragm assembly

10 to 90 bar

With metal bellows assembly

The optional load limiting stage for the HON 650 pilot always features a diaphragm assembly

regardless of the control stage’s setpoint range (Wd).

Gas pressure

regulator versions

HON 650 pilot models

Control stage models

Models for the optional

load limiting stage

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