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General operating instructions
General operating instructions
for rmG Gas pressure reGulators and safety devices
rmG regel + messtechnik GmbH
servinG tHe Gas industry worldwide
2
General operatinG instructions
General operating instructions
3
General operatinG instructions
General operating instructions
contents
Page Hazard warning signs .................................................................................................................................... 4 1. General ......................................................................................................................................................... 5
2. Installation .................................................................................................................................................... 5
2.1 Design of outlet measuring pipe ................................................................................................................... 5
2.2 Leak testing (testing for external leak tightness) .......................................................................................... 7
2.3 Installation examples .................................................................................................................................... 8
2.4 Impulse lines ................................................................................................................................................. 9
3. Operating instructions
3.1 Pressurising the station ................................................................................................................................ 10
3.2 Operation and performance tests ................................................................................................................. 10
3.2.1 Testing internal leak tightness ...................................................................................................................... 10
3.2.2 Testing the response pressure ...................................................................................................................... 10
3.3 Setpoint adjustment ..................................................................................................................................... 10
3.3.1 Changing the setting range ........................................................................................................................... 10
3.4 Commissioning the station ........................................................................................................................... 11
3.5 Setting instructions ....................................................................................................................................... 11
3.6 Decommissioning the system ....................................................................................................................... 11
4. Troubleshooting:
4.1 - Direct-acting gas pressure regulators (without auxiliary power) ................................................................. 12
4.2 - Pilot-operated gas pressure regulators (with auxiliary power) ..................................................................... 13
4.3 -Safetyshut-offvalves .................................................................................................................................. 14
5. Lubricants ..................................................................................................................................................... 15
6. Installation tools ........................................................................................................................................... 16
Additional RMG publications ......................................................................................................................... 18
4
General operatinG instructions
General operating instructions
Hazard warninG siGns
Safetyadviceintheseoperatinginstructionsisindicatedbythefollowingsigns and symbols:
Hazard warning signs, general
sign meaning:
Achtung
Hinweis
Risk of personal injury
Riskofdamagetopropertyandtheenvironment
Additional information
danger
warning
note
!
5
General operatinG instructions
General operating instructions
1. General
TheseGeneralOperatingInstructionsdescribetheinstallation,removalandoperationofgaspressureregulators(GPR)for outlet pressure control, safety shut-off valves (SSVs) and safety relief valves (SRVs). Please refer to the relevantguidelines, particularlyDVGW technical rulesG491andG495, for information regardingdesign, finish, supervision and maintenance.
For technicaldataandspecial featuresofaparticularproduct,pleaserefer to therelevantproductbrochures,testcertificatesandtypeplates.
Gaspressureregulatorsmaybecommissioned,decommissionedandservicedbyqualifiedpersonnelonly.
Pressureoutsidethespecifiedrangemayresultininternalandexternaldamagetothegaspressureregulators.
Gas pressure regulators and components may be opened only in an unpressurised state.
2. installation
Gas pressure regulators and safety devicesmust be installed without pipe distortion. The arrow on themain valvehousingmustindicatetheflowdirection(exceptRMG790inthereturnsection).Pressureregulatorsareusuallyinstalled inanuprightpositionwithhorizontalgasflow(seeinstallationexamplesandtechnicalproductinformationfortherelevantregulator). Pilots and actuators of indirect-acting pressure regulators must always be installed in the normal position. Theinstallationpositionmayaffectthefunctionandthereforespecifictechnicaldata,e.g.settingrangeWd, accuracy class AC, lock-up pressure class SG and accuracy group AG.Please refer to the relevant manual and maintenance instructions for information about alternative installationpositions.
2.1 design of outlet measuring pipe
Chooseapipesectionwithstabilisedflowforthemeasuringpoint.Makesurethatnoinstallationsthatcoulddisrupt theflowareinstalledimmediatelyupstreamordownstreamofthemeasuringpoint,e.g.orificeplates,expansions,bends,branches,shut-offvalvesetc.
rmG general recommendation for outlet measuring pipe:
‐Maximumflowrateatthemeasuringpointuptoapprox.25m/sdependingonstationoperatingconditions.‐Flowratesinexcessof25m/smaybepossiblewithcertainstationarrangements,e.g.gasregulatinglinesforgas
motors and gas burners. Please contact RMG for further information.‐Inthelow-pressurerangeuptoapprox.250mbarwerecommendapprox.15to20m/smaximum. Evenlowerflowratesmaybeusedincertaincases.
Achtung
Achtung
Achtung
danger!
warning
warning
warning
6
General operatinG instructions
General operating instructions
upstream of the measuring point, general
Depending on the design of the station, the length lur of the uninterrupted pipe must be 2.5 to 5 x DN of the pipe, subject to the design of the gas pressure regulator or any downstream pipe expansion.
‐Ifagaspressureregulatorwithbuilt-inexpansionisusedand: •thenominalwidthofthepipeisthesameasthedownstreamnominalwidthofthegaspressureregulator → Lur min. 2.5 x dn
•thenominalwidthofthepipeisthenextlargeststandardnominalwidth → Lur min. 3 x dn
•thenominalwidthofthepipeistwicethestandardnominaljump → Lur min. 4 x dn •thenominalwidthofthepipeismorethantwicethestandardnominaljump → Lur min. 5 x dn
‐Iftheoutletpipesizeofagaspressureregulatoristhesameastheinletpipesizeand: •thenominalwidthofthepipeisthenextlargeststandardnominalwidth → Lur min. 4 x dn
•thenominalwidthofthepipeistwicethestandardnominaljump → Lur min. 5 x dn
downstream of the measuring point
→ Lur min. 1.5 x dnforthermometerimmersionsleeves → Lur min. 1.5 x dn for reductions and expansions, depending on the station operating conditions → Lur min. 3 x dnforshut-offvalves(gatevalves,controllingflaps,ballvalveswithreducedbore) → Lur min. 4 x dn for T-pieces
further recommendations
‐Shut-offvalveswithuninterruptedflow(e.g.ballvalveswithfullbore)and,whereappropriate,pipebends(depending ondesign)arenotregardedasdisruptivetomeasuringlineconnections.‐No restrictions apply to gasmeters (turbine gasmeters including flowmeters, ultrasonic flowmeters, vortex gasmeters,butnotrotarymeters)withregardtothepositioningofmeasuringlines;theyarenotregardedasflow-impeding formeasuringlineconfigurations.‐Forrotarygasmeterstheminimumdistancebetweenthegaspressureregulatororreducer/expansionandthegas
meter must be → Lur min. 3 x dn.Measuring line connections downstream of gas meters must be separated by a distance of → Lur min. 2 x dn.‐Whenusingshut-offvalves(reducedbore),werecommendadistanceof→ Lur min. 3 x dn downstream of a measuring
line connection.‐Allowancesmustbemadeforpressurelossesfromgasmeterswhereapplicable,dependingonthestationoperating
conditions.
All these statements are RMG recommendationsThese recommendations also relate to guidance on measuring line connection conditions in standards (DIN) EN 334 and (DIN) EN 14382. Responsibility lies strictly with the station operator.The following plant schematics illustrate the basic design types.
7
General operatinG instructions
General operating instructions
2.2 leak testing (testing for external leak tightness)
Gas pressure regulators (GPR) and safety shut-off valves (SSV) are pressure and leak tested by the manufacturer inaccordancewith(DIN)EN334(GPR,SBV)and(DIN)EN14382(SSV).IncompliancewithDVGWtechnicalrulesG491,thefullyassembledstationmustbeleaktestedinsituwithairorwithinert gas at 1.1 times the maximum permitted operating pressure (MIPu, MIPd).MIP=1.1⋅MOPu,d
inlet chamber•Chamberuptothemainvalveofthegaspressureregulator Test pressure MIPu=1.1⋅MOPu
outlet chamber •Chamberbetweenthemainvalveofthegaspressureregulator(GPR)andthefirstdownstreamshut-offvalve. Werecommendusing1.1timesthemaximumresponsepressurepdsospecifiedonthesafetyshut-offvalve(SSV). Recommended test pressure MIPd=1.1⋅pdso (but max. MIPd=1.1⋅MOPd). (MIPdmustnotbeexceeded,evenallowingfortheaccuracygroupAGoftheSSV(s).)
outlet chamber downstream of the valves•Chamberdownstreamofthefirstshut-offvalvedownstreamofthegaspressureregulator Test pressure MIPd = 1.1 MOPd.
Alwaysapplythetestpressureslowlyandevenly.
please note:Pressure in the outlet chamber ≤ pressure in the inlet chamberPressure increase always from the inlet side (inlet chamber)Pressure decrease always from the outlet side (outlet chamber)
Hinweis
Achtung Withdirect-actingpressureregulators(withoutauxiliarypower),theoutletpressureactingonthemain valvemustneverbemorethan0.5barabovethesetpoint.Therefore with a setpoint spring adjustment of 0.2 bar, for example, the test pressure in the outlet chamber must not exceed 0.5 + 0.2 = 0.7 bar.
warning
note
8
General operatinG instructions
General operating instructions
Devicedesignation
2.3 installation examples
fig. 1: Gas pressure regulator - direct-acting GPR (without auxiliary power) - with expansion without noise attenuation downstream of the GPR
fig. 2: Gas pressure regulator - indirect-acting GPR (pilot-operated) - with expansion without noise attenuation downstream of the GPR -outletpressuregaugewithoverpressureprotection
fig. 3: Gas pressure regulator - indirect-acting GPR (pilot-operated) - with expansion and integrated noise attenuation -outletpressuregaugewithoverpressureprotection
*)Canincludeshut-offvalvewithunimpededflow(ballvalve)
LuR LuR*
DN
Ventline
Ventline
Ventline
SSVmeasuringline
SSVmeasuringline
SSVmeasuringline
SSV
SSV
SSV
SRV
SRV
SRV
GPR
GPR
GPR
GPR measuring line
GPR measuring line
GPR measuring line
Measuring point for connection lines
Measuring point for connection lines
Measuring point for connection lines
Discharge line
Discharge line
Discharge line
Pilot
Pilot
Release line
Release line
Release line
Outlet shut-offvalve
Outlet shut-offvalve
Outlet shut-offvalve
DN
F
LuR LuR*
DN
F
LuR LuR*
Bleed line
Bleed line
Return line
Return line
9
General operatinG instructions
General operating instructions
fig. 4: Gas pressure regulator - indirect-acting GPR (pilot-operated) -indirect-actingSSV(pilot-operated)(2-fold) - with expansion without noise attenuation downstream of the GPR
*)Canincludeshut-offvalvewithunimpededflow(ballvalve)
Ventline SSVmeasuringline
SSVmeasuringline
GPR measuring line
SAV 2SAV 1 GDR
DN
F
LuR LuR*
2.4 impulse lines
Pleaserefertotherelevanttechnicalproductinformationforthedimensionsoflinesandthreadconnectionsforspecific pressure regulators. The lines must be arranged and dimensioned so as to ensure that the pressure regulators function correctly.Themeasuringlinetransmitstheactualvalueofthepressurefromthemeasuringpointtothemeasuringdiaphragm ofaregulatingassembly,thepilotofaGPRorSRVorthemeasuringdiaphragmofanSSVactuator.Itisconnectedtotheside orthetopofthepipework,dependingonthedevice.Withsafetydevices,themeasuringlinemustalwaysbeconnectedwithoutshut-offmechanismupstreamofthefirstshut-offvalveontheoutletside.Ifameasuringlineisalsoconnecteddownstreamofthefirstshut-offvalveontheoutletside,3-wayballvalveswithnegative-valueoverlapmustbeusedforswitching(theseballvalvesdonothaveavalvepositionwhichallowsbothmeasuringlinestobefullyclosedatthesametime).Theventlineservestoconnectameasuringdiaphragmtotheatmosphere;intheeventofdamagetothemeasuringelement (e.g.diaphragmrupture),itcancarrygas.Ventlinesmaybedispensedwithundercertainoperatingconditionsifventvalves (RMG915)orsafetydiaphragmtypescanbeusedasanalternative.→PleasecontactRMGforfurtherinformation.Thedischargelineofasafetyreliefvalve(SRV)isusedtodischargevolumesofgas(e.g.leakagegas)intotheatmosphere. Theventlinesordischargelinesmaybegroupedtogetherinacollectingline,providedthatthisdoesnotimpairthefunctioning oftheindividualdevices.Therecommendedprofileofthecollectinglineisatleast5xgreaterthanthetotalprofilesoftheindividuallines.Stand-aloneSSVventlinesarerecommendedformainsafetyshut-offvalves(SSV).Ventlinesmustnot be combined with discharge lines in the same collecting line.Withindirect-actinggaspressureregulators(pilot-operated),thebleedlineisusedtodischargeoutflowgasfromthepilot into the outlet chamber of the pressure regulator. In some pressure regulators the bleed line is combined with the return line.Withpilot-operatedgaspressureregulators,thereturnlinefeedstheoutletpressurebacktothemainvalve.
Bleed linePilot
Return line
SRV
Discharge line
Outlet shut-offvalve
Measuring point for connection lines
10
General operatinG instructions
General operating instructions
3. operatinG instructions
Safetyreliefvalve(S
BV)
pres
suris
ing
the
stat
ion
Makesurethattheoutletshut-o
ffvalve
isclosedwhenpressurisingthesystem
.Alwayspressuriseslow
ly.Af
ter c
arry
ing
out m
aint
enan
ce, p
ress
uris
e th
e sy
stem
and
per
form
ope
ratio
nal t
ests
as d
escr
ibed
in 3
.2.
oper
atio
n an
d pe
rfor
man
ce te
sts
Test
ing
inte
rnal
saf
ety
•Increasethepressureintheoutletchamberu
ntil
the
resp
onse
pre
ssur
e is
reac
hed
•Reducepressureintheoutletchamberto0.9tim
es
the
resp
onse
pre
ssur
e•Testforleaks
Test
ing
the
resp
onse
pre
ssur
e
•Slow
lyincreasethepressureuntiltheresponse
pres
sure
psisreached.TheSRV
musto
pen
•Adjusttheresponsepressuresetpointifnecessary
setp
oint
adj
ustm
ent
•Toincreasesetpoint,turnthesetpointadjustm
entscrew
clockwise•To
decreasethesetpoint,turnthesetpointadjustm
entscrew
anticlockwise
chan
ging
the
sett
ing
rang
e
Thesettingrangecanbesw
itchedtoadifferentsetpointspringwhenthepressureregulatorispressurised
Donotinsertadifferentsetpointspringwhen
thesafetyreliefvalveispressurised
indi
rect
-act
ing
gas
pres
sure
(Gpr
)re
gula
tor (
pilo
t-ope
rate
d)
Alock-uppressurecorrespondingtothepresetvalueisgeneratedintheoutletchamber
•Settheloadlimitingpressure
Referencevalues:
-RMG610(RS10d)approx.0.5to1barabovep
d-PilotR
MG650approx.0.5to10barabovep
d-PilotR
MG630approx.0.5to10barabovep
dFo
r fur
ther
info
rmat
ion,
ple
ase
refe
r to
the
oper
atin
g hintsandtipsfortherelevantproductinthespare
part
s ca
talo
gue
•Slow
lyincreasetheoutletp
ressuretothedesiredvalue(seesections3.2.2and3.3)
Test
ing
the
lock
-up
pres
sure
•Pressurisationinaccordancewith3.1
•Dischargeasm
allvolum
eofgasviatheroof
•Slow
lyclosethedischargeline
A co
nsta
nt lo
ck-u
p pr
essu
re m
ust b
e m
aint
aine
d w
ithin
the
lock
-up
pres
sure
gro
up
Test
ing
the
cont
rolle
d pr
essu
re
•Forthefirsto
perationaltest,dischargethegastoairvia
thedischargeline
Thesetcontro
lledpressurecanbereadofffro
mtheoutletp
ressuregauge
•Adjustthesetpointoftheoutletp
ressureifnecessary
Werecommendsettingthesetpointoftheoutletpressuretoslightlybelowthepressureofthe
down
stre
am li
ne s
yste
m
indi
rect
-act
ing
gas
pres
sure
(Gpr
)di
rect
-act
ing
(with
out a
uxili
ary
pow
er)
Si
nce
the
pres
sure
regu
lato
r is
in a
n un
pres
suris
ed s
tate
, slo
wly
pre
ssur
ise
th
e in
let p
ress
ure.
PleasenotethefinalsectiononPage7
Safe
ty s
hut-o
ff va
lve
(SSV
)
•Slow
lyopentheby-passvalve
orp
ressure
compensatingvalve
oftheSSV
Thiswillequalisepressureinthemainvalve
•Op
enandengagetheSS
V,keepingitintheopen
posi
tion
until
it is
sec
urel
y en
gage
d.
Maintainthere-engagem
entd
ifferential
(see
gen
eral
bro
chur
e an
d se
ctio
n 3.
5)An
SSV
withunderpressurereleasecanonlybe
enga
ged
if th
e pr
essu
re a
t the
mea
surin
g po
int
corr
espo
nds
to th
e op
erat
ing
pres
sure
p.
•Closetheby-passvalve
s
Test
ing
inte
rnal
leak
tigh
tnes
s
•CloseSS
V•D
epressurise
theoutletchamberasfarastheoutlet
shut-offvalve
•Pressurisetheinletp
ressure
•Testforleaks
with
two
ssvs
:•ClosethefirstSSV,opentheby-passvalve
s
ofthesecondSSV
andtestforleaks
•Closetheby-passvalve
sonthesecondSSV
Op
enthefirstby-passvalve.TestthesecondSS
Vfo
r lea
ks
Test
ing
the
resp
onse
pre
ssur
e
•Slow
lyincreaseord
ecreasethepressureuntil
the
resp
onse
pre
ssur
e is
reac
hed
•Repeatthetestseveraltimesatthesam
epr
essu
re c
hang
e ra
te
Pleaseobservethere-engagem
ent
differentialswhenperfo
rmingthetest(seegeneral
broc
hure
and
sec
tion
3.5)
•Adjusttheresponsepressuresetting
on th
e ac
tuat
or if
nec
essa
ry
Whenthestationisunderpressure,
theSS
Vcloseswhenthesetpointspringfor
overpressureisremoved
3.1
3.2
3.2.
1
3.2.
2
3.3
3.3.
1
Ach
tung
Ach
tung
Hin
wei
s
Ach
tung
Hin
wei
s
Ach
tung
war
ning
note
note
war
ning
war
ning
war
ning
Hin
wei
sno
te
11
General operatinG instructions
General operating instructions
com
mis
sion
ing
the
syst
em
sett
ing
inst
ruct
ions
deco
mm
issi
onin
g th
e sy
stem
•Aftercom
pletingsections3.1and3.2:Slowlyopentheoutletshut-o
ffvalve
•Slow
lyincreasethesetpointwiththeadjustmentscrew
untilthepressureregulatorh
astakenover
the
gas
supp
ly a
nd th
e de
sire
d ou
tlet p
ress
ure
p ds i
s se
t
fitt
ing
the
regu
latin
g de
vice
to th
e re
gula
ting
line
Whengasistakenup(outsidethelock-uppressurezo
neorthelowflow
range),thecontro
lresponse
oftheGP
Rmustrem
ainstablewithinthegivenaccuracyclass
sett
ing
the
load
lim
iting
pre
ssur
e•Intheevento
fcontro
loscillations:reduce
th
e lo
ad li
miti
ng p
ress
ure
•Intheeventofexcesscontroldeviations:increase
the
load
lim
iting
pre
ssur
e
A lo
ad li
miti
ng p
ress
ure
chan
gem
ay
requiresetpointadjustm
ent
Sett
ing
the
outfl
ow:Avoidchangingthefactory
defa
ult s
ettin
g if
poss
ible
•Intheevento
fcontro
ldeviations,turnthespindle
antic
lock
wis
e (a
djus
tmen
t scr
ew).
Do n
ot e
xcee
d
4 tu
rns
for R
MG
610
defa
ult s
ettin
g of
ble
ed v
alve
(RM
G 61
0 an
d
RMG
650)
and
thro
ttlin
g va
lve
of R
MG
630
for r
mG
610
Num
ber
of ro
tatio
ns
Adju
stm
ent s
crew
Turn
the
adju
stm
ent s
crew
to “-
” (an
ticlo
ckw
ise)
as
far a
s it
will
go;
turn
the
adju
stm
ent s
crew
to “+
” (c
lock
wis
e) to
retu
rn th
e co
unte
r to
zero
for r
mG
650,
rmG
630
and
rmG
630-
1(fo
rmer
ly 6
40)
fact
ory
sett
ing:
Thro
ttle
is ro
tate
d 6
times
(ant
iclo
ckw
ise)
.
1.Slowlyclosetheoutletshut-o
ffvalve
or2.Slowlyreducetheoutletp
ressurevia
thesetpointadjustm
entscrew
untiltheback-upline
hastakenoverthegassupply
or 3
. Slo
wly
incr
ease
the
setp
oint
of t
he b
ack-
up li
ne u
ntil
the
oper
atin
g lin
e is
dec
omm
issi
oned
sett
ing
the
thro
ttle
val
ve in
the
mea
surin
g lin
e•Intheevento
fcontro
loscillations,turnthevalve
clockw
isetorestricttheflow
Thethrottlevalve
shouldremainopenas
faraspossibletoachievesuffi
cientactuatingspeed
St
op s
crew
s fo
r rel
easi
ng s
ampl
es
mustb
eremoved;
Endcaps,w
hichserveasanopeningaid,
mustb
eremovedfrom
thevalve
stem
Re-e
ngag
emen
t diff
eren
tial
There-engagem
entdifferentialspecifiestheam
ount
∆
p w b
y w
hich
the
pres
sure
mus
t be
redu
ced
afte
r anoverpressurereleaseorincreasedafteran
underpressurereleasetoenabletheSSVtobesafely
re-engaged.There-engagem
entd
ifferentialsare
specifiedinthegeneralbrochuresorintheRM
Gbo
okle
t.IftheSS
Vactuatorisdesignedtosimultaneously
protectagainstover-andunderpressure,theminimum
pressuredifferencebetwe
enp
dso
and
p dsu
mus
t additionallybeobserved.Thisisspecifiedinthe
gene
ral b
roch
ures
. Dec
omm
issi
onin
g th
e st
atio
n
3.4
3.5
3.6
Ach
tung Au
sgan
gsdr
uckb
erei
ch, i
n de
mei
ne s
iche
re S
AV-E
inra
stun
gge
gebe
n is
t
Wie
dere
inra
st-D
iffer
enz
p o
Ober
er A
nspr
echd
ruck
pso
Wie
dere
inra
st-D
iffer
enz
p u
Unte
rer A
nspr
echd
ruck
psu
Hin
wei
s
Hin
wei
s
Vers
tärk
ungs
eins
tellu
ng Grun
dein
stel
lung
:Li
nksd
rehe
n bi
s An
-sc
hlag
, X
Umdr
ehun
gen
nach
rech
tsX=
Rille
Spin
del
Hüls
eGr
undp
latte
Schu
tzka
ppe
Lowe
r res
pons
e pr
essu
re p
dsu
Re-engagem
entd
ifferential∆
p wu
Re-engagem
entd
ifferential∆
p wo
Uppe
r res
pons
e pr
essu
re p
dso
note
note
war
ning
Groove
Sleeve
Spin
dle
Defa
ult s
ettin
g: T
urn
antic
lock
wis
e as
far a
s it
will
go,Xrevolutionsclockwise
Amplificationsetting
Protectivecap
Base
pla
te
Outle
t pre
ssur
e ra
nge
at w
hich
theSS
Vcanbesecurelyengaged
12
General operatinG instructions
General operating instructions
4. troublesHootinG
4.1direct-acting gas pressure regulators (without auxiliary power)
Pleaserefertothemaintenancemanuals/sparepartscatalogueformaintenanceinstructionsforspecificproducts
Depressuriseallhousingchambersandassociatedstationpartsbeforeinstallingorremovingadevice.
troublesHootinGfault fault detection possible cause Action
Excess lock-up pressure no lock-up pressure Mainvalve
Compensating diaphragm faulty Replace diaphragm
Mainvalvesoiledordamaged Checkvalveseatandsealingringsfor damage and dirt
Structural sealing element faulty Replace sealing rings
Unstable outlet pressure pattern (oscillations)
Mainvalve Pressure regulator operating in the lock-up pressure range
Tighten the adjustable throttle in the measuring linebyturningclockwise(ifavailable)note: Excess damping reduces the actuating speed.Insert the setpoint spring for the next higher setting range (harder setpoint spring)
Regulating assembly Oscillating resonance in the regulating line
Excesscontroldeviation
Measuring point Unsuitable measuring line connection Choosemeasuringpointwithstableflow,check measuring point
Gas pressure regulator Binding of the regulator due to soiling Servicetheregulator
Measuring or compensating diaphragm faulty or incorrectly installed Check diaphragm
Incorrect pressure peak, excess dynamic lock-up pressure
Gas pressure regulator Excess damping of the pressure regulator, too dynamic regulating line
Open the adjustable throttle further in the measuring line (turn anticlockwise), checkventlinesifnecessary,increase thepipewidthifthelinesareverylong.replaceventvalveRMG915withventline
Regulating line Excess lock-up speed of downstream shut-offdevices Reducelock-upspeedofshut-offdevice
danger!
13
General operatinG instructions
General operating instructions
4.2 pilot-operated gas pressure regulators (with auxiliary power)
Pleaserefertothemaintenancemanuals/sparepartscatalogueformaintenanceinstructionsforspecificproducts
Depressuriseallhousingchambersandassociatedstationpartsbeforeinstallingorremovingadevice.
troublesHootinGfault fault detection possible cause action
Excess lock-up pressure Pilot Amplifyingvalvesoiledordamaged Servicepilot
No lock-up pressurePilot Amplifyingvalvefaulty Servicepilot
Mainvalve Mainvalveleakingduetosoiling or damage Servicemainvalve
Mainvalvedoesnotopenduring commissioning or loadtransfer
GPR does not respond to setpoint adjustment
Sudden or slow outlet pressure loss
PilotToolittleamplification Increase load limiting pressure,
reduceoutflow
Diaphragm in pilot faulty Replace diaphragmFilter Filter soiled Cleanorreplacefilterset
Mainvalve
Diaphragminmainvalvefaulty Replace diaphragm
Pressurecompensationvalveopen(withRMG402/RMG502) Closevalve
Valveseatdiametertoosmall Check design data
Sudden or slow outlet pressure loss or increase
Pilot Diaphragm in pilot faulty Replace diaphragm
Mainvalve Mainvalvebinding Servicetheregulator
Unstable outlet pressure pattern (oscillations)
Pilot ExcessamplificationReduce load limiting pressure, increase gas outflow;insertsetpointspringforthenextsetting range up (harder setpoint spring)
Mainvalve Mainvalveoperatesinlock-uppressurerange Check design data
Measuring point Unsuitable measuring line connection Choose measuring point with stabilised flow,seesection2.1“Designofoutletmeasuring pipe”
Excesscontroldeviation Pilot Toolittleamplification
Increase load limiting pressure, reduce gas outflow
Reduce throttle setting(withRMG630/650-1(formerly640))
danger!
14
General operatinG instructions
General operating instructions
4.3 Safety shut-off valves
Pleaserefertothemaintenancemanuals/sparepartscatalogueformaintenanceinstructionsforspecificproducts
Depressuriseallhousingchambersandassociatedstationpartsbeforeinstallingorremovingadevice.
troublesHootinGfault fault detection possible cause action
No internal tightness in the closing position
Mainvalve Mainvalvenottight Checkvalveseatandsealingringsfor damage and dirt
By-passvalve By-passvalvesopenornottight Checkby-passvalves
Mainvalvewillnotopen By-passvalve No pressure compensation at the main valve
Create pressure compensation by opening theby-passvalve
Mainvalvewillnotengage
Actuator
Differencebetweenresponsepressureand operating pressure or between upper and lower response pressure too small
Correct response pressure setting (seebrochureorRMGbookletforrequiredre-engagementdifferential)
Measuring diaphragm in the actuator faulty (only with underpressure release) Replace diaphragm
Measuring pointPressure at measuring point too high Reduce pressure at measuring point
to operating pressure
No pressure at measuring point only with underpressure release
Increase pressure at measuring point to operating pressure
Ventvalve Ventvalvedischargesinsufficientgas from the spring chamber to engage
Unscrewtopofspringhousing;engageSSVand screw top back down
Trippingdevice Release mechanism binding due to soiling Servicetrippingdevice
Permitted response pressure deviationexceeded
Irregularities in response behaviour
Actuator
Differencebetweenresponsepressureand operating pressure or between upper and lower response pressure too small
Observeprescribedre-engagementdifferentialduringengagement(see brochure or RMG booklet)
Measuring diaphragm twisted Check diaphragm
Trippingdevice
Release mechanism binding due to soiling Servicetrippingdevice
Elements of the release mechanisms worn Replace damaged parts
Checkingdevice Significantvariationinpressurechanges rates during testing Applytestpressureslowlyandevenly
Gasleakviaventlines Actuator Measuring diaphragm faulty Replace diaphragm
danger!
15
General operatinG instructions
General operating instructions
5. lubricants
lubricants
application lubricant remarks
O-ring sealsstationaryormoving
Silicone greasePartsno.: 00 027 081Tube
Apply sparingly to parts
Diaphragm clamping area
Screwed connections and fastening screws in the housing
Slidingsurfacesofvalvestems,sliding guides,spindle bushes
MovingpartsinSSVactuatorsandtrippingdevices,Switching bushes,Switching balls and drums,Ball bearings
Valvesleevesandvalvessleevesealsingaspressure regulators
Unisilicone grease TK 44 N2Part no.: 00 027 052Pack
Setpointadjustmentscrews(drivescrews)Threadmaterialcombination:AL/AL
Anti-seize AS450Parts no.: 00 027 091Pack
Devicesforoxygen
Lubricating oilParts no.: 00 026 562Lubricating pasteParts no.: 00 026 563
Devicesforammonia Fluorosilicone greaseParts no.: 00 027 660 Apply sparingly to parts
Pleaserefertospecificdetailsinthemaintenanceinstructions! Hinweisnote
16
General operatinG instructions
General operating instructions
6. installation tools
installation tools
device type tool stock no.
RMG 330 Regulating assembly 1RMG 361 Regulating assembly 1
Outlet pressure adjustment0.02 to 0.5 bar
00 02 65 02
Outlet pressure adjustment0.5 to 1.0 bar
10 00 49 11
RMG 300RMG 835
Outlet pressure adjustmentSRVadjustment
10 00 42 54
RMG 408 Installation tools 10 00 78 95
Safetyshut-offdevicefor RMG 300, RMG 330, RMG 332, RMG 340, RMG 345, RMG 361, RMG 370, RMG 408Safetyshut-offvalve(SSV)RMG 720
SSVadjustingwrench 10 00 49 12
SSVRMG720K4,K5,K6 Tee wrench 10 00 85 82
SSVRMG720DN150SSVRMG721DN50-150
Tee wrench 10 00 87 90
RMG361/RMG370DN 25 and DN 50
Bolt+installationtoolSSV 15 80 14 21
RMG361/RMG370DN 80 and DN 100
Bolt+installationtoolSSV 15 80 14 22
RMG 361 Regulating assembly 1RMG 370 regulating assembly 1
Leakage gas adjusting wrench 15 80 12 46
RMG 402 InstallationtoolforSSVo-ring 10 03 00 34
RMG 512 b
Installation cone DN 25DN 50DN 80
DN 100
10 00 22 1810 01 35 4719 08 18 4310 01 36 47
17
General operatinG instructions
General operating instructions
installation tools
device type tool stock no.
RMG 265RMG 267, RMG 268RMG 630 to RMG 630-1 (640)RMG 650 to RMG 659RMG 670, RMG 671
Installation tools 19 08 33 19
RMG 710 DN 25 to DN 150RMG 711 DN 200 to DN 300RMG 721 DN 50 to DN 150
Checkingdevicewithadapterfor manual release adjustment
10 00 19 35
Mounting screw M4 (2x) 10 00 07 16
Jig for manual release adjustment and solenoid release setting
10 00 19 43
RMG 672K10, K10a, K11, K11aK12, K13, K14
Jig for actuators 10 00 19 47
RMG 672K12, K13, K14
AllankeyforSSVadjustment 00 02 62 66
RMG 790
Adjusting wrench 10 00 82 99
Testvessel 87 90 90 00
RMG 530DN 200 to DN 300
Mountingsleeveforsealingring 10 02 44 34
RMG 530DN 50 to DN 300
Slip-on bushing for motor shaft 18 35 71 99
Note:Thislistdoesnotclaimtobeexhaustive!
18
General operatinG instructions
General operating instructions
additional rmG publications
Forfurtherinformationaboutgaspressureregulatorsandsafetydevices,pleaserefertothefollowingpublicationsin addition to the general operating instructions:
General brochure
- Technical product information -
Contents: TECHNICAL DATA Dimensions and connections Design and operation Installation Devicedesign Ordering information
manual and maintenance/spare parts
Contents: Specificoperationalhintsandtips Maintenance instructions Spare part drawing Spare parts list
19
General operatinG instructions
General operating instructions
rmG booklet
Contents: Products from the entire RMG GROUP Important technical data for RMG gas pressure regulators
incl.flowparameters,settingranges,accuracyclassesandlock-uppressureclasses ImportanttechnicaldataforRMGsafetydevices
incl. setting ranges and accuracy groups
05/2009 GeneralOperatingInstructionsWereservetherighttomaketechnicalchanges
WÄGAWärme-Gastechnik GmbHOsterholzstraße 45D-34123 KasselTel: +49 (0)561 5007-0Fax: +49 (0)561 5007-207
RMG Gaselan Regel + Messtechnik GmbHJulius-Pintsch-Ring 3D-15517 FürstenwaldeTel: +49 (0)3361 356-60Fax: +49 (0)3361 356-836
CANADA
Bryan Donkin RMG Canada Ltd.50ClarkeStreetSouth,WoodstockOntario N4S 7Y5, CanadaTel: +1 519 53-98531Fax: +1 519 53-73339
USA
Mercury Instruments LLC3940VirginiaAvenueCincinnati, Ohio 45227Tel: +1 513 272-1111Fax: +1 513 272-0211
GERMANY
RMG Regel + Messtechnik GmbHOsterholzstraße 45D-34123 KasselTel: +49 (0)561 5007-0Fax: +49 (0)561 5007-107
RMG Messtechnik GmbHOtto-Hahn-Straße 5D-35510 ButzbachTel: +49 (0)6033 897-0Fax: +49 (0)6033 897-130
ENGLAND
Bryan Donkin RMG Gas Controls Ltd.EnterpriseDrive,HolmewoodChesterfieldS425UZ,EnglandTel: +44 (0)1246 50150-1Fax: +44 (0)1246 50150-0
POLAND
Gazomet Sp. z o.o.ul. Sarnowska 263-900 Rawicz, PolandTel: +48 (0)65 545 0200Fax: +48 (0)65 546 2408
You can count on RMG to provide expertise along thewhole gas supply chain, from exploration to supplying the end user. Our reliable products and systems offer you complete control over your instrumentation, safetyandcontrolequipment.
We also design and build stations according to yourrequirements and provide reliable, contemporarysolutions to station automation.Pleasecontactus–wethriveonchallenge!
www.rmG.com
servinG tHe Gas industry worldwide