Allg.Betriebsanleitung_GB_2009_01

General operating instructions


for rmG Gas pressure reGulators and safety devices

rmG regel + messtechnik GmbH

servinG tHe Gas industry worldwide

2

General operatinG instructions


3



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



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



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



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



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



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



Discharge line

Discharge line

Discharge line

Pilot

Pilot

Release line

Release line

Release line

Outlet shut-offvalve



DN

F

LuR LuR*

DN

F

LuR LuR*

Bleed line

Bleed line

Return line

Return line

9



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



10



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



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



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



4.2 pilot-operated gas pressure regulators (with auxiliary power)



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



4.3 Safety shut-off valves



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



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



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



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



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



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

Documents

Allg.Betriebsanleitung_GB_2009_01