Dungs FRM-NOC Instruction Manual
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Dungs FRM-NOC Instruction Manual

Medium pressure regulator
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Instruction manual
FRM-NOC

1 Target group

This manual is intended for personnel qualified in gas
safety and regulation technology, as well as personnel
trained or instructed by them.
The former are in a position to judge the work assigned
to the latter on the basis of their technical training,
knowledge and experience, as well as knowledge of the
relevant regulations, and are able to recognise potential
dangers. Only they are permitted to carry out assembly,
commissioning, settings and maintenance on the devices
in compliance with the recognised rules for occupational
safety.

2. Warnings

2.1 General warnings

The recognised occupational safety
rules and accident prevention
regulations must be observed and,
if necessary, personal protective
measures must be taken.
All adjustments and settings should
only be performed in accordance
with the instruction manuals of the
connected machines.
Never carry out work as long as gas
pressure or voltage is applied. Avoid
naked flames. Please observe public
regulations.
Prior to assembly, the device must be
inspected for transport damage.
The device must not be exposed to
naked flames. Protection against
lightning strikes must be guaranteed.
Connected line systems must be free
from dirt and contamination.
1 ... 72
Hang this instruction manual in a clearly visible
place inside the installation room! Do not carry out
any work until you have read the safety instructions
of this instruction manual and are qualified to do so.
Protection from environmental
impacts and weather conditions
(corrosion, rain, snow, icing,
humidity (e.g. by condensation),
mould, UV radiation, harmful insects,
poisonous, corrosive solutions/liquids
(e.g. cutting and cooling fluids), must
be guaranteed. Depending on the
installation site, it may be necessary
to take protective measures.
The device may only be operated
in compliance with the operating
conditions stated on the type plate.
The device must be protected from
vibrations and mechanical impacts.
The device must not be used in areas
with increased seismic risk.
Explanation of the symbols
1, 2, 3,... =
•
Act based on
the sequence
=
Instruction

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  • Page 1: Target Group

    Instruction manual FRM-NOC 1 Target group This manual is intended for personnel qualified in gas safety and regulation technology, as well as personnel trained or instructed by them. The former are in a position to judge the work assigned to the latter on the basis of their technical training,...

  • Page 2: Designated Uses

    2.2 Designated use The device is used in accordance with its designated use • Use only in compliance with the operating conditions if the following instructions are observed: stated on the type plate. • Use of the device in gas transport and gas distribution •...
  • Page 3 Produkt / Product FRM-NOC 100... Medium Pressure Regulator 10 bar Produit / Prodotto Hersteller / Manufacturer Karl Dungs GmbH & Co. KG Fabricant / Produttore Karl-Dungs-Platz 1 D-73660 Urbach, Germany bescheinigt hiermit, dass die in dies- certifies herewith that the products certifie par la présente que le...

  • Page 4: Table Of Contents

    EU Approval/statement of conformity Contents Abbreviations Features Technical data Nomenclature Adjustment ranges Accuracy class / closing pressure class Selection of regulating spring 6.5.1 For FRM-NOC 10010/10015/100025 6.5.2 For FRM-NOC 10020/100040/100050 Selection of spring SAV Type plate Function Dimensions Assembly/installation General information Assembly instructions Tightening torques 10.

  • Page 5: Abbreviations

    15. Spare parts 15.1 Regulatory list of spare parts 15.2 List of spare parts SAV 15.3 Storage conditions 16. Tables of flow diagram 16.1 Tables of flow diagram AC 10 explanation 16.2 Valve flow coefficient K 5. Abbreviations Abbreviation Description Accuracy class of the upper response pressure Accuracy class of the lower response pressure Accuracy class...

  • Page 6: Features

    6. Features 6.1 Technical data Technical data FRM-NOC Device Medium pressure regulator with spring loading in accordance with EN 334 Type of construction DSDS Type of gas Family 1+2+3 Nominal diameters Connecting flanges PN 25 in accordance with EN 1092-1 or ANSI 150 lbs (B16.5)

  • Page 7: Nomenclature

    6.2 Nomenclature Example FRM 100025 ND / SAV ND FRM-NOC 100 025 Type Medium pressure regulator spring-loaded 100 … 10 000 mbar Nominal diameter 1" 1 1/2" 2" DN 25 DN 40 DN 50 Outlet pressure ranges Low pressure Medium pressure...

  • Page 8: Adjustment Ranges

    10 % 10 % FRM-NOC 10010 HD 10 % 300-1500 mbar FRM-NOC 10010 UHD 10 % 1000-4000 mbar FRM-NOC 10010 ND / SAV ND 10 % 20 % 20-100 mbar 10-115 mbar 10 % 40-240 mbar 10 % FRM-NOC 10010 MD / SAV MD...

  • Page 9: Accuracy Class / Closing Pressure Class

    6.4 Accuracy class / closing pressure class AC and SG data according to EN 334 do not constitute The AC values of the above table refer to the maximum a declaration with respect to the modulation range. For possible percentage deviation of the output pressure field use it is important to know the minimum and maxi- from the adjusted set-point, in which Q ≥...

  • Page 10: Selection Of Regulating Spring

    6.5 Selection of regulating spring 6.5.1 For FRM-NOC 10010 / 10015 / 100025 Outlet pressure adjustment range W Spring Item Nº Wire diameter Diameter Length Adjustment range [mbar] colour [mm] [mm] [mm] 287881 20-35 White 287882 30-50 Yellow 287883 50-75...

  • Page 11: Selection Of Spring Sav

    6.6 Selection of spring SAV Specific adjustment range under pressure W Spring colour Item Nº Wire diam- Length Diameter Adjustment range [mbar] eter [mm] [mm] [mm] White 270353 10.0 10-32 Yellow 270355 12.3 24-40 Blue 270356 12.3 30-115 35-110 Black 270357 12.3 50-250...

  • Page 12: Type Plate

    6.7 Type plate FRM + SAV Made in Barcelona / Spain 0085 DIN EN334 / DIN EN14382 CE-0085CP0256 FRM-NOC 100050/SAV MD S.N.: 1PDK279082S00000000 Orifice: 12 mm fail-open SG DN50 PN 25 2019-01-28 -20T60 10 bar / 1000 kPa Pin: 0,44 - 10 bar / 44 - 1000 kPa...

  • Page 13: Function

    7. Function The pressure regulator has the task of maintaining con- When the outlet pressure drops, the force on the work- stant outlet pressure despite fluctuations in inlet pressure ing membrane F on the underside of the membrane C is and/or flow.
  • Page 14 Type UHD Type HD 14 … 72...
  • Page 15 ND for G1", G1,5" y DN25 ND, MD for G2", DN40, DN50 15 … 72...

  • Page 16: Dimensions

    8. Dimensions FRM-NOC... Option external line: Only on request. * Ermeto screw connection 12L: GE 12 - 1/4 with screw connection M16 for pipes 12 x 1.5 16 … 72...
  • Page 17 Item Nº Dimensions [mm] Wgt. Type max. [bar/kPa] [kg] FRM-NOC 10010 ND 279054 280236 10 / 1000 1" -240 1/2" G 1/4" G FRM-NOC 10010 MD 279055 280237 10 / 1000 1" -240 1/2" G 1/4" G FRM-NOC 10010 HD...
  • Page 18 FRM-NOC... / SAV Option external line: Only on request. * Ermeto screw connection 12L: GE 12 - 1/4 with screw connection M16 for pipes 12 x 1.5 18 … 72...
  • Page 19 Item Nº Dimensions [mm] Wgt. Type max. [bar/kPa] [kg] 1/2" G 1/4" G FRM-NOC 10010 ND /SAV ND 279042 280224 10 / 1000 1" FRM-NOC 10010 MD /SAV MD 279043 280225 10 / 1000 1" 1/2" G 1/4" G FRM-NOC 10010 HD /SAV HD...

  • Page 20: Assembly/Installation

    9. Assembly/installation 9.1 General information • The performance data on the type plate correspond to • This device should only be installed in the ordering data. compliance with the applicable rules • Flanges on the inlet side and outlet side of the con- and standards and in accordance with necting line are parallel.

  • Page 21: Assembly Instructions

    9.2 Installation instructions • The installation must be carried out according to the • Maximum flow velocity in the stabilisation section: installation scheme specified below. ≤ 30 m/s. • Installation of the safety shut-off valve in the flow • (Version of the pulse lines: steel pipe D= 12 x 1.5, only direction (arrow/housing).
  • Page 22 Mounting position 9.3 Torques Use adequate tools! Tighten the screws crosswise! The device must not be used as lever. max. FRM-NOC... max. max. ⅜ ¾ 1 1/2 2 1/2 1600 2400 5000 6000 7600 max. [Nm] t 10 s max.

  • Page 23: Function Sav

    10. Function SAV The SAV protects downstream components against pres- sures that are too high or too low. Automatically interrupts the flow of gas, as soon as the pre-set triggering pressure falls below or exceeds a limit due to a fault. Under normal operating conditions the SAV is open.

  • Page 24: Adjustment

    11. Adjustment 11.1 Adjusting the regulator Adjusting the outlet pressure (type UHD) The regulator is adjusted by turning the adjustment screw 1. Remove the protective cap A. 2. Turn the external adjusting screw B using the spanner size 24. 3. Clockwise rotation: Increases the initial tension of the adjustment spring, thus increasing (+) the outlet pres- sure p 4.
  • Page 25 Adjusting the outlet pressure (type HD and ND,MD for 1", 1 1/2" i DN25) The regulator is adjusted by turning the adjustment screw B. 1. Remove the protective cap A. 2. Turn the external adjusting screw B using the Allen key size.
  • Page 26 Adjusting the outlet pressure (type ND,MD for 2", DN40 i DN50) The regulator is adjusted by turning the adjustment screw B. 1. Turn the adjusting screw B using the spanner size 2. Clockwise rotation: Increases the initial tension of the adjustment spring, thus increasing (+) the outlet pres- sure p 3.

  • Page 27: Adjusting The Sav

    11.2 Adjusting the SAV Setting the over pressure trip point 1. Remove the protective cap A. 2. Turn the external adjusting screw B using the socket wrench size 22. 3. Turning clockwise: increases (+) the upper shut-down pressure p 4. Turning counter-clockwise: reduces (-) the upper shut- down pressure p 5.

  • Page 28: Example Of Calculations Of Adjustment Values

    11.3 Example of calculations of adjustment values Determination of the setting values by means of a pressure graduation table Regulator chosen FRM-NOC 100025 MD / SAV MD Outlet pressure of the regulator p 200 mbar System-specific operating pressure after the regulator p...

  • Page 29: Regulating Spring Replacement

    11.4 Regulating spring replacement 11.4.1 Type UHD Unscrew adjustment screw E: Unscrew the adjust- Remove the protective cap A. ing nut B counterclockwise as far as it will go. (–) Remove from the spring housing F the shut-off cover C using a hook wrench 90-155. Remove the cap C.
  • Page 30 Remove the adjustment spring E from the spring chamber F. Remove the disc from the spring D incl. ball. 7. Insert a new spring with the appropriate adjustment range. 8. Place the disc D with the ball back on the spring 9.

  • Page 31: Type Nd, Md For 1", 1 1/2", Dn25 And Type Hd

    11.4.2. Type ND, MD for 1", 1 1/2", DN25 and type HD Release the setpoint spring E: Completely loosen adjusting nut B counterclockwise. Remove the protective cap A. Remove the adjusting nut B. Remove the washer D. 31 … 72...

  • Page 32: Type Nd, Md For 2", Dn40 And Dn50

    6. Insert a new spring with the appropriate adjustment range. 7. Place the washer D back on the spring. 8. Screw the adjusting nut B back into the spring dome until the desired initial spring tension is reached. Re-fit the protective cap A. Remove the adjustment spring E from the spring chamber F.
  • Page 33 Remove the adjustment spring E from the spring Remove the disc from the spring D incl. ball. chamber F. 5. Insert a new spring with the appropriate adjustment range. 6. Place the disc D with the ball back on the spring. 7.

  • Page 34: Spring Replacement Sav

    11.5 Spring replacement SAV Remove the protective cap A. 11.5.1 Spring replacement W (–) Unscrew the adjusting spring B from the spring dome G using an open-ended wrench 22. 34 … 72...

  • Page 35: Spring Replacement W

    1. Remove the spring E from the spring dome G. 2. Install new spring. 3. Tighten the adjust- ing screw B and the washer D in the spring dome using an open-ended wrench size 22 until the required spring preload is reached. Remove the white plastic washer D.
  • Page 36 1. Remove the spring F from the spring dome. 2. Install new spring. 3. Tighten the adjust- ing screw C in the spring dome H using a spanner size 17 until the de- sired spring preload is reached. Screw on the protective cap A again. 36 …...

  • Page 37: General Information

    12. Commissioning and Decommissioning 12.1 General information Prior to commissioning • The performance data on the type plate must correspond to the ordering data. • Prevent explosive gas-air mixture: the room atmosphere must constantly be monitored using appropriate gas concentration measuring devices for the detection of gas leakages. •...

  • Page 38: Commissioning/Unlocking/Control Of Adjustment Values

    12.3 Commissioning/unlocking/control of adjustment values 1. Slowly open the shut-off valve on the inlet side. The ball wrench on the outlet side remains closed. 2. Monitor the pressure increase upstream of the device with the pressure gauge on the inlet side. 3.
  • Page 39 6.0 Checking the upper shut-down pressure p 7.0 Check the lower shut-down pressure p 6.1 Assembly of the SBV on the outlet side: 7.1 Release the pressure in the test section on the outlet Block the line upstream of the SBV. side until the operating pressure is reached.

  • Page 40: Recommissioning

    The adjustment springs are not suitable for the application. Replace the adjusting spring. The valve head is damaged or worn. Replace the ASE or have it repaired by DUNGS. The seat of the valve is damaged. Replace the valve seat.
  • Page 41 Fault in the Possible causes Troubleshooting regulator Check the gas installation prior to the The regulator is not receiving gas. regulator. There is no gas The SAV is closed. Unlock the SAV. The regulator contains a spring with the wrong set point. Replace the set point spring.

  • Page 42: Maintenance

    14. Maintenance 14.1 General information Pos. Designation • The Pressure Equipment Directive (PED) requires the devices to be Protective cap checked at regular intervals to ensure Adjusting screw + washers the following in the long term: Safety Sealing plug and functioning of the device, high long-term utilisation ratios, resulting Spring disc with ball in minimum environmental impact.
  • Page 43 Type UHD 43 … 72...
  • Page 44 Type ND, MD for 1", 1 1/2" and DN25 and type HD 44 … 72...
  • Page 45 Type ND, MD for 2", DN40, DN50 45 … 72...

  • Page 46: Regulatory Maintenance Instructions

    14.2 Regulatory maintenance instructions 14.2.1 Preparation Follow the steps shown in section 11.4 to extract the regulating spring. 14.2.2 Replace working membrane 14.2.2.1 Type UHD Loosen the screws G using an Allen key size 5. Remove the upper membrane cover F. 46 …...
  • Page 47 Loosen the nut J (M 8) using a spanner size 13. Remove the disc from the spring K. Remove the working membrane M from the guide rod N. Check the condition of the working membrane. If necessary, use a new working membrane M (maintenance set 20 or 24 as Remove the safety spring L.

  • Page 48: Type Nd, Md For 1", 1 1/2", Dn25 And Type Hd

    14.2.2.2 Type ND, MD for 1", 1 1/2", DN25 and type HD Loosen the screws G using an Allen key size 5. Replace the O-ring H. Remove the upper membrane cover F. Remove the washer Z2. 48 … 72...
  • Page 49 Loosen the nut J using a spanner size 13 (15 for 1", 1 1/2" and DN25 ND and MD). Remove the safety spring L. Remove the working membrane M from the guide rod N. Check the condition of the working mem- brane.

  • Page 50: Type Nd, Md For 2", Dn40 Y Dn50

    14.2.2.3 Type ND, MD for 2", DN40 and DN50 Loosen the screws G using an Allen key size 5. Remove the upper membrane cover F. Loosen the nut J using a spanner size 13. Remove the disc from the spring K. 50 …...
  • Page 51 Remove the working membrane M from the guide rod N. Check the condition of the working membrane. If necessary, use a new working membrane M (maintenance set 21 or 22 as appropriate) when reassembling. Remove the safety spring L. Replace the O-ring H. 51 …...

  • Page 52: Replace Valve Seat

    14.2.3 Replace valve seat 14.2.3.1 Type UHD Remove the screws O from the body X using Loosen the pulse line outlet of the SAV with a spanner size 13 (1", 1 1/2", DN25) or 17 a spanner measuring 14. (2" DN40, DN50). Replace the O-ring Q.

  • Page 53: Type Nd, Md For 1", 1 1/2", Dn25 And Type Hd

    Screw a new valve seat V of the desired size with Replace valve seat V: Unscrew from the body X the a new O-ring W (maintenance set 3, 4, 5, 6 as re- valve seat V using the socket wrench. quired) onto the body X.
  • Page 54 Remove the regulator hood P from the body X. Replace the O-ring Q. Replace valve seat V: Unscrew from the body X the Remove the seal assembly S. valve seat V using the socket wrench. 54 … 72...
  • Page 55 Screw a new valve seat V of the desired size with a new O-ring W (maintenance set 3 or 4 as required) into the body X. 14.2.3.3 Type ND, MD for 2", DN40 and DN50 Loosen the pulse line outlet of the SAV with Remove the screws Y from the body X using a spanner measuring 14.
  • Page 56 Replace valve seat V: Unscrew from the body X the valve seat V using the socket wrench. Remove the regulator hood P from the body X. Screw a new valve seat V of the desired size with a new O-ring W (maintenance set 5 or 6 as required) onto the body X.
  • Page 57 14.2.4 Replace seal 14.2.4.1 Type UHD Loosen the nuts R. Remove the R nuts. Remove the fastening screwsT from the lever set with a size 4 Allen key. Remove the U clamping plates from the lever set. 57 … 72...
  • Page 58 Remove the lever set I. Remove the bottom cover O. Replace seal assembly S (maintenance set 8, 11, 13 or 16 as required). Replace the O-ring Q. 58 … 72...
  • Page 59 14.2.4.2 Type ND, MD for 1", 1 1/2", DN25 and type HD See section 14.2.3.2, steps 1 to 5 and replace with maintenance kit 7, 8, 10, 12, 13 as appropriate). 14.2.4.3 Type ND, MD for 2", DN40 and DN50 Remove the fastening screws T from the lever set with a size 5 Allen key.
  • Page 60 Remove the lever set I. Remove the bottom cover O. Replace seal assembly S (maintenance set 9, 14, 21 or 22 as required). 60 … 72...

  • Page 61: Maintenance Sav

    14.3 Maintenance instructions SAV Pos. Designation Diaphragm shell Push rod O-ring diaphragm shell Lower diaphragm disc Working diaphragm Bottom locking pressure adjustment spring Upper diaphragm disc (only in the version HD) Allen screws, 6 units. Spring dome ASE Top locking pressure adjustment screw Bottom locking pressure adjustment screw Protective cap ASE housing...

  • Page 62: Preparation

    14.3.1 Preparation (–) (–) 1. Loosen the pulse lines and the vent lines and remove them. 2. Remove the protec- tive cap L. 3. Release the adjusting springs at the adjust- ing screws J and K. 14.3.2 Separate the ASE from the body Loosen the four hexago- nal socket grub screws Remove the ASE Q from...

  • Page 63: Assembly Of The Ase On The Body

    Remove the ASE Q. 14.3.3 Mounting the ASE on the body Insert a new O-ring N (maintenance set 4 or 5) into the groove provided in the housing M. Screw the thread of the connecting piece O onto the body M using a hook wrench 60-90. Fix the connecting piece O of the ASE Q using 4 hexagonal socket grub screws P (M5x8).

  • Page 64: Tools Required

    14.4 Tools required 64 … 72...
  • Page 65 Wrench size Pressure Work step Tool designation rating DN 25 DN 40 DN 50 Loosen the pulse line. Open-ended wrench (A) ND/MD/HD Socket wrench (B) Release the adjusting springs. ND/MD/HD Socket wrench (B) Internal hex key (C1) Separate the ASE from the ND/MD/HD Jointed hook wrench with pins according to body...

  • Page 66: Leakage Test

    14.5 Leakage test After carrying out maintenance or repair work, check the device for internal and external leakages. 1. Test gas of the leakage test: air or inert gases. 2. Upstream and downstream shut-off valves must be closed. 3. Test pressure > blow-off pressure SBV: Block the line upstream of the SBV.
  • Page 67 15. Spare parts 15.1 Regulatory list of spare parts Spare part/ Spare part Version Item Nº illustration FRM-NOC10010/12/025 ND/MD TOP COVER ALUMINI CAP 287754 FRM-NOC10010/15/20/025/040/050 HD TOP COVER UHD FRM-NOC100XXX UHD 270396 FRM-NOC10010/15 XX 287755 SHELL M.22 + O-RING FRM-NOC100025 XX 287756 SHELL M.30 + ORING FRM-NOC10020/040XX...
  • Page 68 Spare part/ Spare part Version Item Nº illustration MEMBRANE(1000411) 10/15/25 ND + FRM-NOC10010/15/025 ND 287769 MEMBRANE JOINT MEMBRANE(1000412) 10/15/25 MD + FRM-NOC10010/15/025 MD 287770 MEMBRANE JOINT MEMBRANE(1000413) 10/15/25 HD + FRM-NOC10010/15/025 HD 287771 MEMBRANE MEMBRANE(1000414) 10/15/25 UHD + FRM-NOC10010/15/025 UHD 287772 MEMBRANE JOINT MEMBRANE(1000421) 20/40/50 ND +...
  • Page 69 15. 2 List of spare parts SAV Spare part Version Item Nº Spare part/illustration Protective FRM-NOC 278005 FRM-NOC10010/15ND 287777 FRM-NOC10010/15MD 287778 FRM-NOC10010/15HD/UHD 287779 FRM-NOC10020/040ND 287780 FRM-NOC10020/040MD 287781 ASE WITH FRM-NOC100025ND 287783 O-RING FRM-NOC100025MD 287784 FRM-NOC100025HD/UHD 287785 FRM-NOC100050ND 287786 FRM-NOC100050MD 287787...
  • Page 70 Do not exceed the max. storage periods of 3 years. • Stress condition of the component 16. Flow diagram 16.1 Flow diagrams AC 10 explanation Flow diagram AC10: Please, refer to document number. 288127 “Flow diagrams FRM-NOC”. SZ10 +10% -10%...
  • Page 71 The maximum flow rate indicated refers to natural gas with a density of 0.81 kg/m or to the air with a density of 1.24 kg/m at 15 °C under normal conditions. In the case of different types of gases, a conversion of the volume flow according to the equation shown below is carried out.
  • Page 72 N/A not applicable We reserve the right to make modifications in the course of technical development. Company address: Subsidiary: Karl Dungs, S.L.U. Karl Dungs GmbH & Co. KG Karl-Dungs-Platz 1 Av. Can Roqueta 15 D-73660 Urbach, Pol. Ind. Can Roqueta...

This manual is also suitable for:

Frm-noc 10010 ndFrm-noc 10010 mdFrm-noc 10010 hdFrm-noc 10010 uhdFrm-noc 10010 nd / sav ndFrm-noc 10010 md / sav md ... Show all

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