Fisher RB Series Regulating System (Asia Pacific Only) Manuals & Guides

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Page 1

Instruction Manual

D103251X012

December 2018

RB Series

Regulating System

Page 2

RB Series Regulating System

Contents

1. Introduction ........................................................3

2. Technical Data and Features ..........................................3

3. Structure and Principle of Operation ...................................4

4. Selection of Spring ..................................................5

5. Flow Chart (SCMH) ..................................................5

6. Installation .........................................................5

7. Usage .............................................................7

8. Maintenance .......................................................8

9. Assembly and Disassembly Points to Note ..............................9

10. Ordering Guide ................................................... 12

WARNING

Failure to follow these instructions or to properly install and maintain this equipment could result in an explosion, fire and/or chemical contamination causing property damage and personal injury or death.

Jeon regulators must be installed, operated and maintained in accordance with federal, state and local codes, rules and regulations and Emerson Process Management Regulator Technologies, Inc. instructions.

If the regulator vents gas or a leak develops in the system, service to the unit may be required. Failure to correct trouble could result in a hazardous condition.

Installation, operation and maintenance procedures performed by unqualified personnel may result in improper adjustment and unsafe operation. Either condition may result in equipment damage or personal injury. Call qualified personnel when installing, operating and maintaining the RB Series regulating system.

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RB Series Regulating System

1. Introduction

RB Series (wall-mountable) regulating box can be deployed for natural gas distribution system in the residential or in the commercial

market segment. It can be used for gas services including natural gas, manufactured gas and liqueed petroleum gas, etc.

The basic types include Types RB, RBT, RBQ and RBQT.

R X □ / 0.4 □ □

Internal codes (RB, RBT, RBQ and RBQT) Structure types (A - 1+0; B - 1+1; C - 2+0). See Table 1 for dimensions. Maximum inlet pressure (MPa)

Rated ow

Gas Regulator Box

Figure 1. RB Series Regulating System

Box Body

RB1+0

Backplate

Connecting Bolt

RBQ1+0

RBT1+0

Figure 2. RB Series Parts

Box Body

2. Technical Data and Features

Inlet Pressure Range (P1)

Outlet Pressure Range (P2)

Regulating Accuracy : Up to AC 5

Lockup Accuracy: Up to SG 10

Slam-shut Accuracy: Up to AC5

Temperature Capability

Body Size and End Connection: See Table 1

(1)

: 0.02 to 0.4 MPa / 2.9 to 58.0 psig

(1)

: 1.5 to 30 KPa / 0.22 to 4.35 psig (See Table 2 for available spring ranges)

(1)

: -20 to 60°C / -4 to 140°F

Filtration Module

Regulator Module

Pressure Measuring Nipple

Connecting bolt

Outlet Ball Valve

Inlet Ball Valve

RB1+1 RB2+0

RBQT1+0

Box Body

Bellow

Features:

•Modular design

•Filter system

•Automatic overpressure micro relief

•High-accuracy 2-stage regulator

•Designed for ease of operation and maintenance

•“Loose” inlet/outlet flange connections

•Automatic overpressure shut off

1. The pressure/temperature limits in this Manual and any applicable standard or code limitation for valve should not be exceeded.

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RB Series Regulating System

Table 1. RB Series Body Size and End Connection

STRUCTURAL

MODEL

RBT

RBQ

RBQT

Type RBT is added with bypass connection ports based on RB1+0, with G threaded connection. Type RBQT is added with bypass connection ports based on RBQ1+0, with quick-action coupling acc. to GB/T 5860 or ISO 7241-1.

Note: If you have demands for products with nominal ow higher than 100 SCMH or other special requirements, please contact Emerson Process Management Regulator Technologies Inc. authorized agent or sales company.

TYPE

1+0 25/40 25 25

1+0 50/80/100 25 40 10

1+1 25/40 25 25 35

1+1 50/80/100 25 40 43

2+0 25/40 25 25 35

2+0 50/80/100 25 40 43

1+0 25/40 25 25 15 15 13

1+0 50/80/100 25 40 15 25 16

1+0 25 25 25

1+0 50/80/100 50 50 16

1+0 25 25 25 15 15 15

1+0 50/80/100 50 50 15 25 20

NOMINAL

FLOW,

SCMH

INLET

FLANGE,

OUTLET

FLANGE,

BYPASS

INLET,

N/A N/A

BYPASS

OUTLET,

NET WEIGHT

OF REGULATOR

BOX, kg

CENTER DISTANCE OF

INLET AND OUTLET

FLANGES, mm

155

280/3001+0 40 40 40 14

3001+0 40 40 40 15 15 18

according to

HG20592 PN16

3. Structure and Principle of Operation

RB Series regulator box consists of inlet and outlet ball valves, ltration module, regulator module and box body (see Figures 1

and 2). The regulator module includes shut off, 1st stage regulation, 2nd stage regulation and micro relief.

Regulator operational concept (See Figure 3): After the gas had gone through the rst stage regulator and had stabilized the

intermediate pressure, it will then go through the second stage regulator. The second stage regulator will reduce the pressure to the desired outlet pressure, P2.

When P2 meets the relief set pressure, the relief valve will open to release the sudden increase in pressure caused by environmental

temperature uctuations or other factors. This is to prevent “false shutoff” or accidental trip by the slam-shut valve when there

is a sudden erratic increase in pressure and to maintain the pressure at the setpoint, P2.

When the slam-shut valve registered P2 is higher than the set pressure, the latching mechanism is released and the spring will

assist to close speedily and to seal tightly the slam-shut orice with the pad. This will cut off the ow in the valve and prevent

damages to downstream equipment.

Upon correcting the cause of overpressure, pull and latch the reset bar to allow normal ow operation again.

FLANGE

STANDARD

Flange connection dimensions

Figure 3. RB Series Operational Schematic

FIRST STAGE ORIFICE

FIRST STAGE REGULATOR

FIRST STAGE DIAPHRAGM

INLET PRESSURE

OUTLET PRESSURE

ATMOSPHERIC PRESSURE

INTERMEDIATE PRESSURE

SLAM-SHUT PAD

SLAM-SHUT VALVE

SLAM-SHUT RESET BAR

FILTRATION MODULE

FILTER ELEMENT

FILTER CAP

SECOND STAGE REGULATOR

REGULATOR ADJUSTMENT SCREW CAP

RELIEF ADJUSTMENT NUT

SECOND STAGE ORIFICE PAD

RELIEF VALVE

REGULATOR CAP

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RB Series Regulating System

4. Selection of Spring

Table 2. Regulator Spring Selection

RANGE OF PRESSURE, kPa WIRE DIAMETER OF SPRING, mm SPRING CODE COLOR

1.5 to 3.3 2.5 JJJJ86CXT01 Galvanized

3.0 to 6.0 2.5 JJJJ86CXT02 Yellow

6.0 to 10.0 2.8 JJJJ86CXT03 Red

9.0 to 15.0 3.0 JJJJ86CXT13 Black

15.0 to 22.0 3.5 ERAA15524A0 Blue

22.0 to 30.0 3.5 ERAA15525A0 White

Table 3. Shut-off Selection

RANGE OF PRESSURE, kPa WIRE DIAMETER OF SPRING, mm SPRING CODE COLOR

2.5 to 5.0 1.2 JJJJ86CXT06 Galvanized

5.0 to 10.0 1.5 JJJJ86CXT07 Yellow

9.0 to 15.0 2.0 JJJJ86CXT08 Red

15.0 to 26.0 2.2 ERAA15381A0 Blue

26.0 to 40.0 2.5 ERAA15382A0 White

WARNING

To avoid personal injury, property damage or equipment damage caused by bursting of pressure containing parts or explosion of accumulated gas, never adjust the control spring to produce an outlet pressure higher than the upper limit of the outlet pressure range for that particular spring. If the desired outlet pressure is not within the range of the control spring, install a spring of the proper range.

5. Flow Chart (SCMH)

Table 4. Flow Chart (SCMH)

NOMINAL FLOW

25 10 22 27 28 29 30

40 12 24 42 43 44 45

50 14 28 52 53 54 55

80 21 40 80 80 80 80

100 30 55 100 120 120 120

0.02 0.05 0.1 0.2 0.3 0.4

INLET PRESSURE, MPa

Notes:

• The values shown above are the ow capacity at 3 kPa outlet pressure setting. For the other outlet pressure setting, there is a very small difference of actual ow capacity.

• Flow capacity are based on 0.61 specic gravity, Natural Gas. If other media is used, multiply the shown data by: 1.17 for

manufactured gas; 0.55 for butane; 0.63 for propane; 0.78 for air; 0.79 for nitrogen.

WARNING

Installation, operation and maintenance performed by non-qualified personnel may result in unsafe operation, equipment damage or personal injury. Call a qualified personnel when installing, operating and maintaining the unit.

6. Installation

The regulator installation and usage must only be carried out by qualied and trained personnel. Otherwise, please contact the

company. The company will not be responsible for any consequences due to non-standard operations/compliance of usage.

1. Install the regulator in ambient temperature, away from sources of re and away from vibrations.

2. Check if the pressure in the pipeline is within the pressure range stated on the regulator nameplate.

3. Make sure that the ow direction of the pipeline matches the arrow stamped on the regulator body.

4. Purge and clean the pipeline before installation.

5. Install the inlet and outlet pipeline end connections 155 mm / 6.10 in. apart (from center to center of pipes). Recommended

pipeline end connections shall be ≥1.2 m / 3.94 ft. above ground level. The ange connection face levelling height tolerance

is 3 mm / 0.12 in.; exceeding this will cause leakage or damage to the regulator. Do not use exceedingly strong force while

connecting the ange ends. Sequentially, tighten the inlet anges before tightening the outlet anges. (Please see Figure

5 for the installation dimensions.)

6. Place a suitable cubage between the regulator and any quick alternating pressure equipment (e.g., burner or solenoid

valve) to prevent any “false shutoff”.

Note: Remove the regulator when the pipeline is undergoing pressure test or purging to avoid damaging the regulator.

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RB Series Regulating System

Figure 4. Slam-Shut Valve Position

FULLY OPEN FULLY CLOSE

Figure 5. Installation Dimensions

Inlet Ball Valve

230

D C

Types: RB/RBT/RBQ/RBQT

Structural Type: 1+0

Outlet Ball Valve

D C

Outlet Ball Valve

230

Inlet Ball Valve

Type: RB

Structural Types: 1+1 and 2+0

Table 5. Installation Dimensions of RB Series of Regulator Box

TYPE

RB 1+0 all 310 40 95 155 194 243 327 84

RB 1+1 all 323 40 85 155 345 500 690 84

RB 2+0 all 323 40 85 155 345 500 690 84

RBT 1+0 all 323 40 74 155 225 300 382 84

RBQ

RBQT 1+0 all 470 113 87 300 270 300 382 84

STRUCTURAL

TYPE

1+0 all 455 113 87 300 194 243 327 84

1+0 all 435 113 87 280 194 243 327 84

NOMINAL

FLOW

A B C D E F G H

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RB Series Regulating System

Figure 6. Outlet Pressure Setting Adjustment

Figure 7. Slam-Shut Setting Adjustment

7. Usage

1. Commissioning Procedure

1. Ensure that the slam-shut valve is in the open position; use the handle to open slightly the outlet ball valve. See Figure 4.

2. Slowly turn the handle counterclockwise to open the ball valve.

3. Momentarily stop until the ow stabilizes.

4. Fully open the ball valve when ow stabilizes.

2. Setting the Outlet Pressure

1. Slowly turn the adjustment screw cap to the desired pressure. (Turning clockwise will increase the outlet pressure while turning counterclockwise will decrease the outlet pressure.) See Figure 6.

2. Ensure that the setpoint is within the spring pressure range or it may damage the regulator.

Note: While the regulator is in operation, do not open the test port valve as it will increase the downstream pressure.

3. Setting the Slam-Shut Pressure

1. Slowly turn the adjustment nut with the handle to adjust and set the desired slam-shut set pressure. (Turning clockwise will increase the set pressure while turning counterclockwise will decrease the set pressure.)

2. Determine the set pressure from the test port valve.

3. Ensure that both inlet and outlet ball valves are in close positions before taking the measurements, then vent the gas inside

the regulator. For safety, as a rule of thumb, the slam-shut module set pressure should not be more than 1.5 times the regulator setpoint.

4. Unscrew the regulator adjustment cap (see Figure 3) if the user would need to vent the pressure of the regulator.

5. Use a size 14 wrench to turn the adjustment nut. (Turning clockwise will increase the setpoint while turning counterclockwise

will decrease the setpoint.) Vent pressure is recommended to be 1.3 times of regulator operating pressure.

Note: Calibrate the slam-shut set pressure by turning the adjustment nut but make sure that it is done when the spring is at the

most relaxed spring length, then slowly compress it to the desired set pressure.

4. Reset the Slam-Shut Valve

1. Check the root cause that activated the valve to shut off.

2. Close the inlet ball valve such that it only allows a small ow into the regulator for a build-up inlet pressure.

3. Close the outlet ball valve such that it only allows a small ow through the regulator (or completely close the regulator outlet valve and slightly open the test port valve to allow a small outlet ow).

4. Pull the “Reset Bar” until a small ow through the regulator is achieved and maintain the ow at that.

5. Wait until the pressure is balanced before and after the slam-shut valve. However, if there is resistance while pulling the “Reset Bar”, stop pulling. If the regulator does not work normally, close both the inlet and outlet ball valves and diagnose the root cause of the problem. If the regulator operates normally, pull the “Reset Bar” (there shall be no resistance while pulling) until it is latched

on again.

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RB Series Regulating System

6. Slowly open the inlet and outlet ball valves, respectively. After troubleshooting, reset the slam-shut valve, then slightly open the outlet ball valve and then the inlet ball valve and observe if the regulator is back to normal operation. If the regulator resumes normal operation, fully open both the inlet and outlet ball valves.

Notes:

• Do not attempt to reset the slam-shut valve with fully open inlet and outlet ball valves. Doing so may cause personal injury

and damage to the regulator.

• RB Series regulating box has OPSO shut-off protection. If need UPSO shut-off protection, please contact an authorized agent

or sales company authorized by Emerson Process Management Regulator Technologies Inc.

8. Maintenance

1. General maintenance

1. Ensure that the inlet and outlet ball valves are in close position before any maintenance of the regulator is carried out. Verify

also that the slam-shut valve is in the open position.

2. Open the test port valve to relieve the pressure in the regulator. Make sure not to damage the diaphragm orices and other

components of the regulator while disassembling and assembling.

3. While assembling the moveable parts, ensure that the parts remain functional.

4. After re-installation of the valve, restore the regulator to the required setpoint prior to maintenance.

5. Ensure all end connections are tightly sealed and without leakage.

Our company provides training for maintenance personnel. For further enquiries, please contact our company’s service

department or authorized representatives.

2. Routine maintenance

Routine Maintenance checks should be done by the user’s managing department for regulators. The duration in between the checks should be determined by the user depending on the weather and usage parameters to ensure safe operations:

1. Use a gas detection equipment (or do “bubble check”) to detect any leakage.

2. Check the readings on the pressure gauge for the corresponding outlet pressure.

3. Clean the externals of the regulator.

3. Regular maintenance

Maintenance content: selective checks depending on the actual situation.

1. Regular operational pressure check:

a. Connect a pressure gauge at the test port of the regulator.

b. Open the test port valve and then slowly close the regulator outlet ball valve.

c. Wait for 3 minutes and record the reading on the gauge.

d. Check if the pressure reading is within the operational range. If the reading falls within the operational range, there is no

need to proceed to the next steps of the maintenance instructions.

Figure 8. Box Cover Removal

BOX COVER

BACK OF BOX

Figure 9. Slam-Shut Parts

RESET BAR NUT

SLAM-SHUT BONNET

RESET SHAFT

ADJUSTMENT NUT

CLAMPING NUT

SLAM-SHUT DIAPHRAGM

SLAM-SHUT LOWER CASE

SLAM-SHUT

BOX BRACKET

ORIFICE PAD

BALL BEARING

Page 9

Figure 10. First Stage Regulator Parts

PRESS AND HOLD

RB Series Regulating System

FIRST STAGE REGULATOR COVER

BALANCING SHAFT

FIRST STAGE DIAPHRAGM

CONNECTION SHAFT

2. Slam-shut valve set pressure check:

a. Close the inlet and outlet ball valves and vent the regulator pressure.

b. Allow pressure to ow into the test port (while it is open).

c. Observe if the pressure when the slam-shut tripped is the desired set pressure.

3. Replace consumable parts: Valve and orice pads, diaphragms, O-rings and other elastomer parts.

4. Clean the lter element.

9. Assembly and Disassembly Points to Note

A. Removing the Box cover (See Figure 8):

1. Unlock and swing open the cover by 90°.

2. Lift up the cover to remove it.

B. Removing the filter element (See Figure 3):

1. Vent pressure out of the regulator.

2. Use a size 4 hex-key to remove the screws and the lter cap. (Note: Be careful of the spring inside springing out when the

cap is detached.)

3. Pull the ring attached on the lter and pull out the lter element.

C. Removing Slam-Shut parts (See Figure 9):

1. Use the tools provided to turn the adjustment nut until it is levelled with the bonnet.

2. Use a size 4 hex-key to remove the screws and the slam-shut module.

3. Unscrew the reset bar nut.

4. As shown in Figure 9, lift open the slam-shut bonnet (take note of the 5 ball bearings that will fall out) and remove the reset bar.

5. Use a spring collar tool (JB/T3411.47) to remove Φ7 spring collar on the orice pad and thus removing the orice pad. (During the process of removing the parts, ensure that the reset bar is not bent due to excessive applied force.)

6. Use a size 9 wrench to loosen the clamping nut to remove the diaphragm.

D. Removing the First Stage Regulator Orifice Pad:

1. Do Step “C” to remove the slam-shut module.

2. Use a size “A” spring collar tool (place it into the holes and turn it counterclockwise) to remove the rst stage regulator orice pad.

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RB Series Regulating System

E. Removing the First Stage Regulator diaphragm (See Figure 10):

1. Unscrew the bolts and screws with a size 13 wrench (GB/T4388) that connect the ends of the inlet and outlet ball valves.

2. Remove the regulator.

3. Do Step “D” to remove the rst stage regulator orice pad.

4. Remove the diaphragm assembly.

5. Use a size 17 wrench to loosen the balancing shaft and connection shaft and then remove the diaphragm.

6. While reassembling, apply downward pressure onto the cover and screw in all the screws slightly before tightening them.

Ensure that the entire diaphragm is NOT displaced out of the cover before completely tightening all the screws.

F. Removing the Second Stage Regulator diaphragm (See Figure 11):

1. Unscrew the adjustment screw ap.

2. Use a size 4 wrench to unscrew the surrounding nuts and bolts.

3. Open the bonnet and remove the diaphragm. Altogether, hold onto the diaphragm and the components of the second stage regulator while removing them from the body of the regulator.

4. Use a size 14 wrench to unscrew the second stage diaphragm nut and remove the diaphragm.

G. Removing the Second Stage Regulator Orifice Pad (See Figures 12 and 13):

1. After completing step “F”, use a Phillips screw driver to unscrew 2x M3 screws that are holding the Lever in its position.

2. Remove the lever.

3. Use the special tool to unscrew the regulator cap.

4. Remove the second stage orice pad assembly.

5. Use a Phillips or at screw driver to unscrew the M5 screws holding the second stage orice pad assembly; remove the orice pad.

6. During the reassembly of the second stage regulator, rst assemble the orice pad assembly, then put the lever in its place

and screw back the M3 screws to hold it in position.

7. Hold onto the orice pad to let the lever return to the lifted position while placing the diaphragm back to its original position

in the body.

8. Follow the diagram below (Figure 13) and adjust until the rectangular slot faces are in the direction shown and slot the lever back onto the diaphragm attachment.

9. Place back the bonnet and tighten it with nuts and bolts.

10. Clean all the parts before placing them back into the regulator body.

11. Apply the appropriate grease onto all the seal tight elements (O-rings, diaphragm, etc.) and contact surfaces before placing

them back into the regulator body.

Figure 11. Second Stage Regulator Parts

ADJUSTMENT CAP

SECOND STAGE BONNET

SECOND STAGE COMPONENTS

Page 11

Figure 12. Second Stage Regulator Orice Pad Removal

RB Series Regulating System

Figure 13. Rectangular Spot Positioning

RECTANGULAR SLOT

SHAFT

LEVER

M3 BOLT

SECOND STAGE ORIFICE PAD ASSEMBLY

REGULATOR CAP

RECTANGULAR SLOT

Table 6. Troubleshooting Guide

ISSUE CAUSE REMEDY

• Inlet pressure is low.

Low operating outlet pressure

Regulator is in close position

but pressure increases

Regulator fully opens • Regulator main spring is undersized. • Replace the main spring.

Slam-shut valve doesn’t work

Slam-shut instability

Cannot reset the slam-shut valve • Differential pressure is exceedingly high. • Close inlet and outlet valves, then open the test port valve.

• Downstream ow capacity demand exceeds the regulator capacity.

• The lter is blocked.

• First stage regulator diaphragm is damaged.

• Orice pad is worn out.

• Orice is jammed due to impurities or orice is damaged.

• Slam-shut diaphragm is damaged.

• Sensing port is blocked.

• Slam-shut spring is oversized.

• Spring setting is wrong.

• Latching mechanism has high resistance due to friction.

Table 7. Spare Parts Package of RB Series of Regulator Box

TYPE STRUCTURAL TYPE NOMINAL FLOW

RB 1+0 All JJJJ86BX050 1 RB 1+1 All JJJJ86BX050 2

RB 2+0 All JJJJ86BX050 2 RBT 1+0 All JJJJ86BX050 1 RBQ 1+0 All JJJJ86BX061 1

RBQT 1+0 All JJJJ86BX061 1

• Increase the inlet pressure.

• Correct the size of the regulator.

• Clean the lter.

• Replace the diaphragm.

• Replace the orice pad.

• Clean or replace the orice.

• Replace diaphragm.

• Clean sensing port.

• Replace slam-shut spring with the right spring size.

• Calibrate the setpoint.

• Clean the latching mechanism.

ORDERING NUMBER OF

SPARE PARTS PACKAGE

QTY PER EACH

Page 12

10. Ordering Guide

RB 25 B1 C4 F1 EB1

Typ e

RB RBT RBQ RBQT

Flow Rate

25 40 50 80 100

Regulating

B1 (15 to 33 mbar) B2 (30 to 60 mbar) B3 (60 to 100 mbar) B4 (90 to 150 mbar) B5 (150 to 220 mbar) B6 (220 to 300 mbar)

Slam Shut Spring Selection

C4 (25 to 50 mbar) C5 (50 to 100 mbar) C6 (90 to 150 mbar) C7 (150 to 240 mbar) C8 (240 to 400 mbar)

Structure

N/A 1+0 B1 1+1

(Only for Type RB)

C1 2+0

(Only for Type RB)

Center Distance

None Default

(RB/RBT=155 mm, RBQ/RBQT=300 mm)

F1 280 mm

Nameplate Manual and Manual Language E English None Simplied

Chinese

Emerson Process Management Asia Pacific Pte Ltd

1 Pandan Crescent

Singapore 128461 T: +65 6777 8211 F: +65 6770 8028

FISHER JEON Gas Equipment (Chengdu) Co., Ltd

No. 9, Wukedong 2nd Road, Wuhou Science Technic Park, Chengdu, 610045, P.R. China T: +86 28 85360000 F: +86 28 85371201

Service T: +86 28 85366930 or +86 28 85360000 Ext. 1613

PressureManagement.AP@emerson.com

www.emerson.com

Neither Emerson, Emerson Automation Solutions, nor any of their affiliated entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.

Jeon is a mark owned by one of the businesses of Emerson Automation Solutions. All other marks are the property of their respective owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales

are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specications of

such products at any time without notice.

Emerson Process Management Chennai Ltd

Plot No. 5, 6, 7 and 8 Self Help Industrial Estate

Keelkattalai, Chennai, India - 600117 T +91 44 4903 4405 F +91 44 4903 4400