ITRON RB 4600 Instruction Manual

Gas Pr

www.itron.com

essure Regulator

RB 4600

3400992805

AA

Instruction Manual

EU Declaration of Conformity

Gas pressure regulators for natural gas and all non-corrosive gases
with or without safety shut-off valves for OPSO or OPSO and UPSO

Manufacturer: Itron GmbH, Hardeckstraße 2, D-75185 Karlsruhe

declares under his sole responsibility, that the regulator
RB4710 / 4720 / 4730 without SSV
RB4711/4712/4721/4722/4731/4732 with SSV8500 or SSV8600
RXI4710 / 4720 / 4730 without SSV
RXI4711/4712/4721/4722/4731/4732 with SSV8500 or SSV8600
RB4610 / 4620 / 4630 without SSV
RB4611/4612/4621/4622/4631/4632 with SSV8500 or SSV8600is in conformity
with the Pressure Equipment Directive 2014/68/EU
The regulator has been classified as pressure accessory in category II, by the
manufacturer. The used fluids are classified in group 1 according article 13.

Applied conformity assessment
procedures PED: Module D1

Applied standards and technical
specification: DIN EN 334:2005+A1:2009 and DIN EN 14382:2005+A1:2009+AC:2009

Other applied EC-Directives: 2014/30/EU, electromagnetic tolerance
only for optional electronic device

Engaged notified body:
Module D, Surveillance of the QS-System: TÜV SÜD Industrie Service GmbH, Westendstraße 199, D-80686 München

Examination/inspections/tests
during manufacturing: TÜV SÜD Industrie Service GmbH, Westendstraße 199, D-80686 München

Surveillance of the QS-System: DGR-0036-QS-955-14

Regulators and safety devices according to EN 334 and EN 14382 - if not equipped, with any electronic device – do not have a
potential ignition source and therefore are not in the scope of European directive 2014/34/EU.

Karlsruhe, July 19th, 2016

_____________________

P. Garcia

Head of Production

D2036209_AA_EU_Declaration_RB4700_4600.docx

This manual aims to provides relevant information
for the installation, commissioning and mainte­nance of RB 4600 or regulator.

The RB 4600 pressure regulator is a combination
of active regulator and monitor regulator - both of
RB 4700 type - with upstream slam-shut valve.

RB 4700 instruction manual item no
3400992806 on request

It may be fitted with an integrated safety shut-off
device type SSV 8500 or SSV 8600.
The operation and maintenance of the latter de­vices are described in:

Technical features

Allowable pressure PS: 25 bar
Inlet pressure pumax: 19 bar
Outlet pressure range w

:

h

• 5 mbar to 13 bar

Accuracy class: up to AC 1
Closing pressure class: up to SG2,5
Operating temperature range:

-20°C to +60°C

• The product is classified along the Pressure

Equipment Directive (PED) as Category II

• Instruction Manual 3850992802:

Safety Shutoff Valve Series 8500,

or

• Instruction Manual 3850992803:

Safety Shutoff Valve Series 8600.

Product classification is based on the
volumes:

following

DN 25 40 50 80 100

Volume (dm3) carrying inlet pressure

RB

4600

RB

4600

1,2 2 2,5 6,4 6,4

Volume (dm3) ca rrying outlet pressure

1,2 2 2,5 6,4 6,4

3

TF 511 Pilot

TF 511
Pilot

INLET PRESSURE OUTLET PRESSURE

MOTORIZATION PRESSURE - MONITOR MOTORIZATION PRESSURE - ACTIVE

Fig 2 - RB 4600 sectional view

4

SSV 8500

FEEDING PRESSURE

Regulator spring ranges

Pilot Type Spring Code Spring Characteristics Spring Range

D De Lo It mbar bar

mm mm mm mm

TF 511 20565125 2.5 35 50 6 5 - 25

TF 511 20565126 3 35 50 6 20 - 68

TF 511 20565127 3.5 35 50 6 40 - 140

TF 511 20565128 4 35 50 6 80 - 280

TF 512 20565128 4 35 50 6 6.0 - 1.0

TF 512 20565129 4.5 35 50 6 0.2 - 1.0

TF 513 20565132 3.5 35 60 6.5 0.3 - 1.3

TF 513 20565133 4 35 60 6.5 0.5 - 2.5

TF 513 20565131 5 35 60 6.5 1.5 - 5.5

TF 513 20565134 6 35 60 6.5 4.0 - 13

Spring characteristics:

d : wire diameter
De: external diameter
Lo: height
It: nber of spire

5

Installation

• Check that the maximum inlet pressure is not

higher than the design pressure of the regulator.

• Regulator should be lifted only with belts around

the body.

• Arrange enough room for the serving of the

regulator.

Before installing the pressure regulator in the
piping, the following must be checked:

• the upstream and downstream flanges must be

parallel so as to install the regulator without
undue stress.

• the upstream piping must be cleaned from all

impurities (sand, welding slag, etc.)

• the pressure regulator must not be visibly

damaged.

• the inlet and outlet chambers of the pressure

regulator must be perfectly clean.

Make sure that the direction of gas flow corre­sponds to the arrow on the pressure regulator
body.

Installation with actuator downwards or vertical in­stallation are also possible.

Fig 3 gives a typical example of installation:

• The downstream vent valve eases start-up and

changes in pressure setting

• The creep relief valve - optional -limits pressure

surges (example: gas thermal expansion in case

of downstream piping exposed to sun radiation

at zero flow).

Outlet buffer volume

In case of fast variations of gas demand (ON/OFF),
the response time of the regulator may cause
transient pressure surges or drops that may trig­ger the overpressure or under-pressure protec­tion devices. These pressure changes can be limit­ed to acceptable values by providing for a enough
downstream piping volume.

When tightening the flange bolts, the following
maximum torque - applicable to Class 5.6 bolts ­should not be exceeded:

M12 M14 M16 M20

35 Nm 55 Nm 85 Nm 170 Nm

For ease of operation, we recommend performing
installation with the valve body in horizontal align­ment, with actuator up

wards.

Sensing line

The sensing line must be connected to a section
reasonably free from turbulences, preferably in a
straight section of the downstream
shown in Fig 3. Outlet pipe dimensions shall be
such that the gas velocity at pressure sensing tap
does not exceed those given below:

piping as

• Outlet pressure < 200 mbar

15 to 20 m/s

• Outlet pressure > 200 mbar

20 to 40 m/s

6

Fig 4 - Typical installation - RB 4700 active regulator, monitor regulator and SSV 8600 shutoff valve

RB 4600 operates such as illustrated, but inside of one common body

7

Pipework should be made to prevent impurities
and condensates from collecting and obstructing
the passage of the gas.
Pipework slope upwards from the pressure tap is
recommended - see Fig 5.

Installation with safety systems

SSV

The SSV must have a dedicated sensing line,
whose point of sensing provides a representative
pressure. An isolating valve on the sensing line is
not permitted.

Monitor

The RB 4600 regulator includes 2 separate con­trol systems built onto a single valve body. Both
sensing lines shall be piped downstream, as
shown in the Fig 4.

Fig 5 - Sensing tap

8

Regulator Start-up

Monitor Start-up

After the pressure regulator has been installed,
make sure that the on/off valve upstream and
downstream and the vent valve are all closed.

• partially open the upstream on/off valve slowly

enough to pass a very small amount of gas;

• reset the safety shutoff valve (see the relevant

Instruction Manual). Note that a safety shutoff
valve with over and under-pressure protection

is always closed in absence of gas downstream
from the regulator, where its sensing line is
connected.

• check that the pressure rises slowly; the down

stream pressure must stabilize around the set

value. If the pressure continues to rise, interrupt

the starting procedure by closing the upstream

on/off valve and identify the cause of the mal­function;

• after the outlet pressure has stabilized, open the

on/off valve completely;

• then slowly open the downstream on/off valve

until the piping is completely

filled.

The same procedure must be followed when
starting a monitor and active system, bearing in
mind that the pressure gauge installed in the sec­tion in between the two regulators must indicate
the same pressure value as the upstream gauge.

Pressure Regulator Setting

The pressure regulator is usually delivered already
set to the specifications indicated in the order
sheet. Whenever the set pressure must be modi­fied, this value must be set within the setting range
Wa of the spring installed.

Make sure there is a flow demand or open the
vent valve downstream of the regulator. This valve
should be closed after the desired set pressure is
obtained.

• To increase the set pressure:

rotate clockwise the adjustment screw on top of
the pilot - see Fig 1.

• To decrease the set pressure:

proceed as above, rotating the spring adjust­ment screw counter-clockwise.

At this point, the pressure regulator is operative.

9

Maintenance

Disassembly

The maintenance operations required for the
pressure regulator (and the safety shutoff valve)
are closely linked to the quality of gas supplied (in
terms of moisture content, liquid hydrocarbons
and impurities in general) and to the degree of fil­tration performed upstream of the pressure regu­lator. For this reason we recommend always in­stalling a cartridge filter upstream from the pres­sure regulator that is capable of withholding the
solid and liquid particles present in the gas that
might otherwise compromise efficient operation.

All pressure must be discharged before perform­ing any maintenance operation on the pressure
regulator by proceeding as follows:

• Close the on/off valves upstream and down-

stram,

• Slowly discharge the pressure by opening the

vent valve downstream from the pressure
regulator until the gauge indicates zero.

Check the following before beginning any disas­sembly operations on the pressure regulator:

• The regulator must be depressurized as

described above;

• The wrenches and other tools required for the

operation must be close at hand;

• Spare parts to replace damaged parts must be

immediately available.

Remember to:

• Disassemble all parts carefully in order to avoid

damage. Pay extra attention to the

(using the appropriate tool for the disassembly

of the O-rings) and replace all parts that exhibit
even the slightest signs of damage.

rubber parts

Built-in safety valve

Before performing any maintenance operation on
pressure regulators fitted with overpressure and
underpressure shutoff devices, open the bypass
between the inlet and outlet chambers (see In­struction Manuals for safety shutoff valve). This re­lieves the pressure that otherwise would be
trapped upstream from the valve disc of the safe­ty shutoff device.

Thanks to its modular design, the retrofit - or
change of safety valve model - can be easily
made on the field without dismounting the regu­lator from the gas line.

10

Tools

This table indicates the tool relevant for the various parts as shown by position number
(see Sectional views)

Tool

Type

A

B

C

Nominal

tool
size

2
3 14 - 24 14-24-35 14 - 35 14 - 35
4 48 48 48 48 311
5 24 24 314-319-333-340
6 17 - 51 17-29-51 51 51
8 17 - 29 17 - 29

13 13 13 13 13

30

9 326
10
13 11-20-403 11 11 11 306 - 317
14 301
17 20 - 403
19 21 21 21

22 39 39 20-39-403
30
50 16 - 52 16 - 52 16 - 52

DN 25

35

Regulator size

DN 40

DN 80 DN 100

DN 50

Pilot

Recommended tools

Ref A - Hexagonal

socket T wrench

Fef C - Spanner

Ref B - Box spanner

O-Ring extracting tool

11

Itron GmbH

Hardeckstraße 2

76185 Karlsruhe

BR-1042-06-16 - RB 4600 e - © Copyright 2002, Actaris, All Rights Reserved. 2011/ medialogik

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