ITRON 8600 Series User manual

Safety Shut-off Valve
Series 8600
Instruction manual
www.itron.com
3850992803_385-099-2803 02.03.10 12:22 Seite 1
3850992803
AC

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2
The present "Instruction manual" has to be kept on the place,
which can be easy reached.
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5
General Features
APPLICATION
The safety shut-off valve (SSV) of 8600 series is a self-operated, direct acting, spring loaded safety
device designed for use in gas distribution and pressure regulation systems with network pressure up
to 25 bar.
PRODUCT DESCRIPTION
SSV8600 protects the downstream pipe against over-pressure or low pressure failures.
When the downstream pressure increases or decreases beyond the pre-adjusted values the safety
shut-off valve interrupts immediately the gas flow.
The device operates with a diaphragm control unit and is fitted with an external manual reset of lever
type. The integrated by-pass system and levers mechanism allow easy resetting of the shut-off valve.
Device is also equipped with a botton for manual voluntary intervention.
As option, SSV 8600 can be fitted with remote position indicator (reed contact type) to provide an
information about "opened" or "closed" position of SSV.
SSV 8600 has an application as solo version or as integrated in regulator (upstream side), but
independent safety device (example: RB4000 / 4700 / 4600 Series regulators).
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3
This type of safety devices is produced and tested according to the product standards DIN 3381 and
requirements of EC Pressure Equipment Directive 2014/68/EU.

6
TECHNICAL FEATURES
·Inlet pressure range P zul : 25 bar (Steel body)
19,2 bar (Cast iron body)
·Temperature range -20°C to + 60°C
·Installation Any orientation
CONNECTIONS
·Sizes DN 25 / 40 / 50 / 80 / 100
(Body lenths according to EN 334)
MATERIALS
·Casing and cover Aluminium or Steel
·Diaphragm Rubberised Fabric
·Other internal parts Stainless steel and Brass
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4
·Over pressure shut-off range (OPSO): 0,028 - 20 bar
·Acceptable gases Natural gas, town gas, propane, butane,
air
, nitrogen, hydrogen (upto 30%) or any non-corrosive
gas.Use only for dry and clean gas. Never use with oxigen.
·Type Flanges (according to ISO 7005):
cast iron PN16 / 25/ ANSI 150 (PN20) RF
cast steel PN16 / 25/ ANSI 150 (PN20) RF
·Body Cast- iron spheroid graphite EN-GJS-400-18LT
·O-rings NBR / Viton
·Valve plug Stainless steel / NBR
Cast steel G20Mn5N
·Low pressure shut-off range (LPSO): 0,05 - 5.0 bar
LPSO: AG20 up to AG2.5
·Accuracy class OPSO: AG 5 up to AG 1

8
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9
LOW PRESSURE SHUT-OFF SPRINGS / LPSO
SPRING SELECTION TABLES
OVER PRESSURE SHUT-OFF SPRINGS / OPSO
Code
20565233
20565234
20565330
20565331
20565332
20565333
20565334
20565430
20565431
20565432
20565134
Characteristics of the springs Who (mbar) Who (bar)
d
mm
2.2
2.5
2.7
3
3.5
4
4.2
4.5
5
5.5
6
De
mm
35
35
35
35
35
35
35
35
35
35
35
Lo
mm
60
60
60
60
60
60
60
60
60
60
60
It
7
7
7
7
7
7
7
7
7
7
7
8621/22
(ø150/TR)
0.55 ÷ 0.90
0.90 ÷ 1.70
1.50 ÷ 2.00
1.70 ÷ 2.30
2.30 ÷ 3.00
-
-
8641/8642
(ø 90/TR)
2.30 ÷ 4.10
3.10 ÷ 5.00
3.80 ÷ 6.00
5.70 ÷ 7.50
7.50 ÷ 10.00
Colour
Yellow
Red
White
Blue
Orange
Brown
Green
Black
Grey
Yellow
Red
8631/8632
( ø 90)
10
2.50 ÷ 3.90
3.90 ÷ 4.60
4.60 ÷ 6.30
6.30 ÷ 10.80
8611/12
(ø 150)
28 ÷ 65
45 ÷ 100
80 ÷ 140
100 ÷ 240
190 ÷ 350
350 ÷ 700
450 ÷ 800
600 ÷ 1000
950 ÷ 1300
-
-
Code
2 0 5 6112 4
20 561221
20561222
20 561223
20561224
20 561321
Characteristics of the springs Whu (mbar) Whu (bar)
d
mm
1. 2
1. 5
1.7
2
2.5
2.8
De
mm
15
15
15
15
15
15
Lo
mm
40
40
40
40
40
35
It
10
10
10
10
10
7
8622
(ø150/TR)
-
-
0.11 ÷ 0.29
0.16 ÷ 0.49
0.21 ÷ 0.74
–
8642
(ø 90/TR)
-
-
0.32 ÷ 0.63
0.42 ÷ 1.
Colour
White
Blue
Orange
Brown
Green
–
8632
( ø 90)
-
-
0.23 ÷ 0.37
0.26 ÷ 0.66
0.32 ÷ 1.00
–
60 ÷ 150
100 ÷ 250
–
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7
10.00 ÷20.00
0.60 ÷ 0.90
0.90 ÷ 1.4
1.40 ÷ 2.40
2.00 ÷ 3.
8 612
(ø 150)
5 ÷ 18
10 ÷ 55
30 ÷ 75
10
0.60 ÷ 2.20
2.20 ÷ 5.0

10
OPERATIONAL SCHEMATIC
Figure 1
Solo SSV 8600
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8

10
OPERATIONAL SCHEMATIC
Figure 1
Solo SSV 8600
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11
Figure 2
INTEGRATED SSV 8600
by RB 4000 Regulator
INTEGRATED SSV 8600
by RB 4700 Regulator
INLET PRESSURE
OUTLET PRESSURE
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9

12
OVERALL DIMENSIONS AND WEIGHTS
Figure 3
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12
OVERALL DIMENSIONS AND WEIGHTS
Figure 3
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13
DN Size
DN 25
DN 40
DN 50
DN 80
DN 100
Dimension
A
B
C
D
E
F
Weight, kg
A
B
C
D
E
F
Weight, kg
A
B
C
D
E
F
Weight, kg
A
B
C
D
E
F
Weight, kg
A
B
C
D
E
F
Weight, kg
Model
(dimensions are given in mm)
8611 / 8612
8621 / 8622
43
8631 / 8632
8641 / 8642
43
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11
18 4 18 4
62 62
338 308
15 0
120 90
120
100
14
254
98
393
15 0
120
100
23
90
120
100
23
254
222
87
373
15 0
120
100
21
222
90
120
100
21
98
363
150
120
10 0
298
122
468
298
122
438
90
120
10 0
352
132
452
15 0
120
100
67
352
132
422
90
120
100
67
100
14
87
343

14
OPERATION
Sectional View Figure 4
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12

14
OPERATION
Sectional View Figure 4
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15
SSV OPERATING PRINCIPLE
Safety Shut-off Valve 8600 (SSV 8600) is designed as independent safety device in order to protect
the downstream pipe against over- or under-pressure failures by immediately stopping of the gas flow.
This happens as soon as the downstream pressure reaches the pre-adjusted over pressure (OPSO) or
under-pressure (LPSO) set points.
The SSV is open in the normal working conditions.
The pressure to be controlled is entering through the impulse intake (15) to the shut-off control
chamber (1) above the diaphragm (8). In this chamber the downstream pressure is compared with
the pre-adjusted set values for over pressure- (spring 6) and low pressure shut-off (spring 7).
The diaphragm (8) is moving from the balanced position as soon as the controlled pressure increases
or decreases beyond the established (pre-adjusted) values. This causes rotation of the control levers
(2), which trip from the fixed position and release immediately the stem group (3) - valve plug (4)
assembly. Under the force of the closing spring (5), the valve plug (4) is brought in the contact with
the valve seat (12) and the flow of gas is immediately interrupted.
After closing of SSV no self- or remote resetting is possible. This can be done only manually and
directly on the field.
As option, Safety Shut off Valve can be fitted with remote position indicator (reed contact), which
schematic sketch and application example are shown on the Figure 5 and 6. This device allows to get
an information about closed or open position of SSV.
The shaft coming from SSV is linked to the shaft of position indicator having an integrated magnetic
element (19). In normal case SSV is in the opened position. As soon as the SSV closes, the shaft (19)
turns and its magnetic element comes close to the read contact. The read contact closes the current
circuit and the tension generated by installed externally control unit increases. This tension increase is
evaluated as output impulse.
In opposite case (SSV is resetted), the contact of magnetic element with reed contact disappears (SSV
shaft is turned). The circuit is interrupted and no impulse is more generated.
Item
1
2
3
4
5
6
7
8
9
Item
10
11
12
13
14
15
16
17
18
Description
Shut-off control chamber
Levers system
Stem
Valve plug
Closing spring
OPSO adjustment spring
LPSO adjustment spring
Diaphragm
OPSO adjustment nut
Description
By-pass
Resetting lever
Valve seat
Screws
Body
Sensing line
Breathing vent
LPSO adjustment nut
Button for voluntary intervention
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13

16
Description
Shaft with magnetic element
Connector
Figure 5
Figure 6
REMOTE POSITION INDICATOR (REED CONTACT)
Item
19
20
Reed contact
Reed contact
SSV Shaft Plug
EEx barrier
Cable 2 wire
Non hazardous
area
Hazardous area
towards unit
of control
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16
Description
Shaft with magnetic element
Connector
Figure 5
Figure 6
REMOTE POSITION INDICATOR (REED CONTACT)
Item
19
20
Reed contact
Reed contact
SSV Shaft Plug
EEx barrier
Cable 2 wire
Non hazardous
area
Hazardous area
towards unit
of control
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REMOTE POSITION INDICATOR (REED CONTACT) ASSEMBLY ON THE FIELD:
Remote position indicator can be delivered as "Assembly Kit" and mounted on Safety shut-off device
directly on the field. This has to be done in the following way ( items mentioned below refer only to
Figure 7):
a) Manually trip the Safety Shut-off valve by the mean of button for voluntary intervention
(see Figure 4), so that it is in the closed position;
b) Remove existing SSV cover (1) by unscrewing 4 screws and removing the gasket;
c) Insert slightly greased O-ring (2) and coupling (3) in the hole of the new cover (1);
d) Install gasket and new SSV cover assuring by rotating that the coupling (3) is set into the
SSV pinion (4), tighten all 4 cover screws;
e) Install the mounting flange (5) into the hole of the cover, take care to set the end of the
coupling (3) in the magnetic rotor (square ends match up);
f) Tighten the flange set screw (6) to about 5 Nm, the flange should not move or turn by hand
g) Place the switch housing (7) over the flange (5) and lightly tighten the two small set screws
(8), so that you can still rotate the housing by hand;
h) Connect a continuity tester or directly your control device to the plug to pins 1 and 2
(see Figure 5);
i) Rotate the switch housing (7) until the tester indicates a closing. This position is the one in
which the magnet in the rotor is lined up with the Reed switch;
j) Hold this position of the switch housing (7) and tighten the 2 set screws (8) until the housing
cannot be turned by hand;
k) The retro-fitting is now complete. Test the mounting by resetting the Safety shut-off device, so
that it is in the "open" position: no contact should be indicated! Trip again manually the
Safety shut-off valve, now the contact should be indicated.
Figure 7
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18
Installation
All delivered Safety shut-off valves SSV 8600 are produced, checked for resistance and tightness and
adjusted in accordance with the requirements of EC Pressure Equipment Directive 97/23/EG.
In any case the acting national norms and standards about installation, start-up and maintenance of
the safety devices and gas installations have to be strictly respected.
The handling with the safety shut-off valve has to be done carefully.
The pick up has to be made by using the stretcher eyes or belts.
Installing of the device in the piping must be performed by respecting the following points:
·the upstream and downstream flanges have to be parallel and the safety device must be
capable of being fitted without any mechanical stress;
·the mentioned below torque's values for screws must be respected by tighten of the flanged
connections:
·these torque's values are mentioned per screw and are valid for metal soft material gaskets
(specified as k0xKD=45bDund k1=2,2bD); other gaskets can require other torque's values.
·the screws used for the flange connection must be according to the flange size and must be
adapted to the temperature range of the SSV; please tighten the screws crosswise.
·the upstream piping and connecting lines have to be cleaned from all possible impurities
(welding slag, sand, etc..) to prevent any damage of safety device and function failure;
·to check if the safety device is not visibly damaged (for example after transportation);
possible lacquer damage should be improved; the sealing surfaces of the flanges must be
damage-free and clean;
·the inlet and outlet chambers of the safety device body have to be also perfectly clean;
P N16
ANSI150
PN25
DN25
35Nm( M12 )
55Nm( M14 )
35Nm( M12 )
DN40
85Nm( M16 )
55Nm( M14 )
85Nm( M16 )
DN50
85Nm( M16 )
85Nm( M16 )
85Nm( M16 )
DN80
85Nm( M16 )
85Nm( M16 )
85Nm( M16 )
DN100
85Nm( M16 )
85Nm( M16 )
170Nm( M20 )
Figure 8
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18
Installation
All delivered Safety shut-off valves SSV 8600 are produced, checked for resistance and tightness and
adjusted in accordance with the requirements of EC Pressure Equipment Directive 97/23/EG.
In any case the acting national norms and standards about installation, start-up and maintenance of
the safety devices and gas installations have to be strictly respected.
The handling with the safety shut-off valve has to be done carefully.
The pick up has to be made by using the stretcher eyes or belts.
Installing of the device in the piping must be performed by respecting the following points:
·the upstream and downstream flanges have to be parallel and the safety device must be
capable of being fitted without any mechanical stress;
·the mentioned below torque's values for screws must be respected by tighten of the flanged
connections:
·these torque's values are mentioned per screw and are valid for metal soft material gaskets
(specified as k0xKD=45bDund k1=2,2bD); other gaskets can require other torque's values.
·the screws used for the flange connection must be according to the flange size and must be
adapted to the temperature range of the SSV; please tighten the screws crosswise.
·the upstream piping and connecting lines have to be cleaned from all possible impurities
(welding slag, sand, etc..) to prevent any damage of safety device and function failure;
·to check if the safety device is not visibly damaged (for example after transportation);
possible lacquer damage should be improved; the sealing surfaces of the flanges must be
damage-free and clean;
·the inlet and outlet chambers of the safety device body have to be also perfectly clean;
P N16
ANSI150
PN25
DN25
35Nm( M12 )
55Nm( M14 )
35Nm( M12 )
DN40
85Nm( M16 )
55Nm( M14 )
85Nm( M16 )
DN50
85Nm( M16 )
85Nm( M16 )
85Nm( M16 )
DN80
85Nm( M16 )
85Nm( M16 )
85Nm( M16 )
DN100
85Nm( M16 )
85Nm( M16 )
170Nm( M20 )
Figure 8
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·the functional characteristics indicated on the name plate must correspond to the installing
and operating conditions;
·direction of gas flow has to correspond to the arrow on the safety device body.
Figure 9
Figures 8 and 9:
Position
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Description
Upstream valve
Differential pressure manometer
Filter
Upstream manometer
Safety shut-off valve
Breathing line
Impulse line (SSV)
Regulator
Impulse line (Regulator)
Safety relief valve (SRV)
Downstream manometer
Downstream valve
Downstream isolating connection
Upstream isolating connection
Discharge vent
Meter
Pressure intake tap
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20
The Safety shut-off valve can be installed in the horizontally or vertically.
The device should be not impaired in its function by other installation components. In particular the
effectiveness/operability must be ensured by measuring and breathing lines each time.
To install the safety device the following should be provided:
·an electrically insulating joint upstream and downstream, if the incoming and outgoing piping
are made from ferrous material;
·an on/off valve on the upstream and downstream side of the piping;
·sensing line of the safety device has to be connected to the turbulence free zone of
the downstream side;
·breathing lines (by indoor installations);
·a manometer or pressure gauge on the upstream and downstream side of the piping;
·an upstream filter;
·a pressure intake downstream for start-up and changes in pressure setting;
·electrical earthling of the unit;
·free passage for service, reading of the name plates and maintenance operations;
·all variations in diameter downstream must be performed progressively in order to prevent
negative turbulence of the gas flow.
·vent lines, as for codes of fractice
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The Safety shut-off valve can be installed in the horizontally or vertically.
The device should be not impaired in its function by other installation components. In particular the
effectiveness/operability must be ensured by measuring and breathing lines each time.
To install the safety device the following should be provided:
·an electrically insulating joint upstream and downstream, if the incoming and outgoing piping
are made from ferrous material;
·an on/off valve on the upstream and downstream side of the piping;
·sensing line of the safety device has to be connected to the turbulence free zone of
the downstream side;
·breathing lines (by indoor installations);
·a manometer or pressure gauge on the upstream and downstream side of the piping;
·an upstream filter;
·a pressure intake downstream for start-up and changes in pressure setting;
·electrical earthling of the unit;
·free passage for service, reading of the name plates and maintenance operations;
·all variations in diameter downstream must be performed progressively in order to prevent
negative turbulence of the gas flow.
·vent lines, as for codes of fractice
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To connect the sensing lines:
We recommend to use for impulse sensing lines the 8/10 pipe, which is connected to the angle
(WE10-P/LR) impulse intake (15) and on the downstream pipe to the pressure intake (plug
connection DN
1
⁄ 4 ‘’) as shown on the Figure 10.
These connections must be inserted in a straight section of the downstream pipe.
For this purpose we recommend welding the impulse connections on the upper part of the piping in
order to prevent impurities and condense, which can be collected and obstruct the passage of the gas.
It is also important to make sure that the impulse sensing line slopes slightly downwards to the pipe.
For adequate operation, the gas velocity at the impulse position in the pipe, must not exceed the
following values:
Low pressure < 200 mbar 15 - 20 m/s
Medium / high pressure > 200 mbar 20 - 40 m/s
After installing of the safety device and connecting of all pressure lines (including breathing lines if
required), the complete system has to be checked for tightness.
Figure 10
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Start-up
COMMISSIONING / RESSETING OF THE SAFETY SHUT-OFF VALVE
Safety shut of valve SSV8600 can be delivered having only OPSO function (over pressure shut-off) or
both OPSO + LPSO (over and low pressure shut-off). To identify the delivered model refer please to
"Selection of the SSV 8600 models" on page 5.
SSV having only OPSO safety is normally before use in the "opened" position and ready
to start-up. SSV having both OPSO and LPSO function is should be in "closed" position before any
use. Therefore resetting has to be done to start-up.
If the safety valve has been shut-off (in network) reset must be made only after verifying the reasons
for the intervention and after having re-established normal working conditions.
In such case commissioning and reset must be done as follows (see Figures 8 and 11):
a) close the downstream stop valve (32);
b) open the taps of the manometers (24) and (31);
c) if necessary discharge remaining downstream pressure by the mean of discharge vent (35);
d) check the internal tightness of SSV valve plug by opening the vent (37) (test with soap blows);
e) slowly operate the resetting lever (42) clockwise until the internal by-pass (41) is open:
with this operation pressure fills the downstream pipe, control chamber (38) and equilibrates
the pressure on the both sides of valve plug (40). This can be checked on the manometer
(31) of the downstream side (increase of the pressure);
f) when the pressure indicated on the manometer (31) is stabilised, continue to move the lever
(42) in order to permit the fixation of the control levers (39).
At this point the lever (42) will remain stable in the "opened" position.
h) After above operations (a - f) have been made, the Shut-off valve is into operation and it is
possible to proceed slowly with opening of the downstream valve (32).
Figure 11
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Start-up
COMMISSIONING / RESSETING OF THE SAFETY SHUT-OFF VALVE
Safety shut of valve SSV8600 can be delivered having only OPSO function (over pressure shut-off) or
both OPSO + LPSO (over and low pressure shut-off). To identify the delivered model refer please to
"Selection of the SSV 8600 models" on page 5.
SSV having only OPSO safety is normally before use in the "opened" position and ready
to start-up. SSV having both OPSO and LPSO function is should be in "closed" position before any
use. Therefore resetting has to be done to start-up.
If the safety valve has been shut-off (in network) reset must be made only after verifying the reasons
for the intervention and after having re-established normal working conditions.
In such case commissioning and reset must be done as follows (see Figures 8 and 11):
a) close the downstream stop valve (32);
b) open the taps of the manometers (24) and (31);
c) if necessary discharge remaining downstream pressure by the mean of discharge vent (35);
d) check the internal tightness of SSV valve plug by opening the vent (37) (test with soap blows);
e) slowly operate the resetting lever (42) clockwise until the internal by-pass (41) is open:
with this operation pressure fills the downstream pipe, control chamber (38) and equilibrates
the pressure on the both sides of valve plug (40). This can be checked on the manometer
(31) of the downstream side (increase of the pressure);
f) when the pressure indicated on the manometer (31) is stabilised, continue to move the lever
(42) in order to permit the fixation of the control levers (39).
At this point the lever (42) will remain stable in the "opened" position.
h) After above operations (a - f) have been made, the Shut-off valve is into operation and it is
possible to proceed slowly with opening of the downstream valve (32).
Figure 11
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SETTING
The Safety shut-off valve is supplied with set points specified in the order.
The set point can be adjusted in the range mentionned in the “spring selection table“.
When the installed spring is appropriate to obtain the required pressure, proceed as follows (Figures 8
and 11):
·Over-pressure shut-off (OPSO):
a) close the downstream valve (32) and increase progressively the downstream pressure till
reaching the required value for OPSO;
b) to change this value, rotate in a clockwise direction the external screwing ring (43) in order to
increase the calibration value or in an anticlockwise direction to reduce it.
·Low-pressure shut-off (LPSO):
a) close the downstream valve (32) and exhaust progressively the downstream pressure till
reaching the required value for LPSO;
b) to change this value, rotate in a clockwise direction the internal screwing ring (44) in order to
increase the calibration value or in an anticlockwise direction to reduce it.
Important: The changing of the setting of the shut-off valve must always be performed with the
diaphragm control unit (38) under pressure.
To verify the adjusted set points, actuate the Safety shut-off valve two or three times checking that
it springs up to the required pressure value.
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Maintenance
Maintenance and repairs of the device are allowed to be made only by trained or qualified
personal. Afterwards a tightness test with 1.1 X PS must be performed.
When changing pressure containing parts their compliance with PED must be assured.
After Guarantee only with repair by Itron.
The maintenance works required for the Safety shut-off valve are closely linked to the quality of gas
supplied (moisture content, liquid hydrocarbons, impurities in general) and the degree of filtration
performed upstream of the safety device.
For this reason, we recommend always installing of a catridge filter upstream of the safety device,
which is capable of withholding the solid and liquid particles present in the gas.
We also recommend performing routine preventive maintenance at established intervals in accordance
with:
·the quality of the gas supplied;
·importance of the service rendered,;
·reliability required;
·condition and cleanliness of the piping that supplies the gas to the system.
Recommended maintenance intervals (can differ depending on the above listed factors) are
mentioned in the table here below :
As requested
Maximum
upstream
presure
bar
=< 0,1
> 0,1-1
> 1- 4
> 4-16
> 16-100
Maximum
flow
capacity
m3/h
-
=< 100
> 100
=< 100
> 100
Visual control
quarterly
Inspection
half-yearly
monthly quarterly
Maintenance
Functional check
Monitoring
As requested
As requested twelve-annually
four-annually
six-annually
two-yearly
annually
half-yearly
As rested
eight-annually
As rested
four-annually
two-yearly
two-yearly
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