Escolar Documentos
Profissional Documentos
Cultura Documentos
INSTRUCTION MANUAL
SAFEGUARDS
GENERAL NOTICES Beside the rules here below listed the plant manager must meet the regulation in force concerning safety and health of workers in jobsites. Qualified staff only must be used to operate on the valve. The Company rejects any responsibility for personal injury and damages to equipment imputable to improper operation, use of non original spare parts or repairs executed by unauthorised staff. Transportation must be performed utilising original packing up to job-site. The Company rejects any responsibility for damages occurred to things and people due to packing because of having been tampered with. USE AND MAINTENANCE Safety relief valve, due to its particular function, operate in a discontinuous way. It is therefore necessary to take the necessary precautions when staying near or passing close to the valve, when plant is running. In case of discharge to the atmosphere keep out of discharge duct. The lifting lever must be used for authorised tests or trials only. TEMPERATURE In case that hot fluids flow through the valve, the operator must pay attention to not insulated parts. LIFTING AND HANDLING When lifting use eyebolts, if any, otherwise sling the valve body.
LIMITATION OF USE
Residual hazards with regard to essential safety requirements of Annex I of European Pressure Equipment Directive no. 97/23/EC
If not otherwise specified, the following use limitations have to be considered for PARCOL safety valves. 0 MAXIMUM WORKING PRESSURE AND TEMPERATURE Before placing the valve in pipe line make sure that maximum working pressure and temperature are within the limits of body rating and lower than allowable maximum values indicated on valve serial plate. 1 MINIMUM WORKING TEMPERATURE Valves having Carbon Steel body material (SA-105 or SA216 WCB) are suitable for a minimum working temperature down to 20C when working pressure is at its maximum rating listed value. If working temperature is down to 29C, the maximum pressure must be reduced to 1/3 of its maximum rating listed value. Valves having Cr. Mo. alloy steel body material (SA217 WC6, SA217 WC9, SA217 C12A, SA182 F11, SA182 F22, SA 182 F91, etc.), particularly suitable for high temperature services, the minimum working temperature at maximum rating listed pressure shall be +20C. It is possible to reach a minimum working temperature of 29C but maximum working pressure must be reduced to 1/3 of its maximum rating listed value at ambient temperature. RATING Rating pressure (1) Pressure at ANSI T 20C (1) (2) - bar bar 150 20 7 300 51.7 17 600 103.4 34 900 155.1 52 1500 258.6 86 2500 431 144 4500 775.7 259 (1) Referring to SA217 WC6/WC9 or SA182 F11/F22 (2) Also during hydrostatic pressure test at T 20C 2 EXPECTED WORKING LIFE IN CREEP RANGE No special limitations are required in the expected service life of safety valve, other than those foreseen afterwards. When safety valves are used at a working temperature within the creep range (as listed on the following table), the guaranteed expected lifetime is in any case not lower than 100.000 hours of continuous operation at rating listed pressure corresponding to working temperature. Material Carbon steels (i.e.: A216 WCB-A105) CrMo steels (i.e.: A217 WC9-A182 F22) 300 series cast austenitic steels 9% Cr Mo V steels (i.e.: A217 C12A-A182 F91) 300 series forged austenitic steels 3 SEISMIC STRESSES PARCOL safety valves have been experimentally tested for seismic applications on vibrating table by applying both axial and transversal acceleration up to 5g. Nor damage on pressure containing parts neither performance limitation have been observed after such a test. 4 PIPING STRESSES In general it is not necessary to perform any check and calculation if pipe size is no larger than 1,5 times valve body size (2 times for valve body size up to 3). As the safety valve has not to be used as a fixed point, if inlet and outlet pipe sizes are different, it should be considered the smaller one as it is essential for the piping design. 5 SELF GENERATED FORCES DURING FLUID DISCHARGING During operation, due to the high velocity of the discharged fluid, safety valves can generate not negligible reaction forces. The values of these forces are reported on calculation sheet and must be taken into account for holding point and connected piping design. 6 CORROSION In case of local corrosion, particularly with chlorides, such as pitting, interstitial corrosion on gasket seating surfaces and stress corrosion, it is not possible to make any realistic prediction of expected lifetime of valve. In these circumstances it is essential to properly select the material of disk and valve nozzle. Tbeginning creep 343C 455C 510C 538C 538C 7 EXTERNAL FIRE PARCOL safety valves are not designed to withstand external fire. 8 CYCLIC LOADS OF PRESSURE AND TEMPERATURE For most of installations possible cyclic changes of pressure and/or temperature do not influence the expected lifetime of valves. The above assuming the following working conditions: maximum working temperature not exceeding 550 C; fluid temperature change rate 2 K/min or less; cyclic change of working pressure within 1/3 of maximum allowable rating pressure at corresponding temperature. When working conditions are outside the above specified ones a particular check is necessary to calculate the expected lifetime of the valve. 9 BACKPRESSURE Unbalanced versions can be used only for constant backpressure applications. In this case the set pressure adjustment is performed taking into account the effect of backpressure. For variable back-pressure applications, bellows balanced safety valves with vented bonnet must be used. Parcol guarantees the correct operation of bellows balanced safety valves up to the backpressure values listed in the technical bulletins. When high length discharge piping are connected to the valve outlet, the self-generated back-pressure must be evaluated. The back-pressure value must not exceed 10% of the set pressure for safety valves without balancing bellows (absolute pressures for compressible fluids and gauge pressures for uncompressible fluids). 10 BLOW-DOWN RING SETTING Parcol safety valves are equipped with a blow-down ring screwed on the nozzle for blow-down adjustment. The blow-down ring adjustment is described on this manual and must be performed by skilled personnel only when strictly necessary. 11 BELLOWS Bellows is warranted for high number of valve opening, however it may be accidentally damaged: in this case the balancing function should be compromised. For most severe applications it is suggested to periodically check the bellows integrity by flushing the downstream body and checking any leakage through the vent hole on the bonnet. Be careful to maintain the vent connection on the valve bonnet free to the atmosphere in order to allow the proper balancing function of the bellows. 12 SET PRESSURE Safety valve is supplied after set at the pressure value reported on test valve certificate. Reliability of safety valve set pressure shall always be verified before installation if not otherwise specified. After installation the reliability of safety valve set pressure shall be verified periodically following the prescriptions by laws in force in the country where safety valve is installed. If no prescriptions are available, reliability of safety valve set pressure shall be verified at least every three years in presence of an Authorized Inspector or return the safety valve to manufacturer for overhaul. 13 GUARANTEE If safety valve is supplied with plumbing device, manufacturer guarantee on valve set pressure decays when plumbing device is removed. The User shall then verify safety valve set pressure in presence of a Notified Body Inspector or return the safety valve to manufacturer for overhaul.
NTG 76/553E05
INSTRUCTION MANUAL
2.
3.
INSTALLATION
A correct installation is the keystone of successful valve operation. Pipes, connecting flanges and valve supporting racks must be carefully cleaned. Prevent foreign particles, such as gasket trashes, slag, dirt, sand, etc., from accumulating between nozzle and disk during the installation. Pipelines should be blown if possible, to clean the piping upstream the valve. All of the bolts must be evenly tightened. To prevent deformations of valve body the discharge piping must be properly held. The safety relief valve should be installed in vertical position. The inlet piping from the vessel or the protected equipment should preferably be short and straight. The connection with the vessel should be filleted, to allow a free fluid flow to the valve; furthermore
chattering on the seat during the valve operation, thus reducing valve tightness and life. Where equipment vibrations and upstream pressure pulsations cannot be avoided it is 3-5411, 3-5431 and 3-5432 SERIES CONVENTIONAL DESIGN
advisable to increase the difference between normal operation pressure and set pressure by more than the normally recommended 10%.
AUXILIARY PISTON
DEVICE
Item 1 2 2 3 4 5 6 7 8 9 10 11
Part name Body Tight bonnet Vented bonnet (not shown) Plain cap Nozzle Disk Nozzle ring Spindle (sub-assembly) Guide Disk holder Spring Spring adjusting screw
Item 12 13 14 15 16 23 24 25 26 27 28 29
Part name Lock-nut Pivoting bush Retaining ring Lower spring washer Upper spring washer Body studs Body nuts Plug-nut Nut Adjusting ring set screw Body drain plug Bonnet stud bolt
Item 30 31 41 42 43 44 45 46 48 75 76
Part name Nut Cap plug Guide gasket Cap gasket Plug gasket Cap plug gasket Name plate (not shown) Name plate rivet (not shown) Auxiliary piston Bellows Bellows gasket
SOFT SEAL
Item 81 82 83
Item 5a 5b 5c 5d
SPINDLE
LIFTING LEVER
TEST GAG
Item 17 18 19
Item 51 53 54 55 56 57 58 59 60 61
Part name Cap for lifting lever Stop disk Screw Fork Driving shaft O-Ring seal Bottom ring Lever Nut Adjusting ring nut
Item 65 66 67 68 69 70
Part name Test gag Nut Screw rivet Plug rivet Plug Chain
4.
the nuts (30) and slip the cap from the bottom to the top, inclining it frontward. Remove the screw (54) from the locking disk (53) and unscrew the disk form the stem (7) (measure before the distance between disk and stem end, so that it can be later resettled in the same position). Before removing the spring adjusting screw (11) take note of the protrusion of the stem from the screw itself. This will later enable to remount the screw approximately in the same position. Remove the ring nut (12) and release the spring compression by turning the spring adjusting screw anti-clockwise. Unscrew the nuts (24) and demount the bonnet through the stem. Do not go through this step without ensuring before that the spring is completely released. Remove the spring (10) and the spring seat (15) and (16), or (15) and (83), in case the upper spring seat is provided with the thrust bearing (82) and the guide ring (81). Then raise up and remove the stem (7) together with the spindle and the piston (48), when supplied, from the valve body (1). To draw out the guide (8) lever in some points into the slot located outside the disk, remove the gaskets (41) and the disk (5) assembled with the disk holder (9) (do not loose the pivoting bush (13)). To draw out the disk from the disk holder insert two screw- drivers into the disk holder holes and act onto the disk to release the stop ring (14). If the sealing ring (5c) is mounted on the disk, unscrew the screws (5d), remove the ring locking disk (5b), then remove the sealing ring. Unscrew the blow-down adjusting ring (6) after having released it from the locking screw (27) by unscrewing the plug (25). To remove the nozzle (4) from the valve body (1) firmly clamp the body, then turn the nozzle anticlockwise using a suitable wrench or levering with a pin into the suitable holes, according to the type of nozzle. 5.2 SEAT LAPPING When seating surfaces are slightly scratched, lapping can completely recondition them. The disk is provided with two perfectly machined seating surfaces, so that it can be utilized twice before proceeding to lap it. In case of disks with
4.1 LOCKING DEVICE (TEST GAG) When carrying out the pressure test of the plant the valve must remain closed. For this purpose remove the plug (69) and the gasket (44), tighten the locking screw (65) until it gets in contact with the stem (7); then tighten the test gag nut (66), thus preventing the valve to open. After the pressure test remove the screw (65) and replace it with the plug (69) and the gasket (44) to restore the normal valve operation.
5.
TRIM MAINTENANCE
Unscrew the nuts (30), remove the cap (3) and its gasket (42). In case of threaded caps: turn the cap anticlockwise. To demount the manual control cap (51) place the lifting lever (59) in its lowest position, then unscrew
5.1 DISASSEMBLY
deposit of stellite or soft seat the seating surface is by one side only. If lapping is required use a cast iron lapping plate, or a clean and flat ring lap. Spread a thin layer of emery paste on the lapping plate or ring; hold down the component to be lapped and drive it with a figure-eight (8) motion. When using a ring lap the motion should be oscillatory. When lapping apply a light and uniform pressure avoiding any shock. It is recommended to remove the nozzle from the valve to perform a good lapping. In case this is not possible or the seating surfaces are just slightly scratched a ring lap can be used. In this case the ring must be lapped against the nozzle. Any excess of emery paste could cause the rounding of seat edges. In case the seating surfaces are seriously scratched they should be machined before lapping. Lapping pastes vary from coarse to very fine grain. A coarse grain paste is generally used first, then a very fine to finish the piece. Clean thoroughly the plate when changing any paste. Coarse grain pastes must be used only when removing very deep scratches. Different plates should be available for different pastes. Important points for good results are: A - Cleanliness of lapping plates, of the work piece and of lapping paste B - Flat base surface C - Suitable lapping base D - Correct and light lapping movement (without rocking) E - Changing of lapping compounds
5.3
Lap the surface until the active width attains again the original value. Nozzles should be normally discarded when already machined three times. 5.4 DISK MACHINING Fasten first the disk on the lathe chuck. Avoid excessive chucking. Center the nozzle and ensure by means of a dial gauge that the outside surface of the disk is concentric with the seating surface within a range of 5/100 mm. Machine the seating surface until the damaged areas are removed; surface finishing should be as smooth as possible. Lap the raised seating surface across the full width. Disks should be normally discarded when already machined three times. 5.5 VALVE REASSEMBLY Please, remember that gaskets and sealing rings shall be replaced. Always use Parcol original spare parts. The valve assembling procedure is exactly the reverse of the disassembling one. When assembling the valve the spring adjustor should be completely loose, not to compress the spring when tightening the bonnet nuts. The measure taken when disassembling the valve should be borne in mind when setting the spring adjustor in the same position as it was before disassembling. Aligning the valve trim is critical for successful operation; it is therefore necessary to handle them and reassemble the valve with utmost care. The blow-down adjusting ring should be remounted in the same position as it was before disassembling (rotate by the same number of notches starting with the ring in contact with the disk). To mount the disk inside the disk holder lay the holder with the disk opening oriented upwards; then insert the disk in the opening, complete with its retaining ring, then press it until the ring gets into its slot thus connecting the disk with the holder. In case of soft seat, replace the sealing ring (5c) every time the nozzle and the disk are lapped. Before reassembly, lubricate the surfaces in contact among spindle (7), pivoting bush (13), lower (15) and upper spring washer (16), piston (48) when supplied, other than the seats of gaskets (41) and (42).
NOZZLE MACHINING When scratches are so deep that lapping is not sufficient to completely remove them the work piece must be remachined on a lathe. Fasten first the nozzle flange on the lathe, preferably clamping it with the self-centering three jaw chuck. Center the nozzle and ensure by means of a dial gauge that the inside surface of the nozzle is concentric with the outside surface of the flange within a range of 5/100 mm. Machine the seat surface until the damaged areas are removed; surface finishing should be as smooth as possible.
6.
6.1 DISASSEMBLY
If the test is correctly carried out the results of the two systems are practically identical. Differences up to 1 2% may arise in case of defective tightness between nozzle and plug. The procedure (2) requires a higher capacity vessel and more care in performing the connection with the valve. 7.2 LIQUID SERVICE The test may be carried out with pressurized cold water. Normally a reservoir is not necessary, but an air/water damping reservoir may be necessary in case a reciprocating pump is used. The setting point is reached when a liquid streamlet takes place. 7.3 HOT SETTING A temperature increase causes a reduction of the set pressure of a safety valve or a safety relief valve. It is therefore necessary to compensate for this effect by increasing the set pressure when the valve is tested on the test stand at ambient temperature and is intended for high temperature fluid service. On the contrary no pressure reduction is recommended when setting valves intended for under zero service. Neglecting the low temperature effect is justified by the fact that by this way operation problems are avoided, since the error increases the set pressure. The correction factors listed in this table should be used in cold setting valves intended for fluids over 100C temperature.
Operation temperature Set pressure increase % None 2% 3% 5%
6.5 BELLOWS REPLACEMENT To replace the bellows it is necessary to lock the disk holder (9) in a vice (use soft jaws not to damage it), then insert a pin wrench or a rod into the suitable holes in the threaded ring of the bellows and turn clockwise the bellows to unscrew it from the disk holder. Replace the bellows with a PARCOL original spare and check the gasket (76) for efficiency before screwing the bellows onto the disk holder. Replace the gasket if necessary. Screw the bellows terminal against the disk holder to well press the gasket in between. 6.6 REASSEMBLY See point 5.5. Be careful not to damage the bellows when handling the disk holder with the opening upwards to insert the disk.
7.
up to 100 C from 101 C to 250 C from 251 C to 500 C over than 500 C
The above correction factors must be used also for valves already compensated for downstream backpressure. The exact definition is therefore "cold set pressure differential", i.e. the valve inlet pressure which causes the valve to open on the bench at ambient temperature and with atmospheric backpressure. The calculation for the exact spring setting must therefore take into account, if applicable, the compensation for service temperature over 100C and for backpressure different from the atmospheric one. Examples for calculation of "differential pressure for cold setting" with compensation for back pressure and temperature.
A) DATA: Standard valve without compensating bellows, 20 bar nominal set pressure, 260C service temperature, 1 bar constant back pressure, steam service. - setting pressure in service: 20 bar - 1 bar = 19 bar - correction coefficient for temperature between 251C and 500C (see table): 3% - 3% of 19 bar = 0.57 bar (rounded to 0.6 bar) - cold set pressure: 19 bar + 0.6 bar = 19.6 bar. B) DATA: Valve with compensating bellows, 50 bar nominal set pressure, 180C service temperature, 1.5 bar constant back pressure, steam service. - setting pressure in service: 50 bar (the setting pressure is not affected by the back pressure, due to the presence of the compensating bellows) - correction coefficient for temperature between 101C and 250C (see table): 2% - 2% of 50 bar = 1 bar - cold set pressure: 50 bar + 1 bar = 51 bar. C) Notice that in any case (see examples A and B) the valve inlet temperature is taken into consideration and the correction factor is multiplied for the set pressure. The procedure is always the same and is applicable to any valve type. A different calculation of the set pressure is:
Cold set pressure = spring set pressure x (1 + correction factor)
- remove the top cap (3) (or the lifting gear assembly), thus making the spring adjusting screw (11) accessible. Loosen the counter nut (12), then rotate the spring adjustor clockwise if a set pressure increase is required, or anti-clockwise for a reduction. - When the required value is reached tighten the lock nut and remount the cap (or the assembly cap + lifting lever). - Test once again the valve opening after having tightened the lock nut.
NEVER ADJUST THE SPRING COMPRESSION WHEN THE FLUID PRESSURE IN THE VALVE IS CLOSE TO THE SET VALUE, AS THE SEATING SURFACES OF NOZZLE AND DISK COULD GET DAMAGED. THE FLUID PRESSURE IN THE VALVE SHOULD BE AT LEAST 25% LESS THAN THE SET PRESSURE. BY THIS WAY THE LOAD ON THE SEATING SURFACES WILL PREVENT THE DISK TO ROTATE AND THE SURFACES TO GET DAMAGED.
8.
TIGHTNESS TEST
The test is carried out after that the spring setting is made by using the same pressurized fluid. Lower the pressure upstream the valve to 90% of the set pressure. The recommended method according to API standard for valves operating on vapour and gas service is shown in Fig. 1. The valve outlet is blanked off with a flange connected with a 6 x 8 mm diam. tube 90C bent and dipping in a water reservoir. The tube end must be 12,7 mm under the water surface. When the air pressure in the valve is 90% of the set value the number of bubbles per minute (if any) should not exceed the value stated by API standards (see Fig. 2).
7.4 NOZZLE RING SETTING Loosen the lock screw (27) of the nozzle ring (6) and turn the ring anti-clockwise until it gets in contact with the disk holder (9). This may be done either through the valve outlet, or through the hole for the lock screw using a screwdriver. When the ring is settled reset the lock screw and fasten the plug (25). For the number of notches refer to Appendix 1 and Appendix 2. Ensure that the screw is inserted in the notch. When the screw is tightened the ring should be slightly lose, but not free to turn. NEVER MOVE UPWARDS THE NOZZLE RING WHEN THE VALVE IS UNDER PRESSURE: THE VALVE COULD SUDDENLY OPEN AND DAMAGE SOMEBODY. 7.5 SET PRESSURE ADJUSTMENT If the valve opens at a pressure lower or higher than the set pressure adjust the spring compression as follows:
8.1 EXCESSIVE LEAKAGE If the procedure has been carefully followed and the leakage exceeds the limits it is necessary to disassembly the valve to ascertain that no foreign material is within the seating surfaces, or these are not damaged by foreign particles in the testing fluid. After that the valve has been checked it is recommended to transport it in vertical position. If the leakage is due to dirty build-ups on the seating surfaces cleaning and polishing are sufficient to restore the initial conditions by using not abrasive media soaked in solvents. If the seating surfaces are scored they must be lapped or re- machined and lapped, according to the scratch depth.
10
9.
PRESSURE GAUGES
Pressures are measured by means of marked and certified manometers, which are periodically set by the Quality Assurance Service (SGQ) and meet the requirements of ANSI B 40.1 - Grade A standard.
Pressure gauges are selected with such a full scale that the test pressure is ranging between 25 and 75% of it. By this way the measuring error can be considered as not higher than 1% of the full scale.
11
FIGURE 1
max bubbles per minute 140 120 orifice <= C 100 80 60 orifice >= D 40 20 psi 0 1000 2000 3000 4000 5000 6000
bar 0
50
100
150
200
250
320
420
FIGURE 2
12
TROUBLE CHECK-LIST
FAULT CAUSE REMEDY 1) Presence of foreign particles between 1) Operate the valve once or twice seat and plug. subsequently. If leakage does not stop disassemble the valve and clean the trim. 2) Seating surface galled or scratched. 2) Disassemble the valve and lap the seat. 3) The valve is used with a fluid different 3) Lap seat and disk with smoother finishing from the one which it was intended for. (if the valve, originally intended for liquid, is used for gas). 4) Valve not mounted in vertical position. 4) Change the installation. 5) Set pressure too close to the operation 5) Improve where possible the quality of the seating surfaces (e.g. with hard facing) pressure (when the operation pressure is to reduce the maintenance needs. over 90% of the set pressure the results of the tightness test under point 6.3 may be not valid. CAUSE 1) Variable backpressure. REMEDY 1) For standard valves ensure that the discharge piping diameter is equal or higher than the valve outlet diameter and that the discharge piping is not cloggy. 2) The backpressure is different from the 2) The valve must be reset for the new one specified in the order. backpressure. 3) The ring nut of the spring adjustor is 3) Reset the valve and tighten the counter loose. nut. 4) Poor trim alignment. 4) Operate twice or trice the valve in order to allow self-alignment of the trim. 5) Too much turbulence at valve inlet 5) Modify the valve arrangement. (reduction of the set pressure). REMEDY 1) Ensure that in case of liquid service the ring is in the lowest position. For gas service adjust it correctly. 2) Insufficient discharge capacity. 2) Ensure that the discharge piping is not cloggy or too long. 3) The valve is oversized. 3) Replace the valve with a smaller one. 4) Too high head losses in the upstream 4) Increase the blow-down by setting the piping. blow-down ring closer to the plug. 5) The opening backpressure is too low. 5) Remove the adjusting ring from the plug.
Leakage
FAULT
FAULT
13
APPENDIX 1
VALVES FOR GAS AND VAPOURS SERVICE
BLOW DOWN RING SETTING, EXPRESSED IN NUMBER OF NOTCHES FROM CONTACT AGAINST DISK HOLDER
14
APPENDIX 2
VALVES FOR LIQUID SERVICE
BLOW DOWN RING SETTING, EXPRESSED IN NUMBER OF NOTCHES FROM CONTACT AGAINST DISK HOLDER
The blow down ring settings are also valid for alternating service on compressible and incompressible fluids and for service on bi-phase mixtures (mixtures with max 5% in mass of gas).
15
The blow down ring settings are also valid for alternating service on compressible and incompressible fluids and for service on bi-phase mixtures (mixtures with max 5% in mass of gas).