VOLUME-12 PIPING,VALVESANDACCESSORIES Chapter-6

6.2 RELIEF VALVE

Contents 26/37
 DOCUMENT NO. T-005(0-2

23 October' 96

INSTRUCTION MANUAL
FOR
RES er i es S a f e t y ReI i e f Val v es

REC TYPE (RECI00~REC700)

REB TYPE (REBI00~REB700)
RES TYPE (RESIOO)
RECP TYPE ( RECPIOO~RECP300 )
REBP TYPE ( REBPI00~REBP300 )

FUKUI SEISAKUSHO CO..LTD.

 PRECAUTIONS ON SAFE OPERATION

DO NOT FAIL TO READ THROUGH THE FOLLOWING PRECAUTIONS PRIOR TO USING SAFETY
VALVE, AS IT IS ARRANGED TO ENSURE SAFE OPERATION OF THE EQUIPYENT.

FUKUI SEISAKUSHO CO., LTD. is a professional .anufacturer of safety valves, and has
provided custoaers with .any safety valves.
The instruction .anual describes the warning and safety precautions at its begining,
so that the safety valves can be used in safe and under reliable conditions.
If these warnines and precautions are fully read prior to handline, repair or
aaintenance, it will be possible to .ini.ize any uDstable conditions which .ay be
caused due to accident, incorrect handling or unsafe operation.
It is absolutely I.possible for FUKUI to assure/predi~t all possible daneers or
risks which .ay occur at the custo.er, user or .aintenance/repair co.plny, and
therefore to provide thea with advise.
When perfor.ing aaintenance, repair or operation, using any other .ethod or tool,
which is not covered in the .anual, it is necessary to fully acknowledge, that the
safety of the operator hi.self or the safety valve .ay be co.pro.ised.
Since hieb-pressure/hieh te.perature fluid is used for testing, or during installa-
tion and/or prior to re.oval of safety valve, it is necessary to put on the protec-
tive glasses, earplugs, safety gloves, etc.
Since the work environ.ent for FUKUI's product, including danger which .ay be
present during such work .ay be extre.ely diversified, it is not possible for FUKUI
to predict the provable injury or da.age. It is to be acknowledged that the warning,
precautions, etc. are reco •• endations only for a safety procedure and are provided
as an aid for safety.

PREVENTIVE MEASURES FOR SAFETY

DO NOT FAIL TO OBSERVE THE FOLLOWING PRECAUTIONS, TO ENSURE THE SAFETY DURING TEST,
INSTALLATION, YAINTENANCE, ETC. OF SAFETY VALVE.

1. Do not stand in front of safety valve outlet while the safety valve is being
tested or operating.
2. Be sure to put on earplugs while the safety valve is being tested or operating.
3. Hever atteapt to look through the valve outlet carelessly during adjust.ent or
valve seat leakage test.
4. Hever install the safety valve horizontally, i.e., the valve inlet centerline
shall be vertical with base of valve facing down.
5. Be sure to lead the drain piping to safe place fro. the safety valve should a
connection be provided.
6. Secure a proper space at the clrcu.ference of safety valve, to allow the
accessing in 360· , plus another space at the upper side, to allow the
disasse.bling for test or .aintenance.
7. When re.oving the safety valve fro. the eQuip.ent, .ake sure that the internal
pressure is fully relieved, .aie it a rule to stand at a safe position, and put
on the proper protective clothes, and safety glasses as the residual fluid .ay be
splashed. onto your body.
8. Be sure to put aD the test gag if provided always during ring adjust.ent.
After testing, the gag .ust be re.oved.
9. For the safety valve provided with a lift lever. attach such valve with its lever
located at a proper position. so that the lever should not be pulled up
 accidentally.
10. Keep the discharge port of the back pressure adjust.ent needle pointed in the
direction free of danger. If possible, it is desirable to connect the discharge
port to the discharge pipe if it is not subject to excessive back pressure.
Consult with FUKUI for su,gestions and reco •• endations. Do not atte.pt to
execute excessively lon, pipin, for this dischar,e connection.
 Fukui Seisakusha Co .. Ltd.

CONTENTS

I. Introduction
............................................................................................
2. Handling and Storage

Handling Precautions .....

........
............................................................... I
Storing Precautions ..............................................................................................................................................................
2
3. Installation

3.1 Valve Installation 2

3.2 Work Related To Mounting Base 3
3.3 Discharge Pipe ...........•................................................................... 4

4. Hydrostatic Pressure Test 5

5. Maintenance

5.1 Valve Removal " .. " " '" '~.6

5.2 Disassembly 7
5.3 Checkup 11
5.4 Lapping 13
5.5 Cleaning 16
5.6 Reassembly 16
6. Test and Adjustments

6.1 Set Pressure Adjustments ..... " . . .. .. .... .. . .. . .... .. .. .. . . .. . . . . . ... . ... . .. . . .. .... .. . .. 19
6.2 Blow-off Pressure Tolerance 20
6.3 PerformanceTest (for operational stability) 21
6.4 Nozzle Seat Tightness Test . . .. .. .. ... .. . .. .. ...... . .. . . .. . ... . .. . ... . . .. ... . ..... .. .. 21
6.5 Set-Pressure Changes :.. 22

7. Spare Parts 23
8. Maintenance Tools and Supplies

8.1 Lapping Blocks 24

8.2 Lapping Kit 24
8.3 Disassembly and Reassembly Tools 25
9. D i s a s seab l r and R ea s seab l y for RES type) 26

1 O. D i s a s s eab l y and R ea s seab l y for R E C p. REB P type) •••••••••.. 30

 Fukui Seisakusho Co.. Ltd.

1. Introduction

We, Fukui Seisakusho Co., Ltd., are a Japanese leading valve manufacturer specializing in
the production of safety valves, relief valves and safety relief valves for a variety of
applications ranging from cryogenic to high temperature services and very low to ultra-high
pressure services, thereby contributing to reliable protection of and safety in operation of
various pressure vessels including boilers and other process equipment.

This instruction manual describes the storage, handling, installation, maintenance, tests and
adjustments, spare pans and maintenance tools to ensure that our FUKUI products are used
in the best possible conditions. To perform safe operation and minimize maintenance costs,
all the instructions herein contained should be strictly observed.

2. Handling and Storage

Although our s~fety relief valves may give you an impression of being robust and sturdy,
their vital sections are delicate and significantly susceptible to damage because of their
highly sophisticated pans that are finished to extreme precision to ensure the best valve
performance and perfect gas-tightness between the nozzle seat and the disc.

To realize this, our valves are manufactured under strict quality control and carefully tested
and inspected in accordance with OUT stringent company standards before delivery. To
maintain the valves always in the best possible operating condition, the following
handling/storing instructions are especially important and should therefore be strictly
observed. For related information, see liS B821O, API RP520 and ASME Section VIn,
Appendix M.

Handllaa PrecButlons

(1) Handle the safety relief valves with utmost care in unpacking and transportation so that
no strong shocks are imparted to them. Otherwise their vital and sensitive parts may be
adversely affected, resulting in malfunction or seat leakage .

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(2) Never hook a rope or the like on the lifting lever (of an open type safety relief valve) or
the bonnet at the inside because contact of such a rope with the spring may adversely
affect the valve performance.

StOrlnQ PreCBUUOOS

(1) Safety relief valves are often delivered several months before installation. Therefore. in
order to prevent any possible ingress of dust and other foreign matter into the valve
interior. do no remove the protective plates (or guard packings) from the inlet and outlet
flanges until they are installed on specific equipment or inspected for acceptance. but
store them in this condition in a room free of dust and moisture. Storing in such a clean
environment is the basic requirement for maintaining the perfect function and gas-
tightness of the valves after installation.

(2) Do not stack safety relief valves together with other products. but store them with their
inlet sides facing downwards.

3. Installation

3.1 Valve Installation

(1) Before installinga safety relief valve. perform careful visual inspectionon the valve
and remove all the flange protective materials from the inlet and outlet. and also
temporary fittings or fillings such as a desiccating agent from the space that is
below the nozzle seat, or from the valve outlet interior.

(2) If there is any foreign matter present inside the valve, particularlyon and around the
nozzle seat, wipe it off with a clean cloth or remove it using clean compressed air,
because such foreign matter may be caught between the disc and the nozzle seat
when the valve is closed. resulting in leakage.

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Test gag

Plug
Gasket
'"
Cap

Fig. 2 Test Gag and Plug

S. Maintenance

In order to maintain the valve performance at its best, it is necessary to ensure that the valve
operating conditions are well grasped. In short, the functions and service life of safety
relief valves are totally dependant on how properly maintenance is performed. Therefore,
observe the following procedure.

5.1 Valve Removal

After making sure that no fluid pressure remains inside the facility or pressure
equipment, remove the safety relief valve from the equipment, and carry it into and
disassemble it in a safe and clean room. In order to facilitate later reassembly work,
place parts in the order of disassembly. When it is difficult to move the safety relief
valve to such a place. make a small box available. disassemble the valve and put the
disassembled parts in it so that they will not be lost or mixed up with those of other
safety relief valves.

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5.2 Disassembly

5.2.1 Disassembly Procedure of REB and REC Series

Conventional Type (REC Series) Bellows Type (REB Series)

Cap
Adjusting screw
Adjusting screw locle nut
Gasket
Upper spring washer
Spring
Spindle

. Stud bolt & nut

Lower spring washer
Gaslcet

Belows
Guide
Disc holder

Gasket

Adjusting ring
Nozzle seat
Valve body

Fig. 3 Valve Construction Fig. 4 Valve Construction

(1) Break: the cap seal and remove the cap. (For a lifting lever type. see [he procedure
given in Section 5.2.2.)

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(2) Break the seal for the adjusting ring lock bolt, remove this lock bolt, look at the
adjusting ring through the bolt hole, tum the adjusting ring clockwise notch by
notch until it contacts the disc, and record the number of notches thus moved for
later use in resetting this adjusting ring.

(3) To facilitate the later reassembly procedure, mark: the adjusting screw position or
record the length from the top of the adjusting screw lock nut to that of the bonnet
before loosening the adjusting screw Jock nut. Then, loosen this lock nut and turn
the adjusting screw counterclockwise viewed from above, to remove the
compression force from the spring.

(4) Remove the stud bolt nuts and lift the bonnet off from the valve body.

(5) Remove the assembly consisting of the spring and upper/lower spring ~ashers.

(6) The spindle of a bellows type safety relief valve is connected to the disc holder by
means of a drop screw system. Therefore, lifting the spindle allows simultaneous
removal of the guide, the disc holder and the bellows. The spindle can be removed
from the disc holder by turning the spindle counterclockwise and pulling it out.
Since the bellows is welded directly to the disc holder, it cannot be removed from
the disc holder. Take care not to exert undue force on the bellows as it will be
unnecessarily bent or distorted.

(7) Since the spindle of a conventional type safety relief valve is not connected to the
disc holder, the spindle, the guide and the disc holder can be removed. First
remove the spindle. The guide can be easily removed from the disc holder if they
are put on a plate in the flat area.

(8) Remove the disc from the disc holder, put the disc holder on a V-block in such a
manner that it does not move, and strike the spring pins that are symmetrically
arranged, into the disc using a special disassembly tool (optional). (These spring
pins are designed to drop into the disc holes, which are larger than those of the
pins.) If no such special disassembly or reassembly tool is available, measure and

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record each distance between the outer periphery of the disc holder and the spring
pins so that these pins can be driven at these recorded positions.

Disassembly tool

Spring pin Disc holder

Disc

. V-block

Fig. 5 Removal of Disc from Disc Holder

(9) Remove the adjusting ring from the nozzle seat.

(10) Do not disassemble the nozzle seat. but perform maintenance on it as assembled in
the valve body. However, if its removal becomes necessary, then use a nozzle seat
disassembly tool (optional) as shown in Fig. 6.

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 Fukui Seisakusho Co .. Ltd.

Nozzle seat disassembly tool

Fig. 6 Removal of Nozzle Seat

(11) Make sure that all the gaskets have been completely removed. If there are some
gasket scraps remaining on the flanges, etc., be sure to remove them thoroughly
using a scraper or the like.

5.2.2 Disassembly of the Cap (for Lifting Lever Type)

(I) Open Lever Type (Type C)

Break the cap seal, and pull out the split pin to remove the pin and the lifting lever
from the valve body. Loosen the set screw and remove the cap. Remove the lifting
washer after its position is properly marked or recorded. [This procedure is the
same as that for the packed lever type referred to in Section (2) below.]

(2) Packed Lever Type (Type D)

Tum the lifting lever clockwise by about 90- so that the lifting fork:is housed in the
bulgy section of the cap, remove the nuts from the stud bolts of the cap and lift the
cap while slightly inclining it so that the lifting fork will not be caught by the lifting
washer. This procedure allows easy cap removal from the valve body.

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Open Lever Type (Type C) Closed Lever Type (Type D)

Spindle nut

Spindle nut
Ullin, washcc
Uf1iqlork
_==~~~
Stud bolt & DUt
Owet
Ufting lever

Set screw

(Lever for small-sized safety .valves)

Fig. 7 Cap Removal

5.3 Checkup

Carefully check all the disassembled parts and components one by one while taking
note of the following instructions.

(1) Mating Surfaces of Disc and Nozzle Seat

When there are any indications of damages, biting or scratches on the mating
surfaces, the disc and the nozzle seat should be properly lapped to correct the
situation.

(2) Sliding Surfaces of Disc Holder and Guide

When there are any indications of scratches or attached foreign matter, correct.pte
situation by using fine-grained sandpaper for smooth finish. Upon completion of
the repairs, slide the disc holder through the guide to check for smooth movement

(3) Spindle Concentricity

In order to transmit the spring load to the disc efficiently, the spindle must be free
from bending. As the spindle is susceptible to bending by rough handling or

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excess clamping of the test gag, check: it for bending in accordance with the
following procedure. As shown in Fig. 8, chuck a V-block on the lathe, put the
spindle on this V-block at its end and support the other end of the spindle at the
tailstock center. Put a dial gauge at or near the center of the spindle and tum the
spindle slowly to measure its runout. The max. allowable runout value is 0.15
mm. Therefore. when the measurement obtained exceeds this value. the spindle
. should be touched up (repaired) or replaced with a new one.

V-block

Tailstock center

Dial gauge

Fig. 8 Checking of Spindle Concentricity

(4) Body-Bonnet Mating Sections

If there are scratches. dust or other foreign matter found on the body-bonnet mating
sections, correct the situation by thoroughly removing them. If they are not
removed, the spindle concentricity will be easily impaired, resulting in adverse
effect on the valve performance.

(5) Rust of the Body

When there is any heavily rusted area on the internal or external surface of the valve
body, remove the rust using a wire brush and apply rust inhibiting paint to such an
area (for safety valves for use at high temperatures, use a heat resistant type paint).
This arrangement will be helpful in carrying out future maintenance with ease.

Note: Never apply any such paint to the body-bonnet mating section .

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(6) Corrosion of the Spring

If the spring is corroded or cracked. it is recommended that the spring be subjected

to liquid penetrant tests (or color checking). When its defect is significant enough
to cause concern about its possible damage during operation. replace it with a new

one.

5.4 Lapping

The parts that require lapping are the disc and the nozzle seat. This lapping work is
easily attained if done with utmost care. However. when the disc and/or the nozzle seat
are unrepairablydamaged. be sure to replace with spare parts.

5.4.1 Lapping Tools Required

(1) Lapping blocks

Three (3) types of lapping blocks (i.e., for rough. intermediate and final
finishes). Use with the specified lapping compound is recommended.

(2) ReconditioningBlock

The lapping blocks require constant reconditioning of their surfaces after they are
used for lapping the disc and the nozzle seat. Although these blocks can be
reconditioned by means of mutual lapping. use of this reconditioning block
providesmore efficient reconditioning.

(3) Lapping Compounds

a) # 600 for rough finish

b) #1200 for intermediatefinish
c) #3000 for final finish

(4) Lapping Oil (machineoil used to knead lappingcompounds)

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5.4.2 Lapping Precautions

Observe the following instructions, and lap the disc and the nozzle seat in a clean room.

(1) Clean the disc, the nozzle seat and all the lapping blocks until dust and other foreign
matter are thoroughly removed.

(2) Newly knead each compound to the appropriate hardness, apply it thinly to the
lapping surface of the lapping block and perform lapping. Excess application of such
a compound may cause the lapping surfaces of the lapping blocks to be rounded off
at the annular section, resulting in a convex form.

(3) Lap the disc or the nozzle with the lapping blocks, in the horizontal position.

(4) To correctly judge the quality of the lapped mating surfaces, sufficient experience is
required. However, one of the simplest methods is to apply light to the lapped
surfaces because this makes the concave section look shadowy in contrast to the
normal section .which is shining. Therefore, the disappearance of this shadow-
looking section should be considered as successful completion of the lapping work.

(5) In the course of the lapping procedure, recondition each lapping block from time to
time as required. This reconditioning work: should be conducted when the worn
lapping surface of a specific lapping block has shown a different color tone from its
other pan. or that the slightest level difference is felt when touched with your fingers.

(6) Never lap the disc with the nozzle seat,

5.4.3 Disc Lapping

Proceed as follows:

(1) Fix thelapping block for rough finish, on the horizontally positioned table.

(2) Knead the compound #600 with the lapping oil, apply it on the lapping block thinly
and uniformly, put the disc on the lapping block as shown in Fig. 9, hold down the

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disc lightly, turn it little by little to lap it with the lapping block. Until the disc surface
to be lapped comes to fit the lapping block, do not exert excess force.

Lapping block

Fig. 9 Disc and Lapping Block

(3) When the lapped surface shows a uniform satin finish, cleanly remove the
compound. Use of thinner for this purpose brings about efficient removal. The
number of lappings should be increased depending upon the lapped surface condition
of the disc. As a guideline, complete elimination of scratched or otherwise damaged
area(s) from the disc mating surface indicates successful completion of the lapping
work.

(4) Then, repeat the above lapping procedure using the appropriately kneaded compound
#1200. In this process, use the lapping block for intermediate finish.

(5) For final lapping finish, apply the appropriately kneaded compound #3000 to the
final-finish lapping block, and repeat the same procedure as above. When the
lapping block surface is not oily enough, the lapping block and the disc may be
subjected to seizure. Therefore, exercise good care to ensure that an excellent oil film
is always maintained between the lapping block and the disc.

5.4.4 Lapping of Nozzle Seat

As shown in Fig. 10, lap the nozzle seat in the same procedure as done for the disc. Use
the appropriate compound for each lapping block as also done for the disc.

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Rotatingjig

Lapping block

Nozzle seat

Fig. 10 Lapping of Nozzle Seat

5.5 Cleaning

Thoroughly clean the lapped mating surfaces of the disc and the nozzle seat as well as
other repaired parts. using thinner or other appropriatecleaning solution.

5.6 Reassembly

The safety relief valves can be reassembledjust by reversing the disassembly procedure
except for a: few steps. Replace the gaskets properly by making reference to the
assembly drawing and taking note of the followinginstructions.

(1) Thoroughly clean the interior of the valve body,especially the lapped surfaces of the
disc and the nozzle seat, using a clean and soft cloth, and apply a new anti-seizure
agent again to the parts where it was previously applied (such as threaded sections,
the spindle tip, the adjusting screws, and the upper and lower spring washers).

(2) Screw the adjusting ring to any appropriateposition lower than the top surface of the
nozzle seat. (After the disc is reassembled, this adjusting ring should be located at
the original position.)

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(3) Using a reassembly tool (optional), replace the spring pin that connects the disc to the
disc holder (see Fig. 5).

(4) Before reassembling the guide and the disc holder into the valve body, make sure that
no foreign matter exists on the area where the guide contacts the valve body, and then
replace a new gasket. Wipe the lapped surfaces of the disc and the nozzle seat, with
a clean cloth. Having confirmed that no foreign matter exists on the outer periphery
of the disc holder and on the inner surface of the guide, temporarily reassemble the
disc holder into the guide, and slowly place this disc holder/guide assembly on the
nozzle seat

(5) Temporarily reassemble the upper spring washer, the spring, the lower spring
washer, the spindle and the bonnet together. At this time, apply an anti-seizure agent
to the spindle tip, and place the spindle in such a manner that its tip is positioned in
the center of the disc holder, while taking care not to hit its tip against other valve
sections. Then, place this assembly on the valve body with the bonnet bolt holes
aligned with the stud bolts of the body.

For bellows type safety relief valves, screw the spindle into the disc holder before
starting the above procedure.

(6) Slightly tum the bonnet clockwise and counterclockwise a couple of times to check if
it is correctly positioned on the mating section of the valve body. (If the bonnet
cannot be moved smoothly by the clearance between the stud bolts and the bonnet
bolt holes, this indicates that foreign matter is present or that the mating section(s) is
damaged. It is therefore necessary to eliminate all possible causes and correct the
situation.) Then, alternately fasten the symmetrically arranged nuts to avoid uneven
fastening of the bonnet

(7) Screw the adjusting screw to the position measured just before the disassembly so
that the spring is compressed again to the specified amount. At this time, hold the
spindle at its top using pliers (taking care not to damage it) to prevent rotating.

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(8) Before replacing the lock bolt of the adjusting ring, adjust the adjusting ring to be in
the position that was recorded just before the disassembly. Then, put a new gasket
as shown in Fig. 11 and fasten the lock bolt in such a manner that its tip is positioned
in one of the notches provided on the outer periphery of the adjusting ring.

Lock bolt Valve body Adjusting ring

Gasket abt. 0.5 mm

Fig. 11 Positional Relationship between Adjusting Ring and Lock Bolt

(9) After making necessary adjustments by operating the safety relief valve, replace the
cap and provide a new seal. This will complete the reassembly procedure.

6. Test and Adjustments

It is necessary to perform tests and make adjustments on the safety relief valves that have
been given maintenance, before they are installed on a specific facility or pressure
equipment, The test items are as follows:

1) Set pressure adjustments

2) Performance test (for operational stability)
3) Nozzle seat tightness

To conduct the above tests using a test bench, observe the following instructions.

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(1) Use clean compressed air to remove sand, dust, rust and other foreign matter from the
interior of the test bench.

(2) Thoroughly clean the nozzle seat and its vicinity until no foreign maner exists. Also,
check to see that there is no foreign matter inside the valve outlet

(3) In these tests, use a pressure gauge that has been correctly calibrated by means of a
deadweight type tester or the like.

Safety relief valve

Pressure gauge

Stop valve

Pressure vessel

Drain valve Warer inler

Test bench (optional)

Fig. 12 Test Setup

6.1 Set Pressure Adjustments

The value equal or close to the specified set pressure can be obtained if the adjusting
screw is set at the position that was recorded or marked before the disassembly work.

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However, set pressure adjustments are required when the set pressure is, for some
reason or other, larger than specified, or there is no record about the position of the
adjusting screw. To make such adjustments, first remove the cap from the valve body
and proceed as follows while taking care to ensure that the spindle does not rotate.

Table 1 Set Pressure Adjustments

To increase the set pressure Tum the adjusting screw clockwise (when viewed
from abovel for tightening.

To decrease the set pressure Tum the adjusting screw counterclockwise (when
viewed from above) for loosening.

Table 2 Relationship between Orifice Type and Pressure Change

Orificc~ D E F G H J K L M N .P _Q R T
Change_(%l 39 31 26 21 17 13 11 9 8 8 6 5 4 3
The above table shows me pressure change raIC (t.) for each orifice.

When the sharp popping pressure cannot be obtained for reasons of the test bench in
use, 'allow the adjusting ring to contact the disc, set the adjusting ring at a position
lower by one or two notches, and check the set pressure. After the test is completed,
rerum the adjusting ring to the original position.

6. 2 Blow-off Pressure Tolerance

(l)The blow-off pressure tolerance for safety relief valves for steam

service should be in conf ora i ty wi th Table 3 below. However. when the set

pressure is not allowed to be greater. the tolerance of the positive(t)

side can be added to that of the negative (-)side.

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 Table 3 Tolerance for blow-off Pressure
. MPa
Unit: (kcg:fIem2)
Set pressure Tolerance
0.5 (5) or less ±0.014 (+0.14)
above 0.5 (5) ,below 2.3 (23) ± {3% of set pressure}
above 2.3 (23) ,below 7 (70) ± 0.07 (+ 0.7)
above 7 (70) + {I % of set pressure}

Notes: ,
I. In general, blow-off pressure shall be used as set pressure of a steam-use
safety valve.

2. The blow-off pressure tolerance of steam-use safety valves for other than
boilers may be set at + 3% of set pressure {min. value + 0.014 MPa
(±0.14 kgflem2)}.

(2) The blow-off pressure tolerance for safety relief valves for gas service

should be less than 110' of the co••ence-to-blow pressure. However the

blow-off pressure tolerance for the case where the blow-off pressure is to

be set shall be ±a to the set pressure. (llinimum ±O.014MPa{±O.14kgf/cm'})

[This section 6.2 is based on lt ea (.2 of JIS B 8210(1994). ]

6.3 Performance test (for operational stability)

After the safety relief valve is set at the specified pressure, operate it at least two times
to check if it stably blows at the same pressure at each operation. In addition, each
time the set pressure is readjusted using the adjusting screw, be sure to fasten the lock
nut with a spanner while holding the adjusting screw in position using another spanner
to prevent the adjusting screw from moving. Upon completion of the adjustments,
replace the cap.

6.4 Nozzle seat tightness test

After the set-pressure adjustments have been successfully made, maintain the line
pressure of the test bench at 90% of the set pressure (however, when the set pressure
is less than 3.5 kgf/cm2G, the pressure value obtained by deducting 0.35 kgf/cm2G
from the set pressure should be used) using clean air or N2 gas as test fluid, and apply
soapy water to the valve outlet, the pipe connections, the threaded sections of nipples;
etc. to form a film on them. If this film docs not begin to expand in 10 to 20 seconds,
this safety relief valve shall be considered acceptable. Fig. 13 shows a leakage test
setup specified in API 521.
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Copper pipe (0.0. 8 mm 11.0. 6 mm)

/
Test bench

Fig. 13 Leakage Test Setup specified in API 527

(as per API 527)

Table 4 Leakage ToleI1lJ1Ce

Valve Type Orifice Type No. of Leakage

bu bbles/min. im3/24 b)
REB.REBP up to F (inclusive) 50 0.021
(BelJows__1'}'pe) beyond G (inclusive) 30 0.013
REC,RES,RECP up to F (inclusive) 40 0.017
(Convcabona111Pe) beyond G (inclusive) 20 0.0085

After these tests are completed and the valve concerned is accepted, firmly fasten the
cap and provide a seal accordingly.

6.5 Set-Pressure Changes

When it becomes necessary to change the set pressure value specified on the nameplate
to a different value, the spring may be required to be changed. Since the spring greatly
affects the valve performance, a spring to be used is designed to best suit the set
pressure. Therefore. when the pressure setting is to be changed, this should be

·22·
 Fukui Seisakusha Co.. Ltd.

notified to the valve manufacturer (Fukui Seisakusho Co., Ltd.) to check if the existing
spring is suitable for the intended pressure setting. When spring change is required,
be sure to change the upper and lower spring washers together with the spring. In
addition, the nameplate description about the set pressure should be changed
accordingly by re-starnping or the whole nameplate changed with a nameplate bearing
the new set pressure value.

7. Spare Parts

It is important to have the reasonable number of spare parts in consideration of the service
conditions. When it becomes necessary to repair or replace some pans as a result of the
maintenance or other servicing done, and yet no such spares are available, the facility or
equipment related to this safety relief valve will be forced to shut down for an extended
period of time. This may result in a tremendous loss (economical, time or otherwise) on the
part of the plant operator.

Generally. the supply of spare parts covers gaskets. a spring (with upper and lower spring
washers), a disc, a bellows, a nozzle seat. etc. It is recommended that any part that may be
expected to corrode should be included as spare pans. Since spare spring assembly,
disc/disc holder assembly, and bellows assembly are manufactured in accordance with the
specifications of each safety relief valve, never use them in other safety valves, even if the
size or pressure rating requirement is met

In ordering such spare parts, please advise us, in addition to the pans number, of the serial
number, size, and set pressure value indicated on the nameplate of the applicable safety
relief valve, and other information that is deemed necessary.

·23·
 Fukui Seisakusho Co .• Ltd.

8. Maintenance Tools and Supplies

The following special tools and supplies are optional and are required for proper
maintenance of safety relief valves.

8.1 Lapping blocks designed to suit the valve size and the disc and nozzle seat shapes.
(See Figs. 9 and 10.)

8.2 Lapping kit

(1) Lapping compounds (LP-l for #600, LP-2 for #1200 and LP-3 for #3000)

(2) Lapping oil (LP-4)

Lapping compounds are supplied in a box in the form of a kit, with foamed polystyrene
packed for easy transportation.

Fig. 14 Lapping Compound Kit and Plastic Bottles

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 Fukui SeisaJcusho Co .• Ltd.

8.3 Disassembly and Reassembly Tools

(1) Disassembly and reassembly tools for disc and disc holder (See Fig. 5.)
. (one disassembly tool and one reassembly tool)

For Disassembly
H
2) )

For Reassembly e:::v 1

(2) Disassembly and reassembly tools for nozzle seat (Sec Fig. 6.)

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9. Disassembly and Reassembly (for RES type)

Cap

Adjusting Screw
Lock Nut
Gasket
Spring Case
Spring Retainer
Spring
Valve Spindle
Stud Bolt & Nut
Spring Washer
Gasket
Guide
Disc Holder
Holder Ring
Disc
Adjusting Ring
Valve Seat
Body
Gasket
Lock Bolt of
Adjusting Ring

Fig. 15

l~ Remove the cap.

For a lifting lever type, see
Disassembly of Lifting Lever' on Page /0.

2. For convenience of reassembly work, provide a marking

on the position of the adjusting screw or record the

length of adjusting screw before loosening the lock

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 nut.

J. Remove the lock bolt cf the adjusting ring, lift this

ring until it touches the disc while counting the

number of notches and then record this number.

4. Loosen the adjusting screw to remove the compressive

force from the spring.

5. Remove the hexagon nut of stud bolt and then the

spring case.

(Note]

After confirmation is made that the adjusting screw

is completely loosened, loosen the nut.

6. Remove the spring, the spring washer and the spring

retainer. For safety valves with a small nominal

diameter, these parts can be removed together with

the spindle.
However, in the case of valves with
a large diameter it is suggested that these should

be individually removed because of the large weight.

7. Remove the spindle, the holder and the disc.

In this case, remove the holder and the guide in the

assembled condition, put them on a flat place and

then remove the guide.

8. In order to remove the disc from the holder, fix

the holder on a V-block or the like and strike

in the pins provided on the symmetrical positions

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 as they are. Since the disc holes are larger,

the pins will be allowed to fall into these holes,

thus separating the disc from the holder.

(See Fig. 5.) Take due care not to lose the
pins (2 pcs.).

9. Remove the adjusting ring from the valve seat.

10. It is advisable that the valve seat should not be

disassembled.

[Reassembly]

Reassembly should be carried out in the order reverse to

that of the disassembly, while observing the following

precautions.

1. Wash all the parts with utmost care.

2. Check all the gaskets and replace if necessary.

J. Take special care not to impair the lapped surfaces

of the valve seat and the disc when the reassembly

work is being made.

4. After the adjusting ring has been screwed in the

valve seat and setting thereof made, provide the lock

bolt of the adjusting ring.

Leave the adjusting ring screwed in, in such a posi-

tion that its Upper end is below the valve seat sur-

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 face.

After compressive force is given to the spring, raise

the adjusting ring up to the position where it comes

in contact with the valve disc, lower it one notch by

one notch counting the number of notches and set it

to the number of notches recorded at the time of the

disassembly.

5. When replacing the cap, be sure to provide a clearance

of approx. 1 rom between the lifting lever and the lift-

ing fitting so that no contact can be made between them.

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lO.Disasse.bly and Reasse.bly (for RECP,REBP type)

[Disasse.bly]

REBP TYPE

CAP
ADJUSTING SCREI
ADJ. SCREI LOCI NUT
GASIET
UPPER SPR.rASHER
SPINDLE
SPRING
BONNET
STUD BOLTS/NUTS
LOIER SPR.IASHER

DISC HOLDER
O-RING 3
DISC
DISC RETAINER
ADJUSTING RING
GASlET
ADJ.RING LOCI BOLT
NOZZLE

F i9. 16

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 I. Re a o v e the CAP.

2. Provide I .. rklnc on the position of the ADJUSTING SCREI and

record the hlcht of the ADJUSTING SCREr before loosenlnc the ADJ.
SCREI LOCI NUT. for convenience o t ' r,elssubly work.

3. Re.ove thr ADJ. RING LOCI BOLT.

4. Turn the ADJUSTING RING until It touches the DISC one notch by one
notch coutlnc the nu.ber of notchel Ind then record thll nu.ber.

5. Loo e e n the ADJ. SCREr LOCI NUT Ind then loosen the ADJUSTING SCREf
to tlke IWIY the co.prelslve force fro. the SPRING.

5. Re.ove the all n u t s of s t u d bolt. and then r e a o v e the BONNET.

[ CAUTION)

AFTER ENSURING TnE ADJUSTING SCREI IS COWPLETELY LOOSENED.

LOOS!N TOE NUTS OP STUD BOLTS.

7. Re.ove the UPPER SPR. lASHER. SPRING. LOrER SPI. WASHER and
SPINDLE

8. Re.ove the DISC HOLDEI with the GUIDE.

Pu~ the. flit place and then re.ove the DISC HOLDER fro. the GUIDE.
IE The SPINDLE of a bellow. type safety relief valve is connected to the DISC
HOLDER by aean s of a drop screw syste•. Therefore. lifting the SPINDLE allows

si.ultlneous re.oval of the GUIDE. the DISC HOLDER and the BELLOWS. The
SPINDLE can be re.oved fro. the DISC HOLDER by turning the SPINDLE counter-

clockwise and pulling it out. After rnovinc SET SCREW of the BELLOWS PIECE.
the BELLOrS can be re.oved fro. the DISC HOLDER by turning the BELLOWS PIECES

counterclockwise.
Since the BELLors is welded directly to the BELLOrS PIECE. it cannot be

re.oved fro. the BELLOrS PIECE. Take care not to exert undue force on the

BELLOIS al it will be unnecessarily bent or distorted.

t. Fix the DISC HOLDER by I vice or like. s nd then loosen the DISC
RETAINER.

[ CAUTION)

rnEN LOOSENING Tn! DISC RETAINER. TAlE CARE NOT TO INJUIE SEAT
SURFACE OF THE DISC.

10. Re.ove the DISC and the a-RING 3.

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 11. Remove the O-RING 1 that putting in the DISC HOLDER.
The O-RING 2 is not needed to remove.

[ CAUTION]

WUEN REMOVING THE O-RING 1. TAlE CARE NOT TO INJURE SLIDING

SURFACE OF THE DISC nOLDER.

12. Remove the ADJUSTING RING from the NOZZLE.

13. It is advisable that the NOZZLE should not be disassembled.

Reassembly should be carried out in the order reverse to that of

disassembly. while observing the following precautions.

1. Wash all the parts wi t h u t a o s t care.

2. Check all the GASKETs and O-RINGs and replace if necessary.

3. Take special care not to i.pair the seat surface of NOZZLE and DiSC
when the reassembly work is being made.

(. After the ADJUSTING RING has been screwed in the NOZZLE and setting
therof lade. provide the ADJ. LOCK BOLT.
Leave the ADJUSTUHG RING screwed in. in such a position that its
upper end is below the seat surface of the NOZZLE.
After co.pressive force is given to the SPRING. raise the ADJUSTING
RING up to the position where it comes in contacts with the DISC.
lower it one notch by one notch couting the number of notches
recorded at the ti.e of the disasse.bly.

5. Put the O-RING 3 in the DISC HOLDER. before the DISC is setted in
the DISC HOLDER.

6. Take care not to injure seat surface of the disc when fastening the
DISC RETAINER.

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