OPERATING INSTRUCTIONS - Broady Valves Limited
Contents
1. Setting valves with constant back pressure When there is a constant back pressure valves without a balancing seal are set differentially Example A valve without a balancing seal has a set pressure of 20 kg cm and a constant back pressure of 3 kg cm Set valve at 20 3 17kg cm This value is then increased by the corresponding percentage required for the relative high temperature Valves fitted with a balancing seal are only subject to variation due to high temperature or steam service Safety Warning Consult Broady Technical Staff before making any changes to process conditions Blowdown Broady Safety Relief Valves are fitted with a single blowdown ring which may be used to regulate the blowdown Note Blowdown tests must be carried out with the use of a compressed air plant of high capacity especially for large sized valves To correct the blowdown setting proceed as follows i Loosen Clampscrew 4 to allow rotation of Blowdown ring if the ring is not accessible through the valve outlet remove Clampscrew completely and rotate the ring with a screwdriver inserted into the hole left by the screw ii Rotate blowdown ring 33 upwards to increase downwards to decrease blowdown When the desired blowdown is reached tighten the Clampscrew 4 The blowdown test carried out with low discharge capacities gives a reseating pressure higher than that which would occur in discharge conditions Theref2. 0038 of Middlemarch Office Village Siskin Drive Coventry CV3 4FJ UK under EC Type Examination Certificate RPS 0160353 04 and EC Certificate of Conformity RPS 0160389 01 Locknut Adjusting Screw Screwed Pin Product Description Safety Accessory Clampscrew Product Reference Type 3500 Relief Valve Spring Carrier BE l Locknut Screwed Pin Comprising Not Applicable Pin Collar Large Serial Number Not Applicable Pin Collar Small Applicable Standards None Bellows Washer when Bellows not fitted Other Applicable Directives None Stud Body Bonnet Various Nut Body Bonnet Various A Dew cl Signed JEM Name A J Derrick Joint Guide Position Managing Director Joint Ca Cap Date 24 April 2002 Joint Clampscrew ey Valves not fitted with Bellows have two Guide Joints Declaration of Conformity Form OF 186 B D iss A Recommended spare parts i Lifting Eyebolt 65 Not supplied Broady Flow Control Limited 2002 2003 SD23 3500 Version 2 1 07 03 APD
3. OPERATING INSTRUCTIONS Category IV Safety Accessory Type 3500 Relief Valve CE Notified Body No 0038 Application Suitable for compressed air gas water oil and steam service Operation The set pressure can be varied as required by compressing or relaxing the spring using the adjusting screw Clockwise turns compress the spring increasing the set pressure Anti clockwise turns relax the spring decreasing the set pressure Lifting and Handling Wooden cases should be lifted using either a Fork Lift Vehicle or a Crane with adequate Safety Approved slings applied to carry the weight which will be evenly distributed within the case Important All manual handling operations should be carried out in compliance with the Manual Handling Operations Regulations 1992 SI 1992 2793 EC Directive 90 269 EEC Storage Valves with Screwed ends shall have plugs fitted in their connections to prevent ingress of dirt etc Flanged valves shall have their bores blanked off We recommend that plugs blanks be removed immediately prior to installation Safety Warning Discharge from outlet may be violent and must not be allowed to create a hazard to persons or property Testing It is recommended that the following tests be carried out before installation of the valve Seat tightness and set pressure Test Equipment Connect valve inlet to a pressure vessel of at least 100 litres capacity in whic
4. h pressure may be raised gradually and measured by means of a precision pressure gauge Seat Tightness Test The valve outlet should be fitted with an appropriately sized leakage detector see Fig 1 in accordance with API 527 Raise inlet pressure to 90 of set pressure and check that the number of air bubbles per minute which pass through the water does not exceed the values below Maximum Leakage Bubbles per minute Femget sf Should the leakage exceed the stated value refer to table Faults in Operation Fig 2 EQUIPMENT FOR SEAT TIGHTNESS TEST Valve moutied ano secures Hee EAE MAY g pe tsipa tast rie m Seca Leskege Driecior vih Clampe Retaining Firg Securely tiled Obgervalion Cup _ Serey kembre Him thick Rubbers Pill watar level do botiom ev ipelieevtee Pala Fig 1 API 527 compliant leakage detector Set Pressure Test Check that valve starts opening at required set pressure refer to Valve Nameplate for correct value tolerating a change of 0 1 5kg em for set pressures of less than 5kg cm and of 3 for set pressures of 5kg cm and higher Do not pop the valve if a tank of adequate capacity is not available to avoid denting the seat which would cause leakage Changes outside the stated tolerances must be corrected by varying the spring compression using the Adjusting Screw 13 To regulate the set pressure 1 Fit valve to Test Rig with no pressure on valve inle
5. ill result in an explosion Broady Flow Control Limited 2002 2003 D23 3500 Version 2 1 07 03 APD OPERATING INSTRUCTIONS Danger of Explosion AN Oxygen Service Carefully degrease all components before assembling valves Failure to do so will result in an explosion Reassembly Carry out reverse of operations listed for disassembly taking care to Avoid scratching lapped surfaces Note To prevent damage to Disc Nozzle faces hold Spindle 5 with screwdriver in slot on Spindle end turn whilst compressing Spring Clean the trim thoroughly throughout Lubricate Adjusting Screw Spring Carrier and all threads with graphite grease T jjis r fi Lt 65 Fig 2 Faults in Operation FAULT CAUSES SOLUTIONS Leakage 1 Presence of foreign matter between seat and disc 2 Scratching or pitting on seat surface 3 Valve used with a medium other than specified when ordering 4 Valve not mounted vertically Discharge at _ 1 Variable back pressure incorrect pressure 2 Back pressures different from specified when ordered 3 Loosening of lock nut on spring adjusting screw 4 Poor trim alignment 1 Discharge valve once or twice consecutively Should leakage continue disassemble valve and clean trim 2 Disassemble valve grind and lap seat 3 Lap seat and disc more finely if the valve originally ordered for liquid service is used with gas 4 Cor
6. ly lapping compound to smooth surface of block Pass Nozzle 2 seating surface across smooth surface in a figure of eight movement During lapping operation make sure no foreign matter is on either lapped surface or block Note Lapped parts must be carefully cleaned before assembling to remove every trace of lapping compound Safety Warning Before dismantling ensure that the valve has been isolated from the pressure and the adjusting screw has been removed Dismantling and Reassembly Dismantling 1 Remove Cap amp Joint 3 amp 32 2 Measure position of the Adjusting screw 13 and record for re assembly purposes 3 Unscrew Locknut 14 and remove with Adjusting screw 13 4 Remove Bonnet 10 from Body 1 by unscrewing Nuts 24 5 Remove Spring Carriers 17 and Spring 29 from Spindle 5 6 Using Spindle 5 as a handle lift out remaining internals 7 Remove Pin 9 and unscrew Stem 11 from Disc Holder 6 8 Remove Stem 11 from Guide 25 9 Remove Disc 4 from Disc Holder 6 by tapping Disc Holder firmly onto a clean wooden surface care should be taken not to misplace the Circlip 35 10 Unscrew Clampscrew 16 from Body 1 11 Unscrew Blowdown Ring 8 from Nozzle 2 12 Unscrew Nozzle 2 from Body 1 Note Replace all Joints with new ones Danger of Explosion Oxygen Service Carefully degrease all components before assembling valves Failure to do so w
7. ore to obtain the same reseating conditions as for a valve during operation lower the blowdown ring by two notches In no case must the blowdown ring be fitted in contact with the disc holder The blowdown ring must be rotated at least two notches to lower it away from the disc holder J Installation Handling When moving the valve for installation maintenance purposes it is recommended that an appropriate M10 M20 Lifting Eyebolt 657 fitted in place of Plug Gag 36 be used Utilising this Eyebolt a Safety Approved chain strap of adequate strength may then be used in conjunction with a suitable crane to lift and move the valve Lifting Eyebolt 65 Not supplied Installation and Commissioning 4 It is most important that the pipeline and valve connections be clean and free from dirt scale etc Avoid bumping or shaking valve to prevent misalignment of trim and damage to flange faces Fit valve in pipeline with flow direction as indicated by arrow cast on valve body with inlet down and Adjusting Screw in vertical position above pipeline It is also advisable to fit a stop valve on high pressure side of line Use inlet and outlet pipework as short as possible and of dimensions equal to the valve connections Uniformly tighten fasteners securing valve connections to pipework Secure outlet pipework in order to reduce vibration and avoid strain on outlet flange Avoid elbows with small curvature radii on the o
8. rect the installation 1 Check that discharge takes place in piping whose dimensions are equal to or greater than those of the outlet connections of the valve and that the discharge piping is free from obstruction 2 The valve must be re calibrated correcting the spring compression for the revised set pressure 3 Tighten lock nut after re calibrating the valve 4 Discharge the valve 2 or 3 times to allow self alignment of the trim Chatter rapid 1 Blowdown ring incorrectly adjusted opening and closing cycle 1 Ensure that the blowdown ring is in the lowest position for liquid service For valves used on gas regulate suitably 2 Insufficient discharge capacity 2 Check that the discharge piping is not too long Check that the valve is not undersized rs 4 R A DY Broady Flow Control Limited English Street Foto ow c ONTROL Kingston upon Hull East Yorkshire HU3 2DU www broady co uk Telephone 01482 619600 Facsimile 01482 619700 EC DECLARATION OF CONFORMITY Issued in accordance with the PRESSURE EQUIPMENT DIRECTIVE PED 97 23 EC We hereby declare that in compliance with the above Directive the product s detailed below have been manufactured in accordance with conformity assessment modules B D Type examination and Full quality assurance ISO 9001 for production final inspection and test as approved by Lloyds Register Notified Body No
9. t 2 Remove the cap 3 3 Prevent Disc Holder 7 rotating by holding Spindle 5 with screwdriver in slot on Spindle end 4 Loosen Locknut 14 fitted to Adjusting Screw 13 5 Adjust using Adjusting Screw 13 until the desired set pressure is achieved Do not allow Disc Holder 7 to rotate 6 Reassemble Cap 3 Note For each set pressure check Locknut 14 must be tightened Opening Pressure Adjustment Settings The following table gives an approximate guide to the amount of adjustment needed to vary the opening pressure Variations in springs are not taken into account Percentage variation of opening pressure relative tof 33 22 12 7 5 4 5 4 13 5 2 5 2 2 1mm of adjusting screw stroke Cold Setting of high temperature valves Cold setting of high temperature valves is often necessary In this case valves must be set at a pressure above the set pressure according to the percentages shown in the following table Tfom 265t0 10 This percentage increase offsets relaxation of the spring caused by expansion of the body and bonnet Cold Setting of valves for steam service When possible valves for steam service should be tested with steam When these valves are set with air at ambient temperatures the following percentage increases in set pressure must be borne in mind Set pressure Kg cm2 Percentage increase over set pressure from 0 5 to 7 2 from 7 1 to 21 3 from 21 1 to 70 4 from 70 1 to 210 5
10. utlet pipe for high temperature gas and vapour discharge use expansion joints After valve has been installed make it pop at least twice to allow automatic alignment of trim Maintenance Regular Checks Check at regular intervals for signs of obvious faults Leakages must be repaired immediately especially when the medium is poisonous highly volatile or very explosive When valve is fitted with lifting device vent periodically at least three or four times a year to check operation During these tests the pressure must be at least 75 of the full working pressure Annual Checks Examine annually for signs of defect damage or deterioration Give special attention to contact seating faces if damaged these must be re machined and lapped in Springs should be replaced if there is any sign of deterioration All parts should move freely in their respective guides Note Quote the unique valve serial number when ordering spare parts Lapping the Disc Use a cast iron or plate glass block of suitable size with a perfectly smooth and flat surface Apply a small quantity of lapping compound to smooth surface of block Pass Disc 4 across smooth surface in a figure of eight movement Lift Disc periodically away from block so that lapping compound may flow from edges towards centre Lapping the Nozzle Seat Use a cast iron or plate glass block of suitable size check that it does not tilt to avoid rounding off edges App
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