INSTALLATION AND OPERATING MANUAL SERIES KSEA/F Safety Relief Valves with ASME - certification spring-loaded WARNING All RICHTER products are designed and manufactured to the highest standards of workmanship and design and, as of the printing of this document, they meet all applicable industry standards. These valves are available with components of various materials and should be used only as directed in the product catalog. Installation and maintenance must be performed by qualified personnel.
Series KSEA/F Page 2 List of Contents List of Contents ........................................ 2 Relevant documents................................. 2 1 Technical data...................................... 3 7 Operation............................................ 12 7.1 7.2 7.3 7.4 Initial commissioning ................................. 12 Shutdown .................................................. 12 Recommissioning...................................... 12 Improper operations and their consequences ..
Series KSEA/F 1 Page 3 Technical data Manufacturer: Options : Richter Chemie-Technik GmbH Otto-Schott-Str. 2 D-47906 Kempen, Germany Telephone : +49 (0) 2152 146-0 Fax: +49 (0) 2152 146-190 E-Mail: richter-info@richter-ct.com Internet: http://www.richter-ct.com Travel stop for restricted lift Blocking screw Signal transmitter Design for heavily permeating media (e.g.
Series KSEA/F Page 4 Body identification: The shell bears the following information: Screws body / inlet nozzle Valve type Screws valve size (Inlet x Outlet, inch) pressure rating class KSEA/F 1”/2” KSEA/F 2”/3” KSEA/F 3”/4” KSEA/F 4”/6” shell material manufacturer's identification cast number/foundry identification 4 x N”-16 4 x ½“-13 8 x N”-16 8 x N”-11 Torque [in-lbs] [Nm] 106 354 177 354 12 25 20 25 arrow for direction of flow Hex. socket screws 914/1 of the bellows gasket 1.
Series KSEA/F 2 Page 5 Safety This operating manual contains fundamental information which is to be observed during installation, operation and maintenance. It must therefore be read before installation and commissioning! For valves which are used in potentially explosive areas, see Section 3. Installation and operation are to be performed by qualified staff. The area of responsibility, authority and supervision of the staff must be regulated by the customer.
Series KSEA/F 3 Page 6 Safety notes for applications in potentially explosive areas based on the Directive 94/9/ EC (Atex 95) The valves are intended for use in a potentially explosive area and are therefore subject to the conformity assessment procedure of the directive 94/9/EC (ATEX).
Series KSEA/F 4 Page 7 Safety note for valves, certified to Clean Air Act (TA Luft) On request, this valve can be supplied compliant with the German Clean Air Code. Certificate / Manufacturer Declaration Validity is dependent on the operating instructions being read and observed. 5 In particular, servicing must be conducted at regular intervals, and the bolted connections relevant for tightness must be inspected and retightened if necessary.
Series KSEA/F 5.3 Return consignments Page 8 5.4 Disposal Valves which have conveyed aggressive or toxic media must be well rinsed and cleaned before being returned to the manufacturer's Parts of the valve may be contaminated with medium which is detrimental to health and the environment and therefore cleaning is not sufficient. Observe appropriate safety precautions when cleaning the valves of toxic or aggressive media.
Series KSEA/F Page 9 6.2.2 Drainage of condensate 6.3 Lay horizontal pipes with a gradient away from the valve so that the liquid medium cannot accumulate in the valve body and that, in the case of gases, no condensate collects in the body. If outlet lines are laid with a geodetic level difference (e.g. for vapours or gases with a 90° vertical upright pipe bend out of the valve), the bend must not be located directly downstream of the valve.
Series KSEA/F 6.6 Grounding The valve must be grounded. The simplest solution is to use tooth lock washers which are placed under one pipe bolt of each flange. At the customer's request a setscrew M6 with a hex. nut and washer will be provided at each flange as an additional grounding connection. Otherwise grounding must be ensured by different measures e.g. a cable link. 6.7 Page 10 After the pressure test remove the cap nut 927/1B with the blocking screw 901/4 or threaded rod 918/1 with the hex.
Series KSEA/F Page 11 DN 4"/6" With size 4"/6" the bellows guide 860 made of PTFE protects the stem guide 306. See Fig. 11. With the other sizes the stem guide is made of HC-4. Legend see Section 10.1. Fig. 11 6.11 Shortened or no lifting lever (Option) Fig. 8 Design signal transmitter for blocking screw In order to exclude unauthorised activation, the lifting lever 238 can be shortened; a lever is supplied loose. See Fig. 12.
Series KSEA/F 7 Operation 7.1 Initial commissioning Normally, the valves have been tested for leaks with air or water. Unless otherwise agreed, there could be residual amounts of water in the flow section of the valve; this could result in a possible reaction with the medium. The max. operating pressure of the plant must generally be less than the reseating pressure of the safety valve.
Series KSEA/F 8 Page 13 Malfunctions Safety valve is leaking Is there foreign matter between the seat and plug? Is there any wear or damage to the seat or plug? Have the nuts at the inlet nozzle been unevenly tightened? Actuation of the lifting lever can help to regain the required sealing effect. If this does not succeed in stopping the leak, the sealing surface of the plug must either be reworked or the plug or seat must be replaced.
Series KSEA/F 9.1 Screw connections To prevent leaks, a regular check of the connection screws should be made in line with the operating requirements. For tightening torques, see Section 1.2. To prevent screw connections from becoming loose in the event of pressure fluctuations or plant vibrations, we recommend the installation of expansion joints or pulsation dampers. 9.2 Cleaning Prior to starting any repair work, the valve is to be thoroughly cleaned.
Series KSEA/F 9.6.2 Dismantling of the seat Remove bonnet 513 from the body 100. See Section 9.6.1. Dismantle inlet nozzle 122 from the body 100 and remove the seat 227. 9.6.3 Installation of the seat Insert the new or reworked seat 205 at the bottom into the corresponding centring of the body 100. Then insert the inlet nozzle 122 into the centring of the body 100. The components must be smooth running, i.e. can be centred without any constraining forces.
Series KSEA/F Page 16 Undo hex. nuts at the end of the spindle and also remove spacer sleeve. Undo adjusting screw 538 and screw it out of the spring bonnet 513. The pressure spring 952/1 is only partially relieved in this situation. In order to completely relieve the spring, the two nuts per threaded rod are evenly turned upwards until the spring bonnet is loose.
Series KSEA/F Page 17 Completely mount the lower valve section (body, seat, inlet nozzle). The pressure ring 124 is placed on the sealing strip of the body. See Fig. 21. Undo adjusting screw 538 (turn out of the spring bonnet 513) until the distance between the upper edge of the insert sleeve and the edge of the stem guide is approx. 5 mm. See Fig. 23.
Series KSEA/F Lowering the bellows onto the seat For this purpose screw the adjusting screw 538 into the spring bonnet 513 until the spacer can be freely moved. When tightening the adjusting screw 538, hold the spindle 802 with a wrench on the counter nut to prevent it from turning so that the bellows 206 or the spring-type pin 939/1 are not damaged. See Fig. 25. Page 18 9.9.
Series KSEA/F 9.9.6 Seat tightness test with air Pressure relief valves marked for gas or vapour may be leakage tested with air. According to API 527, the bubbles are led by a test hose with an outside diameter of 7.9 mm (5/16”) and a wall thickness of 0.89 mm (0.035”) in a container filled with water whereby the test hose discharges 12.7 mm (0,5”) below the surface of the water. The tube end shall be cut square and smooth. The tube shall be perpendicular to the surface of the water.
Series KSEA/F 10 Page 20 Drawings 10.
Series KSEA/F 10.
Series KSEA/F Page 22 10.
Series KSEA/F Page 23 10.4 Dimensional drawing valve size d0 1" / 2" 2" / 3" 3" / 4" 4" / 6" Valve type 1"/2" 2"/3" 3"/4" 4"/6" H L mm inch mm inch mm inch mm inch mm 22 40 50 80 0.866 1.574 1.968 3.149 100 125 155 200 3.937 4.921 6.10 7.874 104.7 136.5 155 220 4.125 5.375 6.10 8.661 355 435 525 710 13.98 17.12 20.67 27.95 120 120 140 180 inch 4.72 4.72 5.51 7.08 Connecting dimensions according to ASME B16.
Safety Information / Declaration of No Objection Concerning the Contamination of Richter-Pumps, -Valves and Components 1 SCOPE AND PURPOSE Each entrepreneur (operator) carries the responsibility for the health and safety of his employees. This extends also to the personnel, who implements repairs with the operator or with the contractor. Enclosed declaration is for the information of the contractor concerning the possible contamination of the pumps, valves and component sent in for repair.
Declaration about the Contamination of Richter Pumps, -Valves and Components The repair and/or maintenance of pumps, valves and components can only be implemented if a completely filled out declaration is available. If this is not the case, delay of the work will occur. If this declaration is not attached to the devices, which have to be repaired, the transmission can be rejected. Every aggregate has to have it’s own declaration.
FAX Fax No. () Pages (incl. cover sheet) () To: () Contact person: () Your order No.: Our Kom. No.: Reference: () () () Extension: - () E-Mail Address: () Date: () Serial No.: () Dear Sirs, The compliance with laws for the industrial safety obligates all commercial enterprises to protect their employees and/or humans and environment against harmful effects while handling dangerous materials.
