Trillium SARASIN-RSBD STARFLOW V Series Manual de instrucciones

V SERIES (STARFLOW VTM )

Installation, Operation,

Maintenance Manual

CONTENT

1 SAFETY SIGN AND LABELS ................................................................................................................................................. 3

2 SAFETY INSTRUCTIONS....................................................................................................................................................... 4

3 SAFETY PRECAUTIONS........................................................................................................................................................5

4 WARRANTY INFORMATION.................................................................................................................................................. 6

5 TERMINOLOGY....................................................................................................................................................................... 7

6 GENERAL ADVICE.................................................................................................................................................................. 8

6.1 RESPONSIBILITIES......................................................................................................................................................................... 8

6.2 IDENTIFICATION PLATE..................................................................................................................................................................8

6.3 SPRING ........................................................................................................................................................................................ 9

6.4 STORAGE ......................................................................................................................................................................................9

6.5 HANDLING ....................................................................................................................................................................................10

7 STARFLOWTM BASICS.......................................................................................................................................................... 11

7.1 DESCRIPTION ............................................................................................................................................................................... 11

7.2 FEATURES AND NOMENCLATURES ................................................................................................................................................. 12

8 INSTALLATION......................................................................................................................................................................16

8.1 GENERAL .....................................................................................................................................................................................16

8.2 INLET PIPING ............................................................................................................................................................................... 16

8.3 OUTLET PIPING ............................................................................................................................................................................ 17

8.4 INSTALLATION ON THE PROTECTED EQUIPMENT ............................................................................................................................17

8.5 LEVER ORINTATION ......................................................................................................................................................................20

8.6 OUTDOOR INSTALLATION ..............................................................................................................................................................20

8.7 INDOOR INSTALLATION ................................................................................................................................................................. 20

9 MAINTENANCE.................................................................................................................................................................... 21

9.1 DISASSEMBLY OF THE STARFLOW V™.......................................................................................................................................... 22

9.2 INSPECTION OF THE STARFLOW V™........................................................................................................................................... 27

9.2.1 GENERAL RECOMMENDATIONS ....................................................................................................................................... 27

9.2.1 PART INSPECTION ......................................................................................................................................................... 27

9.3 RE-ASSEMBLY .........................................................................................................................................................................32

9.3.1 NOZZLE/GUIDE ASSEMBLY ............................................................................................................................................32

9.3.2 DISC/DISC HOLDER ASSEMBLY ....................................................................................................................................32

9.3.3 ADJUSTMENT OF THE LIFT ..........................................................................................................................................32

9.3.4 BODY PLATE AND SPINDLE ASSEMBLY ..........................................................................................................................34

9.3.5 ADJUSTEMENT OF OVERLAP RING ................................................................................................................................ 34

9.3.6 ADJUSTMENT OF THE LOWER ADJUSTING RING .............................................................................................................35

9.3.7 ADJUSTMENT OF THE UPPER ADJUSTING RING ............................................................................................................. 35

9.3.8 SPRING ASSEMBLY ..................................................................................................................................................... 36

9.3.9 CAP ASSEMBLY .......................................................................................................................................................... 36

10 TESTING............................................................................................................................................................................... 37

10.1 TEST GAG ............................................................................................................................................................................... 37

10.2 SET PRESSURE AND ADJUSTMENT OF RINGS ............................................................................................................................. 38

10.2.1 SET PRESSURE ADJUSTMEN ........................................................................................................................................ 39

10.2.2 BLOWDOWN ................................................................................................................................................................ 39

10.2.3 UPPER AND LOWER RINGS ADJUSTMENT ..................................................................................................................... 39

10.3 CALIBRATION CHECK WITH ONLINE TESTING DEVICE ................................................................................................................ 40

10.4 VALVE SEALING ..................................................................................................................................................................... 40

11 MAINTENANCE TOOLS....................................................................................................................................................... 40

12 TROUBLESHOOTINGS........................................................................................................................................................ 41

13 SPARE PARTS..................................................................................................................................................................... 42

14 DISMANTLING..................................................................................................................................................................... 42

15 GENUINE PARTS.................................................................................................................................................................. 43

16 CODIFICATION..................................................................................................................................................................... 44

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

SAFETY SIGNS AND LABELS

Signs or labels are included throughout this document.

These signs or labels communicate the following messages:

•

The level of hazard seriousness

The nature of the hazard

The consequence of human or product interaction with the hazard

The instructions if necessary on how to avoid the hazard

The format is characterised by vertical panels. The panels include a signal word shown below which advises the

level of hazard seriousness

• DANGER

• WARNING

• CAUTION

• ATTENTION

DANGER

WARNING

CAUTION

ATTENTION

DANGER

Immediate danger which

WILL cause

serious personal injury

or death.

WARNING

Risk or dangerous

practice which

COULD cause

serious personal

injury or death.

CAUTION

Risk or dangerous

practice which

COULD cause

minor injuries.

ATTENTION

Risk or dangerous

practice which

COULD cause

damage to equipment.

Never face the outlet of a

valve when it is discharging

as this may result in serious

personal injury or death

Be aware of all site safety

procedures to prevent the risk

of serious injury or death.

Protect yourself by wearing

the necessary protective

equipment to prevent

possible injury.

Use the proper lifting

equipment to avoid personal

injury or damage to

equipment.

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

2 SAFETY INSTRUCTIONS

WARNING

CAUTION

ATTENTION

Be aware of all site safety

procedures to prevent the risk

of serious injury or death.

Protect yourself by wearing

the necessary protective

equipment to prevent

possible injury.

Use the proper lifting

equipment to avoid personal

injury or damage to

equipment.

•In order that the product may work as expected, ensure that it has been correctly installed, it is being correctly used

and it is correctly maintained and serviced.

• This document describes the main procedures which are necessary to satisfy to the essential safety requirements in

order to operate the product correctly and to comply with the International rules and regulations for the specified

pressure equipment.

• This document describes each essential step from the receipt of valves through the stages of installation, operation

and service. It is mandatory to ensure that anyone intervening with the product, directly or indirectly, is fully aware of

these steps. Pictograms are used to clearly advise of the potential dangers associated with the use of the product.

• Whilst this document is intended to be informative, it is important to understand that the safety messages provided

are not exhaustive. Trillium Flow TechnologiesTM cannot possibly be aware of, evaluate or

advise, all of the conceivable methods by which tasks might be performed, or of the possible hazardous

consequences of each of those methods.

Consequently, anyone who uses a procedure and/or tool, which is not recommended by Trillium Flow TechnologiesTM,

or deviates from Trillium Flow TechnologiesTM recommendations must be thoroughly satisfied that neither personal

safety nor equipment safety will be jeopardized by the method and/or tools which have been selected.

The installation, operation and maintenance of safety valves could be dangerous. During these activities personnel might be exposed

to direct or indirect injury risks from fluids which are at various high pressures and/or temperatures. Therefore, every precaution

should be taken to prevent injury to personnel during the performance of any procedure. Any person who uses a safety valve shall be

trained in all aspects of handling, installation, operation and service.

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

3 SAFETY PRECAUTION

DANGER WARNING CAUTION

Never face the outlet of a

valve when it is discharging

as this may result in serious

personal injury or death

Never dismantle a valve in

line without making

absolutely sure there is no

remaining or residual

pressure

Protect yourself by wearing

the necessary protective

equipment to prevent

possible injury

•Never stand in front of the discharge side of a safety valve if the valve is operating or being tested.

•Always wear personal protective equipment (PPE): PPE should consist of but not be limited to ear protection, eye

protection, and the use of protective clothing (gloves, headgear, etc). Noise can be extremely high and can occur

suddenly. Steam and hot water can burn. Superheated steam is NOT visible.

•Always lower the operating pressure before making any adjustment to the valve. Always gag the valve before making

any ring setting adjustments.

•Before removing a valve for disassembly, ensure that there is no remaining pressure upstream the valve and that the

valve is isolated from the system pressure.

•Before performing each pop test on the safety valve, ensure that no personnel are close to the valve. The steam which

could escape during the operation could cause serious personal injury.

•When a lift test is performed using the lifting lever, be sure to use a rope or a chain whilst standing at a safe

distance away from the valve and any potential steam escapes.

•Valves under the operating pressure may relieve at any time. Never strike the body or tamper with the valve as such

practice could cause premature relief.

•Never modify or change the valves, especially when they are under pressure. It is essential that you inform Trillium Flow

TechnologiesTM in All instances if any machining of parts is to be considered. Deviation from critical dimensions

can adversely affect the performance of a safety valve.

A safety valve is a self-acting product. Always consider the potential dangers associated with the product and never minimise them.

Each plant or installation has its own safety rules. Be aware of them and follow them carefully.

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

4 WARRANTY INFORMATION

Trillium Flow TechnologiesTM warrants that its products (including performance) and work will meet the specifications of

the customer’s Purchase Order. If any issue arises whilst operating the product, the customer should inform Trillium Flow

TechnologiesTM as quickly as possible. A return to the original plant should then be considered in order for Trillium Flow

TechnologiesTM to inspect the product.

Trillium Flow TechnologiesTM cannot be held responsible for any incorrect sizing and selection of a valve if the original

specification supplied by the customer was incomplete or inaccurate.

Trillium Flow TechnologiesTM does not authorise any third parties (eg, non-Trillium Flow TechnologiesTM service centres) to

repair a product of Trillium Flow TechnologiesTM’s manufacture. Any customer allowing or sub-contracting the repair of a

Trillium Flow TechnologiesTM product which is still within its warranty period will do so entirely it at their own risk.

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

5 TERMINOLOGY

ACCUMULATION

The pressure increase over the maximum allowable working pressure of the vessel, expressed in pressure units or as a percentage of

maximum allowable working pressure (MAWP) or design pressure.

BACK PRESSURE

Back pressure is the static pressure existing at the outlet of a safety valve device due to pressure in the discharge system.

BLOWDOWN

The difference between actual popping pressure of a safety valve and actual reseating pressure expressed as a percentage of set

pressure, or in pressure units.

CDTP (COLD DIFFERENTIAL TEST PRESSURE)

The pressure at which a safety valve is adjusted to open on the factory test bench. The cold differential test pressure includes

corrections for the service conditions of backpressure or temperature or both.

CHATTER

Rapid and erratic motion of the disc from closed to open position. This phenomenon can create damage to the valve internals, the

main effect being on the disc and the nozzle components.

CLOSING PRESSURE

The value of decreasing inlet static pressure at which the valve disc re-establishes contact with the seat or nozzle, or at which the lift

becomes zero.

LIFT

The actual travel of the disc away from closed position when a valve is relieving. LEAK TEST PRESSURE Leak test pressure is the

specified inlet static pressure at which a quantitative seat leakage test is performed in accordance with a standard procedure.

MAWP (maximum allowable working pressure)

The maximum gauge pressure permissible at the top of a vessel in its normal operating position at the designated coincident

temperature specified for that pressure.

OPERATING PRESSURE

The pressure at which protected unit is working and at which the safety valve should be tight.

OVERPRESSURE

The pressure increase over the set pressure of a safety valve, usually expressed as a percentage of the set pressure.

POPPING PRESSURE

The value of increasing inlet static pressure at which the disc moves in the opening direction at a faster rate as compared with

corresponding movement at higher or lower pressures. It applies only to valves in compressible fluid service.

SET PRESSURE

Inlet gauge pressure at which the safety valve is set to open under relief conditions

SIMMER

The audible or visible escape of fluid between the seat and disc at an inlet static pressure below the popping pressure and at no

measurable capacity.

For the purpose of this manual, the following abbreviations, definitions and terms apply

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

6 GENERAL ADVICE

6.1 RESPONSIBILITIES

The recommended practices indicated within this manual must be respected to prevent any potential

damage to goods. It is important that all points of advice are followed closely and are implemented by

suitably qualified personnel. Trillium Flow TechnologiesTM disclaims all responsibility for maintenance operations which may be

performed by persons who are either not suitably qualified or are not considered to be an accepted part the

Trillium Flow TechnologiesTM organisation.

6.2 IDENTIFICATION PLATE

The data shown on the identification plate (figure 1) should be referenced with all requests for work, or for

the supply of spare parts.

The identification plate bears the following information fields fulfilled according code and regulation

requirements:

•Serial number (also stamped on the edge of the outlet flange)

•Safety valve type (model number)

•Inlet dimension - pressure class (rating)

•Outlet dimension - pressure class (rating)

•Orifice

•Set pressure with units

•Capacities (water and steam for economizer application)

•Backpressure with units

•Identification number

•Spring identification number

FIGURE 1 – COMMON NAMEPLATE

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

6.3 SPRING

The correct operation of a pressure relief valve depends upon its spring characteristics, resilience, and compression.

Good pressure relief valve operation requires:

• Effective and accurate lift

• Sufficient flow rating

• Quick closing (no damping effect when reseating)

The adjustment range of the spring must be within ± 5 % of the nominal value

Spring data should be obtained from Trillium Flow TechnologiesTM’s Sarasin-RSBDTM Aftersales Department. When requesting information,

please quote the serial number which is shown on the valve identification plate. Without this number,

it may not be possible to identify the original valve

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6.4 STORAGE

ATTENTION ATTENTION

Never lift the valve

horizontally, or hook to the

lifting lever or the spring.

Always lift by using the lifting

eyes or sling.

Make sure the valve is not

dropped and does not receive

strikes.

Safety valves may be received several months before an actual plant start-up date. In order that the valve performance is not

adversely affected, it is important to follow some clear rules concerning storage and handling prior to installation.

• It is recommended that the safety valves are stored in a clean and dry environment, protected from weather conditions,

the ingress of sand, dust, or any other solid particles or foreign matter.

• Wherever possible, the valves should be stored in their original packaging.

• Blanking plugs, thread protectors and plastic covers should only be removed at the point of installation of the valve.

• Special attention should be given to flange gasket contact surfaces and machined threads. Impact on these areas

should be avoided.

• The valve must remain vertical, always laying on the inlet end (never on the outlet end).

STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

6.5 HANDLING

According to procedure 20.02, the safety valve should be handled very carefully at all times whether they are in the packed or

unpacked condition. The valves should never be subjected to any impact or striking, either directly or indirectly through the

packaging.

Never lift or handle a safety valve by its lifting lever.

The valve should be moved and transported in the upright position at all times to maintain performance accuracy.

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STARFLOW V™PRESSURE RELIEF VALVE

SARASIN-RSBD™

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