Emerson Anderson Greenwood 500 Series Bedienungsanleitung

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

1 GENERAL VALVE DESCRIPTION AND

START-UP

1.1 Operation

The Anderson Greenwood pilot operated

safety-relief valves utilize the principle

pressurizing the top, or large area,

of a differential area piston with line

pressure to hold the piston closed up to set

pressure. At set pressure the pilot valve

relieves, partially evacuating the dome

(volume above piston) and the piston lifts

permitting discharge from the main valve.

When the pilot reseats, line pressure is diverted

to the dome closing the main valve.

The set pressure range is 15 to 720 psig

(1to 51 bar).

Before installation, these instructions must be carefully read and understood

Engineering Doc. #05.9040.272 Rev. H

VCIOM-06022-EN 19/06

Installation and maintenance instructions for

Anderson Greenwood Series 500 Pilot Operated

Safety Relief Valves (POSRV).

The intent of these instructions is to acquaint

the user with the installation and maintenance

of this product.

TABLE OF CONTENTS

1. General valve description and start-up ....... 1

2. Main valve maintenance ............................... 2

3. Pilot maintenance ......................................... 6

4. Pilot set pressure adjustment...................... 9

5. Testing complete valve assembly .............. 10

6. Pilot set pressure field test procedure...... 11

7. Soft goods repair kits.................................. 13

8. Pilot accessories ......................................... 13

9. Pilot conversion kits.................................... 13

1.2 Installation

Either or both inlet and outlet may be standard

ANSI/ASME flanges and the valve should be

installed in accordance with accepted piping

practices.

When remote pressure pick-up is used the

pilot supply tube is connected to a remote

location rather than to the inlet neck of the

valve. If a block valve for shut-off is used in the

remote pilot supply line, be sure it is opened

before pressurizing the system or opening the

isolating block valve, where installed.

NOTE

Remote pressure pick-up piping must have the

equivalent flow area of ½” (12.7 mm) tubing for

lengths up to 20feet (6 m). For lengths greater than

20feet (6 m), larger tubing or pipe should be used.

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

1.4 Storage and handling

Valves are often on hand at the job site months

before they are installed. Unless stored properly

and protected, valve performance may be

affected adversely.

Rough handling and dirt may damage or

cause misalignment of the valve parts. It is

recommended that the valves be left in their

original shipping containers and that they be

stored in a warehouse or at a minimum on a dry

surface with a protective covering until they are

used. Consult factory for soft goods shelf life.

2 MAIN VALVE MAINTENANCE

2.1 Disassembly

Remove the cap from the body. Remove the

piston and liner. A cap bolt may be threaded

into hole in top of piston to aid in removal.

Through holes in seat retainers 2, 3 and 4 in.

(50.8, 76.2 and 101.6 mm) sizes are threaded to

assist in disassembly. Remove the soft goods

from the piston. If the piston is equipped with

a wedge ring, clean and retain it for use during

assembly. The dipper tube is swaged in place

and no attempt should be made to remove

it. Refer to Figure 1 for parts description and

location. The nozzle and nozzle seal should not

be removed unless the nozzle is damaged or

the seal is leaking.

2.1.1 Nozzle and nozzle seal disassembly

Refer to Figure 2 for parts description and

location.

1. Place liner in body and piston, without seat

or seat retainer, into liner and on top of

nozzle.

2. Place appropriate spacer (see Table 1)

on top of piston and then the cap over the

spacer.

3. Thread the appropriate number of cap bolts

(see Table 1) into threaded holes on top

of body. If two bolts are used, they should

be 180° apart. When using four bolts, they

should be 90° apart.

4. Tighten cap bolts evenly to the torque listed

in Table 1 to compress nozzle seal.

5. Use a punch or bar with a light hammer

and tap on the nozzle retainer teeth to

loosen the nozzle retainer. Unthread nozzle

retainer approximately ½ turn.

6. Loosen cap bolts to remove load from

nozzle. Remove components from main

valve.

1.3 Startup

There must be pressure at the valve inlet to

establish a differential in force across the

piston and “load” it in the closed position.

Pressure must pass through the pilot supply

tube and pilot, and exert force on the top of

the piston. On normal plant start-up, the valve

loads itself without incident as plant pressure

increases. It is not uncommon that slight

leakage past the main seat occurs until system

pressure reaches five to ten pounds. This

amount of pressure is sometimes needed to

form the PTFE seat to nozzle surface.

Block valves are often used under safety valves

in order to isolate them when maintenance

is required. When putting the safety valve in

service be sure the block valve is fully opened.

If the block valve is opened after system

start-up, the safety valves may briefly vent to

the atmosphere past the main seat before the

dome gets pressurized-it will then close off

positively. To minimize this venting, open the

block valve slowly.

.010

R.020

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

2.3 Assembly

2.3.1 Nozzle and nozzle seal installation

1. Place nozzle seal and nozzle in body.

2. Place nozzle retainer over nozzle and thread

into body until it stops on nozzle shoulder.

Do not lubricate nozzle retainer threads or

mating body threads.

3. Repeat steps 1 through 4 of disassembly

procedure to compress nozzle seal.

Valve size and type

Min. nozzle projection height

in. mm

1½” Series 546 .045 1.143

2” Series 546 .055 1.397

3” Series 546 .055 1.397

4” Series 546 .055 1.397

6” Series 546 .070 1.778

8” Series 546 .070 1.778

1½” Series 566 .055 1.397

2” Series 566 .055 1.397

3” Series 566 .055 1.397

4” Series 566 .070 1.778

6” Series 566 .070 1.778

8” x 88” Series 566 .070 1.778

8” x 10” Series 566 .070 1.778

10” Series 566 .070 1.778

2.2 Main valve nozzle rework

Should the main valve nozzle seating face

become nicked or scratched such that the main

valve seat does not seal, the imperfections

can be removed by polishing the nozzle face

with 400 grit sandpaper on a flat surface plate.

Certain critical nozzle dimensions and finishes

must be maintained and those are shown in the

Figure and Table below.

Pilot valve

Outlet

Remote sense

Supply tube

Field test

connection

Inlet

Main valve

Minimum

projection

Thread nozzle retainer into body as seal is

compressed to keep nozzle retainer from

binding against piston.

4. Use a punch or bar with a light hammer and

tap on the nozzle retainer teeth to snug the

nozzle retainer threads.

5. Loosen cap bolts to remove load from

spacer and remove spacer from valve.

Replace seat, piston and liner seal. Apply a

light coat of Dow Corning #33 silicone lubricant

on all threads after cleaning. Do not use any

lubricant on the soft goods.

When installing the cap, make sure it is seated

squarely into body. Torque cap bolts uniformly

so as not to “cock” cap. See Table 2 for torque

values. Such a condition may result in leakage

at the liner seal or cause the piston and liner

to bind.

14 12 8

4 6 15 79

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

TABLE 1

Valve size and type Spacer P/N Cap bolt thread

# Cap bolts

to use

Cap bolt torque

ft·lb Nm

1½” x ⅔” Series 546 (G and H Orifice) 06.5612.003 .500-20 UNF 241 30.24

1½” x ⅔” Series 546 (G and H Orifice) 06.5612.003 .625-18 UNF 251 37.62

2” Series 546 06.5612.005 .500-20 UNF 427 19.91

3” Series 546 06.5612.007 .500-20 UNF 435 25.81

4” Series 546 06.5612.008 .750-16 UNF 4130 95.88

6” Series 546 06.5612.009 .750-16 UNF 282 60.48

6” Series 546 06.5612.009 .875-14 UNF 295 70.07

8” Series 546 06.5612.010 .875-14 UNF 4123 90.72

8” Series 546 06.5612.010 1.000-14 UNS 4140 103.26

1½” Series 566 06.5612.005 .500-20 UNF 219 14.01

2” Series 566 06.5612.007 .500-20 UNF 231 22.86

3” Series 566 06.5612.008 .750-16 UNF 2113 83.34

4” Series 566 06.5612.011 .625-18 UNF 263 46.47

6” Series 566 06.5612.012 .750-16 UNF 288 64.91

8” x 88” Series 566 06.5612.013 .875-14 UNF 4119 87.77

8” x 10” Series 566 06.5612.014 1.125-12 UNF 10 89 65.64

10” Series 566 06.5612.015 1.125-12 UNF 10 90 66.38

6 and 8 in. size 1½ thru 4 in. size

FIGURE 1

PARTS LIST

Item Part name

1Body

2Piston

3Liner

4Nozzle [1]

5Seat [2]

6Seat retainer

7Seat retainer bolt

8Cap

9Dipper tube

10 Piston seal [2]

11 Nozzle seal [1]

12 Liner seal [2]

13 Retaining ring

14 Cap bolt

15 Lock washer

16 Dome spring

17 Nozzle retainer

18 Wedge ring [3]

NOTES

1. Do not replace unless required.

2. Recommended spare parts for repair.

3. Used on 4 in. sizes and larger Series 546 and 3 in.

and larger Series 566.

See Section 7 for soft goods repair kit part number.

¼ 7 5.16

16 12 8.85

⅜21 15.49

16 33 24.34

½45 33.19

16 59 43.52

⅝97 71.54

¾130 95.88

⅞202 148.99

1271 199.88

1⅛ 408 300.93

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

FIGURE 2

Body

Nozzle seal

Nozzle

Nozzle retainer

Piston

Liner

Spacer

Cap

Cap bolt

TABLE 2

Bolt size

Torque

ft·lb Nm

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

3 PILOT MAINTENANCE

3.1 Disassembly

To facilitate assembly, place all parts

removed in an orderly arrangement so that

the correct parts can be assembled in the

proper sequence. Refer to Figure 3 for parts

description and location.

NOTE

If pilot is equipped with a lift lever, the lift leverhandle

assembly must be unscrewed from cap before continuing

with disassembly. Hold lift lever in position shown

in Figure 8, unscrew bushing (Item 14) from cap and

remove handle assembly (Items 13, 14, 15, 32 and 45).

Unscrew and remove cap. Loosen jam nuts

and release spring compression by backing out

adjusting screw. Remove bonnet, spring and

spring washer. Remove lift lever adapter, rod

and support spring where used.

Loosen spindle nut before loosening jam nuts.

The spindle jam nuts serve as wrench flats on

the spindle. Remove remainder of accessible

parts except spindle. Remove nozzle

witha⅜ in.

square

drive socket extension. Remove the

spindle assembly by pushing it up through

the body.

3.2 Assembly

Assemble pilot in reverse order of disassembly.

Take care not to scratch the sealing face of

the seat or nozzle. If scratched or nicked, it

must be replaced or lapped to prevent leaking.

Lubricate all screw threads and bearing end

of spring washers with NG-165 Never-Seez

lubricant. Use Dow Corning No. 33 Silicone

grease on all surfaces of the spring washer

bearing if installed. Lubricate the sealing flange

of the nozzle to prevent galling. Do not lubricate

spindle, lower end of spindle seat, nozzle face,

or PTFE seals.

3.4 Bolt make-up (item 38)

Tighten the six ⅜ in. case bolts alternately

opposite each other to approximately 32 to

36ft·lb (23.6 to 26.55 Nm).

3.3 Pilot diaphragm assembly

3.3.1 Boost diaphragm (lower diaphragm)

Install upper diaphragm shield on top

of lower diaphragm shield. Install boost

diaphragm (Item 55) over spindle on

top of the lower and upper diaphragm

shield, with spindle gaskets (Item 56) and

diaphragm gaskets (Item54 or 57) on

both sides of the diaphragm. For pressure

below 120 psi (8.27 bar), use a PTFE

diaphragm with FEP diaphragm gaskets.

For pressure between 121 to 180psi

(8.34 to 12.41 bar), use a Hastelloy

diaphragm with FEP diaphragm gaskets.

For pressure above 180 psi (12.41 bar),

use a Hastelloy

diaphragm with Peek

diaphragm gaskets. Install boost plate

(item 8) on top of the boost diaphragm.

3.3.2 Sensing diaphragm (upper diaphragm)

Install sense diaphragm (Item 55) on

top of spacer ring, with a diaphragm

gasket and a spindle gasket below the

diaphragm. For set pressure up to 30psi

(2.07 bar), use a PTFE diaphragm with

a FEP diaphragm gasket. For pressure

between 30 to 180 psi (2.07

to 12.41 bar)

use a Hastelloy®diaphragm with a FEP

diaphragm gasket. For pressure above

180 psi

(12.41 bar)

, use a Hastelloy®

diaphragm with a PEEK diaphragm

gasket.

Hastelloy®is a registered trademark of

HaynesInternational.

57, 54, 55

26 33

34, 41

57, 54, 55

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

PARTS LIST

Item Description

1Body

2Nozzle

3Spindle

4Seat socket

5Diaphragm support

6Spacer ring

7Sense plate

8Boost plate

9Diaphragm shield, lower

10 Bonnet

11 Spring washer

12 Lift lever cap [1]

13 Lift lever cam [1]

14 Lift lever bushing [1]

15 Lift lever handle [1]

16 Lift rod bushing [1]

17 Lift lever rod [1]

18 Lift lever nut [1]

21 Pressure adjustment screw

22 Lift lever coupling

24 Bonnet screw

25 Retaining O-ring [1]

30 Boost plate seal

31 Spring

32 Cam spring [1]

33 Bonnet vent

34 Lockwasher

35 Shim washer

36 Seal retainer

38 Bolt

39 Diaphragm shield, upper

40 Jam nut

41 Jam nut

45 Spring pin [1]

46 Seat

47 Ball

51 Nameplate

52 Drive screw

54 Diaphragm gasket-FEP

55 Diaphragm

56 Spindle gasket

57 Diaphragm gasket-PEEK

[1] Use with lift lever option only.

Dome

FIGURE 3

15 to 275 psig

(1.03 to 18.96 bar)

NOTE

Refer to next page for Section A - A and 276 to

720psig (19.03 to 49.64 bar).

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Auxiliary dome

Exhaust Supply

276 to 720psig (19.03 to 49.64 bar)

Section A - A

PARTS LIST

Item Description

2Nozzle

3Spindle

4Seat socket

5Diaphragm support

7Sense plate

8Boost plate

9Diaphragm shield, lower

19 Blowdown needle

20 Blowdown bushing

23 Inlet screen

26 Bonnet seal

27 Spindle seal

28 Bushing seal

29 Needle seal

30 Boost plate seal

34 Lockwasher

35 Shim washer

37 Needle retainer

39 Diaphragm shield, upper

42 Jam nut

43 Screw

46 Seat

47 Ball

49 Tubing

50 Elbow connector

53 Pipe plug

55 Diaphragm

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

4 PILOT SET PRESSURE ADJUSTMENT

4.1 General

Two adjustments are provided; one for varying

the pressure at which the pilot opens and

one for varying the pressure at which the

pilot closes. The first adjustment controls the

“set” pressure; the second the “reseat” or

“blowdown” pressure.

4.2 Set pressure

Set pressure is that supply pressure where the

dome pressure is reduced to 70% ± 2% of the

supply. This corresponds to the initial audible

discharge of gas or first steady stream of liquid

from the main valve.

To adjust the set pressure, a test set up similar

to that shown in Figure 4 should be used. The set

pressure adjustment screw should be turned IN

most of the way. Increase the supply pressure

to the nameplate setting and slowly back the

adjustment screw out until the dome pressure

is 70% ± 2% of the supply pressure and supply

pressure meets the required set pressure

tolerance of paragraph 4.5. Lock the adjusting

screw with the jam nut and cycle the pilot several

times to make sure the setting is correct.

4.4 Adjustment tolerances

All pilots can be adjusted ± 5% beyond

the nameplate setting for set pressures

above 275psig (18.96 bar) and ± 10% for set

pressures 275 psig (18.96 bar) and below.

4.5 Range of adjustment

Cracking pressure: 95% of specified set

pressure

Set pressure:

± 3% of specified set

pressure above 70 psig

(4.83 bar) set

± 2 psig for

70 psig

(4.83 bar)

and below

Reseat pressure: Specified as a percent

of set pressure

modulatingaction (0-3%)

4.3 Reseat pressure

Reseat pressure is that supply pressure where

the dome pressure increases to 75 ± 2% of

supply.

4.3.1 Reseat pressure - modulating action

The reseat pressure should be adjusted

with the pilot flowing. Increase the

supply pressure until the pilot opens

and steady flow is obtained. With the

blowdown adjustment screw turned in,

slowly decrease the supply pressure to

97% to 100% of set. Turn the blowdown

adjustment screw OUT until the pilot

reseats. Lock the adjusting screw with

the jam nut and cycle the pilot several

times to make sure the setting is correct.

A small interaction between set pressure

and blowdown may occur. If so, re-adjust

set pressure.

NOTE

If the blowdown adjustment screw is backed out more

than necessary to obtain 0% blowdown, pilot action

will become more sluggish and pilot crack to main

valve opening pressure spread will increase.

4.6 For steam service pilots

Set on steam, check the case bolts (Item 38)

again for tightness at zero pressure. Retighten

to 35 to 39 ft·lbs (25.81 to 28.76 Nm) of torque,

as required. Check set pressure again if bolts

are retightened.

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Dome

pressure

gauge

Bonnet vent

Set pressure adjustment (turn in to increase set pressure)

(turn out to decrease set pressure)

Accumulator

(approx. ¼ cu ft)

Pilot inlet (backside)

Flexible supply hose

Valve “A”

Street

elbow

Pipe nipple

Mounting stud

Vent valve “C”

Flexible supply hose

Valve “B”

Union

Elbow

Inlet supply pressure gauge

Blowdown adjustment (turn in to increase)

(turn out to shorten)

Cross

Bleed

valve

Pilot exhaust (backside)

FIGURE 4

5 TESTING COMPLETE VALVE ASSEMBLY

5.1 General

The complete valve assembly should be tested

for internal and external leakage and to verify

main valve function using a test set-up similar

to that shown in Figure 5.

5.2 Low pressure leakage check

Slowly increase the inlet pressure to 30% of

the set pressure. Check for main valve nozzle,

seat, and piston seal leakage at the main valve

outlet. No visible leakage shall occur in one

minute. To help in seating the valve seat and

piston seal, the valve may be actuated several

times.

5.3 High pressure leakage check

Apply pressure to the inlet equal to 90% of the

set pressure. Check for leakage at the main

valve outlet. Using a suiTable gas or air leak

detector solution, check for leakage at the

cap seal and other pressure connections. No

leakage shall occur at the valve outlet and no

visible leakage shall be detected at the cap seal

or other pressure connections in one minute.

5.4 Main valve function check

CAUTION

This test must be performed at a slow rate of

pressure increase to ensure that the main valve

does not go into full lift. The pressure applied to

the inlet is not to exceed 105% of nameplate set

pressure.

After completing the high pressure leakage

check of paragraph 5.3, verify main valve

opening as follows. Remove the leakage test

device from the outlet flange. Slowly increase

the inlet pressure above 90% of set pressure.

Continue increasing inlet pressure until an

audible discharge at the valve outlet verifies

main valve opening.

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