MEKASTER GROUP

SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

MEKASTERENGINEERINGLIMITED
WORKS:
2508,G.I.D.C.Estate,
Halol389350,
Dist.Panchmahal,Gujarat(India).
Phone:(02676)221032/220986.Fax:(02676)221029
Email:
halolvalves@mekasterengineering.com
service2@mekasterengineering.com

MarketingOffice:
908,AnsalBhawan,
16,KasturbagandhiMarg,
NewDelhi110001.
Phone:(011)23739233/34,Fax:+911123753170

BRANCHES:BANGALORE(03332599010),BARODA(02652320613),CHENNAI(04424332760),KOLKATA(03332599010),
MUMBAI(02226743504/08),SECUNDERABAD(04066327514)

WebSite:www.mekasterengineering.com

TableofContents
1Preinstallationhandlingandinspection ..................................................................................................1
1.1Storageandhandling .........................................................................................................................1
1.2Inspectionandtestingofsafetyreliefvalves.....................................................................................1
1.3Inspectionandcleaningofsystembeforeinstallation ......................................................................1
2Valvemodeltypes,GAdrawingsandpartlist ..........................................................................................2
2.1GAdrawings .......................................................................................................................................3
2.2Partlist ...............................................................................................................................................4
3Installation.................................................................................................................................................5
4Maintenance .............................................................................................................................................5
4.1Proceadureforsafetyreliefvalvesdisassembly ................................................................................5
4.2Proceadureforlapping.......................................................................................................................6
4.2.1Handlapping ...............................................................................................................................6
4.2.1.1Disc .......................................................................................................................................6
4.2.1.2Nozzle...................................................................................................................................6
4.2.2Machinelapping..........................................................................................................................6
4.3Procedureforreassembly ..................................................................................................................6
4.4Procedureforcheckingandadjustingsetpressureandseattightnes ..............................................7
4.4.1Calculatingcolddifferentialtestpressure(CDTP) ......................................................................7
4.4.2Procedureforcheckingandadjustingsetpressurecaliberation: ............................................7
4.4.3Procedureforcheckingseattightness........................................................................................8
4.5Procedureforadjustingringsetting ..................................................................................................8
5Troubleshootingguide ...........................................................................................................................10
6Spareparts ..............................................................................................................................................11
7Operation ................................................................................................................................................11

SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

1PREINSTALLATIONHANDLINGANDINSPECTION
1.1STORAGEANDHANDLING
Safetyreliefvalvesmaybereceivedonasiteseveralmonthsbeforeactualstartup.Ifnotstoredandprotectedas
necessary,safetyreliefvalveperformancemaybeaffected.Becausecleanlinessisessentialtosatisfactoryoperation
and tightness of safety relief valve, take utmost precaution to keep out all foreign particles. The inlet and outlet
connectionshallbeprotectedwithendcover.keepvalveinletabsolutelyclean.
It is recommended that safety relief valves be stored indoor in a clean, dry, place, well protected from the
weather,sand,dustorothercontaminationsources.
Whereverpossible,safetyreliefvalvesshouldbestoredintheiroriginalpackaging.
Safety relief valve should be handled carefully and should not be subjected to shocks, which can result in
considerableinternaldamageormisalignment.Seattightnessmaybeadverselyaffected.

Blankingplugs,threadprotectionsandplasticcoversshouldonlyberemovedwhenasafetyreliefvalve
istestedorinstalled.Aftertestingifthevalveisnotinstalledimmediatelythenblankingplugsshouldbe
refitted
CAUTION Protecttheflangefacing(serrationportion)andthreadsfromanydemages.

1.2INSPECTIONANDTESTINGOFSAFETYRELIEFVALVES
Theconditionofallsafetyreliefvalvesshouldbevisuallyinspectedbeforeinstallation.Ensurethattheallprotective
materialonthevalveflangesandextraneousmaterialinsidethevalvebodyandnozzlearecompletelyremoved.
Theinletsurfacemustbethoroughlycleaned,sinceforeignparticlesclingingtotheinsideofthenozzlewillbe
blownacrosstheseatwhenthevalveisoperated.Someoftheseparticlesmaydamagetheseatorgettrapped
betweentheseatsinsuchawaythattheycauseleakage.Valveshouldbetestedbeforeinstallationtoconfirmtheir
setpressure.
TestGag(30)anoptionalaccessoryofsafetyreliefvalvesusedforblockingtheopeningofvalve.Sometimesbigger
sizevalvesaredispatchedfromfactorywithtestgagfittedoncap(03)ofthevalvetoblockmovementofseatfor
preventingdamagestotheseatduringtransportation.Ifthetestgagisprovidedonthevalvecap(03),itmustbe
removedandreplacedbycapplug(26)andpluggasket(27)beforetesting/installation.Thevalvewillnotopenif
testgagisfittedonthevalve.
Testgagsmaybepreservedandusedforpreventingopeningofthevalvewhenthesystemishydrotestedata
pressuremorethansetpressureofthevalveandwiththevalvefittedonthesystem.TheTestGagmustbe
removedandreplacedwithcapplugaftersuchHydroTestingofthesystem/tank.

Ifthetestgagisprovidedonthevalvecap(03),itmustberemovedandreplacedbycapplug(26)and
pluggasket(27)beforetesting/installation.Thevalvewillnotopeniftestgagisfittedonthevalve.
CAUTION

1.3INSPECTIONANDCLEANINGOFSYSTEMBEFOREINSTALLATION
Newsysteminparticulararepronetocontainingweldingbeads,pipescaleandotherforeignobjectsthat
inadvertentlygettrappedduringconstructionandwilldestroytheseatingsurfacewhenthevalveopen.Thesystem
shouldbethoroughlycleanedbeforethesafetyreliefvalveisinstalled.

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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

2VALVEMODELTYPES,GADRAWINGSANDPARTLIST
ThisdocumentisapplicableforMekastermakesafetyreliefvalvesmodeltype66series,9series,S14series&S15
Seriesforliquid,gasandsteamservices.Normallythefollowingidentificationdetailsareshownonthenameplate
ofvalve:
Manufacturersname
Serialnumber(alsostampedontheedgeoftheoutletflange)
TagNo.
Safetyreliefvalvecode/type.
Size(InletxOutlet)mentionedinthevalvecodealso
Orifice
Capacityatoverpressure
SetPressure
CDTP
BackPressure
Belowisthedetailfordifferentmodeltypesandorifice:

OrificeDesignation
AsperAPI526
D
E
F
G
H
J
K
L
M
N
P
Q
R
T
B
D
E
F
G
S14
S15

NominalOrifice
ActualArea
ActualNozzleBore
AreaasperAPI526(mm2)
(mm2)
diameter(mm)
I)SERIES66VALVES
71
80.12
10.1
126.45
143.14
13.5
198
226.98
17.0
324.5
366.44
21.6
506.45
572.56
27
830.32
940.25
34.6
1185.80
1352.65
41.5
1840.64
2083.07
51.5
2451.6
2471.81
56.1
28
3333.64
65.15
4116.12
4656.63
77
7129
8372.79
103.25
10322.5
11737.82
122.25
16775
19174.76
156.25
II)9SERIESVALVES

28.27
6.0

80.12
10.15

144.20
13.5

226.98
17.0

366.44
21.6
III)S14/S15SERIESVALVES

176.71 15.0

36.48
7.0

66seriesvalvesareconventional/balancedbellowtypewithflangedendconnectionandareinaccordancewith
API526.The9seriesandS14/S15seriesvalvesareavailableinbothscrewedandflangedendconnection.
OptionalaccessoriesforsafetyreliefvalvesareLever,gag,bellowandsteamjacketetc.
HardfacingofSeatfaces(nozzleanddisk)aredonebystellitingforhighpressureapplicationforwearresistance
andlonglife.

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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

2.1GADrawings

66SERIESVALVES

9SERIESVALVES

S14SERIESVALVES
MEKASTERGROUP

S14SERIESVALVES
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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

LEVERASSEMBLYFORALLSERIESVALVES

2.2PARTLIST
P.NO.
01
02
03
04
05
06
07
08
09
10
11
12
13
15
16
17
18
19/20
21
22
23
24
25
26
27
30
40
42
43
44
45
46
47
48
49
50
51
60
61

DESCRIPTION
Body
Bonnet
Cap
Nozzle
Disc
Adj.Ring
Adj.RingPin
DiscHolder/Piston
Guide
Ball
Spindle
BodyBonnetBoltingStud
BodyBonnetBoltingNut
Spring
SpringWasher
Adj.Screw
LockNut
CapBonnetFastener
SetScrewGasket
Gasket
CapGasket
DrainPlug
InletFlange
CapPlug
PlugGasket
TestGag
NozzleGasket
Axel
Fork
Lever
GlandFollower
Packing
Ring
LockNut
Nut
Screw
Washer
Bellow
BellowGasket

MEKASTERGROUP

APPLICABLEFORSAFETYVALVESERIES
66SERIES 9SERIES S14SERIES S15SERIES

NOTES

3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
3
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3

3
3
3
3
3
3
3
3
3
3
2
2
3
3
3
3
2
3
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2

3
3
3
2
3
2
3
2
3
2
2
3
3
3
3
2
3
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2

3
3
3
3
3
2
3
2
3
2
2
3
3
3
3
2
3
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
2

App.forflangetypevalveonly
Optionalaccessory

Optionalaccessory

ApplicableforLevertypevalves
only

ApplicableforBelowtype
valvesonly
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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

3INSTALLATION
Safety relief valves installation should be as per API RP 520 Part 2 and other applicable regulations. Refer these
standardsforcompleteguidelinesandinstruction.
TestGag(30)anoptionalaccessoryofsafetyreliefvalvesusedforblockingtheopeningofvalve.Sometimesbigger
sizevalvesaredispatchedfromfactorywithtestgagfittedoncap(03)ofthevalvetoblockmovementofseatfor
preventingdamagestotheseatduringtransportation.Ifthetestgagisprovidedonthevalvecap(03),itmustbe
removedandreplacedbycapplug(26)andpluggasket(27)beforetesting/installation.Thevalvewillnotopenif
testgagisfittedonthevalve.
Testgagsmaybepreservedandusedforpreventingopeningofthevalvewhenthesystemishydrotestedata
pressuremorethansetpressureofthevalveandwiththevalvefittedonthesystem.TheTestGagmustbe
removedandreplacedwithcapplugaftersuchHydroTestingofthesystem/tank.

Ifthetestgagisprovidedonthevalvecap(03),itmustberemovedandreplacedbycapplug(26)and
pluggasket(27)beforetesting/installation.Thevalvewillnotopeniftestgagisfittedonthevalve.
Blankingplugs,threadprotectionsandplasticcoversshouldberemovedwhenasafetyreliefvalveis
CAUTION testedorinstalled.

4MAINTENANCE
In general the valve is to be maintained as per recommendations given in API RP 576. The procedures for
disassembly,lapping,reassemblyandcheckingsetpressureandsettightnessandadjustingring(Blowdown)setting
aregivenbelow:

4.1PROCEADUREFORSAFETYRELIEFVALVESDISASSEMBLY
Before dismantling a safety valve installed on a pipe circuit or tank it is essential to check that no
pressure exists in the system, by purging the system. A pressure gauge reading is not sufficient for
checkingabsenceofresidualpressure.
CAUTION Clean,degrease,dryallpartsbyusingappropriatesolvent/mechanicalmeans.

Ifthevalveistobeserviced,itistobedismantledasperbelowmentionedprocedure.
STEP1Removecap(03)byopeningcapnut(20)forboltedcaporbyunscrewingthescrewedcap(03)
STEP2Notethelengthofadjustingscrew(17)frombonnet(02)topface.
STEP3 Loosenlocknut(18)andadjustingscrew(17)torelaxthespring(15)
STEP4 Removebonnetnuts(13)andbonnet(02)
STEP5 Removespring(15)andspringwashers(16)(andbearing,ifprovided,ontheupperspringwasherfor
highpressurevalves)
STEP6 Check that the spring (15) is cylindrical by rolling it on a flat surface. If the spring is distorted or
corroded,itshouldbereplaced.
STEP7 RemovetheSpindle(11)andBall(10).
STEP8 Separateguide(9)alongwithpiston(DiscHolder)(08)andbelow(60)(ifprovided)fromthebody(01)
ofthevalvecarefullytoavoiddamagetothediscseatfittedwiththepiston(DiscHolder)(08)
STEP9 UnscrewDisc(05)usingfingersfromthedischolder(08)bykeepingthedischolder(08)verticaland
discseatdownward.
STEP10Inbellowsealedvalve;theBellow(60)isremovedfromthepistonbyunscrewing
STEP11Loosenadjustingringpin(SetScrew)(07)andunscrewtheadjustingring(Blowdownring)(06).
STEP12Invertvalvebody(01)anddismantlenozzle(04)usingdrift.
*ThefiguresmentionedinthebracketindicatepartpositionnoshownintheGAdrawings/partlist.

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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

4.2PROCEADUREFORLAPPING
Ifsafetyreliefvalvestartstoleak,itmustbereconditionedbylappingitsseatsurfacesofthenozzleanddisc,either
byhandorusingamachine.
Lapping operation requires skill and experience and can only be carried out by a qualified personal;
otherwiseirreparabledamagemaybedone.Ifthisskillisnotavailable,thesafetyreliefvalveshouldbe

CAUTION returnedtoMEKASTER.

4.2.1Handlapping
Thediscmustneverbelappedagainstnozzle.
Before lapping, check that parts are not damaged or pitted. This can damage lapping plate or leave
tracesafterlappingoperation.Ifpartsaresodamaged,distortedsurfacesmustberemachinedona lathe
CAUTION machine.
4.2.1.1Disc
Spreadathincoatofgrindingpasteonthelappingtoolsurfaceandplacethedisconthetop.Donotapplyhand
pressure; the weight of the disc will be sufficient. Apply a quick motion in a figure of 8 motions. Lift the disc
periodically.Applyfurthercoatsofpastetothelappingtoolandrepeattheoperationuntilalldefectshavebeen
removed.Theentirecontactsurfacemusthaveanidenticaltextureandappearance,withnotraceofscoring.Clean
thecontactsurfacesofthelappingsetanddisc,usingsolvent.
Forfinishing,useamuchfinergradepasteandspreadathincoatonthelappingset.Proceedasbefore,inafigure
of8motion,forabouttenminutes.Ifthecontactsurfacedoesnotappearfullypolished,repeattheoperationbut
without putting on more paste, just spread the remaining paste evenly, using the finger. The lapping process is
completedwhentheentirecontactsurfacehasnomarksandisuniformlypolishedtoaglazed/mirrorfinish.
Finally, carefully clean the contact surface, using solvent and a very clean white cloth, until all traces of impurity
havebeenremoved.
4.2.1.2Nozzle
Placethenozzleonaflatsurface,withtheseatsurfacefacingdownward.Spreadathincoatoflappingpasteonthe
lappingplateandproceedinthesamewayasforthedisc.
4.2.2Machinelapping
Safety relief valve can be lapped in using a lapping machine, with lapping powder mixed with oil. However, the
polishedsurfacewillonlybeobtainedaftermanualpolishingonthepolishingblock.

4.3PROCEDUREFORREASSEMBLY
Thesafetyreliefvalveshouldbereassembledwithasetofnewgaskets.
Partsmustbethoroughlycleanedbeforeassembly.
Safety relief valve assembly and adjustment is easier if the parts listed below are lubricated before
assembly,whenoperatingconditionsallow:

Nozzle/bodythreads

Nozzle/adjustingringthreads

Disc/discholdercontact

Stem/discholdercontact
CAUTION

Adjustingscrewthreads
Thelubricantusedmustbecompatiblewithoperatingconditions.
Incertainserviceslikeoxygenserviceetc,greasingisnotpermitted andallthepartsmustbecleanand
degreasedthoroughlybeforeassembly.
Checkthattherearenoburrsonmovingpartsnozzle,disc,discholder,guideandadjustingring.
ProceedinreverseorderasmentionedinprocedureforDISASSEMBLY(4.1)

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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

4.4 PROCEDURE FOR CHECKING AND ADJUSTING SET PRESSURE AND SEAT
TIGHTNES

Safetyvalvesettingandadjustmentmustbeexecutedontheappropriatetestbench.(Valvesonliquid
serviceshouldbeadjustedonaliquidorairbench;valveongasserviceshouldbeadjustedonadryoil
freeairornitrogen).
Clampingofvalveontestbenchmustbehomogeneousandhaveatleast3tighteningpoints.
The opening of the valve entails a very high noise level. Persons exposed should be adequately
CAUTION protected.
Theopeningofthevalvecancausetheprojectionofundirectedfluid. Protectivemeasuresshouldbe
takentopreventanyharm.Valveoutletshouldbeintheoppositedirectionoftheoperator.

Theactualserviceconditionsunderwhichasafetyreliefvalveisrequiredtoopenmaybedifferentfromthe
conditionsatwhichthesafetyreliefvalveissettooperateonatestbench.
AColdDifferentialTestPressure(CDTP)isspecifiedforadjustingthesetpressureofthevalveonthetestbench.The
valueofCDTPisgivenonthenameplateofthesafetyreliefvalveorcanbecalculatedasbelow.
4.4.1CalculatingColdDifferentialTestPressure(CDTP)
a)CorrectionDuetoBackPressure:
For a conventional safety relief valve operating with constant backpressure, the differential pressure is the
differencebetweensetpressureandbackpressure.
Forabalanced(Bellowtype)safetyreliefvalveoperatingwithbackpressure,thedifferentialpressureissameasSet
pressure,asthebackpressurehasnoeffectonspringadjustment.
b)CorrectionDuetoTemperature:
Incase,thefluidintestbenchisatlowertemperaturecomparedtotheRelievingTemperatureofsafetyreliefvalve
theCDTPisadjustedtocompensateforvariationinspringload.Thisisdonebymultiplyingthedifferentialpressure
byTemperaturecorrectionfactorKt(TableBelow)

TemperatureFrom
TemperatureTo
TemperaturecorrectionfactorKt
Temp.below66C
66C
1
67C
120C
1.01
121C
200C
1.02
201C
315C
1.03
316C
430C
1.04
430C
maximum
1.05

CDTP=(P1Pb)xKt
CDTP:ColdDifferentialTestPressure
P1:SetPressure
Pb:ConstantBackPressureincaseofconventionalsafetyreliefvalveand0(Zero)incaseofbalanced(Belowtype)
safetyreliefvalve
Kt:Temperaturecorrectionfactor(TableAbove)

4.4.2ProcedureforCheckingandadjustingsetpressureCALIBERATION:
STEP1 Clampthesafetyreliefvalveonthetestbench.
STEP2 Onthetestbench,notetheinitialsettingoftheadjustingring.Loosentheadjustingringpin(07).Movethe
adjustingringtotopandthen2notchesdownforobtainingaclearopeningofthevalve.
STEP3 Increasethepressureandnotethepressureatwhichthesafetyreliefvalvestartstoopen.
STEP4 Drop the pressure on the safety relief valve by at least 50 % and adjust the spring compression, using
adjustmentscrew(setscrew)(06).Ifrequired,thespacermaybeusedbetweenspringandsetscrew.
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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

STEP5 ProceedasinSTEP3andobtaintheCDTPbysuccessiveapproaches.Ensurethatthepressureisdropped
by50%beforeresettingthespringloading.
STEP6 Adjusttheadjustingringaspersettingnotedinstep2.
STEP7Tightentheadjustingringpin(07),ensurethattheadjustingringpinisnotpressingtheringandthereisa
smallgapbetweentheringandthepinsoastohaveafreemovementofadjustingringbetweenthetwo
adjacentnotches.

Ensurethatthepressureisdroppedby50%beforeresettingthespringloading.
Thesetpressurecanbeadjustedwithin10%ofsetpressure.Forgreateradjustmentconsult
MEKASTER.
Dialindicatingpressuregaugesusedintestingshallbegraduatedoverarangeofaboutdoublethe
intendedmaximumtestpressure,butinnocaseshalltherangebelessthan1.5timesnormorethan4

CAUTION timesthatpressure.Digitalreadingpressuregaugeshavingawiderrangeofpressuremaybeused
providedthereadingsgivethesameorgreaterdegreeofaccuracyasobtainedwithdialpressure
gauges.
Alwaysusecalibratedtestpressuregauges.
4.4.3ProcedureforCheckingSeatTightness
SafetyreliefvalveseattightnessischeckedasperAPI527.
After3or4openings,reducethepressureto90%ofthesetpressure(Forsafetyreliefvalvessetto3.45bargor
less, the tightness test pressure will be the pressure setting minus 0.350 bar), close the outlet and measure the
leakagerateforatleastoneminuteaccordingtothestandardAPI527.
Thevalvewithmetalseat,theleakagerateinbubbleperminuteshallnotexceedtheappropriatevaluegivenin
tablebelow(aspertable1ofAPI527)

LeakageRatefor
LeakageRatefor
SetPressure
EffectiveOrificesize<=0.307
EffectiveOrificesize>0.307
inchsq(Forifice)
inchsq(Forifice)
2
PSI(G)
Kg/cm (G)
(bubbles/min)
(bubbles/min)
151000
170
40
20
1500
105
60
30
2000
141
80
40
2500
176
100
50
3000
211
100
60
4000
281
100
80
5000
352
100
100
6000
422
100
100

4.5PROCEDUREFORADJUSTINGRINGSETTING
(NotapplicableforSeriesS14SafetyReliefValves)
Iforiginaladjustmentofthenozzleringistoolowforobtainingcleanopeningandworking,raisetheringbyone
notchandrepeatthisproceduretilldesiredresultisachieved.
Ifthesafetyvalveclosesslowlyorleaksthennozzleringmustbeloweredbyonenotch.
Iftheblowdownishighthenlowertheadjustingringandifblowdownislowtheraisetheadjustingring.

Followingprocedureshouldbefollowedforadjustingringsettings:
STEP1Dropthepressureonthesafetyreliefvalvebyatleast50%.
STEP2Loosen the adjusting ring pin (07). Move the adjusting ring to the required setting. During first trial, for
obtainingblowdownwithin57%,touchthenozzleringtodischolderandthenloweritby5notches.
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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

STEP3Tightentheadjustingringpin(07),ensurethattheadjustingringpinisnotpressingtheringandthereisa
smallgapbetweentheringandthepinsoastohaveafreemovementofadjustingringbetweenthetwo
adjacentnotches.
STEP4Raisethepressuretoopenthevalveforcheckingresultsofadjustment.Ifdesiredresultisnotobtained,
repeatSTEP1to4byloweringadjustingringpin(07)by3to5notcheseachtime.

Ensurethatthepressureisdroppedby50%beforeresettingthespringloading.
Ensurethattheadjustingpinisnottouchingtheringandtheringisnotrevolving.
CAUTION

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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

5TROUBLESHOOTINGGUIDE

Sr.
No.

CommonTrouble

ValvedoesnotOpen/Operate
OR
OpensatPressureotherthanset
pressure.
OR
Earlypopping/passing/Leakage

Leakageatseat/passing

Valveopensatsetpressurebut
doesntclosewithinblowdown
rangeOrcontinuespassing.

LeakagefromjointsofBody
Bonnet/BonnetCap/SetScrew
Cap

Valveflutters(opensandcloses)
inrapidsequence/chattering.

Remedy

TestGagnotremoved

RemoveTestGag&replaceit
byCapPlug

PressureGaugeusedisnot
calibratedorofcorrectrange

UsecalibratedPressureof
correctrange.

Calibratethevalve.Makesure
ValveSetPressuremaybemore/less
correctCDTPiscalculatedfor
thantheTestpressure
testingonbench.
Variablebackpressureeffect

SelectbellowTypevalve

Interferenceduetovibrationsfrom
Rotarym/c&pipingload.

Suppressvibrationsatvalve
byadditionalsupport.

PressuredifferentialbetweenOp.
pressureandleaktestpressureis
toolow.

TheCDTPandLeakTest
PressureofthePSVsshould
beincreased.

ForeignparticlestuckBetweenseat Removeforeignparticlerelap
surfaces/damagedseats bothDisc&Nozzle.
Particlesintestbenchmayhavegot
stuckbetweenseats.

Flush/purgeTestbench
beforetestingthevalve.

Nozzleringisnotadjustedforblow
down.Blowdownmaybehigh.

Adjustthenozzleringtoa
lowersetting.

Damagedseats/foreignparticle
trappedinseat.

Removeforeignparticlerelap
bothDisc&Nozzle.

Wrongvalveorificesize

Valvewithhighersizedorifice
mayberequired.

Fastenersnotproperlytightenedat
thejoints.

Tightenthejointfasteners

Gasketmayhavegotdamaged.

Replacedthegaskets&
tightenthejointfasteners

Blowoffquantityinsufficient

installlowersizevalve

AdjustingRingmayhaverisentoo
high.

LowertheAd.Ring.&lock
withRingPin.

Damagetothebellow/bellow
gasket

Mechanical/defect.

Replacedbellow/bellow
gasketbynewone.

Bellow/Nozzle/Disccorrodes

Servicemediumishighlycorrosive.

UpgradetheMOCofBellow.

Poppingsoundisnotproper

Blowdownringisnotattheright
position.

Positionofblowdownring
hastobechanged.

Blowoffquantityinsufficient

Valveflutters(opensandcloses)
inrapidsequence/chattering.

LowertheAd.Ring.&lock
withRingPin.

AdjustingRingmayhaverisentoo
high.

installlowersizevalve

MEKASTERGROUP

PossibleCause

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SAFETYRELIEFVALVESINSTALLATIONANDMAINTENANCEINSTRUCTIONS

6SPAREPARTS
Asafetyreliefvalveneedstobeoverhauled,afterprolongedorintensiveuseorexceptionalworkingconditions.
ThisoverhaulingshouldbecarriedoutbyourAfterSalesServiceorbyaapprovedrepaircompany
Inanycase,inordertopermittheusertocarryoutthisoverhaulintheshortestpossibletime,werecommenduser
tomaintaininventoryoffollowingspareparts(for10identicalsafetyreliefvalves):
SetofinternalGaskets2No
Bellowassembly(Ifapplicable)1No
Discofseat1No
Nozzle1No
Springassembly1No
Forcriticalservices,acompletesparevalveofeachtypemaybekeptasspare.

UsegenuineMEKASTERsparepartsonly.
Valveserialnumberandvalvecode canbefoundonsafetyvalvenameplateandonalldocumentsfrom
MEKASTER. In case of old installations, these two references are necessary for ordering spare
CAUTION components.

7OPERATION
Whenthepressureunderthediscisbalancedbytheforcewhichiskeepingitseated(thisforcebeingequaltothe
setpressure)thevalvestartstoopen.
Ourvalvesareequippedwithanadjustingringwhentheyaredesignedforuseongasorsteamservice.Inthese
cases,theadjustingringprovokescompleteopeningalmostinstantaneously.
Fullopeningofvalvestakesplaceatbetweensetpressureand10%abovethesetpressureandblowdowntakes
placeatlessthan7%belowsetpressure.
TestGaganoptionalaccessoryofsafetyreliefvalvesusedforblockingtheopeningofvalve.Sometimesbigger
sizevalvesaredispatchedfromfactorywithtestgagfittedoncapofthevalvetoblockmovementofseatfor
preventingdamagestotheseatduringtransportation.Ifthetestgagisprovidedonthevalvecap,itmustbe
removedandreplacedbycapplugandpluggasketbeforetesting/installation.Thevalvewillnotopeniftestgagis
fittedonthevalve.
Testgagsmaybepreservedandusedforpreventingopeningofthevalvewhenthesystemishydrotestedata
pressuremorethansetpressureofthevalveandwiththevalvefittedonthesystem.TheTestGagmustbe
removedandreplacedwithcapplugaftersuchHydroTestingofthesystem/tank.
Balancedsafetyreliefvalvesareincorporatedwithabalancedbellowforminimizingtheeffectofbackpressure
ontheoperationalcharacteristicsofthevalve.Italsopreventscorrosivefluidfromenteringthebonnetandhence
protectsspringfromcorrosion.InBalancedsafetyreliefvalvesthebonnetisventedfortoallowfreemovementof
thepistonofthevalve.
In order to avoid solidification of the fluid in certain process lines, safety relief valves may be supplied with a
steamjacketasoptionalaccessory.

MEKASTERGROUP

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