FL 441

SP Series
Safety Valve with Closed Cap, H2
2

42

86

85 75

19 54

18 59

16
56

H~
55
14
60

12 57

61
C

5
60
Y

2/02 FAINGER LESER April 2006


Instructions for the Treatment and Installation of
Pressure Relief Valves.
1. General Notes
Pressure Relief Valves are highly quality instruments which
should be handled with great care. To ensure the correct
performance of a pressure relief valve all parts are made with
exact precision. Only this precision ensures the correct
functioning of the pressure relief valves. Careless handling of
the finished valve in workshops, stores, during transportation
or installation could cause leakage or possibly permanent
damage (also refer to API Report Guide for inspection of
refinery equipment, Chapt. XVI Pressure Relieving Devices"
Para 1603082 and 1603083).
The sealing surfaces have been ground and lapped with high
precision to ensure the required tightness. Even though the
surfaces are extremely hard, the seal can still be damaged.
By all means, one must take care to prevent impurities from
entering the valve during transportation, installation and
operation.
When installing pressure relief valves with threaded
connections, use only metal seal washers. Seal materials such
as hemp or PTFE tape should not be used as this type of
material can break off and enter the valve causing it to leak.
If valves with open bonnets and/or levers are to be painted
after despatch from the factory, care must be taken to protect
the sliding parts. Otherwise the correct operation of the
pressure relief valve may be affected.
2. Transport Protection
The inlet and outlet of the pressure relief safety valves are
protected during transportation with plastic caps. These caps
should only be removed just before installing the valve.
The lifting lever of spring loaded pressure relief valves is
secured with a wire to the bonnet. This wire should be
removed only after installation. For testing the set pressure or
tightness of the pressure relief valve remove also this wire and
take care that the lever is not engaged with the spindle cap.
3. Installation/Assembly
3.1 General Notes
Spring loaded pressure relief valves should be
installed with the bonnet VERTICALLY UPWARDS.
when
drop
Furthermore, pressure relief valves should be
the
mounted in such a way that no inadmissible static,
dynamic or thermal loads can be transmitted to the
valve due to up and downstream pipe work. If
necessary, expansion possibilities should be
provided. Stresses by incorrect mounting should be
avoided.
3.6Discharge Pipes/Back Pressure
3.2Draining of Condensate
To prevent dirt and all kinds of impurities from the
be
pressure relief valve the drainage of discharge pipe
FAINGER LESER April 2006
FL 441
2
According to rules a drain hole of sufficient size must
be incorporated at the lowest point of pipe work. In all
cases the discharge pipe must first slope in a
downwards direction and fitted with a suitable size
drain hole before any bends are connected (refer to
sketch).
Exception:
In special cases, for instance on board of ships an
optional drain hole may be recommended in the valve
body as it may be that pipe work drainage cannot be
guaranteed at a lower point than the valve. The standard
drain hole which will then be supplied by the factory is
1/4" BSP. But, by all means, the discharge pipe must be
drained too. In extreme cases this hole can be drilled
outside of our factory provided that special care is taken
to ensure that no damage is done to the sealing
surfaces.
All drainage pipes that have been connected must be
free of restriction and the ends easily seen. Care must be
taken when discharging any drainage to prevent injury
to personnel. For example on steam connect a suitable
steam trap.
Note!
When valves are supplied with a drain hole that is not
going to be used the plastic plug fitted in the hole must
be removed and replaced by a metal plug.
3.3Mounting Brackets
For pressure relief valves with mounting brackets a
fastening possibility for the brackets should be
provided to withstand the forces of reaction when
valve blows off. The bracket holes can be drilled
on request.
3.4Insulation
In case any insulation of the pressure relief valve is
provided, the bonnet must be kept free to avoid
unacceptable heating up of the spring.
3.5Inlet Pipe
The inlet pipe for pressure relief valves should be as
short as possible and should be so arranged, that
the valve is in its fully open position the pressure
must not exceed 3% of set pressure, the edging at
inlet pipe should be rounded off or at least be
chamfered.
If the calculation results in a higher than 3% pressure
drop of set pressure then the inlet pipe size must be
enlarged.
The discharge piping on vapours and gases should
installed in an ascending direction, on liquids in an
inclined direction.
2/13
 FL 441
Instructions for the Treatment and Installation of
2 Pressure Relief Valves.
The discharge pipework of all pressure relief valves
should be so arranged that the back pressure, which
is built up during blow off, does not exceed a max.
15% of set pressure.
In case of higher back pressure, pressure relief valves
with pressure compensating metal bellows
(balanced type) shall be used. In case the back
pressure is >0.15 times set pressure the capacity of
the pressure relief valves must be recalculated.
3.7 Pressure Relief Valves with bellows
Pressure relief valves with elastomer bellows (TRD 721)
as well as metal bellows have a vent hole in the
bonnet.
When fitting pressure relief valve with a vent hole care
must be taken to prevent moisture from entering the
bonnet. However, fluid escaping from the vent hole
indicates that the bellows have failed. Repair is
required.
When pressure relief valves with bellows are used with
toxic or inflammable fluids, care must be taken to fit a
suitable vent pipe to provide safe venting. For this
purpose, the vent can be threaded 1/4" BSP female
on request.
4. Mode of Operation/Maintenance
The working pressure of the plant should be at least 5% below
the blow down pressure of the valve to enable a correct
reseat. When a slight leakage occurs, due to deposits
between the sealing surfaces, surfaces can be cleaned by
operating the lifting lever causing the valve to blow off.
The valve should be closed by sudden release of the lever. If
this procedure does not stop the leakage, the valve seals are
probably damaged. Repairs should be carried out at our
2/14
It is recommended and in Germany required by Rules to lift
manually the valve lifting lever from time to time in order to
prevent accumulation of deposits that will affect valve
operation. For steam generators, the following requirements
are established in the German Technical Rules for Steam
Boilers TRD 601, edition 6.83, Section 6.
"Testing of pressure relief valves is required for plants
operating with demineralized water and for hot water
generators at intervals of at least 6 months, with the exception
of power plants. For other steam generators, the test interval
should not exceed 4 weeks".
It is important to ensure that the lifting lever does not engage
the spindle cap after the lift operation. The lever must be
deflected towards the center line of the bonnet until the lifting
fork is disengaged.
For pressure relief valves with open bonnet, a drain groove is
provided in the guide flange. Whilst blowing, condensate
escaping through the clearance between guide disc and
spindle is drained through this groove.
According to DIN specification 4754, Oct. 74 Edition
"Explanations", Para 4.4 pressure relief valves represent the
last step in the line of protection for the vessel, and they should
be able to prevent excess pressure when all other automatic
or pilot operated checking instruments have failed. To
guarantee this function pressure relief valves require, like all
other technical equipment, regular service. How often a
valve must be checked, depends on the actual operating
conditions, so that no general indications can be given.
Usually pressure relief valves operating in a corrosive
atmosphere or on laden fluids require service more often than
valves operating clean conditions. This also applies if the
pressure relief valve operates frequently causing a higher
wear out to the seat and disc.
Special consideration is required if conditions such as
vibration (to be avoided, if possible) pressure pulsation and/or
Add, drain pipe in case of
prepared drain hole
FAINGER LESER April 2006

Dismantling and Assembly Instructions
For Valve Type FL 441, FL 459 & FL 549 Series
1.Loosen the existing lead seal.
2. Press the lever (43) towards the middle until it reaches
the stop so that the lifting fork(44) no longer holds the
spindle cap (46).
3.Loosen and remove the lever cover (41).
4. Loosen the spindle cap (46) from the spindle (12),
remove the securing ring (91) and the pin (74).
5.Loosen the lock nut (19) of the adjusting screw (18).
6. Turn the adjusting screw (18) anticlockwise to remove
the all spring tension.
7. Remove the hex. nuts (56) from the flange of the
bonnet (9).
8.Lift off the bonnet (9).
9.Remove the upper spring plate (16).
10.Lift of the spring (54) and remove lower spring plate
(16) and split rings (14).
11.Remove spindle (12) with guide (8) and disc (7).
12.Carefully clean seat (5) and disc (7), and if required
body internals.
13.Refit spindle (12) with guide (8) and disc (7).
14.Fit the split rings (14) into spindle groove and retain
with the securing ring (59); slip on lower spring plate
(16) to locate on split rings (14).
CAUTION
During all work the spindle has to be secured against twisting in order to prevent damage to the sealing surfaces.
44
41
FAINGER LESER April 2006
FL 441
2
15.Replace spring (54).
16.Slip on the upper spring plate (16) onto the spindle
(12).
17.Align adjusting screw (18), and bonnet (9), over the
spindle (12) and refit.
18.Fit and tighten the hex. nuts (56).
19.Load the spring (54) to obtain the required set
pressure. Clockwise rotation of adjusting screw (18)
increases pressure. Anticlockwise rotation of adjusting
screw (18) reduces pressure.
20.Tighten the lock nut (19) onto the adjusting screw (18).
21.Refit and secure spindle cap (46) by pin (74) and
securing (91).
22.Screw-on the lever cover (41).
23. Pull the lever (43) towards the middle so that the lif ting
fork (44) is pushed under the spindle cap (46).
24.Test spindle will lift correctly by pulling lever .
These instructions are applicable for Relief Valves,
43
18
19
2/15