Complete Clean Service - EN

LESER Information Document LID 1003.
03
Maintenance Handbook for
LESER Product Group Clean Service Page 1/6
MAINTENANCE
public

LESER Product Group
Clean Service Series 48X
disclosure cat.: I resp. depart.: MA published date: 19.05.11 doc. type: LID
author: Bi released by: Bi revision No.: 0
LESER Information Document LID 1003.03
Introduction
About MAINTENANCE
MAINTENANCE provides a collection of documents for repairing or maintaining LESER

safety valves. The following topics are covered:
• Maintenance Fundamentals of LESER safety valves (terminology, design elements
relevant for valve operation)
• Repair process
• Suggested equipment for assembling, disassembling and rework of critical parts
• Disassembly, including sectional drawings
public
• Rework of critical parts including an overview of critical dimensions
• Assembly, including options
• Spring charts
• Testing procedures (set pressure and leak tests)
• Spare parts lists
• Guidelines for inspection, storage and transport
• Trouble shooting
Contents
Chapter Content Sources
LID 1003.03
1.1 Introduction Introduction and table of contents
“Introduction”
1.2 Maintenance Terminology: SIP 1002-00

Fundamentals - Parts “Maintenance
Fundamentals”
- Set pressure
- Overpressure & blowdown
Critical parts:
- Nozzle & disc
public
- Spring
- Adjusting ring
- Parts providing alignment
- Lifting devices
1.3 Repair process -Process of Safety Valves to Repair LGS 1111 “Process for
-Repair Traveller Safety Valves to
Repair”
LGS 1112 “Repair
Traveller”
1.4 Suggested equipment Equipment for disassembly and LWN 369-59 “Clean
lapping Service_Tool-Kit
- Required equipment with technical Specifications”
information LWN 369-56 “Standard
Tool Specification“
- Order numbers of LESER
equipment LGS 1116 “Operating
materials and supplies
- Equipment and materials
for repaired valves“
1.5 Disassembly and Disassembly instruction: LGS 4108 “Dismantling

Cleaning - Step-by-step instruction for instructions for types
disassembly 483, 484, 485, 488 “
LGS 4105 “Dismantling
Cleaning instructions
instructions for types
437, 438, 439, 481 “
LGS 1115 “Cleaning
repaired valves”
1.6 Rework of critical parts The rework of critical

parts like seat and disc
does not apply to the
Clean Service Series,
because all Types have
a soft seat disc.
1.7 Assembly Assembly instruction: LGS 4103 “Assembly

- Step-by-step instruction for instructions for types
483, 484, 485, 488”
assembly
LGS 4100 “Assembly
instructions for types
437, 438, 439, 481”
public
Torques:
- Assembly torques for body-bonnet LWN 322-03 “Torques
connection, caps, test gags, O-ring for screw, nuts and
discs and bellows caps H2 / lifting
devices”
After Assembly: LGS 1114 “Paint touch-

- Color finishing and painting up and painting
repaired valves”
- Component plate
LGS 1118 “Component
plates”
1.8 Spring charts Spring charts: LWN 060-20 “Spring

- Overview of spring ranges for set charts – type 481”
pressure adjustments and spring LWN 062-20 “Spring
selection in bar and psi charts psig – type 481“
LWN 060-21 “Spring

charts – type 483“
charts psig – type 483“

charts – type 484“
charts psig – type 484“


charts – type 485”
charts psig – type 485”

charts – type 488”
charts psig – type 488”
1.9 Testing Procedures Testing set pressure: LWN 331-12 “CDTP”

- Procedures and equipment for LWN 001-69 “CDTP-
setting and testing the cold Cold differential test
public
differential test pressure, including pressure”
tolerances
Leak testing: LWN 369-34

“Performing Leak
- Procedures and equipment for
Tests”
testing functional tightness (disc-
nozzle connection)
- Procedures and equipment for
testing shell tightness (nozzle, cap)
Tightness requirements: LWN 220-01 “Tightness

- Seat tightness Test”
- Shell tightness
- Back seat tightness
Last visual check up LGS 1117 “Final visual

inspection of repaired
valves“
1.10 Spare parts Spare parts list LWN 483.01 “Spare

parts type
481,483,484,485,488”
1.11 Installation & storage Testing and inspection before Extract from LWN 753-
installation: 00 “Testing and
Inspection of Safety
- visual inspection of the valve
Valves before
- hydraulic pressure test Installation”
Inspection intervals Extract from LWN 753-

00 “Recommendation
for Testing and
Inspection during
Operation”
Extract from LWN 753-

00 “Storage and
Storage and transport
Handling of Safety
Valves”
Extract from LWN 765-

01 “Typical Mistakes as
1.12 Trouble shooting Typical errors
a Result of
public
Unauthorized Repair”
LESER Supplementary Information Pool SIP 1002-00
Maintenance Fundamentals Seite 1/9
1 Maintenance Fundamentals
1.1 Introduction ........................................................................................................... 2

1.2 Terminology .......................................................................................................... 3
1.2.1 Parts Description acc. to ASME PTC 25........................................................ 3
1.2.2 Definition of set pressure ............................................................................... 4
1.2.3 Definition of overpressure .............................................................................. 4
1.2.4 Definition of blowdown ................................................................................... 4
1.3 Critical parts .......................................................................................................... 5
1.3.1 Nozzle and disc.............................................................................................. 5
1.3.2 Spring ............................................................................................................ 6
1.3.3 Adjusting Ring................................................................................................ 7
1.3.4 Parts Providing Alignment.............................................................................. 8
1.4 Lifting devices ....................................................................................................... 9
public
disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

author: Bi released by: replaces: 000-00 status: valid
resp. depart.: PM date of release: revision No.: 0
doc. type: SIP change rep. No.: 00687A retention period: 10y.
1.1 Introduction
This chapter deals with basic information considered as necessary for assembly and disassembly
of LESER’s safety valves. Fundamentals include:
- Parts description
- Definition of overpressure, blowdown and set pressure at LESER
- Explanation of relevant construction elements
public

1.2 Terminology
1.2.1 Parts Description acc. to ASME PTC 25

Item Component Description per ASME PTC 25 – Parts used by LESER
1 Body A pressure-retaining or containing component of a pressure relief device
that supports the parts of the valve assembly and has provision(s) for
connecting to the primary and/or secondary pressure source(s).
5 Nozzle A primary pressure- containing component in a safety valve that forms a
part or the entire inlet flow passage.
5 Seat The pressure-sealing surfaces of the fixed and moving pressure-containing
components.
6 Adjusting ring A ring assembled to the nozzle or guide of a direct spring valve, used to
(blowdown ring) control the opening characteristics and/or the reseat pressure.
7 Disc A moveable component of a pressure relief device that contains the primary
pressure when it rests against the nozzle.
9 Bonnet A component of a direct spring valve or of a pilot in a pilot-operated valve
that supports the spring. It may or may not be pressure containing.
public
8 Guide A component in a direct spring or pilot-operated pressure relief device used
to control the lateral movement of the disc or disc holder.
12 Spindle A part whose axial orientation is parallel to the travel of the disc. It may be
(stem) used in one or more of the following functions: (a) assist in alignment, (b)
guide disc travel, and (c) transfer of internal or external forces to the seats.
15 Bellows A flexible pressure-containing component of a balanced direct spring valve
used to prevent changes in set pressure when the valve is subject to
superimposed back pressure, or to prevent corrosion between the disc
holder and guide.
16/17 Spring plate Or spring step: a load-transferring component in a safety valve that
(spring step, supports the spring.
-button, -washer)
18 Adjustment screw A screw used to adjust the set pressure or the reseat pressure of a
reclosing pressure relief device.
40 Cap A component used to restrict access and/or protect the adjustment screw in
a reclosing pressure-relief device. It may or may not be a pressure
containing part.
40 Lift lever A device to apply an external force to the stem of a pressure relief valve to
manually operate the valve at some pressure below the set pressure
54 Spring The element in a safety valve that provides the force to keep the disc on the
nozzle.
Table 1: Parts description acc. to ASME PTC 25
The following parts are described in ASME PTC 25, but are not used in LESER safety valves.
Component Description per ASME PTC 25 Not used in LESER safety valves,
because
Disc holder A moveable component in a pressure One piece spindle with different disc design,
relief device that contains the disc does not require a disc holder
Yoke A pressure-retaining component in a Open bonnets are used for the same
pressure relief device that supports the purpose.
spring in a pressure relief valve or pin in
a non-reclosing device but does not
enclose them from the surrounding
ambient environment
Table 2: Parts description acc. to ASME PTC 25 – not contained in LESER safety valves

1.2.2 Definition of set pressure

ASME PTC 25, 2001, 2.7 OC of PRD
LESER defines the set pressure as the value of increasing inlet static pressure at which the first
audible/visible discharge (first steady flow for liquids) for gas and steam occurs. Furthermore a
“popping” point of safety valve exists when the vessel pressure rises above the set pressure. At
this pressure the valve opens rapidly with small or no increase in system.
1.2.3 Definition of overpressure

ISO 4126-1, 2004, 3.2.3
Overpressure is defined as the pressure increase over the set pressure at which the valve attains
the lift specified by the manufacturer. Usually overpressure is expressed as a percentage of the set
pressure.
For steam and gas applications the maximum overpressure varies between 3% and 10%
depending on applicable code and application. For liquids most codes specify a maximum
overpressure of 10%.
public
1.2.4 Definition of blowdown
ASME PTC 25, 2001, 2.7 OC of PRD
Blowdown is considered as the difference between actual popping pressure of a pressure relief
valve and actual reseating pressure expressed as a percentage of set pressure or in pressure
units.
Typical values for the blowdown are 4% to 15% for steam and gas and 20% to unlimited for liquids.
Figure 1 gives a graphical representation of the definitions.
Figure 1: general characteristic of LESER safety valves for steam/gases acc. to ASME VIII

1.3 Critical parts
This chapter contains a description of critical parts influencing the operation characteristic.
Emphasized were different disc and nozzle constructions, correct spring selection, positioning and
function of the adjustment ring and parts which provide alignment.
1.3.1 Nozzle and disc

The geometry of nozzle and disc is critical to the valve operation. Small changes to the dimensions
of these parts can change overpressure, blowdown and general valve operation significantly.
Maintenance instructions include default dimensions of these parts in chapter rework of critical
dimension. These diameters must be maintained when performing repair and maintenance work.
Nozzle and disc also form the seat of the valve. The surface finish of the contact surfaces is critical
for the tightness of the safety valve. For a metal to metal seat the contact surfaces are lapped for a
specified tightness acc. to API 527 (see chapter rework of critical parts).
Table 3 provides differences between optional disc constructions of flanged and threaded valves.
public
Metal to metal seat Soft seat – o-ring disc
Flanged valves
(type 526)
Lifting aid
Disc O-Ring
Threaded valves
(type 459)
Table 3: soft seat and metal to metal seat constructions of flanged and threaded valves
1.3.2 Spring
The closing force on the disc is applied by the compression of the spring. When the valve opens, a
further compression of the spring must be achieved by the opening forces underneath the disc.
The correct spring rate is critical to overpressure and blowdown of the valve. Each spring has a
defined set pressure range. The spring charts (chapter 6: spring charts) of the manufacturer must
be followed when readjusting or changing the set pressure of the safety valve.
The following table lists the potential consequences of using a spring for a set pressure outside of
its range.
Condition Consequences
Set pressure above spring range - increased blowdown
- risk of excessive spring compression with coils approaching
each other, resulting in restricted lift
- pressure accumulation in the vessel above acceptable
levels due to restricted lift
Set pressure below spring range - increased overpressure
public
- potential pressure accumulation in the vessel above
acceptable levels
Table 4: Influence of incorrect set pressure on overpressure and blowdown

1.3.3 Adjusting Ring

Codes and standards specify limits for the overpressure and blowdown of safety valves. In some
designs adjusting rings are used to adjust the overpressure and blowdown of the safety valve in
order to meet the requirements of codes and standards. In many of them a 10% accumulation
pressure is used as a basis for the design strength calculation of a pressure vessel. Therefore the
overpressure for safety valves is limited to 10% of the set pressure for the majority of the
applications.
The position of these rings is usually factory set to meet overpressure and blowdown requirements
of the applicable codes. The position of the rings can be adjusted to fine tune overpressure and
blowdown of the valve.
For the most common design with one lower adjusting ring, changing the ring position has the
following effects:
Lowering ring: overpressure increases, blowdown decreases

Rising ring: overpressure decreases, blowdown increases
public
The adjusting ring in LESER’s type 526 should be turned to the lowest possible position on the
nozzle to ensure all code requirements are met. No further ring adjustment depending on set
pressure or medium is required.
The benefit for the user is the easier maintenance, because no complicated ring adjustment is
necessary.
Adjusting ring
Figure 2: Blowdown ring of LESER’s Type 526

1.3.4 Parts Providing Alignment
Correct alignment of nozzle and disc

are critical for proper valve operation
and tightness. Disc and spindle of the
valve will move up and down during
Adjusting
valve operation. screw
Proper guiding of the spindle is

essential for trouble free valve
performance. The spindle is guided by Spindle
the guide and the adjusting screw.
When installed, the user must ensure

that no dust, particles in the fluid or
sticky media may enter the guiding Guide
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surfaces and negatively influence the
valve performance. In some cases the Disc
use of a bellows is advisable to
protect the guiding parts. Nozzle/
Inlet body
Figure 3: overview of parts providing alignment

1.4 Lifting devices

The standard design for the valve top is a plain cap, covering and sealing the adjustment of the
safety valve.
Lifting levers allow users to check if the safety valve is still operational by lifting the disc off the
seat. The valve remains in place while testing is performed.
Lifting levers must allow users to lift the disc off the seat when 75% of the set pressure is present
at the valve inlet.
Caps and levers are sealed to prevent any unauthorized modification of the set pressure.
Figure 4 offers different caps and lever used for different LESER safety valves.
public
Plain Cap H2 Plain lever H3- Packed lever H4
- gastight - - not gastight - - gastight -
Bolted Cap H1 Pneumatic lever H8

- gastight - - clean service -
Figure 4: overview of different cap and levers

LESER Global Standard LGS_1111
Process for Safety Valves to Repair Page 1/2
Content
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Introduction.......................................................................................................... 1
4 Safety valve to repair........................................................................................... 2
1 Purpose
This LESER Global Standard (LGS) shows the process for safety valves to repair.
2 Scope
This LGS applies to all members of the LESER Quality Cluster.
3 Introduction
The following flow chart shows the process steps, which are necessary for
valve repair.
The right side give references to forms of inspection documentation,
protected
LESER standards, instructions and spare part lists.
disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

author: Niehus released by: KUW replaces: initial status: valid
resp. depart.: PP date of release: 8.11.10 revision No.: 0
doc. type: LGS change rep. No.: 00651A retention period: 10y
Process for Safety Valves to Repair Page 2/2
4 Safety valve to repair
valve forwarded
visually inspection report 1.1
disassembling assembling instruction (LLS...)
visually inspection
inside parts report 1.2
assembling instruction to cleaning good parts

(LLS…)
Assembling
cleaning good parts instruction
assembling instruction to finishing
protected
original spare parts
finishing (if catalogue

necessary)
assembling the valve assembling instruction (LLS…)

setting of the valve AA-EF and LWN 220-01-0-EN
tighness test
report 1.3
type test approval plate /
or customer identfication assembling instruction
plate (LLS…) AA-EF-080 and
assembling (if LWN 201-01-EN
assembling instruction
paint finish (LLS…)
material safety data sheets
assembling instruction
(LLS...)
visually inspection
report 1.4
delivery to customer

LESER Global Standard LGS 1112
Repair Traveller Page 1/2
Repair Traveller
Customer
Date Valve type
Serial no. / Job no. Medium
1.1 Forwarded Inspection
Repair necessary Remarks
Painting ____________________
Inlet / outlet surface ____________________
protected
Lead seal ____________________
Type test approval plate ____________________
----------------------------------------------------------------------------------------------------------------------------------------
1.2 Disassembling
Spring ____________________
Spring plate ____________________
Disc ____________________
Spindle ____________________
Guide ____________________
Spindle cap ____________________
Lifting device ____________________

Repair Traveller Page 2/2
Seat / full nozzle ____________________
Bellows ____________________
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1.3 Assembling Inspection
Set pressure psig target: actual:
Seat tightness
bubbles / min. target: actual:
i.o. n.i.o.
Backpressure / 6 psig
protected
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1.4 Delivery inspection
i.o. n.i.o.
Type test approval plate
Painting
Components
___________________________________
Date/Signature

LESER WORKS STANDARD LWN 369-56 E
Standardisation of Worldwide Warehouse
Standard Tool Specification page 1
1 General
This LWN describes the recommended Took KIT requirements for equipping an
agency or a warehouse for goods receiving/storage, adjusting, testing and shipping
of safety valves.
2 Contents
1 General ............................................................................................................................1
2 Contents ..........................................................................................................................1
3 Scope...............................................................................................................................2
4 General description........................................................................................................2
5 Designated use ...............................................................................................................2
6 Components of the Standard Tool KIT.........................................................................2
6.1 Double-ended open spanner with unequal widths across flats.................................3
6.2 Single-ended open spanner .....................................................................................5
6.3 Flat-tip and Phillips PH screwdrivers ........................................................................6
6.4 Combination pliers ....................................................................................................7
6.5 Pin punch..................................................................................................................8
6.6 Hammer ....................................................................................................................9
6.7 Punch numbers ......................................................................................................10
6.8 Punch letters...........................................................................................................11
6.9 Brush set ................................................................................................................12
6.10 Sliding vernier calliper ............................................................................................13
6.11 Sealing pliers ..........................................................................................................14
6.12 V-Block ...................................................................................................................15
6.13 Ratchet box ............................................................................................................16
6.14 Torque wrench........................................................................................................17
6.15 Jaw attachments.....................................................................................................18
6.16 Plug-in reversible ratchet ........................................................................................19
6.17 Plug-in adapter .......................................................................................................20
6.18 Socket.....................................................................................................................21
6.19 Wire brush ..............................................................................................................22
6.20 Safety glasses ........................................................................................................23
6.21 Wire twisting pliers..................................................................................................24
6.22 Sealing blocks ........................................................................................................25
6.23 Sealing wire ............................................................................................................26
6.24 Pipe for large spanner ............................................................................................27
6.25 Folding rule.............................................................................................................28
6.26 Glass plate..............................................................................................................29
6.27 Lapping stamp ........................................................................................................30
6.28 Lapping pastes .......................................................................................................32
6.29 Monocrystalline diamond powder ...........................................................................33
6.30 Assembly grease for threads ..................................................................................34
6.31 Leak detection spray ..............................................................................................35
6.32 LESER paint, blue ..................................................................................................36
continues on page 2
processed: Kai Krohn edition: 2009-09-10
LESER
GmbH & Co. KG approved ECO 00465A replaces edition: ----
3 Scope
This document must be applied by all agencies and subsidiaries of LESER

GmbH & Co. KG.
4 General description
• The Took KIT is an important part of the equipment

of an assembly workplace. It is required for the
different work listed for most series of safety valves.
Order number 0161.0000
Internet www.sales@leser.com
5 Designated use
• Assembly of safety valves

• Disassembly of safety valves
• Adjusting the set pressure of safety valves
• Lapping the valve seat
• Repair work
6 Components of the Standard Tool KIT
• All tools found in this LWN are part of the Standard

Tool KIT. The following pages specify the individual
tools through descriptions and by giving practical
examples. The technical illustrations show how the
respective tools look.
continues on page 3
LESER
LESER WORKS STANDARD LWN 369.56 E
6.1 Double-ended open spanner with unequal widths across flats

The double-ended open spanner is used for tightening or unscrewing bolts and nuts.
Designated use
• Tool for tightening or unscrewing bolts and nuts such as caps, levers, and inflow devices
Fig. 1 Unscrewing a screw connection Fig. 2 Sealing the drain hole
Technical requirements (1) Technical illustration

Requirements /
Data Data Data
Quality
DIN 3110
Spanner width
16 x 18 17 x 19 22 x 24
in mm
Length 205 mm 222 mm 250 mm
Manufacturer GEDORE
Material Chrome-vanadium-steel
Vendor Hahn & Kolb

External order
52012-222 52012-230 52012-290
number
LESER order
596.0058.0000
number
Fig. 1: Double-ended open spanner
Tool kit number 0161.0000
Internet www.hahn-kolb.de
Technical requirements (2)

continues on page 4
LESER
GmbH & Co. KG replaces edition: ----
Requirements / Quality Data Data Data

DIN 3110
Spanner width
27 x 32 41 x 46 50 x 55
in mm
Manufacturer GEDORE
Vendor Hahn & Kolb

External order
52012-370 52012-420 52008-370
number
LESER order number 596.0061.000 596.0062.000 596.0063.000
continues on page 5
LESER
6.2 Single-ended open spanner

Single-ended open spanners are required for tightening or unscrewing the lever and cap.
Designated use
• lever and cap screw connections
Fig. 3 Installation of the lever and cap
Technical requirements Technical illustration

Requirements /
Data Data
Quality
DIN 894
Spanner width
41 60
in mm
Manufacturer ORION
Material Special steel
Length 345 mm 495 mm
Head thickness 14 mm 18 mm
Vendor Hahn & Kolb

External order
52002-041 52002-060
number
LESER order
596.0063.0000 596.0030.0000
number
Illustration 2: Single-ended open

spanner
continues on page 6
LESER
6.3 Flat-tip and Phillips PH screwdrivers

The screw driver is required for a variety of auxiliary work such as, for example, to remove
jammed workpieces or to insert an O-ring.
Designated use
• screwing in of locking screws (H4 lever)
• insert O-rings (type 462)
• remove jammed workpieces
Fig. 3 Lifting the protective cap

Requirements /
Data Data Data Data
Quality
DIN 5265A
Edge width mm 3.5 4.5 5.5 6.5

Edge thickness
0.6 0.8 1.0 1.2
mm
Shaft length mm 100 125 150 150
Total length mm 204 236 261 268
Vendor Hahn & Kolb

External order
52736-120 52736-135 52736-141 52736-150
number
LESER order
596.0039.0000
number
Illustration 3: Flat-
Tool kit number 0161.0000 head/Phillips
screwdriver
continues on page 7
LESER
6.4 Combination pliers

The combination pliers are required as an auxiliary tool for various work. For example, it can be
used to cut soft and hard wire. The long cutting edges are suitable for thick cable.
Designated use
• removal of sealing wire

Requirements / Quality Data
DIN ISO 5746
Length 180 mm
Largest Ø that can be cut 3.4 mm
Induction-hardened
Cutting edges
60 HRC
Vendor Hahn & Kolb
External order
52279-130
number
LESER order number 596.0064.0000
Illustration 4: Combination pliers
continues on page 8
LESER
6.5 Pin punch

The pin punch is required for the assembly and disassembly of discs and spindles. The
pins are driven in and out by means of a pin punch.
Designated use
• driving pins in and out

• fixing the spindle in place, when adjusting the set pressure
Technical requirements
Requirements /
Data Technical illustration
Quality
DIN 6450 C
3/4/
Tips – Ø mm 5/6/
7/8
150 x 10/ 150 x 10/
Length x thickness mm 150 x 10/ 150 x 10/
150 x 12/ 150 x 12
Hardened and
Punch head
tempered
Delivery In holder with base
Vendor Hahn & Kolb
External order
51284-500
number
Illustration 5: Combination pliers
continues on page 9
LESER
6.6 Hammer
The hammer is used for marking flanges and bodies and for fastening individual parts
like, for example, discs and spindles.
Designated use
• hammering in punch numbers
• fastening of discs and spindles
• hammering in pins

Requirements /
Data Data
Quality
DIN 1041
Weight without
200 800
handle
Manufacturer ORION
External order
51180-510 51180-560
number
LESER order
596.0066.0000 596.0067.0000
number
Illustration 6: Hammer
continues on page 10
LESER
6.7 Punch numbers

Punch numbers are required for a variety or marking work. At the request of the
customer, the safety valve must also be marked on the edge of the flange or on the body
with the set pressure or tag.
Designated use
• marking flanges and bodies

Requirements /
Data Data
Quality
DIN 1451
Type of characters Numbers
Character height 0.2 mm 0.6 mm
Characters 0-9 0-9
Number of punches 9
Max workpiece
1200 Nm² 1200 Nm²
strength
Hardness on end of
58 – 60 HRC 58 – 60 HRC
punch
Vendor Hahn & Kolb Illustration 7: Punch numbers
External order
56930-020 56930-060
number
LESER order number 596.0068.0000 596.0069.0000
LESER
6.8 Punch letters

Punch letters are required for a variety or marking work. At the request of the customer,
the safety valve must also be marked on the edge of the flange or on the body with the
set pressure or tag or name.
Designated use
• marking flanges and bodies
Technical illustration
Requirements /
Data Data
Quality
DIN 1451
Type of characters Letters
Character height 0.2 mm 0.6 mm
Characters A-Z-&
Number of punches 27
Max workpiece
1200 Nm² 1200 Nm²
strength
Hardness on end of Illustration 8: Punch letters
58 – 60 HRC 58 – 60 HRC
punch
Vendor Hahn & Kolb
External order
56932-020 56932-060
number
LESER order number 596.0070.0000 596.0071.0000
LESER
6.9 Brush set

The brush set consists of brushes of different sizes.
Designated use
• repair of paint damage
• application of lubricants

Requirements /
Data
Quality
Flat brush 1 each 20 / 25 / 35 / 50 mm
Ring brush 1 each Size 2 / 4 / 6
Enamel paintbrush Size 10 / 12 / 16
Vendor Hahn & Kolb

Illustration 9: Brush set
External order
56932-005
number
LESER
6.10 Sliding vernier calliper

Basically, the sliding vernier calliper is used to measure components, for example stroke
limits. The set pressure for several identical safety valves can be roughly adjusted with
the sliding vernier calliper.
Designated use
• pressure setting
• measuring stroke limits
• measuring components

DIN 862
outside, inside, step and depth
Application
measurements
Material INOX steel
Measuring span 150 mm
Measuring jaw length 40 mm
Length of the vernier 15.5 mm
Manufacturer ATRON
Vendor Hahn & Kolb
External order
31065-110
number
Illustration 10: Sliding vernier
Internet www.hahn-kolb.de calliper
LESER
6.11 Sealing pliers

Sealing pliers are required for sealing the bonnet and the body after setting the pressure
of the safety valve.
Designated use
• sealing bonnets and bodies

Requirements /
Data
Quality
Length 150 mm
Seal Ø 9 mm
Colour Blue
Vendor Hahn & Kolb
External order
53205-145 Illustration 11: Sealing pliers
number
LESER
6.12 V-Block
When assembling the disc and spindle, there is a risk of damaging the spindle or disc by
incorrect loading. To prevent this, the V-block is used as an underlay or to fix the round
components in place.
Designated use
• assembly of discs and spindles
• offloading the spindle

Requirements /
Data Data
Quality
Name Small V-block Large V-block
Weight 0.93 kg 0.90 kg
Material Steel
Vendor LESER
Illustration 19: V-block
LESER order
445.0759.0000 445.0859.0000
number
LESER
6.13 Ratchet box

Besides the “ratchet”, the ratchet box contains two different extenders and a number of
different sized sockets.
Designated use
• assembly and disassembly work on safety valves
• various screwing work

Hexagonal
Sockets
13 sockets, 4 drive handles
10, 11, 12, 13, 14, 15, 17,
Widths across flats
19, 22, 24, 27, 30, 32
T handle 1x
Universal joint 1x
Reversible ratchet 1x
Box outside dimensions 410 x 216 x 65 mm
Vendor Hahn & Kolb
External order
58584-025
number
Illustration 20: Ratchet box
LESER
6.14 Torque wrench

A defined torque must be applied for screw connections on
safety valves (for example for connecting the bonnet and the body).
The torque wrench is required for this.
Due to the accessibility of the connection with open-end spanners,
such an attachment is recommended.
Designated use
• screw connections of bonnets and bodies
• use with bolt size 9 / 12 mm or alternatively 14 / 18 mm

Requirements /
Data Data
Quality
Measurement range 20 – 100 Nm 80 – 400 Nm
Scale division value 1 Nm 2 Nm
Ø of seat for heads 9 x 12 mm 14 x 18 mm
Jaw size(s) 19 / 24 19 / 24
+- 2 % of set +- 3 % of set
Margin of error
value value
Torque application left / right
Vendor Hahn & Kolb
External order
52264-010 52264-040
number Illustration 21: Torque wrench
LESER
6.15 Jaw attachments

Jaw attachments for the torque wrench are required, for example, for connecting the
bonnet to the body.
The jaw attachments are used together with the torque wrench (see 6.14).
Designated use
• bolt size 19 / 24 mm

Requirements /
Data Data
Quality
Spanner width 19 mm 24 mm
Width 41 mm 51 mm
Height 9 mm 11 mm
Plug-in shaft 14 x 18 mm 14 x 18 mm
Vendor Hahn & Kolb
External order Illustration 22: Jaw
52286-119 52286-124
number attachment
External order
596.0078.0000 596.0079.0000
LESER
LESER
6.16 Plug-in reversible ratchet

Plug-in reversible ratchets are required, for example, for connecting the bonnet to
the body. The plug-in reversible ratchets are used together with the torque wrench
(see 6.14).
Designated use
• to hold the socket (see 6.18)

Requirements /
Data
Quality
Cross-section of
14x18 mm
the plug-in shaft
Square drive Square 12.5 = 1/2 Inch
Vendor Hahn & Kolb
External order
52286-655
number
Illustration 23: Plug-in reversible
ratchet
LESER
6.17 Plug-in adapter

The plug-in adapter is required as a connecting piece for the torque wrench (see 6.14)
and the plug-in reversible ratchet (see 6.16). It makes it possible to connect the two tools.
Designated use
• holder of the plug-in reversible ratchet (see 6.16) or the jaw attachments (see
6.14)
Figure 6.1

Requirements /
Data
Quality
Plug connection 9 x 12 mm
Drive Square
Step-up 9 x 12 mm to 14x18
Vendor Hahn & Kolb
External order
52286-655 Illustration 24: Plug-in adapter
number
LESER
6.18 Socket
The socket is used together with the torque wrench (see 6.14) and the plug-in reversible
ratchet (see 6.16). It is used, for example, for the screw connection of the bonnet to the
body.
Designated use
Requirements /
Data
Quality
DIN 3120
Width across
36 mm
flats
Size ø 60/49.5 mm
Material 31 Cr V 3
Vendor Hahn & Kolb
Illustration 25:Socket
External order
58596-360
number
LESER order
596.0082.0000
number
LESER
6.19 Wire brush

The wire brush made of stainless steel is used on grey cast iron and stainless steel
safety valves. Any surface rust can be easily removed with the wire brush.
Designated use
• removal of surface rust
• removal of soiling
Requirements /
Data Data
Quality
Wire material Stainless steel Steel
Total length 290 mm 290 mm
Width 35 mm 35 mm
Length of wire
25 mm 25 mm
brushes
Wire Ø 0.3 mm 0.3 mm
Vendor Hahn & Kolb

External order
56726-530 56725-530
number
LESER order
596.0083.0000
number
Illustration 26: Wire brush
LESER
6.20 Safety glasses

The safety glasses are used to protect your eyes. They must be worn during grinding
work on safety valves.
Designated use
• general safety of the eyes
• to be worn during grinding work on the safety valve

Requirements /
Data
Quality
DIN EN 166 F
Manufacturer ARTILUX
Design with side guards
Vendor Hahn & Kolb
External order
55660-100
number Illustration 27:Safety glasses
LESER
6.21 Wire twisting pliers

The wire twisting pliers are required for sealing the bonnet and body. This secures the
pressure setting of the safety valve. The sealing wire is twisted and tightened by the
pliers.
Designated use
• twisting the sealing wire
• sealing bonnets and bodies
Requirements /
Data
Quality
DIN 5256
Manufacturer STAHLWILLE
Weight 0.330 kg
Length 230 mm
Vendor Hahn & Kolb
External order
53137-010
number
Illustration 27:Wire twisting pliers
LESER
6.22 Sealing blocks

The sealing blocks are used to seal the cap / lever and thus certify the set pressure that
has been set.
Designated use
• sealing safety valves
Requirements /
Data
Quality
Size L x H x D 9 x 9 x 5 mm
Hole □ 1.5 mm
Material Plastic
Temp. application limit + 85° C
Vendor Johan Pützfeld B.V.
Illustration 29:Sealing
Internet www.skiffy.com blocks
LESER
6.23 Sealing wire
After adjusting the set pressure on the safety valve, LESER must guarantee that the
pressure cannot be changed without being noticed. For this measure, LESER seals the
lever/cap to the bonnet. Sealing wire is used to connect these components.
Designated use
• sealing the bonnet and the lever/cap

Requirements /
Data
Quality
Wire material Galvanised iron wire
Delivered as On a roll
Wire gauge 0.3 – 0.5 mm
Quantity 1 kg
For sealing Lead 9, 12 mm
Vendor Hahn & Kolb
External order
53212-010
number
LESER order number 525.0208.0000 Illustration 30: Sealing wire
LESER
6.24 Pipe for large spanner
The pipe for the large spanner is an extension of the spanner. It is used to extend the
lever arm when assembling the lever and makes it possible to apply high torque in order
to securely connect the bonnet to the lever.
Designated use
• lever and bonnet connections

Requirements /
Data
Quality
Code EG Class III
Diameter 50 mm
Length 1500 mm
Rod gauge 0.3 – 0.5 mm
Quantity 1 kg
Illustration 24: Pipe for large
For sealing Lead 9, 12 mm spanner
Vendor LESER
LESER
6.25 Folding rule

A folding rule is required for any measuring work.
Designated use
• measuring the outside dimensions of packaging

Requirements /
Data
Quality
Length 2m
Material Wood
Width of sections 16 mm
EC class III
Vendor Hahn & Kolb
External order
37332-005
number
LESER order number TB D
Internet www.hahn-kolb.de Illustration. 32: Folding rule
LESER
6.26 Glass plate

For the finishing of the seat and disc, LESER offers lapping stamps, glass plates and
lapping material.
The seat and disc with the integrally attached lifting aid and with the same do are lapped
with the lapping stamp or glass plate of the same size. Discs with a detachable lifting aid or
generally without a lifting aid are not lapped with a lapping stamp, but are lapped on a glass plate
after disassembling the lifting aid.
Designated use
• re-lapping discs
Requirements /
Data
Quality
LWN 001.32
Ø 140 mm
Vendor LESER
Internet www.sales@leser.com Illustration 17:Glass plate
LESER
6.27 Lapping stamp

For the finishing of the seat and disc, LESER offers lapping stamps, glass plates and
lapping material.
The seat and disc with the integrally attached lifting aid and with the same do are lapped
with the lapping stamp of the same size.
Designated use
• relapping seats and nozzles

Requirements /
Data Data Data
Quality
Number 3 4 5
do 18 23 29
Material 0.6025 / 1.4021 0.6025 / 1.4021 0.6025 / 1.4021
Manufacturer LESER
LESER order
445.1359.0000 445.1459.0000 445.1559.0000
number
LESER

Requirements /
Data Data Data Data
Quality
Number 6 7 8 9
do 37 46 60 74
Material 0.6025 / 1.4021 0.6025 / 1.4021 0.6025 / 1.4021 0.6025 / 1.4021
Manufacturer LESER
Length 172 mm 205 mm 222 mm 250 mm
LESER order
445.1659.0000 445.1759.0000 445.1859.0000 445.1959.0000
number
Requirements /
Data Data Data Data
Quality
Number 10 12 13 14
do 92 125 165 200
Material 0.6025 / 1.4021 0.6025 / 1.4021 0.6025 / 1.4021 0.6025 / 1.4021
Manufacturer LESER
Length 172 mm 205 mm 222 mm 250 mm
LESER order
445.2059.0000 445.2259.0000 445.2359.0000 445.2459.0000
number
LESER
6.28 Lapping pastes

As a lapping paste, LESER uses ready-to-use, water-soluble lapping pastes with different
grit size depending on the damage to the sealing surface.
Designated use
• lapping discs
Requirements /
Data Data Data Data
Quality
LWN 001.32 001.32 001.32 001.32
Name TETRABOR
Identifier F 320 F 600 F 800 F 1200
Grit size in μ 49 – 17 19 – 3 14 – 2 7–1
Packaging Tube
Contents 75 ml
Vendor Artur Glöckler GmbH
LESER order
599.0301.0000 599.0401.0000 599.0101.0000 599.0201.0000
number
Internet http://www.gloeckler.com
Illustration 15: Lapping paste
LESER
6.29 Monocrystalline diamond powder

Monocrystalline diamond powder is mixed with an oil solution to the desired consistency
and then applied selectively.
The workpiece is re-lapped through uniform movements on the nozzle or on a glass
plate.
Designated use
• re-lapping seats and discs

Requirements /
Data
Quality
DIN 001.32
Grit size 1.5 – 3 μ
Package size 50 g
Vendor Peter Wolters
Tool kit number 0161.0000 Illustration 16:
Monocrystalline diamond
Internet www.peter-wolters.com powder
LESER
6.30 Assembly grease for threads
The assembly grease is used for greasing the adjusting screw. It makes it possible to
easily screw the adjusting screw into the bonnet.
Designated use
• greasing the adjusting screw
• greasing components for improved ease of access
• protection against fretting and corrosion

Requirements /
Data
Quality
Name Molikote
- non-combustible
Qualities
- non-corrosive
Packaging Can
Weight 1 Kg
Internet www.molykote.com
Illustration 12: Molikote
LESER
6.31 Leak detection spray

The required body seal tightness is checked by means of a leak detection spray. The
leak is located based on bubble formation after applying the leak detection spray to the
valve contour. In addition, it can also be used to visualise leaks in the manometer screw
connections.
Designated use
• external leak testing of the safety valve
• functional leak testing
• testing the seal tightness of manometer screw connections

Requirements /
Data
Quality
Name Güpoflex
Application Gas and compressed air
- non-combustible
Qualities - non-corrosive
- toxicologically safe
Package size 500 ml spray can
Packaging unit 10 cans
Vendor GÜPO
Internet www.guepo.de Illustration 13: Leak detection
spray
LESER
6.32 LESER paint, blue

Damaged or scratched valve contours must be repaired by LESER blue paint.
Designated use
• repair of damaged valve contours
• repair of scratched valve contours

Requirements /
Data
Quality
Name LESER paint, blue
Colour RAL 5005
Application Valve body
Package size 500 ml can
Packaging unit 1 can
Vendor LESER Illustration 14: LESER blue
paint
Internet www.bfl.dk
End of LWN
LESER
Specification of Clean Service Tool-Kit page 1
1 General
This LWN describes the Took KIT requirements for equipping an agency or a
warehouse for goods receiving/storage, adjusting, testing and shipping of safety
valves.
2 Contents
1 General ............................................................................................................................1
2 Contents ..........................................................................................................................1
3 Scope...............................................................................................................................2
4 General description........................................................................................................2
5 Designated use of the Clean Service Additional Tool KIT..........................................2
6 Components of the Clean Service Additional Tool KIT ..............................................2
6.1 Double-ended open spanner with unequal widths across flats.................................3
6.2 Hook spanner ...........................................................................................................4
6.3 Pin-type spanner wrench ..........................................................................................5
6.4 Aseptic assembly tool ...............................................................................................6
continues on page 2
LESER
Standardisierung weltweiter Lager
3 Scope
This document must be applied by all agencies and subsidiaries of LESER

GmbH & Co. KG.
4 General description
• The Clean Service Additional Tool KIT is an

assembly of tools that are required for the work on
Clean Service safety valves shown in section 5 in
addition to the Standard Tool KIT.
Order number 0161.0003
5 Designated use of the Clean Service Additional Tool KIT
• Assembly of safety valves

• Disassembly of safety valves
• Adjusting the set pressure of safety valves
6 Components of the Clean Service Additional Tool KIT
• All tools found in this LWN are part of the Clean

Service Additional Tool KIT. The following pages
specify the individual tools through descriptions and
by giving practical examples. The technical
illustrations show what the respective tools look
like.
continues on page 3
LESER
6.1 Double-ended open spanner with unequal widths across flats

The double-ended open spanner is used for tightening or unscrewing bolts and nuts.
Designated purpose of double-ended open spanners

• manual tool for tightening or unscrewing bolts and nuts such as caps, levers, and inflow
devices
• screw connection of a variety of nuts and bolts on the safety valve (e.g. pressure setting of
the safety valve).
Fig. 1 Installing the cap Fig. 2 Pressure setting of

the safety valve
Requirements /
Data Data
Quality
Width across flats
12 x 13 41 x 46
in mm
Manufacturer GEDORE
Design chrome-plated
Vendor Hahn & Kolb
Order number
52012-150 52012-420
number
LESER order
596.0089 596.0089
number
Illustration 1: Double-ended open
spanner
continues on page 4
LESER
6.2 Hook spanner

The hook spanner is considered to be an assembly tool specifically for bodies (nuts).
Designated purpose of the hook spanner

• assembly of the body
• assembly of the safety valve on an apparatus
Fig. 3 Installation of the O-ring disc with a

C-spanner with nose Fig. 4 Installation of the O-ring disc

Requirements /
Data
Quality
Code DIN 1810 A
Nuts, outside Ø 40 – 42 mm
Thickness 5 mm
Length 170 mm
For slotted round nuts DIN 1804
For roller bearing nuts DIN 981
Vendor Hahn & Kolb
Order number
52100-060
number
Tool kit number 0161.0003 Illustration 2: Hook spanner
continues on page 5
LESER
6.3 Pin-type spanner wrench

The pin-type spanner wrench is to be used specifically as an assembly tool in the
assembly of bodies.
Designated purpose of a pin-type spanner wrench

• assembly of the body
Fig. 5 Installation of the O-ring disc Fig. 6 Installation of the O-ring disc
with a pin-type spanner wrench

Requirements /
Data
Quality
Code DIN 1810 B
Nuts, outside Ø 20 – 22 mm
Pin Ø 2.5 mm
Length 110 mm
For round nuts with a
DIN 1816
set pin hole in the side
Vendor Hahn & Kolb
Order number
52102-030
number
Internet www.hahn-kolb.de Illustration 3: pin-type spanner
wrench
continues on page 6
LESER
6.4 Aseptic assembly tool

The hook spanner is considered to be an assembly tool specifically for nozzles (nuts).
Designated purpose of the aseptic assembly tool

• assembly of nozzles
• For types 48x, the disc must be installed with the aseptic assembly tool.
Fig. 7 Installation of the Elmoster bellows

Requirements
Data Data Data
/ Quality
LWN 351.49
Sizes DN 25 DN 32 – 50 DN 65 – 100
For valve type 48X
Vendor LESER
LESER order
445.0139.0000 445.0239.0000 445.0339.0000
number Illustration 4: Aseptic
Tool kit number 0161.0003 assembly tool
End of LWN
LESER
Operating materials and supplies for repaired valves Page 1/3
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 2
5 General Information............................................................................................. 2
6 Operating materials and supplies ........................................................................ 2
1 Purpose
This LESER Global Standard (LGS) provides a list of operating materials that are
used during the assembly of LESER safety valves.
2 Scope
This document must be observed by all agencies and subsidiaries of LESER GmbH
& Co. KG.
protected
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are completely correct and error free.
This document is to be used exclusively with the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document about the products of LESER GmbH & Co. KG that is intended for the
LESER subsidiaries at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.

4 Qualified fitting personnel
The operating materials/supplies that are used during the installation of LESER
safety valves must be used exclusively by trained or qualified fitters. The
qualifications must be obtained through the appropriate training measures.
5 General Information
Observe the safety regulations and warnings on the packaging.
6 Operating materials and supplies

Lapping paste - Tetrabor
Grit size 320

600
800
1200
protected
Monocrystalline diamond powder - material number N145
Grit size 1.5 – 3 µm
Assembly grease
Molykotepaste – D Paste
Klübersynth UH1 14-151
Halocarbon oil
Oleic acid - PH. EUR 6.0 material number N-206
Superglue
Delo-Ca
Delo-ML 5449 anaerobic high temperature resistant
Leak detection spray

Güpoflex for gas & compressed air
Quickleen – universal cleaner
Screw glue – LocTITE 222
protected

Cleaning repaired valves Page 1/5
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
6 Cleaning repaired valves ..................................................................................... 2
6.1 Blast cleaning ............................................................................................... 2
6.2 Brushing ....................................................................................................... 3
6.3 Washing ....................................................................................................... 3
7 Handling the components.................................................................................... 4
7.1 Exceptions:................................................................................................... 4
7.2 Process overview ......................................................................................... 4
1 Purpose
This LESER Global Standard (LGS) provides instructions on cleaning LESER safety
valves. The required work steps and materials are described.
protected
2 Scope
This document must be applied when cleaning safety valves in agencies and
subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
that the recommended actions presented here are entirely correct and error. This
document is to be applied exclusively to the specified type. LESER GmbH & Co. KG
declines any liability or responsibility for the correctness and completeness of the
content.
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.

LESER safety valves may only be cleaned by trained or qualified fitters. The
• Gloves must be worn during the entire cleaning process (except for
stainless steel and painted valves).
• Wear safety glasses.
6 Cleaning repaired valves

6.1 Blast cleaning
Stainless steel valves - glass bead blast cleaning
Cast steel - sand or bead blast cleaning
protected
The body and bonnet must be blasted from the inside and outside for as long as it
takes to remove all residual paint, rust or other soiling.
Caution: Protect the seat sealing surface and working surfaces,

otherwise they will be damaged.
Figure 6.1-1: Flange covering, plastic Figure 6.1-2: Flange covering, sticker

6.2 Brushing
The inside parts and inside of the body and bonnet are to be cleaned with a wire-cup
brush and drill / pneumatic grinder until they are clean - until all soiling is removed.
Caution: Protect the seat sealing surface and working surfaces,

otherwise they will be damaged.
6.3 Washing
When washing, make sure that all parts that belong to one repaired safety valve
are washed together. When filling the washing machine, make sure that the washing
medium can flow out of the bodies, bonnets and caps / levers without any residue.
protected
Figure 6.3-1
The bodies must always be placed on the lid section.
Figure 6.3-2 Figure 6.3-3

WRONG RIGHT
Note: Any waste that occurs when cleaning must be disposed of according to
the applicable rules and regulations of the respective country.
7 Handling the components
Generally, the wearing of gloves when handling cleaned and unpainted

components is compulsory.
Such components must never be touched at any time without protection.

This applies both to employees from the operating as well as administrative areas.
Wet gloves must be replaced with dry ones.
Damaged gloves that cannot exclude contact

between the metal surface and skin must not
be used.
Figure 7-1
In particular
protected
In particular, valves, especially the sealing surfaces on the flanges and also the
interior areas, must not be touched without gloves, because these areas will not be
protected even in later process steps by paint. Nor may spare parts be touched
without gloves when unpainted and unpackaged.
7.1 Exceptions:
The requirement for gloves is removed in the following cases:
• assembly of Compact Performance valves (for process-related reasons)
• assembly of stainless steel valves (no danger of corrosion)
It is also mandatory to wear gloves in the initially mentioned cases when performing
the order picking for spare parts.
7.2 Process overview

Parts Warehouse Spare parts Assembly Painting Ident. Packaging
cleaning order (Exceptions: checking &
see 1..1)
picking Shipping
Alkaline corrosion protection Painting as corrosion protection

Gloves are mandatory Gloves are not mandatory
Figure 7.1-1
protected

Dismantling instructions for types 437, 438, 439, 481 Page 1/12
public
Compact Performance
Types 437, 438, 439, 481
disclosure cat.: I proofread: OR published date: 05.2011 effect. date: 05.2011

Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 Disclaimer............................................................................................................ 2
6 General illustration .............................................................................................. 4
7 Dismantling of the Compact Performance series ................................................ 5
7.1 Removal of the levers and caps ................................................................... 5
7.2 Releasing the pressure spring...................................................................... 8
7.3 Dismantling flange connections.................................................................... 9
7.4 Dismantling cylindrical threaded connectors .............................................. 10
7.5 Removal of the spindle assembly............................................................... 11
7.6 Releasing the adjusting screw.................................................................... 12
1 Purpose
This LESER Global Standard (LGS) is disassembly documentation for different
installation types of LESER safety valves of the Compact Performance series. The
public
required work steps and tools are described.
2 Scope
This document must be used in the removal of Compact Performance safety valves
in agencies and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
content.


LESER safety valves may only be disassembled by trained or qualified fitters. The
• Gloves must be worn during the entire disassembly operation.

• Wear safety glasses
public

6 General illustration
public
Figure 6-1: Cross-sectional view of type 437

7 Dismantling of the Compact Performance series

Screw the safety valve onto the clamping device in accordance with the assembly
device catalogue and remove the sealing if it is present.
7.1 Removal of the levers and caps

7.1.1 Removal of lever H3
Illustrations Description Aids / Tools

Remove the Pin punch
retaining clip.
Drive out the pin
with a pin punch.
Pull off the knob.
Unscrew the
lever cover from
the outlet body.
public
Figure 7.1.1-1
Remove the
cylinder pin. Pull
the spindle cap
off the spindle.
Remove the O-
ring from the
groove of the
lever cover.
Figure 7.1.1-2

7.1.2 Dismantling lever H4

Unscrew the cylinder pin. Flat-tip screwdriver
Clamping device
Figure 7.1.2-1
Screw off the lever cap.
Attention: left-handed thread
public
Figure 7.1.2-2
Remove the retaining clip and pin
from the spindle cap.
Figure 7.1.2-3


Unscrew lever cover from the Open-end spanner
outlet body.
Figure 7.1.2-4
Remove the cylinder pin. Pull the
spindle cap off the spindle.
public
Figure 7.1.2-5
Remove the O-ring from the
spindle cap
Figure 7.1.2-6

7.1.3 Dismantling the cap H2

Unscrew cap H2 from Open-end spanner
the outlet body.
Figure 7.1.3-1
7.2 Releasing the pressure spring
public
Remove the lock Pin punch
nut. Secure the Open-end
spindle with the spanner
splint pin against
turning and remove
the adjusting screw.
Turn the adjusting
screw against the
pin punch (do not
remove the pin
punch), until the
spring is completely
unstressed and the
disc is lifted up from
the seat.
Figure 7.2-1

7.3 Dismantling flange connections

Unscrew outlet
adapter from outlet
body and remove
the sealing tape.
Unscrew inlet body
from outlet body
and remove the
sealing tape.
Figure 7.3-1
public

7.4 Dismantling cylindrical threaded connectors

Remove outlet body from inlet Open-end spanner
body (spindle and disc are still Pin punch
secured).
Remove inlet body from
clamping device.
Figure 7.4-1
Screw inlet body out of outlet
body.
public
Figure 7.4-2

7.5 Removal of the spindle assembly

Remove adjusting screw Pin punch
from splint pin. Pull the
splint pin out of the hole.
Pull the spindle assembly
out of the outlet body.
Figure 7.5-1
Pull the spring plate and
spring off the spindle.
Remove the pin (connects
disc/spindle). Separate
disc assembly and
spindle.
public
Figure 7.5-2

7.6 Releasing the adjusting screw

Screw adjusting screw out of
outlet body.
Figure 7.6-1
Unscrew lock nut from
public
adjusting screw.
Figure 7.6-2

protected
Clean Service
Types 483, 484, 485, 488

Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 Disclaimer............................................................................................................ 2
7 Dismantling the Clean Service series .................................................................. 5
7.1 Loosening the cap or lever ........................................................................... 5
7.2 Dismantling the bonnet............................................................................... 17
7.3 Dismantling spindle/disc assembly............................................................. 23
1 Purpose
This LESER Global Standard (LGS) is disassembly documentation for various kinds
of dismantling work on LESER safety valves of the Clean Service series. The work
steps and tools are described.
protected
2 Scope
This document must be used when dismantling Clean Service safety valves in
agencies and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
This document is to be used exclusively with the specified type. LESER GmbH & Co.
content.


LESER safety valves may only be dismantled by trained or qualified fitters. The
• Gloves must be worn during the entire disassembly.

protected

protected
Figure 6-1: Cross-sectional view of type 483 HyThight

7 Dismantling the Clean Service series
7.1 Loosening the cap or lever
7.1.1 Dismantling cap H2
Illustration Description Aids / Tools
Loosen the cap and unscrew it from Open-end spanner
the bonnet.
Figure 7.1.1-1

Loosen and unscrew the screw plug Screwdriver
protected
Figure 7.1.2-1
Unscrew the cap from the lever cover
Figure 7.1.2-2


Unscrew the cap from the lever cover
Figure 7.1.2-3
Pull out the pin.
protected
Figure 7.1.2-4
Loosen the lever cover. Open-end spanner
Figure 7.1.2-5


Unscrew the lever cover from the bonnet.
Figure 7.1.2-6
Pull out the pin and pull the spindle cap off
the spindle.
protected
Figure 7.1.2-7
Pull O-ring off the spindle cap.
Figure 7.1.2-8


7.1.3.1 Lever H8 (simple piston design)

Hold the cap in place with a Open-end spanner
second open-end spanner.
Figure 7.1.3.1-1
Loosening the cap nut also Open-end spanner
loosens the cap.
protected
Figure 7.1.3.1-2
Unscrew and remove the
cap (possibly some counter-
pressure).
Figure 7.1.3.1-3


Remove the spring from the piston.
Figure 7.1.3.1-4
Remove the small O-ring for
securing the pin. Pull the pin.
protected
Remove the spindle cap from the
spindle.
Figure 7.1.3.1-5
Remove O-ring.
Figure 7.1.3.1-6


Pull the piston off the piston
guide.
Figure 7.1.3.1-7
groove on the inside of the
piston.
protected
Figure 7.1.3.1-8
Loosen the piston guide with a C-spanner with a
C-spanner and unscrew it from nose
the bonnet.
Figure 7.1.3.1-9


piston guide.
Figure 7.1.3.1-10
Remove the cap nut from the
bonnet.
protected
Figure 7.1.3.1-11

7.1.3.2 Lever H8 (double piston design)

Loosen and remove the split
ring, and remove the cap.
protected
Figure 7.1.3.2-1
Remove the spring from the
piston.
Figure 7.1.3.2-2


Remove retaining clip and pin.
Remove spindle cap.
protected
Figure 7.1.3.2-3
Remove O-ring and piston.
Figure 7.1.3.2-4


Remove O-ring. Loosen
and remove split ring. Pull
cylinder off the spindle.
Figure 7.1.3.2-5
protected
Pull off the spring.
Figure 7.1.3.2-6


Remove retaining clip and pin.
Remove spindle.
protected
Figure 7.1.3.2-7
Remove the O-ring. Remove
piston from piston guide.
Figure 7.1.3.2-8


piston.
Figure 7.1.3.2-9
Loosen the piston guide with C-spanner with a
a C-spanner and remove it nose
from the bonnet.
protected
piston guide.
Figure 7.1.3.2-10

7.2 Dismantling the bonnet

7.2.1 Dismantling pressure spring and adjusting screw
Secure the spindle from Open-end spanner,
turning with a pin punch. pin punch
Loosen lock nut.
Unscrew adjusting
screw in a clockwise
direction until no more
spring counter-pressure
can be felt.
protected
Figure 7.2.1-1
Screw adjusting screw
completely out of the
bonnet
Screw down the lock
nut. Remove the PTFE
bushing.
Figure 7.2.1-2

7.2.2 Dismantling bonnet with lift indicator
Loosen lock nut. Open-end spanner
Loosen 2 nuts.
protected
Figure 7.2.2-1
Twist out the lift
indicator.
Figure 7.2.2-2


Unscrew split ring Open-end spanner or
until it is loose. ratchet
protected
Figure 7.2.2-3
Remove split ring
Figure 7.2.2-4


Remove bonnet.
protected
Figure 7.2.2-5
Remove the top spring
plate, spring, and control
sleeve from the bottom
spring plate one after the
other.
Figure 7.2.2-6

7.2.3 Dismantling the bonnet without lift indicator

Unscrew split ring Open-end spanner
until it is loose. or ratchet
protected
Figure 7.2.3-1
Remove split ring
Figure 7.2.3-2


Remove bonnet.
protected
Figure 7.2.3-3
Remove the top
spring plate, spring
and bottom spring
plate from the
spindle.
Figure 7.2.3-4

7.3 Dismantling spindle/disc assembly
7.3.1 Dismantling spindle
Pull spindle/guide washer out
of body.
Figure 7.3.1-1
DN 25: Put bottom spring
protected
plate on the spindle and
secure through the holes with
pin.
Figure 7.3.1-2
DN 40: Put half-washers on
the spindle and fasten with
retaining clip.
Figure 7.3.1-3


Push guide washer on the Open-end spanner or
spindle. Screw both guide ratchet
washers finger tight with
hexagon head bolts.
Figure 7.3.1-4
Remove O-ring from
bottom side of the second
guide washer.
protected
Figure 7.3.1-5
Remove PTFE bushing
Figure 7.3.1-6


Pull the elastomer bellows off the
guide washer.
Remove the guide washer from the
spindle.
Figure 7.3.1-7
For DN 40: First remove the lift
stopper.
protected
Figure 7.3.1-8
Use an assembly aid to loosen the Assembly aid
cap nut from the disc body.
Figure 7.3.1-9


Remove the cap nut from the
spindle.
protected
Figure 7.3.1-10
Drive out the pin. Pin punch
Pull the disc off the spindle.
Take the ball out of the disc
body.
Figure 7.3.1-11

7.3.2 Dismantling disc
Push the disc body out of the
lifting aid.
Figure 7.3.2-1
Pull the elastomer bellows out of
the lifting aid.
protected
Figure 7.3.2-2
Elastomer bellows and disc body
Figure 7.3.2-3
groove of the lifting aid.
Figure 7.3.2-4

LESER WORKS STANDARD LWN 322-03-EN
Torques for screw, nuts and caps H2 / lifting devices
page 1
0 Range of application
The above torque ranges are valid for material marked full shaft screws or full shaft bolts and nuts
used for the connection between body and bonnet according to AD-B7 and similar applications.
The torque ranges are valid for lubricated threads with a friction factor or 0,1 and rectangular
facings of the nuts in relation to the bore. With the above torques about 70 – 90 % of the yield
strength of the material are reached.
For higher friction factors (0,12 – 0,15) the higher valves for the torque are required. The maximum
limits must not be exceeded.
Data base: The 70 % valves (low torque valve) for friction factor 0,1 are taken from the
catalogue of „Fa. Gebr. Grohmann, 1991, Wissenswertes über Edelstahlschrauben".
1 Body and bonnet connection
Material Min. – max. Torque [Nm]

Material
equivalent Thread
DIN
ASME M10 M 12 M 16 M 20 M 24
Ck 35/ C 35 Steel 18-22
28 - 36 68 - 87 130 – 166 255 - 288
(1.1181)
A4 Class 70 B8M 25-30
45 - 58 108 - 138 204 – 261 202 - 258
(1.4401)
5.6 - 19-22 30 - 39 73 - 93 -- --
8.8 - 40-45 65 - 84 155 - 198 -- --
Screws 1.7709 B16 - 31 - 37 98 - 118 190 - 228 280 - 320
Table 1 for screws and nuts DIN 931, 933, 938 and EN 24032
Material- Min. – max. Torque [Nm] *

Material
equivalent Thread
DIN
ASME M 12 M 16
Ck 35/ C 35 (1.1181) Steel 25 – 35 40 - 50
5.6 - 25 – 35 40 - 50
Table 2 for screws and nuts for safety valves Type 447/547
*) The above mentioned torques are based on field tests. They allow a tight connection without
destroying the PTFE-material.
continues on page 2
LESER processed: Boy.cw. edition: 18.09.08
GmbH & Co. KG approved: refer to ÄM 152300 replaces edition: 22.10.07
Torques for screw, nuts and caps H2 / lifting devices
page 2
2 Caps and lifting devices
Torque [Nm]** Wrench size

Size Thread
HALAR-coated
Standard gasket
0 M 24 x 1,5 60 – 75 60 - 75 SW 27
I M 33 x 1,5 80 – 100 60 - 75 SW 46
II M 42 x 1,5 100 – 125 100 - 125 SW 55
III M 60 x 1,5 140 – 175 240 - 270 SW 75
IV M 75 x 1,5 175 – 220 n.a. SW 95
Table 3: Caps and lifting devices (sealing torque)
**) To achieve manually with 200 mm extended wrench.
Sufficient for clean and lubricated threads and not damaged sealing surfaces.
n.a. Gasket not available for this size
3 Test Gag
3.1 Short locking screws

For tightening of the short locking screws (pos. 2, e.g. drawing 190.0309-XX-B01) the torque
ranges of table 4 are recommended.
Cap size Thread size Torque

Size lifting device [Nm]***
0 M12
I M12
28 - 32
II M12
III M12
IV M16
72 -76
V M16
Table 4: Test Gag: Recommended starting torque ranges for short screws
***) The used sealing rings out of vulcanised fibre may not be deformed further because they are soft
sealings.
3.2 Long locking screws

For tightening of the long locking screws (pos. 1, e.g. drawing 190.0309-XX-B01) the torque
ranges of table 5 are recommended.
Cap size Thread size Torque

Size lifting device [Nm]***
0 M12
I M12
II M12
20
III M12
IV M16
V M16
Table 5: Test Gag: Recommended starting torque ranges for long screws
End of LWN
LESER processed: PD.cw. edition: 18.11.08
Paint touch-up and painting repaired valves Page 1/4
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
6 Paint touch-up and painting repaired valves........................................................ 2
1 Purpose
This LESER Global Standard (LGS) provides instructions on painting LESER safety
valves. The required work steps and materials are described.
2 Scope
This document must be applied when painting safety valves in agencies and
subsidiaries of LESER GmbH & Co. KG.
protected
3 Disclaimer
that the recommended actions presented here are entirely correct and error free.
content.

The assembly of LESER safety valves may only be performed by trained or qualified
fitters. The qualifications must be obtained through the appropriate training
measures.


• Wear respirator/dust mask
6 Paint touch-up and painting repaired valves

For valves that have to be repainted, the facing and the welded-on
component/customer ID plates must be masked off correctly. Any additional plates
will only be attached after painting, if welding is not required. Open bonnets must be
sealed with protective caps. The same applies to any existing threaded holes.
Outside threads must be protected with a suitable protective cap / existing painting
socket or with masking tape.
protected
Figure 6-1: Protective cap for open bonnet Figure 6-2: Flange sticker

Figure 6-3: Component plate sticker Figure 6-4: Protective cap
protected
Figure 6-5: Component plate sticker Figure 6-6: Protective cap

Figure 6-7: Masking tape Figure 6-8: Protective cap
protected
Figure 6-9
The layer thickness of the coat of paint should be ~ 40µm for one coat of paint.

Component Plates Page 1/10
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
6 Attaching component/customer identification plates............................................ 2
6.1 Standard plate .............................................................................................. 3
6.2 World plate (NGA) ........................................................................................ 4
6.3 Fastening to bonnets with welding spots...................................................... 8
1 Purpose
This LESER Global Standard (LGS) provides instructions on attaching the name
plates of LESER safety valves. The required work steps and materials are described.
2 Scope
protected
This LGS must be applied when attaching the name plates of safety valves in
3 Disclaimer
content.

The name plates of LESER safety valves must attached exclusively by trained or
qualified fitters. The relevant qualifications must be obtained through appropriate
training measures.
• Gloves must be worn for all fitting work (except for stainless steel
and painted valves).
• Wear safety glasses.
6 Attaching component/customer identification plates

If grooved pins with round heads are not required, the plate is to be welded to the
designated place with the spot welding device.
The world plate (NGA) is fastened to the bonnet. In exceptional cases, it may also be
fastened with grooved pins with round heads, in which case it may also be fastened
to the body.
protected
The standard plate is welded to the flat surface designated for that purpose.
Types 437, 438, 439 - outlet body

No fastening with grooved
pins with round heads
Types 459, 462, - bonnet
Flanged valves - on the right side as seen from the outlet side. Exception: Types
457 / 458 / 526 - on the back side using the set screw

6.1 Standard plate
Figure 6.2.1-1
The standard plate comes in two versions.
For valves that are designed according to ASME (feature N68/N70), the version is
created with the UV and NB symbols.
For valves that are designed according to TÜV, the UV and NB symbols are not
protected
included.
Attachment locations for standard component plates
Figure 6.2.1-2: Type 459 Figure 6.2.1-3: Type 462

Figure 6.2.1-4: Type 437 Figure 6.2.1-5: Type 462
protected
Figure 6.2.1-6: Standard plate on a Figure 6.2.1-7: Types 457 / 458 / 526
flanged valve
6.2 World plate (NGA)
Figure 6.2.1-1
The world plate (NGA) comes in two versions.
For valves that are designed according to ASME (feature N68/N70), the version is
created with the UV and NB symbols.

For valves that are designed according to TÜV, the UV and NB symbols are not
lasered on.
6.2.1 Pre-curving of the NGA

For bonnets with a curved cross-section, the plate must be pre-curved with a radius.
To do this, place the labelled plates in the apparatus with the lettering facing down.

Pre-curving the plate Apparatus
protected
Figure 6.2.1-1
Pre-curving the plate for open bonnets Apparatus
(V20-V25)
Figure 6.2.1-2

Adjustment of plate for closed bonnets

(V20 - V32)
Figure 6.2.1-3
When opening bonnets V20-V25, the plate is bent in the longitudinal direction. To do
this, put the labelled plates into the apparatus with the lettering facing down (figure
6.2.1-2).
6.2.2 Corrosion protection

All valves that are painted must have corrosion protection under the world sign. To
do this, apply the standard primer coat (BURCHARTH'S BLUE - 60M.0120.0001) to
the respective place with a sponge.
protected
Figure 6.2.2-1

Sponge
Figure 6.2.2-2
The points where the world
plate will be welded must be
free of paint.
protected
Figure 6.2.2-3

6.3 Fastening to bonnets with welding spots
6.3.1 Quadratic cross-section
For API valves, the world plate is
fastened to the bonnet of the valve
with welding spots. For versions of
closed bonnets with a quadratic
cross-section, the world plate is
attached vertically to the front side of
the valve approx. 5 mm above the
bevelled edge.
Figure 6.3.1-1
protected
6.3.2 High Performance valves
For the High Performance series, the world plate is always attached to the bonnet.
However, the location where the plate is attached is different for individual bonnet
sizes.
a) Closed bonnets (V20 - V32)

The world plate is attached to the
bonnet (V20 - V32).
For closed bonnets, the world

plate is displaced 90° with
respect to the eyelet for the
sealing wire so that the plate is
located on the opposite side of
the outlet for a completely
assembled valve.
Figure 6.3.2-1
b) Open bonnets (V20 - V25)

The world plate is attached
to open bonnets V20 - V25.
It is attached above the cast
LESER lettering and should
be flush with the letter "L".
The plate must be mounted

so that it can be read from
the right (as shown in the
picture).
Figure 6.3.2-2
c) Open bonnet (V32)

For open bonnets V32, the world
plate is displaced 90° with respect
to the eyelet in front of the sealing
wire so that the plate is displaced
by 90° with respect to the outlet for
a completely assembled valve.
protected
The top edge of the plate should be
flush with the bevel of the bonnet.
Figure 6.3.2-3
d) Open bonnet (V40)

Position of the bonnet:
The raised identifier of the product form manufacturer (foundry) is mounted in the
direction of the outlet flange.
Position of the world plate
The world plate is positioned on the free back side on the bottom edge of the bonnet.
6.3.3 Fastening with grooved pins with round heads


The plate is also curved for this
purpose.
When grooved pins with round
heads are used for fastening,
the world plate must be fastened
at the back or at the side of the
body for the API valve.
Figure 6.3.3-1
protected
Figure 6.3.3-2

Assembly instructions for types 437, 438, 439, 481 Page 1/41
public
Compact Performance
TYPES 437, 438, 439, 481
disclosure cat.: I proofread: AW / TS published date: 05.2011 effect. date: 05.2011

Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 References .......................................................................................................... 2
4 Disclaimer............................................................................................................ 2
8 Assembly of the Compact Performance series.................................................... 5
8.1 Assembly of the adjusting screw .................................................................. 5
8.2 Assembly of the spindle / disc assembly ...................................................... 6
8.3 Assembly of the inlet body and outlet body ................................................ 24
8.4 Adjusting the set pressure.......................................................................... 31
8.5 Testing and documenting the seat tightness. ............................................. 32
8.6 Assembly of the cap and lever ................................................................... 33
8.7 Testing the seal tightness to the outside .................................................... 39
8.8 Sealing the valve ........................................................................................ 41
public
1 Purpose
This LESER Global Standard (LGS) is assembly documentation for various assembly
scenarios for LESER safety valves of the Compact Performance series. The required
work steps and tools are described.
2 Scope
This document must be applied to the assembly of Compact Performance safety
valves in agencies and subsidiaries of LESER GmbH & Co. KG.
3 References
LWN 220.01 / LGS 0201
LWN 322-03 / LGS 3322
LWN 614-08 / LGS 3614
Note: LESER LWN standards will be replaced by LGS, latest editions apply.
4 Disclaimer
content.

fitters. The qualifications must be obtained through the appropriate training
measures.
• Gloves must be worn during the entire assembly.
public

public
Figure 7-1: Type 437

8 Assembly of the Compact Performance series

8.1 Assembly of the adjusting screw
Illustration Description Tool / aid

Assemble the adjusting screw (incl.
PTFE-bushing inside) and lock nut.
Figure 8.1-1
Grease the adjusting screw on the Brush
thread and end face. Halocarbon
(OI-56 S / 60H)
public
Figure 8.1-2
Screw the adjusting screw into the
outlet body (a few turns)
Figure 8.1-3

8.2 Assembly of the spindle / disc assembly

8.2.1 Metallic seal 437
8.2.1.1 Spindle / spring plate assembly
Put the spring plate into the Assembly device,
assembly device and fasten Bench vice
in place with bench vice.
public
Figure 8.2.1.1-1
Put a very small amount of Glue
glue on the spindle thread DELO ML 5449
(1 drop on the thread).
Figure 8.2.1.1-2


Put the spindle thread in
the lower spring plate and
screw it in until it is tight to
the touch. Push the pin
punch through the spindle
hole and screw in until it is
tight to the touch.
Figure 8.2.1.1-3
Roundness check of the Indicating calliper
spindle/disc assembly device
Tolerance: max. 0.2mm
Figure 8.2.1.1-4 public

8.2.1.2 Assembly installation

Visual check: Check
sealing surface for
cleanliness and damage.
Sharpen the pin.
Figure 8.2.1.2-1
Assemble the disc body
and lifting aid (holes
public
matching each other).
Figure 8.2.1.2-2
Insert the ball.
Figure 8.2.1.2-3


Assemble the spindle with - Aligning punch,
the spring plate into the Device
preassembled parts and
place them on the
aligning punch in the
device.
Figure 8.2.1.2-4
Install the pin using a - Lever press
lever press.
public
Figure 8.2.1.2-5


Spring plate and spindle
assembled.
Figure 8.2.1.2-6
Install the spring and top Brush, Halocarbon
spring plate on the (OI-56 S / 60H)
spindle.
Only for thrust

bearings: Spring, top
spring plate, thrust
bearings, bearing washer
Grease thrust bearing.
public
Figure 8.2.1.2-7

8.2.2 Plastic sealing plate 437

8.2.2.1 Disc assembly
Visual check: Check sealing
surface of the sealing plate
(outer ring surface) for
undercut
sealing
surface
Figure 8.2.2.1-1
Visual check: Check the
evenness of the sealing plate
(front and back side, no burrs
public
permitted).
Figure 8.2.2.1-2
Screw disc body into the lifting Clamping block,
aid hand tight with fixing the Device
sealing plate inside. Clamp
parts at lifting aid in device.
Figure 8.2.2.1-3


Tighten the disc body with the
special spanner socket using 4
Nm.
Special spanner
socket
Torque wrench
Figure 8.2.2.1-4
Mark the material codes of Punch numbers,
sealing plate into the lifting aid. Hammer
public
Figure 8.2.2.1-5


Put the spring plate in the device - Bench vice
and fasten in place with bench
vice.
Figure 8.2.2.2-1
Put a very small amount of glue Glue
on the spindle thread (1 drop on DELO ML 5449
the thread).
public
Figure 8.2.2.2-2
Put the spindle thread in the Pin punch
lower spring plate and screw it in
until it is finger-tight.
Push the pin punch through the

spindle hole and screw in finger
tight.
Figure 8.2.2.2-3


Put the ball into the disc assembly
and connect to the spindle / spring
plate group.
public
Figure 8.2.2.3-1
Visual check: The pin must have Hammer
some play in the parts through- Support area for
hole of the disc body; connect with disc assembly
pin.
Figure 8.2.2.3-2


Install the spring and top
spring plate on the spindle.
public
Figure 8.2.2.3-3

8.2.3 Soft seal 438/481

8.2.3.1 Disc assembly - soft seal
Visual check: Check sealing surface for
Figure 8.2.3.1-1
public
Wet the O-Ring with soapy water.
Figure 8.2.3.1-2
Wet the lifting aid with soapy water.
Figure 8.2.3.1-3


Place the O-ring in the lifting aid.
Figure 8.2.3.1-4
Press the disc into the lifting aid.
public
Figure 8.2.3.1-5
Mark the material codes of the soft Punch numbers
seal into the lifting aid. Hammer
Figure 8.2.3.1-6


Put the spring plate in the Clamping block
assembly device and
fasten in place with
clamping block.
Figure 8.2.3.2-1
If necessary, remove
excess glue without
leaving any residue.
public
Figure 8.2.3.2-2
Put the spindle thread in Pin punch
the lower spring plate and
screw it in until it is finger-
tight.
Push the pin punch

through the spindle hole
and screw in finger tight.
Figure 8.2.3.2-3


Install the spring and top spring
plate on the spindle.
Figure 8.2.3.3-1
public

8.2.4 Vulcanised sealing surface 439

8.2.4.1 Disc assembly
Visual check: Check sealing surface for
public
Figure 8.2.4.1-1
Put disc in the inlet side of the lifting aid
and screw together hand tight with lock
nut.
Figure 8.2.4.1-2
Clamp the disc in the assembly device
and tighten with the torque wrench.
Comply with torque (4 Nm)
Special spanner
socket
Torque wrench
Vice
Figure 8.2.4.1-3


Put the spring plate into the Clamping block
assembly device and fasten in
place with clamping block.
Figure 8.2.4.2-1
Put a very small amount of glue Glue
on the spindle thread (1 drop DELO ML 5449
on the thread).
Figure 8.2.4.2-2
Put the spindle thread in the Pin punch
public
lower spring plate and screw it
in until it is finger-tight.
Push the pin punch through the

spindle hole and screw in finger
tight.
Figure 8.2.4.2-3


Put the ball in the disc
assembly and connect to the
spindle / spring plate group.
public
Figure 8.2.4.3-1
Install the pin centred. Hammer
Support area for
Visual check: The pin must disc assembly
have some play in the disc
through-hole.
Figure 8.2.4.3-2


Install the spring and top Brush
spring plate on the spindle. Halocarbon
(OI-56 S / 60H)
Only for thrust bearings:
Spring, top spring plate,
thrust bearings, bearing
washer. Grease thrust
bearings.
public
Figure 8.2.4.3-3

8.3 Assembly of the inlet body and outlet body

8.3.1 Insertion of the spindle / disc assembly

Put the spindle assembly (incl. spring and
upper spring plate) in the outlet body.
Make sure that the spindle slides smoothly
into the guide of the adjusting screw
bushing and also the lower spring plate in
the outlet body.
public
Figure 8.3.1-1
8.3.2 Securing the disc

Push the splint pin through the hole of the Pin punch
spindle.
Lift the spindle with the pin punch.
Wedge the splint pin by screwing out the

adjusting screw (for following assembly
steps).
Figure 8.3.2-1

8.3.3 Assembly of the inlet body

8.3.3.1 Assembly of inlet body for threaded connector (cylindrical thread)
Visual check of inlet body: Brush
Check sealing surface for Halocarbon
cleanliness and damage. (OI-56 S / 60H)
Grease the thread of the
inlet body.
Figure 8.3.3.1-1
The disc is in a secured
state (see 8.3.2)
Screw the inlet body into
public
the outlet body hand tight.
Figure 8.3.3.1-2
The disc is in a secured Clamping devices,
state (see 8.3.2) adapter
Clamp the inlet body on

the device (if necessary:
by using an adapter).
Figure 8.3.3.1-3


The disc is in a secured state
(see 8.3.2)
Figure 8.3.3.1-4
Tighten the inlet body with the Torque wrench
specified torque (100 Nm).
public
Figure 8.3.3.1-5

8.3.3.2 Assembly of inlet body for flanged connector (cylindrical thread)
ANSI flange ½” 150 lbs only: Halocarbon

Before gluing the inlet body to the (OI-56 S / 60H)
inlet nozzle, make sure that the
sealing surface and the sealing
strip are lightly greased with
Halocarbon.
Figure 8.3.3.2-1
ANSI flange ½” 150 lbs only:

Inlet body screwed together with
the inlet nozzle.
Figure 8.3.3.2-2
Visual check: Check sealing Brush
public
surface for cleanliness and Halocarbon
damage. (OI-56 S / 60H)
Glue
The disc is in a secured state (see DELO CA 2106
8.3.2)
Grease the inlet body and screw it

into the outlet body.
Figure 8.3.3.2-3

Tighten the inlet body with the Pin punch
specified torque (100 Nm). Torque wrench
Figure 8.3.3.2-4
public

8.3.4 Assembly of the outlet flange

8.3.4.1 Assembly of outlet adapter with cylindrical thread
Grease the sealing lip and Brush
thread of the outlet adapter. Halocarbon
Fit the outlet flange over (OI-56 S / 60H)
the outlet adapter, screw Torque wrench
the adapter into the outlet
body and tighten it.
Tighten the outlet adapter

with the specified torque
(100 Nm).
public
Figure 8.3.4.1-1

8.3.4.2 Assembly of outlet adapter with a conical thread (NPT)

Apply sealing tape to the Sealing tape
thread of the outlet flange.
public
Figure 8.3.4.2-1
Screw the outlet adapter
into the outlet body and
tighten it.
Figure 8.3.4.2-2

8.4 Adjusting the set pressure

Secure the spindle with splint Pin punch
pin against turning when Open-end
adjusting the adjusting screw. spanner
Pressure gauge
Pressurise the valve and adjust
to the set pressure with the
adjusting screw in accordance
with the specification.
Check whether the valve opens

at the set pressure. The set
pressure of the valve has been
reached when you can hear air
escaping. Full opening must be
achieved.
If the valve opens outside the

stipulated set pressure
tolerance, the adjusting screw
public
must be adjusted again.
Figure 8.4-1 Æ Turning in a clockwise

direction causes the valve to
open at higher pressure.
Æ Turning in a counter-
clockwise direction causes the
valve to open at lower
pressure.
When resetting the adjusting

screw, first of all release the
pressure.
Remark: In case of 437 with

d0=6mm, LWN 614-08 / LGS
3614 must be considered.

8.5 Testing and documenting the seat tightness.

Raise the valve to its set Kellog test
pressure 3 times. After the 3rd assembly device
opening, throttle the valve from
the set pressure to the test
pressure. Screw the test cap
on to the outlet body. Seal the
valve outlet with the test plug
thereby connecting it to the
water tank. Adjust the valve to
the given test pressure.
Check the functional seal

tightness according to the order
specifications and LWN 220.01
/ LGS 0201.
If the seal tightness is not met,

then enter the number of
bubbles that are counted in the
fields. If the seal tightness has
public
Figure 8.5-1 not been met after 3 attempts,
then initiate a fault report. If the
seal tightness has been met in
accordance with the
specifications, then document
the results in Report 1.3
"Number of Bubbles".
Unscrew test cap

8.6 Assembly of the cap and lever

8.6.1 Assembly of cap H2

Grease the thread and Brush
sealing lip of cap H2. Put Halocarbon
on the E-CTFE sealing ring (OI-56 S / 60H)
if it is shown in the parts
list.
Caution: The sealing ring

may only be used once. If it
is necessary to
disassemble the cap, the
sealing ring must be
replaced.
public
Figure 8.6.1-1
Screw the cap on and Torque wrench
tighten it with a spanner
(torque as per LWN 322-03
/ LGS 3322).
Figure 8.6.1-2

8.6.2 Assembly of lever H4

Roll the O-ring onto the spindle
cap.
Figure 8.6.2-1
Put the spindle cap onto the
spindle and connect with a
cylinder pin.
public
Figure 8.6.2-2
Grease the O-ring well (1). (1) Klübersynth
UH 14-151 / 60H
Grease the threads of the (2) Halocarbon
spindle cap (2). (OI-56 S / 60H)
Put on the E-CTFE sealing ring

if it is shown in the parts list.
Caution: The sealing ring may

only be used once. If it is
necessary to disassemble the
cap, the sealing ring must be
replaced.
Figure 8.6.2-3


Grease the thread and sealing lip of the Brush
lever cover. Halocarbon
(OI-56 S / 60H)
Figure 8.6.2-4
Screw the lever cover onto the thread of Torque wrench
the outlet body and tighten using approx.
60 - 75 Nm.
public
Figure 8.6.2-5
Fit the pin into the hole of the lever cover
and the slot of the spindle cap and secure
it with the retaining clip.
Figure 8.6.2-6


Press the spindle cap down after assembly.
Figure 8.6.2-7
Grease the threads of the lever cap and install Brush
it. Halocarbon
Attention: left-handed thread (OI-56 S / 60H)
public
Figure 8.6.2-8
Screw in cylinder pin / nut is flush when closed. Flat-tip
Set lever to "closed" / the inscription "CLOSED" screwdriver
can be read on the cap limit stop.
Check the lever after assembly to make sure

that it works (release compressed air with each
lever).
Figure 8.6.2-9


Individual parts of the assembly
Figure 8.6.3-1
Place the O-ring in the groove of the lever
cover.
public
Figure 8.6.3-2
Put the spindle cap onto the spindle and
connect with a cylinder pin.
Figure 8.6.3-3


Grease the thread and Brush
sealing lip of the lever Halocarbon
cover. (Oil 56 S / 60H)
Figure 8.6.3-4
public
Screw the lever cover Torque wrench
onto the thread of the
outlet body and tighten it
using approx. 60 - 75
Nm. Pull up the spindle
cap and install the knob
with the pin and secure
with the retaining clip.
Press the knob down
after assembly.
Figure 8.6.3-5

8.7 Testing the seal tightness to the outside

8.7.1 Testing the seal tightness to the outside (threaded valve)

Seal the valve at the Sealing cap
inlet with a sealing
cap.
public
Figure 8.7.1-1
Install a test Test connector
connector to the
outlet.
Figure 8.7.1-2


Clamp the outlet side of the valve
in the test assembly device and
apply 6 bar of pressure.
public
Figure 8.7.1-3
Pressure testing by immersion:
Check whether any bubbles can be
seen on the outside contour of the
safety valve. If the seal tightness
is good (no bubbles), document
the test result. If there are any
leaks, check the affected sealing
surfaces and seals for damage and
then test again. Dry the valve with
compressed air.
Figure 8.7.1-4

8.7.2 Testing the seal tightness to the outside (flanged valve)

Clamp the outlet side of the valve to
the test bench. Pressurise the valve
with 6 bar.
Wet the valve with leak detector on the

interconnection points and the outlet
area. If the seal tightness is good (no
bubbles), document the test result. If
there are any leaks, check the affected
sealing surfaces and seals for damage
and then test again. Dry the valve with
Figure 8.7.2-1 compressed air.
8.8 Sealing the valve

Connect the sealing wire closely by
using the shortest path. Seal the lever,
public
or alternatively cap H2 to the outlet
body.
Figure 8.8-1

protected
Clean Service
Types 483, 484, 485, 488

Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 Disclaimer............................................................................................................ 2
4 Qualified assembly personnel ............................................................................. 3
7 Assembly of the Clean Service series ................................................................. 5
7.1 Assembly of spindle/disc assembly .............................................................. 5
7.2 Assembly of the bonnet................................................................................ 9
7.3 Adjusting the set pressure.......................................................................... 14
7.4 Testing the seat tightness P12 ................................................................... 15
7.5 Testing of the seal tightness of the pressure-bearing body P11................. 15
7.6 Assembly of the cap / lever ........................................................................ 15
7.7 Sealing the valve ........................................................................................ 33
1 Purpose
This LESER Global Standard (LGS) is assembly documentation for various assembly
protected
scenarios for LESER safety valves of the Clean Service series. The required work
steps, tools and materials are described.
2 Scope
This document must be applied to the assembly of Clean Service safety valves in
3 Disclaimer
content.

4 Qualified assembly personnel
assembly personnel. The qualifications must be obtained through the appropriate
training measures.
• Gloves must be worn during the entire assembly operation.
protected

protected
Figure 6.1-1: Cross-sectional view of type 483 HyTight

7 Assembly of the Clean Service series

7.1 Assembly of spindle/disc assembly
7.1.1 Disc assembly
Put the O-ring into the groove of the
lifting aid.
Figure 7.1.1-1
Elastomer bellows and disc body
protected
Figure 7.1.1-2
Fit the elastomer bellows onto the
other side of the lifting aid.
Figure 7.1.1-3
Put the disc body in the lifting aid.
Figure 7.1.1-4

7.1.2 Assembly of spindle assembly

Insert the ball into the disc
body.
Put the spindle in the disc and
secure with a pin.
Figure 7.1.2-1
Put the cap nut onto the Assembly aid
spindle and screw to disc body
by means of the assembly aid.
protected
Figure 7.1.2-2
Push the guide washer onto
the spindle and pull the
elastomer bellows over it.
Figure 7.1.2-3


For DN 40: Then, push the lift
stopper over the spindle.
Figure 7.1.2-4
Insert the PTFE bushing. insert the
guide washer.
protected
Figure 7.1.2-5
Insert O-ring on bottom side of the
second guide washer.
Figure 7.1.2-6
Push guide washer on the spindle. Ring spanner
Screw both guide washers finger
tight with hexagon head bolts.
Figure 7.1.2-7

7.1.3 Inserting the assembly
DN 25: Put bottom spring plate
on the spindle and secure
through the holes with pin.
Figure 7.1.3-1
DN 40: Put half-washers on the
spindle and fasten with retaining
clip.
protected
Figure 7.1.3-2
Put the assembly on the body. In
the process, carefully lower the
disc onto the seat.
Figure 7.1.3-3

7.2 Assembly of the bonnet
7.2.1 Adjusting screw assembly
Put the PTFE bushing in the
adjusting screw.
Figure 7.2.1-1
Screw lock nut onto adjusting screw. Brush
Halocarbon
protected
Figure 7.2.1-2
Grease the thread and screw into the
bonnet.
Figure 7.2.1-3

7.2.2 Bonnet without lift indicator

Put the bottom spring plate, spring and
top spring plate onto the spindle.
Figure 7.2.2-1
Put the bonnet over the spring onto the
body.
protected
Figure 7.2.2-2
Caution: Surface for BT plate always
opposite the outlet.
Figure 7.2.2-3


Firmly connect the bonnet and
body with a split ring.
Figure 7.2.2-4
Tighten it with the nut. Ring spanner
Figure 7.2.2-5 protected

7.2.3 Bonnet with lift indicator

Put control sleeve on bottom spring
plate. Then put on spring and top
spring plate.
Figure 7.2.3-1
Put the bonnet over the spring onto

the body. (Attention: Surface for BT
protected
plate always opposite to the outlet.)
Figure 7.2.3-2
Firmly connect the bonnet and body
with a split ring.
Figure 7.2.3-3


Tighten it with the nut. Ring spanner
Figure 7.2.3-4
Screw nut onto lift indicator.
Figure 7.2.3-5
protected
Screw lift indicator onto the guide sleeve
as far as it will go.
Afterwards, unscrew it one full turn.
Figure 7.2.3-6
Secure the position with the first nut and Open-end spanner
then tighten the lock nut with the open-
end spanner.
Figure 7.2.3-7

7.3 Adjusting the set pressure

Slowly pressurise the valve on the Open-end
test bench to find out whether the spanner, pin
valve opens at the set pressure. punch
The set pressure of the valve has
been reached when you can hear
air escaping. Full opening must be
achieved.
If the valve opens outside the
stipulated set pressure tolerance,
then the adjusting screw must be
adjusted again. Secure the spindle
from turning with a pin punch.
Turning the adjusting screw in a
Figure 7.3-1 clockwise direction causes the
valve to open at higher pressure.
Turning in a counter-clockwise
direction causes the valve to open
protected
at lower pressure.
Release the pressure before
readjusting the adjusting screw.
Readjust the adjusting screw and
then pressurise the valve again.
If the pressure setting has been Open-end

completed, secure the adjusting spanner
screw with a lock nut.
Afterwards, check the set
pressure once again.
Figure 7.3-2

7.4 Testing the seat tightness P12

This test is performed for every valve after setting the pressure.
7.5 Testing of the seal tightness of the pressure-bearing body P11

This test is performed for every flanged valve without a nozzle after its assembly
P12.
7.6 Assembly of the cap / lever

7.6.1 Assembly of cap H2
Grease the thread and sealing Brush
lip.
Halocarbon
(OI-56 S / 60H)
protected
Figure 7.6.1-1
Screw the cap onto the bonnet Open-end
and tighten. spanner
Figure 7.6.1-2


Pull the O-ring over the Brush
spindle cap and grease.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-1
Put the spindle cap onto

the spindle and secure
with a pin.
protected
Figure 7.6.2-2
Grease the sealing lip and Brush
thread of the lever cover.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-3


Afterwards, screw the Open-end spanner
lever cover (bottom
section) onto the bonnet
and tighten slightly.
Figure 7.6.2-4
Pull the spindle cap out
entirely and secure with a
pin.
protected
Figure 7.6.2-5
Position the spindle cap in
the middle (pin is
positioned centrally in the
elongated hole)
Figure 7.6.2-6
Grease the thread of the Brush
lever cover (top section).
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-7


Grease spindle cap. Brush
Halocarbon
(OI-56 S / 60H)
Figure 7.6.2-8
Screw the cap onto the lever cover.
protected
Figure 7.6.2-9
Screw in and tighten the screw plug.
Figure 7.6.2-10
Afterwards, screw up the cap as far Flat-tip screwdriver
as it will go so that the screw plug
and cap are flush.
Figure 7.6.2-11

Testing the lever:
Pressurise the valve (approx. 90% of the set pressure).
Check the lever by manual venting.
Testing passed: Pressure drops
Testing did not pass: Pressure remains constant
protected


7.6.3.1 Lever H8 (simple piston design)

Grease the threads of Brush
the cap nut.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.1-1
Put the cap nut on the
bonnet.
protected
Figure 7.6.3.1-2
Grease the O-ring Brush
groove of the piston
Halocarbon
guide, and insert the O-
ring avoiding twisting, (OI-56 S / 60H)
possibly with the help of
a pin punch.
Figure 7.6.3.1-3


Grease O-ring. Brush
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.1-4
Screw piston guide to bonnet C-spanner with a
and tighten with a C- nose
spanner.
protected
Figure 7.6.3.1-5
Grease the groove on the Brush
inside of the piston.
Halocarbon
(OI-56 S / 60H)
Pin punch
Figure 7.6.3.1-6


Put the O-ring in the groove Brush
of the piston and grease
Halocarbon
again.
(OI-56 S / 60H)
Figure 7.6.3.1-7
Put the piston on the piston C-spanner with a
guide. nose
protected
Figure 7.6.3.1-8
Grease the groove and Pin punch
stretch the O-ring over the
piston avoiding any twisting
of the ring, possibly with the
help of a pin punch.
Figure 7.6.3.1-9


Afterwards, grease the O-ring. Brush
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.1-10
Put the spindle cap on the
spindle and secure with a roll
pin.
Stretch the small O-ring for
securing the pin onto the spindle
cap.
protected
Figure 7.6.3.1-11
Put the spring into the piston.
Figure 7.6.3.1-12


Twist the angle-screw
with the pneumatic
valve into the cap and
tighten.
Figure 7.6.3.1-13
Grease the inside of Brush
the cap for the O-ring
Halocarbon
guide.
(OI-56 S / 60H)
protected
Figure 7.6.3.1-14
Put the cap on
(possibly some
pressure) and tighten.
Figure 7.6.3.1-15


Tightening the cap Open-end spanner
nut also tightens the
cap.
protected
Figure 7.6.3.1-16
Afterwards, secure Open-end spanner
the cap with a
second open-end
spanner.
(The angle-screw
must always be
opposite the outlet!)
Figure 7.6.3.1-17


Pressurise the
piston to 6-8 bar line
pressure via the
pneumatic valve.
During the
procedure, check
through the outlet
whether the valve
lifts.
protected
Figure 7.6.3.1-18
Spray/brush the Brush
interconnection
Leak detection
points with leak
spray
detector to check the
seal tightness.
Figure 7.6.3.1-19

7.6.3.2 Lever H8 (double piston design)

Grease the piston guide on the groove Brush
for the O-ring.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.2-1
Insert the O-ring and grease again. Brush
Halocarbon
protected
(OI-56 S / 60H)
Figure 7.6.3.2-2
Put piston guide on valve and tighten C-spanner with a
with a C-spanner. nose
Figure 7.6.3.2-3


Insert O-ring avoiding twisting (grease Brush
before and after).
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.2-4
Insert O-ring in piston (grease before Brush
and after).
Halocarbon
protected
(OI-56 S / 60H)
Figure 7.6.3.2-5
Put piston on piston guide and put O- Brush
ring into the outer groove (grease
Halocarbon
before and after).
(OI-56 S / 60H)
Figure 7.6.3.2-6


Put on the spindle cap and secure with
a pin and retaining clip.
Figure 7.6.3.2-7
Put on the spring.
protected
Figure 7.6.3.2-8
Put on the cylinder. In the process,
make sure the pneumatic valve is
opposite the outlet.
Figure 7.6.3.2-9


Fasten cylinder with split ring.
Figure 7.6.3.2-10
Pull on O-ring.
protected
Figure 7.6.3.2-11
Insert O-ring in second piston.
Figure 7.6.3.2-12


Grease all O-rings before and after! Brush
Put piston on and insert O-ring.
Halocarbon
(OI-56 S / 60H)
Figure 7.6.3.2-13
Put on the spindle cap and secure
with a pin and retaining clip.
protected
Figure 7.6.3.2-14
Put the spring onto the piston.
Figure 7.6.3.2-15


Put on the cap. In the process, make
sure the angle-screw is opposite the
outlet.
Figure 7.6.3.2-16
Connect cap with split ring and tighten Ring spanner
the nut.
protected
Figure 7.6.3.2-17
Pressurise the piston to 6-8 bar line
pressure via the pneumatic valve.
During the procedure, check through
the outlet whether the valve lifts.
Afterwards, test the seat tightness P12
and seal tightness of the pressure-
bearing body P11.
Apply leak detector to the
interconnection points and look for
bubbles.
Figure 7.6.3.2-18

7.7 Sealing the valve
Weld on sealing lug if Sealing wire
necessary.
Sealing block
Closely connect the sealing
Wire twisting pliers
hole or lug from the cap/lever
and bonnet in a clockwise
direction. Interlace the wire.
Seal the lever/cap to the
outlet body.
Figure 7.7-1
Sealed cap H2
protected
Figure 7.7-1Fehler! Es wurde keine Folge
festgelegt.
Sealed cap H4

festgelegt.
Sealed cap H8 (simple piston
design)

festgelegt.

Federdaten-Tabellen Type 481 LWN 060.20
Spring data-list Blatt 01/Ende der LWN
Type sheet
Ausgabe 08.07.05
edition
Erklärungen siehe / explanation see : LWN 060.00 + LWN. 060.99
Ausführung
korrosionsfest (stainless steel)
p [ bar ] p [ bar ] p [ bar ]
von bis Feder- Indizes von bis Feder- Indizes von bis Feder- Indizes
p1 p2 Sachnummer p1 p2 Sachnummer p1 p2 Sachnummer
up to stock no. up to stock no. up to stock no.
481 do10
mit vulkanisierter Weichdichtung
(vulcanised soft seal)
0,10 - 0,23 540.0704.0000
0,24 - 0,33 540.3004.0000
0,34 - 0,50 540.3014.0000
0,51 - 0,90 540.3024.0000
0,91 - 1,40 540.3034.0000
1,41 - 1,80 540.3044.0000
1,81 - 3,10 540.3054.0000
3,11 - 4,40 540.3064.0000
4,41 - 7,00 540.3074.0000
7,01 - 10,00 540.3084.0000
10,01 - 16,00 540.3094.0000
481 do10
mit O-Ring-Teller (o-ring-disc)
16,01 - 26,00 540.3114.0000
26,01 - 35,00 540.3164.0000
35,01 - 54,00 540.3174.0000
54,01 - 68,00 540.3204.0000
bearbeitet: Eg geprüft: Haa Ersatz für Ausgabe: 21.12.01 ÄM 007400

Spring data-list Blatt 01
Type sheet
Ausgabe 24.06.04
edition
Ausführung
Standard (standard) Standard (standard) Standard (standard)
483 DN 25 do 13
0,30 - 0,37 540.3014.0000
0,38 - 0,55 540.3024.0000
0,56 - 0,83 540.3034.0000
0,84 - 1,24 540.3044.0000
1,25 - 1,80 540.3054.0000
1,81 - 2,45 540.3064.0000
2,46 - 3,20 540.3074.0000
3,21 - 4,50 540.3084.0000
4,51 - 6,60 540.3094.0000
6,61 - 9,75 540.3104.0000
9,76 - 16,00 540.3114.0000
Federdaten-Tabelle gültig ab 13.12.00

spring data list valid since 13.12.00
483 DN 40 do 25
0,10 - 0,14 540.8014.0000
0,15 - 0,21 540.8024.0000
0,22 - 0,29 540.8034.0000
0,30 - 0,37 540.8044.0000
0,38 - 0,59 540.8054.0000
0,60 - 0,97 540.4004.0000
0,98 - 1,40 540.4014.0000
1,41 - 1,90 540.4024.0000
1,91 - 2,55 540.4034.0000
2,56 - 3,40 540.4044.0000
3,41 - 4,80 540.4054.0000
4,81 - 7,00 540.4064.0000
7,01 - 9,90 540.4074.0000
9,91 - 12,75 540.4084.0000
12,76 - 16,00 540.4094.0000
bearbeitet: Haa.DS geprüft: Ersatz für: 21.12.01 ÄM5345

Federdaten gültig bis 13.12.00 Type sheet
spring data-list valid until 13.12.00 Ausgabe 17.02.04
edition
Ausführung
483 DN 25 do 13
0,10 - 0,20 S
0,21 - 0,27 540.3004.0000
0,28 - 0,41 540.3014.0000
0,42 - 0,65 540.3024.0000
0,66 - 1,00 540.3034.0000
1,01 - 1,40 540.3044.0000
1,41 - 1,98 540.3054.0000
1,99 - 2,85 540.3064.0000
2,86 - 3,75 540.3074.0000
3,76 - 4,55 540.3084.0000
4,56 - 6,10 540.3094.0000
6,11 - 10,40 540.3104.0000
10,41 - 16,00 540.3114.0000
Federdaten gültig bis 13.12.00

spring data-list valid until 13.12.00
bearbeitet: MV geprüft:Cal Ersatz für: 21.12.01 ÄM 5232

Type sheet
Ausgabe 24.06.04
edition
Ausführung
484 DN25 do13
0,30 - 0,37 540.3014.0000
0,38 - 0,55 540.3024.0000
0,56 - 0,83 540.3034.0000
0,84 - 1,24 540.3044.0000
1,25 - 1,80 540.3054.0000
1,81 - 2,45 540.3064.0000
2,46 - 3,20 540.3074.0000
3,21 - 4,50 540.3084.0000
4,51 - 6,60 540.3094.0000
6,61 - 9,75 540.3104.0000
9,76 - 16,00 540.3114.0000
484 DN 40 do 25
0,10 - 0,14 540.8014.0000
0,15 - 0,21 540.8024.0000
0,22 - 0,29 540.8034.0000
0,30 - 0,37 540.8044.0000
0,38 - 0,59 540.8054.0000
0,60 - 0,97 540.4004.0000
0,98 - 1,40 540.4014.0000
1,41 - 1,90 540.4024.0000
1,91 - 2,55 540.4034.0000
2,56 - 3,40 540.4044.0000
3,41 - 4,80 540.4054.0000
4,81 - 7,00 540.4064.0000
7,01 - 9,90 540.4074.0000
9,91 - 12,75 540.4084.0000
12,76 - 16,00 540.4094.0000
bearbeitet: Haa.DS geprüft: Ersatz für: 21.12.01 ÄM 5345

Type sheet
Ausgabe 24.06.04
edition
Ausführung
485 DN 25 do13
0,30 - 0,46 540.3014.0000
0,47 - 0,65 540.3024.0000
0,66 - 1,00 540.3034.0000
1,01 - 1,40 540.3044.0000
1,41 - 1,98 540.3054.0000
1,99 - 2,85 540.3064.0000
2,86 - 4,00 540.3074.0000
4,01 - 5,00 540.3084.0000 *1
5,01 - 7,75 540.3094.0000 *1
7,76 - 10,80 540.3104.0000 *1
10,81 - 16,00 540.3114.0000 *1
485 DN 40 do25
0,10 - 0,14 540.8014.0000
0,15 - 0,21 540.8024.0000
0,22 - 0,29 540.8034.0000
0,30 - 0,37 540.8044.0000
0,38 - 0,59 540.8054.0000
0,60 - 0,97 540.4004.0000
0,98 - 1,40 540.4014.0000
1,41 - 1,90 540.4024.0000
1,91 - 2,55 540.4034.0000 *1
2,56 - 3,40 540.4044.0000 *1
3,41 - 4,80 540.4054.0000 *1
4,81 - 7,00 540.4064.0000 *1
7,01 - 9,90 540.4074.0000 *1
9,91 - 12,75 540.4084.0000 *1
12,76 - 16,00 540.4094.0000 *1
*1)
Druckbereiche ausgeführt mit ORD-Bauteilen
gem. LWN 061.07
Pressure range fitted with ORD-parts acc. to LWN 061.07
bearbeitet: Haa.DS geprüft: Ersatz für:21.12.01 ÄM 5345

Type sheet
Ausgabe 15.11.10
edition
Ausführung
korrosionsfest (stainless steel) korrosionsfest (stainless steel) korrosionsfest (stainless steel)
DN 25 do 23 DN 40 do 37 DN 50 do 46
0,20 - 0,24 S
0,10 - 0,19 540.8024.0000 0,10 - 0,19 540.8404.0000 0,25 - 0,34 540.8404.0000
0,20 - 0,29 540.8034.0000 0,20 - 0,33 540.8414.0000 0,35 - 0,48 540.8414.0000
0,30 - 0,40 540.8044.0000 0,34 - 0,55 540.8424.0000 0,49 - 0,65 540.8424.0000
0,41 - 0,55 540.8054.0000 0,56 - 0,80 540.8434.0000 0,66 - 1,00 540.8434.0000
0,56 - 0,75 540.4004.0000 0,81 - 1,20 540.4654.0000 1,01 - 1,40 540.4654.0000
0,76 - 1,05 540.4014.0000 1,21 - 1,50 540.4664.0000 1,41 - 1,94 540.4664.0000
1,06 - 1,40 540.4024.0000 1,51 - 2,20 540.4674.0000 1,95 - 2,74 540.4674.0000
1,41 - 1,80 540.4034.0000 2,21 - 2,60 540.4684.0000 2,75 - 3,70 540.4684.0000
1,81 - 2,25 540.4044.0000 2,61 - 3,40 540.4694.0000 3,71 - 5,35 540.4694.0000
2,26 - 3,50 540.4054.0000 3,41 - 5,40 540.4704.0000 5,36 - 7,90 540.4704.0000
3,51 - 5,00 540.4064.0000 5,41 - 8,50 540.4714.0000 7,91 -10,90 540.4714.0000
5,01 - 8,50 540.4074.0000 8,51 -12,50 540.9604.0205 10,91 -15,00 540.8494.0000
8,51 -12,50 540.4084.0000 12,51 -16,00 540.4724.0000
12,51 -16,00 540.4344.0000
DN 65 do 60 DN 80 do 74 DN 100 do 92
0,10 - 0,22 S 0,21 - 0,25 S 0,10 - 0,15 S
0,23 - 0,28 540.8424.0000 0,26 - 0,35 540.8534.0000 0,16 - 0,23 540.8534.0000
0,29 - 0,40 540.8434.0000 0,36 - 0,60 540.5704.0000 0,24 - 0,43 540.5704.0000
0,41 - 0,57 540.4654.0000 0,61 - 1,00 540.5714.0000 0,44 - 0,59 540.5714.0000
0,58 - 0,76 540.4664.0000 1,01 - 1,30 540.5724.0000 0,60 - 0,84 540.5724.0000
0,77 - 1,15 540.4674.0000 1,31 - 1,70 540.5734.0000 0,85 - 1,25 540.5734.0000
1,16 - 1,50 540.4684.0000 1,71 - 2,40 540.5744.0000 1,26 - 1,35 540.5744.0000
1,51 - 2,00 540.4694.0000 2,41 - 3,40 540.5754.0000 1,36 - 2,40 540.5754.0000
2,01 - 2,85 540.4704.0000 3,41 - 4,30 540.5764.0000 2,41 - 3,20 540.5764.0000
2,86 - 3,50 540.4714.0000 4,31 - 5,60 540.9724.0205 3,21 - 4,50 540.5774.0000
3,51 - 4,30 540.8494.0000 5,61 - 7,50 540.5774.0000 4,51 - 6,20 540.5784.0000
4,31 - 5,10 540.9604.0000 7,51 -10,34 540.5784.0000 6,21 - 8,20 540.5784.0000
5,11 - 6,90 540.4724.0000 540.9924.0205
6,91 - 8,80 540.4734.0000
8,81 -10,34 540.4704.0000
540.9604.0000
bearbeitet: Schm geprüft: Boy Ersatz für Ausgabe vom 21.09.07 ECO_00650A
Federdaten-Tabellen [psig] Type 481 LWN 062.20
Spring data-list Blatt 01/End of LWN
sheet
Ausgabe 28.07.05
edition
Ausführung (model)
korrosionsfest (stainless steel)
p [ psig ] p [ psig ] p [ psig ]
p1 p2 Materialnummer p1 p2 Materialnummer p1 p2 Materialnummer
481 do10
mit vulkanisierter Weichdichtung
(vulcanised soft seal)
1 - 3 540.0704.0000
3 - 5 540.3004.0000
5 - 7 540.3014.0000
7 - 13 540.3024.0000
13 - 20 540.3034.0000
20 - 26 540.3044.0000
26 - 45 540.3054.0000
45 - 64 540.3064.0000
64 -102 540.3074.0000
102 -145 540.3084.0000
145 -232 540.3094.0000
mit O-Ring-Teller (o-ring-disc)

232 -377 540.3114.0000
377 -508 540.3164.0000
508 -783 540.3174.0000
783 -986 540.3204.0000
revised: Cal checked: Lue New edition ÄM 016500

Spring data-list Blatt 01
sheet
Ausgabe 28.07.05
edition
type
483 DN 25 do 13
4 - 6 540.3014.0000
6 - 8 540.3024.0000
8 - 12 540.3034.0000
12 - 18 540.3044.0000
18 - 26 540.3054.0000
26 - 36 540.3064.0000
36 - 47 540.3074.0000
47 - 65 540.3084.0000
65 - 96 540.3094.0000
96 -142 540.3104.0000
142 -232 540.3114.0000
Federdaten-Tabelle gültig ab 13.12.00

spring data list valid since 13.12.00
483 DN 40 do 25
1 - 2 540.8014.0000
2 - 3 540.8024.0000
3 - 4 540.8034.0000
4 - 6 540.8044.0000
6 - 9 540.8054.0000
9 - 14 540.4004.0000
14 - 20 540.4014.0000
20 - 28 540.4024.0000
28 - 37 540.4034.0000
37 - 49 540.4044.0000
49 - 70 540.4054.0000
70 -102 540.4064.0000
102 -144 540.4074.0000
144 -185 540.4084.0000
185 -232 540.4094.0000
revised: Cal checked:Lue New edition ÄM 016500

Federdaten gültig bis 13.12.00 sheet
spring data-list valid until 13.12.00 Ausgabe 28.07.05
edition
type
483 DN 25 do 13
1 - 3 S
3 - 4 540.3004.0000
4 - 6 540.3014.0000
6 - 10 540.3024.0000
10 - 15 540.3034.0000
15 - 20 540.3044.0000
20 - 29 540.3054.0000
29 - 41 540.3064.0000
41 - 55 540.3074.0000
55 - 66 540.3084.0000
66 - 89 540.3094.0000
89 -151 540.3104.0000
151 -232 540.3114.0000
Federdaten gültig bis 13.12.00

spring data-list valid until 13.12.00

sheet
Ausgabe 28.07.05
edition
type
484 DN25 do13
4 - 6 540.3014.0000
6 - 8 540.3024.0000
8 - 12 540.3034.0000
12 - 18 540.3044.0000
18 - 26 540.3054.0000
26 - 36 540.3064.0000
36 - 47 540.3074.0000
47 - 65 540.3084.0000
65 - 96 540.3094.0000
96 -142 540.3104.0000
142 -232 540.3114.0000
484 DN 40 do 25
1 - 2 540.8014.0000
2 - 3 540.8024.0000
3 - 4 540.8034.0000
4 - 6 540.8044.0000
6 - 9 540.8054.0000
9 - 14 540.4004.0000
14 - 20 540.4014.0000
20 - 28 540.4024.0000
28 - 37 540.4034.0000
37 - 49 540.4044.0000
49 - 70 540.4054.0000
70 -102 540.4064.0000
102 -144 540.4074.0000
144 -185 540.4084.0000
185 -232 540.4094.0000

sheet
Ausgabe 28.07.05
edition
Ausführung (model)
485 DN 25 do13
4 - 7 540.3014.0000
7 -10 540.3024.0000
10 -15 540.3034.0000
15 -20 540.3044.0000
20 -29 540.3054.0000
29 -41 540.3064.0000
41 -58 540.3074.0000
58 -73 540.3084.0000 *1
73 -113 540.3094.0000 *1
113 -157 540.3104.0000 *1
157 -232 540.3114.0000 *1
485 DN 40 do25
1 - 2 540.8014.0000
2 - 3 540.8024.0000
3 - 4 540.8034.0000
4 - 6 540.8044.0000
6 - 9 540.8054.0000
9 -14 540.4004.0000
14 -20 540.4014.0000
20 -28 540.4024.0000
28 -37 540.4034.0000 *1
37 -49 540.4044.0000 *1
49 -70 540.4054.0000 *1
70 -102 540.4064.0000 *1
102 -144 540.4074.0000 *1
144 -185 540.4084.0000 *1
185 -232 540.4094.0000 *1
*1)
Druckbereiche ausgeführt mit ORD-Bauteilen
gem. LWN 061.07
Pressure range fitted with ORD-parts acc. to LWN 061.07

Federdaten-Tabellen psig Type 488 LWN 062-24
sheet
Ausgabe 15.11.10
edition
Ausführung (model)
korrosionsfest (stainless steel) korrosionsfest (stainless steel) korrosionsfest (stainless steel)
DN 25 do 23 DN 40 do 37 DN 50 do 46
2,9 3,5 S
1 - 3 540.8024.0000 1 - 3 540.8404.0000 3,6 5,0 540.8404.0000
3 - 4 540.8034.0000 3 - 5 540.8414.0000 5,1 7,0 540.8414.0000
4 - 6 540.8044.0000 5 - 8 540.8424.0000 7,1 9,5 540.8424.0000
6 - 8 540.8054.0000 8 - 12 540.8434.0000 9,6 14,5 540.8434.0000
8 - 11 540.4004.0000 12 - 17 540.4654.0000 14,6 20,3 540.4654.0000
11 - 15 540.4014.0000 17 - 22 540.4664.0000 20,4 28,2 540.4664.0000
15 - 20 540.4024.0000 22 - 32 540.4674.0000 28,3 39,8 540.4674.0000
20 - 26 540.4034.0000 32 - 38 540.4684.0000 39,9 53,7 540.4684.0000
26 - 33 540.4044.0000 38 - 49 540.4694.0000 53,8 77,6 540.4694.0000
33 - 51 540.4054.0000 49 - 78 540.4704.0000 77,7 114,6 540.4704.0000
51 - 73 540.4064.0000 78 -123 540.4714.0000 114,7 158,1 540.4714.0000
73 -123 540.4074.0000 123 -181 540.9604.0205 158,2 217,5 540.8494.0000
123 -181 540.4084.0000 191 -232 540.4724.0000
181 -232 540.4344.0000
DN 65 do 60 DN 80 do 74 DN 100 do 92
1 - 3 S 3 - 4 S 1 - 2 S
3 - 4 540.8424.0000 4 - 5 540.8534.0000 2 - 3 540.8534.0000
4 - 6 540.8434.0000 5 - 9 540.5704.0000 3 - 6 540.5704.0000
6 - 8 540.4654.0000 9 - 15 540.5714.0000 6 - 9 540.5714.0000
8 - 11 540.4664.0000 15 - 19 540.5724.0000 9 - 12 540.5724.0000
11 - 17 540.4674.0000 19 - 25 540.5734.0000 12 - 18 540.5734.0000
17 - 22 540.4684.0000 25 - 35 540.5744.0000 18 - 25 540.5744.0000
22 - 29 540.4694.0000 35 - 49 540.5754.0000 25 - 35 540.5754.0000
29 - 41 540.4704.0000 49 - 62 540.5764.0000 35 - 46 540.5764.0000
41 - 51 540.4714.0000 62 - 81 540.9724.0000 46 - 65 540.5774.0000
51 - 62 540.8494.0000 81 -109 540.5774.0000 65 - 90 540.5784.0000
62 - 74 540.9604.0000 109 -150 540.5784.0000 90 -119 540.5784.0000
74 -100 540.4724.0000 540.9924.0205
100 -127 540.4734.0000
127 -150 540.4704.0000
540.9604.0000
revised: Schm checked Boy Replaces edition of 21.09.07 ECO_00650A

Cold differential test pressure
CDTP page 1
Content
1 What is CDTP? ......................................................................................................................... 2

2 What is CDTP-correction? ........................................................................................................ 2
3 Which influences on safety valves are covered with the setting at CDTP ? ............................. 2
4 How is the CDTP-correction calculated? .................................................................................. 2
5 How does LESER set the safety valves depending on different service condition with
temperature and back pressure? ...................................................................................................... 5
6 How is the influence of balanced bellows? .............................................................................. 8
6.1 How is the influence of balanced bellows in general for safety valve?............................. 8
6.2 How is the influence of balanced bellows in case of type 459 / 462 safety valves?......... 8
7 How does an open/closed bonnet influences the CDTP?....................................................... 10
8 How does the spring material influences the CDTP?.............................................................. 11
9 How does the medium influences the CDTP? ........................................................................ 11
10 In which documents you will find the CDTP- value? ........................................................... 11
11 EXAMPLE ........................................................................................................................... 12
11.1 Example: Temperature influence ................................................................................... 12
11.2 Example: Temperature and constant backpressure influence ....................................... 13
11.3 Example: Temperature and variable backpressure influence ........................................ 13
12 Original confirmation of German TÜV Nord ........................................................................ 14
continues on page 2
LESER processed: Cal edition: 27.02.08
CDTP page 2
1 What is CDTP?
Cold differential test pressure (CDTP) is defined in standard
- DIN EN ISO 4126-1 Edition 2004, Chapter 3.2.5

- ASME Sec. VIII, Div. 1, Edition 2007, UG 136 (d) 4
- API 520-1 Seventh Edition 2000, Chapter 3.4.1
- ASME PTC 25 - 2001 Chapter 2.7
CDTP is used if correction of set pressure of safety valves according to deviation of service
conditions is necessary.
Extract of ASME Sec. VIII, Div. 1, UG 136 (d) 4:

When a valve is adjusted to correct for service conditions of superimposed back pressure, temperature, or the differential
in popping pressure between steam and air, the actual test pressure (cold differential test pressure) shall be marked on
the valve per 129
Extract of DIN EN ISO 4126-1 Chapter 3.2.5:

The inlet static pressure at which a safety valve is set to commence to open on the test bench
NOTE This test pressure includes corrections for service conditions, e.g. back pressure and/or temperature.
Extract of API 520 Chapter 3.4.1:

The actual service conditions under which a pressure relief valve is required to open, may be different form the
conditions at which the pressure relief valve is set to operate on a test stand. To compensate for this effect, a CDTP is
specified for adjusting the set pressure of the valve on the test stand. The CDTP may include a correction for actual
service conditions of back pressure and/or temperature.
Extract of ASME PTC 25-2001 Chapter 2.7:

the inlet static pressure at which a pressure relief valve is adjusted to open on the test stand. This test pressure includes
corrections for service conditions of superimposed back pressure and/ or temperature.
2 What is CDTP-correction?
The CDTP-correction is the correction of set pressure at test bench condition to achieve the correct
set pressure at service condition.
3 Which influences on safety valves are covered with the setting at CDTP ?
The set pressure on test bench deviating from service condition is influence by:
- temperature
- superimposed back pressure
Basically effects at the setting by:

- set pressure tolerance
- medium
The CDTP covers only influences of superimposed back pressure and/or temperature.
4 How is the CDTP-correction calculated?

The CDTP-correction is provided by the manufacturer. LESER has done measurements on steam
test laboratory at high temperature service conditions. These measurements have been monitored
and ploted as curve which was approved by German TÜV Nord.
In case of superimposed back pressure and temperature the corrected set pressure is calculated
with formula. This formula is valid for conventional or balanced bellows design.
The term ( pset − pa ) considers influences of superimposed backpressure.
The factor kT covers influences of temperature.
continues on page 3
CDTP page 3
Design Superimposed Superimposed Built-up backpressure

backpressure variable backpressure constant
(0 – T) [bar g] y [bar g] [bar g]
Conventional pa = T pa = y Not valid for calculation
Bellows pa = 0 pa = 0 Not valid for calculation
Table 1: backpressure according to different safety valve design
p cdtp = ( p set − p a ) * k T
pset: set pressure at service conditions [psig or barg]
pa: superimposed back pressure, constant or variable [psig or barg]. If variable and
conventional design, the max. superimposed back pressure should be used. If balanced
bellows design is used pa is set to 0 bar or 0 psig.
kT: correction factor for CDTP [-], this is depending on valve design/conventional
design/balanced bellows design/open or closed bonnet
T: temperature in [°C]
Calculation-formulas:
Open or close bonnet with kT=0,97339+0,00039(T-200)-

balanced bellows 0,0000015477(T- equation (1)
200)²+0,0000000029977(T-200)³
Closed bonnet conventional kT=0,97339+0,00039T-

design 0,0000015477T²+0,0000000029977T³ equation (2)
Open bonnet conventional kT=0,97339+0,00039(T-50)-

design 0,0000015477(T- equation (3)
50)²+0,0000000029977(T-50)³
Table 2: Formulas of kT calculation
continues on page 4
CDTP page 4
LESER datasheet of CDTP (Cold differential test pressure)
pcdtp = ( pset − pa ) * kT pcdtp = ( pset * k af − pa ) * kT (Type 459/462 only)
pcdtp: cold differential test pressure [psig or barg]

pset: set pressure at service conditions [psig or barg]
pa: superimposed back pressure, constant (pa is equal paf) [psig or barg]
kT : correction factor for CDTP , temperature influence [-]
kaf: correction factor for type 459 / 462, deviating effective area influence [-]
°C °F Open bonnet Closed bonnet Open bonnet Closed bonnet

conventional conventional balanced bellows balanced bellows
550 1022 Limitation at 427°C 1,049 1,049
Limitation at 350°C
500 932 (only with balanced 1,032 1,032
(only with balanced
450 842 bellows) 1,021 1,021
bellows)
400 752 1,049 1,013 1,013
350 662 1,032 1,049 1,007 1,007
300 572 1,021 1,032
250 482 1,013 1,021
1,000 1,000
200 392 1,007 1,013
150 302 1,000 1,007
100 212
50 122
0 32
-50 -58 No influence of service condition on CDTP,
-100 -148 correction factor: 1,000
-150 -238
-200 -328
-250 -418
Table 3: correction factor kT depending ond safety valve design
LESER diagram kaf for for type 459 / 462
paf/p * 100 [%] d0 = 9 [mm] d0= 17,5 [mm] paf/p * 100 [%] d0 = 9 [mm] d0= 17,5 [mm]
0,0 0,999 0,998 20,0 1,083 0,872

1,0 1,001 0,990 22,0 1,097 0,863
2,0 1,003 0,983 24,0 1,111 0,855
3,0 1,005 0,975 26,0 1,126 0,847
4,0 1,008 0,968 28,0 1,143 0,840
5,0 1,011 0,961 30,0 1,160 0,833
6,0 1,014 0,954 32,0 1,178 0,827
7,0 1,018 0,947 34,0 1,197 0,822
8,0 1,021 0,940 35,0 1,207 0,819
9,0 1,025 0,934
10,0 1,029 0,927
12,0 1,038 0,915
14,0 1,048 0,904
16,0 1,059 0,893
18,0 1,070 0,882
Note: Types 459/462 with do = 13mm is not influenced by correction factor kaf. It is in all case = 1.
continues on page 5
CDTP page 5
5 How does LESER set the safety valves depending on different service condition
with temperature and back pressure?
LESER has made steam tests on LESER test laboratory. These measurements have been
monitored, evaluated and processed into a correction curve. This curve was approved by German
TÜV Nord to be a adequate practible procedure to correct set pressure to cold differential test
pressure concerning deviation of service conditions. The original confirmation of TÜV Nord and a
englisch translation is attached in chapter 9.
Please note, that for gas service the setting is defined as “first audible discharge”. For full opening
of valve pls. add another 10%.
Correction factor kT for conventional design, closed bonnet,

to correct adjusting on cold air for service conditions of high temperature
- cold differential test pressure -
1,120
upward setpressure (+3%) of allowable tolerances

1,100 (±3%) according to EN ISO 4126-1 2003-09
1,080
Approved correction curve by
German TÜV Nord
1,060
Correction factor kT
downward setpressure (-3%) of allowable

1,040 tolarance (±3) according to EN ISO 4126-1
2003-09
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
0,980
Temperature T [°C]
0,960
-508 -308 -108 92 292 492 692 892
Temperature T [°F]
figure 1: correction factor kT for closed bonnet conventional design

Note 1: LESER set safety valves in the range of 0 – 3% set pressure tolerance.
Note 2: The CDTP is not the popping point. It is to LESER definition the set pressure with definition “audible
discharge” for gases/steam and “first steady stream” for liquids. The opening pressure is 10 % higher
than CDTP.
continues on page 6
CDTP page 6
Correction factor kT for conventional design open bonnet to correct adjusting on cold air
for service conditions of high temperature - cold differential test pressure -
1,120
upward setpressure (+3%) of

1,100 allowable tolerances (±3%)
according to EN ISO 4126-1
2003-09
1,080
Approved correction
curve by German TÜV
Nord
1,060
correction factor kT
downward setpressure (-3%) of

allowable tolarance (±3)
1,040 according to EN ISO 4126-1
2003-09
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
Temperatur (°C)
0,980
0,960
-508 -308 -108 92 292 492 692 892
Temperature (°F)
figure 2: correction factor kT for open bonnet conventional design

Note 2: The CDTP is not the popping point. It is to LESER definition the set pressure with definition “audible
discharge” for gases/steam and “first steady stream” for liquids. The opening pressure is 10 % higher
than CDTP.
continues on page 7
CDTP page 7
Correction factor kT, stainless steel bellows design, open or closed bonnet,
to correct adjusting on cold air for service conditions of high temperature
- cold differential test pressure -
1,120
upward setpressure (+3%) of

allowed tolarances (±3%) according
1,100
to EN ISO 4126-1 2003-09
1,080 Approved correction curve

by German TÜV Nord
1,060
Correction factor kT
downward setpressure (-3%) of

allowed tolarances (±3%) according
1,040
to EN ISO 4126-1 2003-09
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
Temperature T [°C]
0,980
0,960
-508 -308 -108 92 292 492 692 892
Temperature T [°F]
figure 3: correction factor kT for open or closed bonnet balanced bellows design
Note 2: The CDTP is not the popping point. It is according to LESER definition the set pressure with definition
“audible discharge” for gases/steam and “first steady stream” for liquids. The pening pressure is 10 %
higher than CDTP.
continues on page 8
CDTP page 8
6 How is the influence of balanced bellows?

6.1 How is the influence of balanced bellows in general for safety valve?
The stainless steel bellows protects the upper area of safety valve against temperature and
compensates backpressure. The medium could not be in contact with the spring. This avoids
changes of mechanical properties of spring material and influences on the setting. This effect is
valid until limits of spring material.
Conventional design: Balanced bellows design:
Figure 3: Figure 4:
6.2 How is the influence of balanced bellows in case of type 459 / 462 safety valves?
For these two types the different discharge diameter do= 9, 13 and 17,5 mm have influence to the
correction of CDTP. This is based on the design of balanced bellows. The same stainless steel
bellows is implemented in all three do´s. The effective area of do = 13mm design is equal to the
balancing area of stainless steel bellows. A correction for differing effective areas (do = 9 mm and
do = 17,5 mm) of seat area and balancing area have to be considered with the additional correction
factor kaf .
Please refer to LWN 037.07 for detailed information.
continues on page 9
CDTP page 9
1,30
kaf
kaf (d0=9 mm) = 1,1575E-4*(paf /p*100%)²+1,899E-3*(paf /p*100%)+0,9987
1,20
1,10
1,00
0,90
kaf (d0=17.5 mm) = 7,78E-5*(paf /p*100%)²-7,8332E-3*(paf /p*100%)+0,998

0,80
0 5 10 15 20 25 30 35
paf/p [%]
diagram 1: correction factor kaf for balanced bellows design for type 459 / 462
CDTP page 10
7 How does an open/closed bonnet influences the CDTP?

The bonnet design could be open or closed design.
Open Design: Closed Design:
Closed Design:
Figure 5: Figure 6:
Open design is recommended for application which are not harmfull for environment. Closed
design is recommended for application with higher safety aspects. This has to be preselected by
customer.
The open bonnet design allows higher temperature of medium because of cooling effect with free
circulation of air. The temperature increase in comparison to closed bonnet design is smaller. The
correction factor is listed in table 1.
CDTP page 11
8 How does the spring material influences the CDTP?

The spring material limits the maximum temperature at spring. These limits are documented by
spring purchaser or in LWN 001.52
Spring material DIN designation ASME Maximum Temperature range,

designation medium temperature
temperature measured at spring
Carbon 1.1200 / Sort SH - 200°C (392°F) -30°C - 100 °C
(-22°F - 212°F)
Creep resistant 1.8159 / 51CrV4 ASTM A322 550°C (1022°F) -60°C - 220 °C
1.7102 / 54SiCr6 Grade 6150 (-76°F - 428°F)
Stainless steel 1.4310 / X10CrNi18-8 ASTM A313 550°C (1022°F) -200°C - 280 °C
Grade 302 (-328°F - 536°F)
Inconel 2.4669 / NiCr15Fe7TiAl ASTM B 637-98 700°C (1292°F) -200°C - 500 °C
(-328°F - 932°F)
Hastelloy C4 2.4610 / NiMo16Cr16Ti ASTM B 574-99 550°C (1022°F) Max. 450°C (842°F)
Tungsten BH12 1.2605 / X35CrWMoV5 EN ISO 4957 550°C (1022°F) Max. 500°C (932°F)
(12/1999)
table 1: material and temperature limits
If these limits are exceeded the spring characteristics are no more valid. The influence on
relaxation is stated in DIN EN 13906-1 or DIN 2089 (old not valid version).
The effect on CDTP-correction is covered with the stated correction factor in chapter 3. The spring
material has no significant effect on the test results.
9 How does the medium influences the CDTP?

The medium has no significant influence on CDTP.
10 In which documents you will find the CDTP- value?

CGA:
CDTP page 12
Nameplate ASME:
LESER-TAG:
11 EXAMPLE
11.1 Example: Temperature influence
Design: Type 441, open bonnet
Service condition: pset = 10barg (145 psig), pa = 0barg, t = 320°C ( 608°F), Steam
pcdtp = ( p set − p a ) * kT
kT: according to equation (3) in chapter 3:
kT = 1,025
pa = 0, because of no backpressure
pcdtp = 10 barg * 1,025 = 10,25 barg (148,66 psig)
Set pressure tolerance: 0–3%
CDTP page 13
pcdtpmin = 10,25 barg +0,00*10,25 barg = 10,25 barg (148,66 psig)
11.2 Example: Temperature and constant backpressure influence

Design: Type 459 do = 9mm, closed bonnet, balanced bellows
Service condition: pset = 50barg (725 psig), pa = 5barg (72,5 psig), t = 400°C ( 752°F), Air
pcdtp = ( pset * k af − pa ) * kT

kT = 1,013
kaf: According to diagram 1 in chapter 5.1:
kaf = 1,029
pa = 0, because of balanced bellows
pcdtp = 50 barg * 1,029 * 1,013= 52,12 barg (755,74 psig)

11.3 Example: Temperature and variable backpressure influence

Design: Type 441, closed bonnet,
Service condition: pset = 10barg (145 psig), pa = 0 – 1,5 barg, t = 320°C ( 608°F), air

kT = 1,038
pa = 1,5 barg, because of conventional design and worst case situation
pcdtp = (10 barg – 1,5barg) * 1,038 = 8,82 barg (127,93 psig)

CDTP page 14
12 Original confirmation of German TÜV Nord
CDTP page 15
CDTP page 16
Translation by LESER:
Dear Mr. Stremme,
We think it is a realistic way to consider the temperature at the Cold Differential Test Pressure of safety
valves according to the enclosed diagram.
The multiplication factor for the Cold Differential Test Pressure at the operating temperature is given by the
enclosed diagram.
This procedure will be applied only if the customer states it explicitly and annotated this on the column
“further manufacturers’ instructions”.
Sincerely yours
Schwenn
TÜV Inspector
End of LWN
Tightness Test
Testing Procedure at LESER Page 1
Contents
1 Scope and Applicability.............................................................................................................. 3
2 Definition.................................................................................................................................... 3
3 Test description for LESER Safety Valves ................................................................................ 3
3.1 Seat tightness test procedure, Test P12 ........................................................................ 3
3.1.1 Definition ................................................................................................................... 3
3.1.2 Requirements of LESER ........................................................................................... 3
3.1.3 Scope ........................................................................................................................ 3
3.1.4 Test media................................................................................................................. 3
3.1.5 Test pressure ............................................................................................................ 3
3.1.6 Test duration ............................................................................................................. 3
3.1.7 Test method for the seat tightness test ..................................................................... 3
3.1.7.1 Testing of seat tightness with air, bubbles emission test procedure ............ 3
3.1.7.1.1 Applicability........................................................................................................ 3
3.1.7.1.2 Test Equipment (Kellog-Test)............................................................................ 3
3.1.7.1.3 Test duration...................................................................................................... 3
3.1.7.1.4 Test pressure..................................................................................................... 3
3.1.7.1.5 Test description ................................................................................................. 3
3.1.7.1.6 Acceptance criteria, Option Code...................................................................... 3
3.1.7.1.7 Certification........................................................................................................ 3
3.1.7.2 Seat tightness test procedure with air, another method ................................. 3
3.1.7.2.1 Applicability........................................................................................................ 3
3.1.7.2.2 Test equipment.................................................................................................. 3
3.1.7.3 Seat tightness test procedure with helium ....................................................... 3
3.1.7.3.1 Applicability........................................................................................................ 3
3.1.7.3.2 Test equipment.................................................................................................. 3
3.1.7.3.3 Test method....................................................................................................... 3
3.1.7.3.4 Test pressure..................................................................................................... 3
3.1.7.3.5 Test duration...................................................................................................... 3
3.1.7.3.9 Certification........................................................................................................ 3
3.1.7.4 Seat tightness test procedure with water ......................................................... 3
3.1.7.4.1 Applicability........................................................................................................ 3
3.1.7.4.4 Certification........................................................................................................ 3
3.1.7.5 Seat tightness test procedure with steam ........................................................ 3
3.1.7.5.1 Applicability........................................................................................................ 3
3.1.7.5.2 Test equipment.................................................................................................. 3
3.1.7.5.3 Test pressure..................................................................................................... 3
3.1.7.5.4 Test duration...................................................................................................... 3
3.1.7.5.7 Certification........................................................................................................ 3
3.2 Shell Tightness test procedure P11................................................................................ 3
3.2.1 Applicability ............................................................................................................... 3
3.2.2 General, Definition..................................................................................................... 3
3.2.3 Test procedure at LESER ......................................................................................... 3
3.2.3.1 Applicability............................................................................................................ 3
3.2.3.2 Test equipment...................................................................................................... 3
3.2.3.3 Test medium.......................................................................................................... 3
Fortsetzung Bl. 2
LESER bearbeitet: La/cw.hei Ausgabe: 24.10.07
GmbH & Co. KG Prüfvermerk: siehe ÄM 100306 Ersatz f. Ausgabe: 25.07.07
Tightness Test
3.2.3.4 Test pressure......................................................................................................... 3
3.2.3.5 Test duration.......................................................................................................... 3
3.2.3.6 Test description ..................................................................................................... 3
3.2.3.7 Certification, Option Code ..................................................................................... 3
3.3 Back seat tightness, test P21 (tightness outwards)...................................................... 3
3.3.1 Scope ........................................................................................................................ 3
3.3.2 Definition ................................................................................................................... 3
3.3.3 Test procedure at LESER’s ....................................................................................... 3
3.3.3.1 Applicability............................................................................................................ 3
3.3.3.2 Test equipment...................................................................................................... 3
3.3.3.3 Test medium.......................................................................................................... 3
3.3.3.4 Test pressure......................................................................................................... 3
3.3.3.5 Test duration.......................................................................................................... 3
3.3.3.6 Test description ..................................................................................................... 3
3.3.3.6.1 Operation with application of the test fluids (DIN EN 1593)............................... 3
This test procedure will be used for safety valves when the dipping is impractical................ 3
3.3.3.6.2 Dipping procedure (DIN EN 1593)..................................................................... 3
3.3.3.6.3 Helium test......................................................................................................... 3
3.3.3.7 Certification, Option Code ..................................................................................... 3
4 Qualifications of the staff ........................................................................................................... 3
5 Certification................................................................................................................................ 3
6 Demands of standards............................................................................................................... 3
7 References to further standards ................................................................................................ 3
8 Appendix 1: Seat tightness requirements acc. to API 527......................................................... 3
9 Appendix 2: Seat tightness LESER Standard tightness requirements ...................................... 3
10 Appendix 3: Seat tightness LESER increased tightness requirements.................................. 3
Fortsetzung Bl. 3
Tightness Test
1 Scope and Applicability

This LWN compiles the requirements of standards and describes the procedure of tightness testing
of safety valves at the LESER sites Hamburg and Hohenwestedt as well as at national and
overseas representatives and approved LESER service repair shops, in case of service on
LESER’s account and also their Certification.
All LESER safety valves have to be tested on tightness except SKD Kits Compact Performance-
Valves (ref. to LWN 704.41).
2 Definition
The tightness test is a production test and is practised at LESER standardly.
3 Test description for LESER Safety Valves

Following test procedures for tightness are to be applied for LESER safety valves:
- Seat tightness test procedure, Test P12
- Shell tightness test procedure, Test P11
- Back seat Tightness test procedure, Test P21
Test medium is water, gas (air or helium) and steam.
3.1 Seat tightness test procedure, Test P12

3.1.1 Definition
Seat tightness means tightness between seat and disc. A safety valve is deemed to be tight
between seat and disc, if all requirements of the relevant standard are performed.
Following measures for determination of seat tightness can be used:
o Leakage Rate in mbar l/s,
o Leakage Volume in cm³/min. and
o Number of bubbles/min.
Testing of seat tightness will be carried out at ambient temperature.
3.1.2 Requirements of LESER

Due to the fact that API 527 is the sole international approved standard which regulates
tightness requirements for safety valves in special, LESER in its function as global
company refers to this standard only. However, LESER considers also tightness
requirements acc. to DIN EN 12266.
Appendix 1: Seat tightness API 527 Requirements

Test conditions and requirements of tightness for seat tightness acc. to API 527 are subject
of this Appendix.
Appendix 2: Seat tightness, LESER standard requirements,

Test conditions and tightness requirements acc. to API 527 and DIN EN 12266 for seat
tightness and general requirements are deviated in this Appendix.
Appendix 3: Seat tightness, LESER improved tightness requirements,

Test conditions and requirements of tightness for increased tightness are summarized in
this Appendix. The allowable leakage rate for metal-sealing safety valves with “increased
tightness” equals half of allowable leakage rate for “general tightness”. It has to be
considered that in case of tightness requirements which exceed the standard higher lapping
effort and higher costs will arise.
Fortsetzung Bl. 4
Tightness Test
3.1.3 Scope
The testing procedure of seat tightness for each safety valve occurs after setting and
checking of cold differential set pressure on test bench in accordance with operation chart,
which is deposited in SAP System.
3.1.4 Test media

The following test media are to be used at LESER: Air, helium, water and steam.
3.1.5 Test pressure

The pressure range is regulated as follows:
- Acc. to ASME Code pressure range starts with 15 psi (1,03 bar)
- Acc. to DGRL 97/23 pressure range starts with 0,5 bar
- Acc. to DIN EN ISO 4126-1 pressure range starts with 0,1 bar.
At LESER the performance of pressure range and test pressure requirements acc. to API
527 is as follows (table 1):
Set pressure / cold differential set Test pressure, ptest

pressure, p0 bar
bar
0,1< p0 < 0,7 0,5* p0
0,7 ≤ p0 ≤ 3,5 p0 - 0,35
p0 > 3,5 0,9* p0

Table 1
3.1.6 Test duration

After a short damping time, the test pressure has to be retained over the entire determined
test period (ref. to App. 2 and 3).
3.1.7 Test method for the seat tightness test

Considering a.m. requirements of LESER, following test procedures are utilized for seat
leakage test:
- Seat tightness test procedure with air, procedure of bubble counting
- Seat tightness test procedure with air, application of test fluid
- Seat tightness test procedure with helium
- Seat tightness test procedure with water
- Seat tightness test procedure with steam
Fortsetzung Bl. 5
Tightness Test
3.1.7.1 Testing of seat tightness with air, bubbles emission test procedure
3.1.7.1.1 Applicability
This procedure of seat leakage test with air, counting number of bubbles, is practised
in case of safety valves with gastight design (lifting device H4, cap H2, closed
bonnet).
3.1.7.1.2 Test Equipment (Kellog-Test)

Testing of seat tightness with air, counting number of bubbles is practised at
assembler working place. Following parts are components of the assembly work
place:
• Clamp station (with adapter discs)
• Pressure system (air)
• Pressure gauge system
• Bubble counting instrument
Following features of bubble counting instrument, shown in fig. 1, correspond to
API 527:
• Inner tube diameter Ø = 6,12 mm
• Water head t =12,7 mm
• Bubble volume = 0,295 cm³
Fig. 1
3.1.7.1.3 Test duration

After a short damping time, the test pressure has to be retained over the entire
determined test period (ref. to App. 2 and 3).
3.1.7.1.4 Test pressure

After setting and checking of cold differential set pressure p0 a blow down up to test
pressure ptest has to be carried out. The test pressure ptest is defined in table 1.
Fortsetzung Bl. 6
Tightness Test
3.1.7.1.5 Test description

Angle typed flanged safety valves are mounted via clamping jaw vertically at the inlet
0flange on the test bench. For the sealing a rubber pad is laid down under the inlet
flange of safety valve. For safety valves with screwed connection, a clamping device
with screwed connection is needed. After valve setting the leakage test is carried out.
The pressure will be reduced by 10% resp. in case of set pressures ≤ 3,5 bar by 0,35
bar. After 10 seconds of slowdown the leakage rate will be determined (test time 10
s). The amount of air leakage escaping from the inlet via the seal between seat and
disc causes a low excess pressure in the closed outlet chamber. This excess
pressure will be decomposed in the water tank in form of escaping bubbles. The
escaping bubbles are counted in determined test time (ref. to appendix 2 and 3). The
volume of bubbles is defined by resp. depends on the water head and inner width of
dipping tube.
The leakage rate shall not exceed the limited leakage rates depending on the flow
area d0 and valve design as mentioned in appendix 2 and 3.
3.1.7.1.6 Acceptance criteria, Option Code

Leakage rates, measured during the determined test period, shall not exceed the
fixed leakage rates defined for the relevant types/designs. The leakages rates are
fixed in Appendix 2 and 3.
The general tightness of LESER safety valves is carried out without option code
controlling (App. 2).
For increased tightness requirements, following option codes are used (App. 3):
Option
Text Remark
Code
Grinding: For increased Cp. LWN 220.01 App. 3

J86
tightness acc. to LWN 220.01 Standard for Type 455-458
Grinding: For increased The Option Code N50 is not used any
N50 tightness acc. to LWN 220.01 longer
(intern)
Table 2
3.1.7.1.7 Certification
The testing of seat tightness with air (bubble emission procedure) is documented in
the SAP system and confirmed by inspection test certificate acc. to DIN EN 10204.
If test report for seat leakage test is required, it has to be accessed with option code
M66.
Fortsetzung Bl. 7
Tightness Test
3.1.7.2 Seat tightness test procedure with air, another method
In case of non-gas tight safety valve design (lifting device H3, open bonnet), the seat
leakage test is carried out with procedure of applying test fluid (acc. to DIN EN 1593).
The application of test fluid is a qualitative test procedure, because the quantitative
procedure of bubble counting (leakage rate) is not possible.
3.1.7.2.2 Test equipment

The seat leakage test by using air, procedure of test fluid application, can be carried
out at the assembly working place. Following parts are components of the assembly
working place:
• Clamp station (with adapter discs)
As test fluid a foamy lotion acc. to DIN EN 14291, leakage finder, is used. The test
fluid shall be non-volatile (it shall not dry at test temperature during test period) and
viscous.

Angle typed flanged safety valves are mounted via clamping jaw vertically at the inlet
flange on the test bench. For the sealing a rubber pad is laid down under the inlet
flange of safety valve (fig. 2).
After setting of safety valve the seat leakage test is carried out. A foamy lotion is
drawn over the outlet orifice. The extension under pressure impact and the
accumulate leakage volume can be observed at the outlet.
Test time amounts 5 seconds. The sealing between seat and disc fulfils the tightness
requirements of this standard, if arises bubble extends not more than 5 mm during
test time.
In case of nominal sizes DNA ≥ DN100 an opening reducing rubber plug is adopted,
because only for nominal sizes up to ≤ DN 80 bubbles can be drawn reliable.
Fig. 2
Austritt
outlet
Eintritt
inlet
Prüftisch
test bench
Fortsetzung Bl. 8
Tightness Test
3.1.7.2.4 Certification, Option Code
The testing of seat tightness with air, applying of test liquid procedure, is documented
in the SAP system and confirmed by an inspection certificate according to DIN EN
10204.
If inspection certificate for seat tightness test is required, it has to be accessed with
option code M22.
3.1.7.3 Seat tightness test procedure with helium

The testing of seat tightness with helium is a special case of testing and is practised
on customer demand only. This test can be carried out for all safety valve types, even
though the helium test is very extensive for open valves.

LESER uses a helium leak detector (Alcatel ASM 120H) for the helium test
procedure, which has a helium gauged leakage of 1,5x10-7 mbar l/s.
The ASM 120H detector is a complete leak detection unit, comprising a Helium gas
analyser with its pumping unit: molecular drag pump, and vane rotary vacuum pump,
the letter also being used as roughing pump.
Accessories: Spraying pistol ( helio probe type) and Helium calibrated leaks
The ASM 120H test range is between 10-9 to 1 mbar l/s.
3.1.7.3.3 Test method

With this helium leak detector different test procedures for seat tightness can be
practised. LESER uses following test methods:
Procedure of overpressure (sniffing method)
Procedure of leakage detector in vacuum.(spraying method)

The test pressure has to correspond to the pressure values at ambient temperature
mentioned in App. 2 and 3.

The test pressure has to hold up at least 5 min.

Overpressure procedure (sniffing method):
After setting the relevant safety valve with air on cold-differential set pressure, it will
be carried to the helium test lab. After safety valve is mounted via clamping jaw at the
inlet flange on the test bench, it will be pressurized with helium. After reaching the test
pressure leakage rate is determined via probe at the outlet.
Procedure of leakage detection in vacuum:
After setting the relevant safety valve with air on cold-differential set pressure, it will
be carried to the helium test lab.
Via adapter the valve is connected airproof with the helium leakage detector at the
inlet.
After evacuation (vacuum occurs in the fitting) an airgun is injection helium between
disc and sealing ín the outlet. The test result is metered after 5 min.
Fortsetzung Bl. 9
Tightness Test

Leakage rates, measured during the determined test period, shall not exceed the
fixed leakage rates defined for the relevant types/designs.
In case of metal-to-metal sealed safety valves leakage rates up to 10-3 mbar l/s are
possible. Dependent on the test procedure leakage rates up to 10-9 mbar l/s can be
reached in case of soft-sealed safety valves.
The standard test value for seat tightness of LESER safety valves with soft seal
amounts < 1x10-5 mbar l/s.
Following option codes shall be used for seat leakage test with helium:
- Option Code N62, for sniffing method
- Option Code M86, for vacuum method
The testing of seat tightness with helium is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204 / test report.
Following information are to be considered:
- Test subject
- Requirements of Standard
- Reference terms / Main technical characteristics
Test medium, Helium
Test equipment: helium leakage detector, Alcatel Type ASM 120H
Helium calibrated leaks, leakage rate 1,5x10-7 mbar l/s
- Test results
- Test method for each test result
- Relevant Units, mbar l/s, for each test result.
If inspection certificate for seat tightness test with helium is required, it has to be
accessed with following option code:
- M 77 for seat tightness, overpressure procedure (sniffing method)
- M 81 for seat tightness, procedure of leakage detection in vacuum
3.1.7.4 Seat tightness test procedure with water
This test procedure is only carried out on customer demand and relevant rules and
regulations. Terms of test conditions and tightness requirements are listed in
Appendix 2 resp. 3.

Testing with water is permitted only, if the functional behaviour of the safety valve is
not influenced unfavourably. A quantitative estimation of the leakage volume acc. to
table 3 is technical not practicable.
DN 10 15 20 25 32 40 50 65 80 100 150 200 250 300 400
3
cm /min 0,166 0,166 0,166 4 5 6 8 11 13 17 25 33 42 50 66
Table 3: Leakage volume depending on nominal size acc. to API 527 (App. 1)
Fortsetzung Bl. 10
Tightness Test
If quantitative information (leakage rate) regarding seat tightness is required for

safety valves which are setted with water, the seat leakage test is carried out with air
(Kellog-Test) after setting and checking of cold-differential set pressure. The seat
leakage test with water can correspond only to a qualitative information.

The valve obtains to be tight, if the qualitative estimation criteria acc. to App. 2 resp. 3
are fulfilled: no noticeable or visible leakage, no pressure drop at the pressure gauge
is recognized.
The testing of seat tightness with water is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204.
3.1.7.5 Seat tightness test procedure with steam
Testing of seat tightness with steam is practised for safety valves which are setted on
cold-differential set pressure with steam.

The test is carried out at the steam test lab in Hohenwestedt site.

The test pressure has to be in accordance with test values determined in Appendices
2 and 3.

The test pressure has to be retained acc. to the determined test period in Appendices
2 and 3.

After setting the relevant valve on cold-differential test pressure and testing, the seat
leakage test is carried out with steam. The pressure is to be dropped to test pressure
and after a short damping time the qualitative statement can be determined.

The valve obtains to be tight, if the qualitative estimation criteria acc. to App. 2 resp. 3
are fulfilled: no noticeable or visible leakage, no pressure drop at the pressure gauge
is recognized.
The seat leakage test with steam is documented in the SAP system and confirmed by
inspection test certificate acc. to DIN EN 10204.
Fortsetzung Bl. 11
Tightness Test
3.2 Shell Tightness test procedure P11

3.2.1 Applicability
The shell tightness test procedure, at LESER called body tightness, is carried out for all
LESER safety valves generally.
3.2.2 General, Definition

The shell tightness test procedure is a collateral production pressure test to prove the
tightness of pressure retaining body incl. sealing of operational subject against internal
pressure.
Designation acc. to DIN EN 12266-1, Edition 2003:

Shell Tightness, test procedure P11-EN 12266-1
DIN EN 12266-1, Edition June 2003 replaces DIN 3230-1: 1974-04, DIN 3230-2:1974-04,
and DIN EN 12266-2:2003-05 replaces DIN 3230-3.
The former designation is: BF, BQ, BW acc. to DIN 3230-3.
3.2.3 Test procedure at LESER

For shell tightness test procedure the test fluid is coated onto body surface at the inlet area.
3.2.3.1 Applicability
Acc. to work schedule the shell tightness test procedure is deposited in SAP system for
every safety valve in gastight design. LESER has integrated this test procedure into
production process standardly.
3.2.3.2 Test equipment

The shell tightness test procedure is carried out on assembly test benches. The assembly
and test work place contains following parts:
• Clamp station
• Pressure system
• Dipping basin
As test fluid a foamy lotion acc. to DIN EN 14291, leakage finder, is used. The test
fluid shall be non-volatile (it shall not dry at test temperature during test period) and
viscous.
3.2.3.3 Test medium

At LESER this test is carried out standardly with air at ambient temperature.
3.2.3.4 Test pressure

The shell tightness test procedure is carried out with test pressure which corresponds to
set pressure / cold-differential set pressure.
3.2.3.5 Test duration

The test pressure has to be retained acc. to the determined test period in table 4 (acc. to
DIN EN 12266-1).
Fortsetzung Bl. 12
Tightness Test
Table 4: Minimum test time for testing of pressure retaining body

Nominal size Minimum test time
s
Up to DN 50 15
From DN 65 up to DN 200 60
DN 250 and larger 180
3.2.3.6 Test description
Application with test fluid:

In standard cases the shell tightness is carried out at mounted safety valves using test
fluid application procedure.
The safety valve is clamped on the test bench sidewards the inlet and then pressurized.
After setting and testing of required set pressure / cold-differential set pressure the body is
spraid with leakage detector solution at the inlet socket. The tested inlet area is found
correct, when no foam appears.
Remark!
During test period the test pressure shall be kept constant.
Afterwards the valve has to be blown dry with compressed air.
3.2.3.7 Certification, Option Code

The shell tightness test procedure with air is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204. As standard testing the
leakage test of pressure retaining body effects without access of option code.
If inspection certificate for shell tightness test with air is required, it has to be accessed
with option code M18.
Fortsetzung Bl. 13
Tightness Test
3.3 Back seat tightness, test P21 (tightness outwards)

3.3.1 Scope
The tightness test of the back sealing, LESER named it tightness outwards, is carried out at
all LESER’s safety valves in gastight design.
3.3.2 Definition
The test is a pre-expediting pressure test for certification that the determined leakage rate
of the back sealing is kept to the moment of the manufacture.
The tightness outwards has reference to the test of the tightness at the connections
body/bonnet, bonnet/lifting device H4 (cap H2) as well as the outlet of the body.
Marking in accordance with DIN EN 12266-2, edition 2003
Tightness of back seal, test P21-EN 12266.2
3.3.3 Test procedure at LESER’s

3.3.3.1 Applicability
The tightness of the back seal, test P21, is in accordance with the task schedule which is
deposited in the data base of the SAP-system for every safety valve in gastight design. At
LESER’s, this test is standard which is integrated in the production process.
3.3.3.2 Test equipment

At LESER’s the test of the tightness of the back seal takes place at the test benches.
A test bench work station consists of following parts:
o A fixing mechanism of the valve to be testing
o A pressure control system / source of fluid under pressure
o Pressure measurement system upstream the valve to be tested
o Bubble test instrument
o Water basin
As test fluid a foamy lotion acc. to DIN EN 14291, leakage finder, is used. The test fluid
shall be non-volatile (it shall not dry at test temperature during test period) and viscous.
3.3.3.3 Test medium

At LESERS’s, this test is carried out standardly with air in room temperature. The back seat
tightness can be realized with helium test procedure if the customer requests.
3.3.3.4 Test pressure

The test pressure for tightness of back seal, test P21, tightness outwards, shall be a
minimum of 1,1 times the allowable pressure or (6±1) bar whereby the lower value counts
(in accordance with DIN EN 12266-2).
Standardly LESER carries out this test with a test pressure of 6 bar with the exception of:
- Safety valves beginning with a nominal size DN 200 will be tested with a test pressure
of 2,5 bar/air 36 psig .
- For safety valves with PTFE - or elastomer components the pressure must be limited as
follows:
• for initial pressures / set pressures p0 < 3 bar to 0,15 x p0 bar1 and
• for initial pressures / set pressures p0 ≥ 3 bar to 2 bar (28 PSIG) to avoid damages
1
“Built-up back pressure For the LESER safety valve, 15 % of the set pressure minus superimposed back pressure
(if applicable) is generally permissible. “ Complete catalogue 21/30
Fortsetzung Bl. 14
Tightness Test
- Test pressures outside of the scope of the standard must be coordinated between the
customer and LESER (VK/TB).
3.3.3.5 Test duration
The test pressure must be maintained at least for the test period determined in table 5 (in
accordance with DIN E 12266-2).
Table 5: Minimum test period for testing of the tightness of the back seal
Nominal size Minimum test period
s
> DN 50 15
from DN 65 to DN 200 15
DN 250 to DN 450 30
3.3.3.6 Test description
3.3.3.6.1 Operation with application of the test fluids (DIN EN 1593)

This test procedure will be used for safety valves when the dipping is impractical.
The testing of the tightness of back seal, tightness outwards, will be controlled in
standard cases. After testing of the seat leakage and the test pressure the safety
valve will be tightened (outlet) on the test bench and admitted with pressure.
Reaching the test pressure, the safety valves will be sprayed at the connections and
the outlet area with a diluation which seeks leaks. If there is no frothing formation
recognizable the tested areas are all right.
3.3.3.6.2 Dipping procedure (DIN EN 1593)
This test procedure is applicable for compact performance safety valves.

The safety valve will be sealed (inlet) with an unscrewed sealing cap. After that the safety
valve will be clamped (outlet) in the test bench and dipped into the diving basin (water)
The specified test pressure 6 bar/air will start. If there are no bubbles on the outside surface
of the safety valve the tested safety valve is all right.
The test pressure will be blowed off and the safety valve will be detached from the test
control unit.
Remark! During the test period the test pressure has to be kept constantly.
The safety vale should be blistered dry with compressed air.
3.3.3.6.3 Helium test

This testing method, tightness of the back seal with helium, will be realized if customer
requires. Apart from testing with air the test can also be realized with Helium. The
determined leakage rate will be >10-5 mbar l / s.in standard cases
With the leak detector used by LESER (Alcatel – ASM 120H), the tightness test with the
vacuum-method is realized.
The safety valve will be sealed (at the inlet) with a sealing cap. Afterwards the safety valve
will be clamped (at the outlet) on the leak detector. When the evacuation process is finished
(in the safety valve is now a vacuum) helium will be sprayed with an air gun on every
connection for 3 – 4 sec. The test result will be read if the LED display is stabled.
Fortsetzung Bl. 15
Tightness Test
3.3.3.7 Certification, Option Code

The back seat tightness test tightness outwards, will be mentioned in the SAP system and
confirmed with the inspection certificate in accordance with DIN EN 10204
As a standard test with air, the tightness test of the back sealing, tightness outwards, will
follow without option code.
The tightness test of the back sealing, tightness outwards, with Helium will be regulated
with option code N64.
If inspection certificate for back seat test tightness outwards is required, it has to be
accessed with following Option Codes:
- M 28 Back seat tightness test outwards, application of test fluids
- M 78 Back seat tightness test outwards, dipping procedure
- M 82 Back seat tightness test outwards with helium, overpressure method (sniffing
method)
4 Qualifications of the staff

The test staffs are in the situation, because of their professional knowledge as well as physical
qualifications to carry out the a. m. test procedures correctly.
5 Certification
Test results are reported standardly in the SAP system and are proved by an inspection certificate
according to 3.1 of DIN EN 10204.
Following information has to be included in APZ 3.1:
- Test subject
- Requirements of Standard
- Used procedures
- Reference terms / technical characteristics
Test medium, test liquid, test device
- Test results
- Test method for each test result
- Relevant units, mbar l/s, for each test result.
6 Demands of standards
Following standards are considered for the tightness tests at LESER’s:
DIN EN ISO 4126-1, Safety devices for protection against excessive pressure Part 1: Safety
valves, chapter. 6 Production testing, 6.6 Seat leakage test:
„The seat leakage test of a safety valve shall be carried out. The test procedure and leakage rate
shall be agreed between the manufacturer and the purchaser”
ASME Code Section VIII Rules for Construction of Pressure Vessels, Edition 2006
Part UG-136(d) Production Testing by Manufacturers and Assemblers
UG- 136 (d) (3) The secondary pressure zone of each closed bonnet pressure relief valve
exceeding NPS 1 (DN 25) inlet size when such pressure relief valves are designed for discharge to
a closed system shall be tested with air or other gas at a pressure of at least 30 psi (200kPa).
There shall not be visible sign of leakage.”
UG- 136(d) (5) After completion of the tests required by (d) (4) above, a seat tightness test shall be
conducted. Unless otherwise designated by a Manufacturer’s published pressure relief valve
specification or another specification agreed to by the user, the seat tightness test and acceptance
criteria shall be in accordance with API 527.”
Fortsetzung Bl. 16
Tightness Test
DIN EN 12266-1 Industrial valves: Testing of valves, part 1: Pressure tests, test procedures
and acceptance criteria- Mandatory requirements, edition 2003, chapter.4 Test requirements:
4.2 „Every valve shall be subjected to the shell tightness test, reference P11, listed in Table 1.“
DIN EN 12266-2 Industrial valves – Testing of valves, part 2: Tests, test procedures and
acceptance criteria, edition 2003, A.3 Back seat tightness, test P21
7 References to further standards

DIN EN ISO 4126-1 Safety devices for protection against excessive pressure
Part 1: Safety valves,
DIN EN ISO 12266-1 Industrial valves: Testing of valves, part 1: Pressure tests, test
procedures and acceptance criteria
DIN EN ISO 12266-2 Industrial valves – Testing of valves, part 2: Tests, test procedures
and acceptance criteria, supplementary requirements
DIN EN 1593 Tightness test, bubble test, Edition 1999
DIN EN 14291 Foam producing solutions for leak detection on gas installations
DIN EN 10204 Metallic products- Types of inspection documents
ASME Code Section VIII Rules for Construction of Pressure Vessels, Edition 2006
API 527 American Petroleum Institute

Seat Tightness of Pressure Relief Valves
Fortsetzung Bl. 17
LESER-WORKS STANDARD LWN 220-01-EN
Tightness test
Testing at LESER Page 17
8 Appendix 1: Seat tightness requirements acc. to API 527

Test conditions Tightness requirements
Test Time d0 ≤ 15,88mm1) d0 > 15,88mm1)
After testing of set pressure Leakage rate Leakage rate
po / BZ = damping time
Test medium
Set pressure Blow down up o PZ = Test Time (related to 16°C; bubble volume (related to 16°C; bubble volume
3 3,
po VB= 0,295 cm , tube ∅ = 6,12mm) VB= 0,295 cm tube ∅ = 6,12mm)
(relating to 16°C) Test pressure Min
DN DN DN
≤50 65...100 >100 Number of Leakage Leakage Number of Leakage Leakage
≤2“ 21/2...4“ >4“ bubbles volume rate bubbles volume rate
3 3
bar MPa bubble/ min cm / min Mbar l/s Bubble/ min cm / min Mbar l/s
BZ PZ BZ PZ BZ PZ
-1 -2
1,03-68,9 0,103-6,896 40 11,80 1,9x10 20 5,90 9,4x10
103 10,3 po ≤ 3,45 bar 60 17,70 2,8x10
-1
30 8,85 1,4x10
-1
Metal-to-metal
130 13,0 (0,345 MPa) 80 23,60 3,8x10

-1
40 11,80 1,8x10
-1
sealing
-1 -1
Air (Gases)
172 17,2 100 29,50 4,7x10 50 14,75 2,3x10

-1
207 20,7 1 1 2 1 5 1 60 17,70 2,8x10
-1
276 27,6 pPrüf = p0 - 0,345 bar 80 23,60 3,8x10
-1
385 38,5 100 29,50 4,7x10
API 527
test (0,0345 MPa) -1 -1

414 41,4 100 29,50 4,7x10 100 29,50 4,7x10
-3
<4,7x10
sealing
Soft
-3
- - 1 1 2 1 5 1 0 0 <4,7x10 0 0
Metal-to-metal
Soft sealing
Steam
sealing
BZ= damping time = 3 min No recognized or visible leakage

- -
PZ= test time = 1 min
p0 >3,45 bar
(0,345 MPa)
NW≥1“ (DN25)
Metal-to-metal
3
Leakage volume ≤10cm /h x Inlet nominal size /
sealing
BZ- damping time = 1 min 3

- - (Leakage volume ≤0,166cm /min x Inlet nominal size)
NW<1“ (DN25)
Water
LWN 220-01
pPrüf.= 0,9*po 3
leakage volume ≤10cm /h*
test
BZ- damping time = 1 min

sealing
- - No leakage
Soft
Fortsetzung Bl. 18
LESER bearbeitet: Ku Ausgabe: 05.01.10
GmbH & Co. KG Prüfvermerk: siehe ECO00191B Ersatz f. Ausgabe: 24.10.07
Tightness test
9 Appendix 2: Seat tightness LESER Standard tightness requirements
Test conditions Tightness requirements

d 0 ≤ 16 mm ( DN10, G1/2“; DN15, G3/4“) d 0 > 16 mm ( DN20, G1“ and bigger)
Set pressure Test pressure Test time
po ptest Leakage rate Leakage rate
Test medium
3 3
(related to 20°C) BZ-damping time (related to 20°C; bubble volume VB= 0,295 cm (related to 20°C; bubble volume VB= 0,295 cm
After testing of set
PZ-Test time tube ∅ = 6,12mm) tube ∅ = 6,12mm)
pressure po
Blow down up to...
Test pressure
Pressure stages acc. to Number of Leakage volume Leakage Number of Leakage volume Leakage
Blow-down of...
LWN 220.03 bubbles rate bubbles rate
Test pressure 3 3
bar MPa s / min bubble/min cm /min mm³/sec mbarl/s bubble/min cm /min mm³/sec mbarl/s
Metal-to-metal
-1 -2
0,1- 66 0,01- 6,6 0,1< po < 0,7 (bar) 40 11,80 196,66 1,9x10 20 5,90 98,33 9,4x10
BZ = 10s
sealing
0,01 < po < 0,07 (MPa)

LESER-Standard
-1 -1
>66-165 >6,6-16,5 PZ = 10s 60 17,70 295,00 2,8x10 30 8,85 147,50 1,4x10
-1 -1
>165- 700 >16,5- 70,0 80 23,60 393,33 3,8x10 40 11,80 196,66 1,8x10
Pprüf = 0,5*p0
Air (Gases)
Soft sealing
test BZ= 10s

plate
-2 -2
- - PZ = 10s 20 5,90 98,33 9,4x10 10 2,95 49,16 4,7x10
0,7 ≤ po ≤ 3,5 (bar)

0,07 ≤ po ≤ 0,35 (MPa)
Soft sealing With vulcanized
O-Ring or disc
Metal-to- Metal-to-metal Soft sealing
soft sealing
BZ =10s
-5 -5
- - PZ = 10s 0 0 0 ≤9x10 0 0 0 ≤9x10
pPrü f= p0 - 0,35bar
test (0,035 Mpa)
Steam
BZ = 3 min
sealing
LWN 220-01
No recognized or visible leakage
- - p0 > 3,5 bar PZ = 1 min
No indication of pressure drop at the pressure gauge
po >0,35 (MPa)
Soft sealing
Water
BZ =10s
sealing
metal
- -
pPrüf. = 0,9*po PZ = 10s
No recognized or visible leakage
test
Fortsetzung Bl. 19
Tightness test
10 Appendix 3: Seat tightness LESER increased tightness requirements

Test conditions Test requirements
d0 ≤ 16 mm ( DN10, G1/2“; DN15, G3/4“) d0 > 16mm ( DN20, G1“ and bigger)
Set pressure Test pressure Test time Leakage rate Leakage rate
po pprüf
Test medium
3 3
(related to 20°C; Bubble volume VB= 0,295 cm (related to 20°C; Bubble volume VB= 0,295 cm
(related to 20°C) After testing of set BZ=damping time
Pz = test time tube ∅ = 6,12mm) tube ∅ = 6,12mm)
pressure po
Blow down up to ...
Test pressure
Pressure stage acc. to Blow-down of... Number of Leakage Number of Leakage
Leakage volume Lekage volume
LWN 220.03 Test pressure bubbles rate bubbles rate
3
bar MPa cm /min mm³/sec cm³/min mm³/sec
bubble/min mbarl/s bubble/min (mbarl/s)
Soft sealing Metal-to-metal
-2 -2
LESER - increased tightness
0,1-66 0,01-6,6 20 5,90 98,33 9,4x10 10 2,95 49,16 4,7x10

0,1< po < 0,7 (bar) BZ- =10s
sealing
0,01 < po < 0,07 (MPa) -1 -2

Air (Gases)
>66-165 >6,6-16,5 PZ = 10s 30 8,85 147,5 1,4x10 15 4,42 73,66 7,0x10

-1 -2
>165-700 >16,5-70,0 40 11,80 196,66 1,8x10 20 5,90 98,33 9,4x10
Pprüf = 0,5*p0
- - test - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
0,7 ≤ po ≤3,5 (bar)

Metal-to-
BZ =3 min
sealing
metal
0,07 ≤ po ≤ 0,35 (MPa) No recognized or visible leakage

- - PZ- = 1 min
No indication of pressure drop at the pressure gauge
Steam
-
Metal-to- Soft sealing
pPrü f= p0 - 0,35bar
- test (0,035 Mpa) - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
metal sealing
p0 > 3,5 bar BZ =10s

po >0,35 (MPa) No recognized or visible leakage
LWN 220-01
- - PZ = 10s
Water
Soft sealing
pPrüf. = 0,9*po
- - test - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
Ende der LWN

Procedures for the testing of cold differential
test pressure page 1
Table of contents
Summary ........................................................................................................................................................... 2
1 General and definitions......................................................................................................................... 2
2 Purpose and area of application........................................................................................................... 2
3 Derivation of standard specifications on LESER safety valves............................................................ 3
4 Testing depth at LESER, practical application of the set pressure tolerances .................................... 3
5 Assembly and test equipment .............................................................................................................. 3
6 Pressure measuring devices ................................................................................................................ 4
7 Test media ............................................................................................................................................ 4
8 Test procedure at LESER..................................................................................................................... 5
8.1 Setting and testing of the cold differential test pressure with air .............................................. 5
8.1.1 Testing depth, option code ............................................................................................................................ 5
8.1.2 Test bench ..................................................................................................................................................... 5
8.1.3 Testing procedure ......................................................................................................................................... 6
8.1.4 Acceptance criteria ..................................................................................................................................... 10
8.2 Setting and testing of the cold differential test pressure with water ....................................... 10
8.2.1 Testing depth, option code .......................................................................................................................... 10
8.2.2 Test bed....................................................................................................................................................... 10
8.2.3 Testing procedure ....................................................................................................................................... 10
8.3 Setting and testing of the cold differential test pressure with steam ...................................... 10
8.3.1 Standards applied ....................................................................................................................................... 10
8.3.2 Testing depth, option code .......................................................................................................................... 10
8.3.3 Test media................................................................................................................................................... 10
8.3.4 Test bed....................................................................................................................................................... 11
8.3.5 Testing procedure ....................................................................................................................................... 11
8.3.7 Testing on capacity test bench of National Board (USA) ........................................................................... 12
9 Qualifications of the test personnel .................................................................................................... 12
10 Documentation and option code......................................................................................................... 12
11 Standards applied............................................................................................................................... 12
12 Normative instructions ........................................................................................................................ 14
13 Terms and abbreviations .................................................................................................................... 14
continues on page 2
LESER processed: Sa.cw. edition: 02.09.08
Summary
This LWN lists the standard requirements and will describe the procedure during the setting and
testing of the cold differential test pressure of safety valves at LESER and its documentation.
The Procedure is valid for all safety valves to be set with steam, water or air at the LESER
production sites Hamburg, Hohenwestedt and at the authorised LESER service partners, In case
they act on behalf of LESER.
The testing of the cold differential test pressure shall not be applied for safety valves carrying out:
− LA Supply, Loosly Assembled

− SKD Kits. Semi Knocked Down (Compact Performance)
The issuing of an inspection certificate about the testing carried out can be order with the following
option codes.
Option code Acceptance test certificate Comments
LESER CGA (Certificate for Global Application) – Inspection
H03
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
N05
cold differential test pressure with air
1 General and definitions

This LWN will put together the standard requirements and will describe the procedure during the
setting and testing of the cold set pressure of safety valves at LESER and its documentation.
The cold set pressure (DIN EN ISO 4126-1, chapter 3.2.5) is the static pressure on the inlet side,
at which a safety valve will start opening on the test bed. This pressure includes corrections for
operational conditions, e.g. counter pressure and/or temperature.
The cold set pressure will be used, if a correction of set pressure is necessary due to deviations to
the operating conditions.
The evaluation of cold differential test pressure (CDTP) under consideration of influencing factors
can be taken from LWN 001-69.
The definition of the cold set pressure of LESER safety valves is:
The pressure, the safety valve is adjusted at LESER on the test bed and the first audible noise in
case of steams/air/gases and/or the first continuous flow of liquid.
The set pressure (EN ISO 4126-1 chapter 3.2.1) is the preset pressure, a safety valve starts
opening under operational conditions (DIN EN ISO 4126-1). It is the excess pressure on the valve
inlet side, where the forces that open the valve under the specific operational conditions, will be
equal to the forces that keep the valve disc in position.
2 Purpose and area of application

The procedure is applicable for all safety valves that are set with steam, water or air at the LESER
production sites in Hamburg, Hohenwestedt and at the authorised LESER service partners, should
they act on behalf of LESER.
continues on page 3
3 Derivation of standard specifications on LESER safety valves

The following LESER specifications are derived from the in point 11 described standard
requirements:
In general tolerances of ± 3% from the specified set pressure are admissible, however in the
case LESER safety valves plus tolerances are admissible. The reason for this is that the plant
operator can then fully utilize the maximum operational parameters like pressure and
temperature.
From 300 psi (20,7 bar) the specifications in accordance with ASME Section I, Rules for
Construction of Power Valves, PG 72.2 General Requirements for all Methods of Construction,
Safety Valves and Safety Relief Valves will be ignored as at present none of such products are
being manufactured. Should this situation change, this will be regulated in this LWN.
Summary: The specifications regarding the set pressure tolerance for all named standards
have been listed in table 1.
Set pressure (range) Tolerance
≤ 1,65 bar ( 23,9 psi) plus 0,05 bar ( 0,725 psi)
1,65 bar ( 23,9 psi) ... 3,96 bar ( 58 psi) plus 0,1 bar ( 1,45 psi)
>3,96 bar (57,4 psi) plus 3 %
Table 1: Summary set pressure tolerances at LESER
4 Testing depth at LESER, practical application of the set pressure tolerances

At LESER all safety valves apart from LA supply (Loosly Assembled) safety valves and SKD kits
for Compact Performance valves as a matter of standard are prepared and test on cold set
pressure in accordance with work schedule recorded in the SAP System.
When adjusting the safety valves three important influencing factors have to be principally
considered:
• Preciseness of the measuring equipment
• Reading exactness of the technician and/or tester (analogue display)
• Repetitive setting exactness of the valves
All three factors have to be covered by the set pressure tolerance, whereby only during the setting
a person can take direct influence.
5 Assembly and test equipment

In general the safety valves at LESER will be assembled, set and checked at the assembly test
bed.
An assembly test bed consists of the following parts:
• Loading station
• Pressure system (air, water or steam)
• Pressure measuring devices system
The setting and testing of the cold set pressures of safety valves with steam is carried out at the
steam test bed and with water at the water test bed in the HOW.
continues on page 4
LESER processed: Sa edition: 04.06.08
6 Pressure measuring devices

LESER safety valves were set and tested using pressure measuring devices with bourdon tubes
that complied with the standard requirements in accordance with ASME Code Section VIII and EN
DIN 837-1.
To realise the ASME-Codes Section VIII, UG 102 (b) each test bed has to be equipped with (for
set pressures up to 396 bar) with 7 pressure measuring devices to cover the entire pressure range.
If higher pressures (> 396 bar) are set at LESER via a pressure transformer, optionally the
pressure measuring device 1000 bar should be used.
The number of manometers is determined by the operational error limit with regard to the full-scale
value. This resulted in the following LESER preferential series for pressure measuring devices of
the precision class 0,6 (Table 2):
Table 2: LESER preferential series for pressure measuring devices (in accordance with ASME-
Code and DIN EN 837-1)
Cold differential test Manometer scale (pressure stages)

pressure [bar]
[bar]
0,5 - 1,65 2,5
1,50 – 3,96 6
4,00 – 10,56 16
10,00 – 26,66 40
25,00 – 66,00 100
62,50 – 165,00 250
150,00 - 396,00 600
250 - 660 1000
Comment:
The LESER preferential series in accordance with ASME starts with manometer 0 - 2,5 bar.
The controlled areas in accordance with ASME-Code start from > 15 psi (1,03 bar). The
controlled areas in accordance with the European pressure appliances guideline (from >
0,5 bar) and the pressure vessel regulation (from > 0,1 bar) have been included.
All mechanical class 0.6 pressure measuring devices with operational error limit ± 0,6% of
the LESER preferential series have to be regularly gauged and/or adjusted in accordance
with LWN 615.07 at a minimum of every 12 months.
The use of pressure measuring devices at the assembly sites is regulated in LWN 220.03.
7 Test media
Safety valve set pressure is normally set with air on a test bed and the valve is then operated with
different media types, steam, gases or liquids.
As a standard air is used for setting and testing of the cold-set pressures of safety valves.
Still, if it is required to adjust the safety valve with the medium water or steam on the test bed, this
has to be specified in the order.
continues on page 5
8 Test procedure at LESER

The following procedures are possible at LESER:
• Cold differential test pressure with air (Standard, without option code)
• Cold differential test pressure with steam (option code M07)
• Cold differential test pressure with water (option code M09)
8.1 Setting and testing of the cold differential test pressure with air
8.1.1 Testing depth, option code
As a standard safety valves for air or other gases have to be set and tested with air at room
temperature. This is carried out in accordance with work schedule recorded in the SAP
System for each safety valve. The control is carried out without option code.
8.1.2 Test bench

The assembly, setting and testing of the cold differential test pressure with air is carried out
at the assembly test bench. An assembly and testing bed consists of the following parts:
• Loading station
• Pressure measuring devices system
continues on page 6
Fig. 1: Example for assembly test bench

Pressure measuring
device system
Loading station Pressure system
8.1.3 Testing procedure
After assembly the safety valve will be pressurized and adjusted via adjusting screw to the given
set pressure acc. to SAP demand (flag Q-feature). Safety valves with lever will be setted up per
positioning the weight.
The set pressure is reached when the discharge of air is audible. A saturated opening with clear
clicking noise or crack shall be reached. Stealthy setting is not allowed.
The procedure of setting and testing of cold differential test pressure with air is described exactly
for each valve type in the working instructions (assembly / installation documentation).
continues on page 7
The following work stages have to be adhered to (Example for a threaded valve):
Work stage 1
• Call up SAP tab Q characteristics and

read the pressure setting area.
• The set pressure should also bet he

mean tolerance value (here 2,55 bar-
ü).
Tools
Software system
Testing equipment
Assembly test bench
continues on page 8
Work stage 2
• Set the scale of the pressure display

(selection window)
• During the setting of the valves it

might be helpful to display both
displays on the screen
Tools
• Software: Visual manometer
• SAP Transaction ZAKL / tab Q-

characteristics
Equipment
• Assembly test bench
continues on page 9
Work stage 3
• Secure the spindle with splint

mandrel against twisting when
setting the forcing screw.
• Impinge valve with pressure and set

in accordance with specifications
(SAP tab Q-characteristics) using
the forcing screw to the level of the
response pressures.
• Control whether the valve opens

during cold differential test pressure.
The set pressure of the valves has

been reached, when you can hear
the air escaping air. You have to
achieve a full cracking noise and/or
bang.
A creeping response is not
admissible.
• Should the valve open outside the

preset pressure tolerance, the
forcing screw has to be re-adjusted.
a) Turning clockwise – valve opens at higher

pressure
b) counter clockwise – valve opens at lower pressure
• By re-setting the forcing screw,

initially pressure will be released, the
forcing screw is being re-set and the
valve will again be impinged with
pressure.
Tools
• Splint mandrel, open-end wrench
• Software Visual Manometer
• SAP Transaction ZAKL / tab Q-
characteristics
Equipment
• Assembly test bench
8.1.4 Acceptance criteria
The safety valve has to open within the preset pressure tolerance.
Escaping air has to be audible. Full opening has to be achieved with a clear bang. A
creeping response is not admissible.
8.2 Setting and testing of the cold differential test pressure with water
The safety valves to set and tested using water are controlled in accordance with SAP
System recorded work schedule, using option code M09.
8.2.2 Test bed

The pressure setting on water and testing of the cold-set pressures is carried out on the
water test bed HOW. The water test bed consists of the following parts:
• Loading station
• Water pressure system
• pressure measuring devices system

The valves to be set with water are initially preset for air.
The assembly and pressure preset on air is carried out in the same way as with the safety
valves, preset for air, on the assembly test bed (see chapter 5.4.1).
After the test valve has responded, set and check the set pressure in accordance with
specifications. The set pressure of the valves has been reached, if you can see the initial
continuous flow (water).

The safety valve has to open within the preset set pressure tolerance.
The set pressure of the valves has been reached, if the initial continuous flow (water) can
be seen.
8.3 Setting and testing of the cold differential test pressure with steam
8.3.1 Standards applied
This testing is valid for safety valves with UV-Stamp (LWN 001.26, LWN 619.12) and for
safety valves that are set by steam. The ASME Code Sec. VIII Div.1 specifies under UG
136(d)(4) that safety valves for steam applications have to be set using steam, whereby
safety valves that due nominal width and response pressure are beyond the possibilities of
the steam test bed, can be tested using air.

The setting and testing of the cold-set pressures with steam is carried out in accordance
with the SAP System recorded work schedule.
If a safety valve has to be set using air and will afterwards be operated using steam, the
cold differential test pressure has to be calculated by considering the correction factor for
an increased operational temperature.
If the setting of the safety valves on the test bed is required to be to medium steam, this has
to be controlled in the order with option code M07.
8.3.3 Test media

The setting of the cold differential test pressures of safety valves with steam is carried out
using the in Table 3 determined test temperature:
Table 3: Test temperature for steam setting

Set pressure Test Set pressure Test Set pressure Test
temperature temperature. temperature
bar °C bar °C bar °C
6,01 – 7 >165 13,01 – 14 >193
<1 >105 7,01 – 8 >170 14,01 – 15 >195
1,01 – 2 >115 8,01 – 9 >175 15,01 – 16 >197
2,01 – 3 >138 9,01 – 10 >180 16,01 – 17 >199
3,01 – 4 >146 10,01 – 11 >185 17,01 – 18 >202
4,01 – 5 >154 11,01 – 12 >187 18,01 – 19 >205
5,01 – 6 >160 12,01 – 13 >190 19,01 – 20 >207
8.3.4 Test bed

The setting and testing of the cold differential test pressures with steam will be carried out at
LESER on the steam test bed in the HOW. (LWN 205.80).
The steam test bed consists of the following parts:
• Steam machine
• Steam setting table
• Pressure measuring devices/measuring appliances
There are three adapters at the setting table for different nominal inlet widths.

The safety valves are initially preset and checked on air.
The assembly and pressure preset on air of safety valves with pressure setting to steam is carried
out the same way as the safety valves that were set to air.
The steam machine and the steam setting table are started up in accordance with the instruction
manual (LWN 220.80, 220.05). The test bed is warmed up via the warming up pipe at approx. 10
% below the set pressures until the test temperature in accordance with Table 3 has been reached.
• Each safety valve has to respond several times (if necessary also pop) to warm up the valve
seat and valve disk.
• After several responses (if necessary also pop) of the test valve the set pressure in accordance
with specifications has to be set and checked.
The set pressure of the valves has been reached, when the escaping steam is clearly audible.
You have to achieve a full opening with a clearly audible cracking and/or bang. A creeping
response is not admissible.
• For evaluation of actual set pressure 3 single serial values have to be within a repeat accuracy
of 1%. The average value of this 3 single values is the determined actual set pressure, which
has to be within an allowable tolerance of +3% of set point. The determined actual set pressure
is definded as set pressure and builds the basis for further testings.
• After cooling of safety valves the tightness test with air acc. to LWN 220.01 will be carried out.
The steel safety valves will be protected against corrosion. Blowing space and sealing strip will be
treated with a silicon-free corrosion oil and then cleaned.
Please note! After that the valve has to be blown dry with pressurised air.

The safety valve has to open within the preset pressure tolerance.
The escaping steam has to be audible. A full opening with a bang has to be achieved. A creeping
response is not admissible.
8.3.7 Testing on capacity test bench of National Board (USA)

8.3.7.1 Capacity test
Depending on demanded capacity of the valve different values will be gathered (six or eight). The
smaller the capacity of valve the more measured values will be gathered and the more longer
takes the measuring process. Exactly one value per minute will be recorded. Reason for this
procedure is the precision of measuring of condensate steam using a water tank on a balance.
The steam will be condensated behind the valve and the water will be pumped in a second
metering box. This quantity of emerged water will be scaled. It will be pumped into two tanks (three
minutes each tank). During measurement of capacity the actual overpressure (10% over set
pressure) as well as the steam temperature will be read off and documented per each single value.
These values will be averaged and build the basis for the required capacity of valve.
8.3.7.2 Blow Down

In case of valves with fixed blow down also the reseating pressure difference will be tested (target
max. minus 7% of set pressure). After testing of capacity it will be noted also, if the valve closed
correctly.
9 Qualifications of the test personnel

The setting and testing on the cold differential test pressure of safety valves is carried out exclusive
by qualified assemblers.
Qualifying personnel is part of the organisational process at LESER. Planning training
requirements and courses like the initial training, in-house training program will be carried out on a
regular basis.
10 Documentation and option code

The cold differential test pressure with air, water or steam will be printed for each safety valve on
the name plate and SAP System documented.
The issuing of a certification about the testing of the cold differential test pressures can be ordered
using the following option codes:
Option code Acceptance test certificate Comments
LESER CGA (Certificate for Global Application) – Inspection
H03
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
N05
cold differential test pressure with air
11 Standards applied
• DIN EN ISO 4126-1 Safety appliances against non-permissible excess pressure, Part 1:
safety valves (edition May 2004), chapter 7- component tests
7.2 Tests for the determination of operational characteristics
“7.2.1 General requirements
.......The permissible tolerances and/or limits for the operational characteristics areas follows:
a) Response pressure: ± 3 % of the response pressures or ± 0,15 bar, the larger

value will apply.“
• ASME Code, Section I, Rules for Construction of Power Boilers

(Edition 2007)
Part PG General Requirements for All Methods of Construction
PG-72 Operation
PG -72.2 the popping point tolerance plus or minus shall not exceed that specified
in the following table:
Set Pressure, psi (MPa) Tolerance, plus or minus

from set pressure
≤ 70 (0,5) 2 psi
> 70 (0,5) and ≤ 300 (2,1) 3 % of set pressure
> 300 (2,1) and ≤ 1000 (7,0) 10 psi
> 1000 (7,0) 1 % of set pressure
• ASME Code, Section VIII, Rules for Construction of Pressure Vessels, Division 1,
(Edition 2007)
Part UG General Requirements for All Methods of Construction and All Materials
UG -134 Pressure Setting of Pressure Relief Devices

UG 134 (d ) (1) The set pressure tolerance for pressure relief valves shall not exceed ±2 psi for
pressures up to and including 70 psi and ±3% for pressures above 70 psi,
except as covered in(d)(2) below.
(2) The set pressure tolerance of the pressure relief valves which comply with
UG-125(c)(3) shall be within -0%, +10%.
• TÜV Nord e.V

“... Suggestion for setting tolerances during the setting of safety valves by TÜV Nord e.V.;
0% + 3% and/or for setting pressures ≤1,0 bar + 0,05 bar; >1,0 bar to ≤ 5,0 bar + 0,10 bar.
Do we do not allow a minus tolerance, since the availability of the plant cannot any longer
guaranteed considering the permissible operation excess pressure. ...“
• AD 2000 memorandum A2, chapter 11

• API 526, API 527, API 576
• DIN EN 837-1
12 Normative instructions
LWN 001.26 Safety valves with ASME certification
LWN 001.69 Cold differential test pressure (CDTP)
LWN 001.78 Set pressure, tightness, operation
LWN 220.01 Tightness test, testing procedure at LESER
LWN 220.03 Use of pressure measuring devices at the test beds (DIN EN- / ASME)
LWN 615.07 Gauging intervals (test media)
LWN 619.12 ASME/National Board- approval for LESER Safety valves (Stamp-
attainment)
LWN 205.80 Operation, maintenance and maintenance steam machine, softening plant,
steam setting table HOW
Pressure Equipment Directive 97/23/EC

DIN EN ISO 4126 –I Safety appliances against impermissible excess pressure,
Part I: Safety valves
DIN EN 837-1 Pressure measuring devices
ASME Code Section I Rules for Construction of Powers Boilers

Section VIII Rules for Construction of Pressure Vessels
API STANDARD 526
Flanged Steel Pressure
Relief Valves, Fifth Edition, June 2002
API STANDARD 527
Seat Tightness of Pressure, Relief Valves
Refining Department, Third Edition, July 1991
API STANDARD 576,
Inspection of Pressure –Relieving Devices,
API Recommended Practice 576, Second Edition, December 2000
13 Terms and abbreviations

LA Supply Loosely assembled = pre-assembled delivery (LWN 704.43)
SKD Kits Semi Knocked Down (LWN 704.41 Compact Performance valves)
End of LWN
Set-up of Equipment in Warehouses
Performing Leak Tests Page 1
Performing
Leak Tests
continues on page 2
LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
1 General
This LWN describes professional application of the test procedures. It summarises
the user information in a target-group-oriented manner.
Information:
Always keep the test manual
at the assembly test bench.
The manual must always be immediately available.
2 Contents
1 General....................................................................................................................................2
2 Contents..................................................................................................................................2
3 Scope ......................................................................................................................................3
3.1 Purpose of the document .................................................................................................3
3.2 Improper use ....................................................................................................................3
3.3 Informal measures............................................................................................................3
4 References to standards .......................................................................................................4
4.1 Operational materials and supplies ..................................................................................5
5 Distinguishing features of valve designs ............................................................................7
5.1 Safety valves in a gas-tight design...................................................................................7
5.2 Safety valves in a non-gas-tight design............................................................................7
6 Test description .....................................................................................................................8
6.1 Safety valves in a gas-tight design...................................................................................8
6.1.1 Flanged valves .........................................................................................................8
6.1.2 Threaded valves .....................................................................................................19
6.2 Safety valves in a non-gas-tight design:.........................................................................33
6.2.1 Flanged valves .......................................................................................................33
continues on page 3
LESER
3 Scope
This manual is valid for the execution of leak tests on safety valves in domestic and
foreign agencies of LESER GmbH & Co. KG.
The leak test is a production test, and must be performed as a standard procedure.
3.1 Purpose of the document

The instructions for leak testing presented here describe the leak tests that are used
for
• safety valves in a gas-tight design and
• safety valves in a non-gas-tight design
3.2 Improper use

Uses of the test equipment other than those given in this document are forbidden.
Improper use may have adverse effects on the operation and consequently lead to
inaccurate test results.
3.3 Informal measures

The operating manual must always be kept at the testing station and used in the
event of any unclarity in the test procedure.
continues on page 4
LESER
4 References to standards
The standards that are taken into consideration and applied by LESER for testing for
leaks are established in LWN 220-01.
It also contains the
• standard requirements for functional seal tightness (seat seal tightness) as well as
• increased seal tightness requirements of the functional seal tightness (seat seal
tightness) for
• gas-tight and non-gas-tight valves.
continues on page 5
LESER
4.1 Operational materials and supplies

The operational materials and supplies given in the following must be ready for use in
testing safety valves in a gas-tight and non-gas-tight design.
Leak detection spray

Material no.: 0161.0000
Fig. 1: Leak detection
Valve-specific test caps

Material no.: not yet defined
Fig. 2: Test caps
Valve-specific test plugs

Fig. 3: Test plugs
continues on page 6
LESER
Bubble counting unit (Kellog Tester)

Fig. 4: Bubble counting

it
Accessories for threaded valves

Fig. 5: Accessories
Water expansion kit

Fig. 6: Water expansion kit
continues on page 7
LESER
5 Distinguishing features of valve designs
5.1 Safety valves in a gas-tight design
Flanged valves Threaded valves
Closed Closed Closed

bonnet lever (H4) lever (H2)
5.2 Safety valves in a non-gas-tight design
Flanged valves
Open Open
bonnet lever (H3)
continues on page 8
LESER
6 Test description
6.1 Safety valves in a gas-tight design
6.1.1 Flanged valves
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
• LWN 369.30
1. • LWN 369.32
• LWN 369.33
Testing of the functional seal tightness (seat seal tight-

ness):
• Testing of functional seal tightness with air
• Testing of functional seal tightness with water
2.
Testing of the body seal:

Testing of body seal tightness with air and application of a test
liquid
3.
Testing of the back seal:

Testing of the interconnection points and the entire outlet area
with the aid of air and by application of a test liquid.
4.
continues on page 9
LESER
1. Valve assembly:
The valve must be assembled according to the assembly documentation.
• LWN 369.30
• LWN 369.32
• LWN 369.33
Fig. 7: API gas-tight
2. Testing of the functional seal tightness with air and water:
Test data for testing the functional seal tightness with air:
The following test data must be observed when testing the functional seal tightness with
gas-tight valves.
Test data
Test characteristic Seal tightness between the seat and disc
Testing standard Number of bubbles per second, see LWN 220-01, Attachment 1-3
Testing depth Every safety valve, 100% testing
Test medium Air
Test pressure 90% of set pressure
Testing device Bubble counting unit
Length of test Settling time of at least 10 seconds + testing time of 10 seconds
Test data for testing the functional seal tightness with water:
gas-tight valves.
Test data
Leak volume [cm³/min.] depending on the nominal diameter, see
Testing standard
LWN 220-01, TABLE 3
Testing depth Only at the request of the customer
Test medium Water
Testing device Water expansion kit, LWN 369.55
LESER
Auxiliary materials:
The following auxiliary materials must be available when testing the functional seal tight-
ness.
Auxiliary material Material no.

Valve-specific test caps not yet defined
Valve-specific test plugs 0172.0001
Bubble counting unit (Kellog tester) 0172.0001
Water expansion kit 0171.0001
(on customer request)
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be ad-
versely affected. A qualitative assessment of the leak volume as per LWN 220-01 Table 3 cannot
be conducted in a technically reasonable way.
If a quantitative statement is requested (leak rate) on the functional seal tightness for safety
valves that must be set with water, then the functional seal tightness of the valves will be tested
with air after finishing the adjustment of the set pressure.
Testing of the functional seal tightness with water can only represent a quantitative statement.
LESER
Testing of functional seal tightness with air
Operations:
a) The inlet side of the safety valve must be vertically at-
tached to the chuck.
Clean sealing surfaces are a basic requirement

for accurate measurement results.
Fig. 8: Clamped on valve
b) Select the correct test cap and then install

the gas-tight test cap on the bonnet.
Tighten the test cap finger-tight.

No test air may escape.
Fig. 9: Select the test cap
c) Select a tapered end-plug to fit the outlet and insert

the test plug in the outlet flange of the safety valve.
Fig. 10: Install the test plug
d) Trigger the safety valve once. Then lower the pres-

sure by 10% of the set pressure, or more precisely, -10%
by 0.35 bar (5.08 psi) for set pressures ≤3.5 bar
(50.76 psi).
Fig. 11: Test pressure reduction
LESER
e) If the pressure has been set as described, then place

the hose of the bubble counting device on the al-
ready-installed end plug.
No test air may escape from the connection.
Fig. 12: Installation of the test hose
f) First, switch on the test lighting in the bubble count-

ing device. Then count the bubbles per minute as
per LWN 220.01.
Allow a settling time of 10 seconds before

counting the bubbles.
The number of air bubbles that are determined

must be less than or equal to the tolerance
specification (LWN 220.01, Appendix 1-3).
Test passed:
If the number of bubbles is less than or equal to
the specification, then the test has been
passed.
Test not passed:

If the number of bubbles is greater than the
. specification in LWN 220.01 Appendix 1-3, then
then test has not been passed. In this case,
the valve will be reworked
(see Reworking 369.37) and the test performed Fig. 13 Test setup
again.
LESER
Testing of functional seal tightness with water
Operations:
a) The inlet side of the safety valve must be vertically at-
tached to the chuck.
Clean sealing surfaces are a basic requirement

for accurate measurement results.
Fig. 14: Clamping on the valve
b) Pressure must be applied to the safety valve with the

help of the water expansion kit (see LWN 369.55)
and caused to trigger one time.
-10%
c) Then lower the pressure by 10% of the set pressure,

or more precisely by 0.35 bar (5.08 psi) for set pres-
sures ≤3.5 bar (50.76 psi).
d) After a settling time of 10 seconds, a qualitative as- Fig .16: Pressure reduction by 10%
sessment of the leak volume must be performed as
per LWN 220-01.
A quantitative assessment of the leak volume cannot

be conducted in a technically reasonable way.
An additional test of functional seal tightness with air

is necessary. Fig .17: Functional seal tight-
ness with water
LESER
3. Testing body seal tightness:
Test data:
The following test data must be observed when testing the seal tightness of the pressure-bearing
body.
Test data
Test characteristic Testing the body seal tightness
Testing standard The valve must not have any visual signs of leaks
Every safety valve with a cast body and a rolled-in seat, 100%
Testing depth
testing
Test medium Air
Test pressure The test pressure is 6 bar (87.02 psi)
Testing device Application of test liquid
Settling time of at least 10 seconds +

15 seconds up to DN 50
Length of test
180 seconds above DN 200
The following auxiliary materials must be provided when testing the body seal tightness.

Leak detection spray 0161.0000
LESER
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
Clean sealing surfaces are the basic

requirement for accurate measurement re-
sults. Fig. 18: Clamped on valve
6 bar
b) Apply test pressure of 6 bar (87.02) psi to the
safety valve.
c) When the test pressure of 6 bar (87.02 psi) is

reached, spray the body with test liquid on the Fig. 19: Test pressure 6 bar
inlet side between the markings (see Figure
19).

the test.
Test passed:
If there is no foam formation on the body,
then the test has been passed.
Test not passed:

If there is foam formation on the body,
then the test has not been passed.
If it is possible to repair the damage, then
the test must be conducted again.
Fig. 20: Testing zone
LESER
4. Testing of the back seal:
Test data:
The following test data must be observed when testing the back seal.
Test data
Test characteristic Testing of the seal tightness of the valve on the outlet side
Testing depth Every safety valve with a gas-tight design, 100% testing
Test medium Air
Test pressure 6 bar (87.02 psi)

Length of test 15 seconds up to DN 200
The following auxiliary materials must be provided when testing the back seal.

LESER
Operations:
a) The outlet side of the safety valve must be
attached to the chuck.
Clean sealing surfaces are the

basic requirement for accurate
measurement results.
Fig.: 21: Clamping on the valve
6 bar
b) Apply test pressure of 6 bar (87.02) psi to

the safety valve with the help of the hand-
wheel needle valves.
Fig. 22: Test pressure 6 bar
c) When the test pressure of 6 bar (87.02 psi)

is reached, spray the body with test liquid
on the outlet side between the markings
(see Figure 23).
Fig. 23: Testing zone
LESER
Allow a settling time of 10 seconds

before testing.
Test passed:
If there is no foam formation on the surface of the valve,
Test not passed:

If there is foam formation on the surface of the valve,
then the test has not been passed.
If it is possible to repair the damage,

then the test must be conducted again.
Fig. 24: Foam formation
LESER
6.1.2 Threaded valves
Valve assembly:
• LWN 369.31
1.
Testing of functional seal tightness (seat seal tightness):

• Testing of the functional seal tightness with air
• Testing of the functional seal tightness with water
2.
Testing body seal tightness:

Testing of the body seal tightness with air and application of
testing liquid
3.
Figure 28
Testing of the back seal:

Testing of the interconnection points and the entire outlet area
with the help of air and by applying test liquid.
4.
LESER
1. Valve assembly:
• LWN 369.31
Fig. 30: CP valve
2. Testing of functional seal tightness with air and water:
Test data for testing functional seal tightness with air:

The following test data must be observed when testing the functional seal tightness
with gas-tight valves.
Test data
Testing standard Number of bubbles per second, see LWN 220-01, Attachment 1-3
Test medium Air
Testing device Bubble counting unit
Test data for testing functional seal tightness with water:

gas-tight valves.
Test data
Leak volume [cm³/min.] depending on the nominal diameter, see
Testing standard
LWN 220-01, TABLE 3
Testing depth Only at the request of the customer
Test medium Water
Testing device Water expansion kit, LWN 369.55
LESER
The following auxiliary materials must be provided when testing the seal tightness of the
seat for threaded valves.

Accessories for threaded valves 0151.0002
Bubble counting unit (Kellog tester) 0172.0001
Water expansion kit 0171.0001

(on customer request)
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be ad-
versely affected. A quantitative assessment of the leak volume as per LWN 220-01 Table 3 can-
not be conducted in a technically reasonable way.
If a quantitative statement is requested (leak rate) on the functional seal tightness for safety
valves that must be set with water, then the functional seal tightness of the valves will be tested
with air after finishing the adjustment of the set pressure.
Testing of the functional seal tightness with water can only represent a quantitative statement.
LESER
Testing of functional seal tightness with air:
Operations:
Figure 31
a) The inlet side of the safety valve must be verti-
cally attached to the clamping device (see LWN
0121.0001).
Clean sealing surfaces are a basic require-

ment for accurate measurement results.
Fig. 32: Clamping the valve in

the clamping device
b) If the test is performed on the Manual Basic Test

Bench, then the valve must be attached to the
test bench with the help of the accessories for
threaded valves (material no.: 0151.0002) as
shown in Figure 33.

Fig. 33: Clamping on the

Manual Basic Test Bench
LESER
c) Select a tapered end-plug to fit the outlet and in-

sert the test plug in the outlet flange of the safety
valve.
Fig. 34: Inserting the test plug
-10%
d) Trigger the safety valve to trigger once. Then
lower the pressure by 10% of the set pressure, or
more precisely, by 0.35 bar (5.08 psi) for set
pressures ≤3.5 bar (50.76 psi).
Fig. 35: Pressure reduction by

10%
e) If the pressure has been set as described, then

place the hose of the bubble counting device on
the already installed end-plug.
No test air may escape from the connection.

Fig. 36: Mounting the bub-
ble hose
LESER
f) First, switch on the test lighting in the bubble count-

ing device. Then count the bubbles per minute as
per LWN 220.01.

counting the bubbles.
The number of air bubbles that are deter-

mined must be less than or equal to the toler-
ance specification (LWN 220.01).
Test passed:
If the number of bubbles is less than or equal
to the tolerance specification, the the test has
been passed.
Test not passed:

If the number of bubbles is greater than the
tolerance specification, then the test has not
been passed. In this case, the valve will be
reworked (see LWN 369.37) and the test per- Fig. 37: Counting
formed again. bubbles
LESER
Testing of the functional seal tightness with water:
Operations:
a) The inlet side of the safety valve must be attached

to the testing device with the help of the additional
screw connections (material no. 0151.0002). To do
this, the respective thread adapter must be first
screwed on.

ment for accurate measurement results. Fig. 38: Thread adapter
b) In addition, the base unit of the accessories for

threaded valves (material no. 0151.0002) must be
attached to the test bench.
Fig. 39: Fixing the base unit in

position
c) The safety valve must be attached to the base unit

with the adapter.
Fig. 40: Screwing in the

valve
LESER
d) Pressure must be applied to the safety valve with

the help of the water expansion kit (see LWN
369.55) and caused to trigger one time.
-10%
e) Then lower the pressure by 10% of the set pres-
sure, or more precisely, by 0.35 bar (5.08 psi) for
set pressures ≤3.5 bar (50.76 psi).
Fig .44: Pressure reduction by 10%
f) After a settling time of 10 seconds, a qualitative

assessment of the leak volume must be performed
as per LWN 220-01.
A quantitative assessment of the leak volume can-

not be conducted in a technically reasonable way.
An additional test of the functional seal tightness

with air is necessary.
Fig .45: Functional seal tight-
ness with water
LESER
Test data:
The following test data must be observed when testing the body seal tightness.
Test data
Test characteristic Testing of the seal tightness of the pressure-bearing body
Testing standard The body must not have any visual signs of leaks
Testing depth
testing
Test medium Air
Length of test Settling time of at least 10 seconds +
The following auxiliary materials must be provided when testing the seal tightness of the
pressure-bearing body for threaded valves.

Accessories for threaded valves 0151.0002
LESER
Operations:
a) The inlet side of the safety valve must be verti-

cally attached to the clamping device.

Fig. 46: Clamping the valve in

the clamping device
b) If the test is performed on the Manual Basic Test

Bench, then the valve must be attached to the
test bench with the help of the accessories for
threaded valves (material no.: 0151.0002) as
shown in Figure 47.

Fig. 47: Clamping on the

Manual Basic Test Bench
LESER
c) Apply test pressure of 6 bar (87.02) psi to the

safety valve. 6 bar
d) When the test pressure of 6 bar (87.02 psi) is

reached, spray the body with test liquid on the inlet
side between the markings (see Figure 49).
Allow a settling time of 10 seconds before the

test. Fig. 49: Testing zone
Test passed:
If there is no foam formation on the body, then
the test has been passed.
Test not passed:

If there is foam formation on the body, then the
Figure 50
test has not been passed.
If it is possible to repair the damage, then the
test must be conducted again.
Fig. 51: Bubble formation
LESER
4. Testing of the back seal:
Test data:
The following test data must be observed when testing the back seal.
Test data
Test characteristic Testing of the seal tightness of the valve on the outlet side
Testing depth Every safety valve with a gas-tight design, 100% testing
Test medium Air

Length of test 15 seconds up to DN 200
The following auxiliary materials must be provided when testing the back seal.

Thread adapter 0151.0002

(Only for the Manual Basic Test Bench)
LESER
a) The outlet side of the safety valve must be at-

tached to the testing device with the help of the
additional screw connections. To do this, the
respective thread adapter must be screwed on
first.
Clean sealing surfaces are a basic re-

quirement for accurate measurement re-
sults. Fig. 52: Screw in the thread
adapter
b) In addition, the base unit must be attached to

the test bench. The safety valve must be at-
tached to the base unit with the adapter.
Fig. 53: Screw the valve into the

adapter
c) The testing zone is marked in colour (see Fig-

ure 54)
Fig. 54: marked testing zone
LESER
d) Test the marked zone with leak detection

spray.
Fig. 55: Applying the

leak detection spray
e) Count the bubbles per minute according to

LWN 220.01.
Allow a settling time of 10 seconds

before counting the bubbles.
Test passed:
then test has been passed.
Test not passed:

then test has not been passed.
Fig. 56: Foam formation
If it is possible to repair the damage, then the test
must be conducted again.
LESER
6.2 Safety valves in a non-gas-tight design:

6.2.1 Flanged valves
Valve assembly:
• LWN 369.30
1. • LWN 369.32
• LWN 369.33
Testing of the functional seal tightness:

Testing of the functional seal tightness with air and application
of testing liquid
2.
Testing the body seal tightness:

Testing of the body seal tightness with air and application of
testing liquid
3.
LESER
1. Valve assembly:
• LWN 369.30
• LWN 369.32
• LWN 369.33
Fig. 58: API non-gas-tight
2. Testing of functional seal tightness:
Test data:
The following test data must be observed when testing functional seal tightness with non-gas-tight
valves.
Test data
Testing standard The blow-hole at the outlet must not extend more than 5mm
Test medium Air
The following auxiliary materials must be provided when testing the functional seal tight-
ness of non-gas-tight valves.

processed: M. Lammers edition: 2009-11-04
LESER
LESER GmbH & Co. KG replaces edition: ----
Operations:
a) The outlet side of the safety valve must be attached
to the chuck.

6 bar

safety valve.

reached, put the rubber test plug in the outlet
flange.
Fig. 61: Inserting the

test plug
LESER
d) The opening of the test plug must be

sprayed with leak detection liquid.
Fig.62: Application of the

leak detection liquid
The extension of the blow-out must be ob-

served for 10 seconds.
Test passed:
If the blow-out remains as it is and does not
burst, then the test is considered to have
passed.
Test not passed:

If the blow-out projects more than 5 mm or
bursts, then the test is considered to have
failed. If it possible to repair the damage,
then the test must be conducted again.
Fig. 63: Blow-out extension
LESER
Test data:
The following test data must be observed when testing the body seal tightness.
Test data
Test characteristic Testing of the seal tightness of the pressure-bearing body
Testing standard The body must not have any visual signs of leaks
Testing depth
testing
Test medium Air
A test pressure must be chosen that is slightly lower than the
Test pressure
set pressure.

Length of test
The following auxiliary materials must be provided when testing body seal tightness for
non-gas-tight valves.

LESER
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
Clean sealing surfaces are the basic

requirement for accurate measurement re-
sults.

safety valve. 6 bar

reached, spray the body with test liquid on the
inlet side between the markings (see Figure
65).

the test.
Test passed:
Test not passed:

then the test has not been passed. If it is
possible to repair the damage, then the
test must be conducted again. Fig. 48 Body with market
testing zone
End of LWN
LESER
Final visual inspection of repaired valves Page 1/8
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
6 Flow chart for the visual inspection (final inspection) .......................................... 2
7 Performing the final inspection ............................................................................ 3
7.1 General inspections...................................................................................... 3
7.2 Visual inspection of other items.................................................................... 4
7.3 Fault notification process.............................................................................. 8
1 Purpose
This LESER Global Standard (LGS) provides instruction on the visual final inspection
of LESER safety valves. The required work steps and materials are described.
2 Scope
protected
This document must be observed in the visual final inspection of safety valves in agencies
and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
content.

The visual final inspection of LESER safety valves may only be performed by trained
or qualified fitters. The qualifications must be obtained through the appropriate
training measures.
• Gloves must be worn during the final inspection of oil and
grease-free safety valves.
6 Flow chart for the visual inspection (final inspection)
Perform the
ident. check
Fault
protected
notification
process
Inspecti
on OK
no
yes
Completion of
the final
inspection and
delivery
Figure 6-1

7 Performing the final inspection
7.1 General inspections
a) Compare the content of the valve inspection plan or repair order to the valve
model.
EXAMPLE /
protected
SPECIMEN
Figure 7.1-1
Figure 7.1-2: Check the type number against the Figure 7.1-3: Check the BT plate / customer ID
valve inspection plan / repair order plate data against the valve inspection plan /
repair order

7.2 Visual inspection of other items

7.2.1 Inspection of the paintwork
a) Valve is not completely painted
OK specimen: Rejected specimen:
protected
Figure 7.2.1-1
Figure 7.2.1-2
b) Paint coat is cracked (too much paint)

Figure 7.2.1-3
Figure 7.2.1-4

c) Paint coat is not complete due to oil / grease
Figure 7.2.1-5
Figure 7.2.1-6
protected
Figure 7.2.1-7
Figure 7.2.1-8

d) Paint on masked off areas
Figure 7.2.1-10
protected
Figure 7.2.1-9
Figure 7.2.1-11 Figure 7.2.1-12
Reason: The legibility of the plate is not guaranteed.

7.2.2 Inspection of the sealing surfaces
Figure 7.2.2-1
Figure 7.2.2-2
protected
7.2.3 Inspection of the seal

Seal is missing for sealed valves, or it is not
crimped.
Figure 7.2.3-1
If the result of the inspection is okay, then the safety valve is sent for packaging and
shipment.

7.3 Fault notification process
• If the result of the inspection is not okay, then the fitting is sent to the fault
notification process that is to be determined.
• The final inspection is performed again after completion of the fault notification
process.
protected

Type 481
Order information – Spare parts
Type 481
Spare parts
Actual Orifice diameter d0 [mm] 10
Actual Orifice area A0 [mm2] 78,5
Actual Orifice diameter d0 [inch] 0,394
Actual Orifice area A0 [inch2] 0,122
Inlet body (Item 1) Material-No. / Art.-No.
3
Inlet CO Connection size / 4" 1"
body 1.4404 – 136.4649.9265
SO Connection size DN 15 DN 25
1.4404 136.4649.9271 136.4649.9263
Disc with vulcanized soft seal (Item 7) Material-No. / Art.-No.
Disc 1.4404 EPDM “D” 200.9049.9041
CR “K” 200.9049.9051
FKM “L” 200.9049.9071
NBR “N” 200.9049.9081
FFKM “C” 200.9049.9091
Disc – soft seal with O-ring (Item 7) Material-No. / Art.-No.
Disc 1.4404 EPDM “D” 200.8349.9741
CR “K” 200.8349.9751
FKM “L” 200.8349.9771
NBR “N” 200.8349.9781
FFKM “C” 200.8349.9721
O-ring – soft seal (Item 7.4) Material-No. / Art.-No.
O-ring EPDM “D” 502.0107.2641
CR “K” 502.0107.2651
FKM “L” 502.0107.2671
NBR “N” 502.0107.2681
FFKM “C” 502.0107.2621
01/14 LWN 483.01-E

Type 483
Spare parts
Actual Orifice diameter d0 [mm] 13 25
Actual Orifice area A0 [mm2] 133 491
Actual Orifice diameter d0 [inch] 0,512 0,984
Actual Orifice area A0 [inch2] 0,206 0,761
Disc (Item 7): Soft seal Material-No. / Art.-No.
Disc 1.4435 EPDM “D” 200.8169.9741 200.2569.9741
CR “K” 200.8169.9751 200.2569.9751
Type 483
FKM “L” 200.8169.9771 200.2569.9771

NBR “N” 200.8169.9781 200.2569.9781
FFKM “C” 200.8169.9791 200.2569.9791
Assembly tool for Aseptic O-ring disc tool not required for this valve size 445.0139.0000
O-ring (Item 7.4): Soft seal Material-No. / Art.-No.
O-ring EPDM “D” 502.0123.2641 502.0250.2641
CR “K” 502.0123.2651 502.0250.2651
FKM “L” 502.0123.2671 502.0250.2671
NBR “N” 502.0123.2681 502.0250.2681
FFKM “C” 502.0123.2691 502.0250.2691
Pin / Split ring (Item 14) Material-No. / Art.-No.
Pin / Spindle Ø [mm] 8 12
Split ring 1.4310 / 1.4404 480.0405.0000 251.0149.0000
Pin (Item 57) Material-No. / Art.-No.
Pin Ø [mm] 3 3
1.4310 480.0405.0000 480.0405.0000
O-ring body / guide (Item 60) Material-No. / Art.-No.
O-ring EPDM “D” 502.0460.3041 502.0600.3041
Ball (Item 61) Material-No. / Art.-No.
Ball Ø [mm] 6 6
1.4401 510.0104.0000 510.0104.0000
Bellows (Item 70) Material-No. / Art.-No.
Bellows EPDM “D” 224.2349.9000 224.2449.9000
FFKM “C” on request on request
02/14 LWN 483.01-E

Type 484
Spare parts
Disc (Item 7): Soft seal Material-No. / Art.-No.
Disc 1.4435 EPDM “D” 200.8169.9741 200.2569.9741
CR “K” 200.8169.9751 200.2569.9751
FKM “L” 200.8169.9771 200.2569.9771
NBR “N” 200.8169.9781 200.2569.9781
FFKM “C” 200.8169.9791 200.2569.9791
O-ring (Item 7.4) Material-No. / Art.-No.
O-ring EPDM “D” 502.0123.2641 502.0250.2641
CR “K” 502.0123.2651 502.0250.2651
FKM “L” 502.0123.2671 502.0250.2671
NBR “N” 502.0123.2681 502.0250.2681
FFKM “C” 502.0123.2691 502.0250.2691
Pin / Split ring Spindle Ø [mm] 8 12
1.4310 / 1.4404 480.0405.0000 251.0149.0000
Pin Ø [mm] 3 3
1.4310 480.0405.0000 480.0405.0000
O-ring EPDM “D” 502.0460.3041 502.0600.3041
FFKM “C” 502.0123.3021 502.0600.3021
Type 484

Ball Ø [mm] 6 6
1.4401 510.0104.0000 510.0104.0000
O-ring vessel connection (Item 67) Material-No. / Art.-No.
O-ring EPDM “D” 502.0460.3041 502.0600.3041
Bellows EPDM “D” 224.2329.9000 224.2429.9000
04/16 LWN 483.01-E

Type 485
Spare Parts
Disc – (Item 7): Soft seal Material-No. / Art.-No.
Disc 1.4435 EPDM “D” 200.8169.9741 200.2569.9741
CR “K” 200.8169.9751 200.2569.9751
FKM “L” 200.8169.9771 200.2569.9771
NBR “N” 200.8169.9781 200.2569.9781
FFKM “C” 200.8169.9791 200.2569.9791
O-ring (Item 7.4): Soft seal Material-No. / Art.-No.
O-ring EPDM “D” 502.0123.2641 502.0250.2641
CR “K” 502.0123.2651 502.0250.2651
FKM “L” 502.0123.2671 502.0250.2671
NBR “N” 502.0123.2681 502.0250.2681
FFKM “C” 502.0123.2691 502.0250.2691
Pin / Split ring Spindle Ø [mm] 8 12
1.4310 / 1.4404 480.0405.0000 251.0149.0000
Pin Ø [mm] 3 3
1.4310 480.0405.0000 480.0405.0000
O-ring EPDM “D” 502.0460.3041 502.0600.3041
FFKM “C” 502.0460.3021 502.0600.3021
Ball Ø [mm] 6 6
1.4401 510.0104.0000 510.0104.0000
O-ring pipework connection (Item 67) Material-No. / Art.-No.
O-ring EPDM “D” 502.0180.3041 502.0300.3041
Bellows EPDM “D” 224.2349.9000 224.2449.9000
Type 485
05/16 LWN 483.01-E

Type 488
Type 488 – HyTight
Actual Orifice diameter d0 [mm] 23 37 46 60 74 92
Actual Orifice area A0 [mm2] 416 1075 1662 2827 4301 6648
Actual Orifice diameter d0 [inch] 0,906 1,457 1,811 2,362 2,913 3,622
Actual Orifice area A0 [inch2] 0,644 1,667 2,576 4,383 6,666 10,304
Disc – soft seal (Item 7) Material-No. / Art.-No.
Disc 1.4404 EPDM “D” 205.3549.9741 205.3649.9741 205.3749.9741 205.3849.9741 205.3949.9741 205.4049.9741
CR “K” 205.3549.9751 205.3649.9751 205.3749.9751 205.3849.9751 205.3949.9751 205.4049.9751
FKM “L” 205.3549.9771 205.3649.9771 205.3749.9771 205.3849.9771 205.3949.9771 205.4049.9771
FFKM “C” 205.3549.9791 205.3649.9791 205.3749.9791 205.3849.9791 205.3949.9791 205.4049.9791
Disc – soft seal (Item 7.4) Material-No. / Art.-No.
O-ring EPDM “D” 502.0249.3541 502.0408.3541 502.0503.3541 502.0660.5341 502.0819.5341 502.1041.5341
CR “K” 502.0249.3551 502.0408.3551 502.0503.3551 502.0660.5351 502.0819.5351 502.1041.5351
FKM “L” 502.0249.3571 502.0408.3571 502.0503.3571 502.0660.5371 502.0819.5371 502.1041.5371
FFKM “C” 502.0249.3591 502.0408.3591 502.0503.3591 502.0660.5391 502.0819.5391 502.1041.5391
Split ring (Item 14) Material-No. / Art.-No.
Split ring Spindle Ø [mm] 12 16 16 16 20 20
1.4404 251.0149.0000 251.0249.0000 251.0249.0000 251.0249.0000 251.0349.0000 251.0349.0000
Pin Ø [mm] 3 4 4 5 5 5
1.4310 480.3205.0000 480.1605.0000 480.1605.0000 480.3005.0000 480.3105.0000 480.3105.0000
O-ring EPDM “D” 502.0600.3041 502.0850.4041 502.0850.4041 502.1130.4041 502.1380.4041 502.1580.5041
Ball Ø [mm] 6 9 9 12 12 15
1.4401 510.0104.0000 510.0204.0000 510.0204.0000 510.0304.0000 510.0304.0000 510.0404.0000
Type 488

Bellows EPDM “D” 224.2849.9000 224.2949.9000 224.2949.9000 224.2649.9000 224.2649.9000 224.2649.9000
Type 488 – Design 2002

Disc – Metal to metal seat (Item 7) Material-No. / Art.-No.
Disc 1.4404 225.4049.9000 210.0949.9000 210.1049.9000 210.1949.9000 210.2049.9000 210.2349.9000
1.4404 electropolished 225.4049.9700 210.0949.9700 210.1049.9700 210.1949.9700 210.2049.9700 210.2349.9700
O-ring disc (Item 7) Material-No. / Art.-No.
O-ring EPDM “D” 200.5049.9041 200.5249.9041 200.5349.9041 200.5449.9041 200.5549.9041 200.5649.9041
disc CR “K” 200.5049.9051 200.5249.9051 200.5349.9051 200.5449.9051 200.5549.9051 200.5649.9051
FKM “L” 200.5049.9071 200.5249.9071 200.5349.9071 200.5449.9071 200.5549.9071 200.5649.9071
FFKM “C” 200.5049.9091 200.5249.9091 200.5349.9091 200.5449.9091 200.5549.9091 200.5649.9091
O-ring for design 2002 version (Item 7.4) Material-No. / Art.-No.
O-ring EPDM “D” 502.0249.3541 502.0408.3541 502.0503.3541 502.0660.5341 502.0819.5341 502.1041.5341
CR “K” 502.0249.3551 502.0408.3551 502.0503.3551 502.0660.5351 502.0819.5351 502.1041.5351
FKM “L” 502.0249.3571 502.0408.3571 502.0503.3571 502.0660.5371 502.0819.5371 502.1041.5371
FFKM “C” 502.0249.3591 502.0408.3591 502.0503.3591 502.0660.5391 502.0819.5391 502.1041.5391
Split ring (Item 14) Material-No. / Art.-No.
Split ring Spindle Ø [mm] 12 16 16 16 20 20
1.4404 251.0149.0000 251.0249.0000 251.0249.0000 251.0249.0000 251.0349.0000 251.0349.0000
Pin Ø [mm] 3 4 4 5 5 5
1.4310 480.0205.0000 480.0605.0000 480.0605.0000 480.0905.0000 480.1005.0000 480.1005.0000
O-ring (Item 60) Material-No. / Art.-No.
O-ring EPDM “D” 502.0600.3041 502.0850.4041 502.0850.4041 502.1130.4041 502.1380.4041 502.1580.5041
Ball Ball Ø [mm] 6 9 9 12 12 15
1.4401 510.0104.0000 510.0204.0000 510.0204.0000 510.0304.0000 510.0304.0000 510.0404.0000
Bellows EPDM “D” 224.0479.0000 521.0307.0000 521.0307.0000 521.0107.0000 521.0408.0000 521.0408.0000
Hose clamp (Item 71) Material-No. / Art.-No.
Hose clamp 1.4301 524.0606.0000 524.0706.0000 524.0706.0000 524.0806.0000 – –
1.4401 – – – – 524.0505.0000 524.0505.0000
Hose clamp (Item 72) Material-No. / Art.-No.
Hose clamp 1.4301 524.0606.0000 524.0706.0000 524.0706.0000 524.0806.0000 524.0906.0000 524.0906.0000
03/16 LWN 483.01-E

6 Installation and Plant Design
6.2.12 Recommendation for Testing and Inspection during Operation
When and how often safety valves should be inspected is a frequently asked question. This question
cannot be answered in general but has to be regarded for each application individually.
6.2.12.1 Inspection Intervals for LESER Safety Valves
Due to the individual operating conditions and in consideration of the different mediums, LESER
gives no general reference for an inspection time interval.
In coordination between LESER, different operators, and the notified body, the following procedure
has proven itself:
1. Determination of an ininitial inspection time interval:

In accordance with the operating conditions an initial interval of 24 month has proven itself. If the
safety valve opens frequently or the medium is corrosive the inspection time interval should be 12
months.
2. Inspection of safety valves after this period of time:

► Set pressure repeat accuracy (this requirement is fulfilled if the set pressure corresponds to the
test pressure with a tolerance of ± 3 %)
► Tightness test of the safety valve (this requirement is fulfilled if the tightness is tested according to
API standard 527 or LWN 220.01)
► Testing of the mobility (this requirement is fulfilled if the safety valve can be opened with the lifting
device at an operating pressure >75 % without the use of any additional tools).
3. Adapting the inspection time interval

The inspection time interval can be increased if the safety valve fulfills the requirements of the above
mentioned tests. If not, the interval should be reduced to 12 months or less. In case the following
inspection fulfills the requirements again the inspection interval can be lengthened by two month.
If the safety valve is leaking the inspection has to be done immediately.
LWN 753.00 edition: 10.05.2010 6.2-10

6.2.12.2 Statements in Codes and Standards
Within the below stated codes and standards the following guidelines for inspection intervals for
LESER safety valves are important:
API Recommended Practice 576, Inspection of Pressure-Relieving Devices

Chapter 6.4:
“The inspection of pressure-relieving devices provides data that can be evaluated to determine a safe
and economical frequency of scheduled inspections. This frequency varies widely with the various
operating conditions and environments to which relief devices are subjected. Inspections may usually
be less frequent when operation is satisfactory and more frequent when corrosion, fouling, and
leakage problems occur. Historical records reflecting periodic test results and service experiences for
each relief device are valuable guides for establishing safe and economical inspection frequencies.
A definite time interval between inspections or tests should be established for every pressure-
relieving device on operating equipment. Depending on operating experiences, this interval may vary
from one installation to another. The time interval should be sufficiently firm to ensure that the
inspection or test is made, but it should also be flexible enough to permit revision as justified by past
test records.”
In API 510, the subsection on pressure-relieving devices establishes a maximum interval between
device inspections or tests of 10 years. It also indicates that the intervals between pressure relief
device testing or inspection should be determined by the performance of the devices in the particular
service concerned.
AD2000-Merkblatt A2: Safety Devices against excess pressure – Safety Valves

Chapter 4.7:
“Tests on the response pressure and checks on the smooth running of moving parts within the guides
shall be carried out at regular intervals. The intervals for regular tests shall be stipulated by the user
in accordance with the operating conditions, using as a basis the recommendations of the
manufacturer and the relevant third party. These tests and checks shall be carried out at the latest on
the occasion of the external or internal tests on the relevant pressure vessel.”
Ordinance on Industrial Safety and Health – BetrSichV (Betriebssicherheitsverordnung).

Section 15 – Recurrent inspection
“ (1) An installation subject to monitoring and its components shall be subjected to recurrent
inspections in certain intervals by an approved body to ensure their proper condition with respect to
its operation. The operator shall determine the inspection intervals of the entire installation and its
components on the basis of a technical safety assessment...“
The following testing periods for category IV pressure equipment (including safety valves) are defined
in section 15:
► External inspection: 2 Years
► Internal inspection: 5 Years
► Strength inspection: 10 Years
LWN 753.00 edition: 10.05.2010 6.2-11

6.2.13 Storage and Handling of Safety Valves

“Because cleanliness is essential to the satisfactory operation and tightness of a safety valve,
precautions should be taken to keep out all foreign materials during storage or transportation. Safety
valves should be closed off properly at both inlet and outlet flanges. Specific care should be taken to
keep the valve inlet absolutely clean.
If possible, safety valves should be stored indoors, on pallets, and away from dirt and other forms of
contamination.
Safety valves should be handled with care and should not be subjected to shock. Otherwise,
considerable internal damage or misalignment can occur and seat tightness may be adversely
affected.”7)
Depending on the size and weight of the safety valve, the quantity of safety valves in one shipment,
and the shipping method, LESER offers different types of packing (see LWN 617.08), e.g.:
Individual safety valve in a cardboard box (Figure 6.2.13-1)
Tied-down on a pallet (Figure 6.2.13-2)
Cardboard or wooden crate (Figure 6.2.13-3)
Figure 6.2.13-1: Individual cardboard Figure 6.2.13-2: Tied-down on a Figure 6.2.13-3 Wooden crate
box pallet
During storage until installation, safety valves should be kept in their own packaging. The advantages
of the LESER types of packing are:
- Due to secure packaging, no damage during transport.
- Unpacking of safety valves before stocking is not necessary.
- Safety valves are protected against dust and dirt during storage.
- Easy and space-saving storage of safety valves on shelves or racking.
- Easy identification of the content from the outside via labels (Figure 6.2.13-4).
Figure 6.2.13-4: Outside label on a cardboard box
It is also possible to transport LESER Safety valves horizontally. The advantages of this kind of
transportation are:
► requires little space
► less freight charge
► lower risk of damages in horizontal transport due to lower center of gravity
7)
API RP 520 Part II, 5th Edition 2003, Sect. 12.2
LWN 753.00 edition: 10.05.2010 6.2-12

6.2.11 Testing and Inspection of Safety Valves before Installation
“The condition of all safety valves should be visually inspected before installation. Before installation
all protective materials on the valve flanges have to be completely removed. Bonnet shipping plugs
must be removed from balanced safety valves.”6)
API 520 Part II recommends that the inlet surface must be cleaned, since foreign materials clinging to
the inside of the nozzle will be blown across the seats when the safety valve is operated. Some of
these materials may damage the seats or get trapped between the seats in such a way that they
cause leakage. Valves should be tested before installation to confirm their set pressure.
LESER Note:
Due to the LESER types of packing, LESER safety valves are delivered ready-to-install. As long
as safety valves remain in the packing during storage, the safety valves do not need to be
inspected, cleaned or tested before initial installation. For more details see the LESER operating
instructions.
6)
API RP 520 Part II, 5th Edition 2003, Sect. 12.3
LWN 753.00 edition: 10.05.2010 6.2-8

6.2.11.1 Pressure Test before Operation
Before a plant can be started up a hydraulic pressure test has to be performed. For this test all safety
valves in the system must be prevented from opening.
Three different possibilities are feasible:
Possibility Figure Description
The test gag blocks the spindle and

keeps the safety valve tight while the
system pressure exceeds the set
pressure.
Advantage: It is possible to perform
Test gag pressure tests in a system without
dismantling the safety valve.
After testing, the test gag must be
removed! Otherwise the safety valve
cannot protect the system against
unallowable overpressure.
The safety valve is replaced by a blind

flange for the duration of the pressure
Blind flange test. After testing the safety valve has to
be reinstalled.
Dismantled
Blind Flange
To block the safety valve during a

pressure test a blanking plate is placed
between inlet pipe and safety valve.
Blanking plate/ After testing, the blanking plate must be
Isolation plate removed! Otherwise the safety valve
cannot protect the system against
unallowable overpressure.
Blanking Plate
Table 6.2.11.1-1:Options for the hydraulic pressure test
LWN 753.00 edition: 10.05.2010 6.2-9

17 Trouble Shooting
4 Typical Mistakes as a Result of Unauthorized Repair
Figure 17.4-1: Twisted stainless steel bellows
Safety valves are safety devices and improper repair may cause damage to equipment and serious
injury or death! The following table lists typical mistakes that are made when repair is performed by
unauthorized or untrained personnel or when maintenance instructions are not followed.
No. Mistake Effect

1 Assembly of incorrect spring 1. Spring is too soft: Safety valve closes too late
2. Spring is too strong: Safety valve opens too late
2 Spring is compressed to solid Safety valve does not open or does not achieve the
after assembly required lift
3 Wrong disc is mounted The safety valve may have the wrong operating char-
acteristic for the application
4 Due to excessive machining of The safety valve will have the wrong operating charac-
seat/ disc the tolerances of the teristic
critical dimensions (chamfer)
may be exceeded
5 After repair lifting aid was not The safety valve will have the wrong operating charac-
reinstalled teristic
6 After repair lift restriction was not The safety valve will blow off with a higher capacity.
reinstalled Pressure drop in the inlet and outlet line may occur as
well as chattering
7 During assembly the spindle was Safety valve does not open
not secured against rotation:
the stainless steel bellows is
twisted
8 Unsuitable or insufficient grease The Lifting device H8 fails; the safety valve continues
is used for the lubrication of the to function
actuator of the pneumatic lifting
device H8
9 Lifting lever left in open position The safety valves stays open
- lever with knob
- H4 for Clean Service
LWN 765.01 edition: 16.07.09 17.4-1

Complete Clean Service - EN

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LESER Information Document LID 1003.

Maintenance Handbook for

Clean Service Series 48X

MAINTENANCE provides a collection of documents for repairing or maintaining LESER

Chapter Content Sources

1.2 Maintenance Terminology: SIP 1002-00

1.5 Disassembly and Disassembly instruction: LGS 4108 “Dismantling

Chapter Content Sources

1.6 Rework of critical parts The rework of critical

1.7 Assembly Assembly instruction: LGS 4103 “Assembly

After Assembly: LGS 1114 “Paint touch-

1.8 Spring charts Spring charts: LWN 060-20 “Spring

LWN 060-21 “Spring

LWN 060-22 “Spring

LWN 060-23 “Spring

Chapter Content Sources

LWN 060-24 “Spring

1.9 Testing Procedures Testing set pressure: LWN 331-12 “CDTP”

Leak testing: LWN 369-34

Tightness requirements: LWN 220-01 “Tightness

Last visual check up LGS 1117 “Final visual

1.10 Spare parts Spare parts list LWN 483.01 “Spare

Chapter Content Sources

Inspection intervals Extract from LWN 753-

Extract from LWN 753-

Extract from LWN 765-

1.1 Introduction ........................................................................................................... 2

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

1.2.1 Parts Description acc. to ASME PTC 25

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

1.2.2 Definition of set pressure

1.2.3 Definition of overpressure

Figure 1 gives a graphical representation of the definitions.

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

1.3 Critical parts

1.3.1 Nozzle and disc

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

1.3.3 Adjusting Ring

Lowering ring: overpressure increases, blowdown decreases

Figure 2: Blowdown ring of LESER’s Type 526

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

1.3.4 Parts Providing Alignment

Correct alignment of nozzle and disc

Proper guiding of the spindle is

When installed, the user must ensure

Figure 3: overview of parts providing alignment

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

1.4 Lifting devices

Bolted Cap H1 Pneumatic lever H8

Figure 4: overview of different cap and levers

disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10

The right side give references to forms of inspection documentation,

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

visually inspection report 1.1

disassembling assembling instruction (LLS...)

assembling instruction to cleaning good parts

assembling instruction to finishing

finishing (if catalogue

assembling the valve assembling instruction (LLS…)

disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010

Date Valve type

Serial no. / Job no. Medium