ACA 3511

Issue 03-2008

INSTRUCTION MANUAL

3-5400 SERIES
SAFETY RELIEF VALVES
SAFEGUARDS
GENERAL NOTICES
Beside the rules here below listed the plant
manager must meet the regulation in force
concerning safety and health of workers in
jobsites.
Qualified staff only must be used to operate on
the valve.
The Company rejects any responsibility for
personal injury and damages to equipment
imputable to improper operation, use of non
original spare parts or repairs executed by
unauthorised staff.
Transportation must be performed utilising
original packing up to job-site.
The Company rejects any responsibility for
damages occurred to things and people due to
packing because of having been tampered with.
2
USE AND MAINTENANCE
Safety relief valve, due to its particular function,
operate in a discontinuous way.
It is therefore necessary to take the
necessary precautions when staying near or
passing close to the valve, when plant is
running.
In case of discharge to the atmosphere keep
out of discharge duct.
The lifting lever must be used for authorised
tests or trials only.
TEMPERATURE
In case that hot fluids flow through the valve,
the operator must pay attention to not
insulated parts.
LIFTING AND HANDLING
When lifting use eyebolts, if any, otherwise
sling the valve body.
 LIMITATION OF USE
Residual hazards with regard to essential safety requirements of Annex I of European Pressure Equipment Directive no. 97/23/EC

If not otherwise specified, the following use limitations have to be 7 – EXTERNAL FIRE
considered for PARCOL safety valves. PARCOL safety valves are not designed to withstand external fire.
0 – MAXIMUM WORKING PRESSURE AND TEMPERATURE 8 – CYCLIC LOADS OF PRESSURE AND TEMPERATURE
Before placing the valve in pipe line make sure that maximum working For most of installations possible cyclic changes of pressure and/or
pressure and temperature are within the limits of body rating and lower temperature do not influence the expected lifetime of valves. The above
than allowable maximum values indicated on valve serial plate. assuming the following working conditions:
- maximum working temperature not exceeding 550 °C;
1 – MINIMUM WORKING TEMPERATURE - fluid temperature change rate 2 K/min or less;
Valves having Carbon Steel body material (SA-105 or SA216 WCB) are - cyclic change of working pressure within 1/3 of maximum allowable
suitable for a minimum working temperature down to –20°C when rating pressure at corresponding temperature.
working pressure is at its maximum rating listed value. If working When working conditions are outside the above specified ones a
temperature is down to –29°C, the maximum pressure must be reduced particular check is necessary to calculate the expected lifetime of the
to 1/3 of its maximum rating listed value. Valves having Cr. Mo. alloy valve.
steel body material (SA217 WC6, SA217 WC9, SA217 C12A, SA182
F11, SA182 F22, SA 182 F91, etc.), particularly suitable for high 9 – BACKPRESSURE
temperature services, the minimum working temperature at maximum - Unbalanced versions can be used only for constant backpressure
rating listed pressure shall be +20°C. It is possible to reach a minimum applications. In this case the set pressure adjustment is performed
working temperature of –29°C but maximum working pressure must be taking into account the effect of backpressure.
reduced to 1/3 of its maximum rating listed value at ambient temperature. - For variable back-pressure applications, bellows balanced safety
RATING Rating pressure (1) Pressure at valves with vented bonnet must be used.
ANSI bar T ≤ 20°C (1) (2) - bar Parcol guarantees the correct operation of bellows balanced safety
150 20 7 valves up to the backpressure values listed in the technical bulletins.
300 51.7 17 - When high length discharge piping are connected to the valve
outlet, the self-generated back-pressure must be evaluated. The
600 103.4 34
back-pressure value must not exceed 10% of the set pressure for
900 155.1 52
safety valves without balancing bellows (absolute pressures for
1500 258.6 86 compressible fluids and gauge pressures for uncompressible fluids).
2500 431 144
4500 775.7 259 10 – BLOW-DOWN RING SETTING
(1)
Referring to SA217 WC6/WC9 or SA182 F11/F22
(2) Parcol safety valves are equipped with a blow-down ring screwed on the
Also during hydrostatic pressure test at T ≤ 20°C
nozzle for blow-down adjustment.
The blow-down ring adjustment is described on this manual and must be
2 – EXPECTED WORKING LIFE IN CREEP RANGE
performed by skilled personnel only when strictly necessary.
No special limitations are required in the expected service life of safety
valve, other than those foreseen afterwards. 11 – BELLOWS
When safety valves are used at a working temperature within the creep
Bellows is warranted for high number of valve opening, however it may
range (as listed on the following table), the guaranteed expected lifetime
be accidentally damaged: in this case the balancing function should be
is in any case not lower than 100.000 hours of continuous operation at
compromised.
rating listed pressure corresponding to working temperature.
For most severe applications it is suggested to periodically check the
Tbeginning bellows integrity by flushing the downstream body and checking any
Material
creep leakage through the vent hole on the bonnet. Be careful to maintain the
Carbon steels (i.e.: A216 WCB-A105) 343°C vent connection on the valve bonnet free to the atmosphere in order to
CrMo steels (i.e.: A217 WC9-A182 F22) 455°C allow the proper balancing function of the bellows.
300 series cast austenitic steels 510°C
9% Cr Mo V steels (i.e.: A217 C12A-A182 F91) 538°C 12 – SET PRESSURE
300 series forged austenitic steels 538°C Safety valve is supplied after set at the pressure value reported on test
valve certificate.
3 – SEISMIC STRESSES Reliability of safety valve set pressure shall always be verified before
PARCOL safety valves have been experimentally tested for seismic installation if not otherwise specified.
applications on vibrating table by applying both axial and transversal After installation the reliability of safety valve set pressure shall be
acceleration up to 5g. verified periodically following the prescriptions by laws in force in the
Nor damage on pressure containing parts neither performance limitation country where safety valve is installed. If no prescriptions are available,
have been observed after such a test. reliability of safety valve set pressure shall be verified at least every three
years in presence of an Authorized Inspector or return the safety valve to
4 – PIPING STRESSES manufacturer for overhaul.

In general it is not necessary to perform any check and calculation if pipe
size is no larger than 1,5 times valve body size (2 times for valve body
size up to 3”).
As the safety valve has not to be used as a fixed point, if inlet and outlet
pipe sizes are different, it should be considered the smaller one as it is
essential for the piping design.
13 – GUARANTEE
If safety valve is supplied with plumbing device, manufacturer guarantee
on valve set pressure decays when plumbing device is removed.
The User shall then verify safety valve set pressure in presence of a
Notified Body Inspector or return the safety valve to manufacturer for
overhaul.

5 – SELF GENERATED FORCES DURING FLUID DISCHARGING

During operation, due to the high velocity of the discharged fluid, safety
valves can generate not negligible reaction forces.
The values of these forces are reported on calculation sheet and must
be taken into account for holding point and connected piping design.

6 – CORROSION
In case of local corrosion, particularly with chlorides, such as pitting,
interstitial corrosion on gasket seating surfaces and stress corrosion, it
is not possible to make any realistic prediction of expected lifetime of
valve. In these circumstances it is essential to properly select the
material of disk and valve nozzle. NTG 76/553E05
INSTRUCTION MANUAL
3 – 5400 SERIES SAFETY RELIEF VALVES
1. GENERAL
This manual holds all the information necessary to
maintain your PARCOL safety valves in perfect
operating conditions.
Normally valve maintaining is necessary when they
are not properly installed, when scales or other type
of slags are in the pipeline, when they are intended
for a different service or when improper testing
procedures were followed.
2. HANDLING AND STORING
Inside components of safety relief valves are
carefully machined and assembled in order to get a
perfect alignment.
Improper handling of valves may damage seat
surfaces or cause misalignment of inside
components, likely to incur leakage and faulty
operation. Safety relief valves must therefore be
handled with care.
Valves are shipped with suitable protective caps at
inlet and outlet, to prevent damages at the flange
sealing surfaces or to avoid that foreign particles
enter the valve body.
If valves are expected to remain long time stored
before the installation, as in case of new
installations, the protective caps should not be
removed before mounting the valve. Moreover the
storage site should be clean, dry and veered.
Should the above be impossible, valves should at
least be covered with suitable and waterproof
material.
3. INSTALLATION
A correct installation is the keystone of successful
valve operation.
Pipes, connecting flanges and valve supporting
racks must be carefully cleaned. Prevent foreign
particles, such as gasket trashes, slag, dirt, sand,
etc., from accumulating between nozzle and disk
during the installation.
Pipelines should be blown if possible, to clean the
piping upstream the valve.
All of the bolts must be evenly tightened.
To prevent deformations of valve body the
discharge piping must be properly held.
The safety relief valve should be installed in vertical
position.
The inlet piping from the vessel or the protected
equipment should preferably be short and straight.
The connection with the vessel should be filleted, to
allow a free fluid flow to the valve; furthermore
4
sharp bends should be avoided for a length equal
to the pipe diameter.
The pressure drop between vessel and valve
should not exceed 3% of the set pressure when the
flow rate through the valve is maximum.
Beyond this limit chattering of the plug may occur.
Inlet piping connection must never have lower
dimension than the valve inlet one.
Trim alignment of a safety relief valve is very
important for correct valve operation.
Though the valve body can tolerate considerable
mechanical overloads, nevertheless the piping
downstream the valve should be designed in such
a way that it does not overstress the valve itself.
Sliding pipe supports should be provided and
excessive straight pipe lengths directly connected
to the valve outlet should be avoided.
For gas and vapour service the downstream piping
should be upwards oriented and provided with
suitable drainages, while for liquid service it should
be downwards oriented, not to flood the valve body.
Install where possible piped drainages to prevent
water or corrosive liquid collection in the valve
body.
Drainage piping should be carefully maintained
either.
When two or more safety relief valves are piped to
discharge into the same header the downstream
pressure generated by opening of one valve may
cause the set pressure of the other valves to
increase by the same amount.
In these cases valves provided with balancing
bellows should be utilized, which, by the way, allow
to use a lower diameter manifold.
Additional recommendations may be found in API
RP 520 - "Design and installation of Pressure
Relieving Systems in Refineries".
In case of reservoir holding saturated vapours, the
safety relief valve must be installed by the vapour
side, as far as possible from the liquid surface.
In any case do not install the valve in a position
where build-ups may accumulate.
Furthermore bear in mind that a free and
accessible area should be provided around the
valve for inspection and maintenance purposes.
Vibrations of the protected piping or vessel may
affect life and tightness of the valve.
Excessive fluid turbulences and pressure
pulsations upstream the valve may cause plug
 chattering on the seat during the valve operation, advisable to increase the difference between
thus reducing valve tightness and life. normal operation pressure and set pressure by
Where equipment vibrations and upstream more than the normally recommended 10%.
pressure pulsations cannot be avoided it is

3-5411, 3-5431 and 3-5432 SERIES 3-5461, 3-5481 and 3-5482 SERIES
CONVENTIONAL DESIGN BALANCED BELLOWS DESIGN

AUXILIARY PISTON

NOZZLE FLUSHING
DEVICE

BELLOWS PROTECTION
DEVICE
VENT

Item Part name Item Part name Item Part name

1 Body 12 Lock-nut 30 Nut
2 Tight bonnet 13 Pivoting bush 31 Cap plug
2 Vented bonnet (not shown) 14 Retaining ring 41 Guide gasket
3 Plain cap 15 Lower spring washer 42 Cap gasket
4 Nozzle 16 Upper spring washer 43 Plug gasket
5 Disk 23 Body studs 44 Cap plug gasket
6 Nozzle ring 24 Body nuts 45 Name plate (not shown)
7 Spindle (sub-assembly) 25 Plug-nut 46 Name plate rivet (not shown)
8 Guide 26 Nut 48 Auxiliary piston
9 Disk holder 27 Adjusting ring set screw 75 Bellows
10 Spring 28 Body drain plug 76 Bellows gasket
11 Spring adjusting screw 29 Bonnet stud bolt

5
 UPPER SPRING SEAT WITH THRUST BEARING SOFT SEAL

Item Part name Item Part name

81 Guide ring 5a Disk
82 Thrust bearing 5b Ring locking disk
83 Upper spring seat 5c Sealing ring
5d Screw

SPINDLE LIFTING LEVER TEST GAG

Item Part name Item Part name Item Part name

17 Spindle 51 Cap for lifting lever 65 Test gag
18 Stem 53 Stop disk 66 Nut
19 Ball 54 Screw 67 Screw rivet
55 Fork 68 Plug rivet
56 Driving shaft 69 Plug
57 O-Ring seal 70 Chain
58 Bottom ring
59 Lever
60 Nut
61 Adjusting ring nut

6
4. SETTING AND PERFORMANCES
All of the valves made and shipped by PARCOL
are supplied with a spring suitable for the operation
conditions as specified in the order.
Using a correctly selected spring is utmost
important.
Any attempt to use a spring below its rated
pressure range at the same temperature will result
in a lower lift (and consequently in a lower
discharge capacity) and generally in a slower valve
action.
Similarly using a spring over its setting range will
cause a blow down increase, i.e. heavier resetting
problems, beside a danger of spring failure.
It is however possible to adjust the spring 10%
above or below the nominal value for set pressures
lower than 17 bar and within ± 5% for higher set
pressures.
Before decreasing the set pressure of any valve
ascertain that the new set pressure complies with
the nominal valve rating; on the contrary, before
reducing the set pressure, check that the valve
capacity at the reduced pressure is suitable for the
protection of the plant.
Valves installed on steam, gas or vapour services
will relieve with a fast plug lift ("pop-action"). In
case that the upstream pressure raises up to 10%
above the set pressure the valve will attain the full
opening. The valve will reseat only when the
pressure, during the discharge, will fall 5 ÷ 7%
under the set pressure. For valves operating on
liquid service there will be no "pop-action"; their
opening will gradually increase with the pressure
rise without any popping.
If the upstream pressure will rise up to 25% above
the set pressure the valve will attain its full opening.
The valve will reseat only when the pressure will fall
5 to 7% under the set pressure.
4.1 LOCKING DEVICE (TEST GAG)
When carrying out the pressure test of the plant the
valve must remain closed. For this purpose remove
the plug (69) and the gasket (44), tighten the
locking screw (65) until it gets in contact with the
stem (7); then tighten the test gag nut (66), thus
preventing the valve to open.
After the pressure test remove the screw (65) and
replace it with the plug (69) and the gasket (44) to
restore the normal valve operation.
5. TRIM MAINTENANCE
5.1 DISASSEMBLY
Unscrew the nuts (30), remove the cap (3) and its
gasket (42).
In case of threaded caps: turn the cap anti-
clockwise.
To demount the manual control cap (51) place the
lifting lever (59) in its lowest position, then unscrew
7
the nuts (30) and slip the cap from the bottom to
the top, inclining it frontward.
Remove the screw (54) from the locking disk (53)
and unscrew the disk form the stem (7) (measure
before the distance between disk and stem end, so
that it can be later resettled in the same position).
Before removing the spring adjusting screw (11)
take note of the protrusion of the stem from the
screw itself. This will later enable to remount the
screw approximately in the same position.
Remove the ring nut (12) and release the spring
compression by turning the spring adjusting screw
anti-clockwise.
Unscrew the nuts (24) and demount the bonnet
through the stem. Do not go through this step
without ensuring before that the spring is
completely released.
Remove the spring (10) and the spring seat (15)
and (16), or (15) and (83), in case the upper spring
seat is provided with the thrust bearing (82) and the
guide ring (81).
Then raise up and remove the stem (7) together
with the spindle and the piston (48), when supplied,
from the valve body (1).
To draw out the guide (8) lever in some points into
the slot located outside the disk, remove the
gaskets (41) and the disk (5) assembled with the
disk holder (9) (do not loose the pivoting bush
(13)).
To draw out the disk from the disk holder insert two
screw- drivers into the disk holder holes and act
onto the disk to release the stop ring (14).
If the sealing ring (5c) is mounted on the disk,
unscrew the screws (5d), remove the ring locking
disk (5b), then remove the sealing ring.
Unscrew the blow-down adjusting ring (6) after
having released it from the locking screw (27) by
unscrewing the plug (25).
To remove the nozzle (4) from the valve body (1)
firmly clamp the body, then turn the nozzle anti-
clockwise using a suitable wrench or levering with a
pin into the suitable holes, according to the type of
nozzle.
5.2 SEAT LAPPING
When seating surfaces are slightly scratched,
lapping can completely recondition them.
The disk is provided with two perfectly machined
seating surfaces, so that it can be utilized twice
before proceeding to lap it. In case of disks with
 deposit of stellite or soft seat the seating surface is
by one side only.
If lapping is required use a cast iron lapping plate,
or a clean and flat ring lap.
Spread a thin layer of emery paste on the lapping
plate or ring; hold down the component to be
lapped and drive it with a figure-eight (8) motion.
When using a ring lap the motion should be
oscillatory.
When lapping apply a light and uniform pressure
avoiding any shock.
It is recommended to remove the nozzle from the
valve to perform a good lapping.
In case this is not possible or the seating surfaces
are just slightly scratched a ring lap can be used.
In this case the ring must be lapped against the
nozzle.
Any excess of emery paste could cause the
rounding of seat edges.
In case the seating surfaces are seriously
scratched they should be machined before lapping.
Lapping pastes vary from coarse to very fine grain.
A coarse grain paste is generally used first, then a
very fine to finish the piece. Clean thoroughly the
plate when changing any paste.
Coarse grain pastes must be used only when
removing very deep scratches. Different plates
should be available for different pastes.
Important points for good results are:
A - Cleanliness of lapping plates, of the work piece
and of lapping paste
B - Flat base surface
C - Suitable lapping base
D - Correct and light lapping movement (without
rocking)
E - Changing of lapping compounds
5.3 NOZZLE MACHINING
When scratches are so deep that lapping is not
sufficient to completely remove them the work
piece must be remachined on a lathe.
Fasten first the nozzle flange on the lathe,
preferably clamping it with the self-centering three
jaw chuck.
Center the nozzle and ensure by means of a dial
gauge that the inside surface of the nozzle is
concentric with the outside surface of the flange
within a range of 5/100 mm.
Machine the seat surface until the damaged areas
are removed; surface finishing should be as
smooth as possible.
8
Lap the surface until the active width attains again
the original value.
Nozzles should be normally discarded when
already machined three times.
5.4 DISK MACHINING
Fasten first the disk on the lathe chuck. Avoid
excessive chucking.
Center the nozzle and ensure by means of a dial
gauge that the outside surface of the disk is
concentric with the seating surface within a range
of 5/100 mm.
Machine the seating surface until the damaged
areas are removed; surface finishing should be as
smooth as possible.
Lap the raised seating surface across the full width.
Disks should be normally discarded when already
machined three times.
5.5 VALVE REASSEMBLY
Please, remember that gaskets and sealing
rings shall be replaced.
Always use Parcol original spare parts.
The valve assembling procedure is exactly the
reverse of the disassembling one.
When assembling the valve the spring adjustor
should be completely loose, not to compress the
spring when tightening the bonnet nuts.
The measure taken when disassembling the valve
should be borne in mind when setting the spring
adjustor in the same position as it was before
disassembling.
Aligning the valve trim is critical for successful
operation; it is therefore necessary to handle them
and reassemble the valve with utmost care.
The blow-down adjusting ring should be remounted
in the same position as it was before disassembling
(rotate by the same number of notches starting with
the ring in contact with the disk).
To mount the disk inside the disk holder lay the
holder with the disk opening oriented upwards; then
insert the disk in the opening, complete with its
retaining ring, then press it until the ring gets into its
slot thus connecting the disk with the holder.
In case of soft seat, replace the sealing ring (5c)
every time the nozzle and the disk are lapped.
Before reassembly, lubricate the surfaces in
contact among spindle (7), pivoting bush (13),
lower (15) and upper spring washer (16), piston
(48) when supplied, other than the seats of gaskets
(41) and (42).

6. BELLOWS ASSEMBLY PROCEDURE
6.1 DISASSEMBLY
The bellows (75) can be drawn out from the body
together with the disk holder (9) and the disk (5)
after having taken out the guide (8) and the gasket
(41).
The group bellows/disk holder/disk can be drawn
7.2 LIQUID SERVICE
out manually for small valves. When the weight of
the group is high use two threaded bars; insert
them into the suitable holes located in the disk
holder inside the bellows.
6.2 / 6.3 / 6.4 Same procedure as for points 5.2, 5.3,
5.4.
6.5 BELLOWS REPLACEMENT
7.3 HOT SETTING
To replace the bellows it is necessary to lock the
disk holder (9) in a vice (use soft jaws not to
damage it), then insert a pin wrench or a rod into
the suitable holes in the threaded ring of the
bellows and turn clockwise the bellows to unscrew
it from the disk holder.
Replace the bellows with a PARCOL original spare
and check the gasket (76) for efficiency before
screwing the bellows onto the disk holder. Replace
the gasket if necessary.
Screw the bellows terminal against the disk holder
to well press the gasket in between.
6.6 REASSEMBLY
See point 5.5.
Be careful not to damage the bellows when
handling the disk holder with the opening upwards
to insert the disk.
7. VALVE TESTING AND SETTING
7.1 GAS AND VAPOUR SERVICE
The setting test may be done on the bench using a
vessel pressurized with air or nitrogen.
The volume of the reservoir volume must be
chosen as a function of the valve discharging
capacity, as well as of the testing procedure. The
connection between reservoir and valve should
possibly be done through a fitting; eventual
connecting piping should have inside diameter
equal to 1/5 of the nozzle diameter and in any case
not less than 8 mm.
The test can be carried out in two different ways:
1) increase the upstream pressure until a
continuous fluid discharge takes place,
perceptible by a whistle or a sudden noise;
2) increase the upstream pressure until the plug
"pops".
This may be done by screwing the adjusting
ring close to the plug (just two or three notches
less.
9
If the test is correctly carried out the results of the
two systems are practically identical. Differences up
to 1 ÷ 2% may arise in case of defective tightness
between nozzle and plug.
The procedure (2) requires a higher capacity vessel
and more care in performing the connection with
the valve.
The test may be carried out with pressurized cold
water.
Normally a reservoir is not necessary, but an
air/water damping reservoir may be necessary in
case a reciprocating pump is used.
The setting point is reached when a liquid streamlet
takes place.
A temperature increase causes a reduction of the
set pressure of a safety valve or a safety relief
valve. It is therefore necessary to compensate for
this effect by increasing the set pressure when the
valve is tested on the test stand at ambient
temperature and is intended for high temperature
fluid service.
On the contrary no pressure reduction is
recommended when setting valves intended for
under zero service.
Neglecting the low temperature effect is justified by
the fact that by this way operation problems are
avoided, since the error increases the set pressure.
The correction factors listed in this table should be
used in cold setting valves intended for fluids over
100°C temperature.
Operation temperature Set pressure increase %
up to 100° C None
from 101° C to 250 ° C 2%
from 251° C to 500° C 3%
over than 500° C 5%
The above correction factors must be used also for
valves already compensated for downstream
backpressure.
The exact definition is therefore "cold set pressure
differential", i.e. the valve inlet pressure which
causes the valve to open on the bench at ambient
temperature and with atmospheric backpressure.
The calculation for the exact spring setting must
therefore take into account, if applicable, the
compensation for service temperature over 100°C
and for backpressure different from the
atmospheric one.
Examples for calculation of "differential
pressure for cold setting" with compensation
for back pressure and temperature.
 A) DATA: Standard valve without compensating
bellows, 20 bar nominal set pressure, 260°C
service temperature, 1 bar constant back
pressure, steam service.
- setting pressure in service: 20 bar - 1 bar
= 19 bar
- correction coefficient for temperature between
251°C and 500°C (see table): 3%
- 3% of 19 bar = 0.57 bar (rounded to 0.6 bar)
- cold set pressure: 19 bar + 0.6 bar = 19.6 bar.
B) DATA: Valve with compensating bellows, 50 bar
nominal set pressure, 180°C service
temperature, 1.5 bar constant back pressure,
steam service.
- setting pressure in service: 50 bar (the setting
pressure is not affected by the back pressure,
due to the presence of the compensating
bellows)
- correction coefficient for temperature between
101°C and 250°C (see table): 2%
- 2% of 50 bar = 1 bar
- cold set pressure: 50 bar + 1 bar = 51 bar.
C) Notice that in any case (see examples A and B)
the valve inlet temperature is taken into
consideration and the correction factor is
multiplied for the set pressure.
The procedure is always the same and is
applicable to any valve type.
A different calculation of the set pressure is:
Cold set pressure = spring set pressure x (1 + correction factor)
7.4 NOZZLE RING SETTING
Loosen the lock screw (27) of the nozzle ring (6)
and turn the ring anti-clockwise until it gets in
contact with the disk holder (9). This may be done
either through the valve outlet, or through the hole
for the lock screw using a screwdriver.
When the ring is settled reset the lock screw and
fasten the plug (25).
For the number of notches refer to Appendix 1 and
Appendix 2.
Ensure that the screw is inserted in the notch.
When the screw is tightened the ring should be
slightly lose, but not free to turn.
NEVER MOVE UPWARDS THE NOZZLE RING
WHEN THE VALVE IS UNDER PRESSURE: THE
VALVE COULD SUDDENLY OPEN AND DAMAGE
SOMEBODY.
7.5 SET PRESSURE ADJUSTMENT
If the valve opens at a pressure lower or higher
than the set pressure adjust the spring
compression as follows:
10
- remove the top cap (3) (or the lifting gear
assembly), thus making the spring adjusting
screw (11) accessible.
Loosen the counter nut (12), then rotate the
spring adjustor clockwise if a set pressure
increase is required, or anti-clockwise for a
reduction.
- When the required value is reached tighten the
lock nut and remount the cap (or the assembly
cap + lifting lever).
- Test once again the valve opening after having
tightened the lock nut.
NEVER ADJUST THE SPRING COMPRESSION WHEN
THE FLUID PRESSURE IN THE VALVE IS CLOSE TO
THE SET VALUE, AS THE SEATING SURFACES OF
NOZZLE AND DISK COULD GET DAMAGED. THE
FLUID PRESSURE IN THE VALVE SHOULD BE AT
LEAST 25% LESS THAN THE SET PRESSURE. BY
THIS WAY THE LOAD ON THE SEATING SURFACES
WILL PREVENT THE DISK TO ROTATE AND THE
SURFACES TO GET DAMAGED.
8. TIGHTNESS TEST
The test is carried out after that the spring setting is
made by using the same pressurized fluid.
Lower the pressure upstream the valve to 90% of
the set pressure.
The recommended method according to API
standard for valves operating on vapour and gas
service is shown in Fig. 1.
The valve outlet is blanked off with a flange
connected with a 6 x 8 mm diam. tube 90°C bent
and dipping in a water reservoir.
The tube end must be 12,7 mm under the water
surface.
When the air pressure in the valve is 90% of the set
value the number of bubbles per minute (if any)
should not exceed the value stated by API
standards (see Fig. 2).
8.1 EXCESSIVE LEAKAGE
If the procedure has been carefully followed and
the leakage exceeds the limits it is necessary to
disassembly the valve to ascertain that no foreign
material is within the seating surfaces, or these are
not damaged by foreign particles in the testing fluid.
After that the valve has been checked it is
recommended to transport it in vertical position.
If the leakage is due to dirty build-ups on the
seating surfaces cleaning and polishing are
sufficient to restore the initial conditions by using
not abrasive media soaked in solvents.
If the seating surfaces are scored they must be
lapped or re- machined and lapped, according to
the scratch depth.

9. PRESSURE GAUGES
Pressures are measured by means of marked and
certified manometers, which are periodically set by
the Quality Assurance Service (SGQ) and meet the
requirements of ANSI B 40.1 - Grade A standard.
11
Pressure gauges are selected with such a full scale
that the test pressure is ranging between 25 and
75% of it.
By this way the measuring error can be considered
as not higher than 1% of the full scale.
 FIGURE 1

max bubbles per minute

140

120
Φ orifice <= C
100

80

60
Φ orifice >= D
40

20

psi 0 1000 2000 3000 4000 5000 6000

bar 0 50 100 150 200 250 320 420

FIGURE 2

12
TROUBLE CHECK-LIST

FAULT CAUSE REMEDY

1) Presence of foreign particles between 1) Operate the valve once or twice
seat and plug. subsequently. If leakage does not stop
disassemble the valve and clean the
trim.
2) Seating surface galled or scratched. 2) Disassemble the valve and lap the seat.
3) The valve is used with a fluid different 3) Lap seat and disk with smoother finishing
from the one which it was intended for. (if the valve, originally intended for liquid,
Leakage
is used for gas).
4) Valve not mounted in vertical position. 4) Change the installation.
5) Set pressure too close to the operation 5) Improve where possible the quality of the
pressure (when the operation pressure is seating surfaces (e.g. with hard facing)
over 90% of the set pressure the results to reduce the maintenance needs.
of the tightness test under point 6.3 may
be not valid.

FAULT CAUSE REMEDY

1) Variable backpressure. 1) For standard valves ensure that the
discharge piping diameter is equal or
higher than the valve outlet diameter and
that the discharge piping is not cloggy.
2) The backpressure is different from the 2) The valve must be reset for the new
Discharge at a pressure
one specified in the order. backpressure.
different from the set
3) The ring nut of the spring adjustor is 3) Reset the valve and tighten the counter
pressure
loose. nut.
4) Poor trim alignment. 4) Operate twice or trice the valve in order to
allow self-alignment of the trim.
5) Too much turbulence at valve inlet 5) Modify the valve arrangement.
(reduction of the set pressure).

FAULT CAUSE REMEDY

1) Blow-down ring not correctly positioned.
1) Ensure that in case of liquid service the
ring is in the lowest position. For gas
service adjust it correctly.
Chattering
2) Insufficient discharge capacity. 2) Ensure that the discharge piping is not
(repeated fast opening
cloggy or too long.
and re-closing of the
3) The valve is oversized. 3) Replace the valve with a smaller one.
valve)
4) Too high head losses in the upstream 4) Increase the blow-down by setting the
piping. blow-down ring closer to the plug.
5) The opening backpressure is too low. 5) Remove the adjusting ring from the plug.

13
 APPENDIX 1
VALVES FOR GAS AND VAPOURS SERVICE
BLOW DOWN RING SETTING, EXPRESSED IN NUMBER OF NOTCHES FROM CONTACT AGAINST DISK HOLDER

3-5411 / 3-5461 SERIES VALVES

Set pressure (barg)
Orifice ≥ 0.5 ≥ 2.5 ≥6 ≥ 10 ≥ 16 ≥ 25 ≥ 40 ≥ 64 ≥ 100 ≥ 160 ≥ 250
÷ 2.5 ÷6 ÷ 10 ÷ 16 ÷ 25 ÷ 40 ÷ 64 ÷ 100 ÷ 160 ÷ 250 ÷ 400
D 2 4 8 10 12 14 16 18 20 22 24
E 2 4 8 10 12 14 16 18 18 18 18
F 2 4 8 10 12 14 16 18 18 18 18
G 2 4 8 10 12 14 16 18 18 18 18
H 2 6 10 14 16 18 18 18 18 18
J 2 6 10 14 16 18 20 22 24 26
K 2 6 10 14 16 18 20 22 24 26
L 3 7 11 15 19 22 24 24 26 26
M 3 8 12 16 20 22 24 26 30
N 3 8 13 17 20 22 25 28 30
P 4 9 14 19 24 28 32 34 36
Q 5 10 15 20 25 28 32 36
R 5 11 16 22 28 32 36
T 6 12 18 24 30

3-5432 SERIES VALVES

Set pressure (barg)
Orifice ≥ 0.5 ≥ 2.5 ≥6 ≥ 10 ≥ 16 ≥ 25 ≥ 40 ≥ 64 ≥ 100 ≥ 160 ≥ 250
÷ 2.5 ÷6 ÷ 10 ÷ 16 ÷ 25 ÷ 40 ÷ 64 ÷ 100 ÷ 160 ÷ 250 ÷ 400
D 29 30 32 34 35 37 38 40 42 43 45
E 22 23 24 25 27 28 29 30 31 33 34
F 22 23 25 26 27 28 29 31 32 33 34
G 24 25 25 27 28 29 30 31 33 34 35
H 26 27 27 28 29 30 31 33 34 35
J 31 32 31 33 34 35 37 38 39 41
K 33 34 33 34 35 37 38 39 41 42
L 41 43 41 43 44 46 48 49 51 52
M 42 44 42 44 45 47 48 50 52
N 32 33 32 33 34 36 37 38 39
P 41 43 41 42 44 45 47 48 50
Q 42 44 42 43 45 46 48 49
R 51 53 51 53 54 56 58
T 38 39 38 39 41

3-5482 SERIES VALVES

Set pressure (barg)
Orifice ≥ 0.5 ≥ 2.5 ≥6 ≥ 10 ≥ 16 ≥ 25 ≥ 40 ≥ 64 ≥ 100 ≥ 160 ≥ 250
÷ 2.5 ÷6 ÷ 10 ÷ 16 ÷ 25 ÷ 40 ÷ 64 ÷ 100 ÷ 160 ÷ 250 ÷ 400
D 16 16 19 21 22 24 26 27 29 30 32
E 11 12 14 15 16 18 19 20 21 22 24
F 10 10 13 14 15 16 18 19 20 21 22
G 8 9 11 12 13 15 16 17 18 19 21
H 6 7 9 10 11 13 14 15 16 17
J 5 5 8 9 11 12 13 15 16 17
K 4 4 7 8 9 11 12 13 15 16
L 3 3 6 8 10 11 13 14 16 18
M 2 3 6 7 9 11 12 14 15
N 2 2 4 5 6 8 9 10 11
P 2 2 4 6 7 9 10 12 13
Q 2 2 4 5 7 8 10 11
R 2 2 4 6 8 10 11
T 2 2 3 4 6

14
 APPENDIX 2
VALVES FOR LIQUID SERVICE
BLOW DOWN RING SETTING, EXPRESSED IN NUMBER OF NOTCHES FROM CONTACT AGAINST DISK HOLDER

3-5411 / 3-5461 SERIES VALVES

THE BLOW DOWN RING MUST BE SET IN FULLY DOWN POSITION

3-5431 / 3-5481 SERIES VALVES

Set pressure (barg)
Orifice ≥ 0.5 ≥ 2.5 ≥6 ≥ 10 ≥ 16 ≥ 25 ≥ 40 ≥ 64 ≥ 100 ≥ 160 ≥ 250
÷ 2.5 ÷6 ÷ 10 ÷ 16 ÷ 25 ÷ 40 ÷ 64 ÷ 100 ÷ 160 ÷ 250 ÷ 400
D 2 4 8 10 12 14 16 18 20 22 24
E 2 4 8 10 12 14 16 18 18 18 18
F 2 4 8 10 12 14 16 18 18 18 18
G 2 4 8 10 12 14 16 18 18 18 18
H 2 6 10 14 16 18 18 18 18 18
J 2 6 10 14 16 18 20 22 24 26
K 2 6 10 14 16 18 20 22 24 26
L 3 7 11 15 19 22 24 24 26 26
M 3 8 12 16 20 22 24 26 30
N 3 8 13 17 20 22 25 28 30
P 4 9 14 19 24 28 32 34 36
Q 5 10 15 20 25 28 32 36
R 5 11 16 22 28 32 36
T 6 12 18 24 30

3-5432 SERIES VALVES (1)

Set pressure (barg)
Orifice ≥ 0.5 ≥ 2.5 ≥6 ≥ 10 ≥ 16 ≥ 25 ≥ 40 ≥ 64 ≥ 100 ≥ 160 ≥ 250
÷ 2.5 ÷6 ÷ 10 ÷ 16 ÷ 25 ÷ 40 ÷ 64 ÷ 100 ÷ 160 ÷ 250 ÷ 400
D 2 2 2 3 4 6 8 10 12 14 16
E 2 2 2 2 3 5 6 8 9 10 12
F 2 2 2 3 3 5 6 8 9 11 12
G 2 2 2 5 5 7 8 10 11 12 14
H 3 4 5 7 8 10 11 13 14 15
J 5 8 10 12 13 15 16 18 20 21
K 6 10 13 15 16 18 19 21 23 24
L 10 15 19 22 23 26 27 30 31 33
M 10 16 21 24 25 27 29 31 33
N 8 13 16 19 19 21 22 24 25
P 11 17 22 25 26 28 30 32 34
Q 12 19 24 27 28 30 32 34
R 15 23 30 34 35 37 39
T 11 18 23 26 26

(1) The blow down ring settings are also valid for alternating service on compressible and incompressible fluids and for
service on bi-phase mixtures (mixtures with max 5% in mass of gas).

15
 3-5482 SERIES VALVES (1)
Set pressure (barg)
Orifice ≥ 0.5 ≥ 2.5 ≥6 ≥ 10 ≥ 16 ≥ 25 ≥ 40 ≥ 64 ≥ 100 ≥ 160 ≥ 250
÷ 2.5 ÷6 ÷ 10 ÷ 16 ÷ 25 ÷ 40 ÷ 64 ÷ 100 ÷ 160 ÷ 250 ÷ 400
D 2 2 2 3 4 6 8 10 12 14 16
E 2 2 2 2 3 4 6 8 9 10 12
F 2 2 2 3 3 4 6 8 9 10 12
G 2 2 2 4 4 5 7 9 10 11 13
H 2 3 3 5 6 7 9 10 12 13
J 4 5 5 8 8 10 12 14 15 16
K 6 7 7 9 10 11 13 15 17 18
L 9 10 10 13 14 15 18 20 22 23
M 9 11 11 14 15 16 19 21 23
N 7 8 8 11 11 13 14 16 17
P 10 11 11 14 15 17 19 21 23
Q 11 12 12 15 16 17 20 22
R 13 15 15 19 20 21 24
T 10 11 11 14 15

(1) The blow down ring settings are also valid for alternating service on compressible and incompressible fluids and for
service on bi-phase mixtures (mixtures with max 5% in mass of gas).