Emerson JOS-E, JBS-E, JLT-JBS-E, JLT-JOS-E Installation Manual

CROSBY STYLE JOS-E, JBS-E, JLT*-JBS-E, JLT*-JOS-E VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Before installation, these instructions must be read carefully and understood�

ATTENTION

The safety of lives and property often depends on the proper operation of the pressure relief valves. Consequently, the valves should be kept clean and should be tested and reconditioned periodically to make sure they function properly.

WARNING

Suitability of the material and product for the use contemplated by the buyer is the sole responsibility of the buyer. Also storage, installation and proper use and application are the sole responsibility of the purchaser. Emersondisclaims any and all liability arising out of the same. Any installation, maintenance, adjustment, repair and testing performed on pressure relief valves should be done in accordance with the requirements of all applicable codes and standards under which those performing such work should maintain proper authorization through appropriate governing authorities. No repair, assembly and test work done by

TABLE OF CONTENTS

1 Introduction �� 4 2 Storage and handling �� 4 3 Installation �� 4 4 Hydrostatic pressure tests �� 5 5 Setting, testing and adjustments �� 6 6 Valve maintenance �� 10 7 Style variations �� 21 8 Service records �� 21 9 Spare parts �� 21 10 Trouble shooting pressure relief valves �� 21 11 Emerson field servicesand

repair programs �� 22

other than Emerson shall be covered by the warranty extended by Emerson to its customers. You assume full responsibility for your work. In maintaining and repairing Crosby products you should use only parts manufactured by Emerson. Call your nearest Emerson regional sales office or representative for a service engineer should you wish assistance with your field needs.

Emerson.com

Engineering Doc� #IS-V3137B

CROSBY STYLE JOS-E, JBS-E, JLT*-JBS-E, JLT*-JOS-E VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

FIGURE 1

40 24 25

Set screw

NOTE

This vent must remain open on JBS-E and JLT-JBS-E

construction

18 19

16 17

24 25

18 19

16 17

3 4

1 2

Style JLT

D-N orifice construction

(P-T orifice have lockscrews)

Style JOS-E

Style JBS-E

PARTS LIST

No. Part name Notes

1 Body 2 Nozzle 3 Nozzle ring 3 4 Set screw 3, except P-T orifice JLT 4A Set screw 3, (M-T orifice) 4B Set screw rod 3, (M-T orifice) 4C Set screw pin 3, (M-T orifice) 5 Disc holder 2 6A Bellows tailpiece 2 6B Bellows 2 6C Bellows flange 2 8 Disc insert 1 9 Retention clip 1 10 O-ring 1 11 O-ring retainer 2 12 Retainer screw(s) 2 13 Nozzle ring lockscrew P-T orifice JLT 14 Set screw plug P-T orifice JLT (not shown) 15 Guide 3

NOTES

1� Consumable spare parts: valve parts which should be replaced as part of any

disassembly, and discs and disc inserts which must be replaced if seats are damaged�

2� Repair spare parts: valve parts exposed to wear and/or corrosion during normal

operation� They are in fluid flow paths and may require replacement as part of any repair�

Soft seat

No. Part name Notes

16 Spindle 3 17 Spindle cotter pin 1 (L-T orifice) 18 Spring 3 19 Spring washers 3 20 Bonnet 21 Bonnet stud 22 Bonnet stud nut 24 Adjusting bolt 25 Adjusting bolt nut 26 Pipe plug 27 Set screw gasket 1 28 Guide gasket 2 29 Tailpiece gasket 1 34 Seal and wire 35 Seal clip (not shown) 36 Nameplate (not shown) 40 Screwed cap 41 Cap gasket 1

Gasket kit 1, 4

3� Insurance spare parts: valve parts exposed to process or environmental wear

and/or corrosion and may require replacement as part of a major repair� Emerson recommends that sufficient inventory of spare parts be maintained to support process requirements� Always be sure to use genuine Emerson parts to ensure continued product performance and warranty�

4� Contains complete set of gaskets for all style of valves�

CROSBY STYLE JOS-E, JBS-E, JLT*-JBS-E, JLT*-JOS-E VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

Sample nameplate after 2014

Restricted lift nameplate

FIGURE 2 - Sample nameplates

Ordering spare parts

When ordering spare parts, the valve size, style and assembly number and/or serial number should be given together with set pressure, part name and reference number from page2� The valve assembly number is shown on the valve nameplate as, 'Shop Number'� Spare parts may be ordered from any Emerson regional sales office or representative�

Safety precautions

Proper handling, storage, installation, maintenance and operation is essential to the safe and reliable functioning of any pressure relief product� Precautionary statements in the form of warnings, cautions and notes are used throughout this instruction to emphasize important and critical factors where applicable�

Examples:

WARNING

An operating procedure or practice which, if not observed strictly, may result in injury to personnel or loss of life.

CAUTION

An operating procedure or practice which, if not observed strictly, may result in damage to or destruction of equipment.

These precautionary statements are by no means exhaustive� Emerson cannot be expected to know, evaluate and advise customers of all the possible applications and operating conditions for its products or of the possible hazardous consequences which may result from the misapplication or misuse of such products�

Consequently, the improper handling, storage, installation, use or maintenance of any Emerson product by a non Emerson employee may void any Emerson guarantees or warranties with respect to such product�

All personnel working with Emerson products should be trained adequately and thoroughly familiar with the contents of the appropriate instruction manual(s)�

Emerson cannot evaluate all conditions in which the products may be used�

However, Emerson offers the following general safety suggestions:

• Never subject valves to sharp impact loads� Rough handling (striking, bumping, dropping, etc�) may alter the pressure setting, deform valve parts and affect seat tightness and valve performance adversely� Striking a valve which is under pressure can cause premature actuation�

• When moving a valve, never use the lifting lever to lift the valve�

• Always lower the system pressure to the pressure level specified in the instruction before making any adjustment to the valve� Furthermore, always install a proper test rod to gag an installed valve before making any ring adjustments on the valve�

• Ear and eye protection should be used when working on a valve which has pressure�

• Never stand in front of the discharge outlet of a pressure relief valve which is under pressure�

• Always stand to the side of and at a safe distance from the valve discharge and use extreme care when observing a valve for leakage�

The above precautions and suggestions are by no means exhaustive and the user should always approach and use any pressure relief valve with great care�

Operation, Installation and Safety Instructions are available at Emerson�com/FinalControl or from your local Emerson regional sales office or representative�

CROSBY STYLE JOS-E, JBS-E, JLT*-JBS-E, JLT*-JOS-E VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

1 INTRODUCTION

Crosby Style JOS-E/JBS-E pressure relief valves have been selected for installation because of their performance features, reliability and ease of maintenance� Adherence to the installation and maintenance procedures specified herein will provide the utmost in safety, a minimum of maintenance, and a long service life� Crosby Style JOS-E, JBS-E and JLT-E valves are manufactured in accordance with the requirements of Section VIII Pressure Vessels, ASME Boiler and Pressure Vessel Code� Style JOS-E is a conventional closed bonnet valve� Style JBS-E has a balanced bellows for minimizing the effect of back pressure� Style JLT-E is a high performance valve designed specifically for liquid service� TheJLT-E features patented contoured liquid trim in a standard JOS-E/JBS-E envelope�

2 STORAGE AND HANDLING

Valves are often on hand at the job site months before they are installed� Unless stored properly and protected, valve performance may be affected adversely� Rough handling and dirt may damage or cause misalignment of the valve parts� It is recommended that the valves be left in their original shipping containers and that they be stored in a warehouse or at a minimum on a dry surface with a protective covering until they are used�

3 INSTALLATION

3.1 Care in handling

Pressure relief valves must be handled carefully and never subjected to sharp impact loads� They should not be struck, bumped or dropped� Rough handling may alter the pressure setting, deform valve parts and affect seat tightness and valve performanceadversely� When it is necessary to use a hoist, the chain or sling should be placed around the valve body and bonnet in a manner that will ensure that the valve is in a vertical position to facilitate installation� The valve should never be lifted or handled using the lifting lever inlet and outlet protectors should remain in place until the valve is ready to be installed on the system�

3.2 Inspection

Pressure relief valves should be inspected visually before they are installed to ensure that no damage has occurred during shipment or while in storage� All protective material, sealing plugs and any extraneous material inside the valve body or nozzle must be removed� The valve nameplate and other identifying tags should be checked to ensure that the particular valve is being installed at the location for which it was intended� The valve seals protecting the spring setting and ring adjustments should be intact� If seals are not intact, the valve should be inspected, tested and seals installed properly before use�

3.3 Inlet piping

Pressure relief valves should be mounted vertically in an upright position either directly on a nozzle from the pressure vessel or on a short connecting fitting that provides direct and unobstructed flow between the vessel and the valve� Installing a pressure relief valve in other than this recommended position might affect its operation adversely� Where rounded or beveled approaches cannot be provided ahead of the valve it is recommended that one size larger nozzle or fitting be used� Avalve should never be installed on a fitting having a smaller inside diameter than the inlet connection of thevalve� Inlet piping (nozzles) must be designed to withstand the total resultant forces due to the valve discharging at the maximum accumulated pressure and the expected piping loads� Themagnitudes of the bending moment exerted on the inlet piping will depend on the configuration and method of supporting the outlet piping� Many valves are damaged when first placed in service because of failure to clean the connections properly when installed� Both the valve inlet and the vessel and/or line on which the valve is mounted must be cleaned thoroughly of all foreign material� The inlet connection bolts or studs should be drawn down evenly to avoid straining the valve body with possible distortion of the nozzle flange orbase�

CROSBY STYLE JOS-E, JBS-E, JLT*-JBS-E, JLT*-JOS-E VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

4 HYDROSTATIC PRESSURE TESTS

Lid

Discharge pipe

Long radius

Short

aspossible

pointdrain

Rounded approach

Low

elbow

Free support

Top of vessel

FIGURE 3 - Recommended installation discharging to atmosphere

3.4 Outlet piping

Outlet piping should be simple and direct� Where possible, for non-hazardous fluids, a short discharge pipe or vertical riser connected through a long radius elbow venting directly to atmosphere is recommended� Such discharge piping should be at least the same size as the valve outlet� All discharge piping should be run as direct as is practicable to the point of final release for disposal� Valve effluent must discharge to a safe disposal area� Where discharge piping is long, due consideration shall be given to the use of long radius elbows, and the reduction of excessive line strains through the use of expansion joints and proper means of support to minimize line sway and vibration under operating conditions� Adequate drainage is required to prevent corrosive media from collecting in the discharge side of the pressure relief valve� When required, low point drains shall be provided in the discharge pipe� Particular care must be observed to ensure that the drains are directed or piped to a safe disposal area� In installations where the pressure relief valve discharges into a closed system, care must be taken to ensure that built up and superimposed back pressure has been calculated properly, specified and accounted for when sizing and selecting the valve� Where built up back pressure is expected to exceed 10% of set pressure or if superimposed back pressure is variable, a bellows valve isrequired�

4.1 Hydrostatic test of vessel or system

When a pressure vessel or system is to be hydrostatically tested, it is recommended that the pressure relief valve be removed and a blank flange be installed in its place� This practice precludes the possibility of any damage to the pressure relief valve� Bent spindles and damaged valve seats are problems that can be caused by improper hydrostatic test procedures� Blank flanges must be removed and the pressure relief valve reinstalled before the vessel is placed in service� When the hydrostatic test must be performed with the valve in place, a test gag may be used� Crosby Style JOS-E/JBS-E valves are designed to accommodate test gags for use with each type of cap� In the case of the Type C cap with lifting lever, the lifting lever assembly must be replaced with a hydrostatic test cap and test rod prior to hydrostatic testing� When test rods are used, care must be exercised to prevent overtightening that could damage the valve spindle and valve seats� Generally, a test rod which is hand tight will provide sufficient force to hold the valve closed� After the hydrostatic test, the test rod (gag) must be removed and replaced by either a cap plug or a cap not fitted with a test rod�

4.2 Hydrostatic test of outlet system

When a hydrostatic test must be conducted on the outlet piping system, with the valve in place, special consideration must be given not to exceed the design pressure limits of the downstream side of the pressure relief valve� The outlet side of a pressure relief valve is known as the secondary pressure zone� Thiszone is normally designed to a lower pressure rating than the inlet and frequently is designed to a lower pressure rating than the outlet flange� This is true particularly in the case of balanced bellows designs and in the larger valve sizes� Consult relevant product specifications for the back pressure design limits of the Style JOS-E/JBS-E or JLT-E valves�

CROSBY STYLE JOS-E, JBS-E, JLT*-JBS-E, JLT*-JOS-E VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

5 SETTING, TESTING AND ADJUSTMENTS

5.1 New valves

Every new Crosby J series pressure relief valve is tested fully and sealed prior to shipment� The external adjustment points of each valve are sealed to ensure that no changes have been made to the valve after shipment and that the valve has not been disassembled or tampered with� The seals and nameplates are your assurance that the valve has been built and tested to the applicable Codes and Standards and are the physical evidence of our product warranty� All new Crosby J series valves are tested fully prior to shipment on the appropriate testing medium, so there is no need to pretest the valve prior to installation� If pretesting is required, in order to maintain the product warranty, a Crosby valves authorized service organization should be contacted to perform the testing� Contact your local sales representative or visit our website to locate the authorized service organization closest to your location� By choosing an authorized service organization to perform testing you can be assured that the correct testing procedure is followed which will save time and cost by avoiding possible valve damage caused by improper testing methods� In any event, if pre-testing is to be performed, several important cautions should be observed� First it is vital that the appropriate test fluid is used to test any valve� See Section 5�5� This will ensure accuracy of the test results as well as avoid possible damage to the valve� All Crosby J series valves are tested for seat tightness after the final set point test and prior to shipment from the factory� If further seat tightness testing is required before installation, it is recommended that the test be performed prior to any set point verification testing� Repeated pressure testing of a metal seated valve can cause damage to the sealing surfaces leading to seat leakage Testing on a low volume test stand requires specific testing techniques in order to ensure accurate test results and to avoid damage to the sealing surfaces of the valve� In many cases this requires temporary adjustment of the nozzle ring during the test as described in Section 5�8 and specifically in Section 5�8�1� For valves with set points in excess of 500 psig (3447 kPa), it is recommended that when testing on a low volume test bench, the lift be restricted temporarily by use of a gag or other suitable device� However, it is good practice to inspect the valve prior to installation� This inspection determines any damage which may have occurred due to rough handling in transit or storage and initiates appropriate service records�

5.2 Reconditioned valves

Valves which have not been in service for extended periods due to plant shutdown or long term storage, or valves which have been repaired or reconditioned, also should be tested before being put into operation�

CAUTION

Improper testing may cause valve damage and seat leakage.

5.3 Valves removed from service

Valves being removed from service should be tested on a shop test bench before being disassembled to determine the set pressure and seat tightness� This is an important phase of the maintenance routine and the test results should be recorded for review and determination of necessary corrective action� The 'as received from service' condition of a pressure relief valve is a most useful tool in establishing the proper time interval between inspections�

5.4 The test bench

The quality and condition of the shop test bench is paramount to obtaining proper test results� The test bench must be free of leaks and the test fluid must be clean� Solids or other foreign material in the test medium will damage the seating surfaces of the pressure relief valve being tested� The test pressure gauge must be calibrated and have a range proper to the pressure level of the valve setting� Set pressure should fall within the middle third of the dial range of the test gauge� The test bench provides an accurate and convenient facility for determining valve set pressure and seat tightness� It does not duplicate all of the field conditions to which a pressure relief valve will be exposed while in service� It is not practical to attempt to measure relieving capacity or blowdown using a test bench�

5.5 Test fluids - set pressure test

The test fluid should be air or nitrogen for valves used on gas and vapor service and water for valves used on liquid service� Valvesfor steam service should be tested on steam� Itmay be necessary to make a correction to the adjusted set pressure to compensate for the difference in temperature of the test fluids (seeappropriate instruction)�

CROSBY STYLE JOS-E, JBS-E, JLT*-JBS-E, JLT*-JOS-E VALVES

INSTALLATION AND MAINTENANCE INSTRUCTIONS

5.6 Valve operation

Crosby Style JOS-E/JBS-E valves intended for compressible fluid service and tested with air or steam will open with a sharp clear popping action at the set point� Valves for liquid service tested with water are considered open when there is a continuous unbroken stream of liquid flowing from the valve�

5.7 Set pressure changes

Set pressure changes beyond the specified spring range will necessitate a change in the valve spring assembly consisting of the spring and two fitted spring washers� The new spring and washers must be obtained from Emerson and the valve must be reset and the nameplate restamped by an authorized valve repair facility�

5.8 Set pressure adjustment

Before making any adjustments, reduce the pressure under the valve seat to at least 10% below the stamped opening pressure� This will prevent seat damage due to turning of the disc on the nozzle seat and minimize the chance of an inadvertent valve opening� A strong (high) ring position is necessary to obtain a good clean popping action of the valve on air or gas with the limited volume available on the test bench�

5.8.1

(Not required for testing on liquid)� Remove the nozzle ring set screw and raise the nozzle ring until it touches the disc holder, then back it down two (2) notches� Exercise care in counting the number of notches moved so that the ring can be returned to its proper position following testing�

Moving the notches on the nozzle ring to

the left will lower the nozzle ring�

Replace the nozzle ring set screw before

each set pressure test� The set screw must engage one of the ring notches, being careful that it does not bear on the top of a tooth�

5.8.2 Remove the cap or lifting lever following the instruction for valve disassembly (seeparagraph 6)�

5.8.3 Loosen the adjusting bolt nut and turn the adjusting bolt clockwise to increase set pressure or counterclockwise to reduce set pressure�

5.8.4 Retighten the adjusting bolt nut following each adjustment�

5.8.5 Two or three consecutive valve openings at the same pressure are necessary to verify the opening pressure accurately�

5.8.6 Opening pressure tolerance shall comply with ASME Section VIII Division 1 UG-136 (d) (1) as below or other tolerance may be used so long as they meet ASME requirement:

The set pressure tolerance for pressure

relief valves shall not exceed ±2 psi (15 kPa) for pressures up to and including 70 psi (500 kPa) and ±3% for pressures above 70 psi (500 kPa)

5.8.7 Once the set pressure has been established, lower the nozzle ring to the installed ring position as indicated in Table 1 and replace the nozzle ring set screw as described above� Seal wire the adjusting bolt and adjusting ring set screw with identifying seals�

5.9 Nozzle ring settings

The nozzle ring adjustment is made at the factory and resetting in service is seldom necessary� Should it be necessary to change blowdown or reduce valve simmer, the nozzle ring may be adjusted as follows: (see the next paragraph for P, Q, R and T orifice Style JLT)�

CAUTION

Should any adjustments be made while the valve is installed on a pressurized system, the valve should be gagged while ring adjustments are made.

TABLE 1

Service Orifice size Nozzle ring setting (below highest lock position) Style JOS-E/JBS-E pressure relief valve recommended nozzle ring settings

Vapor and gases

Style JLT-E pressure relief valve recommended nozzle ring settings

Liquids and gases

NOTE

Minus sign indicates number of ring notches below starting position of nozzle ring which is the highest position with the valve closed (contact with disc holder)�

D through J -5 K through N -10 P through T -15

D, E, and F -2 G, H, and J -3 K and L -5 M and N -10 P and Q (see Table 2) R and T (see Table 2)

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