Emerson SAPAG 8400 Series, SAPAG 8500 Series, SAPAG 8490 Series, SAPAG 8590 Series Installation And Maintenance Instruction
SAPAG
Attention
The safety of
depends on the proper operation of the
pressure relief valves. Consequently, the
valves should be kept clean and should be
periodically tested and reconditioned to
make sure they function properly.
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 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
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
Emerson products you should use only parts
manufactured by Emerson. Call your nearest
Emerson regional sales
office or representative for a Emerson service
engineer should you wish assistance with your
field needs.
lives and property often
WARNING
Sapag Safety Valves Series 8400/8500/8490/8590
Installation and Maintenance Instructions
Table of Contents
1. Introduction
2. Storage and Handling
3. Installation
Care in Handling
Inspection
Inlet Piping
Outlet Piping
4. Hydrostatic Pressure Tests
Hydrostatic Test of Vessel or System
Hydrostatic Test of Outlet System
5. Setting, Testing and Adjustments
New Valves
Reconditioned Valves
Valves Removed from Service
The Test Bench
Test Fluids
Valve Operation
Set Pressure Changes
Set Pressure Adjustment
Nozzle Ring Settings
• Style 8500/8590
Cold Differential Test Pressure Adjustments
• Temperature Correction
• Back Pressure Correction
Seat Leakage Tests
• Metal-to-Metal Seated Valves
• Soft Seated Valves
6. Valve Maintenance
Visual Inspection and Neutralizing
Disassembly
Cleaning
Inspection
Reconditioning of Valve Seats
Lapping Procedures
• Lapping Blocks
• Lapping Compounds
• Machining of Nozzle Seats
• Machining of Disc Insert Seats
Assembly
Assembly of Cap and Lifting Lever Devices
Soft Seat Construction
7. Style Variations
8. Service Records
9. Spare Parts
10. Trouble Shooting Pressure Relief Valves
Seat Leakage
• Seats Damaged by Foreign Matter
• Distortion From Piping Strains
• Operating Pressure too close to Set Pressure
• Chatter
• Incorrectly Adjusting Lifting Gear
• Other Causes of Seat Leakage
• Corrosion
11. Emerson Valves & Controls’ Field Services and Repair Programs
Ordering Information
Emerson.com/FinalControl © 2017 Emerson. All rights reserved.
without notice SAPDR-0060-EN-1308
Sapag Safety Valves Series 8400/8500/8490/8590
Installation and Maintenance Instructions
Figure 1
Set Screw
8400/8500
only
Nozzle ring
Note:
This vent must
remain open on
8490/8590
construction
Style 8400 Style 8490 Soft Seat
Parts list
No. Part Name Notes No. Part Name Notes
1 Body
2 Nozzle
3 Nozzle Ring 3
4 Set screw 3, except P-T Orifice 8500/8590
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 8500/8590
14 Set Screw Plug P-T Orifice 8500/8590 (not shown)
15 Guide 3
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 & Wire
35 Seal Clip
36 Nameplate
40 Screwed Cap
41 Cap Gasket 1
Gasket Kit 1,4
42 Test Gag/Plug ( Plug only shown)
43 Test Gag plug gasket 1
(P-T Orifice
have lockscrews)
Style 8500
D-N Orifice
construction
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.
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 Valves & Controls 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
Emerson reserves the right to change the contents without notice page 2
Sapag Safety Valves Series 8400/8500/8490/8590
Installation and Maintenance Instructions
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
serial number is shown on the valve nameplate. Spare parts may be ordered from any Emerson
Valves & Controls Regional Sales Office or Representative.
Figure 2
Sample nameplate
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 strictly observed may
result in injury to personnel or loss of life.
CAUTION: An operating procedure or practice which if not strictly observed may
result in damage to or destruction of equipment.
These precautionary statements are by no means exhaustive.
Emerson Valves & Controls 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
Valves & Controls Product by a non Emerson Valves & Controls employee may void any Emerson
Valves & Controls guarantees or warranties with respect to such Product.
All personnel working with Emerson Valves & Controls products should be adequately trained and
thoroughly familiar with the contents of the appropriate instruction manual(s).
Emerson Valves & Controls cannot evaluate all conditions in which the products may be used.
However, Emerson Valves & Controls 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 adversely affect seat tightness and valve performance. Striking a valve which is under
pressure can cause premature actuation.
• 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 www.valves.emerson.com or
from your local Emerson regional sales office or representative.
Emerson reserves the right to change the contents without notice page 3
Sapag Safety Valves Series 8400/8500/8490/8590
Installation and Maintenance Instructions
1. Introduction
Sapag Series 8000 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. Sapag type 8400/8500/8490/8590
Valves are manufactured in accordance with the requirements of Section VIII Pressure Vessels,
ASME Boiler and Pressure Vessel Code. Type 8400 is a conventional closed bonnet valve. Type
8490 has a balanced bellows for minimizing the effect of back pressure.
Style 8500 is a high performance valve designed specifically for liquid service. The 8500 features
patented contoured liquid trim in a standard 8400/8490 envelope.
2. Storage and Handling
Valves are often on hand at the job site months before they are installed. Unless properly stored
and protected, valve performance may be adversely affected.
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
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 adversely affect seat tightness and valve performance.
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.
Inspection
Pressure relief valves should be visually inspected 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 properly installed before use.
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 adversely affect its operation. 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 thoroughly cleaned 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.
Emerson reserves the right to change the contents without notice page 4
Sapag Safety Valves Series 8400/8500/8490/8590
Installation and Maintenance Instructions
Discharge pipe
Short as
possible
Rounded
approach
Free
support
Top of vessel
Figure 3
Recommended installationdischarging to atmosphere
Lid
Long radius
elbow
Low point
drain
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 properly calculated, 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. Hydrostatic Pressure Tests
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.
Sapag Series 8000 are provided with test gags as standard. 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. A test rod which is hand tight
will generally 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.
CAUTION: Improper testing may
cause valve damage and seat
leakage.
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
particularly true in the case of balanced bellows designs and in the larger valve sizes.
Consult Sapag products specifications for the back pressure design limits of the Series 8000
valves.
5. Setting, Testing and Adjustments
New Valves
Each Sapag pressure relief valve is carefully set and tested at the factory prior to shipment.
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.
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, should also be tested before being
put into operation.
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.
Emerson reserves the right to change the contents without notice page 5
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