Installation, Operation and Maintenance Manual for
Emergency Pressure Relief Valves
Model 2100
IOM 2100.0
REV. A 12541
TABLE OF CONTENTS
IOM 2100.0
February 2005
INTRODUCTION
DESCRIPTION PAGE
Introduction
Emergency Valve Design & Function
Safety Warnings
Shipping, Inspection and Storage
Installation
Routine Maintenance
Tools
Disassembly
Assembly
Troubleshooting Guide
Certified Drawing Bill of Materials
How to Order
Product Limited Warranty
LIST OF FIGURES
1. Tank Installation - Safety Equip.
2. 2100 Certified Drawing
1
2
3
3
3 - 4
4
5
5
5
6
7 - 8
9
9
2
7
LIST OF TABLES
1. Body Flange Gasket Dimensions
2. Flange Bolt Torque
3. Troubleshooting Guide
4. O-Rings - 2100 Cover (Pressure)
4
4
6
6
Pressure relief valves are used on liquid storage
tanks and other process vessels or systems to
prevent structural damage due to excess
internal pressure.
Storage tanks are pressurized when liquid is
pumped in, compressing the existing vapor or
when increasing temperature causes increased
evaporation or expansion of existing vapor. To
prevent damage, vapor must be allowed to
escape or enter the tank at a specified pressure
condition. The volume rate of venting depends
upon the tank size, volatility of the contents, the
pumping rate and the temperature. See API
Standard 2000 for the procedures to determine
venting requirements.
The 2100 Spring Loaded Emergency Relief
Valve provides pressure relief. Emergency
pressure relief provides protection for fire
exposure and/or failure of the inert gas
blanketing system. The valves can be set for
pressure relief in the range of 1 - 15 PSIG.
High operating pressures reduce evaporation
and total venting volume, thereby reducing
product loss and the cost of processing
emissions.
All valves must be carefully maintained by a
qualified valve technician. They should only be
assembled under clean conditions, preferably in
a service shop environment. Carefully read and
understand this manual before attempting to
repair a 2100 Emergency Pressure Relief Valve.
5. Abbreviations
6. Pressure Spring - Set Ranges
7. Bill of Material (C-91768 Drawing)
6
7
8
1
FIGURE 1: TANK INSTALLATION - SAFETY EQUIPMENT
EMERGENCY RELIEF VALVE DESIGN
AND FUNCTION
The 2100 Series Emergency Relief Valve is
designed to provide pressure relief for API 620
and 650 tanks.
This series of valve is available with a standard
O-Ring seat. Depending on application, it is
available in a wide range of material options.
Each application must be reviewed to ensure
material compatibility of all metal and soft good
This manual is intended to provide
recommended procedures and practices for
installation, operation, and maintenance of the
Groth 2100 Emergency Relief Valve. Any
standard procedures and practices developed
for a specific plant or process may supersede
this manual. Although this manual cannot cover
all possible contingencies, following these
guidelines should provide safe, reliable valve
performance.
components. Consult factory for special
requirements. (See Table 7 for a complete
standard material list.)
The Emergency Relief Valve is set at the factory
to comply with the specification on the purchase
order. The range of adjustment (for pressure
relief) is shown in Table 6. The pressure setting
may be changed within the design range in a
service shop.
For information not contained in this manual,
please contact:
Groth Corporation
A Continental Disc Company
13650 North Promenade Blvd.
Stafford, TX 77477
281-295-6800 [phone]
281-295-6999 [fax]
2
SAFETY WARNINGS
This section is an overview of safety guidelines
that should be followed during the installation,
operation and maintenance of Groth Pressure
Emergency Relief Valves. To understand the
context of these instructions and warnings, it is
necessary to completely read and understand
the contents of this manual.
The purpose of an Emergency Relief Valve
(ERV) is to prevent excessive pressure in a tank
or process system. The valve must be designed
for the proper MAWP and flow requirements of
the system. Consult API Standard 2000 for tank
protection sizing procedures. An improperly
specified or functioning relief valve may result in
structural damage to the tank or system.
SHIPPING, INSPECTION AND
STORAGE
The ERV is normally bolted to a pallet during
shipping. When received inspect the valve for
any sign of damage that may have occurred in
shipment and report this to the carrier.
If the valve is to be stored before installation, it
should be in a clean environment and protected
to prevent intrusion of foreign materials into the
body. Before installation inspect the unit
visually. If there is any indication of physical
damage or internal contamination, the valve
must be cleaned and inspected before
installation.
WARNING: The valve must be installed in a
vertical position as shown in Fig. 1. To
achieve nominal flow capacity, the tank nozzle
bore must be at least the same nominal
dimension as the relief valve body.
Lifting eyes are bolted to the upper body flange
and are to be used for handling the valve. To
avoid damage to the lower flange surface, set
the valve on a soft clean gasket material until it
is ready to be installed.
Do NOT attempt to remove the valve from the
tank or process vessel without first bleeding all
pressure from the system. ALTERNATIVE
MEANS OF PRESSURE RELIEF MUST BE
PROVIDED WHEN THE VALVE IS OUT OF
SERVICE.
The ERV is exposed to process vapors while in
service. Observe all plant procedures and
Material Safety Data Sheet (MSDS)
recommendations for the products in the system
when inspecting, adjusting or servicing the
valve. Take appropriate safety precautions
regarding eye protection, respiration and skin
contact.
SEE PAGES 4, 5, & 7 FOR ADDITIONAL
WARNINGS.
INSTALLATION
The 2100 ERV must be handled carefully to
ensure seat tightness.
1. At installation, the valve should be smoothly
lifted into position using the lifting eyes on
the body flange. Do NOT lift the valve by
the spring assemblies; this can damage the
seat and cause the valve to leak in service.
2. The mating flanges on the valve body and
tank nozzle should be the same type (i.e.
RF with RF and FF with FF). Mating flanges
MUST be flat within .015" and clean, free of
scratches, corrosion and tool marks.
3. Begin by inspecting the gasket; make sure
that the material is suitable for the service.
Gasket dimensions are listed in the Table 1
below. Center the gasket on the tank nozzle.
3
Table 1
Body Flange Gasket Dimensions
150# ANSI Flange
Size OD ID BC Hole No.
16" FF 23.50" 15.25" 21.25" 1.13" 16
20" FF 27.50" 19.25" 25.00" 1.25" 20
24” FF 32.00" 23.25" 29.50" 1.38" 20
16" RF 18.50" 15.25" --- --- --20" RF 23.00" 19.25" --- --- --24” RF 27.25" 23.25" --- --- ---
API 650# Flange
Size OD ID BC Hole No.
20" 26.00" 19.25" 23.50" 0.75" 16
24” 30.00" 23.25" 27.50" 0.75" 20
5. Set the valve carefully on the nozzle
6. Lubricate all studs and nuts with an
appropriate thread lubricant. If stainless
steel fasteners are used, use an anti-seize
lubricant such as moly-disulfide.
7. Install the studs in the valve body and
tighten nuts hand tight.
8. Torque all fasteners to half the value listed
in Table 2 in a staggered, alternating pattern
or follow appropriate Plant Maintenance
guideline standards.
9. Make sure that the flanges are not distorted
and that the gasket is evenly compressed.
API 650# Flange (2 PSIG MAWP)
20" 16 0.63" 22
24” 20 0.63" 25
ROUTINE MAINTENANCE
The 2100 ERV does not require routine
lubrication or adjustments. It should be checked
periodically, at least once a year, to confirm that
the valve is functioning properly and that the set
point is correct.
Periodic inspection for seat tightness should be
done to ensure compliance with local air
pollution control requirements. This may be
accomplished with a gas detector calibrated for
the principle product in the system.
The valve will need to be periodically removed
from the tank for inspection of the main cover
seal. When this is done, the valve must be
carefully lifted using the lifting eyes on the body
upper flange.
Refer to handling instructions listed in the
Installation section of this manual.
If a vapor leak is detected, it will be from one of
the following sources:
1. Cover Seal.
2. Body - nozzle flange joint gasket.
Refer to the Troubleshooting section (p. 6) of
this manual for probable causes for these type
of problems.
10. Make up the final torque and check that no
further nut rotation occurs at the specified
torque value.
Table 2
Flange Bolt Torque [Ft. Lb.]
150# ANSI Flange (30 PSI MAWP)
ANSI
Flange
16" FF 16 1.00” 330
20" FF 20 1.13” 410
24” FF 20 1.25” 630
16" RF 16 1.00” 225
20" RF 20 1.13” 320
24” RF 20 1.25” 500
Number
of Studs
Stud
Size
Torque
TOOLS
Most service, adjustment and assembly of the
2100 valve may be performed with the following
open end wrench sizes:
15/16”, 1-1/8”, 1-1/2", 1-11/16” & 1-7/8”
DISASSEMBLY
Note that throughout this manual, numbers in [ ]
after the part descriptions are item numbers
which refer to the drawings and bills of material.
They apply only to drawing C-91726 [on page 7].
The valve should be handled by the lifting eyes
attached to the main valve body upper flange. It
should be set on a flat surface.
4
WARNING: Before disassembling a valve,
carefully read and understand the Safety
Warnings listed on page 3.
ASSEMBLY:
This valve is built with an integral body seat. If
construction is C.S., a 316 SS weld overlay was
used to build up the seat. Consult the factory
before machining this surface.
Measure the distance from the top of the
pressure upper spring button [4] and the top of
the adjustment screw [6]. This should also be
recorded. Remove the top hex nut [5] from each
adjustment screw and then back off the lower
nut [5], releasing spring compression. Use care
as the nut is removed from the adjustment
screw in case of spring pre-load. Loosen the
lower nuts [11] and remove the adjustment
screws [6]. Lift the springs [3] from the valve;
handle carefully to avoid bending them or
scratching the wire.
Lift the cover (using appropriate equipment) with
one of the lifting lugs [8] and turn it upside down,
exposing the cover seal [7]. Inspect the O-Ring
for signs of mechanical damage or deterioration
from product exposure and replace if necessary.
To install a new pressure O-Ring, the cover
should be turned upside down to provide access
to the groove. It must be cleaned and can be
lubricated with a small amount of grease. The
O-Ring should be started at three or four points
around the circumference to minimize the effect
of -O-Ring stretch. Use your finger or a smooth
tool to roll the O-Ring into the groove.
Using all four lifting lugs [8], carefully lift the
cover assembly onto the body [1]. Align the
adjustment screw holes in the cover with the
body. (Depending on size and set pressure
range there are either four or eight holes.)
Place an adjustment screw [6] into each of these
holes and lock into place using the two 3/4”-10
UNC hex nuts [11] and lock washers [10]. Slide
spring buttons [4] over each of the adjustment
screws [6] and then the springs [3]. Put a spring
button [4] on top and then tighten the two 1”-8
UNC hex nuts [5] until the desired spring
compression is achieved. [Refer to the
dimension that was recorded before the valve
was disassembled.]
TABLE 3: TROUBLESHOOTING GUIDE
PROBLEM INSPECTION SUGGESTED CORRECTIVE ACTION
Vapor leakage
between the
cover & valve
top flange
Vapor leakage
between the
valve body
and tank
nozzle
Visual, audible or
vapor detector
Visual, audible or
vapor detector
Leakage can occur at the cover O-Ring seal and valve body seat.
This will generally occur because of deterioration of the O-Ring,
but can also be caused by mounting the valve on a warped
flange. The seat can be distorted resulting in a leak path; the
tank nozzle must be machined or replaced to correct this
condition.
Leakage between the flanges may be corrected by tightening the
fasteners. Follow installation instructions listed on pages 3 - 4.
The gasket may have deteriorated due to the chemical
environment; replace if required. The tank nozzle may be
warped, corroded or scratched. This will require resurfacing of
the flange face.
5
TABLE 4: O-RINGS - 2100 PRESSURE COVER:
Part Number Description SIZE
891A70384 O-Ring, 2100 ERV, 16”, Aflas, #384 16”
891A70388 O-Ring, 2100 ERV, 20”, Aflas, #388 20”
891A70392 O-Ring, 2100 ERV, 24”, Aflas, #392 24”
89102384 O-Ring, 2100 ERV, 16”, Buna N, #384 16”
89102388 O-Ring, 2100 ERV, 20”, Buna N, #388 20”
89102392 O-Ring, 2100 ERV, 24”, Buna N, #392 24”
891E70384 O-Ring, 2100 ERV, 16”, EPR, #384 16”
891E70388 O-Ring, 2100 ERV, 20”, EPR, #388 20”
891E70392 O-Ring, 2100 ERV, 24”, EPR, #392 24”
891V75384 O-Ring, 2100 ERV, 16”, FKM, #384 16”
89107388 O-Ring, 2100 ERV, 20”, FKM, #388 20”
89107392 O-Ring, 2100 ERV, 24”, FKM, #392 24”
TABLE 5: ABBREVIATIONS
API American Petroleum Institute PH Precipitation Hardened
CS Carbon Steel PSIG Pounds/Sq. Inch - Gauge
EPA Environmental Protection Agency QCP Quality Control Procedure
OSI Oz. per Square Inch SS Stainless Steel
MAWP Maximum Allowable Working Pressure VOC Volatile Organic Compounds
NPT National Pipe Thread WC Water Column
6
Fig. 2: Model 2100 Certified Drawing - (C-91726)
TABLE 6: Pressure Spring - Allowable Set Pressure Ranges:
1 1.00 1.39
2 1.40 1.89
3 1.90 2.49
4 2.50 3.29
5 3.30 4.29
6 4.30 5.59
7 5.60 7.29
8 7.30 9.49
9 9.50 12.29
10 12.30 15.00
WARNING: Failure to properly set a spring loaded valve can result in a valve that is either set too high
or has insufficient lift to attain rated flow capacity. Under these conditions, the valve will not protect the
tank or system from rupturing due to changes in internal pressure. Tank failure can cause material
damage and loss and result in severe personal injury or death.
Range Min. Press.
(PSIG)
Max. Press.
(PSIG)
7
TABLE 7: BILL OF MATERIAL: DRAWING C-91726
(Standard Materials of Construction)
ITEM DESCRIPTION CS 316 SS SPARE
1
BODY (1)
2 COVER CS 316 SS
3 SPRING CS 17-7 PH
4 BUTTON, SPRING CS 316 SS
5 NUT, HEX SS SS
6 SCREW, ADJUSTMENT 316 SS 316 SS
7
O-RING, COVER (2)
8 EYE, LIFTING CS 316 SS
9 BOLT, HEX SS SS
10 WASHER, LOCK SS SS
11 NUT, HEX SS SS
(1) 316 SS Seat Overlay on CS Body
(2) Elastomers Also Available in Aflas, Buna-N, EPR, & FFKM.
The nameplate on the Valve contains the Model Number, Serial Number, set pressures and flow capacity
at a specified over-pressure. The Model Number contains additional information about materials of
construction, soft goods and options. The following chart will assist in relating the Model Number to the
characteristics of your valve:
CS 316 SS
FKM FKM
X
MODEL SIZE MATERIAL OPTIONS
2 1 0 0 -- -- -----------------
16” 3 Carbon Steel O-Ring Material (Seat)
20” 5 316 SS A - Aflas
24” Z Special B - Buna N
E - EPR
V - FKM
1 - ANSI 150# Drilling
2 - API 650# Drilling
O - No Jacket
J - Steam Jacket
O - No Options
Z - Special Options
EXAMPLE: 2100-20-5-V2OO indicates a Model 2100 20” with 316 SS body and seat,
FKM cover O-Ring, API 650 Drilling and no special options.
8
PRODUCT LIMITED WARRANTY
A. Seller warrants that products which are manufactured by Seller, are manufactured in accordance
with published specifications and free from defects in materials and/or workmanship for a period of
(12) twelve months. Seller, at its option, will repair or replace any products returned intact to the
factory, transportation charges prepaid, which Seller, upon inspection, shall determine to be
defective in material and/or workmanship. The foregoing shall constitute the sole remedy for any
breach of Seller's warranty.
B. THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR
WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE REGARDING PRODUCTS) UNLESS SPECIFIED IN THE SALES
CONTRACT. THIS CONTRACT STATES THE ENTIRE OBLIGATION OF SELLER.
Seller makes no warranties, either express or implied, except as provided herein, including without
limitation thereof, warranties as to marketability, merchantability, for a particular purpose or use, or
against infringement of any patent of products. In no event shall Seller be liable for any direct,
incidental or consequential damages of any nature, or losses or expenses resulting from any
defective new product or the use of any such product, including any damages for loss of time,
inconvenience, or loss of use of any such product.
C. The original Manufacturer shall be solely responsible for the design, development, supply,
production, and performance of its products hereunder, and the protection of its trade name or
names, if any. It assumes no responsibility, for products modified or changed in any way by its
agent or customer. Any such modifications or changes to products sold by Seller hereunder shall
make the product limited warranty null and void.
D. The Manufacturer shall be under no obligation to manufacture, sell, or supply, or to continue to
manufacture, sell or supply any of the Products.
9
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