SAPAG
Safety valves type 8100/8200
Storage, Use, Operation and Maintenance Instructions
IMPORTANT NOTICE
Contents
Important notice 1
0 Valve identification 2
1 Storage 2
2 Installation 2
3 Operation 2
4 Maintenance 3
4.1 Dismantling 3
4.2 Inspection 4
4.3 Repair 4
4.4 Assembly 4
4.5 Setting and test 4
5 In service supervision
ofsafetyvalves 5
Trouble shooting 5
Positions of the nozzle ring 5
Appendix A: Parts list 6
Appendix B: Parts list 7
Appendix C 8
Dimensions 8
Re- machining of the disc
and nozzle seats 8
Do not install a SAPAG safety valve before reading and understanding the following instructions.
SAPAG cannot be responsible for situations resulting from a poor knowledge by the installer or the
user of the present instructions.
Each safety valve has been designed for a particular application corresponding to the information
as included onto its nameplate and indicated on the test report supplied with the valve. The
installer shall make sure that the safety valve he is to install is the one which has been designed for
this application at this location. The tag of the safety valve must be checked and compared to its
location, and the Set Pressure of the valve compared to the Design Pressure of the equipment. The
Set Pressure of a safety valve as indicated on its nameplate cannot exceed the Design Pressure of
the vessel on which it is installed. The Cold Differential Test Pressure as indicated on the nameplate
may exceed the Design Pressure of the vessel by no more than 5%, only when the safety valve has
to operate at elevated temperature.
SAPAG has delivered a safety valve corresponding to the service conditions as known when the
order was registered. The materials used for the components are in accordance with SAPAG
standard bills of materials. The materials have been selected together with the buyer within
the various possibilities as offered by the SAPAG catalogue. For the main pressure retaining
components these materials are certified in accordance with EN 10204 3.1.B.
SAPAG cannot be responsible for accelerated damages to components caused by corrosion or
chemical attack by substances constituting or not the process fluid beyond reasonably foreseeable
limits and provided the presence of these substances were clearly stated when the equipment was
ordered.
The nature, the phase, the viscosity, the temperature of the fluid and all other relevant data taken
into consideration by SAPAG are those known at the time of the request for quotation. SAPAG
cannot be responsible for a safety valve operational accident resulting in the fact that one or several
data wandered away from what was specified in the order.
The installation of a safety valve, as it relates to the inlet and outlet pressure drop, as well as the
drainage of the exhaust piping, shall be in accordance with these instructions.
A safety valve is normally closed and should open only to overcome exceptional upset conditions.
However the unexpected opening, full or partial, of a safety valve is an event that needs to be
considered; the installer shall therefore connect the outlet port of the safety valve to a system
allowing the flow to be piped away to an appropriate location. The installer shall consider the
following dangers:
• The blast from the safety valve;
• The potential leakage from the safety valve exhaust of lethal, noxious or polluting substances;
• The temperature (elevated or cryogenic) of the exhausted fluid, and the warm-up or cool down of
the connected exhaust pipe work;
• The loud noise generated by the safety valve when it opens.
The safety valves are supplied adjusted, sealed and gagged.
IT IS MANDATORY TO REMOVE THE GAG AFTER INSTALLATION AND BEFORE USE.
The adjustments of the valves are protected by seals. Breaking the seals will engage the
responsibility of the person doing it. When the seals are broken, SAPAG cannot bear any
responsibility for a valve adjustment carried out without its formal agreement.
The adjustment or modification of a safety valve setting can only be performed by competent and
trained personal using an appropriate test installation fitted with accurate and calibrated pressure
measuring equipment.
Further to any setting modification of a safety valve, a new nameplate, showing the new setting
value and the identification of the authority having performed the adjustment must be affixed onto
the valve.
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without notice SAPSB-0001-EN-1308
Safety valves type 8100/8200
Storage, Use, Operation and Maintenance Instructions
0. Valve identification
Each valve is identified by a nameplate showing, in addition to the CE mark, the following
information:
• Name and address of the manufacturer: SAPAG, Armentières, France;
• Year and month of manufacture;
• Type of safety valve;
• Serial number;
• Set pressure;
• Cold Differential Test Pressure;
• Dimensions and rating of inlet and outlet connections;
• When applicable: the valve tag number.
The value of the Cold Differential Test Pressure is also stamped on the edge of the outlet flange.
The serial number of the valve is stamped on the bonnet flange edge.
1. Storage
The safety valves must be stored away from dust, moisture or weathering.
The valve openings are protected by taps. These taps should remain in place until the valve is
installed.
The safety valve must be handled with care.
The gag on the top of the safety valve can be used as a lifting hook.
2. Installation
2.1 The vessel and the piping must be absolutely clean and free from any foreign matter before
installing the safety valve.
2.2 The pressure drop between the protected vessel and the safety valve should not exceed 3%
of the set pressure of the valve. The safety valve must be installed in the upright position,
the spring on the top side.
2.3 The pressure drop of the exhaust piping should not exceed 10% of the set pressure if the
safety valve is not fitted with a balancing bellows; this limit is extended to 50% if the valve
is fitted with a balancing bellows.
2.4 Clean the flange on which the valve is to be installed using an appropriate solvent.
2.5 Check the dimensions of the ports of the safety valve in comparison to the piping
connections. The inlet and outlet connections are always different the inlet NPS is smaller
than the outlet NPS, so that installation of the safety valve in the wrong position is
impossible.
2.6 Bring the valve carefully to its location.
2.7 Remove the port taps and clean up the flange facings with an appropriate solvent.
2.8 Check piping cleanness.
2.9 Fit the connecting gaskets and put the safety valve in position.
2.10 Tight the stud bolts evenly, commencing by the inlet flange.
2.11 Make sure that the connecting piping does not induce detrimental stresses on the safety
valve body.
2.12 The body of the safety valve is fitted with a drain hole, closed at the factory with a plug. It
is very important that the body of the valve is not continuously filled by a stagnating fluid,
due to either the discharge medium, or the weather, or caused by the discharge of other
pressure relieving or safety devices connected to the same header. The drain hole may be
used for this purpose. It is also advisable to design the exhaust piping in such a way that
the body is never filled in by a stagnating fluid.
3. Operation
3.1 The safety valve is supplied with a GAG. This GAG blocks the valve into the closed position.
WITH THE GAG IN PLACE THE SAFETY VALVE CANNOT OPEN.
3.2 The safety valve must remain gagged if an hydraulic test has to be performed with the valve
in place. SAPAG recommends that, whenever possible, the hydraulic test is performed
without the safety valve, replacing it during the test procedure by a blank tap if it is
impossible, then the hydraulic test may be performed with the safety valve in place, with
its gag. The gag is normally hand tighten only excessive tightening may damage the safety
valve trim.
3.3 After completion of the hydraulic test, and before use, THE GAG MUST BE REMOVED AND
REPLACED BY THE PLUG (21) AND THE GASKET (22) supplied with the safety valve.
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Safety valves type 8100/8200
Storage, Use, Operation and Maintenance Instructions
3.4 The set pressure tolerance is +/- 3%.
The maximum operating pressure should not exceed 90% of the set pressure.
The safety valve is adjusted to be tight at 90% of the set pressure.
3.5 The safety valves are set at ambient temperature. For elevated service temperature, a
correction as per table 1 shall apply.
Table 1: temperature correction
Service temperature Temperature correction
≤ 120°C (250°F) none
121°C to 538°C (250°F to 1000°F) +3%
> 538°C (>1000°F) +5%
3.6 Cold Differential Test Pressure change.
The Cold Differential Test Pressure may be changed by +/- 5% from the pressure marked on
the nameplate.
When the CDTP is to be modified it is necessary to change the marking accordingly and to
affix a new nameplate showing the modified pressure value as well as the identification of
the authority proceeding to the modification.
If the CDTP has to be modified beyond above limitation, consult the factory.
3.7 Use of the lifting lever.
If the safety valve is fitted with a lifting lever, it may be used to check periodically the valve
operation.
To check the valve operation, the pressure underneath the disc shall not be less than 75%
of the set pressure.
3.8 Operation failures.
Operation failures can be solved by applying information as per table 2.
4. Maintenance
Dismantling, maintenance, assembly and setting shall be performed only by trained and skilled
operators using adequate equipment and calibrated measure tools.
The guarantee provided by SAPAG covers maintained and repaired safety valves only if the
components, if replaced, are either SAPAG components or components certified by SAPAG.
The safety valves returned from the site to the maintenance shop should before any maintenance
routine be decontaminated by appropriate media in order to preserve the health of the operators.
After overhaul, each safety valve shall be thoroughly and individually inspected and sealed by an
individual authorised by the user. The individual performing the sealing of the safety valve shall fill
in the corresponding Test Report and show his identification on the inspected valve. The valve shall
be identified by an additional nameplate showing the authority proceeding to the adjustment.
4.1 Dismantling (see Appendix A)
a. Remove the cap (3) and gasket (23).
b. Measure and record the dimension between the top of the adjusting screw (19) and the
topside of the adjusting screw nut (20).
c. Loosen the nut (20) and the adjusting screw (19).
d. Remove the bonnet bolts (18) and the bonnet (2).
e. Remove the spindle (15), the spring and its washers (26-27), the guide assembly
(16-17), the disc holder assembly (14-13-9-7-8), gaskets and bellows if applicable.
f. Pull on the spindle to disconnect from disc holder.
g. Remove the disc (4) from the disc holder (9) by inserting a tool in the lateral hole in the
disc holder (9); handle the disc (7) with extreme care.
If applicable, remove the bellows as follows: the bellows is screwed onto the disc holder
with a right thread. Use a spanner wrench and unscrew by turning anti clockwise.
The wall thickness of the bellows is very thin and it must not be damaged at any time
during dismantling. Remove the bellows gasket.
h. Loosen the nozzle ring screw (6) and its gasket (24).
i. Turn the nozzle ring (5) anti clockwise and remove it through the top of the body.
j. If the nozzle (4) needs to be lapped, jaw the base of the nozzle into a chuck and rotate the
body anti clockwise to remove the nozzle.
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