SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE
OPERATING INSTRUCTIONS
Before installation these instructions must be fully read and understood
Series
VSE/VSR Full lift and normal safety relief valve.
VSE 1 open spring bonnet
VSR 1 open spring bonnet and adjusting ring
VSE 2 closed spring bonnet
VSR 2 closed spring bonnet and adjusting ring
VSE 4 closed spring bonnet, weight-loaded
Orifice letters
SKB (Sempell): A - Z
SKB (API): EA - TA
Design
According to TO.271.01./271.02. and
TO.272.01./271.02.
• Spring-loaded (cylindrical compression
spring)
• Weight-loaded
• Roller bearing up 8 kN spring force
• Cooling spacer for medium
temperatures ≥400°C
Attachment
• Pneumatic measuring device A 143 for
adjusting the set pressure at operating
pressure
For the application of a pneumatic actuator
A160 see corresponding operating instruction
VCIOM-02239.
Observe design data on the tagplate!
ATTENTION
This operating instruction does not specify the
extent of delivery. It is valid for several sizes,
designs, accessories and additional devices.
It contents generally exceeds the contractual
determined extent of delivery.
1 DANGER AND WARNING INDICATIONS
The construction of the Sempell safety valves
corresponds to the latest state of engineering
and the valid safety regulations.
Nevertheless, improper use or improper
installation can cause risks for the personnel
or can lead to restrictions in regard of
the operational safety. Therefore, the
SempellGmbH recommends the operator of
the safety valves to take appropriate measures
and make
instructions are read and understood by the
assigned personnel.
APPLICATION LIMITS
It is only allowed to use the valves according to
the details of these operating instructions and
according to the parameters and application
cases agreed in the delivery contract (see
nameplate). The application of the valve has to
take place adequate to the medium tolerances of
the used materials.
WARNINGS FOR THE OPERATING AND
MAINTENANCE PERSONNEL
Before commissioning and maintenance works
familiarise yourself with the legal accident
prevention regulations, the local safety
instructions and this operating instruction and
observe them.
Use the safety valve and its individual parts and
accessories only for the purpose intended by us.
sure that the present operating
Please observe the following points besides
the notes given in the text:
• Danger of burning at safety valves and with
the connected pipes while operating under
increased temperature.
• Disassembly of the safety valve only in case of
pressureless plant and after cooling down.
• Protection against risks caused by
evaporation also in case of pressureless
system; for information please contact the
safety inspector concerned.
• After assembly check all sealing points in
regard of tightness.
• In case of adjustment make changes at
pressure screw and adjusting ring only with
clearly reduced pressure to avoid unintended
response.
• Carry ear protection during adjustment,
ifnecessary.
• Danger of burning by discharge of small
amounts of possibly hot medium in case
of safety valves with open spring bonnet
(VSE1,VSR 1).
• Danger of injury while discharging at
disconnected discharge line.
• Extreme vibrations can lead to inadmissible
increase of operating pressure with the
possibly destruction of the safety valve or to
the destruction of the balanced bellows with
unintentional escape of medium.
Exclusion of liability
Sempell GmbH cannot be held liable in case
of improper maintenance and adjustment of a
Sempell safety valve, use of inadmissible spare
parts or utilities and in case of a temporary or
permanent connection of equipment with the
safety valve which is not approved by us.
Emerson.com/FinalControl © 2017 Emerson. All rights reserved.
MA.271.01.0116.E
VCIOM-02450-EN 16/07
SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE
OPERATING INSTRUCTIONS
2 DESCRIPTION
Spring-loaded full lift safety relief valves are
direct acting safety valves for protection of
pressure tanks against inadmissible excesspressure.
A cylindrical compression spring creates the
closing force on the valve disc against the
opening pressure of the medium below the
valve disc. At normal operating conditions the
valve seat is held tight.
By changing the spring compression it is
possible to change the set pressure. In case
of exceeding set pressure, the pressure of the
medium prevails and the safety valve opens.
With full lift characteristic the safety valve
opens rapidly at full lift and discharges the
total mass flow necessary to prevent a further
pressure increase.
With normal characteristic the safety valve
reaches the lift necessary for the mass flow to
be discharged after response within a pressure
increase of maximum 10%.
After a defined pressure decrease, the safety
valve closes again.
By means of the lifting lever at the cap the
safety valve can be opened by hand with a set
pressure of 85% at least.
The safety valves are type tested and comply
with the requirements of the standards and
regulations.
Use within areas exposed to danger of explosion
The safety valves underwent a hazard analysis
according to code 94/9/EC with the following
result:
• The safety valves do not have a potential
ignition source. ATEX 94/9/EC is not
applicable to these valves.
• The valves safety may be used in the EX range
• Electrical / pneumatically accessories have to
undergo a separate assessment of conformity
according to ATEX.
• The surface temperature does not depend
from the valve itself but from the operational
conditions. Observe while installing.
3 OPERATION
3.1 Warning indications for the operation
Observe safety regulations!
ATTENTION
Unstable behaviour of safety valves such as
chattering or vibrating can destroy the valve seat,
the safety valve or the pipe and thus causing the
failure of the safety function or the shutdown
of the plant. Therefore, observe regulations
and empirical notes regarding design and
dimensioning, fitting and installation.
ATTENTION
Safety valves with weight loading, Series VSE 4,
areblocked for the transport.
Before commissioning remove blocking stem and
mount gag plug (17) with gasket (40).
• Design and dimensioning: do not use larger
safety valves than necessary! In case of back
pressure use safety valves with bellows.
• Fitting and installation: lay supply line as
short as possible. Use as few bends as
possible.
• Keep supply line free from vibrations.
Absorb or avoid pressure surges and waves,
e.g.caused by pumps or other valves.
• Drain the discharge line and the valve body at
their lowest point. Condensate can impair the
function of the safety valve.
• Protect lines and valve against freezing.
2
SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE
OPERATING INSTRUCTIONS
Max. weight [kg] without
SKB-DIN
A 19 EA 42
B 19 FA 42
C 21
D 35 GA 77
E 70 HA 155
F - G 80 JA 175
H 90 KA 200
J - K 110 LA 245
L 150 MA-NA 310
M 170
N 200 PA 440
P 250 QA 555
Q 270
R 300 RA 665
S 300 TA 665
T 380
U 410
V 460
W 530
X 1260
Y 1600
Z 1870
3.2 Storage rules
To preclude damages during loading and
unloading, move the valve with suitable lifting
accessories about SKB-API
Moisture: to prevent the formation of
condensate, avoid moist storerooms. A relative
humidity of below 65% is at best.
Max. weight [lbs] without
accessories about
gears. Handwheels and other driving elements
are unsuitable as impact points. The transport
shall preferable take place by cable or
transport pallet.
Lighting: the products of elastic materials
are to protect from direct sun light and from
strong artificial light with a high ultraviolet
part. Therefore supply the windows of the
At delivery provide the outsides of all ferritic
parts of the safety valve except the welding
storerooms with a red or orange (in no case
blue) paint.
edges with a coat of paint.
The insides of the body are protected by a
watery corrosion preservative that has a
long-term effect because of the film formative
activeagents.
All connection inlets are closed by
corresponding caps.
Ozone: protect products of elastic materials
from ozone (formation of cracks and
embrittlement). The storeroom may not
contain ozone generating systems (fluorescing
sources of light, mercury vapour lamps,
electricmotors,etc.).
In this state the safety valve can be stored in
closed, dust-free and dry rooms lying on a
pallet without difficulties. Time of storage about
six months. Storage of more than six months
asks for disassembly and visual check of the
inner parts of the safety valve. A weatherprotected outside storage is not allowed.
Oxygen: protect products out of elastic
materials from draught by storage in
airtight tanks. Oxygen causes cracking and
embrittlement.
If these requirements are guaranteed for
products out of elastic materials, the storage
time is about 5 years.
For spare parts out of elastic material
(O-rings, scraper rings, rod and piston gaskets)
additionally apply:
For spare parts out of steel
Store the parts in closed, dust-free and dry
rooms so that damages do not occur.
Temperature: the temperature of the storage
shall be between 0°C and 25°C since otherwise
a hardening of the material and so a shortening
of durability will follow. Shield heating elements
Especially the following protection
measuresapply:
Disc (4): wax coat of the gasket, net coat
Guide bush (6): protection by net coat
and lines in heated storeroom so that no direct
heat irradiation arises. The distance between
the heat source and the stocks has to be 1 m
at least.
3
SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE
OPERATING INSTRUCTIONS
3.3 Installation instructions
NOTE
Clean pipes before installing safety valves as
otherwise the valve seats can be damaged by
foreign bodies when discharging!
Remove transport protection just before
installation.
Check plant identification and details on the
nameplate.
3.3.1 Installation
The installation zone must be easily accessible
for maintenance works. Required free space
above the safety valve see section Dimensions
In case of large safety valves provide for
additional space for lifting gears, at least
500mm.
Position of installation vertical, inlet from
below. Do not brace valve body when fastening;
if necessary compensate bearing of the
supporting brackets.
Lay line in such a way that neither static or
dynamic forces nor forces caused by thermal
expansion may be transferred to the valve body.
PLEASE NOTE
Stresses at the valve body may lead to leaking at
the valve seat!
3.3.2 Inlet line
If possible arrange safety valve directly at the
nozzle of the tank to be protected. Otherwise
lay inlet line between tapping point and safety
valve as short and as poor in resistance as
possible.
In no case the inlet line diameter must be
smaller than the inlet nominal size at the
safetyvalve.
The pressure loss in the inlet line must not
exceed 3% of the set pressure at the greatest
possible discharge quantity.
ATTENTION
Condensate at the inlet of the safety valve
changes the functional behaviour and may lead
to an inadmissible pressure increase. Danger of
explosion!
In case of liquids with temperatures higher than
the ambient temperature, the inlet line must
be assembled with slope to the safety valve, or
designed as a siphon-type bend in front of the
safety valve. Thereby, a heat transmission to
the safety valve is avoided which could impair
the tightness at the valve seat.
3.3.3 Exhaust line
In no case the exhaust line diameter must be
smaller than the outlet nominal size at the
safety valve.
Back pressures in the exhaust line are
admissible up to 15% of the set pressure and
for safety valves with compensating piston
(SN 144) up to 50% of the set pressure, in
case there are no other restrictions, e. g. with
respect to the strength of the body connection
flange.
ATTENTION
Higher back pressures may lead to an unstable,
uncontrollable behaviour of the safety valve;
chattering or vibrating may destroy the valve seat,
the safety valve or the line and thus lead to failure
of the safety function or to shutdown of the plant!
At the deepest point the exhaust line must be
equipped with a drain which is large enough
to enable the discharge of minor leaks, e. g.
in case of untight valve seat. Particularly in
the open air exhaust line, valve body and drain
must be protected against icing and freezing,
e. g. by (electrical) trace heating; merely
insulating is not sufficient!
Do not exchange the drain connection G ¼” at
the valve body for the lock screw (44) at orifice
letters A40 and B40. Removing the lock screw
(44) may change the function of the safety valve!
DIMENSIONS
SKB
A - G
EA - JA
H - R
KA - RA
S - Z
TA
X
Overhead dimension X
300 mm
12"
700 mm
26"
900 mm
36"
Check inlet line in regard of pressure vibrations
according to FBR 153 as far as possible.
ATTENTION
A pressure loss higher than the closing pressure
difference may lead to an unstable, uncontrollable
behaviour of the safety valve; chattering or
vibrating may destroy the valve seat, the safety
valve or the line and thus lead to failure of the
safety function or to the shutdown of the plant!
For discharge of condensate in case of gases
and vapours, the inlet line must have a slope to
the tapping point of 15 degrees at least.
ATTENTION
An icy, frozen or clogged exhaust line leads to the
failure of the safety function! Danger of explosion
in case of excess-pressure!
CAUTION
In case of several safety valves with one common
exhaust line, take special safety precautions for
disassembling of only one safety valve to exclude
danger in case of unintended discharge of other
safety valves!
Recommendation! Sound isolate exhaust line
and/or provide the same with silencer; in doing
so, regard allowable back pressure!
4
SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE
OPERATING INSTRUCTIONS
3.3.4 Insulating
In case of hot medium insulate inlet line and
valve body. In case of gases and vapours
insulate inlet line and valve body very carefully
to avoid condensation.
ATTENTION
Condensate at the inlet of the safety valve
changes the functional behaviour and may lead
to an inadmissible pressure increase; danger of
explosion!
The spring bonnet and a possibly mounted
cooling spacer shall not be insulated as with
heated spring the set pressure decreases.
3.4 Pressure test
The response of the safety valve must be
prevented.
Either flange off the safety valve and close
the supply line with a blind flange or block
the valve. In case of welded-in safety valve a
pressure test insert can be used.
ATTENTION
In case of a blocked safety valve the test pressure
can amount up to 1.5 fold of the set pressure
without consultation with Sempell.
Turn in the blocking screw instead of the gag
plug (17) and tighten it securely by hand so that
the disc (4) is blocked in closed position. In case
of design with supplementary loading (SN 111)
screw off electric solenoid including cooling
spacer and replace it against a cap (13) with
blocking screw SN 100.
ATTENTION
After the pressure test, restore and check the
ready-to-operate state!
3.5 Commissioning
ATTENTION
At safety valves with weight load, Series VSE 4,
remove blocking screw before commissioning and
assemble gag plug (17) with gasket (40).
The safety valve is delivered ready to operate.
The set pressure is adjusted at works and
secured against unauthorized adjustments by
lead seal. Higher medium temperatures can
lower the set point at approx. 1% per 100°C
and ask for a readjustment under operating
conditions. Standard values see table in section
“Adjustment of the set pressure”.
3.6 Operational test
Function and reliability of the safety valves are
proved by the type test. Therefore operational
tests are generally not carried out in the plant.
This is only usual for steam boiler safety valves.
3.7 Discharge test
• Apply ear plugs.
• Slowly increase operating pressure in the
plant until the safety valve has fully opened.
• Lower operating pressure until the safety
valve closes.
In case of several discharge tests with hot
steam allow intermediate cooling down of the
safety valve as caused by heating of the spring a
slight decrease of the set pressure is possible.
ATTENTION
When discharging, some leaking medium may
escape at the open bonnet (8) in case of safety
valves Series VSE 1 / VSR 1. Danger of scalding by
hot steam!
3.8 Adjustment of the set pressure
ATTENTION
A change of the lead sealed spring adjustment
must only take place in the presence of the
competent inspector.
The adjustment of the set pressure takes place
on the test stand. If the set pressure is adjusted
in the plant, the pneumatic measuring device
A 143 should be applied as by means of this
device the set pressure can be adjusted without
increasing the operating pressure.
ATTENTION
Adjusting only with lowered pressure. At operating
pressure working on the tightening screw (11)
may lead to unintended response of the safety
valve. When discharging, some leaking medium
may escape at the spindle guide of the tightening
screw (11). Danger of scalding by hot steam!
Remove lead seal. Unscrew cap (13). Loosen
lock nut (28). For working at the tightening
screw (11) secure spindle (7) e. g. with a pin
against rotation as otherwise the valve seat
may be damaged.
Tighten tightening screw (11) (turn right):
setpressure higher
loosen tightening screw (11) (turn left):
setpressure lower
After the adjustment secure tightening screw
(11) with lock nut (28). Mount cap (13) and
leadseal.
Standard values for the change of the set
pressure in % for a quarter turn of the
tightening screw(11):
Orifice letter SKB Changes in %
AIV EAIV 10
AI-III, B, C EAI-III, FA 7
D-H GA-KA 4
J-M LA-NA 3
N-R PA-RA 1.5
S-W TA 1
X-Z 0.5
Precision of the set pressure adjustment: ± 3%
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