Sempell VSE Series, VSE 1, VSR 1, VSR Series, VSE 2 Operating Instructions Manual

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
A160 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
SempellGmbH 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,
ifnecessary.

• Danger of burning by discharge of small
amounts of possibly hot medium in case
of safety valves with open spring bonnet
(VSE1,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,
areblocked 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
activeagents.
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,

electricmotors,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

measuresapply:

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
500mm.

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
safetyvalve.

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):
setpressure higher
loosen tightening screw (11) (turn left):
setpressure lower
After the adjustment secure tightening screw
(11) with lock nut (28). Mount cap (13) and
leadseal.
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%

5

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

3.9 FUNCTIONAL DIFFERENCES

VSE 1 with compensating

VSE 1 Standard

Opening pressure difference +5% +3% +3% +3%
Closing pressure difference -10% -10% -8% -6%

pistonSN144

VSR 1 (with adjusting ring)

Standard

VSR 1 with compensating

pistonSN144

VSE 2 with valve seat

VSE 2 Standard

Opening pressure difference +5% +10% +3% +10%
Closing pressure difference -10% -20% -8% -10%

For set pressures below 3 bar the closing pressure difference may be up to 0.3 bar.

Changing the closing pressure difference
forVSR 1 and VSR 2

After removing the lock screw (44), the closing
pressure difference can be changed by means
of the adjusting ring (14). The sum of opening
and closing pressure difference remains
approximately the same.

For adjusting, put screwdriver through the
opening and adjust adjusting ring (14) groove by
groove. Its graduation equals about 0.2 mm of
vertical adjustment.
Screw adjusting ring (14) up = closing pressure
difference lowers. Turn in and tighten lock
screw (44) again.

forliquidsSN123

VSR 2 (with adjusting ring)

Standard

VSR 2 with valve seat seat

forliquidsSN 123

ATTENTION

Remove lock screw (44) only with lowered
pressure. At operating pressure adjusting the
adjusting ring (14) may lead to unintended
response of the safety valve. When discharging
the safety valve or in case of untight valve
seat, medium may escape out of the opened
adjusting bore. Danger of scalding by hot media,
e.g.steam!

3.10 TROUBLE SHOOTING

Malfunction Cause Remedies

Safety valve opens at different pressures. 1. Condensate in the inlet line. 1. Improve insulation of line. Observe drain and slope.

2. Pressure change by superimposed vibration. 2. Suppress vibrations at the safety valve.
Safety valve opens and closes in rapid
succession.

Closing pressure differences are too great. 1. Saturated steam with high moisture. Adjusting ring (14) of

Safety valve stays open after
dischargetest.
Safety valve fails to close tightly. 1. Valve seat damaged. 1. Disassemble valve. Rework valve seat and disc (4).

1. Pressure loss in the inlet line is greater than the closing

pressure difference.

2. Discharge quantity is too small because the subsequent

flow is too small.

3. Admissible back pressure is exceeded in the exhaust line. 3. Decrease flow resistance of the exhaust line: e.g. by

4. Dynamic pressure drop in the inlet line, especially in case

of liquids.

VSR is not adjusted correctly.

1. Foreign bodies between seat zone (3) and disc (4). 1. Repeat discharge test or blow off foreign bodies by

2. Difference between operating and set pressure is too small. 2. Enlarge difference or mount supplementary loading.

3. Body forming by line forces. 3. Lay line elastically.

4. No slope of the inlet line in case of hot liquids. 4. Assemble inlet line with slope to the safety valve or lay

1. For VSR enlarge closing pressure difference. Otherwise
reduce flow resistance of the inlet line: expand, shorten
or remove constrictions. Fast remedy: decrease lift
(asfar as allowed), therefore diminish outflow.

2. Install smaller safety valve or adjust discharge quantity.

expanding or shortening the line.

4. Provide safety valve with a vibration damper.

1. For VSR change closing pressure difference.

lifting the lever (36). Otherwise disassemble valve.

siphon-type bend.

6

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

4 INSPECTION AND MAINTENANCE WORKS

Determine inspection intervals depending
on frequency of response and operating
conditions. Keep certificates about performed
works at the safety valve.

Before commissioning again drain safety valve.

While controlling

• Check valve for tightness. In doing so, take
care of the following indications: whistling
noises, medium at the bonnet, medium at the
drain nozzle or in the exhaust line.

Inspection

• Check each sealing. Replace if leaky.

• Check seat faces.

• Smooth valve seat and disc (4) with fine
lapping paste. If necessary, replace disc (4).

• Equalize guide areas of the spindle (7); when
doing so, do not apply material removing
machine works.

At larger intervals, e.g. each 3 years

• Completely disassemble safety valve.

• Clean and check valve parts.

• Smooth valve seat and disc (4) with fine
lapping paste. If necessary, replace disc(4).
Incase of rework observe functionally
important outlines at the valve seat.

• Replace spring (10) when damaged by
corrosion or temperature and readjust set
pressure.

• Equalize guide areas of the spindle (7); when
doing so, do not apply material removing
machine works.

• Lubricate roller bearing (48) and tightening
screw (11).

• Treat ball (18), sliding guides not in contact
with the medium, fits, gaskets and threads
with an assembling lubricant.

ATTENTION

Do not treat valve seats, metallic sealing surfaces
and sliding guides in contact with the medium.

ATTENTION

For oxygen application all parts in contact with
the medium must be free from oil and grease.
Dangerof explosion!

Loosen nuts (9.1) only when the spring (10) is
released as the studs (9) cannot absorb the initial
stress in the spring (10).

5.2 Instructions for disassembly

• First dismount supplementary loading.
Disassemble position indicator only if
necessary.

• For works at lifting nuts (12) or tightening
screw (11) secure the spindle (7) e. g. with a
pin against torsion as otherwise the valve seat
can be damaged.

5.3 Tools

• fixed spanner 10 - 80 mm

• socket wrench 17 mm

• screwdriver 8 mm

• retaining ring pliers for outer rings

• flatnose pliers

• side cutting pliers

• hammer

• punch Ø 2,5; 3; 4 mm

• seal wire

• lead seal

• lead-sealing pliers

• vernier calliper

• lapping wheel

• washer for M10, M16, M24

In case of very great safety valves (SKB X, Y
and Z) it is possible that there are other parts
or parts arrangements than described in this
operating instruction because of special design
conditions. Please observe special, order
specific assembly drawing.

5.4 Operating materials

5.4.1 Lubricating the removable valve components

To lubricate the removable or detachable
valve components during assembly, use the
greases specified in Table A. Removable or
detachable valve components are all screw
connections, especially pressure-retaining
screw connections, and other components
within the distribution of forces. All removable
or detachable valve components are lubricated
with the same grease if they are lubricated in
the assembly process.
The operating temperature of the valve is
definitive for selecting the grease to be applied
for the removable valve components (cf. Table A).

5 DISASSEMBLY

5.1 Danger and warning indications

Take work order and wait until the installation is
switched free.
Check if the valve is pressureless and
cooleddown.
Residual medium may escape when opening and
disassembling the valve; also at pressureless
plant further evaporations are possible.
Before disassembly switch off electrical supply,
loosen plug or disconnect cable.

7

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

TABLE A: Greases for lubricating the removable valve components

Design temperature of the valve T

T

< 400°C Molykote® BR 2 Plus

B

B

400°C ≤ TB < 700°C Molykote® P 37

[1]

Before applying the grease, ensure that the surfaces are metallically blank (free of oil, grease, etc.) and free of

dirt particles.

The greases specified in Table A are manufactured and/or supplied by the following
manufacturers and/or suppliers:

Grease: Manufacturer / Supplier:

®

Molykote

Molykote

BR 2 Plus Dow Corning GmbH Wiesbaden

®

P 37 Dow Corning GmbH Wiesbaden

5.4.2 Lapping abrasives

It is necessary to use special lapping abrasives that contain finely distributed hardened particles
for lapping seat surfaces on body and disk seats. The lapping abrasive specified in Table B is
recommended by Sempell:

TABLE B: Lapping abrasives, suitable for the finishing of valve seats

Lapping abrasive: Manufacturer / Supplier:

TETRABOR
Boron carbide (F 100 - F 1200)
Lapping abrasive for disc out of material 1.4980:
Diamond suspension 2 - 30 µm.

®

Grease

[1]

[1]

Rheingaustr. 34, 65201 Wiesbaden

Rheingaustr. 34, 65201 Wiesbaden

ESK Ceramics GmbH & Co. KG
Max - Schaidhauf-Str. 35, 87437 Kempten - Germany
Mikrodiamant GmbH, Ostfildern

5.4.3 Further operating materials

Further required operating materials and their usage are specified in Table C and are
manufactured and/or supplied by the following manufacturers and/or suppliers:

TABLE C: Further operating materials

Usage Type Manufacturer / Supplier

Degreasing agent Isopropylalkohol (2-Propanol)
Assembly lubricant (colloidal graphite)
for parts in contact with the medium
O-ring grease Molykote

®

DAG

156 Acheson Industries, Dornstadt

®

55 Dow Corning GmbH Wiesbaden

Rheingaustr. 34, 65201 Wiesbaden

ATTENTION

For oxygen application all parts in contact with the medium must be free from oil and grease.
Dangerof explosion.

8

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

5.5 Dismantling the safety valve

To remove or disassemble a possibly mounted
pneumatic actuator A160 see operating
instruction MA.270.07.xxxx E.

Remove lead seal. Dismount cap (13). Remove
split pin (29) and lifting nuts (12) or loosen and
remove checked lifting nuts (12). Measure and
record distance between upper edge of spindle
(7) and tightening screw (11). Loosen lock
nut (28) and release spring (10) by means of
tightening screw (11).

Loosen nuts (9.1) and lift off bonnet (8). Remove
spring (10), cooling spacer (15) (if installed),
gasket (26), spindle (7) and guide bush (6). In
case of VSR 1 and VSR 2 do not change position
of the adjusting ring (14); mark, if necessary.
Remove disc (4) and ball (18); at orifice letter
SKB: D - W drive out dowel pin (19). The guide
piston (5) will not be disassembled. Dismount
cap (13) with lever (36) only if necessary.

6 ASSEMBLY

For SKB D - W: fasten disc (4) and ball (18) by
means of dowel pin (19) to the spindle (7).

Insert guide bush (6); for VSR 1 and VSR 2
observe marked position of the adjusting ring
(14). Insert disc (4), ball (18) and spindle (7).
Put over cover (16) possibly with slide ring (43).
According to design put on cooling spacer (15),
split ring (20), stop bush (21), distance bush
(22), pressure bush (23), spring stop (24), spring
(10), spring plate (25) and roller bearing (48).

Put on bonnet (8) and screw tight with
hexagonal nuts (9.1). Prestress spring (10) by
means of tightening screw (11) onto the same
dimension as measured before disassembling;
thus the same set pressure as before. Secure
tightening screw (11) with lock nut (28). Screw
on two lifting nuts (12) at the upper end of the
spindle (7) and secure them or screw on lifting
nuts (12) and tighten with split pin (29).

Mount cap (13) and lead seal. Check easy
motion and function of the lever (36) with fork
(31). If available, mount supplementary loading.

7 DIMENSIONS FOR MOUNTING BRACKET

Orifice letter SKB Dimensions in mm
Sempell API Group a b c D Thread

A EA III - IV 106 152 10 160 M12 x 65
B FA III 106 152 10 160 M12 x 65

IV 104 194 10 180 M12 x 65

C III 106 152 10 160 M12 x 65

IV 104 194 10 180 M12 x 65

D GA I 98 140 10 150 M8 x 55

II 106 152 10 160 M12 x 65
III - IV 104 194 10 180 M12 x 65

E HA I 98 140 10 150 M8 x 65

II 106 152 10 160 M12 x 65
III - IV 104 194 10 180 M12 x 65

F I 126 180 12 190 M12 x 65

I - IV 138 196 15 200 M16 x 80

G JA I - II 138 196 15 210 M16 x 80

III - IV 138 196 15 210 M16 x 80

H KA I - II 160 230 15 250 M16 x 80

III - IV 160 230 15 250 M16 x 80

J I - III 184 262 15 290 M16 x 80

IV 184 262 15 290 M16 x 80
K LA I - IV 192 274 15 300 M16 x 80
L MA, NA I - IV 200 286 15 310 M16 x 80
M I - IV 230 328 15 370 M16 x 80
N PA I -III 242 344 20 380 M20 x 100
P I -III 288 410 20 460 M20 x 100
Q QA I -III 288 410 20 460 M20 x 100
R RA I -III 288 426 20 480 M20 x 100
S TA I 350 350 25 430 M20 x 135
T I 400 400 30 480 M20 x 135
U I 450 450 30 530 M20 x 140
V I 550 550 30 680 M20 x 140
W I 640 640 30 780 M20 x 140
X I 720 720 60 900 M24 x 180
Y I 860 860 60 1050 M24 x 180
Z I 950 950 60 1140 M24 x 180

MxI

c

D

a

b

9

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

Valve seat for gases,

vapours,steam

Valve seat for liquid Lapping wheel with

grooveforliquid

f2

d1 b

do

f1

8 FUNCTIONALLY IMPORTANT OUTLINES AT THE VALVE SEAT

Functionally important outlines in mm
Orifice letter SKB do d1 b b f1 f2
Sempell API Group H8 - 0,1 min. max. - 0,3 - 0,1 - 0,1

A - IV 13 14.4 1.05 1.20 0.5 0.4 1.1
A EA I - III 18 19.9 1.30 1.45 0.5 0.4 1.1
B-C FA I - IV 18 19.9 1.30 1.45 0.5 0.4 1.1
D-E GA-HA I - IV 24.5 27.1 1.20 1.35 1.0 0.6 1.1
F - I - IV 28 30.9 1.30 1.45 1.0 0.6 1.1
G JA I - IV 33 36.4 1.30 1.45 1.0 0.8 1.6
H KA I - IV 38 41.9 1.55 1.70 1.0 0.8 1.6
J - I - IV 44 48.5 1.25 1.45 1.0 1.0 1.6
K LA I - IV 51 56.2 1.40 1.60 1.0 1.0 1.6
L MA-NA I - IV 59 65.0 1.50 1.70 1.0 1.3 2.1
M - I - IV 69 76.0 1.50 1.70 1.0 1.3 2.1
N PA I - III 80 88.1 1.45 1.75 1.5 1.6 2.1
P QA I - III 93 102.4 1.30 1.60 1.5 1.6 2.1
Q - I - III 107 117.7 1.35 1.65 1.5 1.9 2.6
R RA I - III 126 138.6 1.40 1.70 1.5 1.9 2.6
SPZ TA I

[3] [3] [3] [3] [3] [3] [3]

[1]

[2]

f2

1. For gases, vapours and liquids

2. For steam

3. From orifice letter S on request

10

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

9 METHODS TO PRODUCE SUPERFINISHED
SEALING SURFACES

ATTENTION

Lapping is a precision operation and must
be carried out by trained personnel. Various
operating areas ask for various operating
methods.

9.1 Lapping area production

9.1.1 Disc

Parts with flat seats are normally machine
lapped.

Procedure:

Allow boron carbide lapping emulsion
(amixture of grade 800 lapping powder and
lapping oil) to drip onto the constantly rotating
lapping machine wheel. Load the items to
be lapped into a suitable locator that is set
eccentrically to the table.
The lapping operation takes 15 to 20 minutes
depending on the quality of the prepared
sealing surface. Afterwards the parts will be
polished. In case of parts made of material

1.4980 the parts will additionally polished on
a tin plate with a diamond suspension; grain
size 2 - 3. A sight control and a test with an
interference glass follow to check whether the
surface is plane and not convex or concave.

9.2 Lapping area site

As a rule, there is no lapping machine available
so only a manual method or the method
described in section 9.1.2 can be used.

9.2.1 Disc

Depending upon their size, lap the parts on
glass plates or discs or rings made of grey cast
iron. Lapping abrasive: Tetra Bor lapping paste
(grade 120 to 1200).

Procedure:

Up to a size of about 200 mm diameters lap
the parts on the plates. In case of greater
diameters, use the part to be lapped as a pad
and move the discs or rings. Thinly distribute
the lapping abrasive on one side and up a
grain size > 400 additionally sprinkle it with oil
drops. Oscillatingly move the valve part or the
lapping wheel with constant hand pressure.
This operation takes several minutes. Remove
the paste with a cold cleaning and repeat the
procedure using progressively finer lapping
paste. Finally a sight control follows.
Up to a size of approx. 200 mm diameter lap the
discs with a mobile manual lapping machine
according to section 9.1.2.

9.2.2 Valve seat

Procedure see section 9.1.2.

9.1.2 Valve seat

The preferred method is hand operated
machine lapping in case the valve seat is
installed in the body (screwed in, welded in or
in another connection). Thereby it is important
that the required force is constantly and
steadily transferred through a spring.

Procedure:

Grinding and/or lapping foils of different grain
sizes are pasted onto a plain carrier wheel of
the machine. The prepared seating areas with

3.2 Ra roughness are alternately lapped with
grain sizes of 200-600-1000. After lapping with
200 grain size, there should be no visible tool
marks. The change takes place at intervals
of about 1 minute. Lapping is carried out with
oscillating movements. Finally the seating area
is cleaned and visually inspected.

ATTENTION

Check body seats regularly to verify that the seat
surfaces are still rectangular to the body center.
Ifthis is not the case, restore squareness by using
a flat grinding machine.

10 DECLARATION TO EC-DIRECTIVE

The declaration of conformity can be found in
the documentation.

11

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

11 PART LIST AND ASSEMBLY DRAWINGS VSE 1 AND VSR 1

VSR 1, SKB J - R, WITH ADJUSTING RING

17

40

29

12

13

41

28

39

11

51

25

48

10

7

24

23

22

9

9.1

8

26

16

6

5

18

19

4

2

3

1

PARTS LIST

Part Name

1 Inlet nozzle
2 Body
3 Seat zone
4 • Disc
5 Guide piston
6 Guide bush
7 Spindle
8 Bonnet
9 Stud

9.1 Nut
10 Spring
11 Tightening screw
12 Lifting nut
13 Cap
14 Adjusting ring
15 Cooling spacer
16 Cover
17 Gag plug
18 • Ball
19 • Dowel pin
22 Distance bush
23 Pressure bush
24 Spring stop
25 Spring plate
26 • Gasket
28 Nut
29 Split pin
30 Bush
31 Fork
32 Square shaft
36 Lever
37 Washer
38 Hexagon nut
41 Cap screw
43 Slide ring (for SN 144)
44 Lock screw
45 Gasket
47 Circlip
48 Roller bearing
51 Pressure plate

51.1 Bearing bush
54 Guard ring
55 Baffle plate

• Recommended spare parts

12

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

VSE 1, SKB S - Z

17
40
13
29
12

41
28
39
64

11
25
51

51.1
48

10

8

7
24
23

9

9.1

27

15.4

15.3

15.2
15
26

6

5
18
19

SCREWED CAP
SKB A - H

FLANGED CAP
SKB J - Z

38 37 36 35 34 33 32 31 30

ACCESSORY 110 COOLING SPACER
as spring protection at operating
temperatures between 400°C and - 90°C

4

2

3

1

15

ACCESSORY 144 COMPENSATING PISTON

43

13

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

12 PART LIST AND ASSEMBLY DRAWINGS VSE 2 AND VSR 2

VSE 2, SKB J - R

9.1

PARTS LIST

17

40

29

12

13

41

28

39

11

51

25

48

10

7

24

23

22

9

8

26

16

6

5

18

19

4

2

3

1

Part Name

1 Inlet nozzle
2 Body
3 Seat zone
4 • Disc
5 Guide piston
6 Guide bush
7 Spindle

7.1 Screw bolt
8 Bonnet
9 Stud

9.1 Nut
10 Spring
11 Tightening screw
12 Lifting nut
13 Cap
14 Adjusting ring
15 Cooling spacer
16 Cover
17 Gag plug
18 • Ball
19 • Dowel pin
22 Distance bush
23 Pressure bush
24 Spring stop
25 Spring plate
26 • Gasket
28 Lock nut
29 Split ring
30 Bush
31 Fork
32 Square shaft
33 Bottom ring
34 Packing
35 Gland
36 Lever
37 Washer
38 Hexagon nut
39 Gasket
40 Gasket
41 Cap screw
44 Lock screw
45 Gasket
48 Roller bearing

• Recommended spare parts

14

SEMPELL SERIES VSE/VSR FULL LIFT AND NORMAL SAFETY RELIEF VALVE

OPERATING INSTRUCTIONS

VSE 2, SKB S - Z

17
40
13
29
12

41
28
39
64

11
25
51

51.1
48

10

8

7
24
23

9

9.1

27

15.4

15.3

15.2
15
26

6

5
18
19

SCREWED CAP
SKB A - H

FLANGED CAP
SKB J - Z

38 37 36 35 34 33 32 31 30

VSR 2 WITH ADJUSTING RING (TO SKB S)

4

2

3

1

6
44
45
14

ACCESSORY 110 COOLING SPACER
as spring protection at operating temperatures
between 400°C and - 90°C

15

15

16