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Maintenance Fundamentals Seite 1/9

1 Maintenance Fundamentals

1.1 Introduction ........................................................................................................... 2

1.2 Terminology .......................................................................................................... 3
1.2.1 Parts Description acc. to ASME PTC 25........................................................ 3
1.2.2 Definition of set pressure ............................................................................... 4
1.2.3 Definition of overpressure .............................................................................. 4
1.2.4 Definition of blowdown ................................................................................... 4
1.3 Critical parts .......................................................................................................... 5
1.3.1 Nozzle and disc.............................................................................................. 5
1.3.2 Spring ............................................................................................................ 6
1.3.3 Adjusting Ring................................................................................................ 7
1.3.4 Parts Providing Alignment.............................................................................. 8
1.4 Lifting devices ....................................................................................................... 9

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1.1 Introduction

This chapter deals with basic information considered as necessary for assembly and disassembly
of LESER’s safety valves. Fundamentals include:
- Parts description
- Definition of overpressure, blowdown and set pressure at LESER
- Explanation of relevant construction elements

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1.2 Terminology

1.2.1 Parts Description acc. to ASME PTC 25

Item Component Description per ASME PTC 25 – Parts used by LESER
1 Body A pressure-retaining or containing component of a pressure relief device
that supports the parts of the valve assembly and has provision(s) for
connecting to the primary and/or secondary pressure source(s).
5 Nozzle A primary pressure- containing component in a safety valve that forms a
part or the entire inlet flow passage.
5 Seat The pressure-sealing surfaces of the fixed and moving pressure-containing
components.
6 Adjusting ring A ring assembled to the nozzle or guide of a direct spring valve, used to
(blowdown ring) control the opening characteristics and/or the reseat pressure.
7 Disc A moveable component of a pressure relief device that contains the primary
pressure when it rests against the nozzle.
9 Bonnet A component of a direct spring valve or of a pilot in a pilot-operated valve
that supports the spring. It may or may not be pressure containing.

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8 Guide A component in a direct spring or pilot-operated pressure relief device used
to control the lateral movement of the disc or disc holder.
12 Spindle A part whose axial orientation is parallel to the travel of the disc. It may be
(stem) used in one or more of the following functions: (a) assist in alignment, (b)
guide disc travel, and (c) transfer of internal or external forces to the seats.
15 Bellows A flexible pressure-containing component of a balanced direct spring valve
used to prevent changes in set pressure when the valve is subject to
superimposed back pressure, or to prevent corrosion between the disc
holder and guide.
16/17 Spring plate Or spring step: a load-transferring component in a safety valve that
(spring step, supports the spring.
-button, -washer)
18 Adjustment screw A screw used to adjust the set pressure or the reseat pressure of a
reclosing pressure relief device.
40 Cap A component used to restrict access and/or protect the adjustment screw in
a reclosing pressure-relief device. It may or may not be a pressure
containing part.
40 Lift lever A device to apply an external force to the stem of a pressure relief valve to
manually operate the valve at some pressure below the set pressure
54 Spring The element in a safety valve that provides the force to keep the disc on the
nozzle.
Table 1: Parts description acc. to ASME PTC 25

The following parts are described in ASME PTC 25, but are not used in LESER safety valves.
Component Description per ASME PTC 25 Not used in LESER safety valves,
because
Disc holder A moveable component in a pressure One piece spindle with different disc design,
relief device that contains the disc does not require a disc holder
Yoke A pressure-retaining component in a Open bonnets are used for the same
pressure relief device that supports the purpose.
spring in a pressure relief valve or pin in
a non-reclosing device but does not
enclose them from the surrounding
ambient environment
Table 2: Parts description acc. to ASME PTC 25 – not contained in LESER safety valves

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1.2.2 Definition of set pressure

ASME PTC 25, 2001, 2.7 OC of PRD
LESER defines the set pressure as the value of increasing inlet static pressure at which the first
audible/visible discharge (first steady flow for liquids) for gas and steam occurs. Furthermore a
“popping” point of safety valve exists when the vessel pressure rises above the set pressure. At
this pressure the valve opens rapidly with small or no increase in system.

1.2.3 Definition of overpressure

ISO 4126-1, 2004, 3.2.3
Overpressure is defined as the pressure increase over the set pressure at which the valve attains
the lift specified by the manufacturer. Usually overpressure is expressed as a percentage of the set
pressure.
For steam and gas applications the maximum overpressure varies between 3% and 10%
depending on applicable code and application. For liquids most codes specify a maximum
overpressure of 10%.

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1.2.4 Definition of blowdown
ASME PTC 25, 2001, 2.7 OC of PRD
Blowdown is considered as the difference between actual popping pressure of a pressure relief
valve and actual reseating pressure expressed as a percentage of set pressure or in pressure
units.
Typical values for the blowdown are 4% to 15% for steam and gas and 20% to unlimited for liquids.

Figure 1 gives a graphical representation of the definitions.

Figure 1: general characteristic of LESER safety valves for steam/gases acc. to ASME VIII

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1.3 Critical parts

This chapter contains a description of critical parts influencing the operation characteristic.
Emphasized were different disc and nozzle constructions, correct spring selection, positioning and
function of the adjustment ring and parts which provide alignment.

1.3.1 Nozzle and disc

The geometry of nozzle and disc is critical to the valve operation. Small changes to the dimensions
of these parts can change overpressure, blowdown and general valve operation significantly.
Maintenance instructions include default dimensions of these parts in chapter rework of critical
dimension. These diameters must be maintained when performing repair and maintenance work.
Nozzle and disc also form the seat of the valve. The surface finish of the contact surfaces is critical
for the tightness of the safety valve. For a metal to metal seat the contact surfaces are lapped for a
specified tightness acc. to API 527 (see chapter rework of critical parts).
Table 3 provides differences between optional disc constructions of flanged and threaded valves.

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Metal to metal seat Soft seat – o-ring disc

Flanged valves
(type 526)

Lifting aid

Disc O-Ring

Threaded valves
(type 459)

Table 3: soft seat and metal to metal seat constructions of flanged and threaded valves
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1.3.2 Spring
The closing force on the disc is applied by the compression of the spring. When the valve opens, a
further compression of the spring must be achieved by the opening forces underneath the disc.
The correct spring rate is critical to overpressure and blowdown of the valve. Each spring has a
defined set pressure range. The spring charts (chapter 6: spring charts) of the manufacturer must
be followed when readjusting or changing the set pressure of the safety valve.
The following table lists the potential consequences of using a spring for a set pressure outside of
its range.

Condition Consequences
Set pressure above spring range - increased blowdown
- risk of excessive spring compression with coils approaching
each other, resulting in restricted lift
- pressure accumulation in the vessel above acceptable
levels due to restricted lift
Set pressure below spring range - increased overpressure

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- potential pressure accumulation in the vessel above
acceptable levels
Table 4: Influence of incorrect set pressure on overpressure and blowdown

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1.3.3 Adjusting Ring

Codes and standards specify limits for the overpressure and blowdown of safety valves. In some
designs adjusting rings are used to adjust the overpressure and blowdown of the safety valve in
order to meet the requirements of codes and standards. In many of them a 10% accumulation
pressure is used as a basis for the design strength calculation of a pressure vessel. Therefore the
overpressure for safety valves is limited to 10% of the set pressure for the majority of the
applications.

The position of these rings is usually factory set to meet overpressure and blowdown requirements
of the applicable codes. The position of the rings can be adjusted to fine tune overpressure and
blowdown of the valve.
For the most common design with one lower adjusting ring, changing the ring position has the
following effects:

Lowering ring: overpressure increases, blowdown decreases

Rising ring: overpressure decreases, blowdown increases

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The adjusting ring in LESER’s type 526 should be turned to the lowest possible position on the
nozzle to ensure all code requirements are met. No further ring adjustment depending on set
pressure or medium is required.
The benefit for the user is the easier maintenance, because no complicated ring adjustment is
necessary.

Adjusting ring

Figure 2: Blowdown ring of LESER’s Type 526

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1.3.4 Parts Providing Alignment

Correct alignment of nozzle and disc

are critical for proper valve operation
and tightness. Disc and spindle of the
valve will move up and down during
Adjusting
valve operation. screw

Proper guiding of the spindle is

essential for trouble free valve
performance. The spindle is guided by Spindle
the guide and the adjusting screw.

When installed, the user must ensure

that no dust, particles in the fluid or
sticky media may enter the guiding Guide

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surfaces and negatively influence the
valve performance. In some cases the Disc
use of a bellows is advisable to
protect the guiding parts. Nozzle/
Inlet body

Figure 3: overview of parts providing alignment

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1.4 Lifting devices

The standard design for the valve top is a plain cap, covering and sealing the adjustment of the
safety valve.
Lifting levers allow users to check if the safety valve is still operational by lifting the disc off the
seat. The valve remains in place while testing is performed.
Lifting levers must allow users to lift the disc off the seat when 75% of the set pressure is present
at the valve inlet.
Caps and levers are sealed to prevent any unauthorized modification of the set pressure.
Figure 4 offers different caps and lever used for different LESER safety valves.

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Plain Cap H2 Plain lever H3- Packed lever H4
- gastight - - not gastight - - gastight -

Bolted Cap H1 Pneumatic lever H8

- gastight - - clean service -

Figure 4: overview of different cap and levers

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author: Bi released by: replaces: 000-00 status: valid
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