Operating and Installation Instructions

Safety Valves

SAFE SAFE-P
(Series 900) (Series 920)

SAFE-TC SAFE-TCP/TCS
(Series 940) (Series 960/950)
Contents
1.0 General Information on 4.6 Marking ...................................................................... 8
Operating Instructions ......................................... 3 5.0 Installation .............................................................8
2.0 Notes on Possible Dangers .................................... 3 5.1 Safety note .................................................................. 9
2.1 Significance of Symbols............................................. 3 6.0 Notes on Dangers During Installation,
2.2 Safety-Related Definitions ......................................... 3 Operation and Maintenance ................................9
2.3 Qualified Personnel .................................................... 3 7.0 Putting the Valve into Operation .......................10
3.0 Handling................................................................. 4 7.1 Potential Hazards...................................................... 10
3.1 Storage........................................................................ 4 8.0 Care and Maintenance ........................................10
3.2 Transport..................................................................... 4 8.1 Setting Instructions .................................................. 11
3.3 Handling Before Installation ...................................... 4 8.1.1 Removing the Cap .............................................................12
4.0 Specification ........................................................... 4 8.1.2 Changing the Set Pressure “without” Spring Change .......12
8.1.3 Changing the Set Pressure “with” Spring Change.............12
4.1 Applications................................................................ 4
9.0 Troubleshooting ...................................................13
4.2 Technical Specification............................................... 4
4.3 Technical Data ............................................................ 5 10.0 Troubleshooting Table.......................................14
4.4 Diagram ...................................................................... 6 11.0 Dismantling the Valve .......................................16
4.5 Parts list ...................................................................... 7 12.0 Warranty ............................................................16

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 Operating and Installation Instructions
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1.0 General Information on Operating Instructions
These operating instructions contain information necessary to install and operate the valve both safely
and effectively.
If problems arise which cannot be solved with the aid of these operating instructions, please contact the
supplier/manufacturer for further information. These operating instructions comply with applicable EN
safety standards as well as regulations and codes of practice applicable in the Federal Republic of
Germany. If the valve is used outside the Federal Republic of Germany, the operator or the person
responsible for the system design must ensure that valid national codes of practice are complied with.
The manufacturer reserves all rights to implement technical modifications and improvements at any
time.
The use of these operating instructions assumes the user is qualified as described under Section 2.3
"Qualified Personnel".
The operating personnel must be instructed in accordance with the operating instructions.
2.0 Notes on Possible Dangers
2.1 Significance of Symbols

Warning of general danger

Non-compliance with operating instructions is dangerous!
Read the operating instructions before installation, operation, maintenance or
disassembly and adhere to them strictly.
2.2 Safety-Related Definitions
The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.
DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or
considerable damage to property can occur.
WARNING means that if the relevant information is disregarded, there is a danger of serious injury and
/ or damage to property can occur.
CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or
damage to property can occur.
NOTE means that particular attention must be paid to certain technical aspects.
All other information not specifically emphasised such as transport, installation, operating and
maintenance instructions as well as technical data (in the operating instructions, product documentation
and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in
turn can cause serious injury to persons or damage to property.
2.3 Qualified Personnel
The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-
up and operation of the product and have the qualifications corresponding to their responsibilities such
as:
Instruction and obligation to comply with all operational, regional and in-company regulations and
requirements;
Training or instruction in accordance with safety technology standards with regard to the upkeep and use
of appropriate safety and work protection equipment;
First aid training, etc.

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3.0 Handling
3.1 Storage
- Storage temperature -20˚ to +65˚C dry, free of dirt
- The painting is only a primer, intending to guard against rust during stock or transportation. Don‘t
damage the paintwork.
- A desiccant or heating to prevent condensation is necessary in damp rooms.
3.2 Transport
- Transport temperature -20˚ to +65˚C.
- Protect against external force (impact, vibration etc.).
- Don‘t damage the paintwork.
3.3 Handling Before Installation
- If flange covers are fitted, remove shortly before installation!
- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.
4.0 Specification
4.1 Applications
Safety valves are safety devices designed to prevent the pressure in any pressurised system from
exceeding the maximum permissible pressure by more than the permissible tolerance of, usually +10%.
The engineer planning a plant is responsible for selecting the correct valve for a given application.
The special features of the valve concerned must be taken into account.
Oil and grease free
for oxygen application
- Valves for oxygen application (O2) have a fixed plate.
- Valves for Ammonia (NH3) acc. to TRD 451-452 must be free from nonferrous metals
with flanges DIN 2512 form N.
- ARI-Valves of GG-25 are not allowed in systems acc. to TRD 110.
- Valves for inflammable, aggressive or toxic media, must be off tensile material.
- With applications for media that demand special criteria, please consult.
- -marking for applications acc. to Pressure Equipment Directive on request.
4.2 Technical Specification
Terms as defined in DIN 3320 T1, TRD 421, TRD 721, AD-A2
Direct Loaded Safety Valve
A direct loaded safety valve is a valve, in which the opening force underneath the valve disc is opposed
by a closing force such as a spring or a weight.
Standard Safety Valve
A standard safety valve is a valve which, following opening, reaches the degree of lift necessary for the
mass flow to be discharged within a pressure rise of not more than 10%. No further requirements are
made for the opening characteristics.
Full Lift Safety Valve
A full lift safety valve is a valve which, after commencement of lift, opens rapidly within a 5% pressure
rise up to the full lift as limited by the design. The amount of lift up to the rapid opening (proportional
range) shall not be more than 20% of the total lift.

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4.3 Technical Data
Series 900 : DN 20/32 - DN 150/250
Cast iron grades GG-25, GGG-40.3; cast steel grade 1.0619+N (GS-C25N), 1.4408
PN 16/16, PN 40/16
Approved under:
Figure 901-912 -VdTÜV Notice 100, AD-A2 and TRD 421.
Application letter D/G and F
Figure 903, 904, 990-VdTÜV Notice 100, -100/4, TRD 721, DIN 4751 T1 and 2.
Application letter D/G/H and D (for figures 904, 990)

Series 920 : DN 20 - DN 100

Cast iron grade GG-25; cast steel grade 1.0619+N (GS-C25N), 1.4408
PN 16, PN 40
Approved under:
Figures 921-924 -VdTÜV Notice 100, AD-A2 and TRD 421.
Application letter D/G and F

Series 940 : DN 15 - DN 25
Cast iron grade GGG-40.3; cast steel grade 1.4408
PN 40
Approved under:
Figure 941-943 -VdTÜV Notice 100, AD-A2 and TRD 421.
Application letter D/G and F

Figure 945-946 -VdTÜV Notice 100, -100/4, TRD 721, DIN 4751 T1 and 2.
Application letter D/G/H and D

Series 950/960 : DN 15 - DN 25 (G 1/2 - G 1)

GGG-40.3, 1.4571
PN 100
Approved under:

Figure 951-953 -VdTÜV Notice 100, AD-A2.

Figure 961-963 Application letter D/G and F

Accessories: Stainless steel bellow for back-pressure compensation; Elastomer bellow;

Soft sealing disc; Lock bush; Proximity switch; Heating jacket; Test gag;
Rupture disc; Support tongues; Removable lifting aid

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4.4 Diagram
Fig. 901 Fig. 941 Fig. 961

fig. 1
Fig. 902 / 912 / 903 / 904 / 922 / 924 / 945 / 946
WEDI Bellow

Lever Disc series 950 Bellow series 940

Fig. 951/952; 961/962

fig. 2

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4.5 Parts list
Pos Description Pos Description
1 Body 31 Ring
2 Seat 32 Hex. nut
2a Screwed seat 33 Lift bolt
3 Stud 34 Screw
4 Spindle guide 35 Lift fork
7 Gasket 36 Lifting lever
q Hex. nut 37 Spring
9 Lift limitation ring 38 Screw
10 Spindle ring 39 Bolt
11 Bonnet, closed 40 Split pin
12 Disc unit 41 Lever open
13 Lifting aid 42 Bonnet, open
14 Spindle 43 Bellow
15 Gasket 44 Ring
16 Spring type straight pin 45 Ring
17 Adjusting screw 47 Ball
18 Ball 48 Retaining ring
19 Spindle cap 55 Bellow unit
20 Parallel pin 59 Protective rim
21 Lock nut 60 Spacer
22 Hex. head screw 61 Coupling
23 Lead seal 62 Weight
25 Snap ring 63 Guide bush
26 Spring plate 65 Coupling
27 Gasket 66 O-Ring
28 Cap, closed 67 Lift button
29 Cap open 68 Spring type straight pin

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4.6 Marking

Type test plate acc. to AD-A2 / TRD

fig. 3: Type test plate

Serial-No. BA/BQ Mechanic

Year No.

ARI Set pressure

disc
E = EPDM up to +150°C Approval
V = Viton up to +180°C (e.g. UDT, SZU)
N = Neoprene up to +125°C

fig. 4: Body

Series with thread connections are marked on the body.

5.0 Installation
The following points should be taken into account besides the general principles governing instal-
lation work: - See appropriate TRD 421, AD-A2, DIN rules for piping and installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before installation.
- Safety valves shall be installed with vertical spindle.
- Safety valves shall be installed with upright spindle, not series 950 when marked, „Installation only
horizontal“, then they must be installed horizontally.
- No static, dynamic or thermal loads shall be transferred to the valve.
- Flange gaskets shall be fitted concentrically and not restrict the flow cross section.
- Dirt and foreign bodies shall not be permitted to enter the safety valve.
- Blow-off lines shall be laid with gradient.
- Water shall be drained from the safety valve and blow-off line via the blow-off line (drainage points
always at the lowest point).
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- All drainage systems shall be laid with gradient to a visible discharge.
- The arrangements shall permit the discharge of condensate without danger at all times

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.

Support
Bellow

Drip pan

Drainage Drainage at lowest point

fig. 5
- The blow-off line shall be sufficiently large to ensure that the internal back-pressure while blowing-off
does not exceed 15% of the set pressure.
(Exception: safety valves with metallic bellow for back-pressure compensation).
- The safety valve shall be equipped with a metallic bellow for back-pressure compensation if the back-
pressure exceeds 15% of the set pressure.
- The ratio pao/po shall be taken into account when dimensioning the system.
- The inspection connection on the bonnet of safety valves with metallic bellow is for checking the state
of the bellow as damage to the bellow leads to failure of the safety valve (in this case the bellow would
have no back-pressure compensating effect and the safety valve would not function as required).
- The state of the bellow is checked by connecting a pressure gauge to the inspection connection so that
the back-pressure can be seen in the event of damage.
- Caution: No piping or screws shall project through the inspection connection into the bonnet!
Danger of jamming !
- Safety valves shall be equipped with support tongues to absorb high reaction forces.
- Pressure losses in the line to the safety valve shall not exceed 3%.
- Any blocking screws shall be removed.
5.1 Safety note
Failure to observe the instructions in point 5 may endanger personnel, the plant and other
objects.

6.0 Notes on Dangers During Installation, Operation and Maintenance

DANGER !
Operation can be completely safe only if the valve is properly installed, put into operation and
maintained by trained personnel (cf. point 2.3 “Qualified personnel”) paying full attention to the
warnings in these operating instructions. In addition, the general installation and safety rules for piping
and plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict
attention must be paid to the operating instructions during all work on the valve and when handling it.
Injury or damage can be caused by ignoring them.

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7.0 Putting the Valve into Operation
- Check that the data of the valve are correct for the plant (see Typ test plate).
- Remove protective caps and lever lock before putting the valve into service.
- Clean and flush the plant before it is put into operation as dirty media can cause leaks in safety valves.
(See point 5 “Installation”.)
DANGER !
Before putting a new plant into operation or restarting a plant after repairs or modification, always make
sure that:
- all installation and assembly work has been completed!
- only trained personnel (see point 2.3) are employed to start the plant!
- existing guards have been attached and in good order.
7.1 Potential Hazards
- Always make sure that the safety valve cannot freeze or become clogged or blocked
(see point 5 “Installation”.)
- The surface temperature of the casing can become very high during operations with high media
temperatures. Danger of burns!
- If no blow-off line is provided, medium may suddenly emerge from the valve outlet. Danger of
scalding, explosion or injury!
- Loud noises may be generated when blowing off.
- Hot media may emerge from the inspection opening of the spring bonnet.
- with open bonnet hot media may escape.
8.0 Care and Maintenance
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due to particles
between the seat and disc.
- If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been damaged.
This can only be rectified at our works or by an authorised contractor.
- The safety valve must be lifted from time to time in line with current regulations to ensure that the
valve works correctly.
(The intervals at which this must be done depends on various factors so that no generally applicable
interval can be specified).
Note: Too frequent lifting for test purposes can increase wear of the sealing surfaces.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be returned to the
original position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- Our setting instructions (point 8.1) must be strictly adhered to when changing the set pressure or
changing the set pressure and the spring.
It is best to have these operations done at our works (Schloss Holte- Stukenbrock).
- The manufacturer accepts guarantee liabilities only if tampering by third parties is prevented.

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8.1 Setting Instructions

SAFE-TCS

SAFE-TCP
SAFE-TC
Bellow
Closed cap

Open cap

fig. 6

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8.1.1 Removing the Cap

Open caps

- Remove pin (39/40).

- Extract lifting lever (41).

- Remove screw (38).

- Unscrew cap (29).

Closed caps

- Press lifting lever (36) towards bonnet (11) and against stop.

- Unscrew cap (28).

Closed cap series 960/950

- Remove spring type straight pin (68)

- Remove lift button (67) / lifting lever (36)

- Unscrew cap (28)

8.1.2 Changing the Set Pressure “without” Spring Change

- Check the spring range.

- Spindle (14) must be held fast by all alterations.

- Loosen lock nut (21).

- Turn adjusting screw (17) clockwise to increase and anticlockwise to reduce the set pressure.

- Secure spring setting by tightening lock nut (21).

- Assemble lifting device.

8.1.3 Changing the Set Pressure “with” Spring Change

- Spindle (14) must be held fast by all alterations.

- Extract parallel pin (20) and lift off the spindle cap (19).

- Slacken locknut (21) and relieve spring (37) by turning adjusting screw (17) anticlockwise.

- Unscrew nuts (8) at flange connection and remove bonnet (11/42).

Fig. 940: loosen coupling (61)
Fig. 950/960: loosen bonnet (11)

Note: With higher set pressures, the two nuts (8) on the longer studs (3) must be removed last and
simultaneously!

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- Remove top spring-plate (26) and spring (37).

- Extract spindle (14) with disc (12/12a), guide plate (4/4a) and bottom spring-plate (26).

- Clean seat (2) and disc (12/12a).

- Insert spindle (14) with disc (12/12a), guide plate (4/4a), spring-plate (26) and different spring (37).

- Fit bonnet (11/42) and reset the set pressure; make sure spring setting range is appropriate.

- Secure spring setting by means of lock nut (21).

- Assemble lifting device.

- If necessary, replace both spring plates (26) and use longer studs (3) when fitting a spring for a higher
set pressure.

- Further information obtainable from the manufacturer.

Only for the 900 series.

When changing the set pressure and fitting a new spring, note that safety valves with set pressures
between 0.2 and 1.5 bar have a greater lift.
Therefore:

Set pressure in the range Spring change only in

the range
0.2 to 1.5 bar 0.2 to 1.5 bar
> 1.5 bar > 1.5 bar
Only for the 950 series
Caution:
Safety valves for horizontal application, must also to be set in a horizontal position.

9.0 Troubleshooting
In the event of failures or malfunctions, check that the valve was assembled and installed as described in
these instructions.

Compare the DN, opening pressure, blowing-off power, back pressure, operating pressure and
temperature with the information given in the plans of the piping system. Check also that the service
conditions correspond to VDTÜV, AD, TRD and the data given on the Type test plate and the technical
data.

Danger!
It is essential that the safety regulations are observed when identifying faults!

If malfunctions cannot be eliminate with the help of the following „troubleshooting table“, the supplier
or manufacturer should be consulted.

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10.0 Troubleshooting Table
Fault Possible cause Corrective measures
Safety valve does not respond, Flange covers not removed. Remove flange covers.
no flow Relieve pressure first!
Observe points 7.0 and 11.0!
Test gag still in place. Remove test gag.
Spring blocked. Remove pipe or screw projecting into bonnet
through inspection connection.
Set pressure too high. Reset (point 8.1) or replace the safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
Stainless steel bellow defective, Replace the safety valve.
no back-pressure compensation. Relieve pressure first!
Observe points 7.0 and 11.0!
Back-pressure not taken into account. Reset (point 8.1) or, if necessary, replace the
safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
The use of a stainless steel bellow to
compensate for back-pressure should be
considered.
Medium viscous or sticky Use bellow / heating jacket. Insert rupture
disc upstream if necessary.
Relieve pressure first!
Observe points 7.0 and 11.0!
The valves and piping must be protected Heating !
against freezing and solidifying media.
Stem cannot be lifted. Pressure less than 85% of set pressure. It must be possible to lift the spindle at over
85% of the set pressure.
Safety valve seat leaking. Working pressure higher than 90% of set Working pressure must be less than 90% of
pressure. the set pressure.
At low pressures: lever not in neutral position Press lever into neutral position (towards
with closed cap. bonnet).
Safety valve flattering. See separate point “Flattering”.
Medium contaminated; foreign body between Raise spindle briefly or, if necessary, replace
seat and disc. safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
Use of a soft sealing disc should be
considered.
Flange broken. Damage during transport. Replace safety valve.
Flange bolts not evenly tightened. Replace safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
Pressure surges. Safety valve not installed at highest point. Install safety valve at highest point.
Relieve pressure first!
Observe points 7.0 and 11.0!
Valve drainage inadequate or not fitted. Install drainage system a required by
regulations.
Relieve pressure first!
Observe points 7.0 and 11.0!

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Fault Possible cause Corrective measures
Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screw
above cap, Figure 990).
Spring corroded by medium and broken. Replace safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
In the case of vapour, select open cap or
bonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. liquids) Replace safety valve.
emerging from valve. Relieve pressure first!
Observe points 7.0 and 11.0!
Select design with closed bonnet and cap.
Install a guard if necessary.
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or radius
in connection socket. Select larger line if
necessary.
Relieve pressure first!
Observe points 7.0 and 11.0!
Poor welding (root pass), gaskets at inlet and Change conditions.
outlet flanges too small or not concentric. Relieve pressure first!
Observe points 7.0 and 11.0!
Safety valve capacity too high. Install smaller safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
Burner capacity too low. Install smaller safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
Blow-off line too long or diameter too small. Use larger diameter or back-pressure
compensation by stainless steel bellow.
Relieve pressure first!
Observe points 7.0 and 11.0!
Inlet and/or outlet socket too small. Install with dimensions larger than DN of
inlet and outlet lines.
Relieve pressure first!
Observe points 7.0 and 11.0!
Back-pressure higher than 15%. Install stainless steel bellow for pressure
compensation.
Relieve pressure first!
Observe points 7.0 and 11.0!
Capacity too low. Safety valves not applied unsuitable for plant Select and install suitable safety valves.
conditions. Relieve pressure first!
Observe points 7.0 and 11.0!
Safety valve not applied in line with current Adjust conditions.
DIN, AD, TRD, etc. rules. Relieve pressure first!
Observe points 7.0 and 11.0!

Caution: - Read point 11.0 prior to dismantling and repair work!

- Read point 7.0 before restarting the plant!

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11.0 Dismantling the Valve
The following points must be observed beside the general principals rules governing the assembly work:
- pressureless pipe system.
- medium must be cool.
- plant must be drained.
- purge piping systems in case of caustic, inflammable, aggressive or toxic media.
- have assembly work performed only by qualified personnel (see point 2.3).

12.0 Warranty
The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert
Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale
itself.

We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed
application.

No warranty claims can be made for any damage caused as the result of incorrect handling or disregard
of operating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and
other applicable codes of practice.

Damage arising from operation under service conditions differing from those specified in the VdTÜV
sheet, AD, TRD (cf. point 4.3) or other agreements is also excluded from the guarantee.

Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.

No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is
excluded.

The warranty shall not cover maintenance work, installation of external parts, design modifications or
natural wear.

Any damage incurred during transport should not be reported to us but rather to the competent cargo-
handling depot, the railway company or carrier company immediately or else claims for replacements
from these companies will be invalidated.

Technology for the future.

GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: [email protected]

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