Safety Valve Setting

DEFINITION

• An automatic pressure reliving device

actuated by the static pressure upstream
of the valve, and characterized by rapid
full opening or pop action.
 VALVE TERMINOLOGY
• Relief Valve-An automatic pr relieving
device actuated by static pr upstream from
the valve which opens in proportion to the
increase in pr over the opening pr, used
primarily for liquid service.
• Operating Pressure
• Set pressure-Inlet pressure at which the
SV has been adjusted to open under
service condition.
 VALVE TERMINOLOGY
• Operating and Set Pr. Differential- Valves in process
service will generally give best results if the operating
pressure does not exceed 90% of the set pressure.
• Simmer- Characterized by the audible passage of a gas
or a vapour across the seating surfaces just prior to
‘pop'. The difference between this start to open pr and
set pr is simmer
• Blow down- The difference between set pr and reset pr
expressed as a % of set pr.
• Lift- the disc rise in pr relief v/v.
• Rated Capacity- The % of measured flow at an
authorised % overpr. permitted by the applicable code.
Generally expressed in Kg/sec.
 SAFETY PRECAUTIONS
• Do not go near discharge side of a safety valve
• Body drain and cover vent must be piped to a safe area.
• Always gag a safety valve before making a ring
adjustments.
• When pulling a hand lever for inspection purpose a rope
should be attached to the handle of sufficient length to
protect from escaping steam,dust,fly ash etc.
• Use ear-muffs, hand gloves etc.
• Exercise caution when examining a safety valve for
audible leakage.
SUPERHEATED STEAM IS NOT VISIBLE.
SAFETY VALVE
ASSEMBLY
SAFETY VALVE
ASSEMBLY
Do not plug cover plate vent hole or
reduce vent hole pipe size
 OPERATION
• The safety valve operate during closing with a back
pr.principle,i.e the force of trapped steam on the upper
side of the disc holder is utilized to assist the spring in
forcing the disc back down on its seat.
• All safety valves are steam tested at factory. Every valve
is set to have a clean action and to reset tightly.
• Two methods exist for field testing of valves.Hydroset
Unit and full system pressure.
• Use of hydro set unit will serve to establish set pressure
only and should not be used for blow down adjustment.
• Gagging of other valves not being set is required
depending on the pressure being used.
 REQUIREMENTS
• Boiler should be in lighted up condition
with HFO/LDO firing only.
• Alll boiler protections should be in service.
• All auxiliaries like ID,FD,BFP,CW pump,
vacuum pump,CEP etc should be in a
healthy condition.
• HP/LP bypass system should be available
• Proper communication with personnel
near safety valve and at Control room.
 METHOD
• The valves should be set within ±1% of set
pr.
• Lab standard pr gauge with a minimum
graduation of 0.5% of the full scale reading
and accuracy of ±0.25% to be used.
Gauge should be of sufficient range so
that reading is in the middle third of the
scale.
 METHOD
• Raise drum pressure to 7-8 kg.Charge MS
line through bypass line of Boiler stop
valve.
• Pull vacuum in condenser
• Charge HP Bypass system
• Charge LP Bypass system. Gradually
raise the pr upstream of identified valve.
Normally it is done from lowest pressure to
highest one.
 METHOD
• Initially valves lifting are checked at a less
pressure by the rope lever arrangement to check
its functioning.
• Raise the pressure near to set pr and record the
pop pr and reset pr.
• Popping point adjustment-to change the popping
pr of the valve remove the cap and lever
assembly, loosen the locknut and turn the spring
adjuster clockwise to decrease pr.
 METHOD
• Ring Adjustment - The position of the upper
adjusting ring and the lower adjusting ring are
locked by means of the upper adjusting ring pin
and the lower ring pin respectively. These pins
are threaded into the valve body and engage
notches which are cut in into the rings. To adjust
either ring the corresponding ring pin must be
removed.
• One notch downward of Lower ring adjusts 42.2
ksc of set pr. Lower Ring is not used for
adjusting blow down.
 Guidelines for setting and locking adjusting
rings
• Gag the safety valve for protection while making
ring adjustments.
• Ring pins of any particular valve is not
interchangeable
• The tip of ring pin should NOT touch the bottom
of the ring notch. Also the pins should not bear
against the rings.
• Upper adjusting ring should not be set below the
seat level and lower one above the seat level.
• Lock both the ring pin using a seal wire.
 BLOWDOWN ADJUSTMENT
• In arriving at proper blow down adjustment
of the SV a lift indicator is used.
SAFETY VALVE
ASSEMBLY
 L
BLOWDOWN ADJUSTMENT i
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 Blow down Adjustment
• The upper ring is used to obtain full lift at the
popping pr.However its position also determines the
point at which the valve begins to drop out of full lift
and starts closing portion of its cycle. For example if
the upper ring is in such a position that the valve
barely attains full lift at a slight reduction of Pr, the
first portion of the cycle will be represented by
ABF.If it were not for the lift stop the action of the
valve would be represented by ABCF.For lower
setting the action of the valve would be represented
by ABG and for not the lift stop by ABDG.Most
desirable cycle is represented by ABFJM.
 ELECTROMATIC RELIEF VALVE
• Electrically operated pr relief device which can
be operated manually by closing a switch or
automatically by means of a pr sensitive
element.
• Total valve assembly consists of a controller
consisting pr sensitive element in which a
bourdon tube actuates electrical contacts and a
heavy duty relay to switch the solenoid. The
solenoid actuates a pilot valve which in turn
operates the main valve.
Blow down Chart
ERV
 Lifting/Reset Pr
Location Valve Set Pr % of Blow down Relieving capacity(Kg/hr)
OPEN / CLOSE

Boiler Drum 209/200.6,211.1/ 4/5/5/5 212800/214928/217056/261228

SV1/SV2/ 200.5,213.2/202.
SV3&4/SV5&6 5,215.3/204.5
SH SV- 188.5/181.3 3.8 187441
SV7&SV8,
SH ERV 185.5/180.3, 2.8/3.2 116388/94195
SV9&10,SV11, 186.6/180.6
12&13
CRH SV-SV 52.4/49.8, 5.0/5.0 207460/214147
14&15,SV 54/51.3
16&SV17

HRH SV- SV 49/46.6, 5.0/5.0 162816/167698

18&19,SV20&2 50.5/48.0
1
HRH ERV- SV 48/47,48.5/47 2.0/2.0 121045/122280
22&23,SV
.5
24&25