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Complete Compact Performance - EN
Complete Compact Performance - EN
Complete Compact Performance - EN
00
Maintenance Handbook for
LESER Product Group Compact Performance Page 2/6
1 Introduction
About MAINTENANCE
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relevant for valve operation)
• Repair process
• Suggested equipment for assembling, disassembling and rework of critical parts
• Disassembly, including sectional drawings
• Rework of critical parts including an overview of critical dimensions
• Assembly, including options
• Spring charts
• Testing procedures (set pressure and leak tests)
• Spare parts lists
• Guidelines for inspection, storage and transport
• Trouble shooting
2 Contents
SIP 1003.00
1.1 Introduction Introduction and table of contents
“Introduction”
Terminology:
- Parts
- Set pressure
- Overpressure & blowdown
Critical parts: SIP 1002-00
1.2 Maintenance
“Maintenance
Fundamentals - Nozzle & disc
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Fundamentals”
- Spring
- Adjusting ring
- Parts providing alignment
- Lifting devices
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LGS 4100 “Assembly
instructions for type
437, 438, 439, 481”
LGS 4102 “Assembly
Assembly instruction:
instructions for types
- Step-by-step instruction for 459, 462, 450, 460”
assembly
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charts – type 439“
LWN 062-25 “Spring
charts psig – type 439“
Leak testing:
- Procedures and equipment for
LWN 369-34
testing functional tightness (disc-
“Performing Leak
nozzle connection)
Tests”
1.9 Testing Procedures - Procedures and equipment for
testing shell tightness (nozzle, cap)
Tightness requirements:
- Seat tightness LWN 220-01 “Tightness
- Shell tightness Test”
- Back seat tightness
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Inspection during
Operation”
1 Maintenance Fundamentals
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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
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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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1.2.4 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: general characteristic of LESER safety valves for steam/gases acc. to ASME VIII
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.
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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
disclosure cat.: I proofread: Bi published date: effect. date: 15.12.10
author: Bi released by: replaces: 000-00 status: valid
resp. depart.: PM date of release: revision No.: 0
doc. type: SIP change rep. No.: 00687A retention period: 10y.
LESER Supplementary Information Pool SIP 1002-00
Maintenance Fundamentals Seite 6/9
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
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:
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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
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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
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Plain Cap H2 Plain lever H3- Packed lever H4
- gastight - - not gastight - - gastight -
Content
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Introduction.......................................................................................................... 1
4 Safety valve to repair........................................................................................... 2
1 Purpose
This LESER Global Standard (LGS) shows the process for safety valves to repair.
2 Scope
This LGS applies to all members of the LESER Quality Cluster.
3 Introduction
The following flow chart shows the process steps, which are necessary for
valve repair.
protected
LESER standards, instructions and spare part lists.
visually inspection
inside parts report 1.2
protected
original spare parts
assembling instruction
paint finish (LLS…)
material safety data sheets
assembling instruction
(LLS...)
visually inspection
report 1.4
delivery to customer
Repair Traveller
Customer
Painting ____________________
protected
Lead seal ____________________
----------------------------------------------------------------------------------------------------------------------------------------
1.2 Disassembling
Spring ____________________
Disc ____________________
Spindle ____________________
Guide ____________________
Bellows ____________________
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Seat tightness
bubbles / min. target: actual:
i.o. n.i.o.
Backpressure / 6 psig
protected
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------
i.o. n.i.o.
Painting
Components
___________________________________
Date/Signature
1 General
This LWN describes the recommended Took KIT requirements for equipping an
agency or a warehouse for goods receiving/storage, adjusting, testing and shipping
of safety valves.
2 Contents
1 General ............................................................................................................................1
2 Contents ..........................................................................................................................1
3 Scope...............................................................................................................................2
4 General description........................................................................................................2
5 Designated use ...............................................................................................................2
6 Components of the Standard Tool KIT.........................................................................2
6.1 Double-ended open spanner with unequal widths across flats.................................3
6.2 Single-ended open spanner .....................................................................................5
6.3 Flat-tip and Phillips PH screwdrivers ........................................................................6
6.4 Combination pliers ....................................................................................................7
6.5 Pin punch..................................................................................................................8
6.6 Hammer ....................................................................................................................9
6.7 Punch numbers ......................................................................................................10
6.8 Punch letters...........................................................................................................11
6.9 Brush set ................................................................................................................12
6.10 Sliding vernier calliper ............................................................................................13
6.11 Sealing pliers ..........................................................................................................14
6.12 V-Block ...................................................................................................................15
6.13 Ratchet box ............................................................................................................16
6.14 Torque wrench........................................................................................................17
6.15 Jaw attachments.....................................................................................................18
6.16 Plug-in reversible ratchet ........................................................................................19
6.17 Plug-in adapter .......................................................................................................20
6.18 Socket.....................................................................................................................21
6.19 Wire brush ..............................................................................................................22
6.20 Safety glasses ........................................................................................................23
6.21 Wire twisting pliers..................................................................................................24
6.22 Sealing blocks ........................................................................................................25
6.23 Sealing wire ............................................................................................................26
6.24 Pipe for large spanner ............................................................................................27
6.25 Folding rule.............................................................................................................28
6.26 Glass plate..............................................................................................................29
6.27 Lapping stamp ........................................................................................................30
6.28 Lapping pastes .......................................................................................................32
6.29 Monocrystalline diamond powder ...........................................................................33
6.30 Assembly grease for threads ..................................................................................34
6.31 Leak detection spray ..............................................................................................35
6.32 LESER paint, blue ..................................................................................................36
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Standardisation of Worldwide Warehouse
Standard Tool Specification page 2
3 Scope
4 General description
Internet www.sales@leser.com
5 Designated use
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Standard Tool Specification page 3
Designated use
• Tool for tightening or unscrewing bolts and nuts such as caps, levers, and inflow devices
Manufacturer GEDORE
Material Chrome-vanadium-steel
Internet www.hahn-kolb.de
Material Chrome-vanadium-steel
Internet www.hahn-kolb.de
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Standard Tool Specification page 5
Designated use
• lever and cap screw connections
Head thickness 14 mm 18 mm
Internet www.hahn-kolb.de
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Standard Tool Specification page 6
Designated use
• screwing in of locking screws (H4 lever)
• insert O-rings (type 462)
• remove jammed workpieces
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Standard Tool Specification page 7
Designated use
• removal of sealing wire
Internet www.hahn-kolb.de
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Standard Tool Specification page 8
Designated use
Technical requirements
Requirements /
Data Technical illustration
Quality
DIN 6450 C
3/4/
Tips – Ø mm 5/6/
7/8
150 x 10/ 150 x 10/
Length x thickness mm 150 x 10/ 150 x 10/
150 x 12/ 150 x 12
Hardened and
Punch head
tempered
Delivery In holder with base
Vendor Hahn & Kolb
External order
51284-500
number
LESER order number 596.0065.0000
Tool kit number 0161.0000
Internet www.hahn-kolb.de
Illustration 5: Combination pliers
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Standard Tool Specification page 9
6.6 Hammer
The hammer is used for marking flanges and bodies and for fastening individual parts
like, for example, discs and spindles.
Designated use
• hammering in punch numbers
• fastening of discs and spindles
• hammering in pins
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Standard Tool Specification page 10
Designated use
• marking flanges and bodies
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Standard Tool Specification page 11
Designated use
• marking flanges and bodies
Technical requirements
Technical illustration
Requirements /
Data Data
Quality
DIN 1451
Type of characters Letters
Character height 0.2 mm 0.6 mm
Characters A-Z-&
Number of punches 27
Max workpiece
1200 Nm² 1200 Nm²
strength
Hardness on end of Illustration 8: Punch letters
58 – 60 HRC 58 – 60 HRC
punch
Vendor Hahn & Kolb
External order
56932-020 56932-060
number
LESER order number 596.0070.0000 596.0071.0000
Tool kit number 0161.0000
Internet www.hahn-kolb.de
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Standard Tool Specification page 12
Designated use
• repair of paint damage
• application of lubricants
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Standard Tool Specification page 13
Designated use
• pressure setting
• measuring stroke limits
• measuring components
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Standard Tool Specification page 14
Designated use
• sealing bonnets and bodies
Seal Ø 9 mm
Colour Blue
External order
53205-145 Illustration 11: Sealing pliers
number
LESER order number 596.0053.0000
Tool kit number 0161.0000
Internet www.hahn-kolb.de
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Standard Tool Specification page 15
6.12 V-Block
When assembling the disc and spindle, there is a risk of damaging the spindle or disc by
incorrect loading. To prevent this, the V-block is used as an underlay or to fix the round
components in place.
Designated use
• assembly of discs and spindles
• offloading the spindle
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Standard Tool Specification page 16
Designated use
• assembly and disassembly work on safety valves
• various screwing work
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Standard Tool Specification page 17
Designated use
• screw connections of bonnets and bodies
• use with bolt size 9 / 12 mm or alternatively 14 / 18 mm
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Designated use
• screw connections of bonnets and bodies
• bolt size 19 / 24 mm
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Standard Tool Specification page 19
Designated use
• screw connections of bonnets and bodies
• to hold the socket (see 6.18)
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Standard Tool Specification page 20
Designated use
• holder of the plug-in reversible ratchet (see 6.16) or the jaw attachments (see
6.14)
• screw connections of bonnets and bodies
Figure 6.1
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Standard Tool Specification page 21
6.18 Socket
The socket is used together with the torque wrench (see 6.14) and the plug-in reversible
ratchet (see 6.16). It is used, for example, for the screw connection of the bonnet to the
body.
Designated use
• screw connections of bonnets and bodies
Technical requirements
Technical illustration
Requirements /
Data
Quality
DIN 3120
Width across
36 mm
flats
Size ø 60/49.5 mm
Material 31 Cr V 3
Vendor Hahn & Kolb
Illustration 25:Socket
External order
58596-360
number
LESER order
596.0082.0000
number
Tool kit number 0161.0000
Internet www.hahn-kolb.de
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Standard Tool Specification page 22
Designated use
• removal of surface rust
• removal of soiling
Technical requirements
Technical illustration
Requirements /
Data Data
Quality
Wire material Stainless steel Steel
Total length 290 mm 290 mm
Width 35 mm 35 mm
Length of wire
25 mm 25 mm
brushes
Wire Ø 0.3 mm 0.3 mm
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Standard Tool Specification page 23
Designated use
• general safety of the eyes
• to be worn during grinding work on the safety valve
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Standard Tool Specification page 24
Designated use
• twisting the sealing wire
• sealing bonnets and bodies
Technical requirements
Technical illustration
Requirements /
Data
Quality
DIN 5256
Manufacturer STAHLWILLE
Weight 0.330 kg
Length 230 mm
Vendor Hahn & Kolb
External order
53137-010
number
Tool kit number 0161.0000
Internet www.hahn-kolb.de
Illustration 27:Wire twisting pliers
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Standard Tool Specification page 25
Designated use
• sealing safety valves
Requirements /
Data
Quality
Size L x H x D 9 x 9 x 5 mm
Hole □ 1.5 mm
Material Plastic
Temp. application limit + 85° C
Vendor Johan Pützfeld B.V.
LESER order number 525.0107.0000
Tool kit number 0161.0000
Illustration 29:Sealing
Internet www.skiffy.com blocks
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After adjusting the set pressure on the safety valve, LESER must guarantee that the
pressure cannot be changed without being noticed. For this measure, LESER seals the
lever/cap to the bonnet. Sealing wire is used to connect these components.
Designated use
• sealing the bonnet and the lever/cap
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Standard Tool Specification page 27
The pipe for the large spanner is an extension of the spanner. It is used to extend the
lever arm when assembling the lever and makes it possible to apply high torque in order
to securely connect the bonnet to the lever.
Designated use
• lever and bonnet connections
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Designated use
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Standard Tool Specification page 29
Designated use
• re-lapping discs
Requirements /
Data
Quality
LWN 001.32
Ø 140 mm
Vendor LESER
LESER order number 828.0000.0016
Tool kit number 0161.0000
Internet www.sales@leser.com Illustration 17:Glass plate
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Standard Tool Specification page 30
Designated use
• relapping seats and nozzles
Technical illustration
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Standard Tool Specification page 31
Requirements /
Data Data Data Data
Quality
Number 10 12 13 14
do 92 125 165 200
Material 0.6025 / 1.4021 0.6025 / 1.4021 0.6025 / 1.4021 0.6025 / 1.4021
Manufacturer LESER
Length 172 mm 205 mm 222 mm 250 mm
LESER order
445.2059.0000 445.2259.0000 445.2359.0000 445.2459.0000
number
Tool kit number 0161.0000
Internet www.sales@leser.com
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Standard Tool Specification page 32
Designated use
• lapping discs
Technical requirements
Requirements /
Data Data Data Data
Quality
LWN 001.32 001.32 001.32 001.32
Name TETRABOR
Identifier F 320 F 600 F 800 F 1200
Grit size in μ 49 – 17 19 – 3 14 – 2 7–1
Packaging Tube
Contents 75 ml
Vendor Artur Glöckler GmbH
LESER order
599.0301.0000 599.0401.0000 599.0101.0000 599.0201.0000
number
Tool kit number 0161.0000
Internet http://www.gloeckler.com
Technical illustration
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Designated use
• re-lapping seats and discs
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The assembly grease is used for greasing the adjusting screw. It makes it possible to
easily screw the adjusting screw into the bonnet.
Designated use
• greasing the adjusting screw
• greasing components for improved ease of access
• protection against fretting and corrosion
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Standard Tool Specification page 35
Designated use
• external leak testing of the safety valve
• functional leak testing
• testing the seal tightness of manometer screw connections
Designated use
• repair of damaged valve contours
• repair of scratched valve contours
End of LWN
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LESER WORKS STANDARD LWN 369-58 E
Warehouse Keeper Equipment Specification
1 General
This LWN describes the Took KIT requirements for equipping an agency or
warehouse for goods receiving/storage, adjusting, testing and shipping of safety
valves.
2 Contents
1 General ............................................................................................................................1
2 Contents ..........................................................................................................................1
3 Scope...............................................................................................................................2
4 General description........................................................................................................2
5 Designated use of the CP Additional Tool KIT ............................................................2
6 Components of the CP Additional Tool KIT.................................................................2
6.1 Assembly aid for hexagonal inflow devices ..............................................................3
6.2 Assembly apparatus .................................................................................................4
6.3 Jaw head ..................................................................................................................5
6.4 Plug-in adapter .........................................................................................................6
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Warehouse Keeper Equipment Specification
3 Scope
4 General description
Internet
www.sales@leser.com
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LARC Equipment Specification
Compact Performance Tool KIT page 3
Designated use
• assembly of threaded safety valves
Technical illustration
Technical requirements
Requirements /
Data
Quality
LWN 351.49
Widths across flats SW36 / SW41
Vendor LESER
LESER order number 446.3459.0000
Tool kit number 0161.0002
Internet www.sales@leser.com
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LARC Equipment Specification
Compact Performance Tool KIT page 4
Designated use
• installation of O-ring disc
Requirements /
Data
Quality
LWN 351.49
Measurement range 30 – 150 Nm
Type 462 / 433
Size DN 15
Vendor LESER
LESER order number 445.0559.0000
Illustration 2: Assembly apparatus
Tool kit number 0161.0002
Internet www.sales@leser.com
continues on page 5
processed: Kai Krohn edition: 2010-05-10
LESER
GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369.58 E
LARC Equipment Specification
Compact Performance Tool KIT page 5
Designated use
• assembly of the inflow device
• tightening the lock nut
Fig. 4 Assembly of the inflow device Fig. 5 Assembly of the outflow device
with a fixed torque specification
Requirements /
Data Data
Quality
SW 46 mm 55 mm
Square end 24.5x28 mm 24.5x28 mm
Order number 58218046 58218066
LESER order
number
Tool kit number 0161.0002 Illustration 3: Jaw head
Internet www.sales@leser.com
continues on page 6
processed: Kai Krohn edition: 2010-05-10
LESER
GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369.58 E
LARC Equipment Specification
Compact Performance Tool KIT page 6
Designated use
• connector between the torque wrench and jaw head
Technical requirements
End of LWN
processed: Kai Krohn edition: 2010-05-10
LESER
GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER Global Standard LGS_1116
Operating materials and supplies for repaired valves Page 1/3
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 2
5 General Information............................................................................................. 2
6 Operating materials and supplies ........................................................................ 2
1 Purpose
This LESER Global Standard (LGS) provides a list of operating materials that are
used during the assembly of LESER safety valves.
2 Scope
This document must be observed by all agencies and subsidiaries of LESER GmbH
& Co. KG.
protected
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are completely correct and error free.
This document is to be used exclusively with the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document about the products of LESER GmbH & Co. KG that is intended for the
LESER subsidiaries at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
5 General Information
protected
Monocrystalline diamond powder - material number N145
Assembly grease
Molykotepaste – D Paste
Klübersynth UH1 14-151
Halocarbon oil
Superglue
Delo-Ca
Delo-ML 5449 anaerobic high temperature resistant
protected
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 2
5 General Information............................................................................................. 2
6 Cleaning repaired valves ..................................................................................... 2
6.1 Blast cleaning ............................................................................................... 2
6.2 Brushing ....................................................................................................... 3
6.3 Washing ....................................................................................................... 3
7 Handling the components.................................................................................... 4
7.1 Exceptions:................................................................................................... 4
7.2 Process overview ......................................................................................... 4
1 Purpose
This LESER Global Standard (LGS) provides instructions on cleaning LESER safety
valves. The required work steps and materials are described.
protected
2 Scope
This document must be applied when cleaning safety valves in agencies and
subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error. This
document is to be applied exclusively to the specified type. LESER GmbH & Co. KG
declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
5 General Information
• Gloves must be worn during the entire cleaning process (except for
stainless steel and painted valves).
• Wear safety glasses.
protected
The body and bonnet must be blasted from the inside and outside for as long as it
takes to remove all residual paint, rust or other soiling.
Figure 6.1-1: Flange covering, plastic Figure 6.1-2: Flange covering, sticker
6.3 Washing
When washing, make sure that all parts that belong to one repaired safety valve
are washed together. When filling the washing machine, make sure that the washing
medium can flow out of the bodies, bonnets and caps / levers without any residue.
protected
Figure 6.3-1
Note: Any waste that occurs when cleaning must be disposed of according to
the applicable rules and regulations of the respective country.
disclosure cat.: II proofread: OR published date: 17.11.10 effect. date: 18.11.2010
author: Niehus released by: KUW replaces: initial status: valid
resp. depart.: PP date of release: 8.11.10 revision No.: 0
doc. type: LGS change rep. No.: 00651A retention period: 10y
LESER Global Standard LGS_1115
Cleaning repaired valves Page 4/5
Figure 7-1
In particular
protected
In particular, valves, especially the sealing surfaces on the flanges and also the
interior areas, must not be touched without gloves, because these areas will not be
protected even in later process steps by paint. Nor may spare parts be touched
without gloves when unpainted and unpackaged.
7.1 Exceptions:
The requirement for gloves is removed in the following cases:
• assembly of Compact Performance valves (for process-related reasons)
• assembly of stainless steel valves (no danger of corrosion)
It is also mandatory to wear gloves in the initially mentioned cases when performing
the order picking for spare parts.
protected
public
Compact Performance
Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 Disclaimer............................................................................................................ 2
4 Qualified fitting personnel .................................................................................... 3
5 General Information............................................................................................. 3
6 General illustration .............................................................................................. 4
7 Dismantling of the Compact Performance series ................................................ 5
7.1 Removal of the levers and caps ................................................................... 5
7.2 Releasing the pressure spring...................................................................... 8
7.3 Dismantling flange connections.................................................................... 9
7.4 Dismantling cylindrical threaded connectors .............................................. 10
7.5 Removal of the spindle assembly............................................................... 11
7.6 Releasing the adjusting screw.................................................................... 12
1 Purpose
This LESER Global Standard (LGS) is disassembly documentation for different
installation types of LESER safety valves of the Compact Performance series. The
public
required work steps and tools are described.
2 Scope
This document must be used in the removal of Compact Performance safety valves
in agencies and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are completely correct and error free.
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
5 General Information
public
public
public
Figure 7.1.1-1
Remove the
cylinder pin. Pull
the spindle cap
off the spindle.
Remove the O-
ring from the
groove of the
lever cover.
Figure 7.1.1-2
Figure 7.1.2-1
Screw off the lever cap.
public
Figure 7.1.2-2
Remove the retaining clip and pin
from the spindle cap.
Figure 7.1.2-3
Figure 7.1.2-4
Remove the cylinder pin. Pull the
spindle cap off the spindle.
public
Figure 7.1.2-5
Remove the O-ring from the
spindle cap
Figure 7.1.2-6
Figure 7.1.3-1
public
Illustrations Description Aids / Tools
Remove the lock Pin punch
nut. Secure the Open-end
spindle with the spanner
splint pin against
turning and remove
the adjusting screw.
Turn the adjusting
screw against the
pin punch (do not
remove the pin
punch), until the
spring is completely
unstressed and the
disc is lifted up from
the seat.
Figure 7.2-1
Figure 7.3-1
public
Figure 7.4-1
Screw inlet body out of outlet
body.
public
Figure 7.4-2
Figure 7.5-1
Pull the spring plate and
spring off the spindle.
Remove the pin (connects
disc/spindle). Separate
disc assembly and
spindle.
public
Figure 7.5-2
Figure 7.6-1
Unscrew lock nut from
public
adjusting screw.
Figure 7.6-2
public
Compact Performance
Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 Disclaimer............................................................................................................ 2
4 Qualified fitting personnel .................................................................................... 3
5 General Information............................................................................................. 3
6 General illustration .............................................................................................. 4
7 Dismantling the Compact Performance series .................................................... 5
7.1 Dismantling lift indicator in H4 lever ............................................................. 5
7.2 Dismantling the cap / lever ........................................................................... 6
7.3 Dismantling outlet....................................................................................... 10
7.4 Dismantling the bonnet............................................................................... 12
7.5 Dismantling the spindle/disc assembly....................................................... 13
7.6 Dismantling spindle/disc assembly............................................................. 16
7.7 Dismantling the inlet body .......................................................................... 19
7.8 Dismantling the pressure screw ................................................................. 21
1 Purpose
This LESER Global Standard (LGS) is disassembly documentation for various
public
installation types of LESER safety valves of the Compact Performance series. The
required work steps and tools are described.
2 Scope
This document must be applied to the dismantling Compact Performance safety
valves in agencies and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are completely correct and error free.
This document is to be used exclusively with the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document on the products of LESER GmbH & Co. KG that is intended for the
LESER subsidiaries at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
disclosure cat.: I proofread: OR published date: 05.2011 effect. date: 05.2011
author: Niehus released by: KUW replaces: initial status: valid
resp. depart.: PP date of release: 11.04.11 revision No.: 1
doc. type: LGS change rep. No.: 00779A retention period: 10y
LESER Global Standard LGS 4107
Dismantling instructions for types 459, 462, 450, 460 Page 3/21
5 General Information
public
6 General illustration
public
Figure 6.1-1
Figure 7.1-1
2. Remove nut and screw out
the lift indicator completely.
public
Figure 7.1-2
Figure 7.2.1-1
public
Figure 7.2.2-1
Pull out the lever.
public
Figure 7.2.2-2
Loosen and remove lock
screw. Remove plastic ball.
Figure 7.2.2-3
Figure 7.2.2-4
Remove the retaining clip and
cylinder pin from the spindle
cap. Pull the spindle cap off the
spindle.
public
Figure 7.2.2-5
Spindle cap, retaining clip and
cylinder pin
Figure 7.2.2-6
Figure 7.2.3-1
Remove the retaining clip and cylinder
pin from the spindle cap. Pull the
spindle cap off the spindle.
public
Figure 7.2.3-2
Spindle cap, retaining clip and cylinder
pin
Figure 7.2.3-3
Figure 7.3.1-1
Unwind sealing tape from
the thread of the outlet
adapter.
public
Figure 7.3.1-2
Figure 7.3.2-1
public
public
Figure 7.4.1-1
Unscrew and remove the Open-end spanner
bonnet.
Figure 7.4.1-2
Figure 7.4.2-1
public
7.5 Dismantling the spindle/disc assembly
7.5.1 Dismantling the assembly (with elastomer bellows)
Illustrations Description Aids / Tools
Pull the assembly out of the
outlet body carefully.
Pull the top spring plate, spring
and bottom spring plate from the
spindle one after the other.
Figure 7.5.1-1
Figure 7.5.2-1
public
Loosen the bonnet spacer with C-spanner with a
the C-spanner and remove. nose
Figure 7.5.2-2
public
Figure 7.5.3-1
Figure 7.6.1-1
Remove retaining clip
and half-washers.
public
Figure 7.6.1-2
Pull the guide off the
spindle.
Figure 7.6.1-3
Drive the pin out of the Pin punch
spindle with the pin
punch. Pull disc off the
spindle.
Figure 7.6.1-4
Figure 7.6.2-1
Pull the spindle with the bellows
out of the cooling zone.
public
Figure 7.6.2-2
Remove retaining clip and half-
washers.
The bellows and spindle cannot
be separated because they are
glued together.
Figure 7.6.2-3
Figure 7.6.3-1
Pull elastomer bellows
from the disc and from
the guide. Pull the
bellows and guide from
the spindle.
public
Figure 7.6.3-2
Pull out the 4 pins and
remove the disc.
Figure 7.6.3-3
public
Figure 7.7.1-1
Screw off the outlet body.
Remove the loose flange
from the inlet body.
Figure 7.7.1-2
public
Figure 7.7.2-1
Figure 7.7.2-1
Unscrew lock nut from adjusting screw.
public
Figure 7.7.2-2
Remove PTFE bushing from the
adjusting screw.
Figure 7.7.2-3
Contents
1 General...................................................................................................................................... 2
2 Purpose ..................................................................................................................................... 2
3 Areas of validity ......................................................................................................................... 2
4 Execution................................................................................................................................... 2
4.1 Measures and facing profile .............................................................................................. 2
4.2 Surface quality................................................................................................................... 2
4.3 Test ................................................................................................................................... 2
5 Refinishing of seat and disc for types 441 and 421, metal sealing............................................ 3
6 Refinishing of seat and disc for types 431 and 411, metal sealing............................................ 5
7 Refinishing of seat and disc types 441 and 431, O-ring seals................................................... 7
8 Refinishing of seat and disc for type 455, metal sealing............................................................ 8
9 Refinishing of seat and disc types 455 and 456, O-Ring seals ............................................... 10
10 Refinishing of seat and disc for full nozzle types 457 and 458, metal sealing......................... 11
11 Seat geometry for flat sealing O-ring disc design (for valves delivered before 2002) ............. 13
12 Refinishing of seat and disc type 526, metal sealing............................................................... 14
13 Refinishing of seat and disc type 437, metal sealing, sealing plate......................................... 16
14 Refinishing of seat and disc type 438, O-Ring seals ............................................................... 17
15 Refinishing of seat and disc type 439, Vulcanized soft seat.................................................... 18
16 Refinishing of seat and disc type 459, metal sealing, sealing plate......................................... 19
17 Refinishing of seat and disc type 462, O-Ring disc ................................................................. 20
conticues on page 2
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 2
1 General
If the sealing surfaces of seat and disc have been damaged by frequent setting, for example, or by
impurities in the medium, the original sealing quality can be restored by refinishing of the sealing
surfaces.
2 Purpose
This LESER Works Standard gives information about the dimensions and the surface quality which
have to be observed during the refinishing work, it also provides the work instructions. This LWN
replaces dimensional drawing no. 395 19 09.
3 Areas of validity
This LWN is valid for the LESER production, for repair shops authorized by LESER and foreign
workshops, who have adequate process and test facilities. This LWN is valid for:
4 Execution
The refinishing by smooth turning and grinding with final lapping should be done on the seat and if
necessary also on the disc with the least possible swarf. Please see the limiting values in the
following tables.
4.3 Test
In a final test on the mounted valve, it has to be guaranteed that:
- The semi rings on the spindle must be off the guide when the valve is closed.
- The lower spring plate may not touch the guide when the spring is assembled.
- In lift restricted valves, the lift restriction must be checked and if necessary the lift restriction
bushing extended.
continues on page 3
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 3
5 Refinishing of seat and disc for types 441 and 421, metal sealing
Work is to be done according to illustrations 5.1, 5.2 and 5.3 and according to table 5.1
Illustration 5.3
Illustration 5.1
Illustration 5.2
continues on page 4
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 4
Changes in dimension may only be so large that the highest admissible dimension for t is not
exceeded and the smallest admissible dimension for h is not fallen below. The dimensions A and B
on the seat must be restored with inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. The maximum allowable reduction in "L1" is 0,5 mm.
continues on page 5
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 5
6 Refinishing of seat and disc for types 431 and 411, metal sealing
Work is to be done according to illustrations 6.1, 6.2 and 6.3 and according to table 6.1.
Illustration 6.3
Illustration 6.1
Illustration 6.2
continues on page 6
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 6
Changes in dimension may only be so large that the highest admissible dimension for t is not
exceeded and the smallest admissible dimension for h is not fallen below. The dimensions A and B
on the seat must be restored with inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. The maximum allowable reduction in "L1" is 0,5 mm.
continues on page 7
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 7
7 Refinishing of seat and disc types 441 and 431, O-ring seals
The outer chamfer of these seats is responsible for the sealing (see illustration 7.1), therefore the
diameter of the seat must not be changed. In case of edge damage, the seat surface may be
turned or ground by between 0,2 and 0,4 mm until the damage is removed. After that the edge
should be carefully treated with smooth emery paper to restore an angle of 45°. Please make sure
that the edge is free for burrs.
Illustration 7.1
continues on page 8
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 8
Work is to be carried out according to the illustrations 8.1, 8.2 and 8.3 and according to table 8.1.
Illustration 8.3
Illustration 8.1
Illustration 8.2
continues on page 9
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 9
Changes in dimension may only be so large that the highest admissible dimension for t is not
exceeded and the smallest admissible dimension for b is not fallen below. The dimensions A and B
on the seat must be restored with inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. The maximum allowable reduction in "L1" is 0,5 mm.
continues on page 10
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 10
9 Refinishing of seat and disc types 455 and 456, O-Ring seals
Work is to be carried out according to the illustrations 9.1 and 9.3 and according to table 9.1.
In these valves the seal is made at the inner chamfer, this is therefore the important feature. The
inner chamber is formed with a 30° angle (see Illustration 9.1).
When refinishing according to Table 9.1, the diameter B has to be restored and the chamfer area
with surface quality Rz 10 has to be finished / ground free of burrs.
Illustration 9.2
Illustration 9.1
Refinishing of seat
Seat
C DN depth Tolerance B A
[mm] [mm] t [mm] for t [mm] ∅ [mm] ∅ [mm]
20 25 50,0 +0,5 22,5-0,2 24,5+0,2
40 50 66,0 +0,5 46,5-0,2 49,0+0,2
60 80 85,0 +0,5 66,5-0,3 71,5+0,3
74 100 117,0 +0,8 82,0-0,3 86,0+0,3
continues on page 11
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 11
10 Refinishing of seat and disc for full nozzle types 457 and 458, metal sealing
Work is to be carried out according to the illustrations 10.1, 10.2 and according to table 10.1.
Illustration 10.1
Illustration 10.2
continues on page 12
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 12
Changes in dimension may only be such as not to reduce dimensions b and/or L below the lowest
allowable tolerance (see table 10.1). The dimensions A and B on the seat must be restored with
inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. "L1" can be minimized by about a maximum of … (see table 10.1).
continues on page 13
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 13
11 Seat geometry for flat sealing O-ring disc design (for valves delivered before
2002)
Work is to be carried out according to the illustration 11.1and according to table 11.1.
The flat sealing O-ring-disc has not been supplied since the redesign of the O-ring dics in 2002.
To refinish “old design” discs see the following details.
The flat sealing O-ring disc design is identified internally within Leser by “F-Text” codes L40-43.
Where a customer has an O-ring disc valve supplied before 2002, the customer should contact
Leser to confirm whether these dimensions are to be used before commencing work on the valve.
Illustration 11.1
C B A
closest flow area inner seat chamfer outer seat chamfer
do [mm] ∅ [mm] ∅ [mm]
18 18,4-0,2 22,8+0,2
23 23,4-0,2 29,8+0,2
29 29,4-0,2 37,1+0,2
37 37,4-0,2 46,0+0,2
46 46,4-0,2 54,4+0,3
60 60,4-0,3 71,0+0,3
74 74,4-0,3 89,0+0,3
92 92,4-0,3 111,0+0,3
98 98,4-0,3 111,0+0,3
125 125,4-0,3 138,0+0,3
continues on page 14
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 14
Work is to be carried out according to the illustrations 12.1, 12.2 and according to table 12.1.
Illustration 12.1
Illustration 12.2
continues on page 15
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 15
Changes in dimension may only be such as not to reduce dimensions b and/or L below the lowest
allowable tolerance (see table 12.1). The dimensions A and B on the seat must be restored with
inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. "L1" can be minimized by about a maximum of … (see table 12.1).
Seat Disc
Pressure
range Diameter Length Angle
Tolerance
Valve-
Tolerance
L; L1; L2
[mm]
Size Inlet /
[mm]
Orifice
Outlet D
[lbs] A B ∅ L1 L2 b
L W1 W2 W3
∅ [mm] ∅ [mm] [mm] [mm] [mm] [mm] [°] [°] [°] [mm]
E 1"x2" 300 x 150 19,6+0,2 18,0-0,2 17,4 87,3 10,0 - - 0,2 45,0 60,0 45,0 10,5 -0,1
1 ½"x2" 1500 x 300 18,7+0,2 16,6-0,2 16,1 87,3 5,0 3,0 - 0,2 45,0 60,0 60,0 10,5 -0,1
1 ½"x3" 2500 x 300 18,6+0,2 16,6-0,2 16,1 122,2 5,0 3,0 - 0,2 45,0 60,0 60,0 10,5 -0,1
F 1 ½"x2" 900 x 300 22,5+0,2 20,5-0,2 19,5 106,3 5,0 3,0 - 0,2 45,0 60,0 60,0 10,5 -0,2
1 ½"x3" 2500 x 300 20,5+0,2 19,1-0,2 19,5 122,6 5,0 3,0 - 0,2 45,0 60,0 60,0 10,5 -0,2
G 1 ½"x3" 900 x 300 27,5+0,2 25,0-0,2 23,5 106,3 5,0 3,0 - 0,2 45,0 60,0 60,0 10,5 -0,2
2"x3" 1500 x 300 27,5+0,2 25,0-0,2 23,5 128,1 5,0 3,0 - 0,2 45,0 60,0 60,0 10,5 -0,2
H 1 1/2"x3" 150 x 150 36,0+0,2 33,0-0,2 30,5 106,3 5,0 3,0 - 0,2 45,0 60,0 45,0 10,5 -0,2
2"x3" 150 x 150 35,2+0,2 33,0-0,2 29,4 102,2 5,0 3,0 - 0,2 30,0 60,0 30,0 10,5 -0,2
2"x3" 600 x 300 35,2+0,2 33,0-0,2 29,4 126,5 5,0 3,0 - 0,2 30,0 60,0 30,0 10,5 -0,2
J 2"x3" 150 x 150 43,5+0,2 41,0-0,2 39,0 102,2 6,0 6,0 - 0,2 30,0 60,0 30,0 12,5 -0,2
3"x4" 900 x 300 43,5+0,2 41,0-0,2 37,0 156,5 6,0 6,0 - 0,3 30,0 60,0 30,0 12,5 -0,2
K 3"x4" 150 x 150 50,5+0,3 47,0-0,2 45,0 127,9 6,0 6,0 - 0,2 30,0 60,0 30,0 12,5 -0,2
3"x6" 900 x 300 50,5+0,3 47,0-0,2 45,0 156,5 6,0 6,0 - 0,3 30,0 60,0 30,0 12,5 -0,2
3"x6" 900 x 300 50,5+0,3 47,0-0,2 45,0 169 6,0 7,0 - 0,3 30,0 60,0 45,0 12,5 -0,2
L 3"x4" 150 x 150 61,5+0,3 58,0-0,2 56,0 127,9 6,0 6,0 - 0,2 30,0 60,0 30,0 15,0 -0,2
4"x6" 600 x 150 61,5+0,3 58,0-0,2 56,0 149,9 6,0 6,0 - 0,2 30,0 60,0 30,0 15,0 -0,2
4"x6" 600 x 150 61,5+0,3 58,0-0,3 56,0 149,9 6,0 6,0 - 0,2 30,0 60,0 30,0 15,0 -0,2
4"x6" 600 x 150 61,5+0,3 58,0-0,3 56,0 169 6,0 6,0 - 0,3 30,0 60,0 30,0 15,0 -0,2
M 4"x6" 600 x 150 68,0+0,3 64,5-0,3 61,5 149,9 5,0 6,0 - 0,3 30,0 60,0 30,0 15,0 -0,2
4"x6“ 600 x 150 69,0+0,3 64,5-0,3 61,5 169 5,0 6,5 - 0,3 30,0 60,0 30,0 15,0 -0,2
N 4"x6“ 600 x 150 74,0+0,3 70,0-0,3 67,0 169 4,0 6,0 - 0,3 30,0 60,0 30,0 15,0 -0,2
P 4"x6" 150 x 150 89,0+0,3 85,0-0,3 82,0 153,1 5,0 6,0 - 0,3 30,0 45,0 45,0 15,0 -0,2
4"x6" 300 x 150 89,0+0,3 85,0-0,3 82,0 197,5 5,0 6,0 - 0,3 30,0 45,0 45,0 15,0 -0,2
Q 111,0-
6"x8" 300 x 150 114,5+0,3 108,0 - 0,3 45,0 45,0 45,0 17,0 -0,2
0,3 209,5 6,0 6,0
R 133,0-
6"x8" 300 x 150 137,5+0,3 131,0 - 0,3 45,0 60,0 45,0 17,0 -0,2
0,3 209,5 25,0 6,0
133,0-
6"x10" 600 x 150 137,5+0,3 131,0 - 0,3 45,0 60,0 45,0 17,0 -0,2
0,3 189,3 25,0 6,0
T 167,0-
8"x10" 300 x 150 171,5+0,4 160,0 - 0,3 30,0 60,0 45,0 17,0 -0,3
0,4 225,7 6,0 6,0
continues on page 16
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 16
13 Refinishing of seat and disc type 437, metal sealing, sealing plate
Changes in dimension may only be such as not to reduce dimensions b and/or L below the lowest
allowable tolerance (see table 13.1). The dimensions A and B on the seat must be restored with
inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. "L1" can be minimized by about a maximum of … (see table 13.1).
Important information for do10: Small changes at the seat geometry have big vitiations at the
function of the safety valve. We recommend to change this devices.
Seat Disc
Diameter Length Angle
do max. max.
A B C L L1 L2 Tolerance W1 W2 W3 b Tolerance
∅ ∅ ∅ L; L1; L2 b
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [°] [°] [°] [mm] [mm]
+0,05 +0,05 +0,05
6 10,5 7,5 8,5 17,0 - 1,5 - 0,1 45 18 45 5,1 - 0,1
+0,05 +0,05
14,5 12,0 - - 2,0 - 0,1 18
10 16,5 - - 6,1 - 0,1
continues on page 17
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 17
The outer chamfer of these seats is responsible for the sealing (see illustration 14.1), therefore the
diameter of the seat must not be changed. In case of edge damage, the seat surface may be
turned or ground by between 0,2 and 0,4 mm until the damage is removed. Please make sure that
the edge is free for burrs.
Seat Disc
Diameter Length Angle
do A B D L L1 L2 Tolerance W1 W2 W3 Tolerance
∅ ∅ ∅ L; L1; L2 b
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [°] [°] [°] b [mm] [mm]
-0,01 +0,05
10 15,0 12,0 - 16,5 1,6 7,5 - 0,1 - 18 - 6,3 + 0,1
continues on page 18
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 18
Changes in dimension may only be such as not to reduce dimensions b and/or L below the lowest
allowable tolerance (see table 15.1). The dimensions A and B on the seat must be restored with
inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. "L1" can be minimized by about a maximum of … (see table 15.1).
Seat Disc
Diameter Length Angle
do A B D L L1 L2 Tolerance W1 W2 W3 b Tolerance
∅ ∅ ∅ L; L1; L2 b
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [°] [°] [°] [mm] [mm]
10 14,0 12,0 - 16,5 1,6 7,5 - 0,1 - 18 - 3,8 -
continues on page 19
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 19
16 Refinishing of seat and disc type 459, metal sealing, sealing plate
Changes in dimension may only be such as not to reduce dimensions b and/or L below the lowest
allowable tolerance (see table 16.1). The dimensions A and B on the seat must be restored with
inner and outer chamfering.
The recess dimensions "L1" do not have to be remachined by a lathe, but must be preserved at
their original order of magnitude. "L1" can be minimized by about a maximum of … (see table 16.1).
Seat Disc
Diameter Length Angle
A B L L1 L2 Tolerance W1 W2 W3 b Tolerance
∅ ∅ L; L1; L2 b
do [mm] [mm] [mm] [mm] [mm] [mm] [°] [°] [°] [mm] [mm]
6 10,5 8,5 29,0 2,5 0,9 - 0,1 - 18 45 8,1 + 0,1
9 12,9 11,5 29,0 2,0 1,1 - 0,1 - 18 45 8,1 + 0,15
13 18,1 16,5 29,0 2,0 1,5 - 0,1 - 30 45 8,1 + 0,1
17,5 23,8 22,0 29,0 2,0 1,5 - 0,1 - 30 45 7,9 + 0,2
continues on page 20
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER WORKS STANDARD LWN309.05-E
Refinishing of seats and discs
page 20
The outer chamfer of these seats is responsible for the sealing (see illustration 17.1), therefore the
diameter of the seat must not be changed. In case of edge damage, the seat surface may be
turned or ground by between 0,2 and 0,4 mm until the damage is removed. Please make sure that
the edge is free for burrs.
Seat Disc
Diameter Length Angle
A B Tolerance
∅ ∅ L L1 L2 L; L1; L2 W1 W2 W3 b Tolerance
do [mm] [mm] [mm] [mm] [mm] [mm] [°] [°] [°] [mm] b [mm]
9 12,9 11,5 29,0 2,0 1,1 +0,1 - 18 45 6,0
13 18,1 16,5 29,0 2,0 1,5 +0,1 - 30 45 6,0 +/-0,15
17,5 23,8 22,0 29,0 2,0 1,5 +0,1 - 30 45 6,0 -0,1
End of LWN
LESER processed: Cal edition: 26.09.07
GmbH & Co. KG approved: refer to ÄM 048700 replaces edition: 25.02.05
LESER Global Standard LGS_1113
Reworking repaired valves Page 1/3
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 References .......................................................................................................... 1
4 Disclaimer............................................................................................................ 1
5 Qualified fitting personnel .................................................................................... 1
6 General Information............................................................................................. 2
7 Reworking the of the working surfaces................................................................ 2
8 Re-lapping ........................................................................................................... 2
8.1 Re-lapping seat and disc sealing surfaces ................................................... 2
1 Purpose
This LESER Global Standard (LGS) provides instruction on reworking LESER safety
valves. The required work steps and materials are described.
2 Scope
protected
This document must be applied when reworking safety valves in agencies and
subsidiaries of LESER GmbH & Co. KG.
3 References
LWN 313.32 to 313.40
4 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct documentation
available. Nevertheless, LESER GmbH & Co. KG gives no guarantee that the recommended
actions presented here are entirely correct and error free. This document is to be applied
exclusively to the specified type. LESER GmbH & Co. KG declines any liability or
responsibility for the correctness and completeness of the content.
LESER GmbH & Co. KG reserves the right to change the information contained in this
document, which is for the products of LESER GmbH & Co. KG and is intended for LESER
subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
6 General Information
When re-turning damaged working surfaces, comply with the specifications of LWN
313.32 to 313.40.
8 Re-lapping
8.1 Re-lapping seat and disc sealing surfaces
8.1.1 Lapping with the lapping stamp.
protected
reworking damage on the seat sealing
surface. Lapping paste and oleic acid
must be applied to the lapping stamp.
Select the lapping paste depending on
the degree of damage.
The more severe the damage is, the
coarser the lapping paste that is to be
Figure 8.1.1-1 used at the beginning
Wet the disc with the monocrystalline
diamond powder and the oleic acid.
Glass plate
Figure 8.1.2-1
protected
Mix the monocrystalline diamond
powder together with the oleic acid on
the glass plate and then lap the
nozzle and the disc. Lapping is
performed by slight circular hand
movements.
Nozzle
Figure 8.1.3-1
0 Range of application
The above torque ranges are valid for material marked full shaft screws or full shaft bolts and nuts
used for the connection between body and bonnet according to AD-B7 and similar applications.
The torque ranges are valid for lubricated threads with a friction factor or 0,1 and rectangular
facings of the nuts in relation to the bore. With the above torques about 70 – 90 % of the yield
strength of the material are reached.
For higher friction factors (0,12 – 0,15) the higher valves for the torque are required. The maximum
limits must not be exceeded.
Data base: The 70 % valves (low torque valve) for friction factor 0,1 are taken from the
catalogue of „Fa. Gebr. Grohmann, 1991, Wissenswertes über Edelstahlschrauben".
Table 2 for screws and nuts for safety valves Type 447/547
*) The above mentioned torques are based on field tests. They allow a tight connection without
destroying the PTFE-material.
continues on page 2
LESER processed: Boy.cw. edition: 18.09.08
GmbH & Co. KG approved: refer to ÄM 152300 replaces edition: 22.10.07
LESER WORKS STANDARD LWN 322-03-EN
Torques for screw, nuts and caps H2 / lifting devices
page 2
3 Test Gag
***) The used sealing rings out of vulcanised fibre may not be deformed further because they are soft
sealings.
End of LWN
LESER processed: PD.cw. edition: 18.11.08
GmbH & Co. KG approved: refer to ÄM 146201 replaces edition: 15.05.07
LESER WORKS STANDARD LWN323.05-E
Assembly instruction type 437 / 438 / 439 and 459 / 462
threaded inlet and outlet page 1
1 General
This LWN specifies the assembly and disassembly of inletparts and outletparts, which were
furnished for the types 437 / 438 / 439 and 459 / 462 as threaded design with flanged connections.
2 Part No.
This LWN 323.05 is valued for the following Part No. :
Table 1: Overview
3 Tightening variation
The assembly of the threaded inlet and outlet design occurs on 3 dense principles.
Tightening variation 1:
continues on page 2
LESER processed: Cal.DS edition: 06.05.04
GmbH & Co. KG approved: refer to ÄM 5290 replaces edition: 00.00.00
LESER WORKS STANDARD LWN323.05-E
Assembly instruction type 437 / 438 / 439 and 459 / 462
threaded inlet and outlet page 2
Tightening variation 2:
continues on page 3
LESER processed: Cal.DS edition: 06.05.04
GmbH & Co. KG approved: refer to ÄM 5290 replaces edition: 00.00.00
LESER WORKS STANDARD LWN323.05-E
Assembly instruction type 437 / 438 / 439 and 459 / 462
threaded inlet and outlet page 3
Tightening variation 3:
continues on page 4
LESER processed: Cal.DS edition: 06.05.04
GmbH & Co. KG approved: refer to ÄM 5290 replaces edition: 00.00.00
LESER WORKS STANDARD LWN323.05-E
Assembly instruction type 437 / 438 / 439 and 459 / 462
threaded inlet and outlet page 4
4 Disassembly
For all connection variation is a disassembly possible. Therefore act last in – first out. At the
reassembly is to consider, that the sealing part 1, especially at the thightening variation 1 and 2 are
undamaged, so that the disassembly is warranted with the corresponding tightness.
5 Tightness test
A tightness test at the production is not necessary, because it is made on sample part before.
In generell an order-bound tightness test is made according to LWN 220.07. At a particular request
of the customer a special tightness test can be made.
End of LWN
LESER processed: Cal.DS edition: 06.05.04
GmbH & Co. KG approved: refer to ÄM 5290 replaces edition: 00.00.00
LESER Global Standard LGS_1114
Paint touch-up and painting repaired valves Page 1/4
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 1
5 General Information............................................................................................. 2
6 Paint touch-up and painting repaired valves........................................................ 2
1 Purpose
This LESER Global Standard (LGS) provides instructions on painting LESER safety
valves. The required work steps and materials are described.
2 Scope
This document must be applied when painting safety valves in agencies and
subsidiaries of LESER GmbH & Co. KG.
protected
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error free.
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
protected
Figure 6-1: Protective cap for open bonnet Figure 6-2: Flange sticker
protected
Figure 6-5: Component plate sticker Figure 6-6: Protective cap
protected
Figure 6-9
The layer thickness of the coat of paint should be ~ 40µm for one coat of paint.
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 2
5 General Information............................................................................................. 2
6 Attaching component/customer identification plates............................................ 2
6.1 Standard plate .............................................................................................. 3
6.2 World plate (NGA) ........................................................................................ 4
6.3 Fastening to bonnets with welding spots...................................................... 8
1 Purpose
This LESER Global Standard (LGS) provides instructions on attaching the name
plates of LESER safety valves. The required work steps and materials are described.
2 Scope
protected
This LGS must be applied when attaching the name plates of safety valves in
agencies and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error free.
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
5 General Information
• Gloves must be worn for all fitting work (except for stainless steel
and painted valves).
• Wear safety glasses.
The world plate (NGA) is fastened to the bonnet. In exceptional cases, it may also be
fastened with grooved pins with round heads, in which case it may also be fastened
to the body.
protected
The standard plate is welded to the flat surface designated for that purpose.
Flanged valves - on the right side as seen from the outlet side. Exception: Types
457 / 458 / 526 - on the back side using the set screw
Figure 6.2.1-1
For valves that are designed according to ASME (feature N68/N70), the version is
created with the UV and NB symbols.
For valves that are designed according to TÜV, the UV and NB symbols are not
protected
included.
protected
Figure 6.2.1-6: Standard plate on a Figure 6.2.1-7: Types 457 / 458 / 526
flanged valve
Figure 6.2.1-1
For valves that are designed according to ASME (feature N68/N70), the version is
created with the UV and NB symbols.
protected
Figure 6.2.1-1
Pre-curving the plate for open bonnets Apparatus
(V20-V25)
Figure 6.2.1-2
Figure 6.2.1-3
When opening bonnets V20-V25, the plate is bent in the longitudinal direction. To do
this, put the labelled plates into the apparatus with the lettering facing down (figure
6.2.1-2).
protected
Illustrations Description Aids / Tools
Figure 6.2.2-1
Sponge
Figure 6.2.2-2
The points where the world
plate will be welded must be
free of paint.
protected
Figure 6.2.2-3
Figure 6.3.1-1
protected
6.3.2 High Performance valves
For the High Performance series, the world plate is always attached to the bonnet.
However, the location where the plate is attached is different for individual bonnet
sizes.
Figure 6.3.2-1
protected
The top edge of the plate should be
flush with the bevel of the bonnet.
Figure 6.3.2-3
The raised identifier of the product form manufacturer (foundry) is mounted in the
direction of the outlet flange.
The world plate is positioned on the free back side on the bottom edge of the bonnet.
Figure 6.3.3-1
protected
Figure 6.3.3-2
public
Compact Performance
TYPES 437, 438, 439, 481
Contents
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 References .......................................................................................................... 2
4 Disclaimer............................................................................................................ 2
5 Qualified fitting personnel .................................................................................... 3
6 General Information............................................................................................. 3
7 General illustration .............................................................................................. 4
8 Assembly of the Compact Performance series.................................................... 5
8.1 Assembly of the adjusting screw .................................................................. 5
8.2 Assembly of the spindle / disc assembly ...................................................... 6
8.3 Assembly of the inlet body and outlet body ................................................ 24
8.4 Adjusting the set pressure.......................................................................... 31
8.5 Testing and documenting the seat tightness. ............................................. 32
8.6 Assembly of the cap and lever ................................................................... 33
8.7 Testing the seal tightness to the outside .................................................... 39
8.8 Sealing the valve ........................................................................................ 41
public
1 Purpose
This LESER Global Standard (LGS) is assembly documentation for various assembly
scenarios for LESER safety valves of the Compact Performance series. The required
work steps and tools are described.
2 Scope
This document must be applied to the assembly of Compact Performance safety
valves in agencies and subsidiaries of LESER GmbH & Co. KG.
3 References
LWN 220.01 / LGS 0201
LWN 322-03 / LGS 3322
LWN 614-08 / LGS 3614
Note: LESER LWN standards will be replaced by LGS, latest editions apply.
4 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error free.
disclosure cat.: I proofread: AW / TS published date: 05.2011 effect. date: 05.2011
author: Niehus released by: KUW replaces: initial status: valid
resp. depart.: PP date of release: 11.04.11 revision No.: 1
doc. type: LGS change rep. No.: 00779A retention period: 10y
LESER Global Standard LGS 4100
Assembly instructions for types 437, 438, 439, 481 Page 3/41
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
6 General Information
public
7 General illustration
public
Figure 8.1-1
Grease the adjusting screw on the Brush
thread and end face. Halocarbon
(OI-56 S / 60H)
public
Figure 8.1-2
Screw the adjusting screw into the
outlet body (a few turns)
Figure 8.1-3
public
Figure 8.2.1.1-1
Put a very small amount of Glue
glue on the spindle thread DELO ML 5449
(1 drop on the thread).
Figure 8.2.1.1-2
Figure 8.2.1.1-3
Roundness check of the Indicating calliper
spindle/disc assembly device
Tolerance: max. 0.2mm
Figure 8.2.1.2-1
Assemble the disc body
and lifting aid (holes
public
matching each other).
Figure 8.2.1.2-2
Insert the ball.
Figure 8.2.1.2-3
Figure 8.2.1.2-4
Install the pin using a - Lever press
lever press.
public
Figure 8.2.1.2-5
Figure 8.2.1.2-6
Install the spring and top Brush, Halocarbon
spring plate on the (OI-56 S / 60H)
spindle.
public
Figure 8.2.1.2-7
sealing
surface
Figure 8.2.2.1-1
Visual check: Check the
evenness of the sealing plate
(front and back side, no burrs
public
permitted).
Figure 8.2.2.1-2
Screw disc body into the lifting Clamping block,
aid hand tight with fixing the Device
sealing plate inside. Clamp
parts at lifting aid in device.
Figure 8.2.2.1-3
Special spanner
socket
Torque wrench
Figure 8.2.2.1-4
Mark the material codes of Punch numbers,
sealing plate into the lifting aid. Hammer
public
Figure 8.2.2.1-5
Figure 8.2.2.2-1
Put a very small amount of glue Glue
on the spindle thread (1 drop on DELO ML 5449
the thread).
public
Figure 8.2.2.2-2
Put the spindle thread in the Pin punch
lower spring plate and screw it in
until it is finger-tight.
Figure 8.2.2.2-3
public
Figure 8.2.2.3-1
Visual check: The pin must have Hammer
some play in the parts through- Support area for
hole of the disc body; connect with disc assembly
pin.
Figure 8.2.2.3-2
public
Figure 8.2.2.3-3
Figure 8.2.3.1-1
public
Wet the O-Ring with soapy water.
Figure 8.2.3.1-2
Wet the lifting aid with soapy water.
Figure 8.2.3.1-3
Figure 8.2.3.1-4
Press the disc into the lifting aid.
public
Figure 8.2.3.1-5
Mark the material codes of the soft Punch numbers
seal into the lifting aid. Hammer
Figure 8.2.3.1-6
Figure 8.2.3.2-1
If necessary, remove
excess glue without
leaving any residue.
public
Figure 8.2.3.2-2
Put the spindle thread in Pin punch
the lower spring plate and
screw it in until it is finger-
tight.
Figure 8.2.3.2-3
Figure 8.2.3.3-1
public
public
Figure 8.2.4.1-1
Put disc in the inlet side of the lifting aid
and screw together hand tight with lock
nut.
Figure 8.2.4.1-2
Clamp the disc in the assembly device
and tighten with the torque wrench.
Comply with torque (4 Nm)
Special spanner
socket
Torque wrench
Vice
Figure 8.2.4.1-3
Figure 8.2.4.2-1
Put a very small amount of glue Glue
on the spindle thread (1 drop DELO ML 5449
on the thread).
Figure 8.2.4.2-2
Put the spindle thread in the Pin punch
public
lower spring plate and screw it
in until it is finger-tight.
Figure 8.2.4.2-3
public
Figure 8.2.4.3-1
Install the pin centred. Hammer
Support area for
Visual check: The pin must disc assembly
have some play in the disc
through-hole.
Figure 8.2.4.3-2
public
Figure 8.2.4.3-3
public
Figure 8.3.1-1
Figure 8.3.2-1
Figure 8.3.3.1-1
The disc is in a secured
state (see 8.3.2)
public
the outlet body hand tight.
Figure 8.3.3.1-2
The disc is in a secured Clamping devices,
state (see 8.3.2) adapter
Figure 8.3.3.1-3
Figure 8.3.3.1-4
Tighten the inlet body with the Torque wrench
specified torque (100 Nm).
public
Figure 8.3.3.1-5
Figure 8.3.3.2-1
Figure 8.3.3.2-2
Visual check: Check sealing Brush
public
surface for cleanliness and Halocarbon
damage. (OI-56 S / 60H)
Glue
The disc is in a secured state (see DELO CA 2106
8.3.2)
Figure 8.3.3.2-3
Figure 8.3.3.2-4
public
public
Figure 8.3.4.1-1
public
Figure 8.3.4.2-1
Screw the outlet adapter
into the outlet body and
tighten it.
Figure 8.3.4.2-2
public
must be adjusted again.
public
Figure 8.5-1 not been met after 3 attempts,
then initiate a fault report. If the
seal tightness has been met in
accordance with the
specifications, then document
the results in Report 1.3
"Number of Bubbles".
public
Figure 8.6.1-1
Screw the cap on and Torque wrench
tighten it with a spanner
(torque as per LWN 322-03
/ LGS 3322).
Figure 8.6.1-2
Figure 8.6.2-1
Put the spindle cap onto the
spindle and connect with a
cylinder pin.
public
Figure 8.6.2-2
Grease the O-ring well (1). (1) Klübersynth
UH 14-151 / 60H
Grease the threads of the (2) Halocarbon
spindle cap (2). (OI-56 S / 60H)
Figure 8.6.2-3
Figure 8.6.2-4
Screw the lever cover onto the thread of Torque wrench
the outlet body and tighten using approx.
60 - 75 Nm.
public
Figure 8.6.2-5
Fit the pin into the hole of the lever cover
and the slot of the spindle cap and secure
it with the retaining clip.
Figure 8.6.2-6
Figure 8.6.2-7
Grease the threads of the lever cap and install Brush
it. Halocarbon
Attention: left-handed thread (OI-56 S / 60H)
public
Figure 8.6.2-8
Screw in cylinder pin / nut is flush when closed. Flat-tip
Set lever to "closed" / the inscription "CLOSED" screwdriver
can be read on the cap limit stop.
Figure 8.6.2-9
Figure 8.6.3-1
Place the O-ring in the groove of the lever
cover.
public
Figure 8.6.3-2
Put the spindle cap onto the spindle and
connect with a cylinder pin.
Figure 8.6.3-3
Figure 8.6.3-4
public
Screw the lever cover Torque wrench
onto the thread of the
outlet body and tighten it
using approx. 60 - 75
Nm. Pull up the spindle
cap and install the knob
with the pin and secure
with the retaining clip.
Press the knob down
after assembly.
Figure 8.6.3-5
public
Figure 8.7.1-1
Install a test Test connector
connector to the
outlet.
Figure 8.7.1-2
public
Figure 8.7.1-3
Pressure testing by immersion:
Check whether any bubbles can be
seen on the outside contour of the
safety valve. If the seal tightness
is good (no bubbles), document
the test result. If there are any
leaks, check the affected sealing
surfaces and seals for damage and
then test again. Dry the valve with
compressed air.
Figure 8.7.1-4
public
or alternatively cap H2 to the outlet
body.
Figure 8.8-1
public
Compact Performance
Types 459, 462, 450, 460
1 Purpose ............................................................................................................... 2
2 Scope .................................................................................................................. 2
3 References .......................................................................................................... 2
4 Disclaimer............................................................................................................ 3
5 Qualified fitting personnel .................................................................................... 3
6 General Information............................................................................................. 3
7 General illustration .............................................................................................. 4
8 Assembly of the Compact Performance .............................................................. 5
8.1 Assembly of the adjusting screw .................................................................. 5
8.2 Inlet body assembly...................................................................................... 7
8.3 Assembly of disc assembly .......................................................................... 9
8.4 Assembly of spindle/disc assembly ............................................................ 16
8.5 Inserting the spindle/disc assembly............................................................ 22
8.6 Assembly of the bonnet.............................................................................. 25
8.7 Determination and installation of the lift stopper......................................... 27
8.8 Adjusting the set pressure.......................................................................... 29
8.9 Testing and documenting the seat tightness. ............................................. 30
8.10 Assembly of the outlet ................................................................................ 31
8.11 Assembly of the cap / lever ........................................................................ 33
8.12 Test gag assembly (possible for H2 + H4) ................................................. 39
public
8.13 Documentation and testing the seal tightness to the outside ..................... 40
8.14 Sealing the valve ........................................................................................ 43
8.15 Performing a visual inspection ................................................................... 43
1 Purpose
This LESER Global Standard (LGS) defines the rules and procedures for special
approvals and provides a guideline for local implementation.
2 Scope
This document must be used for the assembly of Compact Performance safety
valves in agencies and subsidiaries of LESER GmbH & Co. KG.
3 References
LWN 220.01 / LGS 0201
LWN 324-01 / LGS 3324
LWN 614-08 / LGS 3614
Note: LESER LWN standards will be replaced by LGS, latest editions apply.
4 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error free.
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document on the products of LESER GmbH & Co. KG that is intended for the
LESER subsidiaries at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
public
6 General Information
7 General illustration
public
Figure 7-1
Figure 8.1-1
Assemble the adjusting screw
public
and lock nut.
Figure 8.1-2
Grease adjusting screw thread Brush
Halocarbon
(OI-56 S / 60H)
Figure 8.1-3
Figure 8.1-4
Screw the adjusting screw into the
cap (a few turns).
public
Figure 8.1-5
Figure 8.2.1-1
Screw the inlet body into
the outlet body hand
tight.
public
Figure 8.2.1-2
Screw the assembly Assembly device, test
device onto the inlet bench
body.
Clamp the body onto the
test bench.
Figure 8.2.1-3
Figure 8.2.1-4
public
(OI-56 S / 60H)
Grease the sealing lip and
thread and clamp the inlet body
onto the test bench.
Figure 8.2.2-1
Screw on the outlet body and Torque wrench
tighten at approx. 100 Nm.
Figure 8.2.2-2
Figure 8.3.1-1
Put the disc body in the lifting aid.
public
Figure 8.3.1-2
Put the disc in the assembly device Vice
and secure with a screw.
Figure 8.3.1-3
Insert the retaining clip in the hole on C-spanner with a
the disc body designated for that nose
purpose.
Clamp the assembly device onto the
vice and tighten the lifting aid with a C-
spanner as far as it will go.
Figure 8.3.1-4
Figure 8.3.2-1
Emboss the code letters of Punch numbers,
the sealing plate on the edge Hammer
of the disc.
public
Figure 8.3.2-2
Put the body with the sealing Assembly Device
plate in the assembly device
and secure with a screw.
Figure 8.3.2-3
Figure 8.3.2-4
Clamp the assembly device Vice
onto the vice and tighten the
C-spanner with a
lifting aid with a C-spanner as
public
nose
far as it will go.
Figure 8.3.2-5
Figure 8.3.3-1
Set pressure <= 5 bar
Wet the O-ring with "soapy water"
and put it on the disc body.
Set pressure > 5 bar
Wet the O-ring with pure water and
put it on the disc body.
public
Hammer the code letter into the O-
ring body according to the O-ring
material.
Figure 8.3.3-2
Put the disc body in the lifting aid.
Figure 8.3.3-3
public
Figure 8.3.3-4
Figure 8.3.4-1
Wet the O-ring with "soapy water" and
put it on the disc body.
Hammer the code letter into the O-
Ring body according to the O-ring
material.
public
Figure 8.3.4-2
Wet the inside of the lifting aid with
"soapy water".
Figure 8.3.4-3
Figure 8.3.4-4
public
public
Figure 8.4.1-1
Put the spindle into the
disc and secure the parts
with a pin (crimp it first
inwards at one end to
make installation easier)
Figure 8.4.1-2
Push the guide onto the
spindle.
Figure 8.4.1-3
Figure 8.4.1-4
Push the lower spring
plate, the spring and
the upper spring plate
public
onto the spindle.
Figure 8.4.1-5
Figure 8.4.2-1
Glue
Put a very small
amount of glue on the
spindle thread (1 drop).
public
Figure 8.4.2-2
Pin punch
Fit the bellows and
tighten it quickly hand
tight with two pin
punches.
Figure 8.4.2-3
Figure 8.4.2-4
Place the sealing ring in the
cooling zone/bonnet spacer.
public
Figure 8.4.2-5
Shift the spindle with the bellows
through the cooling zone into the
disc. Afterwards, put it onto the
assembly device and secure it
with a pin (first crimp pin inwards
at one end to make installation
easier).
Figure 8.4.2-6
Figure 8.4.3-1
Shift the spindle into the disc
and secure with a pin (first
crimp the parts inwards at one
end to make installation
easier)
Figure 8.4.3-2
public
Assembly aid
Push the bellows onto the
assembly aid until the thick
end is flush.
Figure 8.4.3-3
Fit assembly aid with bellows
onto the spindle
Figure 8.4.3-4
Figure 8.4.3-5
Remove the
assembly aid from
the spindle and put
guide on.
Put the other end of
the bellows over the
neck of the guide.
public
Figure 8.4.3-6
Side cutter or
Secure both sides of
similar
the bellows with
cable ties.
Cut off the
overlapping end.
Figure 8.4.3-7
public
Figure 8.5.1-1
public
Figure 8.5.2-2
public
Figure 8.5.3-1
Figure 8.6.1-1
Screw the bonnet on hand tight.
Secure the spindle/disc against
turning.
public
Figure 8.6.1-2
Open-end spanner
Afterwards, tighten the bonnet.
(torque)
Figure 8.6.1-3
Figure 8.6.2-1
public
Screw the bonnet on Open-end spanner
hand tight. Secure
the spindle/disc
against turning.
Afterwards, tighten
the bonnet.
Figure 8.6.2-2
Figure 8.7.1-1
Open the valve completely by hand Pin punch
(e.g. with a pin punch) through the
inlet and determine the spindle
overlap once again.
public
The extent of the lift stopper =
spindle overlap (opened) - (spindle
overlap not opened) - lift given in the
work plan.
Remove spindle assembly carefully
Figure 8.7.1-2
off the body
Figure 8.7.1-3
8.7.2 Installation of the lift stopper with set screw (taken from LWN 324-01 / LGS
3324)
Illustrations Description Aids / Tools
Use a completely
assembled valve to
measure the distance
"h+x" from the top edge of
the cap/lever to the end of
the spindle. In accordance
with this distance, a screw
(DIN 933) is shortened to
the size "x". Install the
shortened screw with a nut
and seal it separately.
During the assembly, the
screw is secured firmly
against the cap, by the nut.
Here, the gap between the
head of the screw and the
nut shall not exceed a
maximum of 0.5 mm
public
(approx 1/4 of a screw
turn).
Figure 8.7.2-1 Seal the screw with PTFE
tape within the cap.
public
If the valve opens outside the
stipulated set pressure tolerance, then
the adjusting screw must be adjusted
again.
Turning in a clockwise direction
causes the valve to open at higher
pressure.
Turning in a counter-clockwise
direction causes the valve to open at
lower pressure.
public
If there are leaks, check the
components. If necessary,
relap the disc and/or seat.
If the seal tightness has
been met, then document
the results.
Remove the test cap
Figure 8.10.1-1
public
Place flange over the outlet of Open-end
the body. spanner
Screw the outlet adapter into
the outlet body and tighten it.
Figure 8.10.1-2
8.10.2 Assembly of outlet flange (outlet adapter with conical NPT thread)
Illustrations Description Aids / Tools
Wrap the thread of PTFE tape
the outlet nozzle with
sealing tape (3 full
windings in a
clockwise direction).
Figure 8.10.2-1
Place flange over the Knife
outlet of the body.
Screw the outlet
adapter into the outlet
public
body and tighten it.
Cut off the sealing
tape that is not
screwed in.
Figure 8.10.2-2
Figure 8.11.1-1
Torque wrench
Screw the lever onto
the thread of the
bonnet and tighten it
by using approx. 80
public
– 100 Nm.
Figure 8.11.1-2
Figure 8.11.2-1
Fasten the spindle cap to the
spindle with the cylinder pin and
retaining ring.
public
Figure 8.11.2-2
Individual parts of lever H3
Figure 8.11.2-3
Screw the lever cover on and put it
into position ("nose" must point in
the outlet direction).
Use spacers, if necessary
Figure 8.11.2-4
Figure 8.11.2-5
... and locking screw against
twisting.
public
Figure 8.11.2-6
Putting on the venting lever.
Figure 8.11.2-7
Fit the bolt and secure it on both
sides with retaining clips.
Figure 8.11.2-8
Figure 8.11.3-1
Fasten the spindle cap to
the spindle with the
cylinder pin and retaining
public
ring.
Figure 8.11.3-2
public
Figure 8.11.3-3
Put on the determined
number of spacers.
Grease each spacer as
well as the metallic sealing
surface individually.
Screw on the lever and
tighten it with approx. 80 –
100 Nm.
Figure 8.11.4-1
Secure the position
with a lock nut.
public
Screw in the lift
indicator as far as it will
go, and then unscrew it
one turn.
Figure 8.11.4-2
Secure the position of
the lift indicator by
tightening the first nut
hand tight.
Then lock with a
second nut.
Figure 8.11.4-3
Figure 8.12-1
Brush
Put on the sealing ring and
Halocarbon
grease it as well.
(OI-56 S / 60H
public
Figure 8.12-2
Torque wrench
Screw the plug screw into the
cap or lever and tighten it with
28-32 Nm (or 72-76 Nm for
thread size M16).
When blocked, the torque for the
longer test gag screw is 20 Nm.
Figure 8.12-3
public
Figure 8.13.1-1
Test nozzle
Screw a test nozzle onto
the outlet.
Figure 8.13.1-2
Figure 8.13.1-3
Immerse the valve.
Test pressure 6 bar
public
Figure 8.13.1-4
Test pressure for valves with elastomer bellows:
Set pressure p0<3 bar: 0.15 x p0
Set pressure p0≥ 3bar: 2bar
If the seal tightness is good (no bubbles), document the test result.
If there are any leaks, check the affected sealing surfaces and seals for damage and then test
again.
8.13.2 Testing the seal tightness to the outside for flanged valve
Illustrations Description Aids / Tools
Test bench
Clamp the outlet side
of the valve to the
test bench.
Pressurise the valve
with 6 bar.
Figure 8.13.2-1
Leakdetector
Wet the valve with
spray
leak detector spray
on the
interconnection
points and the outlet
public
area.
Figure 8.13.2-2
If the seal tightness is good (no bubbles), document the test result.
If there are any leaks, check the affected sealing surfaces and seals for damage and then test
again.
Figure 8.14-1
public
bearbeitet: Lue geprüft Cal Ersatz für Ausg. vom: 17.08.04 ÄM 026200
Federdaten-Tabellen Type 450, 459 LWN 060.08
Spring data-list 460, 462 Blatt 03
sheet
Ausgabe 21.12.01
edition
Erklärungen siehe / explanation see : LWN 060.00 + LWN. 060.99
Ausführung (type)
Standard (standard) warmfest (creep-resistant steel ) korrosionsfest (stainless steel )
p [ bar ] p [ bar ] p [ bar ]
von bis Feder- Indizes von bis Feder- Indizes von bis Feder- Indizes
p1 p2 Sachnummer p1 p2 Sachnummer p1 p2 Sachnummer
up to stock no. up to stock no. up to stock no.
DN 15 do 13 DN 15 do 13 DN 15 do 13
Type 450,459 : Stahl-Teller (steel disk) Type 459 : Stahl-Teller (steel disk) Type 459 : Stahl-Teller (steel disk)
0,20 - 0,25 540.8004.0000 0,20 - 0,25 540.8004.0000 0,20 - 0,25 540.8004.0000
0,26 - 0,32 540.8014.0000 0,26 - 0,32 540.8014.0000 0,26 - 0,32 540.8014.0000
0,33 - 0,45 540.8034.0000 0,33 - 0,45 540.8034.0000 0,33 - 0,45 540.8034.0000
0,46 - 0,70 540.8054.0000 0,46 - 0,70 540.8054.0000 0,46 - 0,70 540.8054.0000
0,71 - 1,00 540.4004.0000 0,71 - 1,00 540.4004.0000 0,71 - 1,00 540.4004.0000
1,00 - 1,40 540.4014.0000 1,00 - 1,40 540.4014.0000 1,00 - 1,40 540.4014.0000
1,41 - 2,20 540.5021.0190 1,41 - 2,20 540.4024.0000 1,41 - 2,20 540.4024.0000
2,21 - 2,90 540.5031.0190 2,21 - 2,90 540.4034.0000 2,21 - 2,90 540.4034.0000
2,91 - 4,00 540.5041.0190 2,91 - 4,00 540.4044.0000 2,91 - 4,00 540.4044.0000
4,01 - 5,80 540.5051.0190 4,01 - 5,80 540.4054.0000 4,01 - 5,80 540.4054.0000
5,81 - 8,70 540.5062.0000 5,81 - 8,70 540.5062.0000 5,81 - 8,70 540.4064.0000
8,71 - 13,80 540.5072.0000 8,71 - 13,80 540.5072.0000 8,71 - 13,80 540.4074.0000
13,81 - 20,50 540.5082.0000 13,81 - 20,50 540.5082.0000 13,81 - 20,50 540.4084.0000
20,51 - 31,00 540.5092.0000 20,51 - 31,00 540.5092.0000 20,51 - 31,00 540.4094.0000
31,01 - 44,00 540.5102.0000 31,01 - 44,00 540.5102.0000 31,01 - 44,00 540.4104.0000
44,01 - 62,00 540.5122.0000 44,01 - 62,00 540.5122.0000 44,01 - 62,00 540.5124.0000
62,01 - 88,00 540.5122.0000 62,01 - 88,00 540.5122.0000 62,01 - 88,00 540.5124.0000
540.5134.0205 540.5134.0205 540.5134.0205
88,01 -120,00 540.8062.0000 88,01 -120,00 540.8062.0000 88,01 -120,00 540.8064.0000
540.4314.0205 540.4314.0205 540.4314.0205
120,01 -135,00 540.8094.0000 120,01 -135,00 540.8094.0000 120,01 -135,00 540.8094.0000
135,01 -170,00 540.8094.0000 135,01 -170,00 540.8094.0000 135,01 -170,00 540.8094.0000
540.5134.0205 540.5134.0205 540.5134.0205
170,01 -200,00 540.8094.0000 170,01 -200,00 540.8094.0000 170,01 -200,00 540.8094.0000
540.4314.0205 540.4314.0205 540.4314.0205
Type 460,462 : O-Ring-Teller (O-ring disk) Type 462 : O-Ring-Teller (O-ring disk)
0,20 - 1,00 540.8054.0000 0,20 - 1,00 540.8054.0000
1,00 - 1,75540.4004.0000 1,00 - 1,75 540.4004.0000
1,76 - 2,70540.5031.0190 1,76 - 2,70 540.4034.0000
2,71 - 4,00540.5041.0190 2,71 - 4,00 540.4044.0000
4,01 - 6,05540.5051.0190 4,01 - 6,05 540.4054.0000
6,06 - 9,50540.5062.0000 6,06 - 9,50 540.4064.0000
9,51 - 14,50
540.5072.0000 9,51 - 14,50 540.4074.0000
14,51 - 21,50
540.5082.0000 14,51 - 21,50 540.4084.0000
21,51 - 32,00
540.5092.0000 21,51 - 32,00 540.4094.0000
32,01 - 48,00
540.5102.0000 32,01 - 48,00 540.4104.0000
48,01 - 73,00
540.8062.0000 48,01 - 73,00 540.8064.0000
73,01 -110,00
540.8062.0000 73,01 -110,00 540.8064.0000
540.4314.0205 540.4314.0205
110,01 -135,00 540.8094.0000 110,01 -135,00 540.8094.0000
135,01 -160,00 540.8094.0000 135,01 -160,00 540.8094.0000
540.5134.0205 540.5134.0205
160,01 -180,00 540.8094.0000 160,01 -180,00 540.8094.0000
540.4314.0205 540.4314.0205
Type 460,462 : O-Ring-Teller (O-ring disk) Type 462 : O-Ring-Teller (O-ring disk)
0,20 - 0,60 540.8054.0000 0,20 - 0,60 540.8054.0000
0,61 - 1,00 540.4004.0000 0,61 - 1,00 540.4004.0000
1,01 - 1,35 540.4024.0000 1,01 - 1,35 540.4024.0000
1,36 - 1,90 540.4044.0000 1,36 - 1,90 540.4044.0000
1,91 - 2,75 540.4054.0000 1,91 - 2,75 540.4054.0000
2,76 - 3,80 540.5062.0000 2,76 - 3,80 540.4064.0000
3,81 - 5,60 540.5072.0000 3,81 - 5,60 540.4074.0000
5,61 - 9,25 540.5082.0000 5,61 - 9,25 540.4084.0000
9,26 - 14,20 540.5092.0000 9,26 - 14,20 540.4094.0000
14,21 - 19,50 540.5102.0000 14,21 - 19,50 540.4104.0000
19,51 - 28,30 540.5122.0000 19,51 - 28,30 540.5124.0000
28,31 - 41,00 540.5122.0000 28,31 - 41,00 540.5124.0000
540.5134.0205 540.5134.0205
41,01 - 48,00 540.8062.0000 41,01 - 48,00 540.8064.0000
540.4314.0205 540.4314.0205
48,01 - 55,00 540.8094.0000 48,01 - 55,00 540.8094.0000
55,01 - 72,50 540.8094.0000 55,01 - 72,50 540.8094.0000
540.5134.0205 540.5134.0205
72,51 - 92,50 540.8094.0000 72,51 - 92,50 540.8094.0000
540.4314.0205 540.4314.0205
bearbeitet: Haa geprüft: Dy Ersatz für Ausgabe vom: 11.02.02 ECO 00043E
Federdaten-Tabellen Type 438 LWN 060.19
Spring data-list Blatt 01/Ende der LWN
sheet
Ausgabe 07.05.09
edition
Erklärungen siehe / explanation see : LWN 060.00
Ausführung
Standard (standard) warmfest (creep-resistant steel) korrosionsfest (stainless steel)
p [ bar ] p [ bar ] p [ bar ]
von bis Feder- Indizes von bis Feder- Indizes von bis Feder- Indizes
p1 p2 Sachnummer p1 p2 Sachnummer p1 p2 Sachnummer
up to stock no. up to stock no. up to stock no.
438 do10 438 do10 438 do10
5,00 - 6,50 540.3084.0000 5,00 - 6,50 540.3084.0000 5,00 - 6,50 540.3084.0000
6,51 - 9,70 540.3094.0000 6,51 - 9,70 540.3094.0000 6,51 - 9,70 540.3094.0000
9,71 - 14,00 540.3104.0000 9,71 - 14,00 540.3104.0000 9,71 - 14,00 540.3104.0000
14,01 - 26,00 540.3114.0000 14,01 - 26,00 540.3114.0000 14,01 - 26,00 540.3114.0000
26,01 - 35,00 540.3164.0000 26,01 - 35,00 540.3164.0000 26,01 - 35,00 540.3164.0000
35,01 - 54,00 540.3174.0000 35,01 - 54,00 540.3174.0000 35,01 - 54,00 540.3174.0000
54,01 - 68,00 540.3204.0000 54,01 - 68,00 540.3204.0000 54,01 - 68,00 540.3204.0000
68,01 - 93,00 540.2152.0000 68,01 - 93,00 540.2152.0000
long version long version long version
68,01 - 93,00 540.9304.0000
93,01 -121,00 540.9314.0000 93,01 -121,00 540.9314.0000 93,01 -121,00 540.9314.0000
121,01 -180,00 540.9324.0000 121,01 -180,00 540.9324.0000 121,01 -180,00 540.9324.0000
bearbeitet: Haa geprüft: Dy Ersatz für Ausgabe vom: 21.12.01 ECO 00043E
Federdaten-Tabellen Type 439 LWN 060.25
Spring data-list Blatt 01/Ende der LWN
Type sheet
Ausgabe 11.06.02
edition
Erklärungen siehe / explanation see : LWN 060.00 + LWN. 060.99
Ausführung
Standard (standard) warmfest (creep-resistant) korrosionsfest (stainless steel)
p [ bar ] p [ bar ] p [ bar ]
von bis Feder- Indizes von bis Feder- Indizes von bis Feder- Indizes
p1 p2 Sachnummer p1 p2 Sachnummer p1 p2 Sachnummer
up to stock no. up to stock no. up to stock no.
439 do10 439 do10 439 do10
0,10 - 0,23 540.0704.0000 0,10 - 0,23 540.0704.0000 0,10 - 0,23 540.0704.0000
0,24 - 0,33 540.3004.0000 0,24 - 0,33 540.3004.0000 0,24 - 0,33 540.3004.0000
0,34 - 0,50 540.3014.0000 0,34 - 0,50 540.3014.0000 0,34 - 0,50 540.3014.0000
0,51 - 0,90 540.3024.0000 0,51 - 0,90 540.3024.0000 0,51 - 0,90 540.3024.0000
0,91 - 1,40 540.3034.0000 0,91 - 1,40 540.3034.0000 0,91 - 1,40 540.3034.0000
1,41 - 1,80 540.3044.0000 1,41 - 1,80 540.3044.0000 1,41 - 1,80 540.3044.0000
1,81 - 3,10 540.3054.0000 1,81 - 3,10 540.3054.0000 1,81 - 3,10 540.3054.0000
3,11 - 4,40 540.3064.0000 3,11 - 4,40 540.3064.0000 3,11 - 4,40 540.3064.0000
4,41 - 7,00 540.3074.0000 4,41 - 7,00 540.3074.0000 4,41 - 7,00 540.3074.0000
7,01 - 10,00 540.3084.0000 7,01 - 10,00 540.3084.0000 7,01 - 10,00 540.3084.0000
10,01 - 16,00 540.3094.0000 10,01 - 16,00 540.3094.0000 10,01 - 16,00 540.3094.0000
Type 460,462 : O-Ring-Teller (O-ring disk) Type 462 : O-Ring-Teller (O-ring disk)
3 -14 540.8054.0000 3 -14 540.8054.0000
15 -26 540.4004.0000 15 -26 540.4004.0000
26 -39 540.5031.0190 26 -39 540.4034.0000
39 -58 540.5041.0190 39 -58 540.4044.0000
58 -88 540.5051.0190 58 -88 540.4054.0000
88 -138 540.5062.0000 88 -138 540.4064.0000
138 -210 540.5072.0000 138 -210 540.4074.0000
210 -312 540.5082.0000 210 -312 540.4084.0000
312 -464 540.5092.0000 312 -464 540.4094.0000
464 -696 540.5102.0000 464 -696 540.4104.0000
696 -1059 540.8062.0000 696 -1059 540.8064.0000
1059 -1595 540.8062.0000 1059 -1595 540.8064.0000
540.4314.0205 540.4314.0205
1595 -1958 540.8094.0000 1595 -1958 540.8094.0000
1958 -2320 540.8094.0000 1958 -2320 540.8094.0000
540.5134.0205 540.5134.0205
2320 -2610 540.8094.0000 2320 -2610 540.8094.0000
540.4314.0205 540.4314.0205
Type 460,462 : O-Ring-Teller (O-ring disk) Type 462 : O-Ring-Teller (O-ring disk)
3 - 9 540.8054.0000 3 - 9 540.8054.0000
9 -15 540.4004.0000 9 -15 540.4004.0000
15 -20 540.4024.0000 15 -20 540.4024.0000
20 -28 540.4044.0000 20 -28 540.4044.0000
28 -40 540.4054.0000 28 -40 540.4054.0000
40 -55 540.5062.0000 40 -55 540.4064.0000
55 -81 540.5072.0000 55 -81 540.4074.0000
81 -134 540.5082.0000 81 -134 540.4084.0000
134 -206 540.5092.0000 134 -206 540.4094.0000
206 -283 540.5102.0000 206 -283 540.4104.0000
283 -410 540.5122.0000 283 -410 540.5124.0000
410 -595 540.5122.0000 410 -595 540.5124.0000
540.5134.0205 540.5134.0205
595 -696 540.8062.0000 595 -696 540.8064.0000
540.4314.0205 540.4314.0205
696 -798 540.8094.0000 696 -798 540.8094.0000
798 -1051 540.8094.0000 798 -1051 540.8094.0000
540.5134.0205 540.5134.0205
1051 -1341 540.8094.0000 1051 -1341 540.8094.0000
540.4314.0205 540.4314.0205
Content
continues on page 2
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Cold differential test pressure
CDTP page 2
1 What is CDTP?
Cold differential test pressure (CDTP) is defined in standard
CDTP is used if correction of set pressure of safety valves according to deviation of service
conditions is necessary.
2 What is CDTP-correction?
The CDTP-correction is the correction of set pressure at test bench condition to achieve the correct
set pressure at service condition.
3 Which influences on safety valves are covered with the setting at CDTP ?
The set pressure on test bench deviating from service condition is influence by:
- temperature
- superimposed back pressure
The CDTP covers only influences of superimposed back pressure and/or temperature.
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Cold differential test pressure
CDTP page 3
p cdtp = ( p set − p a ) * k T
pset: set pressure at service conditions [psig or barg]
pa: superimposed back pressure, constant or variable [psig or barg]. If variable and
conventional design, the max. superimposed back pressure should be used. If balanced
bellows design is used pa is set to 0 bar or 0 psig.
kT: correction factor for CDTP [-], this is depending on valve design/conventional
design/balanced bellows design/open or closed bonnet
T: temperature in [°C]
Calculation-formulas:
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Cold differential test pressure
CDTP page 4
paf/p * 100 [%] d0 = 9 [mm] d0= 17,5 [mm] paf/p * 100 [%] d0 = 9 [mm] d0= 17,5 [mm]
5 How does LESER set the safety valves depending on different service condition
with temperature and back pressure?
LESER has made steam tests on LESER test laboratory. These measurements have been
monitored, evaluated and processed into a correction curve. This curve was approved by German
TÜV Nord to be a adequate practible procedure to correct set pressure to cold differential test
pressure concerning deviation of service conditions. The original confirmation of TÜV Nord and a
englisch translation is attached in chapter 9.
Please note, that for gas service the setting is defined as “first audible discharge”. For full opening
of valve pls. add another 10%.
1,120
1,080
Approved correction curve by
German TÜV Nord
1,060
Correction factor kT
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
0,980
Temperature T [°C]
0,960
-508 -308 -108 92 292 492 692 892
Temperature T [°F]
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Cold differential test pressure
CDTP page 6
Correction factor kT for conventional design open bonnet to correct adjusting on cold air
for service conditions of high temperature - cold differential test pressure -
1,120
1,080
Approved correction
curve by German TÜV
Nord
1,060
correction factor kT
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
Temperatur (°C)
0,980
0,960
-508 -308 -108 92 292 492 692 892
Temperature (°F)
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Cold differential test pressure
CDTP page 7
Correction factor kT, stainless steel bellows design, open or closed bonnet,
to correct adjusting on cold air for service conditions of high temperature
- cold differential test pressure -
1,120
1,060
Correction factor kT
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
Temperature T [°C]
0,980
0,960
-508 -308 -108 92 292 492 692 892
Temperature T [°F]
figure 3: correction factor kT for open or closed bonnet balanced bellows design
Note 1: LESER set safety valves in the range of 0 – 3% set pressure tolerance.
Note 2: The CDTP is not the popping point. It is according to LESER definition the set pressure with definition
“audible discharge” for gases/steam and “first steady stream” for liquids. The pening pressure is 10 %
higher than CDTP.
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Cold differential test pressure
CDTP page 8
Figure 3: Figure 4:
6.2 How is the influence of balanced bellows in case of type 459 / 462 safety valves?
For these two types the different discharge diameter do= 9, 13 and 17,5 mm have influence to the
correction of CDTP. This is based on the design of balanced bellows. The same stainless steel
bellows is implemented in all three do´s. The effective area of do = 13mm design is equal to the
balancing area of stainless steel bellows. A correction for differing effective areas (do = 9 mm and
do = 17,5 mm) of seat area and balancing area have to be considered with the additional correction
factor kaf .
Please refer to LWN 037.07 for detailed information.
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Cold differential test pressure
CDTP page 9
1,30
kaf
kaf (d0=9 mm) = 1,1575E-4*(paf /p*100%)²+1,899E-3*(paf /p*100%)+0,9987
1,20
1,10
1,00
0,90
diagram 1: correction factor kaf for balanced bellows design for type 459 / 462
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Cold differential test pressure
CDTP page 10
Closed Design:
Figure 5: Figure 6:
Open design is recommended for application which are not harmfull for environment. Closed
design is recommended for application with higher safety aspects. This has to be preselected by
customer.
The open bonnet design allows higher temperature of medium because of cooling effect with free
circulation of air. The temperature increase in comparison to closed bonnet design is smaller. The
correction factor is listed in table 1.
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Cold differential test pressure
CDTP page 11
If these limits are exceeded the spring characteristics are no more valid. The influence on
relaxation is stated in DIN EN 13906-1 or DIN 2089 (old not valid version).
The effect on CDTP-correction is covered with the stated correction factor in chapter 3. The spring
material has no significant effect on the test results.
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Cold differential test pressure
CDTP page 12
Nameplate ASME:
LESER-TAG:
11 EXAMPLE
11.1 Example: Temperature influence
Design: Type 441, open bonnet
Service condition: pset = 10barg (145 psig), pa = 0barg, t = 320°C ( 608°F), Steam
pcdtp = ( p set − p a ) * kT
kT: according to equation (3) in chapter 3:
kT = 1,025
pa = 0, because of no backpressure
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Cold differential test pressure
CDTP page 13
pcdtpmin = 10,25 barg +0,00*10,25 barg = 10,25 barg (148,66 psig)
pcdtpmin = 10,25 barg +0,03*10,25 barg = 10,56 barg (153,16 psig)
pcdtp = ( pset * k af − pa ) * kT
continues on page 14
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Cold differential test pressure
CDTP page 14
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Cold differential test pressure
CDTP page 15
continues on page 16
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Cold differential test pressure
CDTP page 16
Translation by LESER:
Dear Mr. Stremme,
We think it is a realistic way to consider the temperature at the Cold Differential Test Pressure of safety
valves according to the enclosed diagram.
The multiplication factor for the Cold Differential Test Pressure at the operating temperature is given by the
enclosed diagram.
This procedure will be applied only if the customer states it explicitly and annotated this on the column
“further manufacturers’ instructions”.
Sincerely yours
Schwenn
TÜV Inspector
End of LWN
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LESER WORKS STANDARD LWN 220-01-EN
Tightness Test
Testing Procedure at LESER Page 1
Contents
1 Scope and Applicability.............................................................................................................. 3
2 Definition.................................................................................................................................... 3
3 Test description for LESER Safety Valves ................................................................................ 3
3.1 Seat tightness test procedure, Test P12 ........................................................................ 3
3.1.1 Definition ................................................................................................................... 3
3.1.2 Requirements of LESER ........................................................................................... 3
3.1.3 Scope ........................................................................................................................ 3
3.1.4 Test media................................................................................................................. 3
3.1.5 Test pressure ............................................................................................................ 3
3.1.6 Test duration ............................................................................................................. 3
3.1.7 Test method for the seat tightness test ..................................................................... 3
3.1.7.1 Testing of seat tightness with air, bubbles emission test procedure ............ 3
3.1.7.1.1 Applicability........................................................................................................ 3
3.1.7.1.2 Test Equipment (Kellog-Test)............................................................................ 3
3.1.7.1.3 Test duration...................................................................................................... 3
3.1.7.1.4 Test pressure..................................................................................................... 3
3.1.7.1.5 Test description ................................................................................................. 3
3.1.7.1.6 Acceptance criteria, Option Code...................................................................... 3
3.1.7.1.7 Certification........................................................................................................ 3
3.1.7.2 Seat tightness test procedure with air, another method ................................. 3
3.1.7.2.1 Applicability........................................................................................................ 3
3.1.7.2.2 Test equipment.................................................................................................. 3
3.1.7.2.3 Test description ................................................................................................. 3
3.1.7.3 Seat tightness test procedure with helium ....................................................... 3
3.1.7.3.1 Applicability........................................................................................................ 3
3.1.7.3.2 Test equipment.................................................................................................. 3
3.1.7.3.3 Test method....................................................................................................... 3
3.1.7.3.4 Test pressure..................................................................................................... 3
3.1.7.3.5 Test duration...................................................................................................... 3
3.1.7.3.7 Test description ................................................................................................. 3
3.1.7.3.8 Acceptance criteria, Option Code...................................................................... 3
3.1.7.3.9 Certification........................................................................................................ 3
3.1.7.4 Seat tightness test procedure with water ......................................................... 3
3.1.7.4.1 Applicability........................................................................................................ 3
3.1.7.4.2 Test description ................................................................................................. 3
3.1.7.4.3 Acceptance criteria, Option Code...................................................................... 3
3.1.7.4.4 Certification........................................................................................................ 3
3.1.7.5 Seat tightness test procedure with steam ........................................................ 3
3.1.7.5.1 Applicability........................................................................................................ 3
3.1.7.5.2 Test equipment.................................................................................................. 3
3.1.7.5.3 Test pressure..................................................................................................... 3
3.1.7.5.4 Test duration...................................................................................................... 3
3.1.7.5.5 Test description ................................................................................................. 3
3.1.7.5.6 Acceptance criteria, Option Code...................................................................... 3
3.1.7.5.7 Certification........................................................................................................ 3
3.2 Shell Tightness test procedure P11................................................................................ 3
3.2.1 Applicability ............................................................................................................... 3
3.2.2 General, Definition..................................................................................................... 3
3.2.3 Test procedure at LESER ......................................................................................... 3
3.2.3.1 Applicability............................................................................................................ 3
3.2.3.2 Test equipment...................................................................................................... 3
3.2.3.3 Test medium.......................................................................................................... 3
Fortsetzung Bl. 2
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Tightness Test
Testing Procedure at LESER Page 2
3.2.3.4 Test pressure......................................................................................................... 3
3.2.3.5 Test duration.......................................................................................................... 3
3.2.3.6 Test description ..................................................................................................... 3
3.2.3.7 Certification, Option Code ..................................................................................... 3
3.3 Back seat tightness, test P21 (tightness outwards)...................................................... 3
3.3.1 Scope ........................................................................................................................ 3
3.3.2 Definition ................................................................................................................... 3
3.3.3 Test procedure at LESER’s ....................................................................................... 3
3.3.3.1 Applicability............................................................................................................ 3
3.3.3.2 Test equipment...................................................................................................... 3
3.3.3.3 Test medium.......................................................................................................... 3
3.3.3.4 Test pressure......................................................................................................... 3
3.3.3.5 Test duration.......................................................................................................... 3
3.3.3.6 Test description ..................................................................................................... 3
3.3.3.6.1 Operation with application of the test fluids (DIN EN 1593)............................... 3
This test procedure will be used for safety valves when the dipping is impractical................ 3
3.3.3.6.2 Dipping procedure (DIN EN 1593)..................................................................... 3
3.3.3.6.3 Helium test......................................................................................................... 3
3.3.3.7 Certification, Option Code ..................................................................................... 3
4 Qualifications of the staff ........................................................................................................... 3
5 Certification................................................................................................................................ 3
6 Demands of standards............................................................................................................... 3
7 References to further standards ................................................................................................ 3
8 Appendix 1: Seat tightness requirements acc. to API 527......................................................... 3
9 Appendix 2: Seat tightness LESER Standard tightness requirements ...................................... 3
10 Appendix 3: Seat tightness LESER increased tightness requirements.................................. 3
Fortsetzung Bl. 3
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Tightness Test
Testing Procedure at LESER Page 3
All LESER safety valves have to be tested on tightness except SKD Kits Compact Performance-
Valves (ref. to LWN 704.41).
2 Definition
The tightness test is a production test and is practised at LESER standardly.
Fortsetzung Bl. 4
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Tightness Test
Testing Procedure at LESER Page 4
3.1.3 Scope
The testing procedure of seat tightness for each safety valve occurs after setting and
checking of cold differential set pressure on test bench in accordance with operation chart,
which is deposited in SAP System.
At LESER the performance of pressure range and test pressure requirements acc. to API
527 is as follows (table 1):
Fortsetzung Bl. 5
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Tightness Test
Testing Procedure at LESER Page 5
3.1.7.1 Testing of seat tightness with air, bubbles emission test procedure
3.1.7.1.1 Applicability
This procedure of seat leakage test with air, counting number of bubbles, is practised
in case of safety valves with gastight design (lifting device H4, cap H2, closed
bonnet).
Fig. 1
Fortsetzung Bl. 6
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Tightness Test
Testing Procedure at LESER Page 6
The leakage rate shall not exceed the limited leakage rates depending on the flow
area d0 and valve design as mentioned in appendix 2 and 3.
Option
Text Remark
Code
Grinding: For increased The Option Code N50 is not used any
N50 tightness acc. to LWN 220.01 longer
(intern)
Table 2
3.1.7.1.7 Certification
The testing of seat tightness with air (bubble emission procedure) is documented in
the SAP system and confirmed by inspection test certificate acc. to DIN EN 10204.
If test report for seat leakage test is required, it has to be accessed with option code
M66.
Fortsetzung Bl. 7
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Tightness Test
Testing Procedure at LESER Page 7
3.1.7.2.1 Applicability
In case of non-gas tight safety valve design (lifting device H3, open bonnet), the seat
leakage test is carried out with procedure of applying test fluid (acc. to DIN EN 1593).
The application of test fluid is a qualitative test procedure, because the quantitative
procedure of bubble counting (leakage rate) is not possible.
As test fluid a foamy lotion acc. to DIN EN 14291, leakage finder, is used. The test
fluid shall be non-volatile (it shall not dry at test temperature during test period) and
viscous.
Fig. 2
Austritt
outlet
Eintritt
inlet
Prüftisch
test bench
Fortsetzung Bl. 8
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Tightness Test
Testing Procedure at LESER Page 8
3.1.7.2.4 Certification, Option Code
The testing of seat tightness with air, applying of test liquid procedure, is documented
in the SAP system and confirmed by an inspection certificate according to DIN EN
10204.
If inspection certificate for seat tightness test is required, it has to be accessed with
option code M22.
Fortsetzung Bl. 9
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Tightness Test
Testing Procedure at LESER Page 9
Following option codes shall be used for seat leakage test with helium:
- Option Code N62, for sniffing method
- Option Code M86, for vacuum method
3.1.7.3.9 Certification
The testing of seat tightness with helium is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204 / test report.
Following information are to be considered:
- Test subject
- Requirements of Standard
- Reference terms / Main technical characteristics
Test medium, Helium
Test equipment: helium leakage detector, Alcatel Type ASM 120H
Helium calibrated leaks, leakage rate 1,5x10-7 mbar l/s
- Test results
- Test method for each test result
- Relevant Units, mbar l/s, for each test result.
If inspection certificate for seat tightness test with helium is required, it has to be
accessed with following option code:
- M 77 for seat tightness, overpressure procedure (sniffing method)
- M 81 for seat tightness, procedure of leakage detection in vacuum
3.1.7.4.1 Applicability
This test procedure is only carried out on customer demand and relevant rules and
regulations. Terms of test conditions and tightness requirements are listed in
Appendix 2 resp. 3.
3
cm /min 0,166 0,166 0,166 4 5 6 8 11 13 17 25 33 42 50 66
Table 3: Leakage volume depending on nominal size acc. to API 527 (App. 1)
Fortsetzung Bl. 10
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Tightness Test
Testing Procedure at LESER Page 10
3.1.7.4.4 Certification
The testing of seat tightness with water is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204.
3.1.7.5.1 Applicability
Testing of seat tightness with steam is practised for safety valves which are setted on
cold-differential set pressure with steam.
3.1.7.5.7 Certification
The seat leakage test with steam is documented in the SAP system and confirmed by
inspection test certificate acc. to DIN EN 10204.
Fortsetzung Bl. 11
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Tightness Test
Testing Procedure at LESER Page 11
DIN EN 12266-1, Edition June 2003 replaces DIN 3230-1: 1974-04, DIN 3230-2:1974-04,
and DIN EN 12266-2:2003-05 replaces DIN 3230-3.
The former designation is: BF, BQ, BW acc. to DIN 3230-3.
3.2.3.1 Applicability
Acc. to work schedule the shell tightness test procedure is deposited in SAP system for
every safety valve in gastight design. LESER has integrated this test procedure into
production process standardly.
Fortsetzung Bl. 12
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Tightness Test
Testing Procedure at LESER Page 12
Remark!
During test period the test pressure shall be kept constant.
Afterwards the valve has to be blown dry with compressed air.
If inspection certificate for shell tightness test with air is required, it has to be accessed
with option code M18.
Fortsetzung Bl. 13
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Tightness Test
Testing Procedure at LESER Page 13
3.3.2 Definition
The test is a pre-expediting pressure test for certification that the determined leakage rate
of the back sealing is kept to the moment of the manufacture.
The tightness outwards has reference to the test of the tightness at the connections
body/bonnet, bonnet/lifting device H4 (cap H2) as well as the outlet of the body.
Marking in accordance with DIN EN 12266-2, edition 2003
Tightness of back seal, test P21-EN 12266.2
The tightness of the back seal, test P21, is in accordance with the task schedule which is
deposited in the data base of the SAP-system for every safety valve in gastight design. At
LESER’s, this test is standard which is integrated in the production process.
1
“Built-up back pressure For the LESER safety valve, 15 % of the set pressure minus superimposed back pressure
(if applicable) is generally permissible. “ Complete catalogue 21/30
Fortsetzung Bl. 14
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Tightness Test
Testing Procedure at LESER Page 14
- Test pressures outside of the scope of the standard must be coordinated between the
customer and LESER (VK/TB).
The test pressure must be maintained at least for the test period determined in table 5 (in
accordance with DIN E 12266-2).
Table 5: Minimum test period for testing of the tightness of the back seal
Nominal size Minimum test period
s
> DN 50 15
from DN 65 to DN 200 15
DN 250 to DN 450 30
Remark! During the test period the test pressure has to be kept constantly.
The safety vale should be blistered dry with compressed air.
With the leak detector used by LESER (Alcatel – ASM 120H), the tightness test with the
vacuum-method is realized.
The safety valve will be sealed (at the inlet) with a sealing cap. Afterwards the safety valve
will be clamped (at the outlet) on the leak detector. When the evacuation process is finished
(in the safety valve is now a vacuum) helium will be sprayed with an air gun on every
connection for 3 – 4 sec. The test result will be read if the LED display is stabled.
Fortsetzung Bl. 15
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Tightness Test
Testing Procedure at LESER Page 15
As a standard test with air, the tightness test of the back sealing, tightness outwards, will
follow without option code.
The tightness test of the back sealing, tightness outwards, with Helium will be regulated
with option code N64.
If inspection certificate for back seat test tightness outwards is required, it has to be
accessed with following Option Codes:
- M 28 Back seat tightness test outwards, application of test fluids
- M 78 Back seat tightness test outwards, dipping procedure
- M 82 Back seat tightness test outwards with helium, overpressure method (sniffing
method)
5 Certification
Test results are reported standardly in the SAP system and are proved by an inspection certificate
according to 3.1 of DIN EN 10204.
Following information has to be included in APZ 3.1:
- Test subject
- Requirements of Standard
- Used procedures
- Reference terms / technical characteristics
Test medium, test liquid, test device
- Test results
- Test method for each test result
- Relevant units, mbar l/s, for each test result.
6 Demands of standards
Following standards are considered for the tightness tests at LESER’s:
DIN EN ISO 4126-1, Safety devices for protection against excessive pressure Part 1: Safety
valves, chapter. 6 Production testing, 6.6 Seat leakage test:
„The seat leakage test of a safety valve shall be carried out. The test procedure and leakage rate
shall be agreed between the manufacturer and the purchaser”
ASME Code Section VIII Rules for Construction of Pressure Vessels, Edition 2006
Part UG-136(d) Production Testing by Manufacturers and Assemblers
UG- 136 (d) (3) The secondary pressure zone of each closed bonnet pressure relief valve
exceeding NPS 1 (DN 25) inlet size when such pressure relief valves are designed for discharge to
a closed system shall be tested with air or other gas at a pressure of at least 30 psi (200kPa).
There shall not be visible sign of leakage.”
UG- 136(d) (5) After completion of the tests required by (d) (4) above, a seat tightness test shall be
conducted. Unless otherwise designated by a Manufacturer’s published pressure relief valve
specification or another specification agreed to by the user, the seat tightness test and acceptance
criteria shall be in accordance with API 527.”
Fortsetzung Bl. 16
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Tightness Test
Testing Procedure at LESER Page 16
DIN EN 12266-1 Industrial valves: Testing of valves, part 1: Pressure tests, test procedures
and acceptance criteria- Mandatory requirements, edition 2003, chapter.4 Test requirements:
4.2 „Every valve shall be subjected to the shell tightness test, reference P11, listed in Table 1.“
DIN EN 12266-2 Industrial valves – Testing of valves, part 2: Tests, test procedures and
acceptance criteria, edition 2003, A.3 Back seat tightness, test P21
ASME Code Section VIII Rules for Construction of Pressure Vessels, Edition 2006
Fortsetzung Bl. 17
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Tightness test
Testing at LESER Page 17
Set pressure Blow down up o PZ = Test Time (related to 16°C; bubble volume (related to 16°C; bubble volume
3 3,
po VB= 0,295 cm , tube ∅ = 6,12mm) VB= 0,295 cm tube ∅ = 6,12mm)
(relating to 16°C) Test pressure Min
DN DN DN
≤50 65...100 >100 Number of Leakage Leakage Number of Leakage Leakage
≤2“ 21/2...4“ >4“ bubbles volume rate bubbles volume rate
3 3
bar MPa bubble/ min cm / min Mbar l/s Bubble/ min cm / min Mbar l/s
BZ PZ BZ PZ BZ PZ
-1 -2
1,03-68,9 0,103-6,896 40 11,80 1,9x10 20 5,90 9,4x10
103 10,3 po ≤ 3,45 bar 60 17,70 2,8x10
-1
30 8,85 1,4x10
-1
Metal-to-metal
-1 -1
Air (Gases)
-3
- - 1 1 2 1 5 1 0 0 <4,7x10 0 0
Metal-to-metal
Soft sealing
Steam
sealing
p0 >3,45 bar
(0,345 MPa)
NW≥1“ (DN25)
Metal-to-metal
3
Leakage volume ≤10cm /h x Inlet nominal size /
sealing
LWN 220-01
pPrüf.= 0,9*po 3
leakage volume ≤10cm /h*
test
- - No leakage
Soft
Fortsetzung Bl. 18
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Tightness test
Testing at LESER Page 18
3 3
(related to 20°C) BZ-damping time (related to 20°C; bubble volume VB= 0,295 cm (related to 20°C; bubble volume VB= 0,295 cm
After testing of set
PZ-Test time tube ∅ = 6,12mm) tube ∅ = 6,12mm)
pressure po
Blow down up to...
Test pressure
Pressure stages acc. to Number of Leakage volume Leakage Number of Leakage volume Leakage
Blow-down of...
LWN 220.03 bubbles rate bubbles rate
Test pressure 3 3
bar MPa s / min bubble/min cm /min mm³/sec mbarl/s bubble/min cm /min mm³/sec mbarl/s
Metal-to-metal
-1 -2
0,1- 66 0,01- 6,6 0,1< po < 0,7 (bar) 40 11,80 196,66 1,9x10 20 5,90 98,33 9,4x10
BZ = 10s
sealing
-1 -1
>66-165 >6,6-16,5 PZ = 10s 60 17,70 295,00 2,8x10 30 8,85 147,50 1,4x10
-1 -1
>165- 700 >16,5- 70,0 80 23,60 393,33 3,8x10 40 11,80 196,66 1,8x10
Pprüf = 0,5*p0
Air (Gases)
Soft sealing
-2 -2
- - PZ = 10s 20 5,90 98,33 9,4x10 10 2,95 49,16 4,7x10
soft sealing
BZ =10s
-5 -5
- - PZ = 10s 0 0 0 ≤9x10 0 0 0 ≤9x10
pPrü f= p0 - 0,35bar
test (0,035 Mpa)
Steam
BZ = 3 min
sealing
LWN 220-01
No recognized or visible leakage
- - p0 > 3,5 bar PZ = 1 min
No indication of pressure drop at the pressure gauge
po >0,35 (MPa)
Soft sealing
Water
BZ =10s
sealing
metal
- -
pPrüf. = 0,9*po PZ = 10s
No recognized or visible leakage
test
Fortsetzung Bl. 19
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Tightness test
Testing at LESER Page 19
3 3
(related to 20°C; Bubble volume VB= 0,295 cm (related to 20°C; Bubble volume VB= 0,295 cm
(related to 20°C) After testing of set BZ=damping time
Pz = test time tube ∅ = 6,12mm) tube ∅ = 6,12mm)
pressure po
Blow down up to ...
Test pressure
Pressure stage acc. to Blow-down of... Number of Leakage Number of Leakage
Leakage volume Lekage volume
LWN 220.03 Test pressure bubbles rate bubbles rate
3
bar MPa cm /min mm³/sec cm³/min mm³/sec
bubble/min mbarl/s bubble/min (mbarl/s)
Soft sealing Metal-to-metal
-2 -2
LESER - increased tightness
Pprüf = 0,5*p0
- - test - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
BZ =3 min
sealing
metal
-
Metal-to- Soft sealing
pPrü f= p0 - 0,35bar
- test (0,035 Mpa) - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
metal sealing
LWN 220-01
- - PZ = 10s
Water
Soft sealing
pPrüf. = 0,9*po
- - test - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
Table of contents
Summary ........................................................................................................................................................... 2
1 General and definitions......................................................................................................................... 2
2 Purpose and area of application........................................................................................................... 2
3 Derivation of standard specifications on LESER safety valves............................................................ 3
4 Testing depth at LESER, practical application of the set pressure tolerances .................................... 3
5 Assembly and test equipment .............................................................................................................. 3
6 Pressure measuring devices ................................................................................................................ 4
7 Test media ............................................................................................................................................ 4
8 Test procedure at LESER..................................................................................................................... 5
8.1 Setting and testing of the cold differential test pressure with air .............................................. 5
8.1.1 Testing depth, option code ............................................................................................................................ 5
8.1.2 Test bench ..................................................................................................................................................... 5
8.1.3 Testing procedure ......................................................................................................................................... 6
8.1.4 Acceptance criteria ..................................................................................................................................... 10
8.2 Setting and testing of the cold differential test pressure with water ....................................... 10
8.2.1 Testing depth, option code .......................................................................................................................... 10
8.2.2 Test bed....................................................................................................................................................... 10
8.2.3 Testing procedure ....................................................................................................................................... 10
8.2.4 Acceptance criteria ..................................................................................................................................... 10
8.3 Setting and testing of the cold differential test pressure with steam ...................................... 10
8.3.1 Standards applied ....................................................................................................................................... 10
8.3.2 Testing depth, option code .......................................................................................................................... 10
8.3.3 Test media................................................................................................................................................... 10
8.3.4 Test bed....................................................................................................................................................... 11
8.3.5 Testing procedure ....................................................................................................................................... 11
8.3.6 Acceptance criteria ..................................................................................................................................... 11
8.3.7 Testing on capacity test bench of National Board (USA) ........................................................................... 12
9 Qualifications of the test personnel .................................................................................................... 12
10 Documentation and option code......................................................................................................... 12
11 Standards applied............................................................................................................................... 12
12 Normative instructions ........................................................................................................................ 14
13 Terms and abbreviations .................................................................................................................... 14
continues on page 2
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Procedures for the testing of cold differential
test pressure page 2
Summary
This LWN lists the standard requirements and will describe the procedure during the setting and
testing of the cold differential test pressure of safety valves at LESER and its documentation.
The Procedure is valid for all safety valves to be set with steam, water or air at the LESER
production sites Hamburg, Hohenwestedt and at the authorised LESER service partners, In case
they act on behalf of LESER.
The testing of the cold differential test pressure shall not be applied for safety valves carrying out:
The issuing of an inspection certificate about the testing carried out can be order with the following
option codes.
Option code Acceptance test certificate Comments
LESER CGA (Certificate for Global Application) – Inspection
H03
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
N05
cold differential test pressure with air
The cold set pressure (DIN EN ISO 4126-1, chapter 3.2.5) is the static pressure on the inlet side,
at which a safety valve will start opening on the test bed. This pressure includes corrections for
operational conditions, e.g. counter pressure and/or temperature.
The cold set pressure will be used, if a correction of set pressure is necessary due to deviations to
the operating conditions.
The evaluation of cold differential test pressure (CDTP) under consideration of influencing factors
can be taken from LWN 001-69.
The definition of the cold set pressure of LESER safety valves is:
The pressure, the safety valve is adjusted at LESER on the test bed and the first audible noise in
case of steams/air/gases and/or the first continuous flow of liquid.
The set pressure (EN ISO 4126-1 chapter 3.2.1) is the preset pressure, a safety valve starts
opening under operational conditions (DIN EN ISO 4126-1). It is the excess pressure on the valve
inlet side, where the forces that open the valve under the specific operational conditions, will be
equal to the forces that keep the valve disc in position.
continues on page 3
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Procedures for the testing of cold differential
test pressure page 3
From 300 psi (20,7 bar) the specifications in accordance with ASME Section I, Rules for
Construction of Power Valves, PG 72.2 General Requirements for all Methods of Construction,
Safety Valves and Safety Relief Valves will be ignored as at present none of such products are
being manufactured. Should this situation change, this will be regulated in this LWN.
Summary: The specifications regarding the set pressure tolerance for all named standards
have been listed in table 1.
1,65 bar ( 23,9 psi) ... 3,96 bar ( 58 psi) plus 0,1 bar ( 1,45 psi)
When adjusting the safety valves three important influencing factors have to be principally
considered:
• Preciseness of the measuring equipment
• Reading exactness of the technician and/or tester (analogue display)
• Repetitive setting exactness of the valves
All three factors have to be covered by the set pressure tolerance, whereby only during the setting
a person can take direct influence.
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Procedures for the testing of cold differential
test pressure page 4
Table 2: LESER preferential series for pressure measuring devices (in accordance with ASME-
Code and DIN EN 837-1)
Comment:
The LESER preferential series in accordance with ASME starts with manometer 0 - 2,5 bar.
The controlled areas in accordance with ASME-Code start from > 15 psi (1,03 bar). The
controlled areas in accordance with the European pressure appliances guideline (from >
0,5 bar) and the pressure vessel regulation (from > 0,1 bar) have been included.
All mechanical class 0.6 pressure measuring devices with operational error limit ± 0,6% of
the LESER preferential series have to be regularly gauged and/or adjusted in accordance
with LWN 615.07 at a minimum of every 12 months.
The use of pressure measuring devices at the assembly sites is regulated in LWN 220.03.
7 Test media
Safety valve set pressure is normally set with air on a test bed and the valve is then operated with
different media types, steam, gases or liquids.
As a standard air is used for setting and testing of the cold-set pressures of safety valves.
Still, if it is required to adjust the safety valve with the medium water or steam on the test bed, this
has to be specified in the order.
continues on page 5
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Procedures for the testing of cold differential
test pressure page 5
8.1 Setting and testing of the cold differential test pressure with air
8.1.1 Testing depth, option code
As a standard safety valves for air or other gases have to be set and tested with air at room
temperature. This is carried out in accordance with work schedule recorded in the SAP
System for each safety valve. The control is carried out without option code.
continues on page 6
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Procedures for the testing of cold differential
test pressure page 6
After assembly the safety valve will be pressurized and adjusted via adjusting screw to the given
set pressure acc. to SAP demand (flag Q-feature). Safety valves with lever will be setted up per
positioning the weight.
The set pressure is reached when the discharge of air is audible. A saturated opening with clear
clicking noise or crack shall be reached. Stealthy setting is not allowed.
The procedure of setting and testing of cold differential test pressure with air is described exactly
for each valve type in the working instructions (assembly / installation documentation).
continues on page 7
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Procedures for the testing of cold differential
test pressure page 7
The following work stages have to be adhered to (Example for a threaded valve):
Work stage 1
Tools
Software system
Testing equipment
continues on page 8
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Procedures for the testing of cold differential
test pressure page 8
Work stage 2
Tools
Equipment
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Procedures for the testing of cold differential
test pressure page 9
Work stage 3
Tools
• Splint mandrel, open-end wrench
• Software Visual Manometer
• SAP Transaction ZAKL / tab Q-
characteristics
Equipment
continues on page 10
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Procedures for the testing of cold differential
test pressure page 10
8.1.4 Acceptance criteria
The safety valve has to open within the preset pressure tolerance.
Escaping air has to be audible. Full opening has to be achieved with a clear bang. A
creeping response is not admissible.
8.2 Setting and testing of the cold differential test pressure with water
8.2.1 Testing depth, option code
The safety valves to set and tested using water are controlled in accordance with SAP
System recorded work schedule, using option code M09.
8.3 Setting and testing of the cold differential test pressure with steam
8.3.1 Standards applied
This testing is valid for safety valves with UV-Stamp (LWN 001.26, LWN 619.12) and for
safety valves that are set by steam. The ASME Code Sec. VIII Div.1 specifies under UG
136(d)(4) that safety valves for steam applications have to be set using steam, whereby
safety valves that due nominal width and response pressure are beyond the possibilities of
the steam test bed, can be tested using air.
• Each safety valve has to respond several times (if necessary also pop) to warm up the valve
seat and valve disk.
• After several responses (if necessary also pop) of the test valve the set pressure in accordance
with specifications has to be set and checked.
The set pressure of the valves has been reached, when the escaping steam is clearly audible.
You have to achieve a full opening with a clearly audible cracking and/or bang. A creeping
response is not admissible.
• For evaluation of actual set pressure 3 single serial values have to be within a repeat accuracy
of 1%. The average value of this 3 single values is the determined actual set pressure, which
has to be within an allowable tolerance of +3% of set point. The determined actual set pressure
is definded as set pressure and builds the basis for further testings.
• After cooling of safety valves the tightness test with air acc. to LWN 220.01 will be carried out.
The steel safety valves will be protected against corrosion. Blowing space and sealing strip will be
treated with a silicon-free corrosion oil and then cleaned.
Please note! After that the valve has to be blown dry with pressurised air.
continues on page 12
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Procedures for the testing of cold differential
test pressure page 12
The escaping steam has to be audible. A full opening with a bang has to be achieved. A creeping
response is not admissible.
Depending on demanded capacity of the valve different values will be gathered (six or eight). The
smaller the capacity of valve the more measured values will be gathered and the more longer
takes the measuring process. Exactly one value per minute will be recorded. Reason for this
procedure is the precision of measuring of condensate steam using a water tank on a balance.
The steam will be condensated behind the valve and the water will be pumped in a second
metering box. This quantity of emerged water will be scaled. It will be pumped into two tanks (three
minutes each tank). During measurement of capacity the actual overpressure (10% over set
pressure) as well as the steam temperature will be read off and documented per each single value.
These values will be averaged and build the basis for the required capacity of valve.
The issuing of a certification about the testing of the cold differential test pressures can be ordered
using the following option codes:
Option code Acceptance test certificate Comments
LESER CGA (Certificate for Global Application) – Inspection
H03
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
N05
cold differential test pressure with air
11 Standards applied
• DIN EN ISO 4126-1 Safety appliances against non-permissible excess pressure, Part 1:
safety valves (edition May 2004), chapter 7- component tests
7.2 Tests for the determination of operational characteristics
“7.2.1 General requirements
.......The permissible tolerances and/or limits for the operational characteristics areas follows:
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Procedures for the testing of cold differential
test pressure page 13
≤ 70 (0,5) 2 psi
> 70 (0,5) and ≤ 300 (2,1) 3 % of set pressure
> 300 (2,1) and ≤ 1000 (7,0) 10 psi
> 1000 (7,0) 1 % of set pressure
• ASME Code, Section VIII, Rules for Construction of Pressure Vessels, Division 1,
(Edition 2007)
Part UG General Requirements for All Methods of Construction and All Materials
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Procedures for the testing of cold differential
test pressure page 14
12 Normative instructions
LWN 001.26 Safety valves with ASME certification
LWN 001.69 Cold differential test pressure (CDTP)
LWN 001.78 Set pressure, tightness, operation
LWN 220.01 Tightness test, testing procedure at LESER
LWN 220.03 Use of pressure measuring devices at the test beds (DIN EN- / ASME)
LWN 615.07 Gauging intervals (test media)
LWN 619.12 ASME/National Board- approval for LESER Safety valves (Stamp-
attainment)
LWN 205.80 Operation, maintenance and maintenance steam machine, softening plant,
steam setting table HOW
End of LWN
LESER processed: Sa.cw. edition: 02.09.08
GmbH & Co. KG approved: refer to ÄM 150900 replaces edition: 04.06.08
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Performing
Leak Tests
continues on page 2
processed: Kai Krohn edition: 2010-05-10
LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
1 General
This LWN describes professional application of the test procedures. It summarises
the user information in a target-group-oriented manner.
Information:
Always keep the test manual
at the assembly test bench.
The manual must always be immediately available.
2 Contents
1 General....................................................................................................................................2
2 Contents..................................................................................................................................2
3 Scope ......................................................................................................................................3
3.1 Purpose of the document .................................................................................................3
3.2 Improper use ....................................................................................................................3
3.3 Informal measures............................................................................................................3
4 References to standards .......................................................................................................4
4.1 Operational materials and supplies ..................................................................................5
5 Distinguishing features of valve designs ............................................................................7
5.1 Safety valves in a gas-tight design...................................................................................7
5.2 Safety valves in a non-gas-tight design............................................................................7
6 Test description .....................................................................................................................8
6.1 Safety valves in a gas-tight design...................................................................................8
6.1.1 Flanged valves .........................................................................................................8
6.1.2 Threaded valves .....................................................................................................19
6.2 Safety valves in a non-gas-tight design:.........................................................................33
6.2.1 Flanged valves .......................................................................................................33
continues on page 3
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
3 Scope
This manual is valid for the execution of leak tests on safety valves in domestic and
foreign agencies of LESER GmbH & Co. KG.
The leak test is a production test, and must be performed as a standard procedure.
continues on page 4
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
4 References to standards
The standards that are taken into consideration and applied by LESER for testing for
leaks are established in LWN 220-01.
It also contains the
• standard requirements for functional seal tightness (seat seal tightness) as well as
• increased seal tightness requirements of the functional seal tightness (seat seal
tightness) for
• gas-tight and non-gas-tight valves.
continues on page 5
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
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Set-up of Equipment in Warehouses
Fig. 5: Accessories
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Flanged valves
Open Open
bonnet lever (H3)
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
6 Test description
6.1 Safety valves in a gas-tight design
6.1.1 Flanged valves
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
• LWN 369.30
1. • LWN 369.32
• LWN 369.33
3.
4.
continues on page 9
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
1. Valve assembly:
The valve must be assembled according to the assembly documentation.
• LWN 369.30
• LWN 369.32
• LWN 369.33
Fig. 7: API gas-tight
Test data for testing the functional seal tightness with air:
The following test data must be observed when testing the functional seal tightness with
gas-tight valves.
Test data
Test characteristic Seal tightness between the seat and disc
Testing standard Number of bubbles per second, see LWN 220-01, Attachment 1-3
Testing depth Every safety valve, 100% testing
Test medium Air
Test pressure 90% of set pressure
Testing device Bubble counting unit
Length of test Settling time of at least 10 seconds + testing time of 10 seconds
Test data for testing the functional seal tightness with water:
The following test data must be observed when testing the functional seal tightness with
gas-tight valves.
Test data
Test characteristic Seal tightness between the seat and disc
Leak volume [cm³/min.] depending on the nominal diameter, see
Testing standard
LWN 220-01, TABLE 3
Testing depth Only at the request of the customer
Test medium Water
Test pressure 90% of set pressure
Testing device Water expansion kit, LWN 369.55
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Auxiliary materials:
The following auxiliary materials must be available when testing the functional seal tight-
ness.
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be ad-
versely affected. A qualitative assessment of the leak volume as per LWN 220-01 Table 3 cannot
be conducted in a technically reasonable way.
If a quantitative statement is requested (leak rate) on the functional seal tightness for safety
valves that must be set with water, then the functional seal tightness of the valves will be tested
with air after finishing the adjustment of the set pressure.
Testing of the functional seal tightness with water can only represent a quantitative statement.
continues on page 11
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The inlet side of the safety valve must be vertically at-
tached to the chuck.
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Set-up of Equipment in Warehouses
Test passed:
If the number of bubbles is less than or equal to
the specification, then the test has been
passed.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The inlet side of the safety valve must be vertically at-
tached to the chuck.
-10%
d) After a settling time of 10 seconds, a qualitative as- Fig .16: Pressure reduction by 10%
sessment of the leak volume must be performed as
per LWN 220-01.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the seal tightness of the pressure-bearing
body.
Test data
Test characteristic Testing the body seal tightness
Testing standard The valve must not have any visual signs of leaks
Every safety valve with a cast body and a rolled-in seat, 100%
Testing depth
testing
Test medium Air
Auxiliary materials:
The following auxiliary materials must be provided when testing the body seal tightness.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
6 bar
b) Apply test pressure of 6 bar (87.02) psi to the
safety valve.
Test passed:
If there is no foam formation on the body,
then the test has been passed.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the back seal.
Test data
Test characteristic Testing of the seal tightness of the valve on the outlet side
Testing standard The valve must not have any visual signs of leaks
Testing depth Every safety valve with a gas-tight design, 100% testing
Test medium Air
Test pressure 6 bar (87.02 psi)
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing the back seal.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The outlet side of the safety valve must be
attached to the chuck.
6 bar
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test passed:
If there is no foam formation on the surface of the valve,
then the test has been passed.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
• LWN 369.31
1.
2.
3.
Figure 28
4.
continues on page 20
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
1. Valve assembly:
The valve must be assembled according to the assembly documentation.
• LWN 369.31
Test data
Test characteristic Seal tightness between the seat and disc
Testing standard Number of bubbles per second, see LWN 220-01, Attachment 1-3
Testing depth Every safety valve, 100% testing
Test medium Air
Test pressure 90% of set pressure
Testing device Bubble counting unit
Length of test Settling time of at least 10 seconds + testing time of 10 seconds
Test data
Test characteristic Seal tightness between the seat and disc
Leak volume [cm³/min.] depending on the nominal diameter, see
Testing standard
LWN 220-01, TABLE 3
Testing depth Only at the request of the customer
Test medium Water
Test pressure 90% of set pressure
Testing device Water expansion kit, LWN 369.55
continues on page 21
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Auxiliary materials:
The following auxiliary materials must be provided when testing the seal tightness of the
seat for threaded valves.
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be ad-
versely affected. A quantitative assessment of the leak volume as per LWN 220-01 Table 3 can-
not be conducted in a technically reasonable way.
If a quantitative statement is requested (leak rate) on the functional seal tightness for safety
valves that must be set with water, then the functional seal tightness of the valves will be tested
with air after finishing the adjustment of the set pressure.
Testing of the functional seal tightness with water can only represent a quantitative statement.
continues on page 22
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
Figure 31
a) The inlet side of the safety valve must be verti-
cally attached to the clamping device (see LWN
0121.0001).
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Set-up of Equipment in Warehouses
-10%
d) Trigger the safety valve to trigger once. Then
lower the pressure by 10% of the set pressure, or
more precisely, by 0.35 bar (5.08 psi) for set
pressures ≤3.5 bar (50.76 psi).
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Set-up of Equipment in Warehouses
Test passed:
If the number of bubbles is less than or equal
to the tolerance specification, the the test has
been passed.
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Set-up of Equipment in Warehouses
Operations:
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Set-up of Equipment in Warehouses
-10%
e) Then lower the pressure by 10% of the set pres-
sure, or more precisely, by 0.35 bar (5.08 psi) for
set pressures ≤3.5 bar (50.76 psi).
continues on page 27
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the body seal tightness.
Test data
Test characteristic Testing of the seal tightness of the pressure-bearing body
Testing standard The body must not have any visual signs of leaks
Every safety valve with a cast body and a rolled-in seat, 100%
Testing depth
testing
Test medium Air
Test pressure 6 bar (87.02 psi)
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing the seal tightness of the
pressure-bearing body for threaded valves.
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Set-up of Equipment in Warehouses
Operations:
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test passed:
If there is no foam formation on the body, then
the test has been passed.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the back seal.
Test data
Test characteristic Testing of the seal tightness of the valve on the outlet side
Testing standard The valve must not have any visual signs of leaks
Testing depth Every safety valve with a gas-tight design, 100% testing
Test medium Air
Test pressure 6 bar (87.02 psi)
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing the back seal.
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Set-up of Equipment in Warehouses
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Set-up of Equipment in Warehouses
Test passed:
If there is no foam formation on the body,
then test has been passed.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
• LWN 369.30
1. • LWN 369.32
• LWN 369.33
2.
3.
continues on page 34
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
1. Valve assembly:
The valve must be assembled according to the assembly documentation.
• LWN 369.30
• LWN 369.32
• LWN 369.33
Fig. 58: API non-gas-tight
Test data:
The following test data must be observed when testing functional seal tightness with non-gas-tight
valves.
Test data
Test characteristic Seal tightness between the seat and disc
Testing standard The blow-hole at the outlet must not extend more than 5mm
Testing depth Every safety valve, 100% testing
Test medium Air
Test pressure 90% of set pressure
Testing device Application of test liquid
Length of test Settling time of at least 10 seconds + testing time of 5 seconds
Auxiliary materials:
The following auxiliary materials must be provided when testing the functional seal tight-
ness of non-gas-tight valves.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The outlet side of the safety valve must be attached
to the chuck.
6 bar
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Set-up of Equipment in Warehouses
Test passed:
If the blow-out remains as it is and does not
burst, then the test is considered to have
passed.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the body seal tightness.
Test data
Test characteristic Testing of the seal tightness of the pressure-bearing body
Testing standard The body must not have any visual signs of leaks
Every safety valve with a cast body and a rolled-in seat, 100%
Testing depth
testing
Test medium Air
A test pressure must be chosen that is slightly lower than the
Test pressure
set pressure.
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing body seal tightness for
non-gas-tight valves.
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
Test passed:
If there is no foam formation on the body,
then the test has been passed.
End of LWN
processed: M. Lammers edition: 2009-11-04
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LESER Global Standard LGS_1117
Final visual inspection of repaired valves Page 1/8
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 2
5 General Information............................................................................................. 2
6 Flow chart for the visual inspection (final inspection) .......................................... 2
7 Performing the final inspection ............................................................................ 3
7.1 General inspections...................................................................................... 3
7.2 Visual inspection of other items.................................................................... 4
7.3 Fault notification process.............................................................................. 8
1 Purpose
This LESER Global Standard (LGS) provides instruction on the visual final inspection
of LESER safety valves. The required work steps and materials are described.
2 Scope
protected
This document must be observed in the visual final inspection of safety valves in agencies
and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error free.
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
5 General Information
• Gloves must be worn during the final inspection of oil and
grease-free safety valves.
Perform the
ident. check
Fault
protected
notification
process
Inspecti
on OK
no
yes
Completion of
the final
inspection and
delivery
Figure 6-1
a) Compare the content of the valve inspection plan or repair order to the valve
model.
EXAMPLE /
protected
SPECIMEN
Figure 7.1-1
Figure 7.1-2: Check the type number against the Figure 7.1-3: Check the BT plate / customer ID
valve inspection plan / repair order plate data against the valve inspection plan /
repair order
protected
Figure 7.2.1-1
Figure 7.2.1-2
Figure 7.2.1-3
Figure 7.2.1-4
Figure 7.2.1-5
Figure 7.2.1-6
protected
OK specimen: Rejected specimen:
Figure 7.2.1-7
Figure 7.2.1-8
Figure 7.2.1-10
protected
Figure 7.2.1-9
Figure 7.2.2-1
Figure 7.2.2-2
protected
7.2.3 Inspection of the seal
Figure 7.2.3-1
If the result of the inspection is okay, then the safety valve is sent for packaging and
shipment.
• If the result of the inspection is not okay, then the fitting is sent to the fault
notification process that is to be determined.
• The final inspection is performed again after completion of the fault notification
process.
protected
Type 437
Spare parts
Actual Orifice diameter d0 [mm] 6 10
Actual Orifice area A0 [mm2] 28.3 78.5
Actual Orifice diameter d0 [inch] 0.236 0.394
Actual Orifice area A0 [inch2] 0.044 0.122
Body (Item 1): Male thread Material-No. / Art.-No.
3/ 1/ " 3/ 3/ " 1/ " 3/
Connection Size 8" 2 4" 1" 8 2 4" 1"
DIN ISO 228-1 G 1.4104 – – – – 136.5239.9000 136.4439.9000 136.4539.9000 136.5839.9000
316L – – – – 136.5249.9000 136.4449.9000 136.4549.9000 136.4849.9000
316L stellited 136.5169.9000 136.4369.9000 136.5569.9000 136.6769.9000 – – – –
R 316L – – – – – 136.4449.9220 136.4549.9220 136.5849.9220
316L stellited – 136.4369.9220 136.5569.9220 136.6769.9220 – – – –
ASME B1.20.1 NPT 316L – – – – – 136.4449.9204 136.4549.9204 136.5849.9204
316L stellited – 136.4369.9204 136.5569.9204 136.6769.9204 – – – –
Spare parts
Actual Orifice diameter d0 [mm] 10
Actual Orifice area A0 [mm2] 78.5
Actual Orifice diameter d0 [inch] 0.394
Actual Orifice area A0 [inch2] 0.122
Type 438
Body (Item 1): Male thread Material-No. / Art.-No.
3/ 1/ " 3/ 1"
Connection Size 8" 2 4"
Spare parts
Actual Orifice diameter d0 [mm] 10
Actual Orifice area A0 [mm2] 78.5
Actual Orifice diameter d0 [inch] 0.394
Actual Orifice area A0 [inch2] 0.122
Body (Item 1): Male thread
3/ 1/ 3/ 1"
Connection Size 8" 2" 4"
Spare parts
Actual Orifice diameter d0 [mm] 9
Actual Orifice area A0 [mm2] 63,6
Actual Orifice diameter d0 [inch] 0,354
Actual Orifice area A0 [inch2] 0,099
Body (Item 1): Male thread Material-No. / Art.-No.
1/ 3/ 11/4" 11/2"
Connection size 2" 4" 1" 2"
DIN ISO 228-1 G 1.4104 – 136.7539.9000 136.7639.9000 – – –
316L – 136.7549.9000 136.7649.9000 – – –
316L stellited – 136.7569.9000 136.7669.9000 – – –
ISO 7-1/BS 21 R 316L – 136.7549.9220 136.7649.9220 – – –
316L stellited – 136.7569.9220 136.7669.9220 – – –
ASME B1.20.1 NPT 316L – 136.7549.9204 136.7649.9204 – – –
316L stellited – 136.7569.9204 136.7669.9204 – – –
Body (Item 1): Female thread Material-No. / Art.-No.
DIN ISO 228-1 G 316L 136.7449.9210 136.7549.9210 136.7649.9210 – – –
316L stellited 136.7469.9210 136.7569.210 136.7669.9210 – – –
ISO 7-1/BS 21 Rc 316L 136.7449.9222 136.7549.9222 136.7649.9222 – – –
316L stellited 136.7469.9222 136.7569.9222 136.7669.9222 – – –
ASME B1.20.1 NPT 316L 136.7449.9211 136.7549.9211 136.7649.9211 – – –
316L stellited 136.7469.9211 136.7569.9211 136.7669.9211 – – –
Spare parts
Actual Orifice diameter d0 [mm] 9 13 17.5
Actual Orifice area A0 [mm2] 63.6 133 241
Actual Orifice diameter d0 [inch] 0.3544 0.512 0.689
Actual Orifice area A0 [inch2] 0.099 0.206 0.374
Body (Item 1): Flange design Material-No. / Art.-No.
DN 15 / PN 40 – 400
NPS 1/2" 316L 136.7449.9208 136.7949.9208 –
CL300 – 2500
DN 20 / PN 40 – 400
NPS 3/4" 316L 136.3949.9208 136.5049.9208 136.8449.9208
CL150 – 2500
DN 25 / PN 40 – 400 316L 136.3449.9208 136.3549.9208 136.3649.9208
NPS 1"
CL150 136.7649.9202 136.8149.9202 136.3649.9202
316L
CL300 – 2500 136.3449.9208 136.3549.9208 136.3649.9208
Disc (Item 7): Metal to metal Material-No. / Art.-No.
Disc 1.4122 420 RM 200.2039.9000 200.2139.9000 200.2239.9000
1.4404 316L 200.2049.9000 200.2149.9000 200.2249.9001
316L stellited 200.2069.9118 200.2169.9118 –
Disc (Item 7): With sealing plate Material-No. / Art.-No.
Disc PTFE “A” 200.2049.9005 200.2149.9005 200.2249.9005
1.4404 PCTFE “G” 200.2049.9006 200.2149.9006 200.2249.9006
SP “T” 200.2049.9007 200.2149.9007 200.2249.9007
Disc (Item 7.3): Sealing plate Material-No. / Art.-No.
Sealing PTFE “A” 236.3559.0000 236.3559.0000 236.0859.0000
plate
PCTFE “G” 236.3569.0000 236.3569.0000 236.0869.0000
SP “T” 236.3579.0000 236.3579.0000 236.0879.0000
Type 459
Pin (Item 57) Material-No. / Art.-No.
Pin 1.4310 480.0505.0000 480.0505.0000 480.0505.0000
Gasket – outlet body / bonnet (Item 60) Material-No. / Art.-No.
Gasket Graphite + 1.4401 500.2407.0000 500.2407.0000 500.2407.0000
Option code L68 Gylon (Filled PTFE) 500.2405.0000 500.2405.0000 500.2405.0000
Ball (Item 61) Material-No. / Art.-No.
Ball Ø [mm] 6 6 6
1.4401 510.0104.0000 510.0104.0000 510.0104.0000
Bellows and bellows conversion kit (Item 15) Material-No. / Art.-No.
Stainless steel 1.4571 / 316Ti p ≤ 40 bar / 580 psig = 400.7949.0000
bellows
1.4571 / 316Ti p > 40 bar / 580 psig = 400.6349.0000
Conversion kit ≤ PN 40/CL600 5021.1050
> PN 40/CL600 5021.1051
Spare parts
Actual Orifice diameter d0 [mm] 6 9 13
Actual Orifice area A0 [mm2] 28.3 63.6 133
Actual Orifice diameter d0 [inch] 0.236 0.354 0.512
Actual Orifice area A0 [inch2] 0.044 0.099 0.206
Body (Item 1): Male thread Material-No. / Art.-No.
Connection Size 1/ 3/ 1/ 3/ " 1/ 1/
2" 4" 1" 2" 4 1" 2" 2" 1"
DIN ISO 228-1 G 316L stellited 136.6969.9000 136.7069.9000 136.7169.9000 – 136.7569.9000 136.7669.9000 – 136.8069.9000 136.8169.9000
ISO 7-1/BS 21 R 316L stellited 136.6969.9220 136.7069.9220 136.7169.9220 – 136.7569.9220 136.7669.9220 – 136.8069.9220 136.8169.9220
ASME B1.20.1 NPT 316L stellited 136.6969.9204 136.7069.9204 136.7169.9204 – 136.7569.9204 136.7669.9204 – 136.8069.9204 136.8169.9204
ASME B1.20.1 NPT 316L stellited 136.6969.9211 136.7069.9211 136.7169.9211 136.7469.9211 136.7569.9211 136.7669.9211 – – –
CL300 –
316L stellited 136.3469.9208 136.3569.9208
CL2500
Disc (Item 7): Metal to metal Material-No. / Art.-No.
Spare parts
Actual Orifice diameter d0 [mm] 9
Actual Orifice area A0 [mm2] 63.6
Actual Orifice diameter d0 [inch] 0.354
Actual Orifice area A0 [inch2] 0.099
Body (Item 1): Male thread Material-No. / Art.-No.
1/ 3/ 11/4" 11/2"
Connection size 2" 4" 1" 2"
DIN ISO 228-1 G 1.4104 – 136.7539.9000 136.7639.9000 – – –
316L – 136.7549.9000 136.7649.9000 – – –
316L stellited – 136.7569.9000 136.7669.9000 – – –
ISO 7-1/BS 21 R 316L – 136.7549.9220 136.7649.9220 – – –
316L stellited – 136.7569.9220 136.7669.9220 – – –
ASME B1.20.1 NPT 316L – 136.7549.9204 136.7649.9204 – – –
316L stellited – 136.7569.9204 136.7669.9204 – – –
Body (Item 1): Female thread Material-No. / Art.-No.
DIN ISO 228-1 G 316L 136.7449.9210 136.7549.9210 136.7649.9210 – – –
316L stellited 136.7469.9210 136.7569.210 136.7669.9210 – – –
ISO 7-1/BS 21 Rc 316L 136.7449.9222 136.7549.9222 136.7649.9222 – – –
316L stellited 136.7469.9222 136.7569.9222 136.7669.9222 – – –
ASME B1.20.1 NPT 316L 136.7449.9211 136.7549.9211 136.7649.9211 – – –
316L stellited 136.7469.9211 136.7569.9211 136.7669.9211 – – –
Actual Orifice diameter d0 [mm] 13
Actual Orifice area A0 [mm2] 133
Actual Orifice diameter d0 [inch] 0.512
Actual Orifice area A0 [inch2] 0.206
Body (Item 1): Male thread Material-No. / Art.-No.
1/ 3/ 11/4" 11/2"
Connection size 2" 4" 1" 2"
DIN ISO 228-1 G 1.4104 – 136.8039.9000 136.8139.9000 – – –
316L – 136.8049.9000 136.8149.9000 – – –
316L stellited – 136.8069.9000 136.8169.9000 – – –
ISO 7-1/BS 21 R 316L – 136.8049.9220 136.8149.9220 – – –
316L stellited – 136.8069.9220 136.8169.9220 – – –
ASME B1.20.1 NPT 316L – 136.8049.9204 136.8149.9204 – – –
316L stellited – 136.8069.9204 136.8169.9204 – – –
Body (Item 1): Female thread Material-No. / Art.-No.
DIN ISO 228-1 G 316L 136.7949.9210 136.8049.9210 136.8149.9210 – – –
316L stellited – – – – – –
ISO 7-1/BS 21 Rc 316L 136.7949.9222 136.8049.9222 136.8149.9222 – – –
316L stellited 136.7969.9222 136.8069.9222 136.8169.9222 – – –
ASME B1.20.1 NPT 316L 136.7949.9211 136.8049.9211 136.8149.9211 – – –
316L stellited – 136.7569.9211 136.7669.9211 – – –
Actual Orifice diameter d0 [mm] 17.5
Actual Orifice area A0 [mm2] 241
Actual Orifice diameter d0 [inch] 0.689
Actual Orifice area A0 [inch2] 0.374
Type 462
Spare parts
Actual Orifice diameter d0 [mm] 9 13 17.5
Actual Orifice area A0 [mm2] 63.6 133 241
Actual Orifice diameter d0 [inch] 0.3544 0.512 0.689
Actual Orifice area A0 [inch2] 0.099 0.206 0.374
Body (Item 1): Flange design Material-No. / Art.-No.
DN 15 / PN 40 – 400
NPS 1/2" 316L 136.7449.9208 136.7949.9208 –
CL300 – 2500
DN 20 / PN 40 – 400
NPS 3/4" 316L 136.3949.9208 136.5049.9208 136.8449.9208
CL150 – 2500
DN 25 / PN 40 – 400 316L 136.3449.9208 136.3549.9208 136.3649.9208
NPS 1" CL150 136.7649.9202 136.8149.9202 136.3649.9202
316L
CL300 – 2500 136.3449.9208 136.3549.9208 136.3649.9208
Disc (Item 7): Soft seal with O-ring Material-No. / Art.-No.
Disc NBR “N” 200.9349.9081 220.4549.9081 220.4649.9081
EPDM “D” 200.9349.9041 220.4549.9041 220.4649.9041
CR “K” 200.9349.9051 220.4549.9051 220.4649.9051
FKM “L” 200.9349.9071 220.4549.9071 220.4649.9071
FFKM “C” 200.9349.9091 220.4549.9091 220.4649.9091
Disc (Item 7.4): O-ring Material-No. / Art.-No.
NBR “N” 502.0123.2681 502.0139.2681 502.0202.2681
EPDM “D” 502.0123.2641 502.0139.2641 502.0202.2641
CR “K” 502.0123.2651 502.0139.2651 502.0202.2651
FKM “L” 502.0123.2671 502.0139.2671 502.0202.2671
FFKM “C” 502.0123.2691 502.0139.2691 502.0202.2691
Pin (Item 57) Material-No. / Art.-No.
Pin 1.4310 480.0505.0000 480.0505.0000 480.0505.0000
Gasket – outlet body / bonnet (Item 60) Material-No. / Art.-No.
Gasket Graphite + 1.4401 500.2407.0000 500.2407.0000 500.2407.0000
Option code L68 Gylon (Filled PTFE) 500.2405.0000 500.2405.0000 500.2405.0000
Ball (Item 61) Material-No. / Art.-No.
Ball Ø [mm] 6 6 6
1.4401 510.0104.0000 510.0104.0000 510.0104.0000
Bellows and bellows conversion kit (Item 15) Material-No. / Art.-No.
Stainless steel p ≤ 40 bar / 580 psig = 400.7949.0000
bellows 1.4571 / 316Ti
p > 40 bar / 580 psig = 400.6349.0000
Conversion kit ≤ PN 40/CL600 5021.1050
> PN 40/CL600 5021.1051
Type 462
Spare parts
Actual Orifice diameter d0 [mm] 9 13
Actual Orifice area A0 [mm2] 63.6 133
Actual Orifice diameter d0 [inch] 0.354 0.512
Actual Orifice area A0 [inch2] 0.099 0.206
Body (Item 1): Male thread
Connection size 1/ 3/ 1/ " 1/
2" 4" 1" 2 2" 1"
DIN ISO 228-1 G 316L – 136.7549.9000 136.7649.9000 – 136.8049.9000 136.8149.9000
ISO 7-1/BS 21 R 316L – 136.7549.9220 136.7649.9220 – 136.8049.9220 136.8149.9220
ASME B1.20.1 NPT 316L – 136.7549.9204 136.7649.9204 – 136.8049.9204 136.8149.9204
DN 20 / PN 40 – 400
NPS 3/4" CL150 – 2500 316L 136.3949.9208 136.5049.9208
When and how often safety valves should be inspected is a frequently asked question. This question
cannot be answered in general but has to be regarded for each application individually.
Due to the individual operating conditions and in consideration of the different mediums, LESER
gives no general reference for an inspection time interval.
In coordination between LESER, different operators, and the notified body, the following procedure
has proven itself:
Within the below stated codes and standards the following guidelines for inspection intervals for
LESER safety valves are important:
In API 510, the subsection on pressure-relieving devices establishes a maximum interval between
device inspections or tests of 10 years. It also indicates that the intervals between pressure relief
device testing or inspection should be determined by the performance of the devices in the particular
service concerned.
The following testing periods for category IV pressure equipment (including safety valves) are defined
in section 15:
► External inspection: 2 Years
► Internal inspection: 5 Years
► Strength inspection: 10 Years
Figure 6.2.13-1: Individual cardboard Figure 6.2.13-2: Tied-down on a Figure 6.2.13-3 Wooden crate
box pallet
During storage until installation, safety valves should be kept in their own packaging. The advantages
of the LESER types of packing are:
- Due to secure packaging, no damage during transport.
- Unpacking of safety valves before stocking is not necessary.
- Safety valves are protected against dust and dirt during storage.
- Easy and space-saving storage of safety valves on shelves or racking.
- Easy identification of the content from the outside via labels (Figure 6.2.13-4).
It is also possible to transport LESER Safety valves horizontally. The advantages of this kind of
transportation are:
► requires little space
► less freight charge
► lower risk of damages in horizontal transport due to lower center of gravity
7)
API RP 520 Part II, 5th Edition 2003, Sect. 12.2
“The condition of all safety valves should be visually inspected before installation. Before installation
all protective materials on the valve flanges have to be completely removed. Bonnet shipping plugs
must be removed from balanced safety valves.”6)
API 520 Part II recommends that the inlet surface must be cleaned, since foreign materials clinging to
the inside of the nozzle will be blown across the seats when the safety valve is operated. Some of
these materials may damage the seats or get trapped between the seats in such a way that they
cause leakage. Valves should be tested before installation to confirm their set pressure.
LESER Note:
Due to the LESER types of packing, LESER safety valves are delivered ready-to-install. As long
as safety valves remain in the packing during storage, the safety valves do not need to be
inspected, cleaned or tested before initial installation. For more details see the LESER operating
instructions.
6)
API RP 520 Part II, 5th Edition 2003, Sect. 12.3
Before a plant can be started up a hydraulic pressure test has to be performed. For this test all safety
valves in the system must be prevented from opening.
Three different possibilities are feasible:
Blind Flange
Blanking Plate
Safety valves are safety devices and improper repair may cause damage to equipment and serious
injury or death! The following table lists typical mistakes that are made when repair is performed by
unauthorized or untrained personnel or when maintenance instructions are not followed.