TABLE OF CONTENTS

Table of contents

Safety valves
General ........................................................................................................................1
Maintenance and start-up of boiler..............................................................................2
Adjustment and dismantling........................................................................................3

Temporary locking of a safety valve

General ........................................................................................................................1

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 SAFETY VALVES OM6040#01.0

Safety valves

1 General
In the following the measures required to achieve a safe and reliable maintenance of
the safety valves will be described, together with adjustment and dismantling
instructions.
An example of an installation of the safety valve is shown in Figure 1.

Mounting of safety valves, example

Figure 1 safe_01a.cdr

2 Maintenance and start-up of boiler

A regular inspection of the safety valve is recommended at least once a year. Some
media and appliances require a more frequent inspection, this is according to the
experience of the supplier.

Warning: Before handling and dismantling of the safety valve ensure that the
system is NOT pressurised!

Before lighting-up the boiler the pipe connections must be thoroughly cleaned for
dirt and foreign bodies.

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 SAFETY VALVES OM6040#01.0

If the valve is not completely tight, which often happens after starting up the plant,
this is usually caused by impurities between the seat and the cone. In order to
remove these impurities the valve must be heavily blown out by means of the lifting
device. If the valve is not tight after several blows, it may be due to the fact that a
hard foreign body has got stuck between the cone and the seat, and it will then be
necessary to dismount the valve for overhaul.

Warning: In case of a leaking safety valve the valve must be inspected and
over-hauled at earliest possible opportunity. It must be ensured that
the boiler is totally depressurised before dismounting the valve.

Note: Before dismantling the safety valve in the workshop the position of the
adjusting screw must be measured and noted which will facilitate the
adjustment later when the valve is to be adjusted when in service.

If the facings between the cone and the seat have been damaged, they must be
grinded.
Step A: The cone can be grinded against a cast iron plate, using a fine grained
carborundom stirred in kerosene.

Step B: The seat in the valve body can be grinded in the same way by using a cast
iron punch of suitable size.

Note: Never use the cone itself when grinding the seat.

Warning: The spindle and the valve cone must always be secured against
turning as the seat and the cone may thus be damaged.

Step C: Before assembly the valve must be thoroughly cleaned, and all traces of
grinding material and impurities must be removed.
When the valve has been mounted the boiler is commissioned, and the valve is then
checked for leakage and adjusted to the set pressure.
Step D: The adjustment screw is secured by means of its lock nut, and the valve is
sealed.

2.2 Routine check

The following should be regarded as recommendations of routine checks on the

safety valves, in order to keep a proper functioning.

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 SAFETY VALVES OM6040#01.0

Yearly
Step A: The safety valve should be tested in operation by raising the boiler pressure.

Step B: Expansion and exhaust pipe should be examined at the same time.
Monthly
Step A: Examine the safety valves for any leaking, such as:

• Is water seeping from the drain plug at the valve body?

• Is the escape pipe hot due to seeping steam from the valve seat?
Step B: Examine the drain and expansion device at the escape pipe.

Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts.

3 Adjustment and dismantling

Safety valves are delivered with the required spring setting and sealed against
unauthorised adjustment.
Adjustments are only allowed in the spring margins. Outside the margin a new
spring is required. The pressure in a system should not exceed 90% of the set
pressure.
All item nos. mentioned in the following sections refer to Figure 2.

3.1 Dismantling of lifting device

Safety valve with open cap

Step A: Remove bolt(39) and remove lift lever (41)

3.2 Set Pressure change without spring change

Note: Pay attention to spring range

Step A: Spindle (14) must be held fast by all alterations

Step B: Loosen lock nut (21)

Step C: Turn the adjusting screw (17) clockwise for higher and anticlockwise for
low set pressures

Step D: Secure the new setting with the lock nut (21) and Reassemble lifting device

3.3 Spring change

Step A: Spindle (14) must be held fast by all alterations

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 SAFETY VALVES OM6040#01.0

Step B: Loosen lock nut (21) and turn adjusting screw (17) anticlockwise, then the
spring (37) is not under tension

Step C: Loosen the nuts (8) and remove the bonnet (42)

Step D: Remove the upper spring plate (26) and spring (37)

Step E: Remove the spindle (14) with disc (12), guide plate (4) and lower spring
plate (26)

Step F: Clean the seat (2) and disc (12)

Step G: Remount the spindle unit with the new spring and upper spring plate

Step H: Assemble bonnet (42) and adjust to the spring range

Step I: Secure the spring setting through the lock nut (21) and remount lifting
device

Assembling drawing of safety valve

47 Ball
42 Bonnet 39, 40
41 Lifting lever
40 Split pin 41
39 Bolt 17
38 Screw 21
37 Spring
29 Cap
27 Gasket 29
26 Springplate
23 Lead seal 23 38, 47
22 Drain screw
21 Lock nut 26
18 Ball
17 Adjusting screw 27
16 Slotted pin
15 Gasket
14 Spindle 37
13 Lift aid
12 Disc 42
10/25 Split cotters 14
9 Lift limitation ring
8 Hex. nut 10, 25
7 Gasket
4 Spindle guide 8
3 Stud
2 Seat
1 Body

16
18
12
13
15, 22
2
1

Figure 2 safe_03a.cdr

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 TEMPORARY LOCKING OF A SAFETY VALVE OM6040#02.0

Temporary locking of a safety valve

1 General
During commissioning work or later tests of the opening pressure for the safety
valves, only one safety valve should be checked at a time. This means that the other
safety valve must be locked. The following instruction describes the temporary
locking of a safety valve.

1.1 Procedure for locking of a safety valve

Step A: Remove the bolt (39) and split pin (40), see Figure 1.

Step B: Remove the lifting lever (41).

Step C: Unscrew the screw (38) and break the lead seal (23), if provided.

Step D: Unscrew the cap (29).

Step E: Place one or two bolts (48) on top of the spindle. The height of the bolts
should be approximately 1-2 mm higher than the normal distance between
the top of the spindle and the inside top of the cap (29).

Step F: Carefully screw on the cap until the spindle and bolts are locked. The safety
valve will be completely locked when the bolts cannot be moved anymore.

Step G: The other safety valve can now be tested without any interference from the
locked safety valve.

1.2 Procedure for unlocking of a safety valve

Warning: As soon as the test procedure for the safety valve has been carried
out the locked safety valve must be unlocked.

Step A: Unscrew the cap (29) and remove the bolts (48).

Step B: Mount the cap (29) again and screw in the screw (38).

Step C: Mount the lifting lever (41), bolt (39), and split pin (40).

Step D: Provide the safety valve with a lead seal (23), if necessary. This depends on
the local rules of the classification society.

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 TEMPORARY LOCKING OF A SAFETY VALVE OM6040#02.0

Temporary locking of a safety valve

48
39, 40

41

29

23 38

Figure 1 safe_06.cdr

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