EA SV Series Installation instructions

END-Armaturen GmbH & Co. KG
Oberbecksener Str. 78 · D-32547 Bad Oeynhausen · Telefon [phone] · Telefax [phone] · http://www.end.de
Original Operating Manual
Safety Valves
SV
GV
NG

2 http://www.end.de 09/12
© by END-Armaturen GmbH & Co. KG
All rights reserved.
END-Armaturen GmbH & Co. KG claims copyright over this documentation.
This documentation may neither be altered, expanded , reproduced nor passed to third parties
without the written agreement of END-Armaturen GmbH & Co. KG . This restriction also applies to the cor-
responding drawings.
END-Armaturen GmbH & Co. KG has the right or change parts of the valves and armatures at any time without
prior or direct notice to the client. The contents of this publication are subject to change without notice.
This publication has been written with great care.
However, END-Armaturen GmbH & Co.KG cannot be held responsible, either for any errors occuring in this
publication or for their consequences.
The products are specified by the statements in this documentation; no assurance or the properties is given.
END-Armaturen GmbH & Co. KG
Oberbecksener Straße 78
D-32547 Bad Oeynhausen
Telefon: 05731 / 7900 - 0
Telefax: 05731 / 7900 - 199
Internet: http://www.end.de
E-Mail: [email protected]
Edition: 09/12
Impressum

09/12 http://www.end.de 3
Contens
Contents
1 Foreword 5
2 General advice 6
2.1 Validity 6
2.2 Inward monitoring 6
2.3 Complaints 6
2.4 Warranty 6
2.5 Symbols and their signification 7
3 Safety advice 8
3.1 Personal advice 8
3.1.1 Safety advices for mounting 8
3.1.2 Safety advice for adjustment / starting 9
3.1.3 Safety advice for maintaining / repairing 9
3.2 Device safety 10
4 Identification of Safety Valves 11
5 Safety Valves 12
5.1 General 12
5.2 Corresponding use 12
5.3 Operation 12
5.3.1 Advice for storage and starting of safety valves 12
5.4 Mounting / Disassembly 13
5.4.1. Inlet pipe 13
5.4.2. Blow-off pipe 14
5.4.3. Open discharge Safety Valves 15
5.4.4. Condensate diversion 15
5.4.5 Mounting with threaded connection 15
5.4.6 Mounting with flanged connection 15
5.4.7 Disassembly 16
5.5. Commissioning 16
5.5.1 Safety Valve with lifting device 17
5.5.2 Safety Valve without lifting device 17
5.6 Maintenance 17
5.6.1 Test intervals 17
5.6.2 Regular releasing of the safety valve 18
5.6.3 Leaks 18
6 Index 23

09/12 http://www.end.de 5
1 Foreword
Dear customer,
Dear assembler / user,
these operation and installation manuals are intended to give you the knowledge, which is
necessary for you to be able to carry out the mounting and adjustment of the safety valves rapidly
and correctly.
Please read these instructions carefully and pay particular attention to the advice and warning
notes.
Only instructed and qualified mechanician should mount, adjust or maintain the safety valves.
If you have any questions in relation to the safety valves we shall be pleased to answer them.
The telephone number will be found on the inside cover of these operation and installation
manual.
Yours
END-Armaturen GmbH & Co. KG
Foreword

6 http://www.end.de 09/12
2 General advice
2.1 Validity
These mounting and installation manual is valid for the standard version of the safety valves.
2.2 Inward monitoring
Please check
• directly after delivery the safety valves for any transport damages and deficiencies
• with reference to the accompanying delivery note the number of parts.
Do not leave any parts in the package.
2.3 Complaints
Claims for replacement or goods which relate to transport damage can only be considered valid if
the delivery company is notified without delay.
In case of returns (because of transport damage / repairs), please make a damage protocol and
send the parts back to the manufacturer, if possible in the original packaging.
In case of a return, please mention the following:
• Name and address of the consignee
• Stock-/ ordering-/ article-number
• Description of the defect
2.4 Warranty
For our ball valves we give a guarantee period in accordance with the sales contract.
The end of the normal duration of life of the wearing parts represents no defect.
The warranty and guarantee rules of END-Armaturen GmbH & Co. KG are applicable.
General advice

09/12 http://www.end.de 7
2.5 Symbols and their signification
Paragraphs which are identified with this symbol contain very important advices; this also includes
advices for averting health risks. Observe these paragraphs without fail!
Paragraphs which are identified with this symbol contain very important advices, this also includes
how to avoid damage to property. Observe these paragraphs without fail!
This symbol indicates paragraphs which contain comments / advices or tips.
This spanner identifies the description of actions which you should carry out.
Symbols and their signification

8 http://www.end.de 09/12
3 Safety advice
Depending on the technical circumstances and the time under and at which the armatures and
valves are mounted, adjusted and commissioned, you must take into account particular safety
aspects in each case!
If, for example, a pneumatic actuator works a slide in an operational chemical plant, the potential
hazards of commissioning have another dimension from that when this is only being carried out for
test purposes an a „dry“ part of the plant in the assembly room!
Since we do not know the circumstances at the time of the mounting/adjustment/commissioning,
you may find advices on hazards in the following descriptions which are not relevant to you.
Please observe (only) the advices which applies to your situation!
3.1 Personal advice
3.1.1 Safety advices for mounting
We wish to point out expressly that the mounting, adjusting and at accessories the pneumatically
and electrical installation of the armatures and valves must be carried out by trained specialist
personnel having mechanical, pneumatically and electrical knowledge!
Secure that the machine / plant come up to the Machinery Directive after the mounting and
installing of the armatures and valves.
Switch off all the devices / machines / plant affected by mounting or repair.
If appropriate, isolate the devices / machines / plant from the mains.
Check (for example in chemical plants) whether the switching off of devices / machines / plant
will cause potential danger.
If appropriate, in the event of a fault in the armature / valve (in a plant which is in operation)
inform the shift foreman / safety engineer or the works manager without delay about the fault, in
order, for example, to avoid an outflow / overflow of chemicals or the discharge of gases in good
time by means of suitable measures!
Before mounting or repairing, remove the pressure from pneumatic / hydraulic devices / machines
/ plant.
If necessary, set up warning signs in order to prevent the inadvertent starting up of the devices /
machines / plant.
Observe the respective relevant professional safety and accident prevention regulations when
carrying out the mounting / repair work.
Check the correct functioning of the safety equipment (for example the emergency push off but-
tons/ safety valves, etc)!
Safety advice

09/12 http://www.end.de 9
3.1.2 Safety advice for adjustment / starting
As a result of the starting (pneumatic, electric or by hand) of the armatures and valves the flow
of gases, steam, liquids, etc. may be enabled or interrupted! Satisfy yourself that, as a result of
the starting or the test adjustment no potential hazards will be produced for the personnel or the
environment!
If necessary, set up warning signs in order to prevent the inadvertent starting up or shutting down
of the device / machine / plant.!
By ending the adjustment check the correct function of the armature.
Check the right function of all safety devices (for example emergency push off buttons / safety
valves)!
Carry out the starting and the adjustments only in accordance with the instructions described in
this documentation!
3.1.3 Safety advice for maintaining / repairing
Do not carry out any maintenances / repairs if the armature will be under pressure.
Before disassembling or a armature or valve some essential points should be clarified!
• Will the armature/valve to be disassembled be replaced by another immediately?
• If appropriate, does the production process of the plant needed to be stopped?
• Is it necessary to inform specific personnel about the disassembly?
If necessary, inform the shift foreman/ safety engineer or the manager about the maintenance
or repair without delay in order, for example, to avoid an outflow/ overflow of chemicals or a
discharge of gases in good time by means of suitable measures!
Observe that some valves / armatures are able to enclose the pressured medium e.g. the ball
in the ball valve. You have to relieve the pressure in the pipes in which the armature/valve is
mounted.
Switch off pilot pressure and the power supply and relieve the pressure in the pipes.
If necessary, set up warning signs in order to prevent the inadvertent starting up or shutting down
of the device / machine / plant.!
In case of defect in the armature/valve make contact to the supplier. The telephone number will
be found on the back cover of these mounting and installation manual.
If you ascertain a damage of the armature/valve, isolate the device from the mains. Please
observe the safety advices.
Do not mount, start or adjust the armature/valve if itself, the pipes or a mounted actuator will be
damaged.
After the maintenance or repair check the right function of the armature/valve and the tightness
of the pipe connections.
Safety advice

10 http://www.end.de 09/12
3.2 Device safety
The armatures/valves
• are quality products which are produced in accordance to the recognized industrial
regulations.
• left the manufacturer`s work in a perfect safety condition.
In order to maintain this condition, as installer / user you must carry out your task in accordance
with the description in these instructions, technically correctly and with the greatest possible
precision .
We assume, as a trained specialist you are having mechanical and electrical knowledge!
Satisfy yourself that the armatures/vales will only be used within their admissible limiting value
(see the technical data) .
The armatures/valves must be used only for a purpose corresponding to their construction!
The armatures/valves must be used within the values specified in the technical data!
The operating of the armature/valve outside the nominal temperature range could destroy the
sealing and the bearings.
The operating of the armatures/valves outside the nominal pressure range could destroy the inner
parts and the body.
Never remove a cap or a other component part if the armature/valve will be under pressure.
Do not mount, start or adjust the armature/valve if itself, the pipes or a mounted actuator will be
damaged.
After the maintenance or repair check the right function of the armature/valve and the tightness
of the pipe connections.
Also check the function of the accessories e.g. actuators, limit switches, etc.
Safety advice

09/12 http://www.end.de 11
4 Identification of Safety Valves
The safety valves will be provided with a name-plate (identification, which permits a definite iden-
tification of the safety valves and shows the most important technical data to you. The name-plate
should not be displaced or changed.
Identification
TÜV-symbol
Safety Valve
Year of component test
Component test number
Narrowest flow cross-section
Code letters:
D/G/H designed for heating systems
D/G designed for steam / gas
F designed for liquids
F/K/S designed for blowing off air from
tanks for liquids, granular or dust goods
Coefficient of discharge
Set pressure in bar
The safety valves will always be set by the manufacturer.
Fig. 4.1 - Identification
TÜV.SV. xx-xxx .xx. D/G/H . 0,xx. xx
D/G
F
F/K/S

12 http://www.end.de 09/12
5 Safety Valves
5.1 General
Before you are mount, adjust, operate or disassemble a safety valve you have to read
Safety advices
If you have not read the safety advices until now, read this important advices now and turn back
to this point..
5.2 Corresponding use
Safety valves have to protect pipes and tanks for inadmissible over pressure. Safety valves rep-
resented the final safety device for pipe and tanks. Safety valves must be able to prevent tanks
and pipes from inadmissible over pressure, if all the other control and safety devices would break
down. To secure the function of a safety valve, safety valves required particular attention by
mounting and maintaining.
A safety valve is a part of equipment with safety function for the protection of pressure devices in
the case of exceeding the permissible limits and thus is governed by the directive 2014/68/EU of the
European Parliament and of the Council (“Regulation for Pressure Devices“) Article 1 Section 2.1.3.
It should only be used clean liquids and gases on which the material of the safety valve will be
resistant. Pollution and using outside the nominal pressure and/or the nominal temperature range
should causes damages on the safety valve especially on the seals.
At non-neutral media and media which do not tread out into the environment and also applications
with a back pressure at the outlet port safety valves with bellows must be choosen.
5.3 Operation
Safety valves do not need any special operation. But the ventilation should be operated in periodi-
cal turns. (see chapter 5.6. „maintenance“).
5.3.1 Advice for storage and starting of safety valves
After transport and storage for some time at armatures with a formerly adjusted action pressure
a delayed opening at the first time will be normal. This effect causes by the pasting up seat and
cone of a valve. This will be happen at sealing areas metal / elastomer and also at sealing areas
metal / metal.
After mounting the valve the sealing areas will be loosen by actuating the ventilation knop / lever
and feeding the valve with compressed air and increasing the pressure range above the action
pressure.
After this procedure the armature will be serviceable with the formerly adjusted action pressure in
consideration for the permitted increasing pressure / closing pressure.
Corresponding use

09/12 http://www.end.de 13
5.4 Mounting / Disassembly
Safety valves are high-grade armatures, which will be handle with great care. The sealing areas
at the seat and the cones are hardened resp. tempered and abraded. The safety valve will be
damage by inexpert handling. Therefore observe the following notes:
• In- and outlet port have to been close for delivery.
• Do not drop the safety valves.
• You have to avoid the insert or pollution during the mounting or during working.
• The tightness of the safety valve could be impaired by using hemp, PTFE- ribbon or
something similar like that.
• If the safety valve will be painted you have to observe that no sliding part will be come
into contact with the paint.
The hole system has to be rinsed before installation of the valve. If the plant should not be suf-
ficiently clean in the case of an appropriate assembly, the valve may be leaky already upon first
response.
The assembly of the threaded valves should be carried through without using hemp or PTFE- tape.
Metal sealing rings are to be preferred.
Safety valves are to be installed always in a vertical direction, while taking into account the flow
direction, that is with spring bonnet standing upright.
To ensure a satisfactory operation of the safety valves they must be installed in such a way that the
safety valve is not exposed to any impermissible static, dynamic or thermal loads.
It is not permitted to have the possibility to make safety valves ineffective by blocking devices,
neither upstream nor downstream of the valve.
Mounting
Fig.4.1 - Safety Valves, Installation (Fig. shows Art. NG301023 with head „A“)
o.k.
5.4.1. Inlet pipe
The feed nozzle for the valve must be as short as possible and must have at least the same nominal
width as the valve.
The pressure loss in the inlet pipe of the safety valves should not exceed 3% of the set pressure.

14 http://www.end.de 09/12
Mounting
5.4.2. Blow-off pipe
Suitable protective measures should be taken at the installation point in the case of any safety
valves posing a direct or indirect risk to persons or the environment as a result of discharge of
the operating medium. Precautions must also be taken against fumes escaping through the relief
vents in the spring cap.
Blow-off pipe for vapours and gases are to be installed in a rising position , for liquids in a falling
position .
The blow-off pipe of the safety valves must be designed to ensure that the required mass flow can
be discharged during the blowing-off process. The cross section should be equal at least as the
feed-out cross section of the safety valve.
Inside the blow-off pipe the counter pressure of max. 10% of the set pressure should not be
exceeded.
Precautions must be taken by means of suitable devices to ensure that foreign bodies or rain water
can not penetrate into the blow-off pipe.
The discharging of the blow-off pipe must not present a risk. Risks caused by emerging fluid are to
be prevented by suitable measures.
Fig. 4.2 - Safety Valves, Mounting with threaded connection (Fig. shows Art. NG301023 with head „A“)
flow direction
o.k.
blow-off pipe
steam / gas
upwards!
blow-off pipe
liquids
downwards!

09/12 http://www.end.de 15
Mounting
5.4.3. Open discharge Safety Valves
The spring bonnet of the open discharge safety Valve has to be protected against pollution.
In case of blowing-off by a open discharge safety valve the operating medium will flow off
through the spring bonnet. Therefore open discharge safety will only be used for non-toxic and
non-flamable media.
Appropriate protection devices must be installed to protect people or the environment against hazards.
5.4.4. Condensate diversion
Any fluid or condensate is not permitted to remain in the safety valve housing since the function-
ing of the safety valve is impaired as a consequence.
The discharging of the condensate is usually effected via the blowing off pipe. At the lowest point
a draining tube with sufficient dimensions must be installed.
Hazard-free removal of the condensate or medium discharge must be ensured. The body, pipes
and silencers must be protected against freezing.
5.4.5 Mounting with threaded connection
Before lay on sealing compounds, check the hardly screwing by the pipes into the valve body.
The assembly of the threaded connection should be carried out by using metal sealing rings.
Screw the pipes into the connection ends of the safety valve.
Check the tightness of all connections.
5.4.6 Mounting with flanged connection
In the following description we assume that you have mounted the flanges at the end of the pipes
and the safety valve (welded flanges) and they are cooled down.
Insert the safety valve and the flange seals between the flanges.
Align the flange boring and put fit screws through the boring.
Put fit nuts onto the screws and tighten them equally and crosswise. Observe the max. torque of
the screws.
Check the tightness of all connections.

16 http://www.end.de 09/12
5.4.7 Disassembly
Before you disassemble the safety valve you have to read the
Safety advice
If you have not read the safety advices until now, read this important advices now and turn back
to this point.
Prior to the disassembly of a safety valve, the device is to be made unpressurized.
Residues of fluid in a safety valve or the spring bonnet bear a great risk of burning and poisoning.
Prior to the disassembly of a safety valve from the device, it must be determined which fluid might
be contained in the safety valve, and corresponding safety measures have to be taken.
5.5. Commissioning
After transportation and prolonged storage of the safety valves with a pre-set reaction pressure it
is possible that there will be a delayed initial opening due to what is called a sticky effect of the
seat and the cone of the safety valve.
After the valve has been installed the sealing surfaces are separated from each other through an
increased pressurization above the release pressure as proper as well as through the activation
of the release of the sealing surfaces. Subsequently, the safety valve is again fully functioning
with the pre-set reaction pressure, taking into account the permissible pressure increase / closing
pressure.
Fig. 4.3 - Safety Valve, Operating of the ventilation
Disassembly

09/12 http://www.end.de 17
Maintenance
5.5.1 Safety Valve with lifting device
A safety valve with a lifting lever will be secured by a binding wire. This locking device of the lifting
lever is to be removed only after the installation has been completed.
Increase the pressure in the pipes to 85% of the set pressure.
Carry out the lifting either by means of a knurled nut above the spring bonnet or by actuating the
lifting lever on the upper part of the safety valve.
In the event of minor leaks, which may be caused by contamination between the sealing surfaces,
the valve can be made to blow off through lifting, for cleaning purposes.
5.5.2 Safety Valve without lifting device
Safety valves without lifting device, like e.g. valves with head “C” (gas tight with cap) should be
brought to the release pressure only externally with gas or at a 100% clean device.
5.6 Maintenance
Before you maintain or shut down the safety valve you have to read the
Safety advice
If you have not read the safety advices until now, read this important advices now and turn back
to this point.
Safety valves are designed regarding design and construction in such a way the an optimum of
quality is achieved, and that they are easy to service. Therefore a minimum of care and mainte-
nance for the safety valves is required.
The maintenance work, however, is permitted to be carried out only by trained personnel.
5.6.1 Test intervals
In steam generating equipment, testing the ease of movement of safety valves must be carried out
at least every 4 weeks in compliance with TRD601.
Test intervals for other applications must be determined by the use in compliance with the operat-
ing conditions.
Tests and examinations are to be executed at least during each internal and external examination
of the pertaining pressure device.

18 http://www.end.de 09/12
5.6.2 Regular releasing of the safety valve
It is recommended to make the safety valve blow off from time to time through lifting, in depend-
ence for the respective system, in order to check the correct operation of the safety valve.
The lifting device is not to be operated when in a pressure-free state.
For safety vales with lifting device you have to increase the pressure in the pipes to 85% of the set
pressure.
Carry out the lifting either by means of a knurled nut above the spring bonnet or by actuating the
lifting lever on the upper part of the safety valve.
Safety valves without lifting device, like e.g. valves with head “C” (gas tight with cap) should be
brought to the release pressure only externally with gas or at a 100% clean device.
5.6.3 Leaks
Leaks may be caused in the case of safety valves due to pollution between the valve disc and seat.
By operating the lifting device small deposits of pollution can be effectively cleared from the valve
disc and seat. (In doing this, a clear stroke of the valve stem must be achieved).
If it fails to remove the pollution by operating the lifting device, it must be assumed that the sealing
surfaces are damaged. The damage can be removed be post-processing the sealing surfaces or
by changing the seat seal.
Repair work on safety valves in only to be carried out by the manufacturer or by officially approved
specialist workshops authorized by the manufacturer.
Leaks may also occur when the operating pressure is too close to the set pressure of the safety
valve.
The operating pressure of the device is to be at least 5% lower than the closing pressure of the
safety valve.
Leaks

09/12 http://www.end.de 19
Notes