Fort Vale 0R3/ 006 Series User manual

Maintenance Manual
Part Number: 0R3/XXXX006X
2.7"NB Super Maxi
Rail Relief Valve
MM050 REV03-12.12.19
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MM050_CONTENTS REV02-12.12.19
© Fort Vale Engineering Ltd. 2019
www.fortvale.com
CONTENTS
Maintenance Manual
2.7"NB Super Maxi Rail Relief Valve
Introduction 3
Maintenance Safety Precautions 4
Chapter 1 Disassemble the valve 5
Chapter 2 Assemble the valve 11
Chapter 3 Test & adjust the set pressure 17
Chapter 4 Install the anti-tamper screw 23
Appendix 27
A Tools & Equipment 28
B Bolt Torque Guide & Step Loading Procedure 29
C Client Responsibilities 31
D Data sheet: USREL147 & USREL148
2.7”NB Super Maxi pressure only rail car relief valve
Part number: 0R3/XXXX006X
33
E Data sheet: USREL185
Flanged high-pressure Super Maxi relief valve
Part number breakdown
35
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MM050_INTRO REV00-12.12.19
© Fort Vale Engineering Ltd. 2019
www.fortvale.com
Maintenance Manual - Introduction
2.7"NB Super Maxi Rail Relief Valve
To prevent damage to the valve:
·use the recommended tools to do the maintenance and to test the valve.
IMPORTANT
This maintenance manual contains instructions to do the maintenance and testing on the 2.7" Super Maxi rail relief valve,
part number series 0R3/XXXX006X.
·use the recommended tools.
WARNING :A relief valve is a spring-loaded device which can cause serious injury to personnel. Obey
all the maintenance and safety precautions.
·be careful during maintenance.
·use the applicable PPE.
Read all the information and instructions before you start the procedure. Keep this manual.
Overview
Maintenance Precautions
To prevent injury to personnel:
·obey all warnings.
The valve illustrated in this manual is part number 0R3/X165006R with a set pressure of 165 PSIG and a raised face
flange.
·injury to personnel.
·valve malfunction.
WARNING: If you install a replacement part that is not a genuine Fort Vale part, there is a risk of:
Identify your relief valve - the part number series will be marked on the valve cap. Please contact Fort Vale to order new
seal kits and replacement parts. Install only genuine spare parts.
·permanent damage to the valve or tank.
Replacement Parts
You will need general workshop equipment and hand tools and some special tools to do relief valve maintenance. Please
refer to Appendix A: Tools & Equipment.
·obey the recommended bolting sequence and Step Loading Procedure when you remove and install the valve
(see : Bolt Torque Guide & Step Loading Procedure).Appendix B
·use genuine Fort Vale spare parts.
·read Client Responsibilities ( ).see Appendix C
If you have a problem that you cannot solve using this manual, please contact us.
Tools & Equipment
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OPIN41 REV01-31.10.19
© Fort Vale Engineering Ltd. 2019
www.fortvale.com
Maintenance Safety Precautions
Maintenance Manual
·make sure the vessel and valves have been cleaned correctly.
·has experience and qualifications related to valve maintenance and testing.
When you have completed the maintenance, you must do an approved leak test to the valve before you install it onto the
vessel.
·knows the operation limits of the valve.
WARNING: Vessels and systems operate under pressure and can contain dangerous cargo (liquid
and gas) that can cause death or serious injury to personnel.
Before you remove a valve from the vessel/system, you must:
·make sure the vessel/system is empty (liquid and gas).
·knows the function of the valve.
Approved Person
Important Safety Notice
·make sure that the vessel/system pressure is at zero. When all the vessel/system pressure is released, use an
approved method to release all residual pressure before you loosen the fasteners.
·make sure the vessel has been certified safe for human entry.
·read the SDS (Safety Data Sheet) for the last cargo and obey the recommended precautions.
·use the applicable PPE (Personal Protection Equipment) for the cargo and operating conditions.
Precautions
·do a Hazard Identification and Risk Assessment.
You must be an “approved person” to do valve maintenance and testing. An approved person:
·knows how the valve is assembled, installed and operated.
·knows and obeys all the related in-company and regional/national regulations.
After maintenance
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© Fort Vale Engineering Ltd. 2019
www.fortvale.com
CHAPTER 1
Disassemble the valve
2.7"NB Super Maxi Rail Relief Valve
This chapter contains instructions to fully disassemble the valve and the pressure plate assembly.
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2.7”NB Super Maxi rail relief valve - Disassemble the valve
© Fort Vale Engineering Ltd 2019
Step 1. Identify the valve. The part number will be laser
marked on the cap. If you are unsure please contact Fort
Vale. WARNING: Relief valves are spring-loaded and can
cause serious personal injury. Obey all the instructions
and wear eye protection during this procedure.
Step 2. The cap is locked to the valve body with an anti-
tamper screw filled with lead shot. Note the wall thickness
of the relief valve cap. CAUTION: It is important not to drill
fully through the cap and body because if can cause
damage to the spring.
Step 3. Put the valve on a V block on a pedestal drill. Use
a No 22 (4mm) drill and drill to a depth of 0.2" (5mm) to
remove the lead shot and screw. This will unlock the cap.
CAUTION: Do not drill to a depth of more than 0.2" (5mm)
to prevent damage to the spring.
Step 4. Clean the hole using compressed air.
Step 5. Use a sharp-edged tool to detach the stainless
steel plug.
Step 6. Remove the stainless steel plug. Keep the plug.
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2.7”NB Super Maxi rail relief valve - Disassemble the valve
© Fort Vale Engineering Ltd 2019
Step 7. Select the nylon lifting spacer, part number
FIX/A/0035.
Step 8. Install the nylon lifting spacer onto a bench press
with a minimum 1 tonne load.
Step 9. Install the valve onto the spacer. Make sure that
the valve is central on the spacer.
Step 10. Select the cap tightening tool, part number
FIX/A/0034. Engage the two pins on the cap tightening
tool into the two blind holes of the top cap.
Step 11. Make sure that the cap tightening tool is
installed correctly on the cap.
Step 12. Apply pressure onto the top cap tightening tool
until the spring is compressed enough so that the valve
body is free to move. Then turn the valve body clockwise
until it is disassembled from the top cap. WARNING: Make
sure that you lock the press before you start to unscrew
the valve.
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2.7”NB Super Maxi rail relief valve - Disassemble the valve
© Fort Vale Engineering Ltd 2019
Step 13. When the valve and the cap are disassembled,
unlock the press and gradually retract the press to release
the spring load. WARNING: Be careful when you retract
the press. Make sure that the spring is fully decompressed
before you remove the ram.
Step 14. When the spring is fully decompressed, retract
the ram fully.
Step 15. Remove the cap tightening tool. Step 16. Remove the top cap. Examine the top cap for
signs of damage or wear. If there is damage, contact Fort
Vale.
Step 17. Remove the springs. Examine the springs for
signs of corrosion or damage. If there is damage, contact
Fort Vale.
Step 18. Remove the valve body and pressure plate from
the press and put it onto a work bench.
NOTE: Valves manufactured after March 2017 have a
retaining ring clip installed in a groove in the valve body.
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2.7”NB Super Maxi rail relief valve - Disassemble the valve
© Fort Vale Engineering Ltd 2019
Step 19. Use a sharp-edged tool to release the retaining
ring clip from the groove. Remove the clip.
Step 20. Remove the pressure plate assembly.
Step 21. Examine the body for signs of damage or
corrosion. Look carefully at the pressure plate sealing face
and the gasket sealing face. If there is damage, contact
Fort Vale.
Step 22. DISASSEMBLE THE PRESSURE PLATE:
Use a ½" (13mm) spanner to loosen the 5/16" UNF nut on
the pressure plate assembly.
Step 23. Remove the 5/16" UNF stud and nut. Step 24. Use a ½" (13mm) spanner to remove the 5/16"
nut from the stud. If you cannot move the nut, use 2x
5/16" nuts as shown to prevent damage to the thread:
Hold nut 1 in a vice and tighten nut 2. Unlock nut 3 by
turning it clockwise and anti-clockwise. Remove nut 3.
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2.7”NB Super Maxi rail relief valve - Disassemble the valve
© Fort Vale Engineering Ltd 2019
Step 25. Use a wire brush to clean any remaining
adhesive from the stud. Examine the thread on the stud. If
there is damage, replace the stud.
Step 26. To disassemble the inner and outer pressure
plate, insert a 3/16" diameter rod into the hole in the inner
pressure plate. Gently tap the rod with a hammer.
Remove the retaining washer. CAUTION: Take care not to
cause damage. Do not let the inner pressure plate fall.
Step 27. Examine the inner pressure plate and the
washer for signs of damage or corrosion. If there is
damage, contact Fort Vale.
Step 28. Remove the O ring and discard it. Inspect the
outer pressure plate for signs of damage or corrosion. If
there is damage, contact Fort Vale.
The disassembly procedure is complete.
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© Fort Vale Engineering Ltd. 2019
www.fortvale.com
2.7"NB Super Maxi Rail Relief Valve
CHAPTER 2
Assemble the valve
This chapter contains instructions to assemble the pressure plate and to fully assemble the valve.
MM050_REV0311
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2.7”NB Super Maxi rail relief valve - Assemble the valve
© Fort Vale Engineering Ltd 2019
Step 29. ASSEMBLE THE PRESSURE PLATE:
Clean all pressure plate components and examine them
for signs of damage or corrosion. If there is damage,
contact Fort Vale.
1. 5/16"UNF x 30mm stud; 2. 5/16"UNF nut;
3. Retaining washer; 4. Inner pressure plate;
5. O ring; 6. Outer pressure plate.
Step 30 Apply thread adhesive to the thread of the inner
pressure plate.
Step 31. Install the 5/16" UNF stud and tighten it. Step 32. It is important to fully tighten the stud/pressure
plate assembly: Install 2x 5/16" nuts onto the stud. Hold
the nuts in a vice to avoid damage to the thread. Tighten
the pressure plate by hand. Remove the assembly from
the vice and remove the 2x nuts.
Step 33. Install a new O ring into the outer pressure plate
seal groove. Make sure that the O ring is fully installed
around its circumference.
Step 34. Assemble the outer pressure plate onto the
inner pressure plate assembly.
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2.7”NB Super Maxi rail relief valve - Assemble the valve
© Fort Vale Engineering Ltd 2019
Step 35. Make sure that the O ring is correctly installed.
The O ring must be held equally around its circumference
by the inner pressure plate.
Step 36. Note the correct orientation of the retaining
washer.
Step 37. Install the retaining washer. Step 38. Apply thread adhesive to the thread of the stud
and install the nut.
Step 39. Use a ½" (13mm) torque wrench to tighten the
nut to a torque of 15 ft.lbs (20 Nm).
Step 40. The assembly of the pressure plate is complete.
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2.7”NB Super Maxi rail relief valve - Assemble the valve
© Fort Vale Engineering Ltd 2019
Step 41. ASSEMBLE THE VALVE:
Clean the body. Examine the body for signs of damage or
corrosion. Look carefully at the pressure plate sealing face
and the gasket sealing face. If there is damage, contact
Fort Vale.
Step 42. Install the pressure plate assembly into the
body.
Step 43. If the valve has a retaining ring clip, install it into
the body and push it into the groove. Make sure it is fully
installed around the circumference. If the valve has no
ring clip, go to Step 44. CAUTION: Be careful - spring-
loaded part.
Step 44. Examine the springs for signs of damage or
corrosion. If satisfactory, install the springs. If there is
damage, contact Fort Vale.
Step 45. Apply thread lubricant that is compatible with
stainless steel on the thread of the top cap. Lubrication
helps the threads to engage between the body and the
cap.
Step 46. Install the top cap onto the springs. Make sure
that the springs engage into the groove inside the cap.
To complete the assembly procedure, move the valve to a
bench press with a minimum 1 tonne load. WARNING:
Relief valves are spring-loaded and can cause serious
personal injury. Obey all the instructions and wear eye
protection during this procedure.
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2.7”NB Super Maxi rail relief valve - Assemble the valve
© Fort Vale Engineering Ltd 2019
Step 47. Select the nylon lifting spacer, part number
FIX/A/0035 and install it onto the bench press. Make sure
that the ram is retracted to allow enough space to accept
the valve height.
Step 48. Install the valve onto the spacer. Make sure that
the valve is central on the spacer.
Step 49. Select the cap tightening tool, part number
FIX/A/0034. Engage the two pins on the cap tightening
tool into the two blind holes of the top cap.
Step 50. Make sure that the cap tightening tool is
installed correctly on the cap.
Step 51. Make sure that the valve assembly is centrally
aligned to the ram. Apply pressure slowly onto the top cap
to compress the spring. CAUTION: Align the body with the
cap to prevent cross-threading.
Step 52. Stop the press when there is a gap of approx.
1/8" (2-3mm) between the top cap and the valve body. Lift
the valve body and rotate it anti-clockwise to engage the
threads between the valve body and the top cap. Continue
to screw the body fully into the cap until there are no
threads visible. WARNING: Make sure that you lock the
press.
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2.7”NB Super Maxi rail relief valve - Assemble the valve
© Fort Vale Engineering Ltd 2019
Step 53. When the top cap and valve are fully engaged,
release pressure from the top ram.
Step 54. Remove the cap tightening tool. The assembly
procedure is complete.
NOTE: You must do the pressure test and adjustment
procedure before you install the valve onto the tank. Refer
to Chapter 3.
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© Fort Vale Engineering Ltd. 2019
www.fortvale.com
CHAPTER 3
Test and adjust the set pressure
2.7"NB Super Maxi Rail Relief Valve
This chapter contains instructions to test the set pressure of the relief valve and to make small adjustments to get the
correct set pressure.
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MM050_REV03©FortValeEngineeringLtd.2019 18
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