THE GREENBRIER COMPANIES ARI1118 Instruction Manual

ARI1118 & ARI1148
Safety Relief Valve
THE GREENBRIER COMPANIES
One Centerpointe Drive, Suite 200
Lake Oswego, Oregon 97035
[email protected]
www.gbrx.com
INSPECTION &
MAINTENANCE BULLETIN
October 5, 2020
These instructions
are applicable to the
following models:
ARI1118
ARI1148
Only facilities with AAR Activity
Code C5 are certied to
recondition, repair, retest and
qualify tank car safety relief valves.
Personnel performing inspection
and test must be certied Level
I per AAR Manual of Standards
and Recommended Practices,
M-1002, Appendix T, 1.4.3.

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October 5, 2020
New Valves for Replacement of Existing Equipment
New valves are tested, sealed and packaged at the time of manufacture. A new valve can be applied provided it is still in its original
packaging and tested within 6 months of the installation date. A valve with a test date older than 6 months must have the O-rings
replaced and retested.
Safety relief valves are spring loaded devices that can store a significant amount of energy. Assembly and disassembly
must be performed by trained, qualified personnel.
Disassembly Procedure
Disassembly of the Top Guide and O-ring Retainer
1. Remove the seal wires, items #14.
2. Remove the four nuts securing the top guide,
items #17.
3. Lift off the top guide, item #2. It may be
necessary to loosen the guide by tapping with a
soft-faced hammer.
4. Peel off the bumper washer, item #9.
5. Using two wrenches, one applied to the hex on
the retainer, item #6, and the other to the locknut,
item #10, loosen and remove the locknut.
6. Remove the O-ring retainer with the use of a
wheel puller or gently prying under and around the
lip with a screwdriver.
7. Use a packing removal pick, remove the O-rings,
items #7 & 8, from the retainer taking care not to
mar the O-ring grooves.
8. Lay the valve on its side. Using a packing removal
pick or a thin blade screwdriver, pry off the gasket.
Take care not to mar the sealing surface.
Disassembly of the spring and stem
1. Clean the stem threads with a wire brush and
lubricate the threads with a light oil, like WD-40.
2. Loosen and remove the locknut, item #16. Do NOT
remove the spring adjustment nut, item #15, at
this time.
3. Measure and record the distance from the end
of the stem to the spring adjustment nut. This
dimension will be used at reassembly.
4. Place the valve into a press with the spring in the upward position and a means to prevent the stem from dropping out.
5. Using a press yoke to allow access to the spring adjustment nut, item #15, compress the valve spring to remove all force from
the nut. Remove the adjustment nut.
6. Slowly back off the press head until the valve spring, item #4, expands to the relaxed state.
7. Remove the spring follower, item #5.
8. Remove the valve body and stem from the press taking care to prevent the stem from dropping out.
9. Lay the valve body on its side and withdraw the stem.

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October 5, 2020
Inspection of Valve Components
Top Stem Guide
The inside of the top stem guide should be free of paint, debris, nicks, burrs or other discontinuities. Visually inspect the inside
of the guide and the mating area on the upper stem. Any sign of signicant wear should be reported to GBX Engineering for
review and disposition.
Valve Stem
Remove all scale, residue and other foreign material from the stem with a wire brush. Inspect the stem for signs of corrosion or
pitting. Any evidence of corrosion or pitting is grounds for replacement.
The seating surface and O-ring contact areas can be cleaned with 400 grit emery cloth. Any discontinuity that would prevent sealing
is grounds for replacement. Machining, grinding, welding or other alterations are not permitted.
The stem must be inspected for cracking using either magnetic particle or dye penetration inspection methods. Cracking is
unacceptable. If found, the stem must be replaced.
Place the stem in a set of V-blocks and measure straightness with a dial indicator. The stem must be straight within .015 TIR. If out
of tolerance, the stem must be replaced. Straightening by bending or heat is not permitted.
O-Ring Retainer
Clean the O-ring setting surfaces inside the retainer with 400 grit emery cloth. Visually inspect the O-ring grooves. They must be free
of pits, corrosion or gouges that would prevent proper sealing of the O-rings.
Valve Body
The area around the valve seat must be free of debris, corrosion and foreign objects. Cleaning can be accomplished with a light
brush off blast using glass bead media. The seating surface must be free of nick, burrs and gouges. The area should be cleaned and
lightly polished with 400 grit emery cloth. Any discontinuity that would prevent the valve from sealing is grounds for replacement.
Machining, grinding, welding or other alterations are not permitted.
Turn the valve body over to inspect the mounting ange and gasket groove. The gasket groove must be free for residual gasket
material, corrosion, nicks, burrs and gouges. Any discontinuity that would prevent sealing is grounds for replacement.
Valve Spring
Remove all scale, residue and other foreign material from the spring with a wire brush. Inspect the spring for signs of corrosion or
pitting. If found, the spring must be replaced.
The spring must be inspected for cracking using either magnetic particle or dye penetration inspection methods. Cracking is
unacceptable. If found the spring must be replaced.
Stand the spring upright on a level surface. Place a straight edge against the outside and measure for straightness. Turn the spring
90 degrees and measure again. The spring must straight within ¼”. If out of tolerance, the stem must be replaced.
Aluminized springs cannot be inspected with magnetic particle or dye penetration methods. After cleaning, visually inspect the
coating. Any evidence of peeling or aking of the aluminum is grounds for replacement.
Spring Follower
Remove all scale, residue and other foreign material from the stem with wire brush. Inspect the follower for signs of corrosion or
pitting. Any evidence of corrosion or pitting is grounds for replacement.
Visually inspect the outside diameter of the follower for signs of signicant wear. Wear could be an indication of a bowed spring,
misassembled spring or misalignment of the valve with the safety valve nozzle. Any sign of excessive wear should be reported to
GBX Engineering for review and disposition.
O-Rings
O-rings must be replaced any time the retainer is removed from the stem.

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October 5, 2020
Assembly Procedure
1. With the valve body on its side, insert the stem into the body through the top.
2. Place the valve in the press ensuring the spring is seated in the body and the stem is aligned. Install the spring and spring
follower then position the yoke, and compress the spring enough to apply the adjustment nut. With the nut fully engaged, further
compress the spring and tighten the nut to the previously recorded dimension from the nut to the end of stem.
3. Release the press and move the valve to the workbench.
4. Install the O-rings in the O-ring grooves of the O-ring retainer taking care not to tear, stretch or otherwise damage the O-rings.
Sharp tools should never be used for this operation.
5. Place the retainer with the O-rings on the stem.
6. Install the bumper washer on the retainer.
7. Install the locknut on the stem with a wrench applied to the hex on the retainer and one to the nut. Torque to 50 ±5 ft-lbs
8. Place the top guide over the studs and secure with the 4 nuts. Torque to 30 ± 5 ft-lbs.
9. Move the valve to the test stand.
10. After testing is complete, install the stem locknut and, using two wrenches, tighten to 50 ±5 ft-lbs.
11. Install new seal wires, items #14.
Guidelines for Testing and Adjustment
Determining Applicable Pressure Values
The ARI1118 and ARI1148 safety relief valves are designed to operate at 75 psig. The start-to-discharge pressure (STD) must be 75
psig +/- 3 psig and vapor-tight at 60 psig minimum.
Test Stand and Gauge Requirements
The test stand must have a mounting that complies with AAR M-1002, Section C-III, Appendix E, Figure E21 A. Test stand pressure
gauge must meet the requirements of AAR M-1002, Section C-III, Appendix D section 4.5, Test Gauge Standards. Gauges must be
date tagged.
Valve Leak Testing
1. Safety Relief Valve leak tests must be conducted in accordance with AAR M-1002, Section C-III, Appendix T. The inspector must
be Level I qualied or higher.
2. Apply the safety valve to the test stand.
3. Cycle the valve by applying shop air or nitrogen to the stand.
4. Plug the valve body drain opening using putty or a foam ear plug. Fill the cavity to the top of the O-ring retainer.
5. Increase air pressure under the valve until the valve opens or “pops.”
6. Reduce pressure until the valve is closed and there are no bubbles present.
7. Rell the chamber and begin slowly increasing pressure under the valve until the rst bubble appears. This is the start-to-
discharge pressure (STD) and must be 75 psig +/- 3 psig.
8. If the start-to-discharge pressure falls outside the specied range, adjust the valve spring by tightening the adjustment nut to
increase the discharge pressure and loosen to decrease. Repeat Steps 4-6.
9. NOTE: If adjusting the spring tension produces the opposite of the desired effect, the spring could be defective and must be
replaced.

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October 5, 2020
10. Once the proper start-to-discharge pressure is attained, slowly decrease the pressure until the bubbles stop. This is the vapor-
tight pressure and must be a minimum of 60 psig.
11. A vapor-tight pressure falling below the specied minimum could indicate a problem with the Orings not sealing properly.
Release all pressure from under the valve and remove the O-ring Retainer following the instructions under section, Disassembly
of the Top Guide and O-ring Retainer, steps 2-6. Visually inspect the O-rings for nicks, gouges or improper setting in the retainer.
Visually inspect the seating surface. A nger nail run across the surface can pick up discontinuities that are not readily visible.
Any defect must be corrected.
12. Once the start-to-discharge and vapor-tight pressures are attained, test a second time to conrm the settings then tighten the
stem lock nut and install the seal wires per steps 10 & 11 in the Assembly Procedure section.
13. Mark the valve per AAR M-1002, Section C-III, Appendix A, Paragraph 7.1.2.
The undertaking of repair or replacement by the Purchaser, or its agents, without the expressed written consent of The Greenbrier Companies (GBX) shall void the
warranty and relieve GBX of all responsibility. Under no circumstances shall GBX be liable for any direct, incidental, consequential or other damages of any kind in
connection with the installation, operation, maintenance, repair, inspection or other use of any product purchased from it.