Flow Safe F7000 SERIES Installation, Operation & Maintenance Manual
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Flow Safe F7000 SERIES Installation, Operation & Maintenance Manual

Pilot-operated safety relief valve
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High Performance Safety Relief Valves
F7000 / 8000 SERIES
PILOT-OPERATED
SAFETY RELIEF VALVE
INSTALLATION,
OPERATION, & MAINTENANCE MANUAL
Revision:
T
Date of Issue:
December 17, 2018
jwo
Approved by:
Engineering Projects Dir.

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  • Page 1 High Performance Safety Relief Valves F7000 / 8000 SERIES PILOT-OPERATED SAFETY RELIEF VALVE INSTALLATION, OPERATION, & MAINTENANCE MANUAL Revision: Date of Issue: December 17, 2018 Approved by: Engineering Projects Dir.

  • Page 2: Table Of Contents

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 2 of 43 TABLE OF CONTENTS Topic Page General ....................3 Description, Operation, Service Envelope, Installation, & Startup Description / Operation ................ 5 Service Envelope .................

  • Page 3: General

    FLOW SAFE believes that when maintenance and reassembly is performed as outlined in this manual there is no safety hazard. FLOW SAFE recommends that all valves be placed on a regular maintenance schedule that includes the routine replacement of softgoods. FLOW SAFE recommends softgoods replacement every three years but cautions that each customer make their own determination and set their own schedule based upon use and environment.

  • Page 4: Description, Operation, Service Envelope, Installation, & Startup

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 4 of 43 DESCRIPTION, OPERATION, SERVICE ENVELOPE, INSTALLATION, and STARTUP Conventional / Tubed Pilot: Integral Module (IM) Construction:...

  • Page 5: Description / Operation

    Elastomeric and plastic seals seal the main valve and pilot valves. The orifice size may be easily selected by choosing a full-bore inlet nozzle (F7000 Series), or by converting to a reduced-size orifice (F8000 Series) through the attachment of FLOW SAFE's unique annular-flow plug to the bottom of the piston assembly.

  • Page 6: Storage And Handling

    Page 6 of 43 STORAGE AND HANDLING STORAGE Prior to installation, Flow Safe pressure relief valve assemblies and parts should be stored in a clean, dry environment if possible. Inlet and outlet connections should remain covered until the item is ready for installation.

  • Page 7: Installation

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 7 of 43 INSTALLATION Prior to installation, check that the set pressure on the nameplate is as required, and meets the system requirements. Lifting and handling should follow the instructions in Section 2.3. If the valve has been in storage for a significant length of time, verify that the main piston can still freely move by pushing on it manually through the valve inlet.

  • Page 8: Remote Sense / Field Test Connection

    SET PRESSURE CONSIDERATIONS FOR BACK PRESSURE In general, backpressure has no effect on the flow capacity of the FLOW SAFE F7000 / 8000 Series of pilot-operated valves as long as a critical flow condition exists. The critical flow pressure ratio for a particular gas may be estimated by equations given in API 520 Part I, or by contacting FLOW SAFE Engineering.
  • Page 9 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 9 of 43...

  • Page 10: Startup

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 10 of 43 STARTUP Foreign particles or dirt can damage the valve and make it inoperative. Prior to installation, clean out the piping thoroughly. If the valve is not installed immediately, inlet and outlet connections should be protected and covered.
  • Page 11 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 11 of 43 Replace softgoods in the piston, liner, and (if applicable) pressure isolation spool per the instructions in Section 3.2. Replacement soft goods are listed in Section 8.0 of this manual.

  • Page 12: Reassembly Of The F7000/8000 Series Main Valve

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 12 of 43 REASSEMBLY OF THE F7000 / 8000 SERIES MAIN VALVE Reassembly of these valves is basically the reverse of disassembly. Care must be taken in the handling of all items, particularly sealing surfaces and softgoods.

  • Page 13: Pilot Valve Maintenance

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 13 of 43 If the valve is IM construction, reinstall the spool piece with new softgoods. Apply a light coat of lubricant (Molykote or equivalent) to the seals. If the valve is fitted with a dome spring, reinstall the spring in the piston.
  • Page 14 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 14 of 43 Carefully assemble the diaphragm to the top of the spindle by slowly turning the diaphragm clockwise on the spindle threads until it bottoms on the shoulder. Make sure that there are no tears or rips in the diaphragm material.

  • Page 15: F200 Pilot Valve

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 15 of 43 F200 PILOT VALVE (See Illustrations on Page 16) F200 Disassembly CAUTION: It is extremely dangerous to attempt to disassemble any valve while it remains in service with incoming line pressure.
  • Page 16 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 16 of 43 F200 PILOT VALVE ASSEMBLY...

  • Page 17: F300 Pilot Valve, Diaphragm-Style (15 To 500 Psig)

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 17 of 43 F300 PILOT VALVE, DIAPHRAGM-STYLE (15-500 psig) (See Illustration below) F300 (Diaphragm-style) Disassembly CAUTION: It is extremely dangerous to attempt to disassemble any valve while it remains in service with incoming line pressure.
  • Page 18 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 18 of 43 F300 (Diaphragm-style) Assembly NOTE: Exercise care in handling softgoods, nozzles, and other sealing surfaces. Confirm pressure setting and associated parts required. Place the valve body in a vise.
  • Page 19 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 19 of 43 Lightly lubricate lower sleeve seal with Dow Corning Molykote 33 or equivalent, and install into groove of sleeve. Lightly lubricate upper sleeve seal and place onto the top of the sleeve. Install the seat into the bottom side of the seat retainer nozzle, and assemble on top of the sleeve.

  • Page 20: F300 Pilot Valve, Piston-Style (286 To 6000 Psig)

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 20 of 43 F300 PILOT VALVE, PISTON-STYLE (501 to 6000 psig) (See Illustrations below and on Page 21) F300 (Piston-style) Disassembly CAUTION: It is extremely dangerous to attempt to disassemble any valve while it remains in service with incoming line pressure.
  • Page 21 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 21 of 43 See Page 18 for Backflow Preventer details F300 PILOT VALVE ASSEMBLIES – PISTON-STYLE...
  • Page 22 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 22 of 43 F300 (Piston-style) Assembly NOTE: Exercise care in handling softgoods, nozzles, and other sealing surfaces. Confirm pressure setting and associated parts required. Place the valve body in a vise.

  • Page 23: F500 Pilot Valve

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 23 of 43 Install vent / bug screen into the bonnet, and the inlet screen into the body. Assemble the face seals to the external mounting face of the pilot body. The ‘IM’ style body has an additional face seal at the inlet port.
  • Page 24 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 24 of 43 Apply small amount of Loctite to threads of spindle. Install retainer securely onto spindle using 3/16” Allen wrench in bottom of spindle and a wrench on the OD flats of the retainer. Install the spindle assembly up through the bottom of the pilot body.
  • Page 25 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 25 of 43 Install the vent / bug screen into the bonnet, ensuring that the male NPT end does not contact the spring. Apply Teflon tape to threads before installing. Assemble the PA screw and lock nut into the top of the bonnet.
  • Page 26 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 26 of 43 See Page 18 for alternate BFP nozzle design. F500 PILOT ASSEMBLY – INTERMEDIATE PRESSURE (286 – 1480 psig)
  • Page 27 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 27 of 43 F500 PILOT ASSEMBLY – HIGH PRESSURE (1481 – 6000 psig)

  • Page 28: Pilot Valve Set Pressure Adjustment

    VIII tolerance on set pressure is + 2 psi for set pressures < 70 psig, and + 3% of set pressure for set pressures > 70 psig. Contact Flow Safe for confirmation of spring range or new spring part number before resetting any pilot to a different set pressure.
  • Page 29 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 29 of 43 5.2.2 Testing of Complete Assembly CAUTION: Extreme care must be taken when testing or servicing a pressure relief valve used in gas or incompressible fluid service.

  • Page 30: F100 Pilot Valve Adjustment

    (See Illustrations on Pages 16 and 28) The set pressure for the F200 Pilot Valve may be adjusted only by turning the pressure adjusting (PA) screw or changing springs. Contact Flow Safe to verify the proper spring for the desired set pressure.

  • Page 31: F300 Pilot Valve Adjustment

    The set pressure for the F300 pilot valve may be adjusted by turning the pressure adjusting (PA) screw, changing springs, or by exchanging diaphragm-style and piston-style internals. Contact Flow Safe to verify the proper parts for the desired set pressure. Attach pilot valve assembly to the test tank with the cap removed and the pressure adjustment screw turned out to below where the set point is believed to be.

  • Page 32: F500 Pilot Valve Adjustment

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 32 of 43 F500 PILOT VALVE ADJUSTMENT (See Illustrations on Pages 25, 26, 27, and 28) The set pressure for the F500 pilot valve may be adjusted by turning the pressure adjusting (PA) screw, or by changing springs, corresponding diaphragm, or sense piston arrangements.

  • Page 33: Pilot Auxiliary Setter Adjustment

    (See Illustration below) The set pressure for the pilot auxiliary setter may be adjusted by turning the pressure adjusting (PA) screw or changing springs. Contact Flow Safe to verify the proper spring for the desired set pressure. The auxiliary setter must be installed on its designated pilot valve when being adjusted. This may be verified by means of matching serial numbers.

  • Page 34: Supplemental Testing And Accessories

    To enable separate control of pressure sources to the main valve dome and inlet, a hydro test plate (available from FLOW SAFE) should be installed on the pilot mounting pad, as shown in the figure below.

  • Page 35: Final Assembly Testing

    F300 PILOT VALVE PROPORTIONAL BAND ADJUSTMENT Purpose The FLOW SAFE F300 Series is a modulating-style pilot valve used with the F7000/8000 Series. As received from the factory, the F300 is lockwired to prevent any adjustments to the set pressure. This lockwire is also attached to the proportional band screw (see drawings on Page 17, 18, 20, or 21).

  • Page 36: Inservice Testing With The Field Test Connection

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 36 of 43 INSERVICE TESTING WITH THE FIELD TEST CONNECTION (FTC) CAUTION: Extreme care must be taken when testing or servicing a pressure relief valve used in gas or incompressible fluid service.
  • Page 37 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 37 of 43 NOTE: 1. For an F200 snap-acting pilot, pilot valve “reseat” pressure will be that pressure at which the dome gage repressurizes. 2.

  • Page 38: Harguard Clean Pilot Supply Tank

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 38 of 43 HARGUARD CLEAN PILOT SUPPLY TANK The Harguard clean pilot supply tank isolates critical relief valve parts from a corrosive or dirty system process, and permits only a clean liquid such as glycol and water to enter the pilot and main valve dome.

  • Page 39: Troubleshooting Guide

    INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 39 of 43 TROUBLESHOOTING GUIDE: Symptom Possible Cause Remedy Inadequate or uneven bolt torque. Retighten the cap bolts per Section 3.2. The main valve Sealing surface on cap is damaged.

  • Page 40: Softgoods Kits

    EPR / EPDM Kalrez Chemraz Lo-temp nitrile Most common materials listed; contact Flow Safe for availability of other materials. Approximate pressure ranges of plastic seats shown in Section 2.2 on Page 5. Main Valve Softgoods Kit contents: Standard kit Qty.

  • Page 41: Pilot Valve Softgoods

    These pressure ranges are approximate only. Most common materials listed; contact Flow Safe for availability of other materials. Seals made from other materials noted below. NOTE: Softgoods kits may contain extra O-rings for older part versions that may not be needed.
  • Page 42 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 42 of 43 PILOT VALVE SOFTGOODS (cont’d) See Page 41 for terminal digits “D”, “X”, “Y”, & “Z”. F300 Softgoods Kits: F300-DI-DXYZ Diaphragm-style (15 - 500 psig) Contents (See drawings on Page 17-18): Qty.
  • Page 43 INSTALLATION, OPERATION, & MAINTENANCE MANUAL TITLE: F7000 / 8000 Series Rev. T Pilot-Operated Safety Relief Valve Page 43 of 43 PILOT VALVE SOFTGOODS (cont’d) See Page 41 for terminal digits “D”, “X”, “Y”, & “Z”. F500 Softgoods Kits: F500-LPS-DXYZ LP (to 285 psig) F500-LPT-DXYZ LP (to 285 psig), with set point indicator Contents (See drawing on Page 25):...

This manual is also suitable for:

8000 series

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