Installation and Maintenance Manual: Forbes Marshall Safety Relief Valve
Installation and Maintenance Manual: Forbes Marshall Safety Relief Valve
Installation and Maintenance Manual: Forbes Marshall Safety Relief Valve
1. Preface .................................................................................1
8. Troubleshooting....................................................................11
FMSRV (DN20-50) 1
2.4 Depressurizing of systems and normalizing of temperature:
Ensure isolation and safety venting of any pressure to the atmospheric pressure. Even if the
pressure gauge indicates zero, do not make an assumption that the system has been
depressurized.
To avoid danger of burns allow temperature to normalize after isolation.
2.5 Tools and consumables:
Ensure you have appropriate tools and / or consumables available before starting the work.
Use of original Forbes Marshall replacement parts is recommended.
2.6 Protective clothing:
Consider for the requirement of any protective clothing for you/ or others in the vicinity for
protection against hazards of temperature (high or low), chemicals, radiation, dangers to
eyes and face, noise and falling objects.
2.7 Permits to work:
All work to be carried out under supervision of a competent person. Training should be
imparted to operating personnel on correct usage of product as per Installation and
Maintenance instruction. “Permit to work” to be complied with (wherever applicable), in
case of absence of this system a responsible person should have complete information and
knowledge on what work is going on and where required, arrange to have an assistant with
his primary goal and responsibility being safety. “Warning Notices” should be posted
wherever necessary.
2.8 Handling:
There is a risk of injury if heavy products are handled manually. Analyze the risk and use
appropriate handling method by taking into consideration the task, individual, the working
environment and the load.
2.9 Freezing:
Provision should be made to protect systems which are not self-draining, against frost
damage (in environment where they may be exposed to temperatures below freezing point)
to be made.
2.10 Product Disposal:
It is necessary to dispose this product only in accordance with local regulations at the
authorized, qualified collecting point specified for equipment’s and its parts—Please refer
the part details mentioned in the material table of this manual. Please follow all waste
disposal guidelines (Management & Handling) as published by local governing authorities in
India & abroad
2.11 Returning products:
Customers and Stockist are reminded that, when returning products to Forbes Marshall they
must provide information on any hazards and the precautions to be taken due to
contamination residues or mechanical damage which may present a health, safety or
environmental risk.
This information must be provided in writing including Health and Safety data sheets
relating to any substances identified as hazardous or potentially hazardous.
3.1 Description:
The Forbes Marshall Safety Relief Valve FMSRV is a high lift safety relief valve with gun
metal seat, valve and brass internals suitable for use on steam, air and water.
3.2 Size and Pipe Connections:
DN 20, 25, 40 and 50
Screwed BSPT/BSP/NPT
Available with IBR certificate
3.3 Limiting Conditions:
05 to 15 psi White
15 to 35 psi Yellow
35 to 75 psi Green
75 to 125 psi Blue
125 to 175 psi Red
175 to 250 psi Black
FMSRV (DN20-50) 3
Figure 1: Forbes Marshall Safety Relieve Valve
Materials:
No Part Material
1 Seat Gun metal
2 Seat ring Gun metal
3 Valve Gun metal
4 Spindle lock nut Brass
5 Bonnet IS 210 Gr. FG260
6 Spindle Brass
7 Spring Stainless steel
8 Bottom spring guide C 20
9 Top spring guide C 20
10 Adj. locking nut Brass
11 Adj. bolt Brass
12 Cap C20
13 Lever Aluminium
14 Lever fulcrum pin C20
15 Seat ring locking screw and nut (not shown) Brass
Dimensions: (approx. ) in mm (Refer to Figure 1)
Size DN A B C
20 48 60 145
25 60 65 160
40 73 84 205
50 80 108 250
STEAM
4600
4400
4200
DN50
4000
3800
3600
3400
3200
3000
2800
2600
DN40
kg/hr
2400
2200
2000
1800
1600
1400
1200
DN25
1000
800
DN20
600
400
200
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Set Pressure in bar g
WATER
80000
DN50
70000
60000
50000
Litres/hr
40000
DN40
30000
20000
DN25
DN20
10000
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
AIR
1600
1550
1500
1450
DN50
1400
1350
1300
1250
1200
1150
1100
1050
1000
950
dm3/sec
900 DN40
850
800
750
700
650
600
550
500 DN25
450
400
350
300 DN20
250
200
150
100
50
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
FMSRV (DN20-50) 5
4. Product Working Principle : (Refer to Figure 1 )
The Forbes Marshall safety relief valve is normally set at a pressure which is 10% above the
working pressure of the system. This is referred to as a set pressure. When the safety pressure
reaches blow off pressure the safety relief valve opens to its full lift to discharge full capacity. The
valve closes at reset pressure.
The steam enters the safety relief valve through the inlet from the bottom. When the steam
reaches the set point, it lifts the valve (3) off the seat (1), working against the spring (7) present
inside the valve body. (The set pressure can be changed using the adjustment bolts (11)). As long
as the steam pressure exceeds the set pressure, the valve remains open. As soon as it comes below
the set pressure, the spring force pushes the valve (3) back onto the seat (1).
The seat ring (10) guides the valve (3) back to the seat (1).
5. Installation Guidelines:
Note: Before implementing any installations observe the 'Important Safety notes” in
section 2. Referring to the Installation and Maintenance Instructions, name-plate and
Technical Information Sheet, check that the product is suitable for the intended
installation.
1. The valve should always be mounted vertically upwards with its main axis kept vertical.
2. There should be no intervening valve or any fitting between the piping and the safety relief
valve which could isolate the FMSRV (Refer to 2a).
3. The inlet connection should never be smaller than the valve inlet and output pipe should be
either equal or larger than the valve outlet.
4. Where the outlet pipework is directed upwards a small bore drain should be provided at the
lowest point. Take the drain to a place where discharge will not create any hazard or
inconvenience (Refer to 2b).
5. Each safety relief valve should have its own discharge pipe.
6. Make sure that safety relief valve is set to the correct pressure.
7. safety relief valves should not be insulated.
8. Excessive pressure loss at the inlet of a safety relief valve when it operates will cause
extremely rapid opening and closing of the valve, observed as chattering or hammering. This
may result in reduced capacity as well as damage to seating faces and the other parts of the
valve. When normal pressure is restored it is possible that the valve will leak. Therefore the
Valve should be fitted 8-10 pipe diameters downstream of Converging or Diverging Fittings
or Bends (Refer to 2c)
2a 2b
FMSRV (DN20-50) 7
6. Startup and Commissioning :
6.1 Flushing of lines:
As part of pre-installation all fluid handling equipment particularly piping should be
thoroughly cleaned of scale and the internal debris which accumulates during construction.
This is accomplished by blowing or flushing with air, steam, water and other suitable
medium.
Note: For a detailed procedure on flushing of lines please visit Forbes Marshall website.
6.2 Safety relief valve setting : (Refer to Figure 1)
1. The safety relief valve should be set at a pressure, which is 10% above the working
pressure of the system.
2. Forbes Marshall safety relief valve, FMSRV (DN20-50) comes with 6 color-coded springs
w.r.t. set pressure ranges
White - 05 to 15 psi Yellow – 15 to 35 psi
Green – 35 to 75 psi Blue 75 to 125 psi
Red – 125 to 175 psi Black 175 – 250 psi
The range is marked on the safety relief valve cover body; safety relief valve can be set in
this range.
3. To set the safety relief valve, please remove the cir clip, pin, lever (13) and cap.
4. Before setting of safety relief valve, please ensure that the safety relief valve discharge is
routed at safe location.
5. Charge the steam line and ensure that the steam pressure is 10% more than the system
operating pressure and test the safety relief vale by shutting down the downstream
stop valve without the chance of downstream process being over pressurized.
6. If safety relief valve is not blowing at that pressure, then loosen the adjustment lock nut
(10) and do the set pressure adjustment with adjustment bolt (11). By rotating
adjustment bolt in clockwise direction, set pressure increases and it decreases by
rotating it in anticlockwise direction.
7. After setting the required set pressure, hold the adjustment bolt and tighten the
adjustment lock nut (10).
3 Cleaning of internals Y
FMSRV (DN20-50) 9
7.3 Maintenance/Replacement Procedure : (Refer to Figure 1)
1. Before carrying out any maintenance on the valve, make sure that the system is isolated
and depressurized.
2. Unscrew the whole safety release valve from the pipeline.
3. Remove the pin to release the easing lever (13).
4. Remove the top cover.
5. Loosen the adjustment bolt locknut.
6. Rotate the adjustment bolt (11) anti clockwise to ease the spring tension inside the
body.
Note: It is very important to ease off the spring tension before carrying out any further
maintenance.
7. Clamp the Hexagonal valve seat to the vice.
8. Unscrew the blow down locking nut and screw (15).
9. Use a pipe wrench to rotate the upper body to free the internals. A flat surface is
provided on the body to get a good grip on the body.
10. Remove the whole internal assembly off the body valve.
11. Unscrew the seat ring (2) and clean the threads.
12. Clean the valve seat (1) and valve head (3). Lap the head against seat in oscillation
motion if required.
13. Reassemble the internals and fit it back in the valve body .
14. Fit the valve back on the pipeline.
15. For seat ring setting refer to section 7.4
16. Fit the easing lever (6) on the valve.
17. Set the valve to set pressure following the steps given in section 6.2.
7.4 Seat Ring Setting: (Refer to Figure 1)
To have the required reset pressure for a particular set pressure, the seat ring (2) should be
adjusted after removing the seat ring locking screw (15). Rotate the seat ring (2) in the
clockwise direction towards the valve (3). Once the seat ring (2) touches the valve (3),
rotate the seat ring (2) in anticlockwise direction, away from the valve (3) by 1/4th of a turn.
Ensure that the seat ring locking screw (15) is tightened and locked after adjustment.
Check for spring range Refer to the spring ranges given in section 3.3
FMSRV (DN20-50) 11
9. Available Spares:
SPARE
Í ĦÊ Ì Ĕ Î İ ĦĔ SPARE CONSIST OF SPARE CODE
SPECIFICATION
(STEAM SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN20 SPARE-20FMSRV-VHSKIT
EACH
(STEAM SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN25 SPARE-25FMSRV-VHSKIT
EACH
(STEAM SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN40 SPARE-40FMSRV-VHSKIT
EACH
(STEAM SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN50 SPARE-50FMSRV-VHSKIT
VALVE HEAD
EACH
AND SPINDLE
( LIQUID SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
KIT
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN20 SPARE-20FMSRVL-VHSKIT
EACH
(LIQUID SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN25 SPARE-25FMSRVL-VHSKIT
EACH
(LIQUID SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN40 SPARE-40FMSRVL-VHSKIT
EACH
(LIQUID SERVICE) VALVE HEAD ,SPINDLE ,SPINDLE
LOCK NUT ,SEAT RING SCREW & NUT PACK OF 1 DN50 SPARE-50FMSRVL-VHSKIT
EACH
SPINDLE & LOCK NUT PACK OF 1 EACH DN20 SPARE-20FMSRV-SLKIT
FMSRV
SPINDLE & LOCK NUT PACK OF 1 EACH DN25 SPARE-25FMSRV-SLKIT
SPINDLE & LOCK NUT PACK OF 1 EACH DN40 SPARE-40FMSRV-SLKIT
SPINDLE AND SPINDLE (LIQUID SERVICE) & LOCK NUT PACK OF 1 DN20 SPARE-20FMSRVL-SLKIT
LOCK NUT EACH
SPINDLE (LIQUID SERVICE) & LOCK NUT PACK OF 1
DN25 SPARE-25FMSRVL-SLKIT
EACH
SPINDLE (LIQUID SERVICE) & LOCK NUT PACK OF 1
DN40 SPARE-40FMSRVL-SLKIT
EACH
SPINDLE (LIQUID SERVICE) & LOCK NUT PACK OF 1
DN50 SPARE-50FMSRVL-SLKIT
EACH
SPRING & SPRING 05-15-PSI,TOP AND BOTTOM SPRING
DN20 SPARE-20FMSRV-5-15SGKIT
GUIDE KIT GUIDE PACK OF 1 EACH
FMSRV (DN20-50) 13
SPARE
Ï Í ĒĨ F Ī J Í F SPARE CONSIST OF SPARE CODE
SPECIFICATION
VALVE HEAD,SEAT,SEAT RING,RUBBER INSERT ,SEAT
DN25 SPARE-25FMSRV-VSGKIT
RING SCREW& NUT PACK OF 1 EACH
VALVE HEAD,SEAT,SEAT RING,RUBBER INSERT ,SEAT
DN40 SPARE-40FMSRV-VSGKIT
RING SCREW& NUT PACK OF 1 EACH
VALVE HEAD,SEAT,SEAT RING,RUBBER INSERT ,SEAT
DN50 SPARE-50FMSRV-VSGKIT
RING SCREW& NUT PACK OF 1 EACH
VALVE & SEAT KIT VALVE HEAD,SEAT,SEAT RING,SEAT RING SCREW& NUT
DN20 SPARE-20FMSRV-VSSKIT
(GAS) PACK OF 1 EACH
VALVE HEAD,SEAT,SEAT RING,SEAT RING SCREW& NUT
DN25 SPARE-25FMSRV-VSSKIT
PACK OF 1 EACH
FMSRV
VALVE HEAD,SEAT,SEAT RING,SEAT RING SCREW& NUT
DN40 SPARE-40FMSRV-VSSKIT
PACK OF 1 EACH
VALVE HEAD,SEAT,SEAT RING,SEAT RING SCREW& NUT
DN50 SPARE-50FMSRV-VSSKIT
PACK OF 1 EACH
ADJUSTMENT BOLT FOR LIQUID APPLICATION DN20 SPARE-20FMSRV-ABKIT
How to Order:
Example: 1 No. Forbes Marshall Forbes Marshall Safety Relief Valve, FMSRV, DN20 with BSPT
ends and a set pressure of 6 bar g.
How to Order Spares:
Always order spares by using the description given in the column headed available spares. For
codes refer user manual.
Doc# FMSS/0317/UM-FMSRV(Dn20-50)/V2.R0