F80 Manual RevE PDF
F80 Manual RevE PDF
F80 Manual RevE PDF
F80 SERIES
SAFETY RELIEF VALVE
• TYPE F84 (PLASTIC-SEATED)
• TYPE F85 (ELASTOMER-SEATED)
• -4, -6, -8 Orifices (WITH INTEGRAL BONNET)
• -4, -6, -8, -F, -G, -H, -J Orifices (WITH BOLTED BONNET)
INSTALLATION,
OPERATION, & MAINTENANCE MANUAL
Revision: E
Date of Issue: July 24, 2007
TABLE OF CONTENTS
Topic Page
Illustrations
1.0 GENERAL
1) This manual is intended to provide users with direction and guidance for the maintenance of
FLOW SAFE F80 Series safety relief valves. This manual indicates the proper method of valve
disassembly, soft goods replacement, and valve reassembly. FLOW SAFE provides this manual
as a guideline and reference only. It is not intended to serve as a training manual or
manufacturing guide. FLOW SAFE assumes no responsibility for personal or property damage
that may occur in conjunction with this manual.
2) 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. FLOW SAFE believes that when
maintenance and reassembly is performed as outlined in this manual there is no safety hazard.
During routine maintenance the internal components of the valve should be inspected for damage
or abnormal wear. The valve should also be inspected for excessive corrosion. A corrosion
allowance of 0.06” (1.5 mm) is designed into all carbon steel components subject to corrosion.
Operating the valve with corrosion exceeding this allowance is not recommended.
Cycling the valve at least once a year is considered to be good practice to verify operation and to
confirm that parts are not seized.
3) When a new valve leaves FLOW SAFE, it has been manufactured and tested by trained and
experienced personnel. When you remove a valve from your system and perform the
maintenance tasks that are outlined herein you will need proper training.
Do not attempt to accomplish these tasks without adequate training and understanding of the
valve operation.
4) Any and all stated or implied warranties that are in effect during the purchase of a new FLOW
SAFE valve are null and void once the valve has been disassembled by someone other than
approved FLOW SAFE personnel.
All repair and resetting of "UV"-stamped safety relief valves should be performed either by FLOW
SAFE, Inc., or by a National Board-certified valve repair shop holding a "VR" (Valve Repair)
stamp.
5) It is highly recommended that all instructions herein be read in full prior to any assembly,
disassembly, or operation of this equipment.
6) The noted manufacturer’s standard lubricants should be used only if compatible with process fluid
and application.
7) Specific design details described in this document are subject to change without notice.
8) Should the need arise for general assistance, contact the FLOW SAFE Sales department at (716)
662-2585 or (800) 828-1036. For more detailed technical assistance, contact the FLOW SAFE
Engineering department at (716) 667-3640.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
The FLOW SAFE F80 Series safety relief valve is a direct-acting spring-loaded relief valve, suitable for
gas service. The Type F84 is plastic-seated and the F85 is elastomer-seated.
Orifice sizes are available in -4, -6, -8, -F, -G, -H, and -J with set pressures from 15 to 9612 psig
(depending on the orifice size).
Blowdown, up to approx. 20%, is readily controlled by adjusting the blowdown ring. FLOW SAFE valves
are typically shipped with 7% blowdown, allowing the valve to reseat bubbletight to approximately 93% of
the set point.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
2.3 INSTALLATION
Prior to installation, check that the set pressure on the nameplate is as required, and meets the system
requirements.
The F80 Series safety relief valve should be installed in the upright position per the figure on the next
page, as close as possible to the pressure source, to minimize pressure losses between the system and
the valve. This should be in accordance with accepted piping practices, as set forth in the API RP 520,
Part II, which recommends that inlet piping pressure losses should not exceed 3% of the set pressure
when the valve is flowing.
The valve discharge pipe should be sufficiently large so that backpressure does not exceed 10% of the
set pressure when relieving. Higher backpressures may cause the valve to chatter (rapid cycle), or affect
capacity.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
The F80 Series valves are not balanced against superimposed backpressure,
so that the set pressure will change one-for-one with the backpressure.
This means that for each 1 psi of backpressure, the set pressure will increase
by 1 psi. Refer to Section 4.3 for setting instructions. Check the valve
manufacturer’s nameplate(s) to determine if the valve was already
set with a correction for backpressure.
Make sure that the inlet piping / flanges have an opening equal
to or greater than the valve's inlet diameter. Make sure that there
are no obstructions like gaskets, fittings, etc., in the flow path to restrict the
flow or cause chatter. Also, misaligned piping connections may result in
leaks or induce stresses in the valve assembly that interfere with good
operation. Discharge stacks exposed to the elements should be configured
so as to avoid the accumulation of ice and snow.
If a block valve is used below the relief valve, it should be opened before
pressurizing the system. This block valve should be locked open during
normal system operation.
Use only the wrench flats on the valve inlet bushing, taking care not to
make any wrench marks, for tightening and installation. Do not wrench
on cast body or bonnet.
2.4 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.
Pressure can be applied to the valve as system pressure increases, or by opening the block valve (if
there is one) after the system has attained operating pressure. Verify the valve seat is leak-tight, in
accordance with Section 4.4.
The valve is now ready for service. Inspection and maintenance should be performed on a regular basis,
typically once a year, depending on the service conditions.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
1) Remove the valve from service, or adequately and safely block the incoming pressure before
disassembling the valve and performing maintenance.
NOTE: If bushing remains connected to the system piping, then the valve's internal
components (spring, washer, spindle) will fall out of the body as it is removed.
NOTE: Care must be taken in the handling of all items, particularly softgoods and nozzle
surfaces.
2) Inspect condition of nozzle seating surface and spindle guide surface inside body. Buff out or
polish any scratches that may interfere with a good seal, or replace part if necessary.
3) Apply Neverseez or DuPont Krytox (for oxygen service) to all straight threads.
4) Complete the seat assembly as follows:
a) F84: Insert the plastic seat, seat retainer, and retainer screw into the spindle. Install the
seat dry. Apply Loctite or Vibra-tite to retainer screw threads. As screw is tightened,
ensure that it meets firm resistance against the locking Heli-Coil in spindle.
b) F85: Insert the O-ring seat into the spindle. To ease seat installation, apply a light coat
of Dow Corning 33 or 55 (or Molykote) or Krytox (oxygen service). If fitted with a push-in
retainer, the retainer must fit tight as it is pushed in against the seat (tapered end inward).
If fitted with a set screw, install the screw in the top of the spindle. Newer models will
incorporate a retainer screw; apply Loctite or Vibra-tite to threads and tighten firmly.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
5) Assemble the spring washer(s), spring, and lift lever (if applicable) into the body.
6) Insert the spindle assembly into the body, making sure that it travels freely on the guide surface.
7) Screw the blowdown ring onto the bushing, to the same gap as previously recorded.
8) Position the bushing seal on the appropriate shoulder of the bushing.
9) Screw the bushing / seal / BD ring assembly into the body and tighten using the wrench flats.
10) Screw the PA screw, lock nut, and seal into the top of the body, with top of screw at previously
recorded value.
11) For lift levers, assemble the PA screw, lock nut, and seal around lifting rod. Then reassemble the
lift nut and jam nut to the previously recorded position. Assemble the lift lever housing and then
the bushing, seals, shaft, lift lever, and lock nut.
12) Screw the BD ring lock screw, lock nut, and seal into the back of the body.
13) The valve is now completely assembled and ready to be tested. See Section 4.0.
1) Remove the valve from service, or adequately and safely block the incoming pressure before
disassembling the valve and performing maintenance.
NOTE: If bushing remains connected to the system piping, then the valve's spindle will
fall out of the body as it is removed.
NOTE: Care must be taken in the handling of all items, particularly softgoods.
2) Inspect condition of nozzle seating surface and spindle guide surface inside body. Buff out or
polish any scratches that may interfere with a good seal, or replace part if necessary.
3) Apply Neverseez or DuPont Krytox (for oxygen service) to all straight threads.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
The following tests and adjustments are necessary for gas service valves: set pressure, reseat pressure
(blowdown), and seat tightness.
Where practical, a sufficiently large accumulator or pressure vessel should be used to read and set
blowdown. At a minimum a four (4) ft3 vessel is recommended for the -4 orifice to 4000 psig, -6 orifice to
1500 psig, and -8 to 600 psig. The supply pipe should have an ID equal to or greater than the valve's,
and should be no more than 10" long.
Seat Tightness: There should be ZERO leakage with inlet pressure at or below:
1) Remove the PA screw cap (if installed), loosen the PA screw lock nut, and screw the PA screw in
(clockwise) most of the way.
2) Increase the inlet pressure to the desired level, and then unscrew (counterclockwise) the PA
screw until the valve pops. Tighten down the lock nut and retest. Readjust as required.
3) To adjust blowdown:
a) Be sure the blowdown lock screw and lock nut are loosened.
b) Raise or lower the blowdown ring using a screwdriver through the valve outlet. Raising
the ring shortens blowdown; lowering the ring lengthens blowdown.
c) Re-tighten lock screw and lock nut after adjustments have been made. Tighten lock
screw firmly into blowdown ring knurls enough to prevent ring from turning.
4) Install and tighten down the PA screw cap. Test valve at least one more time to verify pop
pressure and blowdown.
1) After any repairs and set pressure adjustments, seat tightness should meet the criteria stated in
Section 4.2.
2) If the valve leaks after repair refer to the troubleshooting guide on Pages 12 & 13. Check for:
• Even seating between the spindle and bushing. With the F84’s, you should be able to
see a full circular line contact on the bushing surface. Make sure that the seat is installed
all the way in the spindle and that the retainer is tight.
• Foreign particles trapped between the seat and bushing. If found, they may have
damaged the seat, requiring that it be replaced.
• Scratches in the seating area of the bushing. On the F84, this is the top beveled surface,
near the ID. On the F85, this is the top crown on the bushing.
CAUTION: Do not operate a lift lever unless valve inlet pressure is at least 75% of nameplate set
pressure. Prepare the system as necessary to handle a discharge from the valve.
NOTE: The lift lever enables verification that the valve spindle and seat can open freely, but does
not allow set pressure to be verified.
1) With inlet pressure as stated in the above CAUTION, rotate the lift lever handle clockwise or
counterclockwise until it meets resistance.
INSTALLATION, OPERATION, &
MAINTENANCE MANUAL
2) Continue rotating the handle slowly until there is indication of flow through the valve. The F80
spindle should pop open following initial simmer and then quickly reclose, assuming inlet
pressure is below reseat pressure (normally 90-93% of set pressure). If the valve is opened
above its reseat pressure, the valve should stay open long enough to blow down to that pressure.
3) Return the lift lever handle to the down position. If flow through valve could not be achieved, or if
the valve does not close, have the valve disassembled and serviced by a qualified organization.
5.0 ACCESSORIES
1) Softgoods Kits