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Trillium Starflow P Series Installation, Operation & Maintenance Manual

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P series (Starflow
Installation, Operation, Maintenance Manual
"Copyright©2020, Trillium Flow Technologies France
Trillium Flow Technologies France ("the Company") is the owner of the copyright and confidential information in this document. The document may
contain information that is private, confidential or privileged. The document must not be copied in whole or part, in any form or by any means, and the
information in it must not be disclosed to any person, or used for any other purpose other than the specific purpose for which it is provided, without the
prior consent of the company".
)
™
P series (Starflow
)
™

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  • Page 1 “Copyright©2020, Trillium Flow Technologies France Trillium Flow Technologies France (“the Company”) is the owner of the copyright and confidential information in this document. The document may contain information that is private, confidential or privileged. The document must not be copied in whole or part, in any form or by any means, and the information in it must not be disclosed to any person, or used for any other purpose other than the specific purpose for which it is provided, without the prior consent of the company”.

  • Page 2: Table Of Contents

    P series (Starflow ™ Installation, Operation, Maintenance Manual TABLE OF CONTENTS SAFETY INSTRUCTIONS ........................1 SAFETY PRECAUTIONS ........................2 WARRANTY INFORMATION ......................3 TERMINOLOGY ..........................3 GENERAL ADVICE ..........................4 RESPONSIBILITIES ........................4 IDENTIFICATION PLATE ......................4 SPRING ............................ 5 STORAGE ..........................
  • Page 3 P series (Starflow ™ Installation, Operation, Maintenance Manual RECOMMENDATIONS......................23 9.1.1 OPERATION USING GAS ....................24 9.1.2 OPERATION USING LIQUID .................... 24 9.1.3 OPERATION USING STEAM.................... 25 SET PRESSURE AND ADJUSTMENT ON LINES ................ 25 9.2.2 ADJUSTING RING SETTING .................... 27 9.2.3 TEST PRESSURE CORRECTION ACCORDING TEMPERATURE (COLD ADJUSTMENT) ..

  • Page 4: Safety Signs And Labels

    P series (Starflow ™ Installation, Operation, Maintenance Manual SAFETY SIGNS AND LABELS Signs or labels are included throughout this document. These signs or labels communicate the following messages:  The level of hazard seriousness  The nature of the hazard ...

  • Page 5: Safety Instructions

    “Copyright©2020, Trillium Flow Technologies France Trillium Flow Technologies France (“the Company”) is the owner of the copyright and confidential information in this document. The document may contain information that is private, confidential or privileged. The document must not be copied in whole or part, in any form or by any means, and the information in it must not be disclosed to any person, or used for any other purpose other than the specific purpose for which it is provided, without the prior consent of the company”.

  • Page 6: Safety Precautions

    Never modify or change the valves, especially when they are under pressure. It is essential that you inform Trillium in ALL instances if any machining of parts is to be considered. Deviation from critical dimensions can adversely affect the performance of a safety valve.

  • Page 7: Warranty Information

    Trillium warrants that its products (including performance) and work will meet the specifications of the customer’s Purchase Order. If any issue arises whilst operating the product, the customer should inform Trillium as quickly as possible. A return to the original plant should then be considered in order for Trilium to inspect the product.

  • Page 8: General Advice

    It is important that all points of advice are followed closely and are implemented by suitably qualified personnel. Trillium disclaims all responsibility for maintenance operations which may be performed by persons who are either not suitably qualified or are not considered to be an accepted part the Trillium organisation.

  • Page 9: Spring

    The adjustment range of the spring must be within ± 5 % of the nominal value Spring data should be obtained from Trillium’s Sarasin-RSBD Aftersales Department. When requesting information, please quote the serial number which is shown on the valve identification plate.
  • Page 10 P series (Starflow ™ Installation, Operation, Maintenance Manual  It is recommended that the safety valves are stored in a clean and dry environment, protected from weather conditions, the ingress of sand, dust, or any other solid particles or foreign matter. ...

  • Page 11: Handling

    P series (Starflow ™ Installation, Operation, Maintenance Manual HANDLING According to procedure 20.02, the safety valve should be handled very carefully at all times whether they are in the packed or unpacked condition. The valves should never be subjected to any impact or striking, either directly or indirectly through the packaging.

  • Page 12: Features And Nomenclatures

    P series (Starflow ™ Installation, Operation, Maintenance Manual STARFLOW Inlet x Outlet Size Combinations (in.) Orifice Area (sq. in) Inlet Outlet Actual 0.881 1.457 2.097 3.284 4.093 4.987 7.215 12.91 17.81 28.87 46.75 70.10 Flange Flange 0.785 1.287 1.838 2.853 3.6 4.34 6.38 11.05 Evaluation...
  • Page 13 P series (Starflow ™ Installation, Operation, Maintenance Manual Part SPARE Part Name N° PARTS Body Bonnet Nozzle Adjusting ring Guide Disc Spindle Adjusting screw Adjusting screw locknut Retaining ring Balanced Bellows Adjusting ring screw Bonnet stud Bellows plate Body/bonnet gasket Bonnet/cap gasket Adjusting ring screw gasket...

  • Page 14: Installation

    P series (Starflow ™ Installation, Operation, Maintenance Manual 7. INSTALLATION GENERAL DANGER WARNING CAUTION CAUTION Never face the outlet of Be aware that the Protect against high Helmets and gloves a valve when it is environment might be noise levels which must be worn to discharging as this may extremely hot.

  • Page 15: Outlet Piping

    P series (Starflow ™ Installation, Operation, Maintenance Manual In order to avoid chattering, the following recommendations should be followed to reduce pressure drop: Une réduction concentrique arrondie de l'installation créera un minimum de turbulence.  A rounded concentric reducer from the installation will create a minimum of turbulence.

  • Page 16: Recommandations

    P series (Starflow ™ Installation, Operation, Maintenance Manual Separate manifolds must be installed for operation with both low and high pressures. If the safety relief valves only operate consecutively, the relevant manifold dimensions must be at least equal to those of the safety relief valve with the greatest flow rate. Great care must be taken with the calculations determining interdependent operation between the safety relief valves, and the possibility of their being open at the same time.

  • Page 17: Maintenance

    P series (Starflow ™ Installation, Operation, Maintenance Manual DA (mm) DB (mm) DC (mm) 8. MAINTENANCE DANGER CAUTION CAUTION Never face the outlet of a Any person who is Helmets and gloves must be valve when it is discharging working on the valve worn to prevent any injures as this may result in serious should be aware of any...

  • Page 18: Disassembly

    P series (Starflow ™ Installation, Operation, Maintenance Manual If the safety relief valve includes a relieving device, it can be necessary to plan periodic tests of • manoeuvrability according the inspection department recommendation. At least one test a year is recommended. If the safety valve is installed on a compressible fluid, a simmer would warn about a leakage.
  • Page 19 P series (Starflow ™ Installation, Operation, Maintenance Manual Unscrew nut (50) and take off bonnet stud (35) • I n s t a l l a t i o n , O p e r a t i o n , M a i n t e n a n c e M a n u a l...
  • Page 20 P series (Starflow ™ Installation, Operation, Maintenance Manual Remove the bonnet (2), the bearing (104) (if there’s one) the spring and washers (46-45) and the • stem (12) Check that the spring remains cylindrical by rolling it on a flat surface. If the spring is •...
  • Page 21 (7), followed by the nozzle (6), for sizes above 4”, the use of a special tool can be required which may be ordered from Trillium Flow Technologies. I n s t a l l a t i o n , O p e r a t i o n , M a i n t e n a n c e M a n u a l...
  • Page 22 If they are damaged, then they must be relapped or remachined. Any machining must be subject to the tolerances defined by Trillium Flow Technologies. Any machining subsequently outside tolerances will not give correct operation or performance. The Trillium Flow Technologies Sales Department remains at your disposal for any other information you may require concerning tolerances.

  • Page 23: Lapping

    This operation requires specific skills and experience and may be carried out only by qualified personnel. If such essential skills are not available, the valve should be returned to Trillium Sarasin-RSBD or one of its identified accredited partners to be reconditioned (Your nearest Trillium representative should be contacted in such an occurrence).
  • Page 24 P series (Starflow ™ Installation, Operation, Maintenance Manual Disc • Use the disc lapping block • Laid down flat on the work table Cover it with a slight coat of lapping paste • Hold firmly then apply the bottom face of the valve disc (seat) •...
  • Page 25 P series (Starflow ™ Installation, Operation, Maintenance Manual NOZZLES AND DISCS MAXIMUM REPAIR DIMENSIONS The maximum repair dimension must not go below 0.1 mm for all orifices. If the repair dimension is out of the tolerance, the disc or nozzle must be replaced. I n s t a l l a t i o n , O p e r a t i o n , M a i n t e n a n c e M a n u a l...

  • Page 26: Assembly

    P series (Starflow ™ Installation, Operation, Maintenance Manual ASSEMBLY 8.3.1 RECOMMANDATIONS The safety relief valve should be reassembled with a set of new gaskets. Parts must be absolutely clean before assembly. Trim parts: nozzle, disc, disc-holder, guide and adjusting ring must be thoroughly degreased and dried before reassembly. Check that there are no burrs on these parts.

  • Page 27: Testing

    P series (Starflow ™ Installation, Operation, Maintenance Manual M92x2 50.0 M92x3 50.0 M118x2 50.0 M165x2 50.0 M205x2 50.0 9. TESTING RECOMMENDATIONS Safety valve setting and adjustment must be executed on the appropriate test bench (valves on liquid service should be adjusted on a liquid bench). Flanging must be homogeneous and have at least 3 tightening points.

  • Page 28: Operation Using Gas

    P series (Starflow ™ Installation, Operation, Maintenance Manual 9.1.1 OPERATION USING GAS The safety relief valve must be adjusted using clean, dry air on nitrogen. 9.1.2 OPERATION USING LIQUID The safety relief valve is adjusted using clean water with a corrosion inhibitor. Do not use oil or similar fluids.

  • Page 29: Operation Using Steam

    2 p30. NOTE: For these tests, it is recommended that the fluid used be the same as that used by Trillium Flow Technologies. The specification of this fluid is shown on the test certificate supplied with all equipment.
  • Page 30 The set pressure adjustment must not be above ± 5 % of the original nameplate set pressure. Any adjustment beyond this limit, please consult Trillium so that we may check the possibility. Once the adjustment is acceptable, screw the locknut (15) into place.

  • Page 31: Adjusting Ring Setting

    P series (Starflow ™ Installation, Operation, Maintenance Manual Seat tightness area (mm2) - To be used for set pressure Inlet class Orifice 1500 2500 117,86 117,86 117,86 241,90 241,90 241,90 241,90 241,90 241,90 241,90 241,90 241,90 330,06 330,06 330,06 339,79 339,79 339,79 510,71...

  • Page 32: Test Pressure Correction According Temperature (Cold Adjustment)

    P series (Starflow ™ Installation, Operation, Maintenance Manual SOUPAPE TYPE STARFLOW NOMBRE DE CRANS / NUMBER OF NOTCHES ORIFICES / OPENINGS VAPEUR * LIQUIDE STEAM * LIQUID May be adjusted in-situ.  For set pressure higher than 5 bar, the ring down to maximum. ...

  • Page 33: Tightness Check Using Gas

    P series (Starflow ™ Installation, Operation, Maintenance Manual TABLE 2 Operating temperature °C (°F) Vapeur Gaz ou liquide Yoke + Open Closed Bonnet + cooling Closed B.+ Closed Bonnet From Bonnet Bonnet cooling spool extension Bellows -196 (-320) 66(150) 67(151) 315(600) 1.5% 1.5%...
  • Page 34 P series (Starflow ™ Installation, Operation, Maintenance Manual N.B.: For steam valves with yoke (P5), test criteria is as follows: a) on an air test bench : acceptable bubble rate according to above table 3 divided by 2 (outlet flange sealed and body filled with water).
  • Page 35 P series (Starflow ™ Installation, Operation, Maintenance Manual I n s t a l l a t i o n , O p e r a t i o n , M a i n t e n a n c e M a n u a l...

  • Page 36: Tightness Check Using Liquid

    It is sometimes necessary to modify the set pressure of a Sarasin-RSBD safety relief valve. In this case, Trillium Flow Technologies Sales Department should be consulted in order to find out whether or not the spring needs to be changed and whether the new setting is compatible with the characteristics of the valve concerned.

  • Page 37: Calibration Check With Online Testing Device

    It is sometimes required to check for the calibration of the valve at the commissioning stage or periodically. Such activity can be achieved using a specific online testing electronic device. Trillium can arrange to perform such activity. The use of such a method instead of the lifting of the disc under operating pressure allows to prevent certain risks such a valve seat damages, superheater tube damages.

  • Page 38: Maintenance

    P series (Starflow ™ Installation, Operation, Maintenance Manual Once the valve is correctly adjusted and all the tests have passed succesfully, it is necessary to seal the valve in compliance with most of the international regulations. This prevents changing the adjustments. It allows also to identify the last intervening organisation (manufacturer, service centre or end-user) that will be responsible for the last adjustments.

  • Page 39: Troubleshooting

    Change the disc-holder and the guide chattering The disc does not Upstream capacity lower Contact Trillium to find the possible go to the rated lift than the rated valve capacity alternative according your application (smaller valve, modulating POPRV, etc …) Simmer Adjusting ring too low.

  • Page 40: Spare Parts

    After prolonged and intensive use or in exceptional working conditions, a safety valve will need to be serviced or overhauled. Such work must be carried out by a skilled technician. The Trillium Group offers trainings and education programmes to cover all areas of maintenance and repair. Please consult your nearest Trillium representative for more details.

  • Page 41: Dismantling

    14. GENUINE PARTS The use of spare parts which are not obtained from a genuine Trillium source or a Trillium accredited company exposes product, plant and personnel to high risk.Les pièces Sarasin-RSBD ™ sont conçues et fabriquées pour être utilisées uniquement dans les conceptions de soupapes Sarasin-RSBD ™.
  • Page 42 P series (Starflow ™ Installation, Operation, Maintenance Manual J - M Position 1) Position 10) Flanges finish P: STARFLOW P3 / P4 / P5 - M** Inlet or outlet smooth finish S: STARFLOW S5 Inlet flange finish RJ (according ASME B16.5) - E2 ‘’...
  • Page 43 Trillium Flow Technologies France Rue Jean-Baptiste Grison – ZI du Bois Rigault 62880 Vendin-le-Vieil - France Tel: +33 3 21 79 54 50 Fax: +33 3 21 28 62 00...

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