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Reyco Series R, RB, & RSDirect Spring Acting Safety Relief Valves

for Gas, Liquid, and Steam Service

API 526

Maintenance Manual

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Maintenance Manual Reyco Series R, RB, & RS

Direct Spring Acting Safety Relief Valves for Gas, Liquid, and Steam Service

API 526



Reyco – R Series Maintenance Manual Reyco – R Series Maintenance Manual4 Reyco – R Series Maintenance Manual Reyco – R Series Maintenance Manual

About Reyco Valve Division

The Reyco line of direct spring acting pressure relief valves utilizes sound engineering principles and undergoes thorough testing and continuous quality control in manufacturing. These measures ensure that Reyco valves deliver the precision, durability, and value our customers expect and demand.

For more information about the complete line of products and services by Reyco Valve Division, visit our web site or contact the sales representative nearest you.

www.reycovalve.com

Reyco Valve Division 6614 Dixie Drive Houston, TX 77087

T 713.845.1500 F 713.845.1515 E [email protected]

Reyco valves are built to established industry standards and codes.



Reyco – R Series Maintenance Manual Reyco – R Series Maintenance ManualReyco – R Series Maintenance Manual Reyco – R Series Maintenance Manual 5

Maintenance Manual for Direct Spring Acting Pressure Relief Valve

R, RO, RB, RBO, RS, and JR Series

Table of Contents

General Specifications ................................................................................................... 4

Reyco Valve Diagrams R Series ................................................................................................................... 5 RB Series ................................................................................................................ 6 RS Series ................................................................................................................. 7

Model Number Guide ................................................................................................... 8Installation ..................................................................................................................... 9Maintenance .................................................................................................................. 11Disassembly ................................................................................................................... 12

Part Reconditioning Part Maintenance .................................................................................................... 14 Re-Machining Parts ................................................................................................ 15 Figure 6: Minimum Nozzle Dimensions ............................................................... 16 Disc Holder Conversion ......................................................................................... 17 Bellows Conversion ................................................................................................. 18 O-Ring Conversion ................................................................................................ 19

Reassembly .................................................................................................................... 20

Setting and Testing Set Pressure Adjustments ........................................................................................ 22 Blowdown Adjustment ........................................................................................... 23 Leakage Testing ...................................................................................................... 24




General Specifications

Model Identification

Models covered in this maintenance manual are described below. Refer to the R Series Catalog information for more details or contact your local factory representative at 713.845.1500.

R Series General purpose valves which are ASME Section VIII certified for steam, air/gas, and liquid service.

RO Series Soft seat relief valve design for non-chattering, stable performance. ASME VIII certified.

RB Series Bellows version of the R series where back pressures (constant or variable) exists. ASME Section VIII certified.

RBO Series Soft seat relief valve design and balanced bellows version of the R series for tight seat seals with back pressure conditions. ASME Section VIII certified.

RS Series Exposed springs typically used in ASME Section VIII certified steam service.

JR Series Bolt on steam jacket for preserving vale temperature in body. For use on fluids to prevent solidification of the flowing viscous fluids.

Ordering Information

When you call us to order your part, be sure you have the following valve information handy:

Quantity•Reyco Model Designation•Inlet/Outlet Flange Rating and Facing•Construction Material•O-Ring Seat Seal Specifications •(See Material and Pressure/Temperature limit charts in our catalog)Set Pressure•Back Pressure (Constant or Variable)•Maximum Inlet Temperature•Service •(For gas/vapor service, know the molecular weight or specific gravity; for liquid service, know the specific gravity and viscosity)Required Capacity•Accessories•Code Requirements•

The name of this product informs us of its importance. Without the use of safety relief valves, considerable danger exists. Reyco valves are built to withstand long periods of trouble free service. Under normal operating conditions and with correct maintenance procedures, your valve should provide many years of safe and dependable operation. We must consider that, although the valve is rugged in construction, it actually is a precision device. Since safety depends on correct operation, the valves described herein have been National Board tested for capacity in accordance with Section VIII (Unfired Pressure Vessels) of the ASME Boiler and Pressure Vessel Code (steam, air/gas, and liquid services).




Reyco Valve Diagram

R Series

Pipe Plug

Spring

Bonnet

Top Spring Step

Cap

Bottom Spring Step

Nozzle

Guide

Disc

Adjusting Ring

Compression Nut

Compression Screw

Stem

Point

Body

Stud

Stud Nut

Disc Holder




Reyco Valve Diagram

RB Series

Spring

Bonnet

Top Spring Step

Cap

Bottom Spring Step

Point

Nozzle

Guide

Disc Holder

Disc

Adjusting Ring

Compression Nut

Compression Screw

Stem

Bellows

Body

Stud

Stud Nut




Reyco Valve Diagram

RS Series

Cap

Compression Nut

Compression Screw

Stem

Nozzle

Guide

Disc

Adjusting Ring

Point

Body

Stud

Stud Nut

Disc Holder

Spring

Bonnet

Top Spring Step

Bottom Spring Step




R Series Model Number Guide

R 1 0 D S1 (Model number continued on next page)

Valve TypeR- Conventional Valve, Enclosed Spring RO Conventional Valve, Enclosed Spring, O-ring Seat (see note 1) RB Balanced Bellows, Enclosed Spring RBO Balanced Bellows, Enclosed Spring, O-ring Seat (see note 1)RS Open Yoke, Exposed Spring (see note 2) JR Conventional Valve, Enclosed Spring, Steam Jacketed Body JRB Balanced Bellows, Enclosed Spring, Steam Jacketed Body

Inlet/Outlet Connections (RF connections are standard) 1 ANSI Class 150 × 150 5 ANSI Class 600 × 150 (see note 3) 2 ANSI Class 300LW 7 ANSI Class 900 × 150 or ANSI Class 900 x 300 (see note 4) (285 psig max) × 150 8 ANSI Class 1500 × 300 or ANSI Class 1500 x 150 (see note 5) 3 ANSI Class 300 × 150 9 ANSI Class 2500 × 300

Standard Materials Temperature Range 0 -20°F to +450°F [-29°C to +232°C] CS Body, CS Bonnet, Chrome Vanadium Spring (RS Series +750°F [+399°C] max.) 2 +450°F to +800°F [+232°C to +427°C] CS Body, CS Bonnet, Alloy Spring 3 +800°F to +1000°F [+427°C to +538°C] Alloy Steel Body, Bonnet, & Spring

Standard API 526 Orifice Sizing D 0.110 in2 J 1.287 in2 P 6.38 in2

E 0.196 in2 K 1.838 in2 Q 11.05 in2

F 0.307 in2 L 2.853 in2 R 16.00 in2

G 0.503 in2 M 3.60 in2 T 26.00 in2

H 0.785 in2 N 4.34 in2

Materials and Trim (see note 6) S1 316 SS Disc, Nozzle, CS Body, Bonnet, and Vanadium Spring S2 316 SS All Trim S3 316 SS All Trim plus Body, Bonnet, and Cap S4 316 SS Entire Valve S5 316 SS All Parts below Bellows

H1 Hastelloy® C Disc and Nozzle H2 Hastelloy® C All Trim H3 Hastelloy® C All Trim plus Body, Bonnet, and Cap H4 Hastelloy® C Entire Valve H5 Hastelloy® C All Parts below Bellows

M1 Monel® Disc and Nozzle M2 Monel® All Trim M3 Monel® All Trim plus Body, Bonnet, and Cap M4 Monel® Entire Valve M5 Monel® All Parts below Bellows M6 Monel® Body Only

L1 Low Temperature Trim -21°F to -75°F [-29°C to -59°C] L3 Low Temperature Trim -76°F to -400°F [-60°C to -240°C] SG NACE MR-01-75 (Carbon Steel) SS NACE MR-01-75 (Stainless Steel)




R Series Model Number Guide

Caps and Accessories18 Bolted Cap without Gag19 Bolted Cap with Gag20 Screwed Cap without Gag21 Screwed Cap with Gag22 Open Lift Lever without Gag23 Open Lift Lever with Gag24 Packed Lift Lever without Gag25 Packed Lift Lever with Gag

Design Revision – Unbalanced D and E Bellows A Standard Valve B Special Inlet/Outlet requirement (i.e. 2.5 inch or RTJ Inlet/Outlet) Z All other custom valves

Service J ASME Section VIII Liquid K ASME Section VIII Gas and Vapors L ASME Section VIII Steam (Limited to 2900 psig [200 barg]) M Non Code Liquid N Non Code Gas, Vapor P Non Code Steam

Spring Material B Inconel X750 C Chrome Vanadium G 316 Stainless Steel

Set Pressure, i.e. 0008 = 8 psig 0015 = 15 psig 0125 = 125 psig 6000 = 6000 psig

NotesThe standard soft seat material in Models RO and RBO is Viton®.1. Model RS is limited to ANSI Class 150 through ANSI Class 600 2. inlet only, standard CS or Alloy Steel Body and Yoke.For T-orifice valves, Inlet/Outlet rating code ‘5’ is an ANSI 300 3. × 150, not ANSI 600 × 150.Orifices D through G have ANSI Class 300 Outlets. Orifices H 4. through P have ANSI Class 150 Outlets.Orifices D through K have ANSI Class 300 Outlets. Orifice L 5. has an ANSI Class 150 Outlet.Duplex and other materials available upon request.6.

20 A K C 0200




Correct installation will always provide the best and most trouble free operation since each Reyco safety relief valve is set, adjusted, and tested by the factory authorized facility. More seat damage results from dirt and foreign material than any other cause. Flange protectors provided on the valve should not be removed until the valve is to be installed. When storage is required, the valve should be stored in “as-received condition” in a clean, dry environment. All valve openings should be covered.

When ready for installation, remove the flange protectors and any particles which may have entered the inlet and outlet. The valve should be installed in an upright position as close as possible to the vessel or line it is to protect. Piping to and from the valve should not be smaller than the valve openings and gaskets should be centered and large enough to permit full flow. All bolting to the valve flanges should be tightened evenly. The valve inlet and outlet piping should be as short and direct as possible.

Outlet piping should be properly supported to prevent excess strain on the valve body. (We recommend drip pan elbows or flexible pipe sections in discharge lines on steam service.) It is good practice not to allow condensate to drain back to the valve. All R, RB, & RS Series pressure relief valves are manufactured with drain connections in the bodies.

It is recommended that the difference between operating pressure and valve set pressure be at least 10% of the valve set pressure or 5 psig, whichever is greater. This will provide better seat tightness and longer seat life.

Installation




Maintenance

Periodic planned maintenance will ensure longer and better performance from any product. Always be careful during any phase of maintenance since carelessness can be very destructive and costly. Maintenance of the Reyco R, RB & RS Series valves should include, but not be limited to, the following:

1. Pretest Testing of the valve prior to disassembly to determine opening points, blowdown, and seat tightness. Pretest results will assist maintenance planning in determining service schedules. On RB Series (bellows valve), check the bellows by applying air pressure to the discharge (outlet) and check the bonnet vent hole for leakage. Leakage out of the vent hole is a sign the bellows is ruptured and needs to be replaced.

2. Disassembly Inspect parts to determine extent of required repairs.

3. Repairs Cleaning, reconditioning, replacement, lapping and minor machining of parts.

4. Assembly Assembly of the valve and valve components (parts).

5. Valve Testing Set valve to the nameplate set pressure and check seat tightness.

Changing the set pressure may require a different spring. Changes from pressure setting less than 25psi to high pressure settings may require disc holder modification. Changing service media does not require changing of any parts. Consult the manufacturer’s representative.

Maintenance of the Reyco Model R & RB safety relief valves should be performed by qualified repair personnel at facilities holding National Board Valve Repair Stamps (V.R.).

Table 1: Special Tools

Orifice Required Tools

Seat Removal(Nozzle)

D, E, F, G, & 1½" H

Adjustable pin spanner wrenchPin diameter: 1/4"Pin length: 1/4"

2" H, J, K, L, M, N, P, Q, R, & T Pull down driving tool

Bellows Removal

D, E, F, G, H, J, K, L, & M

Combination wrench used on bellows nut

N & PAdjustable pin spanner wrenchPin diameter: 1/4"Pin lenght: 1/4"

Q, R, & TAdjustable pin spanner wrenchPin diameter: 3/8"Pin lenght: 1/4"

NotesNozzle lapping blocks are available upon request. Reference orifice size 1. when ordering.

Table 2: Recommended Spare Parts

Orifice Valve SeriesR RO RB RBO RS

1 Disc X X X2 Stem X X X X X3 Nozzle X X X X X4 Guide X X X X X

5 Compression Screw X X X X X

6 Gasket Kit X X X X X7 Disc Holder X X X X X8 Bellows X X

9 Disc O-ring Assembly X X

NotesCompression screw lengths may change with set pressure change. Always 1. give valve set pressure when ordering compression screws.




Disassembly

1. Remove the seal wire from the adjusting ring pin. Then remove the adjusting ring pin by turning counter-clockwise. Placing a flat head screwdriver through the ring pin hole, count the number of notches as the ring is turned counter-clockwise until it contacts the disc holder. Record the number of notches. This will allow you to reposition the adjusting ring to the original setting during valve re-assembly.

2. Removal of the valve cap: The model R & RB has four cap options.

a. Screwed Cap: Remove seal wire and turn counter-clockwise to remove cap.

b. Bolted Cap: Cut seal wires, remove bolts, and lift cap off bonnet.

c. Packed Lift Lever: Remove the seal wire. Remove the bolts and lift the cap upward and toward the front of the valve (outlet). The lever may have to be moved backward or forward slightly to free it from the stem adjusting nut.

d. Open Lift Lever: Remove the seal wires; remove the yoke pin and yoke. Loosen all cap set screws enough to lift the cap from the bonnet.

3. Lifting disc only supplied with open lever and packed lever caps. Remove the jam nut and turn the lifting disc counter-clockwise to remove it from the stem. To remove the jam nut, turn the locknut counter-clockwise while holding the jam nut.

Disassembly of the Reyco R & RB safety relief valves for inspection and maintenance. Proceed as follows:

4. Before removing the compression screw it is suggested that a measurement be taken from the top of the bonnet to the top of the compression screw. This will enable the compression screw to be replaced in approximately the same position. Loosen the locknut and release the spring compression by turning the compression screw counter-clockwise.

5. Remove the bonnet nuts by turning counter-clockwise and lift the bonnet up over the stem.

6. Remove the spring, spring steps, and the stem.

7. Lift the point and disc assembly out of the valve body. The guide will be attached to the point and disc assembly. Be careful with the RB Series valves so as not to damage or distort the bellows assembly.

8. To remove the guide from the point and disc holder assembly, lift the point. While holding the disc holder assembly and guide, turn the point counter-clockwise until the point and guide are free of the disc holder assembly.

9. The RB Series valve bellows assembly is attached to the disc holder by threads. To remove the bellows, secure the disc holder in a vise (soft jaws) and turn the bellows nut counter-clockwise. Never try to remove the bellows by turning the bellows or the bellows flange. The bellows nut is hex, up to and including the M Orifice. Above the M Orifice the bellows nuts is round and has holes for standard spanner wrenches. In both cases the nut is large than the bellows. Always be careful when handling the bellows to avoid damage to it (Bellows Assembly drawing Figure 1).




10. The disc can be removed from the disc holder by placing the disc holder down on a flat surface and inserting a screwdriver in each disc holder hole so that they rest on top of the disc. Pull up evenly on the screwdrivers to cause the disc to snap out of the holder as the disc retaining ring is compressed. Be careful when using the screwdrivers since the top of the disc is actually a built-in spare seat (Figure 2). O-ring disc: O-rings and retaining plates are held to the disc by a retaining screw. To remove the O-ring, secure the disc in a soft jaw vise and remove the retaining screw by turning it counter-clockwise (Figure 3).

11. The adjusting ring can be removed by turning it counter-clockwise.

12. To remove the nozzle from the body, secure the body in a vise, and grip the nozzle raised face OD with the strap wrench or pipe wrench with brass jaws and turn counter-clockwise. It is always good practice to allow penetrating oil to soak the threaded area before trying to remove nozzle. As an alternative, secure the nozzle raised face in a vise with soft jaws. Place pipe in the outlet (do not touch the nozzle) and turn the body counter-clockwise.

13. In valve disassembly, remove gaskets and disc retaining ring carefully to avoid their loss. Note: Refer to Figure 7 to verify correct disc holder for low pressure (up to 24 psi) or standard pressure (25 psi and above).

Disassembly

Retaining Ring

AdjustingRing

Nozzle

Ring Pin

DiscBellows Gasket

Holder Insert

Bellows Assembly

BellowsFlange

Disc HolderBellows Nut

Point

Guide

GuideGasket

RetainingScrew

O-ring

Retaining Ring

AdjustingRing

NozzleRing Pin

Retaining Plate

Disc

HolderInsert

RetainingRing

DiscHolder

Disc

(Screwdriver)(Screwdriver)

Figure 1

Figure 2

Figure 3




Part Reconditioning

Part Maintenance

Valve Cleaning

Clean valve parts using solvents or abrasives. Glass bead and sandblasting are acceptable. Considerable care should be taken to protect valve seating surface and threaded parts when cleaning with abrasives and/or sandblasting.

Disc and Nozzle Seat Lapping

The R & RB Series disc is supplied with seating surfaces on both sides. Should one side be damaged the other side can be used after lapping. Lapping of the disc is done by hand or machine. Hand lapping may be accomplished using a ring lap or lapping plate. When using a ring lap, be sure the lap covers the entire seating surface. Apply a thin, even amount of compound to the ring lap and place it on the disc. Begin lapping in an oscillating motion (back and forth) applying light, even pressure, careful not to rock the piece. Lap part for 1-2 minutes. Remove ring lap and clean both parts thoroughly. Continue lapping sequence until disc seat surface exhibits a gray shadow across entire surface.

Polishing is accomplished in much the same way with a few exceptions. Use a different ring lap for polishing. This will allow the seat to be polished quicker. Apply a thin even amount of polishing compound to the ring lap; begin polishing using a slow, oscillating motion. Continue polishing until the ring lap begins to drag on the seat. Remove and clean both surfaces. Repeat polishing sequence until the seat exhibits a mirror-like finish across the entire seat. Lapping plates are used in much the same manner as a ring lap, except the seating surface of the disc is lapped on the plate in a figure eight motion as shown in Figure 4. The nozzle seat for R & RB Series valve may be lapped using the same methods as the disc, but note that the 2 ½ degree angle on the nozzle seat has a seat width requirement. (Refer to Figure 6.) Seat width should be measured after lapping is complete. The seat width requirement does not apply to RO or RBO (O-ring) design nozzle seats because they are machined flat. Machine lapping offers a fast precise method for lapping several parts at the same time.

Lapping compounds vary from coarse to very fine. Generally a medium compound is used first, then a very fine compound to finish the piece. Clean the plate thoroughly after each different compound is used.

Coarse compounds are to be used only when removing deep scratches and must always be followed by finer grades. It is advisable to have different plates for different compounds.

The important considerations for good results are:1. Cleanliness of lapping plates, parts and

compounds.2. Flat surface for a base.3. Flat lapping plate.4. Light and correct lapping motion (no rocking

of piece).5. Change lapping compounds frequently.

Recommended Lapping Compounds:#400 – #800 Medium #1000 – #1200 Fine 1 – 5 Micron polishing compound

Coarse compounds may be obtained. Be aware, when using these compounds deeper scratches may occur.

Figure 4

LappingRing with

OscillatingMotion

Lapping Plate withFigure 8Motion




Part Reconditioning

Re-machining Parts

Reconditioning Nozzle Seat

Warning: It is not recommended to re-machine the nozzle seating surfaces because this may result in alteration of the design geometry. Parts damaged to the extent that the surface cannot be restored by lapping should be replaced.

When re-machining has to be done, in lieu of replacement as recommended, the following must be adhered to (Refer to Figure 6 on page 16 for surface description):

1. Remove the nozzle from the body and secure the nozzle in a four jaw (independent) chuck. Use a soft material between the nozzle flange and the chuck jaws to protect the nozzle flange surface. Using a dial indication, align both E and F surfaces to within +/- .001" of each other.

2. As an alternative to Step 1, with the nozzle still in the body, secure the valve inlet in a four jaw (independent) chuck. Using a dial indicator, indicate roundness of the nozzle bore with the roundness of the guide surface of the body. Both areas are to be within +/- .001" of each other. Replace nozzle in body and check for the concentricity.

3. Once the nozzle is aligned in the four jaw chuck, machine seat surface at 2 ½ degree angle until damaged areas are removed, or until minimum dimension C is reached, at which time the nozzle must be replaced.

4. Restore A and B dimensions shown in Figure 6.5. Do not change any diameters.6. Lap seat lands of nozzle to dimension D as shown

in Figure 6 and illustrated in Figure 5.

Reconditioning Disc Seat

Machining is not recommended on the R Series disc. Once both sides are damaged beyond repair by lapping, the disc should be discarded.

Figure 5

2 ½°

Seat Width

DISC

DISC HOLDeR

NOzzLeADjuSTINGRING




Part Reconditioning

Figure 6: Minimum Nozzle Dimensions

NotesIf you have a RTJ faced nozzle, contact your local factory representative at 713.845.1500 to verify your minimum nozzle dimensions.1. The blank space on the above nozzle part numbers will normally show a three digit material code.2.

Figure 6: Minimum Nozzle DimensionsOrifice Nozzle Part Number Nozzle Seat Dimensions (inches)

A B Min. C D Seat Width

D REY-009-____-0118 0.015 – 0.020 3/64 3 7/8 0.012 – 0.022D REY-009-____-0119 0.015 – 0.020 3/64 3 7/8 0.012 – 0.022D REY-009-____-0120 0.015 – 0.020 3/64 4 9/16 0.012 – 0.022

E REY-009-____-0121 0.015 – 0.020 3/64 3 3/8 0.012 – 0.022E REY-009-____-0122 0.015 – 0.020 3/64 3 7/8 0.012 – 0.022E REY-009-____-0123 0.015 – 0.020 3/64 4 9/16 0.012 – 0.022

F REY-009-____-0124 0.015 – 0.020 3/64 3 15/16 0.012 – 0.022F REY-009-____-0125 0.015 – 0.020 3/64 4 9/16 0.012 – 0.022

G REY-009-____-0126 0.015 – 0.020 3/64 3 15/16 0.012 – 0.022G REY-009-____-0127 0.015 – 0.020 3/64 5 0.012 – 0.022

H REY-009-____-0128 0.015 – 0.020 3/64 3 15/16 0.015 – 0.025H REY-009-____-0129 0.015-0.020 3/64 3 15/16 0.015 – 0.025H REY-009-____-0130 0.015 – 0.020 3/64 4 7/8 0.015 – 0.025

J REY-009-____-0131 0.020 – 0.025 1/16 4 3/16 0.015 – 0.025J REY-009-____-0213 0.020 – 0.025 1/16 4 3/16 0.015 – 0.025J REY-009-____-0214 0.020 – 0.025 1/16 4 9/16 0.015 – 0.025J REY-009-____-0134 0.020 – 0.025 1/16 5 7/16 0.015 – 0.025

K REY-009-____-0135 0.020 – 0.025 1/16 4 3/4 0.015 – 0.025K REY-009-____-0136 0.020 – 0.025 1/16 5 7/16 0.015 – 0.025K REY-009-____-0137 0.020 – 0.025 1/16 6 3/8 0.015 – 0.025

L REY-009-____-0138 0.020 – 0.025 1/16 4 3/4 0.025 – 0.035L REY-009-____-0139 0.020 – 0.025 1/16 5 0.025 – 0.035L REY-009-____-0140 0.020 – 0.025 1/16 5 3/4 0.025 – 0.035

M REY-009-____-0141 0.025 – 0.030 1/16 5 0.025 – 0.035M REY-009-____-0142 0.025 – 0.030 1/16 5 3/4 0.025 – 0.035

N REY-009-____-0143 0.025 – 0.030 5/64 5 3/4 0.025 – 0.035

P REY-009-____-0144 0.025 – 0.030 5/64 5 1/8 0.025 – 0.035P REY-009-____-0145 0.025 – 0.030 5/64 6 7/8 0.025 – 0.035

Q REY-009-____-0146 0.030 – 0.035 3/32 6 7/8 0.037 – 0.047

R REY-009-____-0147 0.030 – 0.035 3/32 6 7/8 0.037 – 0.047

T REY-009-____-0148 0.030 – 0.035 1/8 6 7/8 0.050 – 0.062

B 2° – 3°

A D

NOzzLe

SeAT AReA DeTAIL

C Min

e

F




Part Reconditioning

Disc Holder Conversion

The R series has different disc holders, depending on the valve set pressure. If the set pressure is going to be changed from below 25 psi to above 25 psi, then the disc holder will need to be replaced. The set pressure limits are shown in Figure 7. Low pressure disc holders should be ordered from a Reyco representative. When this is not practical, machining a low pressure disc holder from a standard disc holder may be accomplished using the dimensions shown in Figure 7.

Caution: Converting the disc holder should always be avoided if possible.

Figure 7: Disc Holder Conversion Chart

Orifice Low Pressure Disc Holder

Part Number

Standard Disc Holder

Part Number

Lip Dimensions (inches)

A B

D REY-006-____-0086 REY-006-____-0035 0.853 1/32

E REY-006-____-0087 REY-006-____-0036 0.853 1/32

F REY-006-____-0088 REY-006-____-0037 1.064 1/32

G REY-006-____-0089 REY-006-____-0038 1.242 3/64

H REY-006-____-0090 REY-006-____-0039 1.535 3/64

J REY-006-____-0091 REY-006-____-0040 1.953 1/16

K REY-006-____-0092 REY-006-____-0041 2.326 1/16

L REY-006-____-0093 REY-006-____-0042 2.871 1/16

M REY-006-____-0094 REY-006-____-0043 3.200 1/16

N REY-006-____-0095 REY-006-____-0044 3.535 1/16

P REY-006-____-0096 REY-006-____-0045 4.285 1/16

Q REY-006-____-0097 REY-006-____-0046 5.627 3/32

R REY-006-____-0098 REY-006-____-0047 6.617 3/32

T REY-006-____-0099 REY-006-____-0048 8.447 3/32

CAST DISC HOLDeR

High pressure above 25 psi

Low pressure 24 psi and below

up to 24 psi

B

A Diameter

30°

BAR STOCk DISC HOLDeR

High pressure above 25 psi

Low pressure 24 psi and below

up to 24 psi

A Diameter

B

30°




Part Reconditioning

Bellows Conversion

Use Table 3 below to convert the standard R Series valves to the bellows RB Series valve. Refer to catalog information, or contact your sales representative, for part numbers and materials for bellows conversion.

Warning: Conversion will require a name plate change. For this reason bellows conversion is limited to Reyco assemblers who hold ASME Certification for R and RB Series valves.

Table 3: Bellows Conversion Chart

Orifice Needed Replacement Parts

D & E

BellowsBellows GasketBellows Spacer Body StudsGuideGasketStem

F

Adjusting RingAdjusting Ring PinBellowsBellows GasketBody Gasket DiscDisc HolderDisc Ring SetNozzle

G, H, J, K,L, M, N, P,Q, R, & T

BellowsBellows GasketBody Gasket




Part Reconditioning

O-Ring Conversion

Conversion from the R- series metal-to-metal seat to the RO soft-seat O-ring will require an O-ring disc assembly and an O-ring seat nozzle.

It is recommended to replace the existing disc and nozzle when converting. It is not recommended to re-machine the nozzle seating surfaces because this may result in undesirable alterations of the design geometry. When re-machining to convert from a conventional nozzle to an O-ring nozzle, in lieu of replacement as recommended, the following must be adhered to:

1. Align the nozzle in a four-jaw chuck as described in the “Reconditioning Nozzle Seat” section of this Maintenance Manual.

2. Remove standard nozzle seats to E dimension depth, as shown in Figure 8.

3. Machine for O-ring in accordance with dimensions shown in Figure 8.

NOzzLe SeAT CONveRSION(STeP 2)

O-RING SeAT DIMeNSIONS(STeP 3)

e C D

0.05 R 0.005 R Max

0.005 R

B

A

45°

NotesFlat seat lap and polish after machining. 1. Remove sharp corners.2.

Figure 8: O-Ring Nozzle Seat Dimensions

Orifice Nozzle Seat Dimensions (inches)A B C D e

D 0.623 - 0.628 0.717 - 0.721 5/64 3/64 3/64E 0.623 - 0.628 0.717 - 0.721 5/64 3/64 3/64F 0.778 - 0.783 0.886 - 0.890 5/64 3/64 3/64G 0.903 - 0.908 1.018 - 1.022 5/64 3/64 3/64H 1.122 - 1.127 1.268 - 1.272 3/32 3/64 3/64J 1.435 - 1.440 1.591 - 1.595 3/32 1/16 1/16K 1.716 - 1.721 1.878 - 1.882 3/32 1/16 1/16L 2.122 - 2.127 2.332 - 2.336 3/32 1/16 1/16M 2.372 - 2.377 2.590 - 2.594 3/32 1/16 1/16N 2.622 - 2.628 2.840 - 2.845 3/32 5/64 5/64P 3.185 - 3.191 3.438 - 3.443 3/32 5/64 5/64Q 4.184 - 4.190 4.434 - 4.440 3/32R 4.935 - 4.942 5.238 - 5.244 7/64T 6.309 - 6.316 6.727 - 6.733 7/64

Figure 8




Reassembly

Visually inspect all the parts to make certain they are clean, free from burrs and not damaged. Blow off loose foreign material with an air hose as required. Pay particular attention to the seats on the nozzle and disc. Seats must be free from nicks and scratches. Care must be exercised in handling and installation of the disc holder to avoid scratching the disc surface. It is recommended to always replace gaskets and O-rings.

1. Disc Holder Assembly : Standard Model (R & RS) Apply anti-seize compound to the hub on the back side of the disc. Assemble the disc to the holder by compressing the retaining ring around the groove in the disc and sliding the disc into the disc holder. Make sure the lapped seat is facing outward, taking care not to scratch the lapped seat surfaces.

O-Ring Model (RO) Apply a small amount of silicone to the O-ring. Place the O-ring into the radius undercut on the disc. Make sure the seat on the O-ring side of the disc, the side with the threaded hole, has been lapped. Install the O-ring retainer on top of the O-ring and thread the retaining screw(s) into the disc. Visually inspect assembly for uniform O-ring protrusion from retainer. (Refer to Figure 3.) Bellows Model (RB & RBO) Place the fiber gasket, with the sealant on both sides, on the disc holder over the threaded hub. Screw the bellows onto the disc holder and tighten using the wrench flats on the bellows nut. Complete the installation of disc as detailed above – Standard Model or RB and O-ring Model for RBO. Caution: Do not damage any part of the bellows during installation. If a bellow shows damage to the convolutions or gasket surfaces, replace it prior to use.

Figure 3

Retaining Screw

O-ring Seat Seal

Disc Retaining Ring

Adjusting Ring

Nozzle

Ring Pin

O-ring Retainer

Disc

Holder Insert




Reassembly

2. Apply a small amount of anti-seize compound to the flat end of the disc holder insert and place into the disc with the conical surface of the insert facing up. Make sure the insert seats all the way into the disc holder. Disc holder inserts are standard for all disc assemblies.

3. For one piece stem, slide the guide onto the stem making sure the large diameter (plate) of the guide is at the top. For two piece stem slide the spud through the guide. For bellows models, use caution when installing the guide in the bellows to avoid bellows damage. Apply a small amount of anti-seize compound to the bottom of the stem and thread the stem into the disc holder assembly, until it drops down and pivots freely.

4. Reinstall the nozzle if it was removed during maintenance. First apply a thin coat of anti-seize compound and tighten the nozzle using a spanner wrench and hammer for 1" D through 1 ½" H orifices and pull-down tool for 2" H through 8"T orifices. Check that nozzle flange seats against body inlet flange face.

5. Thread adjusting ring onto nozzle so that the face of the ring is below the nozzle seat.

6. Insert the disc holder/guide subassembly very carefully into the body. While holding the guide in place, lift the stem slightly to make sure vertical movement is possible. Apply anti-seize compound to the spring step bearing surface on the stem.

7. Verify the spring correctness prior to assembly. Assemble the spring steps to the springs and slide it over the stem, making sure the spring steps turn freely without binding on the spring. Apply anti-seize compound to the bearing surface of the top spring step.

8. Install the bonnet gasket, with sealant on both sides, onto the body. Align the bonnet stud holes with the body studs so that the bonnet vent hole is on the same side as the outlet of the body. If the valve is an exposed spring model (RS), align the bonnet or yoke so that the solid faces or stanchions are in line with the outlet. Install the vented bonnet or yoke, with gaskets, over the spring and stem, being careful not to bind the stem or severely jar the stem assembly.

9. Install the body stud nuts and tighten evenly by alternating sides.

10. Thread the compression screw locknut onto the compression screw with the chamfered side on top. Apply anti-seize compound to the bottom of the compression screw and on the bottom half inch of threads. Install the compression screw in the bonnet or spring yoke. After contact is made with the upper spring step, turn the compression screw to the dimension measured at disassembly. Set pressure change may require more compression (clockwise) for higher pressures and less compression (counter-clockwise) for lower pressures.

11. Install the bonnet vent pipe plug with sealant on the threads in all non-bellows models. Warning: Pipe plugs must not be installed on valves equipped with bellows. The vent port is left open. Plugging bonnet vent will severely affect valve performance.

12. Reposition the adjusting ring by turning it counter-clockwise until it contacts the disc holder and then clockwise the notch amount recorded at disassembly. The valve is now ready for test and setting.




Setting and Testing

Set Pressure Adjustments

Valves should be tested on the medium for which they service. Prior to mounting the valve to the test stand, clean the test plate and purge the system to remove any loose contaminates. Secure the valve inlet flange to the test fixture filling all bolt holes. Tighten bolts evenly being careful not to over tighten. This could distort or crack the flange. With the valve safetly mounted on the test stand bring system pressure up slowly until set pressure (popping point) is reached or 10% above set pressure. To increase set point, turn the compression screw clockwise. To decrease turn the compression screw counter-clockwise. When adjusting set pressure, follow these guidelines:

Set Pressure Adjustment

1. Reduce system pressure 50% below set point or isolate test valve.

2. Prevent disc from rotating on the nozzle by holding the stem while making adjustments. If the stem is allowed to rotate, it may cause galling of the disc and nozzle seats.

3. Tighten compression screw locknut after each adjustment to prevent movement of adjustment while testing

4. Tighten adjusting ring lock pin prior to popping valve to eliminate movement of the adjusting ring during testing.

To verify set point after adjustments, pop valves a minimum of two (2) times to check set pressure consistency.

Temperature and Back Pressure Correction

R & RB Series valves are sometimes used in systems which see temperatures above ambient. To compensate for temperatures above 250 degrees Fahrenheit, a correction factor is added to the valve set pressure when it is set at ambient temperature. This set pressure is called “Cold Differential Test Pressure.”

Back pressure may also require a correction to set pressure. This is required only on R & RO Series (without bellows). The back pressure will be listed on the nameplate and the corrected pressure will also be the “Cold Differential Test Pressure.”

CDTP formula:

CDTP = (Set Pressure – Back Pressure) × (1 + Temp. Correction)

Example:

Set Pressure is 250 psigBack Pressure is 50 psigTemp. is 500°F

CDTP = (250 psig – 50 psig) × (1 + 3%)CDTP = 200 psig × (1 + 3%)CDTP = 200 psig + 6 psigCDTP = 206 psig

Table 4: Seat Leakage Test Criteria Operating

TemperatureSet PressureCorrection

-45°F to 0°F None0°F to 250°F None

250°F to 1000°F 3%




Setting and Testing

Blowdown Adjustment

Blowdown Adjustment

In order to set true blowdown, the test system should have adequate flow capacity to overpressure the valve 10% above set pressure. To increase blowdown, turn the adjusting ring counter-clockwise toward the nozzle seat. To decrease blowdown, turn clockwise away from the disc. Move the ring only 1-2 notches at a time.

If the test system is too small to set blowdown, return the adjusting ring to its original position or to the recommended setting shown in Table 5. Notch positions shown in Table 5 are obtained by turning the adjusting ring until it contacts the disc holder, then turning the adjusting ring clockwise away from the disc the recommended number of notches.

Certified Liquid Valve Final Ring Settings: Set adjusting ring 1-2 notches below contact with disc seat when testing on liquid.

Table 5: Adjusting Ring Settings for Gas & Steam

Orifice Set Pressure (psig)< 30 30-100 100-300 300 +

D & E 2 5 7 9F & G 2 6 9 12H & J 2 6 10 14K & L 3 8 12 16M & N 3 8 14 20P & Q 4 10 16 24

R 5 12 18 28T 7 14 24 36

NotesThe chart numbers refer to how many notches the ring should be moved to.1. Certified Liquid Valve Final Ring Settings: Set adjusting ring 1-2 2. notches below contact with disc seat when testing on liquid.




Setting and Testing

Leakage Testing

1. Back Pressure Back pressure test is accomplished using a test fixture secured to the valve outlet through which 30 psi air is applied. Using a soap solution while the valve is pressurized, check pressure boundaries (cap, gear to bonnet interface, body to bonnet flange, adjusting ring pin, and nozzle to body interface) for leakage (bubbles). Bellows are also checked at the time of back pressure test. Apply soap solution to bonnet vent hole. Signs of leakage reflect damaged bellows or damaged bellows gaskets.

TeST ReCIeveR

Tube Wall 5/16" OD 0.035" Wall

1/2" of water

Cover Plate

Test fixture to body connection

Micellaneous drain/vent plugsCap to bonnet connection

Body to bonnet connection

Nozzle to body connection

Adjusting warn ring pin to body connection

Figure 9




2. Seata. Air/Gas:

The recommended test fixture requires a 5/16" OD tube with a 0.035" wall thickness. One end of the tube will attach to the valve outlet and the other end will be placed ½" deep into a beaker of water as shown in Figure 9. Prior to leak rate test, apply soap solution to all pressure boundaries of the valve indicated by arrows in Figure 9. The pressure boundaries must be free of leakage (bubble) in order to measure the actual seat leakage, if any. Test pressure should be 90% of set pressure. R, RB & RS valves will pass testing based on the values shown in Table 6. RO & RBO Series valves will be tested as above, except the test pressure shall be 95% of the set pressure or 3 PSI below the set pressure, whichever is lower and there shall be zero (0) bubbles.

Setting and Testing

Leakage Testing

Table 6: Seat Leakage Test CriteriaSet Pressure at 60°F

(psig)F Orifice & Smaller G Orifice & Larger

Max. Leakage(Bubbles/Min)

Approx. Leakage(SCF/Day)

Max. Leakage(Bubbles/Min)

Approx. Leakage(SCF/Day)

15 – 1000 40 0.60 20 0.301001 – 1500 60 0.90 30 0.451501 – 2000 80 1.20 40 0.602001 – 2500 100 1.50 50 0.752501 – 3000 100 1.50 60 0.903001 – 4000 100 1.50 80 1.204001 – 5000 100 1.50 100 1.505001 – 6000 100 1.50 100 1.50

b. Steam: Increase pressure to 90% of set pressure. Check for leakage by holding a cold steel bar at the top portion of the discharge. Any noticeable condensation forming on the bar is considered leakage. Leak test duration is 15 seconds.

c. Liquid: No visible sign of leakage at 90% of the valve set pressure. Fill body bowl with water up to the edge of the discharge flange. Valve is considered tight if no water spills off edge of discharge while valve inlet is pressurized for 90%. Holding time is two (2) minutes for 1" D through 2" H orifices, five (5) minutes for 2" J through 8" T orifices.




Notes



Reyco – R Series Maintenance Manual Reyco – R Series Maintenance Manual30



Reyco – R Series Maintenance Manual Reyco – R Series Maintenance Manual



www.reycovalve.com

Reyco Valve Division6614 Dixie Drive Houston, TX 77087

T 713.845.1500 F 713.845.1515 E [email protected]



€¦ · asme viii certified. rb series . bellows version of the r series where back pressures...

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