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R4 Series Relief Valve 
Maintenance Instructions

Spring Installation

 Warning:  

Relieve system pressure 
before installing spring.

1.  Loosen lock nut and remove the 

cap from bonnet.

2.  Remove existing spring if necessary.
3.  Make sure all components are 

clean.

4.  Place spring support bearing in 

valve with bearing side UP.

5.  Install proper spring for desired set 

pressure range.

6.  Replace existing label with new 

label. Check this label against 
spring identification table for proper 
set pressure range.

7.  Thread cap onto bonnet to initial 

position indicated in Spring Kit 
Identification Table. Tighten lock 
nut against cap and test for set 
pressure.

8.  Relieve system pressure, unthread 

cap as needed, and retest. Repeat 
procedure as necessary to obtain 
desired set pressure.

9.  Tighten lock nut against the cap to 

100 in.·lb (11 N·m).

Plug

Cap

Spring

Label

Lock Wire Hole

Lock Nut

Spring Support 
Bearing

Bonnet

Lock Wire Hole

Body

10.  Lock wire the cap and body 

together to maintain relief setting.

Manual Override Conversion

 

Warning: 

 Relieve system pressure 
before installing manual 
override handle.

1.  Loosen lock nut and remove the 

cap from bonnet.

2.  Remove the plug from the cap.
3.  Remove existing spring and spring 

support bearing.

4.  Place new bearing and thrust wash-

ers over pull rod, resting them on 
the spring support.

5.  Install pull rod into bonnet.
6.  Place blue “A” spring over pull rod, 

resting it on the thrust washer.

7.  Place the cap over pull rod, resting 

it on bonnet.

8.  Thread handle onto pull rod. Tighten 

set screw on handle to 20 in.·lb. 
(2.2 N·m) with a 5/64 in. hex wrench.

9.  Engage the cap threads.

To adjust the set pressure, refer to 
steps 7 through 10 in the “Spring 
Installation” section.

Handle

Set Screw

Cap

Label

Pull Rod

Spring

Spring 

Support

A Swagelok Pre-Engineered Subsystem        Fast Loop Module

37

Содержание Fast Loop Module

Страница 1: ...lok Pre Engineered Subsystem Pre engineered subsystems available in weeks not months Field tested design ensures optimum system performance A Swagelok Pre Engineered Subsystem User s Manual Fast Loop...

Страница 2: ...alves MS INS 40 27 Packing Adjustment for 40G Series Ball Valves MS INS 40G 28 R3A Series Externally Adjustable Relief Valve Maintenance Instructions MS CRD 0013 29 R4 Series Relief Valve Maintenance...

Страница 3: ...Fast Loop Module FLM System Manual Configuration 4 1 2 in Liquid System with Optional Grab Sample and Relief Outlets Shown A Swagelok Pre Engineered Subsystem Fast Loop Module 3...

Страница 4: ...ge gas for system cleaning The FLM extracts a sample through a filter while using the high flow rate of the fast loop to keep the filter element clean All FLM subsystems feature dual interlocked ball...

Страница 5: ...NV FI FFL Filter fast loop FP FM FC NV1 FI PSV C CV SHV V FFL SN PV NV FI NV Needle valve grab sample or purge outlet PR FP BV BV PI RV FM FP FM FC MV NV1 NV FI PSV C CV SHV SSV FFL SN PV NV FI NV Ne...

Страница 6: ...NV1 NV1 NV2 FFL SN RV FI C C Fast Loop Out Fast Loop In To Analyzer Liquid Gas Liquid Grab Sample Outlet Relief Outlet Needle valve NV1 Ball valve BV1 BV2 Relief valve RV Pressure indicator PI Grab s...

Страница 7: ...V C C FI Fast Loop Out Fast Loop In To Analyzer From Analyzer Liquid Liquid Gas Needle valve NV1 Ball valve BV1 BV2 Pressure indicator PI Grab sample needle valve NV2 Flow indicator FI Filter FFL Reli...

Страница 8: ...Fast Loop Out Fast Loop In To Analyzer Oily Drain Vent Oily Drain Vent From Analyzer Liquid Liquid Gas Needle valve NV1 Ball valve BV1 BV2 Ball valve BV3 BV4 Plug valve PV Pressure indicator PI Grab s...

Страница 9: ...In To Analyzer Oily Drain Vent Purge Oily Drain Vent From Analyzer Liquid Liquid Gas Needle valve NV1 Ball valve BV1 BV2 Ball valve BV3 BV4 Plug valve PV Pressure indicator PI Grab sample needle valve...

Страница 10: ...e outputs to the analyzer on the right System operation is not recommended in any other orientation Dimensions in inches centimeters are for reference only and are subject to change Top 7 50 19 0 1 50...

Страница 11: ...Right Side Fast loop inlet Fast loop outlet Relief outlet option 5 94 15 1 1 81 4 60 16 2 41 1 13 8 35 1 1 09 2 77 6 70 17 0 18 7 47 5 8 10 20 6 9 39 23 9 10 7 27 2 0 88 2 24 Return from analyzer Out...

Страница 12: ...ple conditioning system prior to the analyzer 3 Return from Analyzer option connect to the outlet line from the analyzer There must be sufficient pressure to create flow back into the FLM return 4 Pur...

Страница 13: ...moving the black handle BV1 BV2 to the left 2 Configurations 3 and 4 Close the sample return valve by moving the red handle BV3 BV4 to the up position 3 Open flow to the FLM by opening all fast loop...

Страница 14: ...4 in R3A Series Externally Adjustable Relief Valve Maintenance Instructions page 29 1 2 in R4 Series Relief Valve Maintenance Instructions page 36 Note 1 2 in systems with perfluorcarbon FFKM seals wi...

Страница 15: ...le to the down position to switch the analyzer return line to drain mode and opens the purge lines Purge lines are in Configuration 4 only 5 Configuration 4 To adjust purge flow turn the handle of the...

Страница 16: ...purge valve PV 5 Configurations 4 After a suggested minimum of five minutes close the purge line by moving the red handle to the up position 6 Verify that the FLM is depressurized by checking the pre...

Страница 17: ...just the valve packing according to 1 4 in Packing Adjustment Card for 40G Series Ball Valves page 28 1 2 in Packing Adjustment Card for 40 Series Ball Valves page 27 9 Configurations 3 and 4 To adjus...

Страница 18: ...tem according to VCO Fittings Installation Instructions page 25 Verify that the O ring is in place when reassembling the fitting The locations of the VCO fittings within a Configuration 4 FLM are indi...

Страница 19: ...outlet 3N series Flow indicator 1 4 in FLM M1 series 1 2 in FLM M3 series Variable Area Flowmeters G Series and M Series MS 02 346 Ball valve 40G or 40 series One Piece Instrumentation Ball Valves 40...

Страница 20: ...re in the process pipe near the sampling nozzle If flow rate is acceptable there may be a partial blockage in probe or sample transport lines to the FLM Partially close the needle valve NV1 and check...

Страница 21: ...lvent to remove oil and solid deposits Remove the flowmeter and clean the inside of the flow tube Replace the flowmeter One of the bypass valves is not fully closed Move the black handle to the right...

Страница 22: ...nstalling a larger size tube or pipe for sample return line to process Consider changing the method of disposing of the analyzed sample There is high flow resistance in the sample path to the analyzer...

Страница 23: ...e is backflow into the analyzer Check valve CV1 is stuck open Maintain or replace the check valve Verify orientation when the check valve is reinstalled Pressure indicator PI pointer is vibrating exce...

Страница 24: ...inspection gauge next to the gap between the nut and body Fig 4 If the gauge will not enter the gap the fitting is sufficiently tightened If the gauge will enter the gap additional tightening is requi...

Страница 25: ...6 Finger tight Swagelok VCO Fittings Installation Instructions Bodies without weld fittings 7 45 GTAW 4 5 3 1 4 in 6 mm 2 1 16 1 8 3 16 in 2 3 4 mm 1 2 4 5 6 7 11 10 9 8 12 3 A Swagelok Pre Engineered...

Страница 26: ...1 4 5 9 Bodies with weld fittings 8 Finger tight 45 GTAW 3 GTAW 2 6 7 Swagelok VCO Fittings Installation Instructions A Swagelok Pre Engineered Subsystem Fast Loop Module 26...

Страница 27: ...y be required during the service life of the valve to prevent leakage Before servicing any installed valve you must depressurize the system cycle the valve and purge the valve Adjust the packing by tu...

Страница 28: ...uring the service life of the valve to prevent leakage Adjusting the Packing 1 Adjust the packing by turning the packing bolt clockwise in 1 16 turn increments until leak tight performance is achieved...

Страница 29: ...rque wrench capable of 10 in lb 1 1 N m Set screw 100 in lb 11 3 N m Lock nut Pic n a O rings Spring Kit Spring Label Lockwire Spring Designator and Color Set Pressure Range psig bar Initial Cap Posit...

Страница 30: ...Loosen Cap Bonnet Discard Lubricate WARNING Before servicing any installed valve you must depressurize system cycle valve purge the valve WARNING Residual material may be left in the valve and system...

Страница 31: ...pressure 14 15 Lock nut Cap Tighten against cap Lock nut Tighten to 100 in lb 11 3 N m Body Lockwire Cap Lead seal 1 Follow steps 1 through 4 in the Spring Installation section Springs A B or C can be...

Страница 32: ...ction Pull rod Handle Thread onto pull rod Set screw Tighten to 10 in lb 1 1 N m Cap Thread to initial position indicated in Spring Kit Identification table R3A Series Externally Adjustable Relief Val...

Страница 33: ...iner Bonnet O ring WARNING Before removing any installed valve you must depressurize system cycle valve purge valve WARNING Residual material may be left in the valve and system CAUTION Do not scratch...

Страница 34: ...rt Seat O ring Insert 11 12 13 14 Insert assembly Seat retainer Tighten to 250 in lb 28 2 N m Seat retainer Teeth facing away from quad seal Quad seal Retainer Stem Lubricate top of stem R3A Series Ex...

Страница 35: ...at retainer Seat O ring Insert Lock wire hole Swagelok proportional relief valves should never be used as code safety relief valves Some system applications require relief valves to meet specific safe...

Страница 36: ...valve in system Grip valve on wrench pad during installation Spring Kit Identification Spring Kit Ordering Number Color Code Nominal Cracking Pressure psig bar Initial Cap Position number of turns 177...

Страница 37: ...p to 100 in lb 11 N m Plug Cap Spring Label Lock Wire Hole Lock Nut Spring Support Bearing Bonnet Lock Wire Hole Body 10 Lock wire the cap and body together to maintain relief setting Manual Override...

Страница 38: ...ht down into body See Fig 3 Note Do not pinch O rings between body and plug 5 Install snap ring with snap ring pliers or similar tool See Fig 4 6 Test the valve for proper operation Large O rings Smal...

Страница 39: ...o the bonnet on top of the packing Place the gland into the bonnet Proceed to step 10 9b UHMWPE Packing Lubricate the stem threads with MS LT NNS 1 and re insert the stem through the bottom of the bon...

Страница 40: ...w into the bonnet 11 Lubricate the top 2 or 3 threads on the bonnet and screw lock nut onto the bonnet 12 Place the handle on the stem Be certain that the set screw hole is aligned with the indentatio...

Страница 41: ...s procedure is shown with Swagelok Tube Fitting end connections These instructions also apply to check valves with pipe ends and check valves with VCR and VCO ends Component Identification End Connect...

Страница 42: ...pressure 3 Test the valve to ensure it stops reverse flow Testing Nominal End Connection Size Tool Size and Quantity Wrenches Socket for body Hex Qty 2 for End Connection Qty 1 for body Hex Qty 1 1 8...

Страница 43: ...n the outlet body 3 Slide the O ring over the threads against the backup ring 4 Insert the spring into the body 5 Lubricate the body threads with a system compatible lubricant 2 Lubricate the O ring w...

Страница 44: ...assembly The O ring must fit tightly into the inlet body 9 Look into the valve outlet port to verify that the spring is aligned in the center of the poppet stop 10 Tighten the valve bodies 11 Refer t...

Страница 45: ...e a backup wrench End connection leakage Inspet end connection for damage replace if damaged Reinstall the fitting to the valve end connection Contamination on body O ring 4 Clean O ring and reassembl...

Страница 46: ...responsibilities of the system designer and user Caution Do not mix or interchange parts with those of other manufacturers Poppet O ring Good Contaminated Ref 1 Swollen Ref 2 Damaged Ref 3 Good Conta...

Страница 47: ...Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 5TX A Swagelok Pre Engineered Subsystem Fast Loop Module 47...

Страница 48: ...Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 5TX A Swagelok Pre Engineered Subsystem Fast Loop Module 48...

Страница 49: ...Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 6XX A Swagelok Pre Engineered Subsystem Fast Loop Module 49...

Страница 50: ...Tornado Model 601 Element Replacement Kit Instructions Element Kit Part 601 6XX A Swagelok Pre Engineered Subsystem Fast Loop Module 50...

Страница 51: ...Tornado Model 602 Maintenance Instructions A Swagelok Pre Engineered Subsystem Fast Loop Module 51...

Страница 52: ...Tornado Model 602 Maintenance Instructions A Swagelok Pre Engineered Subsystem Fast Loop Module 52...

Страница 53: ...Tornado Model 602 Maintenance Instructions A Swagelok Pre Engineered Subsystem Fast Loop Module 53...

Страница 54: ...Tornado Model 602 Maintenance Instructions A Swagelok Pre Engineered Subsystem Fast Loop Module 54...

Страница 55: ...A Swagelok Pre Engineered Subsystem Fast Loop Module 55...

Страница 56: ...foil TM GrafTech International Holdings Inc 2011 2019 Swagelok Company MS 13 219 RevB April 2019 Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a copy...

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