Kunkle pressure relief valves are designed to protect equipment from overpressure situations. Proper installation and operation are critical to ensure effective protection and adherence to safety standards. These valves require careful handling, verification of specifications, and installation according to established codes, such as those defined by the ASME Boiler and Pressure Vessel Code. The following details outline essential procedures and considerations for installing and operating Kunkle pressure relief valves, based on available documentation.
Handling and Pre-Installation Checks
Kunkle pressure relief valves should be handled with care to avoid damage. The documentation emphasizes protecting the valve from heavy shock loads and preventing internal contamination. Before installation, a thorough verification process is necessary. This includes confirming the model number on the valve tag matches the original order. For valves intended for European service, the presence of a ‘CE Mark’ tag should be verified.
Crucially, the service media, capacity, temperature, and pressure limits of the valve must be checked against the specific application requirements. The marked capacity is based on standard temperature and pressure conditions and is only valid for the service media specified in the catalog order guide. Adjustments to the capacity must be made by the end user for differing temperatures or service media.
Personal Protective Equipment
Prior to commencing any installation or operational procedures, appropriate personal protective equipment (PPE) must be worn. This includes, without exception, safety glasses and ear protection. These precautions are essential to protect personnel from potential hazards during the installation process.
Mounting and Positioning
The documentation consistently stresses the importance of mounting the valve in a vertical position. This orientation ensures the valve body is self-draining, which is essential for proper operation. If the valve is equipped with a body drain port, it must be open when required by the ASME code.
Inlet piping should be kept as short as possible, ideally without any elbows. The goal is to maintain an inlet pressure drop of 3% or less when the valve is relieving pressure. The diameter of the inlet piping should be equal to or greater than the size of the pressure relief valve inlet connection.
Care must be taken during hoisting to avoid contact between lifting straps and the valve lift lever, which could cause damage.
Discharge Piping Considerations
When discharge piping is connected to the valve outlet, it must also be self-draining if a body drain port is not utilized. The valve should not be connected to any discharge pipe containing pressure before the valve opens, nor to any pipe where pressure build-up exceeds 10% of the set pressure during relief.
Discharge piping, beyond a short tailpipe, requires adequate support. For steam service applications, a drip pan elbow or flexible connection is recommended.
Bonnet Vent Openings
The documentation explicitly states that bonnet vent openings should not be plugged. If a valve is supplied with bonnet vents open, they must remain open.
Gag Screw Removal
Before starting up the system, any gag screw equipped on the valve must be removed. The gag screw is a temporary fixture used during testing and transport and must be disengaged for the valve to function correctly.
Adherence to Codes and Standards
Throughout the installation process, adherence to the ASME Boiler and Pressure Vessel Code requirements is paramount. Failure to comply with these codes can result in inspection tagging, leading to increased downtime.
Operational Considerations
The primary function of a Kunkle pressure relief valve is to protect systems and equipment from overpressure. Proper installation, as detailed above, is the first step in ensuring this protection. Regular inspection and maintenance, as outlined in the valve’s specific documentation (not provided in the source material), are also crucial for long-term reliability. The documentation does not provide details on maintenance schedules or procedures.
Importance of Vertical Installation
The repeated emphasis on vertical installation highlights its critical role in valve functionality. A vertically mounted valve facilitates self-drainage, preventing the accumulation of debris or process fluids that could compromise the valve’s sealing capability. Horizontal or angled installations may not meet code requirements and could negatively impact seat tightness and set pressure accuracy.
Inlet Piping Design
Minimizing the length of inlet piping and avoiding elbows are key to reducing pressure drop. A significant pressure drop can affect the valve’s ability to relieve pressure accurately and efficiently. Maintaining a consistent pipe diameter equal to or greater than the valve inlet further contributes to optimal performance.
Conclusion
Proper installation of Kunkle pressure relief valves is essential for ensuring reliable overpressure protection. Key considerations include careful handling, thorough pre-installation verification, adherence to ASME codes, correct mounting orientation, appropriate discharge piping, and the removal of any gag screws. Following these guidelines will help to maximize valve performance and safeguard equipment and personnel.