The document is a maintenance manual for the Fort Vale 2.7"NB Super Maxi Rail Relief Valve, part number series 0R3/XXXX006X. This valve is a spring-loaded device designed for pressure relief in rail car applications.
Function Description:
The 2.7"NB Super Maxi Rail Relief Valve is a pressure-only relief valve, meaning it is designed to open and release pressure when the internal pressure of the vessel exceeds a predetermined set point. This prevents over-pressurization of the tank, which could lead to serious injury to personnel, valve malfunction, or permanent damage to the valve or tank. The valve is specifically designed for flanged tank connections and is available with either a tongue and groove or a raised face flange. It is crucial that the valve is correctly installed, maintained, and tested to ensure its proper function and the safety of the system it protects.
Important Technical Specifications:
- Part Number Series: 0R3/XXXX006X (e.g., 0R3/X165006R for a 165 PSIG set pressure with a raised face flange).
- Design Pressure (MAWP): 165 PSIG (11.38 Barg).
- Test Pressure: 248 PSIG (17.1 Barg).
- Standard Pressure Settings: 75 PSIG (5.17 Bar) and 165 PSIG (11.38 Bar). Other pressure settings are available upon request from Fort Vale.
- Materials: Contact parts are manufactured in 316 stainless steel.
- Seal Materials: Fitted with Viton A, Viton B, or Viton GFLT seals as standard. Other seal materials are available as options.
- Flange Specifications:
- Ø7.5" flange: Drilled 4 x 0.87" holes equi-spaced on a 6.25" PCD.
- Ø12.0" flange: Drilled 8 x 0.75" holes equi-spaced on a 10.3" PCD.
- Available in tongue & groove or raised face configurations.
- Weight: Varies from 30 to 39 Lbs, depending on the specification.
- Design Temperature: Dependant upon seal material; contact Fort Vale for specific information.
- Valve Height (in Inches):
- For 75 PSIG: Dim. T (4.43"), Dim. R (4.26"), Dim. S (4.78"), Dim. V (4.72").
- For 165 PSIG: Dim. T (5.51"), Dim. R (5.34"), Dim. S (5.78"), Dim. V (5.72").
- Bore Diameter: 2.70" (68.1 mm) or 2.85" (72.5 mm).
- AAR Application No: PRD139511.
- Part Number Breakdown (USREL185):
- Valve Type: 0R3/ (Stainless steel body & springs), 0U3/ (PFA coated wetted areas & Halar coated springs), HR3/ (Metal parts SB574 UNS10276 & Inconel springs).
- Seal Type: A wide range of proprietary brand materials including Viton A®, Fortyt (FEP outer/silicone core), Kalrez 6375®, Black Buna N (HNBR), Perfluoroelastomer, EPDM, Aflas®, Viton B®, Chemraz 505®, White EPDM, Viton GF-S® (Trelleborg CS5350), Black Neoprene, Viton GFLT®, Black EPDM (Trelleborg EP787), Kalrez 1050LF®, White Neoprene (Food grade), PFA lined pressure plate, Viton GF-S® (Peroxide cured), Hi-temp. Fortyt (PFA outer/silicone core), White Buna N (Food grade).
- Pressure Setting (PSIG): 075 (75 PSIG), 165 (165 PSIG).
- Vacuum Setting: 00 (No vacuum).
- Bore Diameter: 6 (2.70" / 68.1 mm), 7 (2.85" / 72.5 mm).
- Flange Specification: A (8 holes on 10.3" PCD - Raised face PFA coated - AAR Fig. E21 (A)), J (3 holes on 5.50" PCD - Raised face PFA coated), R (4 holes on 6.25" PCD - Raised face), S (8 holes on 10.3" PCD - Tongue & groove), T (4 holes on 6.25" PCD - Tongue & groove), V (8 holes on 10.3" PCD - Raised face - AAR Fig. E21 (A)).
Usage Features:
The valve is designed for pressure relief in rail car applications, ensuring the safe operation of tanks by preventing over-pressurization. It is available in various configurations to suit different tank connection types and pressure requirements. An anti-tamper screw with lead shot is used to lock the cap to the valve body, preventing unauthorized adjustments to the set pressure.
Maintenance Features:
The manual provides detailed instructions for the complete disassembly, assembly, testing, and adjustment of the 2.7"NB Super Maxi Rail Relief Valve.
- Disassembly:
- Identification: Valves are laser-marked on the cap for easy identification.
- Anti-Tamper Screw Removal: Involves drilling out the lead shot and screw to unlock the cap. A specific drill size (No 22 / 4mm) and depth (0.2" / 5mm) are specified to avoid damaging the spring.
- Spring Compression: Requires a bench press with a minimum 1-tonne load and a nylon lifting spacer (FIX/A/0035) to compress the spring safely before unscrewing the cap. A cap tightening tool (FIX/A/0034) is used to engage the cap.
- Component Removal: Step-by-step instructions for removing the cap, springs, valve body, pressure plate, and its components (retaining ring clip, stud, nut, inner and outer pressure plates, O-ring, washer).
- Inspection: Emphasizes examining all components for signs of damage or corrosion, with instructions to contact Fort Vale if damage is found.
- Assembly:
- Pressure Plate Assembly: Involves cleaning components, applying thread adhesive, installing the stud and nut, tightening with 2x 5/16" nuts in a vice, installing a new O-ring, and assembling the inner and outer pressure plates. The nut is torqued to 15 ft.lbs (20 Nm) using a 1/2" (13mm) torque wrench.
- Valve Assembly: Cleaning and inspecting the valve body, installing the pressure plate assembly, installing the retaining ring clip (if applicable), inspecting and installing springs, applying thread lubricant to the top cap thread, and installing the top cap.
- Spring Compression for Assembly: Similar to disassembly, requires a bench press and nylon lifting spacer to compress the spring and engage the cap threads with the valve body.
- Testing and Adjustment of Set Pressure:
- Test Rig: Recommends using a Fort Vale Relief Valve Test Rig, but provides precautions for other test rigs.
- AAR Standards: Pressure test procedures must obey AAR standards.
- Approved Personnel: Only "approved persons" with specific knowledge and qualifications are permitted to perform valve maintenance and testing.
- Pressure Test Procedure: Involves installing the valve onto a test rig flange with 4x studs, washers, and nuts, tightening nuts in a diametrically opposite sequence, applying leak detection fluid, and gradually increasing pressure to observe the initial set pressure (where bubbles appear).
- Pressure Adjustment: Uses a relief valve adjustment tool (FIX/A/0015/23) and a 1½" (38mm) A/F spanner to adjust the jacking nut. Turning the cap clockwise increases pressure, and anti-clockwise decreases it.
- Safety Warning: A maximum of one full thread is permitted to show when turning the valve cap to avoid serious injury.
- Pressure Setting Tolerance: ±3% for the set pressure/Start to Discharge (STD). Examples provided for 75 PSI (Min 72.75 PSI, Max 77.25 PSI) and 165 PSI (Min 160.1 PSI, Max 169.95 PSI).
- Troubleshooting: Instructions for adjusting pressure if too low or too high, including turning the spring 180° or installing a new spring if necessary.
- Re-Seal Pressure Test: After satisfactory set pressure, reduce test rig pressure by approx. 10% and check for no leakage (small bubbles) for 30 seconds.
- Installation of Anti-Tamper Screw:
- Procedure: Involves drilling the existing hole in the cap to a specific depth (0.2" / 5mm), tapping the hole with a 3/16" BSW tap to a depth of 0.14" (3.5mm), installing a 3/16" x 3/16" long socket head screw, and then inserting a 1/8" lead shot into the screw top.
- Sealing: Lightly tapping the lead shot with a pin punch and hammer to compress it and seal the screw.
- Final Check: Ensure information marked on the cap matches valve specifications.
- General Maintenance Precautions:
- Safety: Emphasizes caution, obeying warnings, using recommended tools, and applicable PPE to prevent injury.
- Valve Protection: Using recommended tools, obeying bolting sequence and Step Loading Procedure, reading Client Responsibilities, and using genuine Fort Vale spare parts to prevent damage.
- Approved Person: Defines requirements for an "approved person" to perform maintenance and testing.
- Post-Maintenance: Requires an approved leak test before installing the valve onto the vessel.
- Tools & Equipment: Lists general workshop equipment, hand tools, and special tools required for maintenance, including cap tightening tool (FIX/A/0034), nylon lifting spacer (FIX/A/0035), relief valve adjusting tool (FIX/A/0015/23), and a relief valve test rig.
- Bolt Torque Guide & Step Loading Procedure: Provides instructions for flange bolting, including torque values for different thread sizes (3/8", 1/2", 5/8") and a 5-round step loading procedure to ensure uniform tightening and prevent gasket deformation.
- Client Responsibilities: Outlines responsibilities related to valve compatibility, maintenance checks, replacement parts, external fire considerations, compatibility of accessories, and mis-use.
The manual is comprehensive, providing detailed, step-by-step instructions with accompanying images to guide users through the maintenance process, ensuring safety and proper functionality of the Fort Vale 2.7"NB Super Maxi Rail Relief Valve.
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