Machine manual

en-11092.001-F

Pressure relief device

Code Word

Order Number

POLYSIUS Order Code (POC)

Machine manual Contents
Pressure relief device

Contents

1 Technical data......................................................................................... 1-1

2 Safety...................................................................................................... 2-1
3 Components and description of functioning.......................................3-1
3.1 Components............................................................................................. 3-1
3.2 Description of functioning.........................................................................3-4
4 Transport and assembly........................................................................4-1
4.1 Transport and storage requirements........................................................4-1
4.2 Assembly.................................................................................................. 4-1
5 Lubrication..............................................................................................5-1
6 Preparation for the test run...................................................................6-1
6.1 Checks prior to the test run......................................................................6-1
6.2 Setting and adjustment.............................................................................6-1
6.3 Test run.................................................................................................... 6-1
7 Maintenance...........................................................................................7-1
7.1 Inspection.................................................................................................7-1
7.2 Servicing.................................................................................................. 7-1
7.3 Trouble shooting.......................................................................................7-1
7.4 Repair....................................................................................................... 7-2
8 Spare parts............................................................................................. 8-1
9 Appendix.................................................................................................9-1
9.1 Technical drawings...................................................................................9-1

en-11092.001-F
Machine manual Technical data
Pressure relief device 1

1 Technical data

NOTE
Information concerning the electrical equipment is contained in
the separate electrical documentation or in the subsuppliers'
documentation.

Information on the intended use

The pressure relief device is for POC................................................

Basic data

Series / type........................................................................................
Size......................................................................................................
Year of manufacture............................................................................
Opening pressure - suction side.........................................................
Opening pressure - discharge side.....................................................
Dimensions..........................................................................................
Total weight.........................................................................................
Machine manual Safety
Pressure relief device 1

2 Safety

NOTE
Be sure to comply with the general safety instructions in the
supplement Important notes on the documentation.

Use

 Be sure to comply with the information concerning the

intended use of the machine in the section Technical data.
 Any use of the machine other than for the specified purpose,
such as the use at another place of installation is forbidden.
POLYSIUS AG is not responsible for any damage resulting from
any other than the specified use of the machine. All other use
is at the operator’s own risk.
 The observance of these and the maintenance instructions is
part of the specified use.

Transport and assembly

 All transport instructions in this manual refer exclusively to the

transport of the machinery in the plant area.
 Use only suitable hoisting and lifting equipment, which is in
serviceable order and has a sufficient load bearing capacity.
 Never work under a suspended load.
Operation

 Any safety checks before or during operation depend on the

relevant national regulations. The operator is responsible for
the performance and recording of such checks.
 If changes in the machine or its operating behaviour relevant
to safety occur, the machine must be immediately stopped.
 To ensure that the pressure relief valve opens at the set
pressures, the weights at the flaps must neither be changed
not their movements be impeded.
Safety Machine manual
2 Pressure relief device

Maintenance

 Ensure that for the entire duration of the maintenance work, all
machines and motors whose operation might endanger
persons or equipment are switched off, isolated and
safeguarded against restarting.
 During all work at the pressure relief valve, filling of the silo
must be impossible. Make sure that the silo plant has been
depressurized.
 Before performing any work on the machine, make sure that
there is no burning hazard when the machine is touched.
Ensure that there is no hot material inside the machine when
inspection flaps and maintenance hatches are opened.
 Keep the machine free of oily and explosive matters. Never use
benzine or other flammable substances for cleaning the
machine.
 Strictly observe the welding instructions when performing any
welding work.
 If electrical welding is executed on any part within the
machine, the welding current must never be conducted through
sliding or anti-friction bearings, other moveable connections or
measuring equipment. Return lead welding current must
always be connected close to the point of welding and directly
connected to the part being welded.
 All safeguards have to be re-installed and all inspection flaps
and maintenance hatches must be properly closed when
maintenance work has been terminated.
Machine manual Components and description of functioning
Pressure relief device 1

3 Components and description of functioning

The safety unit described in this document is a pressure relief

device for silo and large-vessel applications.

3.1 Components

NOTE
Some details of the drawings in this manual may not be identical
with the drawings supplied under the contract.

The pressure relief device includes inter alia:

 the housing of welded and bolted design, including

 pressure pipe socket
 suction pipe socket
 cover
 mounting frame
 inspection door
 the flaps on the suction and pressure side
Components and description of functioning Machine manual
2 Pressure relief device

Items in the drawings

1 Housing
1.1 Pressure pipe socket
1.2 Suction pipe socket
2 Cover
2.1 Seal
3 Mounting frame
3.1 Seal
4 Inspection door
4.1 Seal
5 Flap, discharge side
5.1 Flap seal, discharge side
6 Flap, suction side
6.1 Flap seal, suction side
7 Shaft, discharge side
8 Shaft, suction side
9 Flap lever, discharge side
10 Flap lever, suction side
11 Lever, discharge side
12 Lever, suction side
13 Weights, discharge side
14 Weights, suction side
15 Stuffing box with graphitized packing cord
16 Bolt
17 Split pin
18 Spring-type straight pin
19 Spring-type straight pin
20 Adjusting ring with screw
21 Retaining ring
Machine manual Components and description of functioning
Pressure relief device 3

Figure 1
Components and description of functioning Machine manual
4 Pressure relief device

3.2 Description of functioning

The pressure relief device is designed to ensure controlled
pressure compensation between the silo interior and the external
atmosphere during filling and evacuation operations.
At an internal excess and negative pressure this is effected by
opening a gravity-held flap upward of a certain differential
pressure. (See section Technical data).
Machine manual Transport and assembly
Pressure relief device 1

4 Transport and assembly

4.1 Transport and storage requirements

The pressure relief device is ready for installation. It must be
observed that suitable lifting equipment is employed in removing
the parts from the transport vehicles and transferring them to the
storage area.
When they arrive at the site, all parts must be inspected for
transport damage and placed on wooden beams with the
provision of suitable protection against rain, contamination and
damage. The parts must not be stored directly on the ground.

4.2 Assembly
The pressure relief device is delivered in a condition ready for
installation.
During installation, the mounting frame (3) is to be fitted and
welded in horizontal position (functional position).

CAUTION
If electrical welding is carried out in any place of the machine,
welding current must never be conducted through plain bearings
and antifriction bearings, other moveable connections or
measuring equipment to prevent damage to such parts.
Return lead (of welding current) must always be directly
connected to the part being welded.
Machine manual Lubrication
Pressure relief device 1

5 Lubrication

NOTE
This machine/unit requires no lubrication.
Machine manual Preparation for the test run
Pressure relief device 1

6 Preparation for the test run

6.1 Checks prior to the test run

After completion of the assembly work and prior to the first test
run, check all parts of the plant according to the list below. Take
particular care that all material remnants, tools and assembly
aids are removed.

 Have all the bolts been firmly tightened?

 Are connection flange and cover bolted up tightly?
Have the seals provided for this purpose been inserted?
 Has the movability of the flaps been verified?
 Are limitations to the flap movement excluded?
 Have the weights (13 and 14) been correctly adjusted?

6.2 Setting and adjustment

NOTE
for the adjustment of the weights at levers (11 and 12).
Opening pressure, see section Technical data.
 with minimum length of lever, the opening pressure is approx. 5
mbar;
 with maximum length of lever, the opening pressure is approx.
20 mbar;

CAUTION
Position and size of the weights must not be altered after
commissioning.

6.3 Test run

Subsequent to all checks, proper functioning of the pressure
relief device can be verified during the cold test run of the silo
installation.
Machine manual Maintenance
Pressure relief device 1

7 Maintenance

7.1 Inspection

WARNING
The pressure relief device can be very hot.
You can burn yourself.
Wait until the pressure relief device has cooled down before you
start any repair work.

No. Work to be performed Frequency Remarks

1 General visual inspection for every 4 weeks

 leaks
 damage
2 Checking of free movability of the every 4 weeks by moving the
flaps outer levers (11
(5 and 6) and 12)

7.2 Servicing

No. Work to be performed Frequency Remarks

1 Cleaning of housing interior every 4 weeks through

inspection door
(4),
with
depressurized
system

7.3 Trouble shooting

Fault Cause Elimination

Flaps (5 and 6) do not Flap seals (5.1 and 6.1) Replace flap seals
close tightly defective
Maintenance Machine manual
2 Pressure relief device

Sluggish movement of Dust deposits at or Remove dust. To do so,

flaps inside the housing (1) also open inspection
(5 and 6) door (4)
Dust deposits on sealing Replace sealing cord
cord in stuffing box (15)
Machine manual Maintenance
Pressure relief device 3

7.4 Repair
Before performing any repair work, make sure all electrical
components are disconnected.
Ensure the utmost cleanliness at all times during the repair work
in order to guarantee that the bearings, the drive system, or other
sensitive parts of the machine are kept free of contamination.

WARNING
The pressure relief device can be very hot.
You can burn yourself.
Wait until the pressure relief device has cooled down before you
start any repair work.

Dismantling the pressure relief device from the complete plant

 Verify that a filling of the silo is impossible and that there is no

pressure within the silo installation.
 Loosen the flanged connection between housing (1) and
mounting frame (3).
 Remove the pressure relief device.
 Cover the flange opening of the fastening socket.
(No foreign matter must penetrate into the silo!)

Instructions for dismantling the unit

For dismantling the pressure relief device, the following steps are
required:

 Loosen flaps (5 and 6) from the flap levers (9 and 10) by

removing the bolts (16) and split pins (17).
 Remove the flap levers (9 and 10) from the shafts (7 and 8) in
the following way: remove the spring-type straight pins (18 and
19), dismantle the adjusting ring (20) and levers (11 and 12) on
one side, remove the retaining ring (21), open the stuffing box
(15) and withdraw the shafts (7 and 8) laterally from the
housing (1).

Repair and replacement

If damage is established during the checks, the damaged parts
must be repaired or replaced by new ones.
Maintenance Machine manual
4 Pressure relief device

The following work can be carried out at the installed pressure

relief device:

 Replacement of the packing cord in the stuffing box.

For replacement of the flaps (5 and 6) or/and the flap seals (5.1
and 6.1) either the pressure relief device as a whole must be
dismantled or the cover (2) removed.
Machine manual Maintenance
Pressure relief device 5

Assembly instructions
The pressure relief device must be assembled in the following
order (all parts must first be checked and cleaned):

 Insert the shafts (7 and 8) into the housing (1), lining up the
flap levers (9 and 10). Fix the levers by spring-type straight
pins (18 and 19) on the shafts, fit the retaining rings, connect
the flaps (5 and 6) including the stuck-on flap seals (5.1 and
6.1) by bolt (16) and split pins (17) to the flap levers, axially
align the shafts and secure them with the adjusting ring (20)
(distance between housing and adjusting ring to be 1 mm).
 Fix the levers (11 and 12) by spring-type straight pins (18 and
19) on the shafts (7 and 8) and, if applicable, bolt the weights
(13 and 14) onto the levers.
 Mount cover (2) and inspection door (4) including seals (2.1 and
4.1).

Consumables

Description Manufacturer Remarks

Adhesive Teroson GmbH, for sticking on the flap

Heidelberg seals (5.1 and 6.1)
TEROKAL BE-WEISS

CAUTION
After you have completed the repair work, you must check the
machine/plant again according to the section Preparation for
the test run.

Tools and auxiliary devices

No special tools are required for repair work on the machine.
However, torque wrenches of a bigger size than normal may be
necessary.
The need for scaffolds or hoists depends on the conditions in your
plant.
Machine manual Spare parts
Pressure relief device 1

8 Spare parts

Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part
order place-ment as easy and efficient as possible. For this
purpose we have prepared a table containing all data required by
our spare parts department to ensure optimum processing in the
most speedy and trouble-free manner.
Please copy the title page and the page with the table. Fill in the
columns Quantity and Unit. Please mark those parts which you
require with a cross in the column Order or Enquiry. Send the title
page together with the table to the Spare Parts Department of
POLYSIUS AG.
If the table relates to more than one machine, please also inform
us of the POLYSIUS Order Code (POC) of the machine for which
you require the spare parts.
Spare parts Machine manual
2 Pressure relief device

Figure 2
Machine manual Spare parts
Pressure relief device 3

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

1.1 Pressure pipe socket 1 piece

1.2 Suction pipe socket 1 piece

2 Cover 1 piece

2.1 Seal 1 set

3 Mounting frame 1 piece

3.1 Seal 1 set

4 Inspection door 2 piece

4.1 Seal 1 set

5 Flap, discharge side 1 piece

5.1 Flap seal, discharge side 1 set

6 Flap, suction side 1 piece

6.1 Flap seal, suction side 1 set

Spare parts Machine manual
4 Pressure relief device

Figure 3
Machine manual Spare parts
Pressure relief device 5

Code word: Order no.: POC:

Item Designation Qty. Unit Order Enquiry

7 Shaft, discharge side 1 piece

8 Shaft, suction side 1 piece

9 Flap lever, discharge 1 set

side

10 Flap lever, suction side 1 set

11 Lever, discharge side 1 piece

12 Lever, suction side 1 piece

13 Weights, discharge side 1 set

14 Weights, suction side 1 set

15 Stuffing box with 2 set

graphitized packing cord

16 Bolt 2 set

17 Split pin 2 set

18 Spring-type straight pin 1 set

19 Spring-type straight pin 1 set

20 Adjusting ring with 1 set

screw

21 Retaining ring 1 set

Machine manual Appendix
Pressure relief device 1

9 Appendix

9.1 Technical drawings

NOTE
For drawing numbers, please refer to the table of contents of
this folder.

Designation Drawing no.

Pressure relief device