PROCEDURE FOR

ELECTROMATIC RELIEF VALVE FLOATING

Document No: PWR/TSX/BLR/03/247/00/11

Bharat Heavy Electricals Limited

Power Sector: Technical Services
Kribhco Bhawan, A-8-10, Sector 1, Noida, 201301

PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING

Procedure for Electromatic Relief Valve Floating

Document No: PWR/TSX/BLR/03/247/00/11
Designation

Name

Signature

Prepared by:
DHRUV GARG

Sr. Engineer (Boiler)

.D1\91tAl .1.Y.

Reviewed by:
G. Murali

AGM (Boiler)

Issued by:
N. K Bansal

GM (PS-TS)

Date of Issue

.o, , o

Issued to:

a . --,

2 %I I

As Pte. Visk9u ,--t,k446-1-

/,`&4

Copy No:
Type of Copy

Controlled/ Information

Bharat Heavy Electricals limited

Power Sector: Technical Services (HQ)
Kribhco Bhawan, A-8-10, Sector 1, Noida, 201301

Document No: PWR/TSX/BLR/03/247/00/11

Power Sector Technical Services

2

PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING

Content
S. No.

Description

Page No.

1. Objective

2. Electromatic Relief Valve (ERV) Assembly, System &

Terminology

3. ERV Floating Principle

4. Checks for ERV Floating (Mechanical & Electrical)

5. Pre Floating Activity

6. Safety Precautions

7. Safety Equipments

8. Procedure for ERV Floating

9. ERV Setting Values

10

10. Appendix 1: ERV Details in a typical drawing for Safety

Valve Setting for Boiler, Superheater, Reheater & Soot
Blower for a 500 MW Boiler

11

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Document No: PWR/TSX/BLR/03/247/00/11

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PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING
1. Objective
Electromatic Relief Valve (ERV) is provided in the system to prevent boiler pressure
going beyond the required level at any load by operating it electrically from remote
according to requirement and to prevent frequent operation of safety valves, thereby
increasing its life and availability.
ERV Floating is one of the last commissioning activities before boiler is ready for load
operations. The objective of ERV Floating activity is to determine and ensure:
Popping or Set Pressure for the ERVs
Clean popping of the ERVs
Reseating or Closing Pressure of the ERVs
Clean reseating of the ERVs
Blowdown for the ERVs
Cleanliness of the ERVs and its exhaust system

2. ERV System, Assembly & Terminology

Isolating Valve Shown in Figure 1. It is the mechanical isolating gate valve provided
for isolating ERV from the system.
Pilot Valve Shown in Figure 1. Pilot Valve is the main component of ERV which
when operates relieves the pressure of the system.
Solenoid Assembly Shown in Figure 1. Solenoid gets energized from electrical
supply via actuated pressure switch, which in turn operates the pilot valve.
Control Station Shown in Figure 1. Control Station is equipped with 3 point switch
(manual, off and automatic) and corresponding 3 lamps (red, blue & green). Green
light indicates auto position. Blue light indicates system pressure reaching the set
point or corresponding relay for pressure switch has been energized at manual
position. Red light glows, when the valve remains open fully at the time of floating.
Hand operation is performed by putting the switch to manual position for opening
and then to off position for closing.
Controller Shown in Figure 1. Controller houses pressure switches for set & reseat
pressure and get impulses through impulse line originating from MS Line. By
adjusting the screws, the operating point (i.e. set pressure & blowdown) can be
decided.
Set Pressure Pressure at which ERV starts floating. Basically, it is the gauge
pressure at the valve inlet, for which the ERV is adjusted to open under service
conditions.
Reseat Pressure Pressure at which ERV stops floating i.e. the pressure at which the
disc reseats.

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Document No: PWR/TSX/BLR/03/247/00/11

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PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING
Blow Down It is the difference between set pressure and reseating pressure
expressed as a percentage of the set pressure. It signifies the amount of pressure
relieved from the system.
Blowdown (%) =

(Set Pressure Reseat Pressure) * 100

Set Pressure

Figure 1: Electromatic Relief Valve System

Power Sector Technical Services

Document No: PWR/TSX/BLR/03/247/00/11

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PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING

Figure 2: Electromatic Relief Valve Assembly

Nomenclature List (for Figure 2)

226
229
303
305
307
311
322
323
324
332
341

Base Stud
Nut
Main Base
Inlet Neck
Support Plate
Pilot Valve Tube
Nipple Extension
Discharge Collar
Pipe Elbow
Solenoid Assembly
Seat Bushing Main

344
345
347
351
355
356
376
377
378
379
383

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Disc
Guide
Disc Spring
Pilot Seat Bushing
Pilot Disc
Pilot Stem
Pilot Spring
Pipe ELL
Pipe Nipple
Lever
Solenoid Plunger Head

Document No: PWR/TSX/BLR/03/247/00/11

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PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING
3. ERV Floating Principle
ERV Floating principle is explained below with the help of Figure 2 giving details of ERV
Assembly.
Steam under pressure from the superheater enters the main valve through the inlet
chamber A, and passes upward around the disc guide, to chamber B, steam enters
chamber C through the clearance space between the main valve disc (344) and its guide
(345). The main valve disc (344) is held in the closed position by steam pressure in
chamber C. the pressure in chamber c is the same as in chamber b when the escape
through port D is prevented by the closure of the pilot valve disc (355). The pilot valve
disc (355) is held in the closed position by pilot valve spring (347) and by the steam
pressure in chamber E. It is opened by the operating lever (379) under the action of the
solenoid plunger head (383). When the pilot valve is opened steam is released from
chamber D through port F at a faster rate than supplied through the clearance space
between the main valve disc and the main valve disc guide. The resultant unbalance of
pressures in chambers B and C produces a force which moves the main valve disc from
its seat, permitting steam to escape from chamber B to outlet G.

4. Checks for ERV Floating

Mechanical Checks
Visually inspect all the ERV for correction erection and installation as per drawing.
No load transmission from discharge piping to ERV.
Vertical installation (within 1).
Body drain to a safe area.
Adequate 360 access around valve & overhead.
Controller away from location of vibration and several looping in impulse pipe.
Slope of impulse line towards the controller & provided with siphon.
Gap between solenoid plunger end and pilot valve operating lever is 22.7 to 35.4
mm.
Pressure connection at 8 to 10 pipe dia. upstream from ERV.

Electrical Checks
Terminal connection correctness w.r.t. wiring diagram.
Installation of recommended fuses.
Power supply.
Cut off switch in solenoid for proper function.
Pressure switch for correct range.

Smooth action of solenoid by pressing.

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Document No: PWR/TSX/BLR/03/247/00/11

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PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING
5. Pre Floating Activity
Close the ERV Isolating gate valve.
Put the switch on Auto and green light will indicate correctness.
Turn the switch to Manual. Measure the movement of solenoid plunger. It should
press the operating lever in such a way that pilot stem moves by 2.4 to 3.2 mm.
Red and blue lamps should be glowing now. Blue lamp shows that relay is energized.
Red light shows that plunger has reached the bottom of stroke i.e. the valve has
opened.
Put the switch back to Auto. Red & blue lights should go off. Solenoid & operating
lever returns to normal position.
Put the switch to off. All lights should go off.

6. Safety Precautions
a) Do not stand in front of discharge side of an ERV during floating.
b) Never install a ERV in a horizontal position, as they are designed for vertical
operation only. Always provide Isolating Valve for ERV to isolate it from the system.
c) Drains of ERV must be piped to a safe area.
d) 360 and overhead access to ERV should be there.
e) Minimum number of people, only who are required for the floating & setting of ERV
should be present on the ERV floor during the activity.
f) Cordon off the area where valves are going to be tested to avoid trespassing during
the activity and warn people at the site about the activity and precautions to be
taken.
g) Use safety equipments listed in the section of Safety Equipments for personnel
safety from noise and high temperature during the activity.

7. Safety Equipments
a)
b)
c)
d)
e)
f)
g)

Asbestos Gloves
Safety Helmet
Ear Muffs
Eye Protector
Safety Shoes
Protective Clothing
First Aid Box (Containing Eye Lotion, Tincture of Iodine, Burnol, Bandages, Cotton
etc.)

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Document No: PWR/TSX/BLR/03/247/00/11

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PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING
8. Procedure for ERV Floating
Light up the boiler following O&M instructions. Keep Main Steam Stop valve closed.
Raise the pressure to 35 kg/cm and hold.
Disconnect the impulse line from controller and steam flush the line for 15 30
minutes by opening isolation valve.
Restore back the impulse line.
Open slightly the ERV isolation gate valve. Allow at least 30 minutes for warming up
of valve. Open the isolation valve fully.
If valve leakage is visible (it can happen due to entrapment of dirt or scale in seat),
operate the switch on Manual for few seconds. If the valve leakage persists even
after 5 minutes of operation, valve seat requires rectification.
Increase the boiler pressure. As the pressure increases, first the low pressure (closing
pressure) switch indicating light will glow indicating its actuation. On further increase
of pressure, ERV will pop.
Note down the popping pressure & blow down. Check set pressure, reseat pressure
and blowdown for the ERV in the Safety Valve Details Chart provided in the drawing
Safety Valve Setting for Boiler, Superheater, Reheater & Soot Blower (Typical
Drawing No.: 200047XXXXX). A typical drawing for ERV Setting for 500 MW Boiler
is enclosed in Appendix 1.
If popping pressure is less than recommended, turn the corresponding setting screw
counter clockwise. For decreasing popping pressure, turn it clock-wise.
For setting blow down, the recommended graph (as in Figure 3) may be referred. By
turning corresponding setting screw for blow down, same can be increased
(clockwise) or decreased (counter clockwise).

Power Sector Technical Services

Document No: PWR/TSX/BLR/03/247/00/11

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PROCEDURE FOR
ELECTROMATIC RELIEF VALVE FLOATING

Figure 3: Typical Graph for Setting Blowdown of SH ERV

9. ERV Setting Values

A typical set of values for ERV Setting for a 500 MW Boiler is given in Table 1 as below.
Table 1: Typical ERV Setting Values for a 500 MW Boiler
S.No.

Location

Valve
Tag No.

Valve Model No.

1.
2.
3.
4.
5.
6.
7.
8.
9.

Super Heater
Super Heater
Super Heater
Super Heater
Super Heater
HRH
HRH
HRH
HRH

SV9
SV10
SV11
SV12
SV13
SV22
SV23
SV24
SV25

CONSOL 1538 VX-10W

CONSOL 1538 VX-10W
CONSOL 1538 VX-10W
CONSOL 1538 VX-10W
CONSOL 1538 VX-10W
CONSOL 1525 VX
CONSOL 1525 VX
CONSOL 1525 VX
CONSOL 1525 VX

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Valve Set Pressure Blowdown Type Of Valve

(in kg/cm2) (G)
(%)
OPEN
CLOSE
185.5
180.3
2.8
ERV
185.5
180.3
2.8
ERV
186.6
180.6
3.2
ERV
186.6
180.6
3.2
ERV
186.6
180.6
3.2
ERV
48.4
47.1
2.7
ERV
48.4
47.1
2.7
ERV
48.9
47.6
2.7
ERV
48.9
47.6
2.7
ERV

Document No: PWR/TSX/BLR/03/247/00/11

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Appendix 1:
ERV Details in a typical drawing for Safety Valve Setting for Boiler, Superheater, Reheater & Soot Blower for a 500 MW Boiler

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