PSV Oil-Free SOP

LESER WORK STANDARD LWN325.
03-E
Producint and Testing Safety Valves Oil- and Grease-
Free Design (QM Standard Operating Procedure) page 1
This LESER company standard is used as a production and testing instruction.
The Process
1 Planning
Oil- and grease-free valves up to DN 65 are planned for the set-up working space (work sheet
number 222) where there are also tests and assembly. The oil- and grease-free valves are
mounted in the assembly area and tested for sealing in the official acceptance testing space from
DN 80.
2 Providing Materials
The warehouse personnel brings the all of the components provided for washing. The assembly
personnel picks up the washed parts and assesses them as per Point 5.
3 Washing and Degreasing Valve Components and Phosphating Them

The following process shall be complied with:
Charge the washing basket so that all of the components are in separate places and move the
filled basket back into the washing machine.
procedure:
a) wash the components by spraying them for a washing time of 6 minutes and at a bath
temperature of 80°C.
use the cleansing additives of degreasing concentrate VRX81, article number 1103.
supplier: Wigol W. Stache GmbH, chem. Fabrik Textorstr. 2, 6520 Worms.
Only ferritic and austentic materials may be washed with degreasing concentrate VRX81.
b) liquid phosphating the components by spraying them.

approximately 3 minutes and at a bath temperature of 80°C.
use the cleansing additives:
phosphating component FE II, liquid, article number 000872
supplier: Wigol W. Stache GmbH, chem. Fabrik Textorstr. 2, 6520 Worms.
Only steel casting (GS), cast iron with lamella graphite (GG) or spheroidal graphite (GGG)
may be liquid phosphorated.
c) clear rinsing by spraying with clear water.
d) Dry the components with rotating condensation. Drying time approximately 3 minutes.
After drying, the parts should be moved out of the washing machine and blown off immediately with
oil-free compressed air so that none of the components of the water remain. The personnel have to
place the cleaned component parts in clean red stacking boxes wearing fabric gloves. The
assembly personnel picks up all of the component parts and does checks 100% if they are free of
oil and grease.
End of LWN
LESER processed: Gi edition: 18.02.04
GmbH & Co. KG approved: refer to ÄM 5252 replaces edition: 04.02.03
LESER WORK STANDARD LWN325.03-E
Producint and Testing Safety Valves Oil- and Grease-
Free Design (QM Standard Operating Procedure) page 2
4 Handling and Transport

There are special criteria for handling and transport such as using linen gloves and sealing the
flange openings with new plastic covers, as long as this does not make handling difficult. Pack the
cleaned and dried valve components in clean containers or lockable plastic bags and then
transport them to a UV-light observation cabin. If they are put into intermediate storage or
transported, please ensure that the surfaces they are placed on are clean surfaces such as cloth,
carton or paper.
5 Assessing the Cleaning Process

The components are assessed to see if they are free of oil and grease under UV-light at a
wavelength of 320-380 nm (3,200-3,800 A). The light source has to have a minimum intensity of
800 myW/cm² at a maximum distance of 38 cm and there may not be any bluish-white fluorescent
spots. Repeat the test under white light. Should it not be possible to make a visual inspection at
inaccessible points or if there are invisible results, make a wipe test with a white lint-free linen or
paper cloth and the cloth should then be assessed with both types of light to see if there are
impermissible residues (testing frequencies 100%). If there is no objection, it should be released
for assembly. If the testing results are negative, trained personnel will clean and test again and
documented in the working papers (batch process card or assembly adjustment order) with a
stamp, comments and initialling it.
6 Assembly
After the cleaned components have been released, they are assembled in the work room for
valves free of oil and grease with safety valves up to DN 65 (work sheet no. 222). The pressure
setting (with air free of oil) and sealing test are also made there along with official acceptance for
the company accepting. Safety valves with rated widths greater than DN 65 are assembled at an
especially cleaned assembly location in the assembly hall and then set at a testing table in the
testing room exclusively for valves free of oil and grease (using nitrogen). All of the tools have to
be cleaned to be free of oil and grease. Section 4 applies to handling and transport.
7 Final Test for Valves being Free of Oil and Grease

After setting and testing the components, they are tested once again with UV-light to see if they are
free of oil and grease as per Point 5. They are then packed in the area free of oil and grease in
conformity with LESER company standard 617.01 ensuring that there is not any textile lint in the
inside of the valve. If there is lint, it should be removed with the suction cleaner.
8 The Lubricant Used with Pressure Screws:

halocarbon 56 S, article number 000507.
supplier: Chemie-Mineralien AG u. Co. KG, Post Office Box 106523, 2800 Bremen
BAM acceptance number: D/BAM 7792 KHV
End of LWN
GmbH & Co. KG approved: refer to ÄM 5252 replaces edition: 04.02.03
LESER-WERKNORM LWN 325.03-E
Producing and Testing Safety Valves Oil- and Grease-
Free Design (QM Standard Operating Procedure) p. 3
9 Seals Used
Asbestos-free seals with BAM acceptance (for instance, in conformity with LESER company
standard 026.01).
remarks:
a) a coating of rust film is permissible with valves of not made of corrosion-resistant material
b) they shall be marked with a sticker in conformity with LESER company standard 617.01:
refer to drawing 335.0509-01 (sign of parts free of oil and grease)
(This sticker does not exempt the plant operator of his obligation / responsibility to select
the materials for fitting in conformity with Section 28 of the Accident Prevention Regulations
on Oxygen (VGB 62) Section 13)
c) packaging in hose foil in conformity with LESER company standard 617.01 adding drying
agents in conformity with DIN 55473.
commercial name: blue gel

design: JBP, low-dust
size: approximately 5g (1/6 units of drying agents)
bag size: approximately 80 x 60 x 4 mm
manufacturer: Südchemie AG, Lehnbachplatz 6, 8000 Munich 2
d) Implementing this company standard meets the specifications listed in the following:
- MGI "Standard 06401-1..3"

- Air Products Engineering "AO2 Rev. 06 Process Clean Acceptance Criteria"
- Mannesmann Demag Cleaning Regulation 010 008 99 Rev. 3 and Acceptance
Regulation 010 964 99 Rev. 3.
End of LWN
GmbH & Co. KG test note: refer to ÄM 5252 replaces edition: 04.02.03

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LESER WORK STANDARD LWN325.

3 Washing and Degreasing Valve Components and Phosphating Them

b) liquid phosphating the components by spraying them.

c) clear rinsing by spraying with clear water.

4 Handling and Transport

5 Assessing the Cleaning Process

7 Final Test for Valves being Free of Oil and Grease

8 The Lubricant Used with Pressure Screws:

refer to drawing 335.0509-01 (sign of parts free of oil and grease)

commercial name: blue gel

- MGI "Standard 06401-1..3"

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