Operation- and maintenance

manual for explosion relief valves

type EVO
Application: Oil mist- and Gas explosions
Version 4.01

HOERBIGER Wien GmbH

Seestadtstraße 25
A-1220 Vienna
Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

Content

1. INTRODUCTION ............................................................................................................... 3
2. DESIGN OF EXPLOSION RELIEF VALVE TYPE EVO .................................................... 5
3. DESIGN LIMITS ................................................................................................................ 6
4. OPERATION ..................................................................................................................... 7
5. FITTING ON THE MACHINE ............................................................................................ 8
5.1 General remarks ............................................................................................................ 8
5.2 Leak oil return ................................................................................................................ 9
5.3 Recommended safety area .......................................................................................... 10
6. INSPECTION .................................................................................................................. 11
6.1 Regular inspection........................................................................................................ 11
6.2 Inspection after an explosion ........................................................................................ 11
6.3 General inspection procedure ...................................................................................... 11
6.3.1 Inspection of the flame arrester ............................................................................................. 11
6.3.2 Inspection of the valve sealing ............................................................................................... 13
7. MAINTENANCE .............................................................................................................. 14
7.1 Cleaning of flame arrester and exchange of O-ring ...................................................... 14
8. MARKING ....................................................................................................................... 17
9. TABLE OF CHANGES .................................................................................................... 18

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

1. Introduction
This operation- and maintenance manual is valid for the following valves:

EVO Series
1
Valve Relief area
Part number Old-Part number
type [cm²]
98EVO 59.4 1077 30-WS9098
122EVO 95 81127 30-WS9122
150EVO 143 147751 30-WS9150
162EVO 177 1076 30-WS9162
173EVO 201 135135 30-WS9173
224EVO 346 137830 30-WS9224
266EVO 499 1004 30-WS9266
1
Please consider the efficiency mentioned in the table on page 6 “design limits”.

CE type examination certificate: FTZU 15 ATEX 0196X

Issued by: Physikal Technical Testing Institute

FTZU 1026
Pikartaska 7
71607 Ostrava Radvanice
Czech Republic

Manufacturer: HOERBIGER Wien GmbH

Seestadtstraße 25
A-1220 Vienna, Austria
Phone: +43-1-22 440
mailto: sales.ev@hoerbiger.com

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

Used symbols:

Read and understand operator’s

manual before using this equipment!

Safety advice
Risk of injury

Functional advice
Concerning correct function

IACS UR M9, M10 and M66 Rules

IACS Directive for application of explosion relief valves on marine engines.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

2. Design of explosion relief valve type EVO

Position Description
1 Seat
2 O-ring
3 Distance bolt
4 Distance tube
5 Valve plate
6 Flame arrester
7 Expand metal (filter strip)
8 Spring
9 Cover
10 After final test and inspection the valve gets equipped with a shear nut. The shear
nut must not be removed!
11 Leak oil return
Delivery scope doesn’t include bolts and gasket required for mounting.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

3. Design limits
The HOERBIGER explosion relief valve type EVO covered in this manual is designed for
protection of engines crankcases within following design limits:

Operating pressure: 1 bar absolute (atmospheric conditions in the

crankcase)

Operating temperature: -20° to + 100°C

KGmax
Size Pred max [barg] Pstat [barg] Pmax [barg] EF [%]
[bar.m.s-1]
98 EVO
122 EVO
150 EVO
162 EVO
3 0,05 ~ 0,1 50 8 60
173 EVO
204 EVO
224 EVO
266 EVO
*The largest protected volume Vmax which may be protected by one explosion relief valve
has to be clarified together with the manufacturer.

Operation beyond these design limits is prohibited. HOERBIGER’s warranty and

liability becomes invalid immediately in case of improper application.

HOERBIGER explosion relief valves type EVO are components for diesel, dual
fuel and gas engines which necessarily require a connection to the engine to
describe a functional machine. Thus the instructions of the engine manufacturers
are of prior validity to the operator.

The selection of the venting area has to be done according to existing standards
and guidelines. It is not allowed to change one of the parameters that are part of
the calculation of the venting area. This means as soon as anything changes for
example the KG value, the sizing of the venting area has to be checked against all
design limits.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

4. Operation
Explosion relief valves type EVO protect personnel and equipment in the event of an oil mist- or
gas explosion in crankcases of diesel, dual fuel and gas engines. In this document diesel, dual
fuel and gas engines are called “machine”.

In case of an explosion the valve plate lifts up and relieves the overpressure through the
integrated flame arrester. Therefore no flame transmission to the outside of the valve must be
considered. Immediately after the pressure vent, the valve plate closes and prevents a fresh air
inrush. Hence secondary explosions are avoided.

Since the valve closes immediately after the pressure vent, no gas will be released to the
environment. For that reason no immediate shutdown of the engine is required.

The below mentioned and all relevant instructions given by the engine manufacturer have to be
obeyed.

The valve also is approved for indoor applications according to ATEX.

For reasons of the remaining heat, the explosion relief valve must not be touched
after an explosion – Danger of severe injury!

After an explosion the relief valve has to be exchanged at the next scheduled
IACS maintenance shutdown. Furthermore the instructions of the engine manufacturer
have to be observed.

Contact the manufacturer HOERBIGER Wien GmbH in case of any damages or

malfunctions of the valve, e.g. leakage.

During operation of the system, no work at the valve is allowed.

In case of visible damage of the valve, the valve has to be replaced.

The shear nut (position 10) must not be removed. All work to disassemble the
valve is forbidden. HOERBIGER’s warranty and liability becomes invalid
immediately in case of an opened seal.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

5. Fitting on the machine

5.1 General remarks
All work done on the valve like mounting or dismounting has to be carried out by
skilled personnel wearing suitable protective clothes and using appropriate tools.

Sharp edges and the weight of the valve may lead to injuries of personnel. Due to
improper handling the valve might drop and hurt personnel.

The lamellas of the flame arrester must not be painted, coated or manipulated in
any other way. All components of the flame arrester must not be damaged during
work.

The valve always has to be mounted on the outside surface of the machine /
protected volume. Mounting the valve in wrong way inside of the protected
volume leads to a non-fulfilment of its safety function!

During fitting the valve to the machine the information stated in the assembly
drawing must be observed. The required number of bolts has to be used, the
assembly torque is specified in the assembly drawing. A suitable gasket has to be
used in between the explosion relief valve and the counter flange of the machine.

It has to be observed that there is enough space for accessing the valves, to
enable a visual check of the condition at any time.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

5.2 Leak oil return

The valve has a bore hole for leak oil return. The leak oil return can be activated
by setting a counter hole through the sealing and counter flange of the protected
machine if required. If the leak oil return has been activated, design modifications
are required to avoid oil mist-/ gas escape to the outside (e.g. syphon, oil trap).

The diameter of the counter hole and syphon shall be at least the diameter of the
oil return hole (10mm). The explosion relief valve has to be mounted with the leak
oil return hole in “six o’clock” position to maintain the backflow of the leaking oil.
The siphon (U-shaped piece of pipe) is welded to the counter flange (see pictures
below). As an alternative standard hydraulic fittings can be used to mount a piece
of pipe to the counter flange.

Syphon

Activated leak oil drain Leak oil drain not activated

(Syphon is not scope of supply)

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

5.3 Recommended safety area

The valve shall be located such, that hot gases are not directly blowing to areas
where operating personnel will typically remain (such as gangways,
panels,…etc.). It is recommended to maintain a safety distance of 2 meters in
radial direction and 0.5 meters in axial direction, which is defined as hazardous
area (see sketch below).

Individuals, who have to stay due to operational reasons around the defined
hazardous area, have to be instructed about the predominant hazards.

HOERBIGER explosion
0,5m relief valve

Recommended
safety distance

2m

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

6. Inspection
6.1 Regular inspection
For a safe operation of the explosion relief valve a regular inspection (acc. to chapter 6.3) is
mandatory, depending on the operating condition, but at least 1 time a year.

6.2 Inspection after an explosion

After an explosion the valve needs to be inspected according to chapter 6.3.
In addition the instructions of the engine/machine manufacturer have to be obeyed.

After an explosion the relief valve has to be exchanged at the next scheduled
IACS maintenance shutdown. Furthermore the instructions of the engine manufacturer
have to be observed.

6.3 General inspection procedure

During the inspection the following points should be checked and recorded:

- Visual inspection of the overall condition of the valve (no damage or corrosion)
- Inspection of the flame arrester according to chapter 6.3.1.
- Inspection of the valve sealing according to chapter 6.3.2.

If no deviations are detected, the explosion relief valve can continue the operation.

6.3.1 Inspection of the flame arrester

The flame arrester has to be inspected in terms of possible damages (abnormal gaps of
the flame arrester layers).

The following pictures demonstrate a flame arrester in proper condition and in bad
condition as well:

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

In this case the flame arrester is in good condition:

In this case the valve has to be replaced:

Additionally the flame arrester has to be checked against extensive contamination and
deposits, which might influence the pressure relief function.
When a flash light is placed on one side of the flame arrester, the light shine must be
visible at the opposite side, to make sure that the flame arrester is not clogged by dirt
accumulations.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

flash light

In case of extensive dirt accumulations between the flame arrester layers,

the flame arrester has to be cleaned by suitable cleaning equipments (e.g.
vacuum cleaner) or with other adequate methods (e.g. compressed air, non-
corrosive and inflammable substance), at standstill of the engine.

If abnormal gaps on the flame arrester can be observed, the valve has to be
replaced.

Furthermore you have to obey the instructions of the engine/machine

manufacturer.

6.3.2 Inspection of the valve sealing

If there is leakage observed, the internal O-ring seal has to be replaced – see
chapter 7.1.

Furthermore the instructions of the engine/machine manufacturer have to be

obeyed.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

7. Maintenance
The explosion relief valve is almost maintenance free, nevertheless to guarantee a proper valve
function during the lifetime, we recommend to replace the sealing ring of the explosion relief
valve after 16,000 hours in operation.

Additionally following remarks have to be obtained for a safe explosion relief valve operation:

For proper operation the flame arrester has to be kept clean.

In case that dirt is collected on the flame arrester, it has to be cleaned with
compressed air or respectively with a non-corrosive and inflammable substance
(degreaser) at standstill of the machine.

The internal O-ring might lose the sealing function through ageing or chemical
attacks. In case of gas/oil leakage the O-ring has to be replaced during the next
scheduled shutdown, either by HOERBIGER or by trained stuff according
procedure described in chapter 7.1.

All instructions of engine–manufacturers and all advices for secure operating and
mounting of explosion relief valves given in the previous chapters are valid.

7.1 Cleaning of flame arrester and exchange of O-ring

The cleaning of the flame arrester and the exchange of the O-ring should be done by skilled
personnel according to the following steps:

1. Dismantle the explosion relief valve from the counter flange.

2. Push the valve plate open against the spring force by using adequate tool (i.e. hydraulic
press, drilling machine etc.). Before you reach into the valve with your hands it is mandatory
to add protection against sudden reclosing (i.e. appropriate piece of wood or similar)

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

The pictures above are showing how to push the valve plate open by using a drilling machine
with a simple rod (the machine must be not switched on). Please make sure that the coating of
the valve plate won`t be damaged.

3. Clean the flame arrester by blowing air from the inside to the outside of the flame arrester.

4. Remove the old O-ring by using an adequate tool (i.e. screwdriver) and clean the O-ring
groove.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

5. Before mounting the new O-ring apply glue to the O-ring groove. Please make sure that the
glue is spread uniformly in the O-ring groove.

6. Insert the O-ring and clean the O-ring before closing the valve plate.

7. Mount the valve onto the machine, as described in chapter 5.

Take care when using cleaning agents or glue! Please follow the manufacturer’s
safety instructions carefully.

NOTE:

As glue “PATTEX classic” made from Henkel corp. can be used:

To ensure an even and thin application,

4 parts of glue can be mixed with 1 part cellulose thinner.

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

8. Marking
The marking of the type plate is as following:

Marking explosion relief valve EVO

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Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01

9. Table of changes

The operational manual is part of the documentation for the classification society
IACS to obtain the approvals according IACS Rules M66. HOERBIGER has to report to
the classification society if there are any changes.

version date author comment

1.01 21.7.2008 BHA, HAT, RAX first version
1.02 2.12.2008 RAX Pictures added for
siphon and service
procedure
1.03 16.07.2012 HAT Safety Distance
2.00 04.11.2015 DSU Marking, Design limits,
ATEX conform
3.00 20.12.2016 EH Address change,
Marking, adding number
of type approval and
company, which has
issued the type
approval
4.00 08.08.2017 HAT, EH, DSU Layout, Inspection,
Delete of the warranty
4.01 01.08.2018 EH Change company name

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