Overpressure Relief Valve Overpressure Relief Valve Overhaul Procedures

Overpressure Relief Valve

Contents
OPRV-1 1.1 Overpressure Relief Valve OPRV-2 1.1.3 Overpressure Relief
Overhaul Procedures Valve Reassembly
OPRV-1 1.1.1 Overpressure Relief OPRV-2 1.1.4 Overpressure Relief
Valve Valve Lift Check/Setting
OPRV-1 1.1.2 Overpressure Relief OPRV-3 1.1.5 Troubleshooting The
Valve Disassembly and Overpressure Relief Valve
Cleaning

1.1 Overpressure Relief Valve Repair parts are available by purchasing P/N
Overhaul Procedures 225-017 overpressure relief valve rebuild kit.
Replacement parts include the O-ring, poppet
1.1.1 Overpressure Relief Valve with rubber, spring, and adjustment screw. The
O-ring should be replaced at least annually. The
The overpressure relief valve should always be other parts require replacement only if worn or
used on all Emergency Gas Supply (EGS/bail- damaged. An exploded view of the valve is lo-
out) first stage regulators to prevent the hose cated in all KMDSI Helmet and Band Mask Op-
from rupturing if the first stage happens to de- erations and Maintenance Manuals. The text on
velop a slight leak, causing the pressure to creep. the next three pages refers to the drawing "Over-
The Kirby Morgan relief valve body is made of pressure Relief Valve Component Breakdown" on
stainless steel. page OPRV-1.

OVERPRESSURE
RELIEF VALVE BODY
Tools Required:

• Torque Wrench

SPRING • 1/2" Open-End Wrench Attachment for Torque

O-RING Wrench

• 1/8" Allen Wrench

POPPET WITH
RUBBER
• Nylon Toothbrush
ADJUSTMENT
SCREW • Vinegar and Fresh Water

• Mild Dish Soap

Overpressure Relief Valve Component Breakdown
• Ultrasonic Sink, if Available
The basic components last a long time, but the
valve should be disassembled, cleaned, and in- • Magnifying Glass
spected at least once a year or whenever it fails
testing. The valve should be tested monthly.
1.1.2 Overpressure Relief Valve
Cleaning and overhaul is easily performed using
Disassembly and Cleaning
a nylon toothbrush and a solution of 50% vinegar
and 50% fresh water. Cleaning for 15 minutes 1) Turn off the gas supply to the first stage reg-
in an ultrasonic sink, if available, with the 50% ulator, then bleed off any remaining pressure.
vinegar and 50% fresh water solution is highly Remove the first stage regulator from the air/
recommended. breathing gas source so it cannot be accidentally
turned on, i.e., pressurized. Make sure the inter-

© MMXVIII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 180503020 OPRV-1
Overpressure Relief Valve Overhaul Procedures  Overpressure Relief Valve

mediate pressure in the regulator hose is also 1/2 thread from being flush with the top of the
fully drained of pressure. valve body.

2) Remove the overpressure relief valve from the 2) Lightly lubricate the new O-ring, then install
regulator body using the 1/2" open-end wrench. on the valve body.

3) Remove, cut, and discard the overpressure re- 3) Test the overpressure relief valve according to
lief valve body O-ring. the test procedure below.

4) Using the 1/2" open-end wrench to hold the over- 1.1.4 Overpressure Relief Valve Lift
pressure relief body, use the 1/8" Allen wrench to Check/Setting
remove the Allen head adjustment screw. Then,
shake out the spring and poppet. Tools Required:

5) Place all parts in the solution of 50% vinegar • Adjustable First Stage Scuba Regulator or
and 50% fresh water and allow to soak for 15 to Controlled Adjustable Pressure Source
30 minutes. If using an ultrasonic sink, reduce • Intermediate Pressure Test Gauge
time to 15 minutes.
• Torque Wrench
B WARNING • 1/2" Open-End Wrench Adapter for Torque
Do not use cleaning solvents (i.e. min- Wrench
eral spirits, bleach, etc.) when clean-
ing the overpressure relief valve. The • 1/8" Allen Wrench
use of cleaning solvents may lead to • HP Air Source (Scuba Tank) with at Least
failure of the overpressure relief valve.
500 p.s.i.g. (34.4 Bar).
6) Using the nylon toothbrush, brush all compo- • Mild Dish Soap
nents to remove corrosion and mineral deposits.
Then, rinse with fresh water and blow or air dry.
The purpose of lift checking the overpressure
7) Using the magnifying glass, carefully inspect relief valve is to ensure it operates properly, al-
all components for excessive corrosion and/or lowing excess pressure to escape if the first stage
damage. Replace the spring and/or adjustment develops a slight leak. Without the overpressure
screw if either part is excessively corroded or relief valve, high-pressure gas will continue to
shows signs of wear and/or damage. build until the emergency supply hose ruptures,
possibly causing injury and a complete loss of gas
Inspect the poppet for nicks, cuts, and wear and from the Emergency Gas System (EGS).
replace if any damage is found. If the overpres-
sure relief valve body is damaged, then the entire
overpressure relief valve (P/N 200-017) should be
B WARNING
replaced. Ensure the overpressure
relief valve is only in-
stalled in a low-pressure
NOTE: A deep groove in the poppet is normal. port of the first stage
Replacement is only necessary if the rubber seat regulator. Installation in
is deteriorated, cut, and/or chipped. a high-pressure port will
lead to loss of EGS sup-
1.1.3 Overpressure Relief Valve ply and possible serious
Reassembly personal injury if the
valve fails.
1) After cleaning, inspection and/or parts replace-
ment, reassemble the valve by installing the pop- This procedure explains the steps necessary for
pet, spring, and adjustment screw. Tighten the readjusting the overpressure relief valve after it
adjustment screw down until it is approximately

OPRV-2 © MMXVIII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 180503020
Overpressure Relief Valve Overpressure Relief Valve Overhaul Procedures

is cleaned, overhauled or any time the valve is 3) Install the 1st stage regulator on the cylinder.
tested. Ensure the relief valve and intermediate pres-
sure gauge are attached to low-pressure ports.
NOTE: The overpressure relief valve is lift
checked and/or adjusted using an adjustable first 4) Wet the relief valve with soapy water to help
stage regulator, equipped with a low-pressure indicate gas flow
test gauge, which is used for adjusting the inter-
mediate pressure of scuba regulators. The check/ 5) Slowly bring up air pressure while watching
adjustment can be performed using a standard the intermediate pressure gauge until the pres-
scuba test stand, or a gas control console, using sure gauge indicates 180- 200 p.s.i.g. (12.40-
air or mixed gas with an oxygen content below 13.78 bar). If the relief valve starts venting at a
23% by volume. pressure below 180- 200 p.s.i.g. (12.40-13.78 bar),
secure the air supply and adjust the adjustment
screw in (clockwise) 1/8th turn. Slowly bring up
B WARNING pressure and recheck.
Do not use oxygen, or
mixed gas containing Continue this procedure as necessary until the
more than 23% oxygen relief valve consistently vents at a pressure be-
by volume, for lift check- tween 180- p.s.i.g. (12.40-13.78 bar). If the valve
ing the overpressure
relief valve. The use of does not start venting when the gauge reads 200
oxygen, or mixed gas, p.s.i.g. (13.78 bar), slowly back out on the adjust-
in a high-pressure sup- ment screw (counter clockwise) until the valve
ply system not designed starts venting, forming bubbles in the soap solu-
and cleaned for oxygen tion.
service, can result in a
fire or explosion causing 6) After the valve has been adjusted, adjust the
serious injury or death. 1st stage regulator intermediate setting to 135
p.s.i.g. (9.3 bar), re-wet the valve, then slowly
If a first stage scuba regulator is used, it must increase the intermediate pressure on the 1st
be able to be adjusted to the desired lifting pres- stage regulator one last time to recheck the lift
sure. The pressure gauge should be compared to pressure. The valve should start forming bubbles
a gauge of known accuracy. or venting between 180- 200 p.s.i.g. (12.40-13.78
bar). Back the 1st stage pressure to 180 p.s.i.g.
NOTE: If the Allen screw on the overpressure and observe the bubbles. They should stop just
relief valve hex nut is rotated too far, too fast, under 190 p.s.i.g.
the overpressure relief valve will pop open. This
could possibly require the air to be secured at the 7) After final lift check reset the regulator to the
cylinder or supply source to reset the seat before appropriate over bottom setting. Remove the in-
the adjustment can be accomplished. termediate pressure gauge.

NOTE: The overpressure relief valve can be in- 1.1.5 Troubleshooting The Overpressure
stalled in any first stage regulator, providing the Relief Valve
first stage has an intermediate setting of 135–
165 p.s.i.g. (9.3–11.4 bar). Problem: Valve pops open and will not stop
flowing:
1) Install the relief valve in a low-pressure port
on an adjustable 1st stage regulator. Or install Check: If while setting the overpressure relief
on the scuba test stand. valve the valve pops open and will not stop flow-
ing, secure the air supply valve and allow the
2) Install the intermediate pressure gauge in one overpressure relief valve to reseat. Try the proce-
of the low-pressure ports of the first stage regula- dure again, ensuring that the supply valve is only
tor. slightly cracked open, allowing full test pressure
but minimizing high flow potential.

© MMXVIII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 180503020 OPRV-3
Overpressure Relief Valve Overhaul Procedures  Overpressure Relief Valve

Problem: After resetting the first stage to 135

p.s.i.g. (9.3 bar), the valve continues to leak:

Check: This indicates the seating surface of the

relief valve body or the poppet is either dirty or
damaged. Usually, cleaning both the metal seat-
ing surface in the valve body and cleaning the
poppet will fix the problem.

If, after cleaning, the problem persists, replace

the poppet and spring then retest the unit. If the
seat continues to leak, then replacement of the
overpressure relief valve, P/N 200-017, will be
necessary.

OPRV-4 © MMXVIII Kirby Morgan Dive Systems, Inc. All rights reserved. Document # 180503020