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Consolidated 2700 Series Safety Valve Instruction Manual

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XIV. Re-Assembly Instructions (Cont.)

determine the number of notches that the ring is to

be lowered.

9. Once the upper adjusting ring/guide assembly is

properly set, lubricate the guide seating surface

in the valve base, and re-install the assembly into

the base, then lubricate the threads of the upper

adjusting ring pin and lock the ring/guide assembly

in place by installing in the pin.

10. Verify that the upper ring is capable of a slight

movement. If the upper ring does not move, the pin

is too long. Should this be the case, grind the end

of the pin to shorten it, while retaining the original

tip contour, then reinstall the pin.

11. Clamp the spindle in a padded vise, with the “ball

end” of the spindle upward.

12. Verify that the spindle bearing has been ground to

the disc pocket, as specified in Section XII.B.6.e.,

of this manual.

Note:

This step must be accomplished before

proceeding with re-assembly.

13. If the lift stop was removed from the spindle,

lubricate the threads and install the lift stop. Do not

install the cotter pin at this time.

14. If the disc collar was removed, lubricate the

threads and install on the spindle. Do not install

the cotter pin at this time. Then, carefully lower the

disc holder onto the spindle, allowing it to sit on the

face of the disc collar.

15. Place the disc on the spindle, ensuring that the

disc is free to “rock” on the spindle tip as specified

in Section XII.B.6.f., of this manual. If disc “rock”

is not satisfactory, correct the cause before

proceeding.

16. When disc “rock” is satisfactory, remove the disc

and disc holder, and secure the disc collar with

a stainless steel cotter pin. Using side cutters,

carefully cut off excess cotter pin legs, and bend

the cotter pin for a neat installation.

17. Lubricate the spindle tip, and assemble the disc

holder and disc to spindle. Recheck the rock.

18. Remove complete assembly from the vise, being

sure to protect the disc seat surface at all times.

19. Prior to installing the spindle assembly into the

valve base, wipe the disc seat with a soft, lint-free

cloth. Then, carefully install the spindle assembly

into the guide.

20. Lubricate the compression screw threads with

“Fel-Pro Nickel Ease,” and thread into the yoke.

Install the lower washer on the spring and then

install the upper washer on the spring. Lubricate

the bearing assembly with “Fel-Pro Nickel Ease”

and install on the upper spring washer.

21. For orifice sizes 5-Q, place the compression screw

adaptor on top of the bearing.

22. Place the spring and bearing assembly into the

yoke.

Table 8: Required Lift for Capacity Verification

Orifice

Capacity Lift

Required Additional

Lift

Total Lift

1 & 2

in.

.281

7.14

.020

0.51

.301

7.65

Approx. 31 Notches

.338

8.59

.020

0.51

.358

9.09

Approx. 36 Notches

.450

11.43

.030

0.76

.480

12.19

Approx. 48 Notches

.516

13.11

.050

1.02

.566

14.12

Approx. 62 Notches

.563

14.30

.040

1.27

.603

15.57

Approx. 56 Notches

.750

19.05

.060

1.52

.810

20.57

Approx. 81 Notches

.987

25.07

.070

1.78

1.057

26.85

Approx. 106 Notches

1. For full lift valves only.

2. Total lift tolerance is

+ .020” + 0.51 mm

- .000” - 0.00 mm

[

]

. Per the ASME Section I code, the valve lift must be mechanically verified

and shall meet or exceed the required lift.

Summary of Contents for Consolidated 2700 Series

Page 1: ...Consolidated 2700 Series Safety Valve Instruction Manual Rev F Baker Hughes Data Classification Public ...

Page 3: ...E SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION OPERATION OR MAINTENANCE SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUST...

Page 4: ... values using the following conversion factors USCS Unit Conversion Factor Metric Unit in 25 4 mm lb 0 4535924 kg in2 6 4516 cm2 ft3 min 0 02831685 m3 min gal min 3 785412 L min lb hr 0 4535924 kg hr psig 0 06894757 barg ft lb 1 3558181 Nm F 5 9 F 32 C Conversion Table Note Multiply USCS value with conversion factor to get metric value ...

Page 5: ...alve Installation 16 XII Disassembly Instructions 17 A General Information 17 B Specific Steps 17 XIII Inspection and Part Replacement 19 A General 19 B Specific Components 19 XIV Re Assembly Instructions 24 A General Information 24 B Specific Steps 24 XV Setting and Testing 27 A General Information 27 B Application of Test Gags 27 C Presetting Adjusting Rings 28 D Steam Testing Instruction 29 E C...

Page 6: ...vi Baker Hughes 2022 Baker Hughes Company All rights reserved XX Manufacturer s Service Repair and Training Program 40 A Field Service 40 B Repair Facilities 40 C Safety Valve Maintenance Training 40 ...

Page 7: ... Selection or Misapplication of Products Baker Hughes cannot be responsible for customer s incorrect selection or misapplication of our products Unauthorized Repair Work Baker Hughes has not authorized any non Baker Hughes affiliated repair companies contractors or individuals to perform warranty repair service on new products or field repaired products of its manufacture Therefore customers contr...

Page 8: ...iates from Baker Hughes recommendations must be thoroughly satisfied that neither personal safety nor valve safety will be jeopardized by the procedure and or tools selected If not so satisfied contact your local Green Tag Center if there are any questions relative to procedures and or tools The installation and start up of valves and valve products may involve proximity to fluids at extremely hig...

Page 9: ...ction with the hazard In some instances of risk to human health and safety the pictorial may instead depict what preventive measures to take such as wearing wearing the appropriate personal protective equipment PPE The bottom panel may contain instructions on how to avoid the hazard If there is a risk to human health and safety this message may also contain a more precise definition of the hazard ...

Page 10: ...ents or fluids can cause severe personal injury or death 2 WARNING Always read and comply with safety labels on all containers Do not remove or deface the container Do not remove or deface the container labels Improper handling or misuse could result in severe personal injury or death 3 WARNING Never use pressurized fluids gas air to clean clothing or body parts Never use body parts to check for l...

Page 11: ...uld result in personal injury or product damage Wear necessary protective equipment to prevent possible injury Always use appropriate restoration procedures 7 WARNING The misuse of a tool or the use of an improper tool could result in personal injury and or product property damage 1 CAUTION Heed all service manual warnings Read installation instructions before installing valve s 2 CAUTION Wear the...

Page 12: ...wn Uncrated valves should be moved or hoisted by wrapping a chain or sling around the discharge neck then around the upper yoke structure in such manner as will ensure the valve is in a vertical position during lift Never lift the full weight of the valve by the pilot assembly tubing lifting lever or other external device When a valve is uncrated and the flange protectors removed prior to installa...

Page 13: ...ntenance Occasionally remachining may be necessary to extend the service life of a valve Keep all parts for each valve separated to ensure replacement in the same valve DANGER Insure there is no pressure in the inlet of the valve before attempting to remove it from the piping system Note For maintenance questions not covered in this manual please contact your local Green Tag Center Decontaminate o...

Page 14: ...e is relieving G Maximum Allowable Working Pressure The maximum gauge pressure permissible in a vessel at a designated temperature A vessel may not be operated above this pressure or its equivalent at any metal temperature other than that used in its design Consequently for that metal temperature it is the highest pressure at which the primary pressure relief valve is set to open H Operating Press...

Page 15: ... Spring Washer 11 Bottom Spring Washer 12 Seat Bushing 13 Disc 14 Disc Collar 15 Lift Stop 16 Spindle 17 Compression Screw 18 Compression Screw Adaptor 4 to 7_Q orifices only 19 Thrust Bearing 20 Lever and Cap Assembly 21 Studs Studded Inlet 22 Nuts 23 Compression Screw Locknut 24 Cotter Pins not shown 2747 THRU 2777Q 2737 THRU 2777Q VENT 90 OUT OF POSITION DO NOT PLUG 9 1 11 4 15 2 14 5 6 8 7 13 ...

Page 16: ... Bottom Spring Washer 12 Seat Bushing 13 Disc 14 Disc Collar 15 Lift Stop 16 Spindle 17 Compression Screw 18 Compression Screw Adaptor 4 to 7_Q orifices only 19 Thrust Bearing 20 Lifting Gear 21 Studs Studded Inlet 22 Nuts 23 Compression Screw Locknut 24 Cotter Pins not shown 2745W THRU 2775QW 2735W THRU 2775QW VENT 90 OUT OF POSITION DO NOT PLUG 9 1 11 4 15 2 14 5 6 8 7 13 12 19 10 20 17 16 21 22...

Page 17: ...t of the upper adjusting ring allows the disc to go into full lift at overpressure When full lift is attained lift stop H rests against the yoke to prevent hunting thus adding stability When the inlet pressure drops to the desired closing pressure the disc C moves downward causing the valve to close The arrangement of the disc and its complement of parts that is disc holder E spindle G disc collar...

Page 18: ...ons will assist in eliminating the factors that produce chatter 1 The downstream corner of the header nozzle must be rounded to a radius of not less than 250 6 35 mm of the opening diameter See Figure 5 2 Pressure drop due to friction flow to the inlet of the valve should not be greater than 50 percent of the expected blowdown of the safety valve To decrease the effects of a phenomenon known as so...

Page 19: ...ne Excessive line vibrations are known to produce shifts in safety valve set pressures Vibrations may possibly introduce chatter causing damage to the valve and reducing its capacity Vibration also contributes to increased incidents of seat leakage Considerations should be given to eliminating this problem prior to installing the valve on the unit Steam flowing vertically out of a discharge elbow ...

Page 20: ...f the valve seat and this drain should be piped to a safe discharge area If a silencer is used on a safety valve it should have sufficient outlet area to prevent back pressure from interfering with the proper operation and discharge capacity of the valve The silencer or other piping components should be constructed so as to avoid the possibility of creating corrosion deposit restrictions in the st...

Page 21: ...ork Studs are to be lubricated with an appropriate lubricant 5 Install the outlet gasket studs and nuts Stud nuts are to be pulled down finger tight An initial value of torque is to be applied The additional procedures outlined in Step 3 should also be followed After being assured that the valve is properly installed the drainage piping from the valve body bowl is to be connected This line also mu...

Page 22: ...ons The inlet neck of the safety valve and safety valve body up to the top of the base should be insulated The exterior surface of any such insulation should be made weather proof by any suitable means In addition to maintaining a more even temperature within the valve body especially during widely fluctuating ambient temperatures this insulation will effectively reduce thermal stresses due to hig...

Page 23: ...d top lever 2 Loosen the cap set screw and remove the lever and cap assembly 3 Remove the cotter pin that retains the release nut and then remove the release nut 4 Refer to Figure 6 and measure and record Dimension A as this information will be required to correctly re assemble the valve 5 Loosen the compression screw locknut and the compression screw to remove tension from the spring 6 Loosen and...

Page 24: ... with a depth micrometer or other suitable measuring device Record Dimension B 12 Place a scale or other thin flat metal surface against the lower face of the upper adjusting ring and measure from the top of the guide to the face of the upper adjusting ring Dimension C Figure 8 Record Dimension C 13 Remove the upper adjusting ring pin from the valve base 14 Remove the guide and upper adjusting rin...

Page 25: ...sher a 320 grit Clover 1A lapping compound is used for roughing in and then finish the lap with 1000 grit Kwik Ak Shun lapping compound until a satisfactory bearing band is obtained The bearing width should be 1 800 3 20 mm minimum to 3 160 4 80 mm maximum Clean the lower spring washer and spindle when complete 5 Spring Visually inspect for pitting and corrosion of coils that will reduce the coil ...

Page 26: ...either of these devices is used to verify valve set pressure d Apply a small amount of lapping compound 1A on the tip of the spindle Install the disc without the disc holder onto the spindle tip turning it clockwise until the disc threads drop out Place a ring lap on a table or similar flat surface and wipe the exposed surface of the lap clean Insert the disc nose into a ring lap so that the seat ...

Page 27: ...nce with Table 4 8 Disc Holder The surface on the end of the disc holder closest to the disc must be free from steam erosion The two small holes must be open to ensure the passage of steam to the chamber above the disc Make sure the outside diameter is not egg shaped and the surface is smooth If any small indication of galling is present polish the high spots with an emery cloth If serious or larg...

Page 28: ...ing the lapping plate 10 Seat Bushing a A Consolidated reseating machine should be used to recondition badly worn and out of tolerance bushing seats This machine can be provided by Consolidated s Service Department and eliminates the need to remove a valve from the unit The machine is mounted in place of the yoke and cuts the top face inside diameter and outside of the bushing to establish the cor...

Page 29: ...of defects such as gray areas or scratches will require a repeat of the whole lapping procedure until a mirror finish is attained v While the finer points of lapping and grinding in may be considered as a mechanical art it is not beyond the ability of the average mechanic to produce good seats with some practice No effort has been made in this manual to establish an exact procedure to cover each a...

Page 30: ...osition determined during field testing 4 Once the lower adjusting ring is in its correct location lock it in place by installing in the lower adjusting ring pin Verify that the lower ring is capable of a slight movement If the lower ring does not move the pin is too long Should this be the case grind the end of the pin slightly to shorten it while retaining the original tip contour then reinstall...

Page 31: ...t satisfactory correct the cause before proceeding 16 When disc rock is satisfactory remove the disc and disc holder and secure the disc collar with a stainless steel cotter pin Using side cutters carefully cut off excess cotter pin legs and bend the cotter pin for a neat installation 17 Lubricate the spindle tip and assemble the disc holder and disc to spindle Recheck the rock 18 Remove complete ...

Page 32: ...he valve is now ready for testing after which the following steps can be taken a After testing the compression screw should be locked firmly in place with the lock nut b Install the release nut onto the spindle Then thread clockwise until the release nut is fully engaged on the spindle thread and the cotter pin hole is aligned For numbers 1 2 3 and 4 orifices run the release nut down enough to all...

Page 33: ...p by upstream bends Valve inlet nozzle configuration or other internal piping configuration problems 6 High water level in the drum When the valves are subjected to working hydrostatic tests not exceeding the set pressure of the low set valve valves may be gagged rather than using hydrostatic test plugs For higher pressures hydrostatic plugs should be used A common source of safety valve trouble i...

Page 34: ...ng pressure install gags on all boiler valves not being tested Gags should be installed hand tight no wrenches or mechanical force 4 On the valve to be tested use the following procedure and Table 9 to bring the adjusting ring to seat level a Gag the valve to prevent the disc from accidentally lifting from the seat during adjustment b Remove both service port plugs c Remove the upper ring pin d Mo...

Page 35: ...e ASME Boiler and Pressure Code Section I or Section XIII UV Valve Operation Standards for more details To determine which standard to use look at the nameplate on the valve The symbol that is present on the nameplate will indicate the proper standard of operation See Table 11 4 If the valve operation is in compliance with the standard proceed to step 7 5 If the valve is not in compliance reduce b...

Page 36: ...172 37 15N up Level w Holder 20N down 36N down 2501 172 44 2800 193 05 15N up Level w Holder 20N down 36N down 2801 193 12 3000 206 84 15N up Level w Holder 20N down 36N down 5 3 341 21 555 101 6 96 300 20 68 1N down per 600 psig 413 68 barg Max 5N down 8N down 25N down 8N down 25N down 301 20 75 500 34 47 50N up 34N up Seat Level 16N down 501 34 54 900 62 05 40N up 24N up 10N down 26N down 901 62...

Page 37: ...e set pressure is 301 psig 20 75 barg up to and including 1000 psig 68 75 barg 10 psig 0 69 barg If valve set pressure is 1001 psig 69 02 barg or greater 1 percent of set pressure CODE SYMBOL STAMP ASME Section XIII UV If valve set pressure is less than or equal to 70 psig 4 83 barg 2 psig 0 14 barg After opening the valve must reclose before the system pressure returns to normal operating pressur...

Page 38: ...ce or the EVT software repeatedly produces exactly the same lifting force Second gauge calibration and vibration in the effective seating area between valves of the same size and type will also affect accuracy With well calibrated gauges and valve seats in good condition accuracy on the order of 1 percent of set pressure may be expected Upon request Baker Hughes will provide pertinent written mate...

Page 39: ...ncreased to a point where the valve will not leak at one and one half times design boiler pressure It is not necessary to gag the safety valves when hydrostatic plugs are used DRAIN SERVICE PLUG HYDRO PLUG CAUTION DO NOT STEAM TEST UNTIL THE PLUG HAS BEEN REMOVED This safety valve is equipped with an internal plug for hydrostatic test D O N O T R E M O V E THIS TAG UNTIL PLU G I S R E M O V E D Fi...

Page 40: ... fall from the spindle and become damaged 6 Lap the disc and seat bushing and thoroughly clean the seats with a clean cloth 7 Lubricate the spindle tip with Anti Seize and assemble the disc and disc holder to thr spindle by turning the disc until the dropout threads disengage 8 Reassemble the yoke and spring assembly See Figure 19 into the base being careful not to damage the disc Locate the yoke ...

Page 42: ...lower spring washer or spindle compression screw spindle straightness etc C Disc has insufficient rock C Disassemble the valve and check the disc rock per Section XIX E of this manual D Discharge stack binding on outlet D Correct as required Hangup or the valve does not close completely A Lower ring too high A Move the lower ring to the left one notch per adjustment and test Repeat until problem i...

Page 43: ...ium for lapping and polishing the seats and bearing surfaces in Consolidated Series 2700 Safety Valves Gags Lubricant Wrench Sizes XVII Maintenance Tools and Supplies Ring Laps1 Valve Orifice 2 Lap Part No 1 1672806 2 1672807 3 1672808 5 1672810 4 1672809 6 1672811 Q 1672812 Brand Grand Grit Lapping Function Size Container Part No Clover 1A 320 General 4 oz 199 3 Clover C 220 Coarse 4 oz 199 2 Kwi...

Page 44: ...roper operation of the valve Included are Valve Type ASME and National Board of Boiler and Pressure Vessel Inspectors Approval Stamp Serial Number Set Pressure or Opening Pressure Disc Lift Operating Temperature Capacity The Consolidated 2700 Series Safety Valve nameplate is located on the base of the valve to the left of the Adjusting Ring Pins If the nameplate is missing a duplicate nameplate ca...

Page 45: ...tWeld Inlet Series Series Orifice Designation Orifice Designation Pressure Class Pressure Class The next time replacement parts are needed keep these points in mind Baker Hughes designed the parts Baker Hughes guarantees the parts Consolidated valve products have been in use since 1879 Baker Hughes has worldwide service Baker Hughes has fast response availability for parts XIX Consolidated Genuine...

Page 46: ...epairs and product modiﬁcations e g bushing replacements hydroset calibrations electromatic relief valve repairs code welding pilot replacement etc For further information please contact your local Green Tag Center C Maintenance Training Rising costs of maintenance and repair in the utility and process industries indicate the need for trained maintenance personnel Baker Hughes conducts service sem...

Page 48: ...The Baker Hughes logo Consolidated EVT Thermodisc Thermoflex Hydroset and Green Tag are trademarks of Baker Hughes Company Other company names and product names used in this document are the registered trademarks or trademarks of their respective owners BHCN 2700 IOM 19384F 0222 0 2022 Direct Sales Office Locations valves bakerhughes com Find the nearest local Channel Partner in your area valves b...

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