Baker Hughes Consolidated 2900-40 Series Instruction Manual Download Page 31

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Consolidated 2900-40 Series POSRV Instruction Manual

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XIV. Maintenance Instructions (Cont.)

1. Do not remachine threaded areas of the nozzle to reestablish “D” dimension. Once “D” minimum is reached, replacement

of nozzle is necessary.

Table 2: Nozzle Critical Dimensions

Orifice

Nozzle Bore

min.

±.005” (0.13

mm)

C (metal seat)

B (metal seat)

min.

max.

in.

.404 10.26 .409 10.39 .313 7.95 .030 0.76

.954

± .001

24.23

± 0.03

.831

± .001

21.11

± 0.03

.539 13.69 .544 13.82 .313 7.95 .030 0.76

.954

± .001

24.23

± 0.03

.831

± .001

21.11

± 0.03

.674 17.12 .679 17.25 .313 7.95 .030 0.76

.954

± .001

24.23

± 0.03

.831

± .001

21.11

± 0.03

.863 21.92 .869 22.07 .313 7.95 .035 0.89 1.093

± .001

27.76

± 0.03

.953

± .001

24.21

± 0.03

1.078 27.38 1.083 27.51 .250 6.35 .035 0.89 1.224

± .001

31.09

± 0.03

1.123

± .001

28.52

± 0.03

1.380 35.05 1.385 35.18 .375 9.53 .035 0.89 1.545

± .001

39.24

± 0.03

1.435

± .001

36.45

± 0.03

1.650 41.91 1.655 42.04 .438 11.13 .063 1.60 1.836

± .002

46.63

± 0.05

1.711

± .002

43.46

± 0.05

2.055 52.20 2.060 52.32 .438 11.13 .063 1.60 2.257

± .002

57.33

± 0.05

2.133

± .002

54.18

± 0.05

2.309 58.65 2.314 58.78 .438 11.13 .063 1.60 2.525

± .002

64.14

± 0.05

2.400

± .002

60.96

± 0.05

2.535 64.39 2.540 64.52 .500 12.70 .063 1.60 2.777

± .002

70.54

± 0.05

2.627

± .002

66.73

± 0.05

3.073 78.05 3.078 78.18 .625 15.88 .093 2.36 3.332

± .002

84.63

± 0.05

3.182

± .002

80.82

± 0.05

4.045 102.74 4.050 102.87 .875 22.23 .093 2.36 4.335

± .003

110.11

± 0.08

4.185

± .003

106.30

± 0.08

4.867 123.62 4.872 123.75 1.000 25.40 .093 2.36

5.110

± .003

129.79

± 0.08

4.960

± .003

125.98

± 0.08

6.202 157.53 6.208 157.68 .750 19.05 .093 2.36 6.510

± .003

165.35

± 0.08

6.315

± .003

160.40

± 0.08

Table 2: Nozzle Critical Dimensions

Orifice

F (metal seat)

Radius B

.001” (0.03 mm)

F (soft seat)

±.005” (0.13 mm)

C (soft seat)

B (soft seat)

in.

.035 +-

.002

.003 0.97

0.05

0.08

.016

0.41

.079

2.01

.867 ± .001

22.02 ± 0.03

.813 ± .001

20.65 ± 0.03

.035 +-

.002

.003 0.97

0.05

0.08

.016

0.41

.079

2.01

.867 ± .001

22.02 ± 0.03

.813 ± .001

20.65 ± 0.03

.035 +-

.002

.003 0.97

0.05

0.08

.016

0.41

.079

2.01

.867 ± .001

22.02 ± 0.03

.813 ± .001

20.65 ± 0.03

.035 +-

.002

.003 0.97

0.05

0.08

.022

0.56

.090

2.29

1.058 +-

.002

.001

26.87 +-

0.05

0.03

.998 ± .001

25.35 ± 0.03

.035 +-

.002

.003 0.89

0.05

0.08

.022

0.56

.060

1.52

1.214 +-

.002

.001

30.84 +-

0.05

0.03

1.165 +-

.002

.001

29.59 +-

0.05

0.03

.035 ± .005 0.89 ± 0.13

.022

0.56

.074

1.88

1.532 +-

.002

.001

38.91 +-

0.05

0.03

1.479 +-

.002

.001

37.57 +-

0.05

0.03

.063 ± .005 1.60 ± 0.13

.022

0.56

.126

3.20

1.836 ± .002

46.63 ± 0.05

1.780 +-

.001

.002

45.21 +-

0.03

0.05

.063 ± .005 1.60 ± 0.13

.017

0.43

.126

3.20

2.206 ± .002

56.03 ± 0.05

2.156 ± .002

54.76 ± 0.05

.063 ± .005 1.60 ± 0.13

.022

0.56

.126

3.20

2.534 ± .002

64.36 ± 0.05

2.478 ± .002

62.94 ± 0.05

.063 ± .005 1.60 ± 0.13

.022

0.56

.101

2.57

2.706 ± .002

68.73 ± 0.05

2.650 ± .002

67.31 ± 0.05

0.093 ± .005 2.36 ± 0.13

.022

0.56

.150

3.81

3.332 ± .002

84.63 ± 0.05

3.277 +-

.002

.003

83.24 +-

0.05

0.08

.093 ± .005 2.36 ± 0.13

.022

0.56

.188

4.78

4.335 ± .003

110.11 ± 0.08

4.281 ± .003 108.74 ± 0.08

.093 ± .005 2.36 ± 0.13

.022

0.56

.215

5.46

5.092 ± .003 129.34 ± 0.08

5.033 ± .003 127.84 ± 0.08

.093 ± .005 2.36 ± 0.13

.022

0.56

.142

3.61

6.510 +-

.003

.004 165.35

0.08

0.10

6.420 +-

.004

.003 163.07

0.10

0.08

Summary of Contents for Consolidated 2900-40 Series

Page 1: ...Consolidated 2900 40 Series Pilot Operated Safey Relief Valves Instruction Manual Rev D Baker Hughes Data Classification Public ...

Page 2: ...QUIREMENTS 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 CUSTOMER OPERATOR S PURPOSES THE...

Page 3: ...ance Conversion Table Note Multiply USCS value with conversion factor to get metric value All the United States Customary System USCS units are converted to metric units 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 N...

Page 4: ... Valve 18 X Operating Principles 19 A PV Valve Closed Normal Position 19 B PV Valve Open Relieving Position 20 XI General Planning for Maintenance 21 XII Recommended Installation Practices 21 A Mounting Position 21 B Inlet Piping 22 C Outlet Piping 22 D Remote Sensing 23 E Freeze Protection 23 XIII Disassembly of the 2900 40 POSRV 25 A Removal of the Pilot Valve from the Main Valve 25 B Disassembl...

Page 5: ... Pilot Valve 43 A 39PV07 37 Disassembly 43 B Cleaning 43 XVIII Part Inspection of Pilot Valve 46 A 39PV07 37 46 XIX Reassembly of Pilot Valve 47 A Lubricants and Sealants 47 B Assembly of 39PV07 37 47 XX Setting and Testing 50 A General Information 50 B With Standard Options 50 C With Sensing Ring Option 51 D Functional Testing 51 E Field Testing of POSRV Assembly 53 54 E 1 Mitigation of Main Valv...

Page 6: ...te Sensing 65 O Sensing Ring 65 XXIII Maintenance Tools and Supplies 66 A Adjuster Top Seal Insertion Tool 66 B Insert Installation Tool 67 C Lapping Tools 68 D Disc Holder and Guide Removal and Assembly Tool 69 70 XXIV Replacement Parts Planning 71 A Basic Guidelines 71 B Identification and Ordering Essentials 71 C Positive Identification of Main Valve and Pilot Valve Combinations 72 XXV Genuine ...

Page 7: ...n or product interaction with the hazard The instructions if necessary on how to avoid the hazard The top panel of the format contains a signal word DANGER WARNING CAUTION or ATTENTION which communicates the level of hazard seriousness The center panel contains a pictorial which communicates the nature of the hazard and the possible consequence of human or product interaction with the hazard In so...

Page 8: ...charge rates of areas Pressurized fluids gas air injected into or near the body can cause severe personal injury or death 4 WARNING It is the responsibility of the owner to specify and provide guarding to protect persons from pressurized or heated parts Contact with pressurized or heated parts Contact with pressurized or heated parts can result in severe personal injury or death 5 WARNING Do not a...

Page 9: ...hysics procedures if applicable to avoid possible severe personal injury or death Note Any Service questions not covered in this manual should be referred to your local Green Tag Center GTC Cautions Concerning Product Warning Labels Appropriate service and repair important to safe reliable operation of all valve products Restoration to original quality and manufacturing specifications will accompl...

Page 10: ...al Green Tag Center GTC if there are any questions relative to tools methods The installation and start up of valves and or valve products may involve proximity to fluids at extremely high pressure and or temperature Consequently every precaution should be taken to prevent injury to personnel during the performance of any procedure These precautions should consist of but are not limited to ear dru...

Page 11: ...tion 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 contracting...

Page 12: ...ature 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 POSRV is set to open Operating Pressure The gauge pressure to which the vessel is normally subjected in service A suitable margin is provided between operating pressure a...

Page 13: ... prevent damage to the flanged surfaces and to prevent entry of foreign material into the valve ATTENTION Never lift the full weight of the valve by the pilot assembly external devices or tubing ATTENTION Do not rotate the valve horizontally or lift carry using the pilot assembly ATTENTION Only lift the valve by the eyebolts inserted into the cover plate ATTENTION Handle carefully Do not drop or s...

Page 14: ...ted for easy access and removal for service Remote Sensing If the pressure drop between the source of pressure in the equipment to be protected and the pressure at the relief valve inlet exceeds 3 the sensing line to the pilot valve should be connected directly to the equipment being protected The optional sensing ring should not be installed For remote sensing 375 9 53 mm diameter tubing is adequ...

Page 15: ...ent or remachining Standard O Ring sizes readily available easily replaced National Board certified capacities Uses many parts standard on 1900 Series SRV C Pilot Valve Introduction Standard pilot construction consists of 316SS parts with nitrile O Rings with Teflon based seals throughout Alternate materials can be provided by contacting the factory Pilot Valve Features One pilot fits all main val...

Page 16: ... 11 10 9 8 7 15 16 1 2 13 14 Figure 1 2900 40 Metal Seat Valve Construction Part No Nomenclature 1 Base 2 Nozzle 3 Coverplate 4 Coverplate Gasket 5 Main Valve Piston 6 Main Valve Piston Spring Energized Seal 7 Disc 8 Disc Retainer 9 Disc Holder 10 Guide 11 Guide Gasket 12 Guide Ring 13 Stud Base 14 Nut Base 15 Plug Adaptor 16 Plug Adaptor Gasket 20 Spring ...

Page 17: ...X 2900 40 Safety Relief Valves Cont B 2900 40 Main Valve Soft Seat 8 7 17 9 19 18 2 9 17 19 2 18 D Thru J K Thru T Figure 2 2900 40 Soft Seat Valve Construction Part No Nomenclature 2 Nozzle 7 Disc 8 Disc Retainer 9 Disc Holder 10 Guide 17 O Ring Retainer Lock Screw 18 O Ring Retainer 19 O Ring Seat Seal ...

Page 18: ...ied Part No Nomenclature 1 Main Base 2 Adjuster Cap 3 Adjuster Top 4 Adjuster Bottom 5 Adjuster Lock Nut 6 Compression Screw 7 Compression Screw Lock Nut 8 Spring Washer 9 Spring 10 Insert Top 11 Insert Bottom 12 Main Piston 13 Cap Compression Screw 14 Cap Screw Top Plate 15 O Ring Adjuster Bottom 16 O Ring Adjuster Top 17 O Ring Insert 18 O Ring Top Plate 19 Bonnet 20 Spring Seal Main Piston 21 S...

Page 19: ...m pressure from the main valve inlet is fed to the dome by the pilot through interconnecting tubing This equalizes the pressure on the top of the piston with inlet pressure on the seating surface bottom of the disc Since the area of the top of the piston is larger than the area of the seating surface the differential area results in a net downward force keeping the main valve tightly closed ...

Page 20: ...d to lift off the seat as the fluid force overcomes the now removed pressure load above the main valve piston The valve discharges to relieve system pressure When the discharging main valve reduces the inlet pressure to the pre set blowdown pressure of the pilot the pilot piston closes the vent seal Simultaneously the inlet seal is reopened in the pilot The main valve inlet pressure is again allow...

Page 21: ...sition The POSRVs should be mounted in a vertical upright position in accordance with API RP 520 Installing a pilot operated safety relief valve in any position other than vertical 1 degree will adversely affect its operation as a result of induced misalignment of moving parts A stop valve may be placed between the pressure vessel and its relief valve only as permitted by code regulations If a sto...

Page 22: ...rly designed discharge piping and support systems and forced alignment of discharge piping can cause excessive stresses and distortions in the valve as well as the inlet piping The stresses in the valve may cause a malfunction or leak Therefore discharge piping must be independently supported and carefully aligned Vibrations in the inlet piping systems may cause valve seat leakage and or fatigue f...

Page 23: ... For remote sensing 375 9 53 mm diameter tubing is adequate for distances up to 10 feet 3 048 mtr If distance is longer than 10 feet 3 048 mtr please contact Baker Hughes s Consolidated Products Application Engineering ATTENTION Change in elevation between relief valve and source of sensing line may cause set pressure changes For block valve and other special installation features consult API 520 ...

Page 24: ...afety relief valve Types of freeze protection a Insulation by fiberglass blankets or wrap b Heat tracing with electrical heat tape c Radiant heat sources such as a heat lamp For applications where heat tracing or radiant heaters are used the temperature should be limited to approximately 200ºF 93 3ºC so that the elastomers are not damaged Higher temperatures may be allowed upon review of the appli...

Page 25: ...personal injury or death Know all valve exhaust Leakage points to avoid possible severe personal injury or death A Removal of Pilot Valve from Main Valve Note If the pilot valve has not been removed then refer to the appropriate section above 1 If applicable remove sensing tube fitting from Sensing Tube 2 Remove and discard Plug Filter from Sensing Tube if applicable 3 Loosen and remove the Stud N...

Page 26: ...26 Baker Hughes 2020 Baker Hughes Company All rights reserved XIII Disassembly of the 2900 40 POSRV Cont 1 3 13 14 15 16 2 7 8 9 11 20 10 4 5 12 6 Figure 10 Metal Seat Valve Disassembly ...

Page 27: ...pring from Disc Holder 14 Remove the disc from the disc holder as follows Clamp the stem portion of the disc holder disc end up firmly between two wooden V blocks in a vise Start inserting special drift pins into the holes in the disc holder Figure 15 with the tapered portion of the pins working against the top of the disc Lifting Tool Guide Disc Holder Top of Base Disc Holder 9 Disc Retainer 8 Th...

Page 28: ...e area of the nozzle threads ATTENTION Should heat be applied use care to prevent cracking of cast parts 17 Using a three or four jaw chuck welded vertically to a stand bolted to a concrete floor clamp the nozzle into the chuck and break the body loose with a heavy rod or pipe Figure 17 ATTENTION Exercise care when inserting a rod or pipe in the outlet Ensure the valve nozzle is not damaged during...

Page 29: ... agents include demineralized water nonphosphate detergent acetone and isopropyl alcohol Parts must be blown dry or wiped dry after cleaning 4 If you are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations and equipment 5 Do not sand blast i...

Page 30: ...lve seats the nozzle seating surface and the disc seating surface must be lapped flat B O Ring Seat The nozzle must not have any defects to prohibit the O Ring from sealing properly especially the OD of the seat where the surface must maintain a minimum of 32 RMS finish See Figure 18 and Table 2 for reworking O Ring Nozzle The O Ring Retainer must also maintain a flat surface for it to sit on the ...

Page 31: ...0 08 4 185 003 106 30 0 08 R 4 867 123 62 4 872 123 75 1 000 25 40 093 2 36 5 110 003 129 79 0 08 4 960 003 125 98 0 08 T 6 202 157 53 6 208 157 68 750 19 05 093 2 36 6 510 003 165 35 0 08 6 315 003 160 40 0 08 Table 2 Nozzle Critical Dimensions Orifice F metal seat Radius B 001 0 03 mm F soft seat 005 0 13 mm C soft seat B soft seat in mm in mm in mm in mm in mm D 035 002 003 0 97 0 05 0 08 016 0...

Page 32: ...ring magnifier or an equivalent seven power glass with a 3 4 19 05 mm scale showing graduations of 0 005 0 13 mm Figure 19a and 19b illustrate the use of this tool in measuring the nozzle seat width If additional lighting is required for measuring use a gooseneck flashlight similar to the Type A Lamp Assembly Standard Molding Corp or equivalent E Lapping Disc Seats Use a ring lap or lapping plate ...

Page 33: ...51 3 52 100 6 89 028 0 71 033 0 84 101 6 96 250 17 24 033 0 84 038 0 97 251 17 31 400 27 58 038 0 97 043 1 09 401 27 65 800 55 16 043 1 09 048 1 22 801 55 23 Above Note 2 Note 2 P R 1 0 07 50 3 45 030 0 76 034 0 86 51 3 52 100 6 89 034 0 86 041 1 04 101 6 96 251 17 31 041 1 04 049 1 24 251 17 31 400 27 58 049 1 24 056 1 42 401 27 65 800 55 16 056 1 42 062 1 57 801 55 23 Above 062 1 57 064 1 63 T 1...

Page 34: ... complete any lines appearing as cross scratches can be removed by rotating the lap on its axis which has been wiped clean of compound on the seat Thoroughly clean the lapped seat using lint free cloth and a cleansing fluid ATTENTION Before assembly grind the contact surfaces of the nozzle and O Ring retainer to provide metal to metal seat tightness in the event of O Ring failure G Reconditioning ...

Page 35: ... When the minimum dimension H is reached discard the nozzle I Re Machining the Disc Seat Take the following steps to machine the standard disc seating surface Figure 23 1 Grip the disc in a four jaw independent chuck or collet if appropriate using a piece of soft material such as copper or fiber between the jaws and the disc as shown at A 2 True up the disc so that the surface marked B and C run t...

Page 36: ...hining Dimensions Disc Type Orifice Size T min N min in mm in mm Type 1 D 174 4 42 010 0 25 E 174 4 42 010 0 25 F 174 4 42 010 0 25 G 174 4 42 010 0 25 H 335 8 51 010 0 25 Type 2 J 359 9 12 010 0 25 K 422 10 72 015 0 38 L 457 11 61 015 0 38 M 457 11 61 015 0 38 N 485 12 32 015 0 38 P 610 15 49 015 0 38 Q 610 15 49 015 0 38 R 610 15 49 015 0 38 T 822 20 88 015 0 38 T B C N L T B C N L C D B A XIV M...

Page 37: ...apping If the seat can be lapped flat without exceeding the required seat width as indicated in Table 3 or 4 it does not require machining To reduce the seat width the 5º angle surface must be machined The nozzle must be replaced if the D min is reduced below the minimum as indicated in Table 2 6 Spring Check for any corrosion or pitting 7 Standard Metal Seated Disc This disc Figure 24 can be mach...

Page 38: ... be determined that it will not affect product performance All O Rings and seals should be replaced each time the valve is disassembled Refer to Tables 20 for a list of recommended spare parts and Table 21 for a list of O Ring repair kits XV Inspection and Part Replacement Cont Table 7 Thermodisc Replacement Criteria Orifice A min Orifice A min in mm in mm D 006 0 15 L 014 0 36 E 006 0 15 M 014 0 ...

Page 39: ...te finger or hand force Do not use excessive force to assemble these parts Be sure that the Disc is free to wobble after it is in place C Assembly Procedure with O Ring Seats 1 If the valve Nozzle was removed apply thread lubricant to the nozzle threads before reinstalling in the Base Insert it into the inlet flange of the Base and torque to the correct value listed in Table 9 2 Assemble the disc ...

Page 40: ... Base 8 Using a small amount of Silicone Grease supplied with soft goods replacement kit rub a small amount on the seals and O Rings prior to assembly 9 Take the Main Valve Piston and measure and cut diagonally the proper length of Guide Ring material to fit in the groove of the Main Valve Piston Allow 1 16 of an inch 1 59 mm gap between the ends for proper fit 10 For Teflon seals make sure of the...

Page 41: ... sensing port on the Main Base of the pilot valve Install the bracket between the Cover Plate and the Nut or Cap Screw Be sure that the bracket is aligned so that the two smaller pilot attachment holes are above the horizontal plane of the Cover Plate 16 Remove pipe plug from Cover Plate 17 Torque to the values found in Table 11 using the torque patterns in Figure 29 and Table 12 18 Once the Main ...

Page 42: ...75 102 75 102 90 122 90 122 140 190 140 190 M 95 129 95 129 110 149 95 129 95 129 N 105 142 105 142 130 176 85 115 85 115 P 120 163 120 163 145 197 125 169 125 169 Q 105 142 105 142 125 169 150 203 R 115 156 115 156 115 156 135 183 T 95 129 95 129 95 129 125 169 Table 11 Cover Plate Nut Torque Orifice 2920 2922 2923 2924 2926 2928 ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm D 55 75 55 75...

Page 43: ... Base with tool 4995401 as shown in Figure 59 Remove and discard the O Ring Insert on the bottom of the Insert Assembly Disassemble Insert Assembly by removing the Insert Bottom from the Insert Top Discard Spring Seal Insert 13 Remove Adjuster Cap from the bottom of the Pilot Base by turning counterclockwise 14 Loosen Adjuster Lock Nut by turning counterclockwise 15 Removing the Adjuster Assembly ...

Page 44: ...ghes 2020 Baker Hughes Company All rights reserved XVII Disassembly of Pilot Valve Cont 13 12 10 22 11 1 3 4 5 2 21 15 16 18 17 7 6 19 8 39PV37 8 14 34 20 12 9 25 27 23 24 26 24 20 Figure 30 39PV07 37 Disassembly ...

Page 45: ...lature 53 Lifting Lever Assembly 53a Cam Bushing 53b Cam Shaft 53c Lifting Lever 53d Drive Pin 53e Release Nut 53f Release Locknut 54 Gag Bolt 55 Lower Spring Washer Assembly 55a Lower Spring Washer 55b Lifting Stem 55c Drive Pin 5 Do not sand blast internal parts as it can reduce the dimensions of the parts Follow recommendations for safe handling in the solvent s Material Safety Data Sheet and o...

Page 46: ...g or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting Also check for galling of threads 5 Adjuster Bottom Galling or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting Also check for galling of threads 6 Top Plate Galling or excessive wear on the inside diameter that guides the Main Piston Check f...

Page 47: ...Install Spring Seal Adjuster Top onto Plunger Cylinder with spring facing away from Plunger Cylinder iii Insert Plunger into Plunger Cylinder until Plunger lightly contacts Spring Seal Adjuster Top iv Insert Funnel Tube chamfer side first over the Plunger and Spring Seal Adjuster Top Stop when Spring Seal Adjuster Top is about half way inside the Funnel Tube as shown in Figure 32 v Remove Plunger ...

Page 48: ...s do not fit loosely 2 The Insert Assembly of the pilot consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O Ring Insert a Press Spring Seal Insert into groove on the Insert Bottom Make sure spring is facing upwards b Install Insert Top over Insert Bottom with the spring seal side going in first c Lightly lubricate O Ring groove now formed by the two insert parts This lubrication is u...

Page 49: ...top of Pilot Base assembly ensuring that the spherical radius located on the Bottom Spring Washer engages with spherical nose on Main Piston 9 Install the Bonnet over the Spring and Spring Washer Assembly Thread the Bonnet onto the Top Plate Tighten wrench tight Install and tighten Set Screw 10 Turn Compression Screw clockwise until dimension has been reached that was noted during disassembly 11 T...

Page 50: ...essure gauge with a shutoff valve c Drain line with a shutoff valve d Adequate receiver volume for the valve to be tested and to achieve proper operation 3 Test Media Valves shall be tested on steam 4 Pretesting It is recommended that the pilot valve be tested prior to installation on the main valve B With Standard Options Note Seal all pipe threads with a non organic sealant or Teflon tape 1 Atta...

Page 51: ...ichever is greater ii 39PV model liquid between 7 and 4 If set pressure is less than 30 psig 2 1 barg 3 psig 0 20 barg or less Note Customer requirements may note a variation to the standard blowdown Customers request takes priority CAUTION Do not adjust blowdown compression screw or adjuster while pilot is pressurized f If adjustments are necessary adjust Compression Screw or Adjuster and retight...

Page 52: ... 2 1 barg minimum or system backpressure whichever is higher Air or nitrogen shall be used as the test medium for applying backpressure d Backpressure tests are to be performed by applying pressure with air or nitrogen to the valve outlet and the valve dome Pressure may be applied directly to the valve dome or via the pilot valve Leakage may be detected by application of soap solution or equivalen...

Page 53: ...t have a minimum pressure rating of 2x the maximum desired set point E In the cases when the auxiliary pressure is higher than the set pressure of the valve these procedures may interfere with normal valve operation and the valve may not perform its intended function The process system pressure shall be monitored at all times during the performance of these tests If system pressure increases past ...

Page 54: ...on for a POSRV to experience instability due to pressure fluctuations and differentials present between the main valve and the pilot Instability may take the form of rapid opening and closing of the system called chatter or a transient relieving condition until pressure within the pilot stabilizes with the main valve pressure Proper POSRV startup procedures can be practiced to mitigate these issue...

Page 55: ...eps i Close the Isolation Valve 1 ii Reduce the output pressure of the Nitrogen Regulator to 90 of set pressure iii Slowly open Vent Valve 1 until all pressure in the pilot is below 90 of set pressure iv Close Vent Valve 1 v Open Isolation Valve 1 6 With the pilot pressurized to 90 of set pressure system startup may begin 7 After startup close Nitrogen Bottle Valve 8 Fully open Vent Valve 1 until ...

Page 56: ...e will be relieving its rated capacity Proper safety precautions including process controls administrative controls and PPE controls should be taken to ensure the safety of the test personnel who can be in close vicinity of the relieving pressure relief valve 8 Close Isolation Valve 1 and open Vent Valve 1 to begin to drop pressure at a rate of 2 psi sec until the main valve closes Record the rese...

Page 57: ...sphere 3 With system pressure operating at 90 of set pressure connect Field Test Arrangement to Field Test Connection 4 Close all valves and regulators 5 Slowly open Nitrogen Bottle Valve to its fully open position 6 Slowly adjust Nitrogen Regulator pressure increase should not exceed 10 psig sec till the downstream pressure is equal to 90 of the set pressure as indicated by Pressure Gauge 1 7 Aft...

Page 58: ...ables 3 and 4 Main Valve leaks under the Nozzle Seat A Damaged Nozzle O Ring A Disassemble Main Valve and replace damaged Nozzle O Ring Pilot Valve is not opening at set pressure and Main Valve will not open A Wrong set pressure A Readjust the set pressure of the valve Main Valve does not close upon start up P2 chamber does not load with system pressure A Start up procedures pressurize the valve t...

Page 59: ... agents include demineralized water nonphosphate detergent acetone and isopropyl alcohol Parts must be blown dry or wiped dry after cleaning 4 If you are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations and equipment 5 It is not recommend...

Page 60: ...a means of connecting or applying pressure to the pilot to verify that the moving parts essential to good operation are free to move Reference UG 136 a 3 The lifting lever or field test connection may be omitted under Code Case 2203 All orders for pressure relief valves without levers or field test connection for steam air and water over 140 F 60 C must state specifically that the valves are being...

Page 61: ...epending on the amount of contamination expected to be introduced to the valve these filters need to be regularly inspected and replaced to ensure proper flow through the valve is maintained Regular maintenance intervals should be established based on inspection of the filter at the time of service Heavy accumulation at the filter is an indication that more frequent maintenance is needed In applic...

Page 62: ...at Exchanger This allows the temperature range for the 2900 40 POSRV with metal seats to be extended to 450 F to 1200 F 267 8 C to 648 9 C Not available above 3750 psig 258 5 barg When the heat exchanger is selected the POSRV shall be piped so that the media enters the heat exchanger first to condition the media s temperature Option s such Figure 50 Gag Figure 52 Heat Exchanger Cold Service Figure...

Page 63: ... that the main valve can open I Manual Electrical or Pneumatic Blowdown Valve Figures 53 54 An optional manual blowdown valve is available for relieving the pilot operated safety relief valve Consult factory for applications requiring a pneumatic or electrical solenoid blowdown valve which may be connected to a distant location such as an operator station for remote actuation The blowdown valve is...

Page 64: ...ired to an operator station or some other remote location The switch will provide a signal that indicates when the main valve is opening The standard pressure differential switch is a single pole double throw rated at 5 amps and 30 volts DC with a NEMA 4 enclosure For other configurations consult the factory Pneumatic For applications that do not permit an electrical differential switch an option ...

Page 65: ...able the user to group several pilots together for control of ambient conditions in a smaller space In addition this promotes easier maintenance N Remote Sensing As standard the pilot valve inlet is piped to a location remote from the main valve In this application the customer pipes the inlet sensing line to some location other than where the main valve is located and where the pressure will be r...

Page 66: ...ø 234 5 95 mm ø 563 14 29 mm A ø 465 003 11 85 0 08 mm ø 520 002 13 21 0 05 mm 031 0 79 mm 1 938 23 81 mm 1 063 26 99 mm 250 6 35 mm DETAIL OF PLUNGER 1 063 26 99 mm 1 000 25 40 mm ø 145 002 3 68 0 05 mm ø 375 002 9 53 0 05 mm DETAIL OF PLUNGER CYLINDER ASSEMBLY VIEW OF INSERTION TOOL ø 380 002 9 65 0 05 mm 156 3 97 mm Figure 59 Adjuster Top Seal Insertion Tool XXIII Maintenance Tools and Supplies...

Page 67: ...on Tool ASSEMBLY VIEW OF INSERT INSTALLATION TOOL Weld Weld Weld 2 1 2 2 2 3 375 9 53 mm 148 3 76 mm 297 7 54 mm 3 500 88 90 mm REF 3 125 125 90 90 ITEM 1 4 1 500 38 10 mm ITEM 2 ITEM 3 125 2 9375 74 61mm ø 250 6 35mm 313 794mm SQ 750 19 05mm 32 10 32 ø 238 ø 002 6 05mm 0 005mm ø 080 2 03mm 125 3 18 mm TYP 250 6 35 mm HEX Note 1 Figure 60 Insert Installation Tool ...

Page 68: ...arger valves as specified in Table 17 Table 14 Lapping Compound Types Brand Grade Grit Lapping Function Size Container Part No Clover 1A 320 General 4 oz 199 3 Clover 3A 500 Finishing 4 oz 199 4 Kwik Ak Shun 1000 Polishing 1 lb 199 11 2 lb 199 12 Table 15 Drift Pin Types Orifice A B Part No in mm in mm D E F G H J K 1 75 44 5 219 5 55 430401 L M N P 2 50 63 5 375 9 53 430402 Q R 3 00 76 2 625 15 8...

Page 69: ... Tool Table 17 Wrench Types Valve Orifice Description of Wrench Pin Spanner Wrench No Valve Orifice Description of Wrench Pin Spanner Wrench No Wrench Radius Pin Wrench Radius Pin in mm in mm in mm in mm F 750 19 05 219 5 56 4451801 M 1 675 42 55 328 8 33 4451806 G 750 19 05 219 5 56 4451801 N 1 875 47 63 359 9 13 4451607 H 875 22 23 266 6 75 4451802 P 1 875 47 63 359 9 13 4451607 J 1 125 28 58 26...

Page 70: ...E F G H J 156 3 96 047 1 19 034 0 86 798 20 27 375 9 53 Note 7 250 20 thd 6 35 20 thd K L 188 4 78 062 1 57 040 1 02 927 23 55 375 9 53 313 7 94 375 16 thd 9 53 16 thd M N 188 4 78 062 1 57 047 1 19 1 126 28 60 500 12 70 313 7 94 375 16 thd 9 53 16 thd P Q R T 375 9 53 094 2 39 055 1 40 1 834 46 58 750 19 05 531 13 49 625 11 thd 15 88 11 thd Notes 1 Use a Standard Eye Bolt 250 6 35 mm 20 thd x 3 5...

Page 71: ...ble nomenclature see Figures 1 to 7 Be sure to state the size type and serial number of the valve for which parts are required When ordering pilot parts please state specific pilot type 39PV07 37 etc For ease of maintenance O Ring kits are available for each main valve and pilot type A stock of these kits should be kept on hand for maximum operating efficiency See Tables 23 24 and 25 in Section XX...

Page 72: ...are identical 4 Check O Ring and Seals Kit material code to ensure they are the same for main valve and pilot valve Any discrepancies should be promptly report to the appropriate plant authority Specify parts required by 1 Part Name See Nomenclature Figures 1 7 2 Part Number if known 3 Quantity In addition the main valve serial number is stamped on the top edge of the outlet flange Be sure to incl...

Page 73: ...or Gasket Disc Guide Ring on Piston Piston O Ring2 Disc Retainer Ring O Ring Retainer O Ring Retainer Lock Screw O Ring Seat Seal Class II parts should be stocked at the rate of one 1 part per each five 5 valves in the population Class II parts will provide replacement parts of an additional 15 of possible maintenance requirements II Piston Disc Holder Guide Sensing Tube If Equipped Class III III ...

Page 74: ...T006 H 2905 06 10 12 20 22 M0RK29003T006 H 2914 16 24 26 M0RK29022T006 J 22905 06 10 20 22 M0RK29004T006 J 2912 14 16 24 26 M0RK29018T006 K 2905 06 10 12 20 22 24 M0RK29005T006 K 2914 16 M0RK29023T006 K 2926 28 M0RK29026T006 L 2905 06 10 12 20 22 M0RK29006T006 L 2914 16 24 26 M0RK29024T006 M 2905 06 10 12 14 20 22 24 M0RK29007T006 N 2905 06 10 12 14 20 22 24 M0RK29008T006 P 2905 06 10 20 M0RK29009...

Page 75: ...7E002 G 2914 16 18 24 26 28 M0RK29021E002 H 2905 06 10 12 20 22 M0RK29003E002 H 2914 16 24 26 M0RK29022E002 J 22905 06 10 20 22 M0RK29004E002 J 2912 14 16 24 26 M0RK29018E002 K 2905 06 10 12 20 22 24 M0RK29005E002 K 2914 16 M0RK29023E002 K 2926 28 M0RK29026E002 L 2905 06 10 12 20 22 M0RK29006E002 L 2914 16 24 26 M0RK29024E002 M 2905 06 10 12 14 20 22 24 M0RK29007E002 N 2905 06 10 12 14 20 22 24 M0...

Page 76: ...912 M0RK29017E019 G 2914 16 18 24 26 28 M0RK29021E019 H 2905 06 10 12 20 22 M0RK29003E019 H 2914 16 24 26 M0RK29022E019 J 22905 06 10 20 22 M0RK29004E019 J 2912 14 16 24 26 M0RK29018E019 K 2905 06 10 12 20 22 24 M0RK29005E019 K 2914 16 M0RK29023E019 K 2926 28 M0RK29026E019 L 2905 06 10 12 20 22 M0RK29006E019 L 2914 16 24 26 M0RK29024E019 M 2905 06 10 12 14 20 22 24 M0RK29007E019 N 2905 06 10 12 14...

Page 77: ...ield Test Connector Consist of one of the Select Shuttle Valve assemblies shown above SP561 Q replaced by 6000609 SP561 R replaced by 6000608 SP468 G replaced by 6000622 Table 22 39PV 2 Pilot Valve Seal Kits Material Class CC per configuration Pilot Valve Seal Kits Pilot Material Part No 39PV07 2 GS LS E P R Ethylene Propylene 70 PSGK 38E019 39PV07 2 GS LA SS Teflon PSGK 38T006 39PV07 2 SS E P R E...

Page 78: ...1 High Capacity Filter S4 Seal Material Part No Teflon 9465 18191 Table 28 High Capacity Filter Replacement Parts Description Part No No Required Per Valve Filter Element 6027301 1 O Rings 31006131 2 Table 29 Mounting Bracket Screws Description Part No No Required Per Valve SS Screw 2310166 2 Table 30 Tubing Description Part No Low Pressure Tubing S31607310004 High Pressure Tubing1 S31607310124 1 ...

Page 79: ...ing of all safety valves B Repair Facilities The Consolidated factory maintains a Consolidated Repair Center The Repair Department in conjunction with the manufacturing facilities is equipped to perform specialized repairs and product modifications e g butt weld bushing replacements code welding pilot replacement etc C Safety Relief Valve Maintenance Training Rising costs of maintenance and repair...

Page 80: ...formation The Baker Hughes logo Consolidated Thermodisc 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 2900 40 IOM 19553D 0520 05 2020 Direct Sales Office Locations Find the nearest local Channel Partner in your area valves bakerhughes com contact us valves ...

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