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XI. General Planning for Maintenance

A 12 month maintenance interval is recommended for general service conditions.
For severe service applications, a 3 to 6 month inspection and test interim may
be more appropriate. The specific plant's operating and service history will better
determine this frequency. BHGE encourages preventive maintenance.

The 2900 series Pilot Operated Safety Relief Valve (POSRV) is easily maintained.
Normal maintenance usually involves:

• Removal of pilot valve from main valve

• Disassembly of both the pilot and main valve

• Cleaning

• Component Inspection

• Parts Replacement as Needed

• Reassembly

• Setting, Testing and Resealing the Valve

Occasionally, remachining the nozzle may be necessary to extend the service

life of the valve. Keep all parts for each valve separated to ensure replacement

in the same valve.

Note: Insure there is no pressure in the inlet of the valve before attempting to

remove it from the piping system.

XII. Recommended Installation

Practices

A. Mounting Position

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 stop valve is located between the pressure vessel
and POSRV, the stop valve port area should equal or exceed the nominal internal
area associated with the pipe size of the POSRV inlet. The pressure drop from the
vessel to the POSRV shall not exceed 3% of the valve’s set pressure,

when flowing at full capacity.

Ensure the flanges and sealing faces of the valve and connective piping are free from
dirt, sediment, and scale.

Ensure all flange bolts are drawn evenly to prevent distortion of the valve body

and the inlet nozzle.

Position the POSRVs for easy access and/or removal so that servicing can be
properly performed. Ensure sufficient working space is provided around and

above the valve.

Decontaminate or

clean if necessary

before pretesting or

disassembly. Safety

and environmental

precautions must

be taken for the

decontamination or

cleaning method used.

Do not interchange

parts from one valve

to another.

Consolidated 2900 Series POSRV Maintenance Manual

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© 2018 Baker Hughes, a GE company. All Rights Reserved.

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Summary of Contents for Consolidated 2900 series

Page 1: ...BHGE Data Classification Public Consolidated 2900 Series Pilot Operated Safety Relief Valves Maintenance Manual Rev B ...

Page 2: ...ENT 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 MATTER SHOULD BE REFERRED TO BHGE THE R...

Page 3: ...sing the following conversion factors 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 1 Multiply USCS value with conversion factor to get metric value Consolidated 2900 Series POSRV Maintenance Manual 3 2018 Baker Hughes a GE comp...

Page 4: ...Orifice with Bellows 16 D V W Orifice with Bellows 16 E 39PV07 37 Pilot Valves Standard Service 17 F 39MV07 Pilot Valve Standard Service 18 G 39MV22 72 Pilot Valve Standard Service 19 X Operating Principles 20 A 2900 Series with Type 39PV Pop Pilot Operational Descriptions 20 B 2900 Series 39MV07 Modulating Pilot Operational Description 22 XI General Planning for Maintenance 24 XII Recommended Ins...

Page 5: ...mbly Procedure with O Ring Seats 45 XVII Disassembly of Pilot Valve 48 A 39PV07 37 Disassembly 48 B 39MV07 Disassembly 51 C 39MV22 72 Disassembly 54 D Cleaning 57 XVIII Part Inspection of Pilot Valve 58 A 39PV07 37 58 B 39MV07 58 C 39MV22 72 59 XIX Reassembly of Pilot Valve 60 A Lubricants and Sealants 60 B Assembly of 39PV07 37 60 C Assembly of 39MV07 62 D Assembly of 39MV22 72 65 A General Infor...

Page 6: ...nsing 81 O Sensing Ring 81 XXIII Maintenance Tools and Supplies 82 A Adjuster Top Seal Insertion Tool 82 B Insert Installation Tool 83 C Lapping Tools 84 D Disc Holder and Guide Removal and Assembly Tool 85 XXIV Replacement Parts Planning 87 A Basic Guidelines 87 B Identification and Ordering Essentials 87 XXV Genuine Consolidated Parts 88 C Positive Identification of Main Valve and Pilot Valve Co...

Page 7: ...l 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 some instances of human hazards the pictorial may instead depict what preventive measures to take such as wearin...

Page 8: ...jury 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 allow anyone under the influence or intoxicants or narcotics to work on or around pressurized systems Workers...

Page 9: ...eye and clothing protection 4 CAUTION Wear protective breathing apparatus to protect against toxic media Note Any Service questions not covered in this manual should be referred to BHGE s Service Department Phone 318 640 6255 Restoring Safety Appropriate service and repair are important to safe reliable operation of all valve products Restoration to original quality and manufacturing specification...

Page 10: ...s 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 drum protection eye protection and the use of protec...

Page 11: ... selection or misapplication of our products Unauthorized Repair Work BHGE has not authorized any non BHGE affiliated repair companies contractors or individuals to perform warranty repair service on new products or field repaired products of its manufacture Therefore customers contracting or performing such repair service from unauthorized sources do so at their own risk Unauthorized Removal of S...

Page 12: ...s 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 and maximum allowable working pressure For assured safe opera...

Page 13: ... protective covering over the inlet and the outlet flanges This is to 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 inse...

Page 14: ... to determine the appropriate length size and maximum change in height for the sensing line and to determine the correct capacity of the pressure relief valve Before start up be sure all threaded joints are tight and secure Hydrostatic Testing Prior to hydrostatic test of the pressure vessel system the pilot operated safety relief valve should be removed and the mounting flange for the valve block...

Page 15: ...imits of the Pilot Valve are presented separately Note When replacing or repairing the main valve and pilot valve assembly pay particular attention to the pressures and temperature limitations for both the main valve and pilot valve to ensure compatibility C Pilot Valve Introduction Standard pilot construction consists of 316SS parts with Nitrile O Rings with Teflon based seals throughout Standard...

Page 16: ...sket 12 Guide Ring s 13 Stud Base 14 Nut Base 15 Plug Adaptor 16 Plug Adaptor Gasket 17 O Ring Retainer Lock Screw 18 O Ring Retainer 19 O Ring Seat Seal 5 6 13 14 3 4 11 10 9 8 7 15 16 2 12 1 Figure 1 Main Valve Construction Metal Seat A Metal Seat Valve B Soft Seat Valve 9 17 19 2 18 D Thru J Orifice K Thru U Orifice 8 7 9 19 18 17 2 Figure 2 Main Valve Construction Soft Seat 16 BHGE 2018 Baker ...

Page 17: ...ion Bellows V W orifices Part No Nomenclature 20 Bellows Assembly 21 Bellows Gasket 8A Disc Retainer Screws 8B Retainer Screw Lock Washer 9 Disc Holder Assembly 20 Bellows Assembly 21 Bellows Gasket 22 Bellows Bolts 23 Bellows Bolts Lock Washers 24 Guide Ring Guide 25 Bug Screen Not Shown Consolidated 2900 Series POSRV Maintenance Manual 17 2018 Baker Hughes a GE company All Rights Reserved ...

Page 18: ... 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 Spring Seal Adjuster Top 22 Spring Seal Insert 23 Field Test Connector 24 Vent Assembly Bug Screen Field Test Connection 25 Vent Assembly Bonnet Vent 1 26 Pipe Plug Pilot Valve 27...

Page 19: ...0 Spring Seal Main Piston 21 Spring Seal Adjuster Top 22 Spring Seal Insert 23 Field Test Connector 24 Vent Assembly Bug Screen Field Test Connection 25 Vent Assembly Bonnet Vent 1 27 Set Screw Bonnet 34 Top Plate 35 Plug Filter Used in Sensing Tube When Equipped Not Shown 36 Modulator Base 37 Modulator Stop 38 Modulator Piston Top 39 Modulator Piston Bottom 40 O Ring Retainer 41 Lock Screw Retain...

Page 20: ... 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 Spring Seal Adjuster Top 22 Spring Seal Insert 23 Field Test Connector 24 Vent Assembly Bug Screen Field Test Connection 25 Vent Assembly Bonnet Vent 1 27 Set Screw Bonnet 28 Piston Nose 29 Piston Retainer Nut 30 Set Screw Piston 31 Vent Seal Adaptor...

Page 21: ...qualizes 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 Figure 8 PV Valve Closed Normal Position Consolidated 2900 Series POSRV Maintenance Manual 21 2018 Baker Hughes ...

Page 22: ...he main valve piston The valve discharges to relieve system pressure When the discharging main valve reduces the inlet pressure to the preset 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 allowed to enter the dome above the main valve piston As the dome pressure equalizes with the i...

Page 23: ...d 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 Consolidated 2900 Series POSRV Maintenance Manua...

Page 24: ...odulator Since the dome pressure has not been dropped to atmospheric pressure the main valve only partially opens at the set point The modulator piston will remain closed until the main valve disc is forced into higher lift by increasing inlet pressure As this occurs the modulator piston may relieve further pressure from the dome as necessary to achieve the required main disc lift within 10 overpr...

Page 25: ... 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 stop valve is located between the pressure vessel and POSRV the stop valve port area should equal or exceed the ...

Page 26: ...d by external loading vibration and loads due to thermal expansion of the discharge piping The determination of reaction forces during valve discharge is the responsibility of the vessel and or piping designer BHGE publishes certain technical information about reaction forces under various fluid flow conditions but assumes no liability for the calculations and design of the inlet piping External l...

Page 27: ...ipe size must sometimes be much larger D 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 adequate...

Page 28: ...rotection 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 application Valve illustrations showing a...

Page 29: ...plug into Cover Plate where dome line is installed Pipe plug will prevent Main Valve Piston from falling out of Cover Plate when the assembly is removed 6 Remove Cover Plate and Main Valve Piston assembly from Base ATTENTION If Main Valve Piston O Ring or Spring Energize Seal is damaged then Main Valve Piston may fall out of Cover Plate during disassembly 7 Remove pipe plug from Cover Plate 8 Remo...

Page 30: ...XIII Disassembly of the 2900 POSRV Contd 5 4 10 11 9 8 7 12 6 14 13 3 1 2 15 16 Figure 16 Conventional Metal Seat Valve Disassembly 30 BHGE 2018 Baker Hughes a GE company All Rights Reserved ...

Page 31: ...9 21 11 20 10 4 5 12 6 15 16 Figure 17 Bellows Metal Seat Valve Disassembly XIII Disassembly of the 2900 POSRV Contd Consolidated 2900 Series POSRV Maintenance Manual 31 2018 Baker Hughes a GE company All Rights Reserved ...

Page 32: ...1 Lift the Guide off the Disc Holder If the valve has a Bellows avoid damage to the gasket seating surfaces and if present the convolutions or the flange section of the Bellows Eye Bolts Disc Holder Guide Top of Base Lifting Tool Guide Disc Holder Top of Base Figure 21 Disc Holder Removal Tool P U Disc Holder 9 Disc Retainer 8 Thermodisc 7 Figure 18 Thermodisc Disc Holder 9 O Ring Seat Seal 19 O R...

Page 33: ...as follows Turn the disc holder on its side Remove the retaining bolts Attach the lifting lug to the disc and lift out 15 For O Ring seat seal valves only remove the Retainer Lock Screw s O Ring Retainer and O Ring Seat Seal 16 The nozzle is threaded onto the base and is removed by turning it counterclockwise from right to left Before removing the nozzle soak the threaded joint with a suitable pen...

Page 34: ...rties of the part 3 Acceptable cleaning 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 recommendati...

Page 35: ... and lapping compound Anytime the V or W orifice valve is disassembled be sure to inspect the Guide Rings for wear If worn replace before reassembly ATTENTION In order to establish leak free valve 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 ...

Page 36: ...13 8 336 005 211 73 0 13 W 10 029 254 74 10 034 254 86 1 750 44 45 350 8 89 11 058 005 280 87 0 13 10 458 005 265 63 0 13 Table 2 Nozzle Critical Dimensions Contd Orifice N P 0 5 Radius B 001 0 03 mm J 005 0 13 mm K L in mm in mm in mm in mm in mm D 038 002 003 0 97 0 05 0 08 30 016 0 41 079 2 01 0 867 001 22 02 0 03 813 001 20 65 0 03 E 038 002 003 0 97 0 05 0 08 30 016 0 41 079 2 01 0 867 001 22...

Page 37: ...al Since the seat must be wide enough to carry the bearing load imposed upon it by the pressure force the higher pressure valves must have wider seats than the lower pressure valves The nozzle seat width should conform to the measurements in Table 3 and Table 4 To measure the seat width use a Model S1 34 35 37 Bausch and Lomb Optical Co measuring magnifier or an equivalent seven power glass with a...

Page 38: ...17 24 049 1 24 057 1 45 251 17 31 300 20 68 057 1 45 060 1 52 U 1 0 07 50 3 45 040 1 02 043 1 09 51 3 52 100 6 89 043 1 09 049 1 24 101 6 96 250 17 24 049 1 24 057 1 45 251 17 31 300 20 68 057 1 45 060 1 52 V 1 0 07 50 3 45 075 1 91 083 2 11 51 3 52 100 6 89 083 2 11 103 2 62 101 6 96 250 17 24 103 2 62 123 3 12 251 17 31 300 20 68 123 3 12 130 3 30 W 1 0 07 50 3 45 100 2 54 110 2 79 51 3 52 100 6...

Page 39: ...ine the seat with the same lap using the lapping method as described above Low sections on the seating surface show up as shadow in contrast to the shiny portion If shadows are present further lapping is necessary Only laps known to be flat can be used It should take only a few minutes to remove the shadows When lapping is complete any lines appearing as cross scratches can be removed by rotating ...

Page 40: ... cuts across surface A 45º until the damaged areas are removed Turn to the smoothest possible finish b Re machine radius R c The nozzle is now ready for lapping d 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 33 1 Grip the disc in a four jaw independent chuck or collet if appropri...

Page 41: ... 0 97 N 495 12 57 038 0 97 P 620 15 75 068 1 73 Q 620 15 75 068 1 73 R 620 15 75 068 1 73 T 832 21 13 068 1 73 U 833 21 16 068 1 73 Type 3 V 1 230 31 24 120 3 05 W 1 855 47 12 168 4 27 Figure 34 Metal and Soft Seat Disc Inspection Areas Figure 34b Type 2 J U Orifice T B C N L Figure 34d Disc O Ring Soft Seat K U Orifices Only C D B A Figure 34a Type 1 D H Orifice T B C N L Figure 34c Type 3 V W Or...

Page 42: ...eral condition for cracks or holes Look for any corrosion issues 3 Bellows Inspect general condition for cracks holes or deformation of convolutions Check for any corrosion or pitting 4 Cover Plate Cover Plate Should be reused if a The sliding surface in the dome area is not galled scratched corroded or pitted b The Gasket surface is not scratched corroded or pitted 5 O Ring Retainer Inspect surfa...

Page 43: ...or pitting 8 Standard Metal Seated Disc This disc Figure 34 can be machined until the T dimension is reduced to the minimum as listed in Table 5 The N minimum dimension must be maintained as well 9 Thermodisc Metal Seated Disc This disc Figure 37 cannot be machined It can be lapped as long as the A minimum dimension has been maintained If lapping does not fix damaged area part must be discarded Th...

Page 44: ...er types if it can 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 23 for a list of recommended spare parts and Table 24 for a list of O Ring repair kits XV Inspection and Part Replacement Contd Figure 38 Main Valve Piston B E Figure 38a D G Orifice Bellows E B Figure 38b H W Orifice Bellows D W ...

Page 45: ...k of the Disc Use 1000 grit grinding compound on the bearing surface to grind the Disc into the Disc Holder to properly establish the bearing surface b For D through U orifice valves place the Disc Retainer into the groove in the disc The Disc with the Disc Retainer should snap into the Disc Holder pocket with moderate finger or hand force Do not use excessive force to assemble these parts Be sure...

Page 46: ...pecial cable type wrench to turn the Bellows Ring down until a pressure tight joint is obtained b For bellows valves V and W place a new Bellows Gasket on the Disc Holder Bolt down using proper torque as found in the assembly instructions c For Spring Assist valves place the Spring down onto the Disc Holder 5 a For D through U orifice valves Place the Guide over the Disc Holder DO NOT DROP If Bell...

Page 47: ... 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 U 95 129 95 129 95 129 125 169 V 130 176 130 176 130 176 W 130 176 130 176 130 176 Table 11 Cover Plate Nut Torque Contd 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 60 81 60 81 115 156 E 55 75 55 75 60 81 60 81 115 156...

Page 48: ... line of the inlet 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 40 and Table 12...

Page 49: ...e Main Piston from Pilot Base Note For Dirty Service Option please refer to Dirty Service Option Section XXII B for disassembly instructions 12 Removing the Insert Assembly The Insert Assembly consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O Ring Insert Remove Insert Assembly from the top of the Pilot Base with tool 4995401 as shown in Figure 81 Remove and discard the O Ring Inser...

Page 50: ...sembly of Pilot Valve Contd 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 41 39PV07 37 Disassembly 50 BHGE 2018 Baker Hughes a GE company All Rights Reserved ...

Page 51: ...t 18 O Ring Top Plate 19 Bonnet 20 Spring Seal Main Piston 21 Spring Seal Adjuster Top 22 Spring Seal Insert 23 Field Test Connector 24 Vent Assembly Bug Screen Field Test Connection 25 Vent Assembly Bonnet Vent 1 27 Set Screw Bonnet 34 Top Plate 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 W...

Page 52: ... Ring Top Plate 11 Remove Main Piston from Pilot Base Note For Dirty Service Option please refer to Dirty Service Option Section XXII B for disassembly instructions 12 Removing the Insert Assembly The Insert Assembly consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O Ring Insert Remove Insert Assembly from the top of the Pilot Base with tool 4995401 as shown in Figure 81 Remove and ...

Page 53: ... 11 17 18 1 16 3 21 15 4 5 2 42 37 45 41 40 46 39 47 48 38 49 43 36 44 27 Figure 43 39MV07 Disassembly XVII Disassembly of Pilot Valve Contd Consolidated 2900 Series POSRV Maintenance Manual 53 2018 Baker Hughes a GE company All Rights Reserved ...

Page 54: ...dard material is a filter plug For special materials vent assembly is supplied 19 Remove Socket Head Cap Screw 2 Nos to remove Modulator Assembly from Pilot Base Remove and discard both O Rings Modulator Base The Modulator Assembly consists of 1 Modulator Base 1 Modulator Stop 1 Modulator Piston Assembly The Modulator Piston Assembly consists of 1 Modulator Piston Top 1 Modulator Piston Bottom 1 O...

Page 55: ...e Piston Nose Note For Dirty Service Option please refer to Dirty Service Option Section XXII B for disassembly instructions 13 Remove Spring Seal Main Piston and Backup Ring if applicable and discard 14 Removing the Insert Assembly The Insert Assembly consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O Ring Insert Remove Insert Assembly from the top of the Pilot Base with tool 49954...

Page 56: ... 14 8 9 8 25 19 6 7 13 12 37 36 10 22 11 17 18 1 16 39 3 21 40 15 4 5 2 24 24 23 Figure 44 39MV22 Disassembly XVII Disassembly of Pilot Valve Contd 56 BHGE 2018 Baker Hughes a GE company All Rights Reserved ...

Page 57: ... 12 37 36 10 22 11 17 18 1 16 39 3 21 40 15 4 5 2 20 24 23 27 Figure 45 39MV72 Disassembly XVII Disassembly of Pilot Valve Contd Consolidated 2900 Series POSRV Maintenance Manual 57 2018 Baker Hughes a GE company All Rights Reserved ...

Page 58: ...ling recommendations and equipment 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 observe safe practices for any cleaning method 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...

Page 59: ...y corrosion or pitting 10 Pilot Base Check for any corrosion or pitting Also check for galling of threads 11 Spring Check for any corrosion or pitting B 39MV07 1 Main Piston Galling or excessive wear on the small diameter end where it engages the spring seals or on the spherical bearing surface Any corrosion or pitting that appears detrimental to the function of the valve The part can be polished ...

Page 60: ...3 mm The stem itself must have a T I R of 001 0 03 mm along its length 3 Insert Top 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 4 Insert Bottom Galling or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting 5 Adjuster Top Galling or excessive wear o...

Page 61: ...ts 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 46 v Remove Plunger vi Insert Funnel Tube Assembly into Adjuster Top until Funnel Tube contacts Spring Seal Adjuster Top gland viii Push down on Plunger cylinder to insert Spring Seal Adjust...

Page 62: ...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 used to hold the O Ring in place when it is being inserted into Pilot Base d Place O Ring Insert into groove e Final Insert Assembly is shown in Figure 49 ...

Page 63: ...Stem Turn clockwise until it matches the dimension noted during disassembly 14 Install Filter Plug into Bonnet vent hole if removed 15 Install Pipe Plug Pilot Valve in port above vent hole if removed 16 Refer to Field Test Connection Backflow Preventer Option Section XXII A for reassembly of Field Test Connection C Assembly of 39MV07 1 Making the Main Pilot 2 Making the Adjuster Assembly This asse...

Page 64: ...nsert 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 used to hold the O Ring in place when it is being inserted into Pilot Base d Place O Ring Insert into groove e Final Insert Assembly is shown in Figure 49 f...

Page 65: ...lator Piston Bottom in outer groove Make sure spring is facing down e Insert Modulator Piston Top into Modulator Piston Bottom through the side with the O Ring Modulator Piston Bottom and the Spring Seal Piston Bottom f Turn assembly over and install O Ring Retainer The chamfered outside diameter goes in first g Thread Lock Screw through the O Ring Retainer into Modulator Piston Top Tighten 40 5 i...

Page 66: ...t during installation and that the Spring Seal Adjuster Top is oriented as shown in Figure 48 c Install the Spring Seal Adjuster Bottom onto the Adjuster Bottom with spring side down as shown in Figure 48 d Place the Vent Seal Adaptor onto the Spring Seal Adjuster Bottom with flat side up e Thread Adjuster Top clockwise onto Adjuster bottom and torque to 27 2 ft lbs 37 2 7 N m f Lubricate Main Pis...

Page 67: ...ly before installing Install Main Piston into the Top Plate with Spring Washer bearing point going in first Be careful not to damage Spring Seal Main Piston 5 Install Main Piston Top Plate Assembly into Pilot Base by inserting small diameter end of Main Piston through Insert Assembly Note For Dirty Service Option install Main Piston Top Plate Assembly into Dirty Service Insert instead of Pilot Bas...

Page 68: ...V07 37 1 Attach pilot to main valve using two Socket Head Cap Screws Bracket 2 Install the 3 8 O D tubes Refer to Table 13 for sizing of tubing into the fittings for the inlet and dome ports Make sure the tube ends are fully inserted before torquing Begin torquing the fitting about midway down verify that Swagelok Gap Inspection Gauge Swagelok P N MS IG 468 will go Continue to torque down fitting ...

Page 69: ... be inserted between the Valve Nozzle and the Sensing Ring and between the Sensing Ring and the test system flange Reasons for failure 1 Any leakage from Pilot at 4 below valve set pressure or 2 psig 0 14 psig whichever is greater The 39MV22 and 39MV72 may have 50 bubbles per minute at 5 below the set pressures at or above 2251 psig 155 2 barg and none at pressures below 2250 psig 155 1 barg 2 Mai...

Page 70: ...in valve 2 Leakage from main valve can come from either the main valve seat nozzle seal or dome seal To determine if the leakage is from either the main valve seat or nozzle seal the outlet must be filled to above the seat line and checked for bubbles If no bubbles are present then leakage is either coming from the dome seal 3 The leakage rate shall be determined with the valve mounted vertically ...

Page 71: ...e main valve only if the system can achieve 10 over pressure i 39PV model gas steam less than or equal to 5 or 3 psig 0 20 barg whichever 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 iii 39MV model gas steam less than or equal to 4 or 2 psig 0 14 barg whichever is greater iv 39MV model liquid between 7 and 4 If set pressure ...

Page 72: ...pe Plug 3 Disc holder for bellows valve 4 Cover Plate1 Note 1 Conventional Cover Plate may be modified to work on a bellows valve F Field Testing of POSRV Assembly F 1 Field Test Connection A 1 4 FNPT field test connection Figure 59 is standard on all pilot valve types This allows the stroking of the valve with an auxiliary media e g air or nitrogen An internal check valve is present in the field ...

Page 73: ...emble Main Valve and replace dam aged Nozzle O Ring Pilot Valve is not open ing 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 pres sure A Start up procedures pressurize the valve too rapidly A Slowly increase the inlet pressure B Sensing Tube is installed upside...

Page 74: ...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 recommended to sand blast internal part...

Page 75: ...al Insert 26 Pipe Plug Pilot Valve 29 Piston Retainer Nut 30 Set Screw Piston 31 Vent Seal Adaptor 32 Spring Seal Vent Seal Adaptor 50 Dirty Insert 51 Omni Plug 52 Breather Filer Vent B Dirty Service Option Severe dirty service precipitation and viscous fluid problems can be solved using the dirty service option offered on the 3900 POSRV A dirty service option can be added to the standard pilot va...

Page 76: ...Do not sand blast internal parts as it can reduce the dimensions of the parts B 3 Parts Inspection 1 Insert Top 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 2 Insert Bottom Galling or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting B 4 Reassembly...

Page 77: ...rmally in the event of a system over pressurization during a field test The test port connection is a 375 9 53 mm tube fitting equipped with a bug screen For all applications on air water over 140 F 60 C or steam service ASME Section VIII Division 1 requires each pressure relief valve to have a lifting device such as a field test connection or a means of connecting or applying pressure to the pilo...

Page 78: ... manually operated needle valve which allows for purging the filtered material while the valve is in operation All filter elements are stainless steel and all filters including carbon steel conform to NACE Standard MR0103 and MR0175 A dual filter arrangement Figure 70 is available for applications in which the customer is unsure of the filter maintenance requirements In these cases a preventive ma...

Page 79: ...vailable 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 as line filter canister filter 5 way manifold valve pressure differential switch pressure spike snubber etc shall be piped downstream of the heat exchanger Figures 72 73 Figure 72 Heat Exchanger Hot Ser...

Page 80: ...tory 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 ported directly to the main dome area so that the media in the dome is vented when the blowdown valve is actuated thus allowing the main valve to open Figure 74 Manual Blowdown Valve Figure 75 Electrica...

Page 81: ...ote 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 is available to provide pneumatic signal to i...

Page 82: ...of ambient conditions in a smaller space In addition this promotes easier maintenance N Remote Sensing The pilot valve inlet may be piped to a location remote from the main valve In this application the customer may pipe the inlet sensing line to some location other than where the main valve is located and where the pressure will be relieved for tubing size and maximum length consult factory for r...

Page 83: ...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 80 Adjuster Top Seal Insertion Tool XXIII Maintenance Tools and Supplies Consolidated 2900 Series POSRV Maintenance Manual 83 2018 Baker Hughes a GE compan...

Page 84: ... 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 81 Insert Installation Tool 84 BHGE 2018 Baker Hughes a GE company All Rights Reserved ...

Page 85: ...ntainer 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 19 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 88 430403 T U 3 50 88 9 875 22 23 430404 Table 20 Nozzle Lap Dimensions Orifice Nozzle Bore Nozzle Lap Nozzle La...

Page 86: ...ice 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 N 1 875 47 63 359 9 13 4451607 G 750 19 05 219 5 56 4451801 P 1 875 47 63 359 9 13 4451607 H 875 22 23 266 6 75 4451802 Q 2 500 63 50 438 11 11 4451808 J 1 125 28 58 266 6 75 4451803 R 3 000 76 20 500 12 70 4451809 K 1 250 31 75 281 7 14 4451804 T 3 750 95 25 500...

Page 87: ...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 88 90 mm Long 2 Use a Standard Eye Bolt ...

Page 88: ...he 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 24 25 and 26 in Section XXVI B Identification and Ordering Essentials Identification and Ordering Essentials When o...

Page 89: ... N s Those shipped unconnected to the BHGE Green Tag network may have main valves and pilot valves with different S N s During service and repair the following inspection steps will ensure the proper match of main valves to pilot valves 1 Record main valve and pilot valve S N s of original POSRV s in plant records 2 Inspect S N s for agreement with Step 1 after any disassembly involving removal of...

Page 90: ...ng Kit Plug Filter Main Valve O Ring Kit Gasket Kit Metal Disc Nozzle Bellows if required Disc Retainer 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 for an additional 15 of possible maintenance requirements II Pilot Valve Main Piston Tube Fittings 2 Modulator Stop O Ring Retainer Backflow Preventer...

Page 91: ...9048B008 J 22905 06 10 20 22 M0RK29004B008 M0RK29030B008 J 2912 14 16 24 26 M0RK29018B008 M0RK29044B008 K 2905 06 10 12 20 22 24 M0RK29005B008 M0RK29031B008 K 2914 16 M0RK29023B008 M0RK29049B008 K 2926 28 M0RK29026B008 M0RK29052B008 L 2905 06 10 12 20 22 M0RK29006B008 M0RK29032B008 L 2914 16 24 26 M0RK29024B008 M0RK29050B008 M 2905 06 10 12 14 20 22 24 M0RK29007B008 M0RK29033B008 N 2905 06 10 12 1...

Page 92: ...24 26 M0RK29022B018 M0RK29048B018 J 22905 06 10 20 22 M0RK29004B018 M0RK29030B018 J 2912 14 16 24 26 M0RK29018B018 M0RK29044B018 K 2905 06 10 12 20 22 24 M0RK29005B018 M0RK29031B018 K 2914 16 M0RK29023B018 M0RK29049B018 K 2926 28 M0RK29026B018 M0RK29052B018 L 2905 06 10 12 20 22 M0RK29006B018 M0RK29032B018 L 2914 16 24 26 M0RK29024B018 M0RK29050B018 M 2905 06 10 12 14 20 22 24 M0RK29007B018 M0RK29...

Page 93: ...J 22905 06 10 20 22 M0RK29004T006 M0RK29030T006 J 2912 14 16 24 26 M0RK29018T006 M0RK29044T006 K 2905 06 10 12 20 22 24 M0RK29005T006 M0RK29031T006 K 2914 16 M0RK29023T006 M0RK29049T006 K 2926 28 M0RK29026T006 M0RK29052T006 L 2905 06 10 12 20 22 M0RK29006T006 M0RK29032T006 L 2914 16 24 26 M0RK29024T006 M0RK29050T006 M 2905 06 10 12 14 20 22 24 M0RK29007T006 M0RK29033T006 N 2905 06 10 12 14 20 22 2...

Page 94: ...4 16 24 26 M0RK29022E002 M0RK29048E002 J 22905 06 10 20 22 M0RK29004E002 M0RK29030E002 J 2912 14 16 24 26 M0RK29018E002 M0RK29044E002 K 2905 06 10 12 20 22 24 M0RK29005E002 M0RK29031E002 K 2914 16 M0RK29023E002 M0RK29049E002 K 2926 28 M0RK29026E002 M0RK29052E002 L 2905 06 10 12 20 22 M0RK29006E002 M0RK29032E002 L 2914 16 24 26 M0RK29024E002 M0RK29050E002 M 2905 06 10 12 14 20 22 24 M0RK29007E002 M...

Page 95: ...M0RK29048E019 J 22905 06 10 20 22 M0RK29004E019 M0RK29030E019 J 2912 14 16 24 26 M0RK29018E019 M0RK29044E019 K 2905 06 10 12 20 22 24 M0RK29005E019 M0RK29031E019 K 2914 16 M0RK29023E019 M0RK29049E019 K 2926 28 M0RK29026E019 M0RK29052E019 L 2905 06 10 12 20 22 M0RK29006E019 M0RK29032E019 L 2914 16 24 26 M0RK29024E019 M0RK29050E019 M 2905 06 10 12 14 20 22 24 M0RK29007E019 M0RK29033E019 N 2905 06 10...

Page 96: ...J 22905 06 10 20 22 M0RK29004V005 M0RK29030V005 J 2912 14 16 24 26 M0RK29018V005 M0RK29044V005 K 2905 06 10 12 20 22 24 M0RK29005V005 M0RK29031V005 K 2914 16 M0RK29023V005 M0RK29049V005 K 2926 28 M0RK29026V005 M0RK29052V005 L 2905 06 10 12 20 22 M0RK29006V005 M0RK29032V005 L 2914 16 24 26 M0RK29024V005 M0RK29050V005 M 2905 06 10 12 14 20 22 24 M0RK29007V005 M0RK29033V005 N 2905 06 10 12 14 20 22 2...

Page 97: ...K29004V022 M0RK29030V022 J 2912 14 16 24 26 M0RK29018V022 M0RK29044V022 K 2905 06 10 12 20 22 24 M0RK29005V022 M0RK29031V022 K 2914 16 M0RK29023V022 M0RK29049V022 K 2926 28 M0RK29026V022 M0RK29052V022 L 2905 06 10 12 20 22 M0RK29006V022 M0RK29032V022 L 2914 16 24 26 M0RK29024V022 M0RK29050V022 M 2905 06 10 12 14 20 22 24 M0RK29007V022 M0RK29033V022 N 2905 06 10 12 14 20 22 24 M0RK29008V022 M0RK290...

Page 98: ...47E002 PSGK 47V005 PSGK 47T005 Table 26 Pilot Valve O Ring Kit Options1 Options Buna N Ethylene Propylene Viton Teflon Field Test Connector PSGK 37E019 Backflow Preventer Seal Kit PSGK 37B018 PSGK 37E0022 PSGK 37V022 PSGK 37T006 Line Filter Seal Kit SP540 JKIT Note 1 For steam service at pressures below 50 psig 3 45 barg the 39PV07 2 SS or 39MV07 2 SS with EPR O Rings should be used E962 90 Note 2...

Page 99: ... contact your local Green Tag Center B Factory Repair Facilities The BHGE Consolidated 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 For further information please contact your local Green Tag Center C Maintenance Training Rising costs of m...

Page 100: ...99 Melbourne Phone 61 3 8807 6002 Fax 61 3 8807 6577 BELGIUM Phone 32 2 344 0970 Fax 32 2 344 1123 BRAZIL Phone 55 19 2104 6900 CHINA Phone 86 10 5738 8888 Fax 86 10 5918 9707 FRANCE Courbevoie Phone 33 1 4904 9000 Fax 33 1 4904 9010 GERMANY Ratingen Phone 49 2102 108 0 Fax 49 2102 108 111 INDIA Mumbai Phone 91 22 8354790 Fax 91 22 8354791 New Delhi Phone 91 11 2 6164175 Fax 91 11 5 1659635 ITALY ...

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