Baker Hughes Consolidated 4900 Series Instruction Manual Download Page 29

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XII. Disassembly of the 4900 Series POSRV (Cont.)

Consolidated 4900 MPV Series POSRV Manual

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Figure 12: POSRV Assembly with MV22/72 Pilot

Summary of Contents for Consolidated 4900 Series

Page 1: ...Consolidated 4900 MPV Series Pilot Operated Safety Relief Valve Instruction Manual Rev B Baker Hughes Data Classification Public...

Page 3: ...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...

Page 4: ...sing 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 06...

Page 5: ...Freeze Protection 27 XII Disassembly of the 4900 POSRV 28 A Removal of Pilot Valve From Main Valve 28 B Disassembly of Main Valve 28 C Cleaning 30 XIII Maintenance Instructions 31 A General Informatio...

Page 6: ...69 G Hydrostatic Testing and Gagging 69 XX Trouble Shooting 70 XXI 4900 Series POSRV Options 71 A Backflow Preventer 71 B Field Test Connection 71 C Filter High Capacity 72 D Gag 72 E Lifting Lever 72...

Page 7: ...pict what preventive measures to take such as wearing protective equipment The bottom panel may contain an instruction message on how to avoid the hazard In the case of human hazard this message may a...

Page 8: ...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 ca...

Page 9: ...Wear protective breathing apparatus to protect against toxic media Note Any Service questions not covered in this manual should be referred to your local Green Tag Center GTC Restoring Safety Appropri...

Page 10: ...stions 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 precauti...

Page 11: ...ated repair companies contractors or individuals to perform warranty repair service on new products or field repaired products of its manufacture Therefore customers contracting such repair services f...

Page 12: ...mperature 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...

Page 13: ...y The internal parts of a pilot operated safety relief valve are precision machined and fitted together to maintain perfect alignment Rough handling may damage the external tubing pilot and main valve...

Page 14: ...hes Company All rights reserved Part No Nomenclature M1 Base M2 Base Plug M3 Nozzle M4 O Ring Nozzle M5 Retainer Nose1 M6 O Ring Seat M7 O Ring Retainer M8 Lockscrew1 M9 Guide Ring M10 Disc M11 O Ring...

Page 15: ...ot Valve Construction Consolidated 4900 MPV Series POSRV Manual 15 2020 Baker Hughes Company All rights reserved Figure 2 4900 Series POSRV Assembly with 49PV07 37 Pilot A B Manual Blowdown Field Test...

Page 16: ...4 P2 P6 P7 P6 P8 P9 P10 P11 P12 P14 P15 P1 P23 P18 P22 P20 P19 P21 P5 P13 P17 P16 P24 P25 P26 P33 P28 P31 P29 P32 P27 P30 P34 P47 P50 P48 P49 P47 P46 P35 P36 P39 P38 P41 P42 P43 OUT OF POSITION P44 P4...

Page 17: ...flow Preventer P33 O Ring Ball Seat Backflow Preventer P34 Breather Filter Vent Bonnet P35 Manual Blowdown Needle Valve P36 Ball Field Test P37 Tube Filter P38 Field Test Body P39 Breather Filter Vent...

Page 18: ...nt C 49MV07 Pilot Valve Construction 18 Baker Hughes 2020 Baker Hughes Company All rights reserved A A C C B B Manual Blowdown Field Test Connector Canister Filter Backflow Preventor Figure 5 4900 Ser...

Page 19: ...P4 P2 P6 P6 P8 P9 P11 P12 P10 P14 P15 P1 P23 P18 P22 P20 P19 P21 P7 P5 P34 P13 P17 P16 P24 P25 P27 P32 P29 P30 P28 P31 P33 P36 P49 P48 P59 P50 P67 P58 P60 P71 P59 P61 P66 P68 P63 P65 P62 P64 OUT OF PO...

Page 20: ...e Plug Backflow Preventer P32 O Ring Backflow Preventer Part No Nomenclature P33 O Ring Ball Seat Backflow Preventer P34 Breather Filter Vent Bonnet P35 Manual Blowdown Needle Valve P36 Ball Field Tes...

Page 21: ...72 Pilot Valve Construction Consolidated 4900 MPV Series POSRV Manual 21 2020 Baker Hughes Company All rights reserved A B B A C C Manual Blowdown Field Test Connector Canister Filter Backflow Preven...

Page 22: ...ed P3 P4 P2 P6 P7 P6 P8 P13 P9 P12 P11 P10 P15 P14 P1 P23 P18 P22 P20 P19 P21 P25 P24 P16 P17 P34 P5 P26 P32 P29 P30 P31 P33 P28 P27 HIGH PRESSURE P56 P13 P12 P52 P53 P51 P54 P55 OUT OF POSITION P40 P...

Page 23: ...apter Part No Nomenclature P26 O Ring Pilot Base P27 O Ring Inlet Adapter P28 Ball Backflow Preventer P29 Backflow Preventer Guide P30 Backflow Preventer Body P31 Pipe Plug Backflow Preventer P32 O Ri...

Page 24: ...ve 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...

Page 25: ...ping should never be smaller in diameter than the inlet connection of the valve Excessive pressure drop in gas vapor or flashing liquid service at the inlet of the POSRV will cause extremely rapid ope...

Page 26: ...flexibility of the discharge piping can prevent stresses caused by thermal changes Do not use fixed supports C Outlet Piping Alignment of the internal parts of the POSRV is important to ensure proper...

Page 27: ...ications Applications where the process media in the liquid state has a freezing point between the ambient temperature limits of the local region Steam service applications where the pilot operated va...

Page 28: ...e if it did not come out with the Disc 5 Remove the Sensing Retainer Nut Note For valves with separate retainer and sensing tube remove the retainer from the disc and then remove the tube 6 O Ring Dis...

Page 29: ...Series POSRV Cont Consolidated 4900 MPV Series POSRV Manual 29 2020 Baker Hughes Company All rights reserved M2 M1 M3 M4 M17 M15 M16 M19 M5 M6 M7 M8 M14 M18 M13 M20 M11 M12 M10 M9 M21 Figure 12 POSRV...

Page 30: ...eaning 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...

Page 31: ...discard and replace 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 C Re Machining Nozzl...

Page 32: ...0 152 4 Q R 5 592 003 142 04 0 08 5 533 003 140 54 0 08 125 3 18 2 844 72 24 022 0 56 8 00 203 2 T 6 484 003 004 142 04 0 08 0 10 6 420 003 004 163 07 0 08 0 10 125 3 18 3 469 88 11 022 0 56 Full Bore...

Page 33: ...cts that might cause the disc not to sit flush with nozzle 5 Spring Check for any corrosion issues that might cause the spring not to operate as designed 6 Nozzle Nozzle should be replaced if a Dimens...

Page 34: ...ck Screw s and tighten to the torque values listed in Table 3 3 For valves with separate retainer and sensing tube assemble the tube to the retainer before attaching to the disc Insert the tube throug...

Page 35: ...e Torque to 50 5 ft lbs 67 8 6 8N m Table 4 Coverplate Cap Screw Nut Torque Bore Type Valve Size Orifice 4905 4910 4912 4914 4916 4918 in mm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm Stand...

Page 36: ...4 Insert Disc Assembly into Guide with the Disc seat going in first Continue pushing Disc into Guide being careful of not pinching the Guide Rings Push Disc in until the Disc is in contact with the No...

Page 37: ...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 44 Remove and discard the O Rin...

Page 38: ...Hughes Company All rights reserved P5 P8 P9 P13 P12 P17 P14 P16 P11 P15 P44 P46 P3 P4 P2 P34 P6 P7 P6 P10 P21 P20 P19 P22 P24 P18 P46 P38 P41 P41 P36 P40 P40 P35 P1 P37 P5 P26 P23 P47 P49 P48 P50 P47...

Page 39: ...e P26 O Ring Pilot Base P27 O Ring Inlet Adapter P28 Ball Backflow Preventer P29 Backflow Preventer Guide P30 Backflow Preventer Body P31 Pipe Plug Backflow Preventer P32 O Ring Backflow Preventer P33...

Page 40: ...P2 Bonnet P3 Compression Screw P4 Compression Screw Lock Nut P5 Cap Compression Screw P6 Spring Washer P7 Spring P10 Set Screw Bonnet P34 Breather Filter Vent Bonnet Part No Nomenclature P72 Sealing P...

Page 41: ...ings and discard B 49MV07 Figures 18 and 19 1 Remove and discard the aluminum seals and sealing wire 2 Remove Cap Compression Screw by turning counterclockwise 3 If a lifting lever is installed also u...

Page 42: ...any All rights reserved P5 P3 P4 P2 P6 P7 P6 P10 P21 P20 P19 P22 P24 P24 P18 P46 P38 P41 P41 P36 P40 P40 P37 P17 P14 P16 P11 P15 P35 P1 P8 P9 P13 P12 P30 P31 P32 P32 P33 P28 P3 P5 P21 P4 P19 P42 P8 P2...

Page 43: ...No Nomenclature P32 O Ring Backflow Preventer P33 O Ring Ball Seat Backflow Preventer P34 Breather Filter Vent Bonnet P35 Manual Blowdown Needle Valve P36 Ball Field Test P37 Tube Filter P38 Field Tes...

Page 44: ...ckflow Preventer consists of 1 Backflow Preventer Body 1 Backflow Preventer Guide 1 Ball 1 O Ring Backflow Preventer Small 1 O Ring Backflow Preventer Large 2 O Ring Ball Seat 1 Pipe Plug Backflow Pre...

Page 45: ...e Lifting Lever assembly Then return to Figure 20 or 21 to continue disassembly a The Lifting Lever Assembly consists of 1 Lifting Lever 1 Drive Pin 1 Cam Shaft 1 Cam Bushing b Remove Lifting Lever As...

Page 46: ...ker Hughes Company All rights reserved P5 P3 P4 P2 P34 P6 P7 P6 P10 P8 P9 P56 P56 P13 P12 P51 P52 P14 P17 P16 P11 P53 P15 P46 P38 P41 P41 P40 P36 P37 P40 P35 P21 P20 P19 P35 P22 P24 P54 P18 P23 P30 P3...

Page 47: ...enclature P26 O Ring Pilot Base P27 O Ring Inlet Adapter P28 Ball Backflow Preventer P29 Backflow Preventer Guide P30 Backflow Preventer Body P31 Pipe Plug Backflow Preventer P32 O Ring Backflow Preve...

Page 48: ...ker Hughes Company All rights reserved P8 P21 P20 P19 P35 P22 P24 P54 P18 P23 P35 P9 P56 P56 P13 P12 P51 P52 P14 P17 P16 P53 P15 P46 P38 P41 P41 P40 P36 P37 P40 P35 P11 P5 P3 P4 P2 P34 P6 P7 P6 P10 P3...

Page 49: ...ottom 20 Removal of the Backflow Preventer The Backflow Preventer consists of 1 Backflow Preventer Body 1 Backflow Preventer Guide 1 Ball 1 O Ring Backflow Preventer Small 1 O Ring Backflow Preventer...

Page 50: ...perties 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...

Page 51: ...l bearing surface or in the thread Check for any corrosion or pitting 9 Spring Washer s Galling at the spherical bearing surface Check for any corrosion or pitting 10 Pilot Base Check for any corrosio...

Page 52: ...valve The part can be polished as long as the outside diameter of the stem remains at 243 001 6 17 0 03 mm The stem itself must have a T I R of 001 0 03 mm along its length 3 Insert Top Galling or exc...

Page 53: ...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...

Page 54: ...and tight Note Make sure Adjuster Cap and Adjuster Lock Nut threads freely on Adjuster Bottom Adjuster Assembly may be inadvertently rotated if these two parts do not fit loosely 2 The Insert Assembly...

Page 55: ...ase Lock Nut onto Lifting Stem Turn clockwise until it matches the dimension noted during disassembly 13 Install Filter Plug into Bonnet vent hole if removed 14 Install Pipe Plug Pilot Valve in port a...

Page 56: ...to filter base The 1 8 27NPT thread in the end cap must be facing toward the pilot base inlet flange face tighten the bolt until metal to metal make up with the guide sleeve is obtained C Assembly of...

Page 57: ...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 sh...

Page 58: ...Fitting opening of the body 3 Insert an O Ring Ball Seat into the Field Test Body seat ring counter bore 4 Insert the O Ring Field Test Body Small and the O Ring Field Test Body Large into the Pilot B...

Page 59: ...side of the Modulator Base 13 Thread the Cap Screws Modulator through the Modulator Stop into the Modulator Base Tighten to 365 30 in lbf 41 2 3 4 Nm 14 Do not install Modulator Assembly at this time...

Page 60: ...ng 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...

Page 61: ...e Main Piston stem and cycle Main Piston through Spring Seal Insert five times 4 Install O Ring Top Plate into groove on top of Pilot Base a 49MV22 i Lubricate the Spring Seal Main Piston and Top Plat...

Page 62: ...ckflow Preventer Guide 6 Thread the Backflow Preventer Body into the Pilot Inlet Adaptor Torque the fitting to 50 5 ft lbs 68 7 N m D 3 Reassembly of the Field Test Fitting 1 Insert an O Ring Ball Sea...

Page 63: ...ges 5 Inlet supply throttle valve 6 Inlet supply vent throttle valve 7 Inlet supply and dome simulator pressure gauges The inlet accumulator and dome simulator should be fitted with a drain valve at t...

Page 64: ...mble a Swagelok fitting sealing the vent port with a 90 tube facing downwards Place this tube in a cup of water when pilot is at full overpressure If bubbles are present 0 bpm then Spring Seal Insert...

Page 65: ...lve set pressure e Note the inlet pressure when the dome pressure is at 70 of set pressure This will be the blowdown f If blowdown is too long turn Adjuster one flat counterclockwise If blowdown is to...

Page 66: ...any options is shown in Figure 32 D 2 49MV07 49MV22 and 49MV72 1 Insert O Rings in the inlet sensing port dome port and vent port ring grooves of the Pilot Base 2 Place an O Ring in the O Ring should...

Page 67: ...akage that may be coming from the pilot disconnect the pilot vent line if applicable from the main base outlet and plug the main valve outlet connection If wet paper still bulges then leakage is occur...

Page 68: ...te Customer requirements may note a variation to the standard blowdown Customers request takes priority 6 If adjustments are necessary adjust Compression Screw or Adjuster and retighten corresponding...

Page 69: ...while maintaining pressure on the main valve dome area thereby allowing only the pilot to actuate The system shown in Figure 41 is available for remote or local testing G Hydrostatic Testing and Gaggi...

Page 70: ...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...

Page 71: ...same time allowing the valve to open normally in the event of a system over pressurization during a field test The test port connection is a 3 8 tube fitting equipped with a bug screen For all applic...

Page 72: ...static test 49MV72 limited to 4800 psig 330 95 barg with gag option E Lifting Lever Figure 18 in Section XVI This is an external physical means of allowing the pilot valve to relieve dome pressure so...

Page 73: ...w 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 avai...

Page 74: ...e A A A 375 002 9 53 0 05 mm 156 3 97 mm 234 5 95 mm 563 14 29 mm A 465 003 11 85 0 08 mm 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...

Page 75: ...rved ASSEMBLY VIEW OF INSERT INSTALLATION TOOL Weld Weld Weld 2 1 2 2 1 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 61m...

Page 76: ...50 33 35 4 375 111 13 750 19 05 6 00 152 4 7 500 190 50 6 500 165 10 1 000 25 4 8 00 203 2 8 500 215 90 6 500 165 10 1 000 25 4 6 00 x 8 00 x 8 00 152 4 x 203 2 x 203 2 1 062 26 97 mm Socket Wrench 8...

Page 77: ...s 1 to 8 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 49PV07 37 etc For ease of maintenance O R...

Page 78: ...Any discrepancies should be promptly reported to the appropriate plant authority Specify parts required by 1 Part Name See Section IX Figures 1 2 3 4 5 6 7 and 8 2 Part Number if known 3 Quantity Cont...

Page 79: ...flow Preventer Seal Kit Piston Nose Main Valve Nozzle O Ring Retainer Tube Fittings 2 1 A combination of Class I and II parts will satisfy maintenance requirements 85 of the time Table 11 Main Valve O...

Page 80: ...GK 46V022 PSGK 46T006 49MV72 LA GS PSGK 47B008 PSGK 47E002 PSGK 47V005 PSGK 47T005 1 For steam service at pressures below 50 psig 3 45 barg the 49PV07 2 SS or 49MV07 2 SS with EPR O Rings should be us...

Page 81: ...000609 Male Elbow 375 9 53 mm T x 250 6 35 mm MNPT 6000608 Nut and Ferrule Set 375 9 53 mm T 6000669 Plug Filter N A 4818801 Union Tee 375 9 53 mm T x 375 9 53 mm T x 375 9 53 mm T 6000615 1 The above...

Page 82: ...es Repair Center The repair department in conjunction with the manufacturing facilities is equipped to perform specialized repairs and product modifications e g bushing replacements hydroset calibrati...

Page 84: ...s Phone 1 713 966 3600 Copyright 2020 Baker Hughes Company All rights reserved Baker Hughes provides this information on an as is basis for general information purposes Baker Hughes does not make any...

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