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Dresser Consolidated 1900, Installation, Operation And Maintenance Manual

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Dresser Consolidated 1900 Installation, Operation And Maintenance Manual Download Page 45

CON-2

Page 43

XVII. (Continued)

LAPPING TOOLS

The following tools are required for proper
maintenance of Consolidated

®

 Safety Relief

Valve seats, and may be purchased from DVCD
upon request.

Nozzle Lap - The nozzle lap is used for lapping
the nozzle seat and has one flat side and one
side with a 5

°

 angle.  This lap guides in the bore

of the nozzle; therefore, a different size lap is
required for each valve orifice.

Ring Lap - The ring lap is used for lapping the
disc seat and finish lapping of the nozzle seat.

Lapping Plate - The lapping plate is used for
reconditioning the ring lap.  It may also be used
for lapping the disc.  One 11" diameter plate is
required for the entire line of valves (Part No.
0439004).

Lapping Compound - Used as a cutting
medium when lapping the valve seats (as
specified below).

Lapping

Size

Part

Brand

Grade Grit

Function Container No.

Drift Pins - Two pins are required for the
removal of the disc from the disc holder.  (See
Figure 45, below.)

Lifting Tools - For removal of upper internal
parts of larger valves (as specified below).

M, N

4464602

P, Q, R, T

4464604

Orifice

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

Valve

Pin Spanner

Orifice

Description of Wrench

Wrench No.

F

3/4" Radius - 7/32" Pin

4451801

G

3/4" Radius - 7/32" Pin

4451801

H

7/8" Radius - 15/64" Pin

4451802

J

1-1/8" Radius - 17/64" Pin

4451803

K

1-1/4" Radius - 9/32" Pin

4451804

L

1-3/8" Radius - 19/64" Pin

4451805

M

1-5/8" Radius - 21/64" Pin

4451806

N

1-7/8" Radius - 23/64" Pin

4451807

P

1-7/8" Radius - 23/64" Pin

4451807

Q

2-1/2" Radius - 7/16" Pin

4451808

R

3" Radius - 1/2" Pin

4451809

T

3-3/4" Radius - 1/2" Pin

4451810

D, E, F

G, H, J, K

1-3/4

44.5

7/32

55.5

0430401

L, M, N, P

2-1/2

63.5

3/8

95.3

0430402

Q, R

3

76.2

5/8

158.7

0430403

T

3-1/2

88.9

7/8

222.2

0430404

Orifice

A (in.)

A (mm)

B (in.)

B (mm) Part No.

FIGURE 45

Wrenches - For removal of bellows from disc
holder (as specified below).

Summary of Contents for Consolidated 1900

Page 1: ...E MANUAL Consolidated Safety Relief Valve Type 1900 Industrial Valve Operation Dresser Valve and Controls Division Alexandria Louisiana 71309 1430 USA Design Options Include Bellows 30 O Ring Seat DA Liquid Trim LA and Thermodisc TD CON 2 Revised 7 97 ...

Page 2: ...ventive 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 also contain a more precise definition of the hazard and the consequences of human interaction with the hazard than can be communicated solely by the pictorial DANGER Do not remove bolts if pressure in line as this...

Page 3: ...Pressure Change Disc Holder 28 L Checking Lift on Restricted Lift Valves 28 XI Reassembly 29 A General Information 29 B Lubrication 30 C Specific Steps 30 XII Setting and Testing 35 A General Information 35 B Test Equipment 35 C Test Media 35 D Setting the Valve 35 E Set Pressure Compensation 35 F Seat Tightness Testing 37 XIII Hydrostatic Testing and Gagging 38 XIV Manual Popping of the Valve 39 ...

Page 4: ... hazard both to themselves and other employees and can cause severe personal injury or death to themselves or others 6 WARNING Incorrect service and repair could result in product or property damage or severe personal injury or death WARNING All potential hazards may not be covered in this manual WARNING Improper tools or improper use of right tools could result in personal injury or product damag...

Page 5: ... instructions before installing valve s 1 CAUTION Heed all service manual warnings Read installation instructions before installing valve s 2 CAUTION Wear hearing protection when testing or operating valves 3 CAUTION Wear appropriate eye and clothing protection 4 CAUTION Wear protective breathing apparatus to protect against toxic media NOTE Any service questions not covered in this manual shouldb...

Page 6: ...ift is the actual travel of the disc away from the closed position when a valve is relieving Maximum Allowable Working Pressure Maximum allowable working pressure is the maximumgaugepressurepermissibleinavessel at a designated temperature A vessel may not beoperatedabovethispressure oritsequivalent at any metal temperature other than that used in its design Consequently for that metal temperature ...

Page 7: ... Design Features and Nomenclature Cap and Lever Interchangeability Many times it is necessary to change the type of cap or lever in the field after a valve has been installed All flanged Consolidated Safety Relief Valves are designed so they can be converted to any type of lever or cap desired It is not necessary to remove the valve from the installation nor will the set pressure be affected when ...

Page 8: ...ainer 17 Spring Washer 18 Spring 19 Adjusting Screw 20 Adjusting Screw Nut 21 Screwed Cap 22 Bolted Cap 23 Packed Cap 24 Plain Cap 25 Cap Bolt 26 Cap Set Screw 27 Cap Gasket 28 Release Nut 29 Release Locknut 30 Lever 31 Lifting Fork 32 Lever Shaft 33 Packing 34 Packing Nut 35 Top Lever 36 Drop Lever 40 Eductor Tube 41 Bonnet Vent Plug Shown in Figures 38 42 on page 39 of this manual FIGURE 1 CONSO...

Page 9: ...E 4 FIGURE 6 V W Orifice Only FIGURE 2 Page 7 DESIGN OPTIONS THERMODISC TD DESIGN FIGURE 3 THERMODISC FIGURE 5 LA Liquid Trim Design See Fig 20 DISC RETAINER DISC GUIDE ADJUSTING RING NOZZLE DISC HOLDER PART INTEGRITY ESPECIALLY DESIGNED FOR SHORT BLOWDOWN AND SMOOTH CHATTER FREE OPERATION AT MAXIMUM CAPACITY ...

Page 10: ...pping during loading or unloading from a truck While hoisting to the installation care should be taken to prevent bumping the valve against steel structures and other objects Do not lift horizontally or hook to lifting lever WARNING Handle carefully Do not drop or strike WARNING Storage Safety relief valves should be stored in a dry environment to protect them from the weather They should not be r...

Page 11: ...ld be located for easy access and or removal so that servicing can be properly performed Sufficient working space shouldbeprovidedaround andabove thevalve B Inlet Piping The inlet piping see Figure 7 below to the valve should be short and direct from the vessel or equipment being protected The connection to the vessel should be provided with a radius to permit smooth flow to the valve Sharp corner...

Page 12: ...e of the valve Forced alignment of the discharge piping will also induce such stresses Discharge piping should be independently supported and carefully aligned Do not locate valve at end of pipe thru which there is normally no flow or near elbows tees bends etc WARNING 3 Vibrations in the inlet piping systems may cause valve seat leakage and or fatigue failure of the piping These vibrations may ca...

Page 13: ...illation of the discharge piping introduces stressdistortioninthevalvebodyandtheresultant movement of the internal parts may cause leakage Where possible drains should be piped away to prevent the collection of water or corrosive liquid in the valve body Attention should be given to the support of the drainage piping When two or more valves are piped to discharge intoacommonheader thebuilt upbackp...

Page 14: ... Remove the a d j u s t i n g ring pin and gasket Ifthe e x i s t i n g blowdown is to be r e s t o r e d u p o n reassembly the position of the a d j u s t i n g ring with respect to the disc holder should bedetermined Todothis turntheadjusting ring counterclockwise i e move notches on the adjusting ring from left to right Record the number of notches passing the ring pin hole which are required ...

Page 15: ... thin and fragile and care should be taken to protect them from damage at all times Next remove the bellows gasket For V and W orifice bellows valves the bellows is bolted to the guide and disc holder These bolts should be removed before removal of the guide FIGURE 11 pressure testing Remove the Compression Screw from the Bonnet Use pliers to prevent the Spindle from turning when removing the Comp...

Page 16: ...protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommen dations and equipment It is not recommended to sandblast internalpartsasitcanreducethedimensions of the parts The base bonnet and cap castings may be sand blasted with care not to erode internal surfaces or damage machined surfaces Follow r...

Page 17: ...13 00 05 00 05 00 08 00 08 00 08 00 08 00 10 00 10 00 10 00 10 00 10 00 15 00 15 00 18 TABLE 1A D Radius L Orifice Min E F H N P B J K Max Nozzle Metal To Metal O Ring Seat Seal D 1 13 32 015 518 30 015 062 573 537 E 1 15 32 020 788 686 025 30 015 060 733 688 D 2 E 2 F 5 16 030 955 832 035 30 015 079 868 814 G 5 16 035 1 094 954 035 30 021 090 1 060 999 H 1 4 035 1 225 1 124 035 45 021 060 1 216 1...

Page 18: ...nsion is reduced below the minimum as indicated in table 1 or 1a NOTE Flangethicknesschangesthecenter to face dimension The minimum dimension for ori fices D through P is 43 64 and orifices Q through T is 51 64 C Nozzle Bore Inspection Criteria All Type 1900 Valve nozzles manufactured after August 1978 have increased bore diam eters Physically the nozzles original versus new areinterchangeable but...

Page 19: ...IN A MIN SIZE DIMENSION IN DIMENSION MM D E F G H 006 153 J 013 331 K L M N 014 356 P 017 432 Q R 015 381 T 025 635 V W DISC ORIFICE TYPE SIZE D 1 E 1 TYPE 1 F D 2 E 2 G H J K L M TYPE 2 N P Q R T TYPE 3 V W TABLE 3 N Minimum 005 005 010 010 010 010 015 015 015 015 015 015 015 015 015 015 INCHES T Minimum 155 158 174 174 335 359 422 457 457 495 610 610 610 822 1 692 N Minimum in millimeters 127 12...

Page 20: ...a There are several designs of disc holders De pendingontheserviceandthetypeofvalve The particular type may be found in the details of Figure 16 for identification purposes the G dimension is provided Please note that there are low pressure and high pressure disc holders ...

Page 21: ... T W Low Pressure 0 715 1 012 1 167 1 167 1 167 1 272 1 491 1 929 2 126 2 527 2 126 3 088 3 950 5 197 6 115 7 494 12 21 32 High Pressure 0 715 0 922 1 032 1 032 1 032 1 183 1 394 1 780 2 126 2 527 2 126 3 088 3 950 5 197 6 115 7 494 12 21 32 LA Design 0 765 Detail 3 1 061 Detail 3 1 265 Detail 3 1 265 Detail 3 1 265 Detail 3 1 374 Detail 3 1 655 Detail 3 2 155 Detail 3 2 468 Detail 3 3 062 Detail ...

Page 22: ... Detail 2 57 50 64 19 57 50 64 19 75 69 132 00 156 34 190 35 n a High Pressure 20 6 24 66 33 53 26 21 26 21 30 05 35 41 45 21 57 50 64 19 75 69 65 28 75 69 132 00 156 34 190 35 n a Standard Disc Holder O Ring Disc Holder Liquid Trim LS Design 20 6 24 66 29 64 29 64 29 64 32 31 37 87 49 0 57 50 70 15 77 57 88 39 110 77 140 87 166 70 199 14 n a For valve manufactured prior to June 1987 use dimension...

Page 23: ... inches D E F G H J M K L N P Q R T Q 2 R 2 T 3 W 450 496 527 995 682 1 119 994 1 119 1 744 1 242 1 367 1 870 2 242 2 304 2 491 3 488 3 988 5 190 2 304 8 425 003 007 004 008 004 009 005 010 005 010 007 012 004 009 007 012 008 013 010 017 012 020 008 014 013 026 Disc Holder Disc Holder Nominal Barrel Size Diametral Clearance in millimeters in millimeters 11 43 12 6 13 38 25 27 17 32 28 42 25 24 28 ...

Page 24: ... of nozzle and disc seating surfaces see Paragraphs X H and X I which follow NOTE In order to determine if the valve contains Glide Aloy treated components i e the disc holder and or the guide which will be identified for a particular valve by the coding found on the valve nameplate please consult the Appendix to this manual for pertinent supplemental information The seating surfaces of the metal ...

Page 25: ...1 300 17 31 20 68 155 165 3 94 4 19 mm Suggested Lapped Seat Width in Inches mm Set Pressure psig bar for Metal Seated Valves except TD Orifice D thru F 15 50 1 03 3 45 020 030 50 76 mm 101 300 6 96 20 68 035 045 89 1 14 mm 301 800 20 75 55 17 045 055 1 14 1 40 mm 801 plus 55 24 plus Add 005 13 mm for each additional 100 psig G thru J 15 100 1 03 6 89 025 035 64 89 mm 101 300 6 96 20 68 035 040 08...

Page 26: ...ly after wiping off the old compound and apply more pressure to speed the cutting action of the compound 8 To check the seating surfaces remove all compound from both the seat and the lap Then shine the seat with the same lap using the lapping motion described above Low sections on the seating surface will show up as a shadow in contrast to the shiny portion If shadows are present further lapping ...

Page 27: ...chiningNozzleSeatsandBores The nozzle should be removed from the valve to be machined see Figure 29 See Nozzle Removal Instructions in paragraph VII B 14 If it can not be removed from the base it should be machined inside the base 1 Lathe Set Up Nozzle Removed a Gripthenozzleinafour jawindependent chuck using a piece of soft material such as copper or fiber between the jaws and the nozzle as shown...

Page 28: ... the smoothest possible finish b Cut back the outside surface at M until dimension J is obtained c Machine radius B d The nozzle is now ready for grinding e When the minimum dimension D is reached thenozzleshouldbediscarded I Remachining the Disc Seat The standard disc seating surface see Figure 30 can easily be machined as follows 1 Gripthediscinafour jawindependentchuck orcollet ifappropriate us...

Page 29: ...ed 1 V Block Support Set Up a Theballpointedspindlesshouldbeplaced in a piece of material B that has been recessed to permit free rotation of the spindle Forhollowspindles aballpointed support is required See Figure 31 b Support the spindle with a V block A placed near the upper end of the spindle but below the threads Page 27 c Apply a machinist s indicator at approximately45 totheouteredgeofthe ...

Page 30: ...e a special nozzle with the overall height and flange FIGURE 33 Restricted lift valves may be identified by the restricted lift nameplate see Figure 33 dimension of the D 1 or E 1 and the actual seat dimensions and bore diameter are identical to the F orifice nozzle Other 1900 series valves may be restricted in the same manner when necessary These valves mayberestrictedtoaminimumliftof30 ofthefull...

Page 31: ...stud nuts 12 Thevalveisnowreadyforsettingandtesting NOTES The limit washer must be chamfered to fit over the radius on the disc holder This chamfered end must be located down next to the backface of disc holder when assembled For bellows Type D and E valves the limit washer must be chamfered on the lowerend toremovetheknifeedgeofthe cut off For bellow valves the outside diameter must also be check...

Page 32: ...d W orifice discs place disc into discholderandsecurediscretainingbolts c ForO RingdiscsizesKthruT reassemble the disc using a new O Ring O Ring retainer and new screws Assemble the disc into the disc holder as described in Paragraph 4 a above d ForO RingdiscsizesDthruJ reassemble the disc holder using a new O Ring O Ring retainer and new screw s These disc holders are ready for the next step 5 Fo...

Page 33: ...g coumpound onto the ball end of the spindle and place it in the spindle socket ofthedischolder Turnthespindleclockwise and then counter clockwise to seat the spindle disc holder bearing point 9 Place the spindle retainer over the end of the spindle head or disc holder as applicable Apply lubricant sparingly to the ball tip of the spindle Place the spindle in the disc holder TABLE 10 Bonnet Nut To...

Page 34: ...ern as displayed in Figure 35 Use table 10 or 10A to determine the required torque for the subject valve Then use Table 11 to determine the torque values for each round of the pattern The last round insures that all the stud nuts are at the required touque Page 32 TABLE 10A Bonnet Nut Torque in nm 10 0 1910 75 75 75 75 75 75 82 102 82 123 150 177 197 170 156 170 177 177 1912 75 82 75 82 82 82 102 ...

Page 35: ... from turning in the disc holder Turn the adjusting screw clockwise until the original distance between the end of the spindle and the top of the adjusting screw is obtained This method of compressing the spring will approximately re establish the original set pressure The valve must still be reset for the required pressure 17 Restore the adjusting ring to its original position with reference to t...

Page 36: ...ches 24 2 Notches 6 Notches E 1 16 1 Notch 4 Notches E 2 16 1 Notch 4 Notches 24 2 Notches 6 Notches F 16 1 Notch 4 Notches 24 2 Notches 6 Notches G 18 1 Notch 4 Notches 30 2 Notches 6 Notches H 24 1 Notch 5 Notches 30 2 Notches 6 Notches J 24 1 Notch 5 Notches 30 2 Notches 8 Notches K 24 2 Notches 5 Notches 32 2 Notches 7 Notches L 24 2 Notches 6 Notches 40 4 Notches 11 Notches M 24 2 Notches 7 N...

Page 37: ...from ambient causes the set pressure to decrease Thisdecreaseinsetpressureisduetothermalexpan sion of the seating area and spring relaxation Therefore it is important to compensate for the differ ence between production test temperature and ser vice temperature The service temperature is the normal operating temperature of the valve If the operating temperature is unavailable no correction duetote...

Page 38: ...e Xa X1 013 Cold Differential Set Pressure 405 psig 4 Setting Procedure NOTE Valves for steam service should be set using saturatedsteam Valvesforgaseousserviceshould be set using air or nitrogen Valves for liquid service should be set using water NOTE TheASMEBoilerandPressureVesselCodeSection VIII set pressure tolerance is 2 psi 14 bar for set pressures less than 70 psig 4 8 bar and 3 for pressur...

Page 39: ...Testing can be conducted by installing the cap with gasket and applying air or nitrogen to the base drain connection or to the valve outlet All other openings must be sealed Test pressure should be the greater of 30 psi 2 bar or the actual valve back pressure Air ornitrogen pressureshould be held for 3 minutes before applying leak detector solution to all connections joints Set Pressure Test Press...

Page 40: ...ired it can be obtained as follows a To increase the blowdown lower reseatingpressure theadjustingring mustberaisedbymovingthenotches from left to right past the ring pin hole Page 38 b To decrease the blowdown raise reseatingpressure theadjustingring must be lowered by moving the notches from right to left past the ring pin hole NOTES Unless the test stand capacity is equal to or greater than tha...

Page 41: ...ximum lift to snap the valve back on its seat Since in some cases the dead weight of the lever will have a tendency to lift the valve the lever should be hung supported or counter weighted so the lifting fork does not contact the release nut The air operated lifting device is designed to fully open the valve with 75 of set pressure under the valve disc in compliance with ASME Section VIII For cert...

Page 42: ...ISI 316L Stainless Steel 2 Set of gaskets for bellows valve 3 Guide for bellows valve 4 Disc holder for bellows valve 5 Drill 23 32 dia on bonnet boss and tap 1 2 N P T as required 6 Studs 1905 30 N P 1906 30 N P only 1 Bellows Assembly 2 Set of gaskets for bellows valve 3 Guide for bellows valve 4 Lift restricting ring 5 Studs 1 Eductor tube for conventional valve 2 Set of gaskets for conventiona...

Page 43: ...d by the bellows flange Next machine the existing lower spring washer in accordance with Figure 43 and Table 20 below C Conversion from Bellows to Conventional Type In converting from a bellows to a conventional valve the eductor tube may be secured in the base by expanding or swaging into the hole provided The upper end of the tube should project above the guide surface of the base approximately ...

Page 44: ...3005 1 078 1 083 4451505 0544601 1672805 J 1 335 1 340 0543006 1 380 1 385 4451506 0544601 1672805 K 1 595 1 600 0543007 1 650 1 655 4451507 0544601 1672807 M 2 234 2 239 0543102 2 309 2 314 4451602 0544601 1672809 N 2 445 2 450 0543103 2 535 2 540 4451603 0544601 1672809 P 2 965 2 970 0543104 3 073 3 078 4451604 0544602 1672810 Q 3 900 3 905 0543105 4 045 4 050 4451605 0544602 1672812 R 4 623 4 6...

Page 45: ...ft Pins Two pins are required for the removal of the disc from the disc holder See Figure 45 below Lifting Tools For removal of upper internal parts of larger valves as specified below M N 4464602 P Q R T 4464604 Orifice 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 Valve Pin Spanner Orifice Description of Wrench Wre...

Page 46: ...e types covered by this manual are classified on page 46 Qty Parts is the number of parts or sets which isrecommendedtoachieveadesiredneed probability as it relates to the total number of valves in service by size and type For example a Qty Parts of 1 for Valves in Service of 5 means that 1 part should be stocked for each 5 valves of the same type and size in service 4 When ordering replacement pa...

Page 47: ...late see Figure 49 below stamped with the DVCD insignia the National Board VR symbol and stamp number and the date of repair is permanently attached to the valve near the original nameplate This repair nameplate may also contain information regarding altered set pressures capacities or blowdown as applicable FIGURE 49 XIX Geniune Dresser Parts The next time replacement parts are needed keep these ...

Page 48: ...class of parts will provide sufficient replacement parts on hand for 70 of all possible maintenance requirements II Class II parts should be stocked at the rate described in the column Qty Parts Stocking Class II parts in addtion to Class I parts will provide sufficient replacement parts on hand for 85 of all possible maintenance requirements 1900 CONVENTIONAL 1900 30 BELLOWS 1900 CONVENTIONAL 190...

Page 49: ...uide C B 1 6 85 Studs Base C B 1 Set 6 Nuts Base Stud C B 1 Set 6 CLASS I Class I Parts should be stocked at the rate described in the column Qty Parts Stocking this class of parts will provide sufficient replacement parts on hand for 70 of all possible maintenance requirements II Class II parts should be stocked at the rate described in the column Qty Parts Stocking Class II parts in addtion to C...

Page 50: ...valve performance and are capable of modernizing valves in the field It is highly recommended that the professional talents of a DVCD Field Service Engineer be employedtomakefinalfieldadjustmentsduring theinitialsettingofallCONSOLIDATED valves All Field Service Engineers activities are coordinated from the Alexandria Louisiana FieldServiceOffice Uponreceiptofapurchase order number authorizing the ...

Page 51: ...ing testing installation and conversions The Program can also be used as an instructor led course The training package includes five Participant Training Manuals five Consolidated 1900 and 1900 30 Safety Relief Valve Installation Operation and Maintenance Manuals an integral 1900 SRV video tape a Coaches Guide to facilitate learning Program Kits as well as additional Training and Maintenance manua...

Page 52: ...ional Glide Aloy Parts and the Repair Processing of Such Components Glide Alloy is a proprietary process of DVCD which is utilized to provide a combination of low coefficient of friction between sliding components and to protect the surfaces of the components to which the process has been applied A Glide Aloy surface hardened valve component may be readily recognized by its flat dull gray color an...

Page 53: ...e 1 508 941 5407 Fax 1 508 427 8959 Northern Region 3201 North Wolf Road Franklin Park Illinois 60131 Telephone 1 847 451 3913 Fax 1 847 451 3997 Southern Region 15112 Morales Road 77032 P O Box 60078 Houston Texas 77205 0078 Telephone 1 713 986 6600 Fax 1 713 986 6608 Western Region 1040 South Vail Avenue Montebello California 90640 Telephone 1 213 722 6731 Fax 1 213 721 9113 Latin American Regio...

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