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© 2019 Baker Hughes, a GE company. All Rights Reserved.

b.   For disc sizes “K” through “T”, reassemble the Disc 

using a new O-Ring, O-Ring Retainer, and new Lock 
Screws. Refer to Table 10 for the proper torque.

(i)   Prior to assembly of the Disc into the Disc Holder, 

remove the Disc Retainer from the back 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.

(ii)  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 that the Disc is free to 
“wobble” after it is in place.

3.  Set the Disc Holder (disc side down), on the work surface. 

Place a small amount of 1000 grit grinding compound 
onto the ball end of the Main Valve Piston and place it 
in the disc holder pocket. Turn the Main Valve Piston 
clockwise, and then counter clockwise, to seat the Main 
Valve Piston. Clean all grinding compound from parts.

4.  Place the Spring down onto the Disc Holder.

5.  Place the Guide over the Disc Holder. (DO NOT DROP.)  If 

Bellows is present, the weight of the Guide will slightly 
compress the Bellows.

6.  Place the Guide Gasket in the Base.

7.  Install disc guide assembly. Use the same lifting tool (see 

XVI.  Reassembly of the 2900-40 Main Valve (Cont.)

Main Valve Piston

Main Valve 

Piston O-Ring

Guide Ring

Figure 28:  Main Valve Piston

Summary of Contents for Baker Hughes 2900-40 Series

Page 1: ...Consolidated 2900 40 Series Pilot Operated Safety Relief Valve Maintenance Manual Rev C BHGE Data Classification Public ...

Page 2: ...LE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION OPERATION OR MAINTENANCE SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMSARISEWHICHARENOTCOVEREDSUFFICIENTLYFORTHECUSTO...

Page 3: ...tance Conversion Table Note 1 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 355818...

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 Disassembly...

Page 5: ...mbly Procedure with O Ring Seats 39 XVII Disassembly of 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 Test...

Page 6: ...Sensing Ring 61 XXIII Maintenance Tools and Supplies 62 66 A Adjuster Top Seal Insertion Tool 62 B Insert Installation Tool 63 C Lapping Tools 64 65 D Disc Holder and Guide Removal and Assembly Tool 65 66 XXIV Replacement Parts Planning 67 A Basic Guidelines 67 B Identification and Ordering Essentials 67 C Positive Identification of Main Valve and Pilot Valve Combinations 68 XXV Genuine Consolidat...

Page 7: ...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 some in...

Page 8: ...ischarge 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...

Page 9: ...uclear healthphysics procedures ifapplicable to avoidpossibleseverepersonal injuryordeath Note Any Service questions not covered in this manual should be referred to your local Green Tag Center 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 acc...

Page 10: ...r local Green Tag Center 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 dr...

Page 11: ...ect Selection or Misapplication of Products BHGE cannot be responsible for customer s incorrect selection or misapplication of our products Unauthorized Repair Work BHGE has not authorized any non BHGE affiliated repair com panies contractors or individuals to perform warranty repair service on new products or field repaired products of its manufacture Therefore customers contracting or performing...

Page 12: ...ture 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 an...

Page 13: ... 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 inserted into the cover plate ATTENTION Handle carefully Do not drop o...

Page 14: ...ed 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 adequa...

Page 15: ...ement 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 v...

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: ... IX 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: ...lied 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 ...

Page 19: ...stem 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: ... 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 allowe...

Page 21: ...ion 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 v...

Page 22: ...charge 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 failure These vibrations may cause the disc seat to slide back and forth acros...

Page 23: ...e for distances up to 10 feet 3 048 mtr If distance is longer than 10 feet 3 048 mtr please contact BHGE 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 or the factory E Freeze Protection Type of Applications 1 Applicat...

Page 24: ...ted safety 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 ...

Page 25: ...e 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...

Page 26: ...26 BHGE 2019 Baker Hughes a GE 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: ...he 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 as indicated See Figure 61 and Table 18 in the Maintenance Tools Lifting Tool Guide Disc Holder Top of Base D...

Page 28: ...TION 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 the operation 18 Use a large pipe...

Page 29: ...ng 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...

Page 30: ... 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 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 ...

Page 31: ...0 11 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 ...

Page 32: ... S1 34 35 37 Bausch and Lomb Optical Co measuring 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 Lappin...

Page 33: ... 64 028 0 71 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...

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 o...

Page 35: ... 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 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...

Page 36: ...ning 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 Mai...

Page 37: ...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 machined until the T dimens...

Page 38: ... 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 36 F 006 0 15 N 014 0 36 G ...

Page 39: ... 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 disc holder ...

Page 40: ...ssive force to assemble these parts Be sure that the Disc is free to wobble after it is in place 3 Set the Disc Holder disc side down on the work surface Place a small amount of 1000 grit grinding compound onto the ball end of the Main Valve Piston and place it in the disc holder pocket Turn the Main Valve Piston clockwise and then counter clockwise to seat the Main Valve Piston Clean all grinding...

Page 41: ...0 81 135 183 145 197 L 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...

Page 42: ...on in until bottom of Main Valve Piston is even with the bottom of the Cover Plate 14 Install 1 4 MNPT pipe plug into Cover Plate where dome line connects 15 Install Cover Plate Gasket Install Cover Plate on top of Base such that the pilot will be aligned for proper tubing connections Make note of the length of the studs The two longer ones will straddle the vertical line of the inlet sensing port...

Page 43: ...t 1 O Ring Insert Remove Insert Assembly from the top of the Pilot Base with tool 4995401 as shown in Figure 58 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 ...

Page 44: ...019 Baker Hughes a GE 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: ...t 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 fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations and equipment 5 Do not sand blast internal parts as it can reduce the dimensions of the parts Follow recommendations f...

Page 46: ... 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 fo...

Page 47: ...pring 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 vi Insert...

Page 48: ... 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 us...

Page 49: ...n 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...

Page 50: ...sure 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 Attach...

Page 51: ...rg 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 retighten corresponding lock nut Starting position of adjuster shall be 8 turns Retest beginning at step 9...

Page 52: ...m 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 equivalent at points of possible leakage Pressure is to be held constant at the test pressure while the valve is bein...

Page 53: ...alve dome area thereby allowing only the pilot to actuate The system shown in Figure 41 is available for remote or local testing F Hydrostatic Testing and Gagging When hydrostatic tests are required after installation of a POSRV remove the POSRV and replace it with a blind flange If the hydrostatic test pressure will not be greater than the set pressure of POSRV a test gag may be used see Figure 4...

Page 54: ...bles 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 to...

Page 55: ... 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 56: ... 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 purchased per Code Case 2203 The purchaser i...

Page 57: ...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 applications that call for exposure to a signi...

Page 58: ...lows 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 as line filter canister filter 5 way Figure 48 Gag Figure 50 Heat Exchanger Co...

Page 59: ...alve can open I Manual Electrical or Pneumatic Blowdown Valve Figures 51 52 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 ported directly...

Page 60: ...ed 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 is...

Page 61: ...enable 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...

Page 62: ... 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 57 Adjuster Top Seal Insertion Tool XXIII Maintenance Tools and Supplies ...

Page 63: ...tion 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 58 Insert Installation Tool ...

Page 64: ...lves 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 88 430403...

Page 65: ...bly 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...

Page 66: ...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 8...

Page 67: ...icable 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...

Page 68: ...alve 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...

Page 69: ...r 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 N...

Page 70: ...006 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 M0RK29009T...

Page 71: ...9017E002 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...

Page 72: ...2 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 2...

Page 73: ...Note 1 Field 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...

Page 74: ...gh 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 Note 1...

Page 75: ...fety valves B Factory 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 in t...

Page 76: ...76 BHGE 2019 Baker Hughes a GE company All Rights Reserved Notes ...

Page 77: ...Consolidated 2900 40 Series POSRV Maintenance Manual 77 2019 Baker Hughes a GE company All Rights Reserved Notes ...

Page 78: ...78 BHGE 2019 Baker Hughes a GE company All Rights Reserved Notes ...

Page 79: ...Consolidated 2900 40 Series POSRV Maintenance Manual 79 2019 Baker Hughes a GE company All Rights Reserved Notes ...

Page 80: ...rth Phone 61 8 6595 7018 Fax 61 8 6595 7299 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 9...

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