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Consolidated 2700 Series Safety Valve Instruction Manual

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All face surfaces that require gaskets, to seal pressure,

should be inspected for cleanliness, or any defects that

can cause leakage. Burrs, mashed serrations, uneven

surfaces, etc., are all possible leakage-producing

defects. Proper gasket sizes and pressure ratings

should be checked prior to starting valve installation.

It is of utmost importance that the gaskets used be

dimensionally correct for the specific flange, and that

they fully clear the valve inlet and outlet openings.

Gaskets, flange facings, and bolting should meet the

service requirements for the pressure and temperature

involved. Other valve installation considerations

include:

1. Install the inlet gasket, if required, on the header

mounting flange. Check for cleanliness, surface

alignment condition, gasket condition, etc. When

possible, inlet studs on the mounting flange

should be used to guide the valve on the header

mounting flange. Inlet studs should be lubricated

with the appropriate lubricant.

2. When installing flanged valves, the flange bolts

must be pulled down evenly to prevent body

distortion, misalignment, and leakage.

3. With valve in position, screw on the stud nuts

until all nuts are finger tight. An initial torque shall

be placed, in turn, on each stud nut. Increase

the torque progressively until the final torque is

applied. Upon completion, recheck each stud

nut’s torque. Required torque will vary with bolting

material and gaskets used. See your company

engineering or specification department for details

on torquing sequence and torque values. As an

extra precaution, the gap between the two mating

flanges should be checked during the torquing

process to ensure that the flanges are being

pulled together evenly. A final inspection and

review should be made to ensure that all of the

requirements for bolting the valve inlet have been

implemented.

4. The outlet piping may now be installed. A

complete inspection of components and their

cleanliness is to be made prior to further work.

Studs are to be lubricated with an appropriate

lubricant.

5. Install the outlet gasket, studs and nuts. Stud

nuts are to be pulled down finger tight. An initial

value of torque is to be applied. The additional

procedures outlined, in Step 3 should also be

followed.

After being assured that the valve is properly installed,

the drainage piping from the valve body-bowl is to be

connected. This line also must be flexible, so it will not

create stress on the valve under operating conditions.

Prior to completing the installation, a visual check

should be made to ensure that the valve lifting lever

has room and is free to operate.

At the time of installation, an inspection of the valve

should be made to confirm that all adjustment

components (i.e., ring pins, cap, etc.) are properly

locked and sealed, as required by the ASME Code.

For operational hydrostatic tests at the valve inlet, that

do not exceed valve set pressure, the valve should be

gagged. Refer to the final “Field Testing” portion of this

manual for proper techniques. Ensure that the gag is

removed upon completion of the inlet hydrostatic test.

Prior to startup of the unit on steam, the sections of

this manual that specify requirements for set pressure

testing should be reviewed. For conditions where the

valve is subjected to high steam pressures (i.e., those

exceeding normal operating conditions), preparations

should be made to gag the valves. These preparations

should then be cleared with the boiler manufacturer

and Baker Hughes. Refer to Section XIV. B.3 of this

manual for the proper gagging techniques.

The safety valve should be tested with full steam

pressure to ensure that the safety valve installation

has been properly accomplished. In some cases

this is not practical, thus the use of Consolidated

Hydroset

™

Test Device or

EVT

™

software, should be

considered. For valves being tested for set pressure

by using a Consolidated Hydroset Test Device or

EVT software, only the set pressure is being verified.

Other factors such as blowdown, lift, reaction force,

proper discharge stack sizes and effects of thermal

expansion cannot be determined, using these setting

devices. Full flow steam testing is recommended at

initial start-up to adjust blowdown and verify proper

XI. Recommended Installation Practices (Cont.)

Содержание Consolidated 2700 Series

Страница 1: ...Consolidated 2700 Series Safety Valve Instruction Manual Rev F Baker Hughes Data Classification Public ...

Страница 3: ...E 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 PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUST...

Страница 4: ... values using the following conversion factors USCS Unit Conversion Factor Metric Unit in 25 4 mm lb 0 4535924 kg in2 6 4516 cm2 ft3 min 0 02831685 m3 min gal min 3 785412 L min lb hr 0 4535924 kg hr psig 0 06894757 barg ft lb 1 3558181 Nm F 5 9 F 32 C Conversion Table Note Multiply USCS value with conversion factor to get metric value ...

Страница 5: ...alve Installation 16 XII Disassembly Instructions 17 A General Information 17 B Specific Steps 17 XIII Inspection and Part Replacement 19 A General 19 B Specific Components 19 XIV Re Assembly Instructions 24 A General Information 24 B Specific Steps 24 XV Setting and Testing 27 A General Information 27 B Application of Test Gags 27 C Presetting Adjusting Rings 28 D Steam Testing Instruction 29 E C...

Страница 6: ...vi Baker Hughes 2022 Baker Hughes Company All rights reserved XX Manufacturer s Service Repair and Training Program 40 A Field Service 40 B Repair Facilities 40 C Safety Valve Maintenance Training 40 ...

Страница 7: ... Selection or Misapplication of Products Baker Hughes cannot be responsible for customer s incorrect selection or misapplication of our products Unauthorized Repair Work Baker Hughes has not authorized any non Baker Hughes affiliated repair companies contractors or individuals to perform warranty repair service on new products or field repaired products of its manufacture Therefore customers contr...

Страница 8: ...iates from Baker Hughes recommendations must be thoroughly satisfied that neither personal safety nor valve safety will be jeopardized by the procedure and or tools selected If not so satisfied contact your local Green Tag Center if there are any questions relative to procedures and or tools The installation and start up of valves and valve products may involve proximity to fluids at extremely hig...

Страница 9: ...ction with the hazard In some instances of risk to human health and safety the pictorial may instead depict what preventive measures to take such as wearing wearing the appropriate personal protective equipment PPE The bottom panel may contain instructions on how to avoid the hazard If there is a risk to human health and safety this message may also contain a more precise definition of the hazard ...

Страница 10: ...ents or fluids can cause severe personal injury or death 2 WARNING Always read and comply with safety labels on all containers Do not remove or deface the container Do not remove or deface the container labels Improper handling or misuse could result in severe personal injury or death 3 WARNING Never use pressurized fluids gas air to clean clothing or body parts Never use body parts to check for l...

Страница 11: ...uld result in personal injury or product damage Wear necessary protective equipment to prevent possible injury Always use appropriate restoration procedures 7 WARNING The misuse of a tool or the use of an improper tool could result in personal injury and or product property damage 1 CAUTION Heed all service manual warnings Read installation instructions before installing valve s 2 CAUTION Wear the...

Страница 12: ...wn Uncrated valves should be moved or hoisted by wrapping a chain or sling around the discharge neck then around the upper yoke structure in such manner as will ensure the valve is in a vertical position during lift Never lift the full weight of the valve by the pilot assembly tubing lifting lever or other external device When a valve is uncrated and the flange protectors removed prior to installa...

Страница 13: ...ntenance Occasionally remachining may be necessary to extend the service life of a valve Keep all parts for each valve separated to ensure replacement in the same valve DANGER Insure there is no pressure in the inlet of the valve before attempting to remove it from the piping system Note For maintenance questions not covered in this manual please contact your local Green Tag Center Decontaminate o...

Страница 14: ...e is relieving G Maximum Allowable Working Pressure The maximum gauge pressure permissible in a vessel at a designated temperature 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 relief valve is set to open H Operating Press...

Страница 15: ... Spring Washer 11 Bottom Spring Washer 12 Seat Bushing 13 Disc 14 Disc Collar 15 Lift Stop 16 Spindle 17 Compression Screw 18 Compression Screw Adaptor 4 to 7_Q orifices only 19 Thrust Bearing 20 Lever and Cap Assembly 21 Studs Studded Inlet 22 Nuts 23 Compression Screw Locknut 24 Cotter Pins not shown 2747 THRU 2777Q 2737 THRU 2777Q VENT 90 OUT OF POSITION DO NOT PLUG 9 1 11 4 15 2 14 5 6 8 7 13 ...

Страница 16: ... Bottom Spring Washer 12 Seat Bushing 13 Disc 14 Disc Collar 15 Lift Stop 16 Spindle 17 Compression Screw 18 Compression Screw Adaptor 4 to 7_Q orifices only 19 Thrust Bearing 20 Lifting Gear 21 Studs Studded Inlet 22 Nuts 23 Compression Screw Locknut 24 Cotter Pins not shown 2745W THRU 2775QW 2735W THRU 2775QW VENT 90 OUT OF POSITION DO NOT PLUG 9 1 11 4 15 2 14 5 6 8 7 13 12 19 10 20 17 16 21 22...

Страница 17: ...t of the upper adjusting ring allows the disc to go into full lift at overpressure When full lift is attained lift stop H rests against the yoke to prevent hunting thus adding stability When the inlet pressure drops to the desired closing pressure the disc C moves downward causing the valve to close The arrangement of the disc and its complement of parts that is disc holder E spindle G disc collar...

Страница 18: ...ons will assist in eliminating the factors that produce chatter 1 The downstream corner of the header nozzle must be rounded to a radius of not less than 250 6 35 mm of the opening diameter See Figure 5 2 Pressure drop due to friction flow to the inlet of the valve should not be greater than 50 percent of the expected blowdown of the safety valve To decrease the effects of a phenomenon known as so...

Страница 19: ...ne Excessive line vibrations are known to produce shifts in safety valve set pressures Vibrations may possibly introduce chatter causing damage to the valve and reducing its capacity Vibration also contributes to increased incidents of seat leakage Considerations should be given to eliminating this problem prior to installing the valve on the unit Steam flowing vertically out of a discharge elbow ...

Страница 20: ...f the valve seat and this drain should be piped to a safe discharge area If a silencer is used on a safety valve it should have sufficient outlet area to prevent back pressure from interfering with the proper operation and discharge capacity of the valve The silencer or other piping components should be constructed so as to avoid the possibility of creating corrosion deposit restrictions in the st...

Страница 21: ...ork Studs are to be lubricated with an appropriate lubricant 5 Install the outlet gasket studs and nuts Stud nuts are to be pulled down finger tight An initial value of torque is to be applied The additional procedures outlined in Step 3 should also be followed After being assured that the valve is properly installed the drainage piping from the valve body bowl is to be connected This line also mu...

Страница 22: ...ons The inlet neck of the safety valve and safety valve body up to the top of the base should be insulated The exterior surface of any such insulation should be made weather proof by any suitable means In addition to maintaining a more even temperature within the valve body especially during widely fluctuating ambient temperatures this insulation will effectively reduce thermal stresses due to hig...

Страница 23: ...d top lever 2 Loosen the cap set screw and remove the lever and cap assembly 3 Remove the cotter pin that retains the release nut and then remove the release nut 4 Refer to Figure 6 and measure and record Dimension A as this information will be required to correctly re assemble the valve 5 Loosen the compression screw locknut and the compression screw to remove tension from the spring 6 Loosen and...

Страница 24: ... with a depth micrometer or other suitable measuring device Record Dimension B 12 Place a scale or other thin flat metal surface against the lower face of the upper adjusting ring and measure from the top of the guide to the face of the upper adjusting ring Dimension C Figure 8 Record Dimension C 13 Remove the upper adjusting ring pin from the valve base 14 Remove the guide and upper adjusting rin...

Страница 25: ...sher a 320 grit Clover 1A lapping compound is used for roughing in and then finish the lap with 1000 grit Kwik Ak Shun lapping compound until a satisfactory bearing band is obtained The bearing width should be 1 800 3 20 mm minimum to 3 160 4 80 mm maximum Clean the lower spring washer and spindle when complete 5 Spring Visually inspect for pitting and corrosion of coils that will reduce the coil ...

Страница 26: ...either of these devices is used to verify valve set pressure d Apply a small amount of lapping compound 1A on the tip of the spindle Install the disc without the disc holder onto the spindle tip turning it clockwise until the disc threads drop out Place a ring lap on a table or similar flat surface and wipe the exposed surface of the lap clean Insert the disc nose into a ring lap so that the seat ...

Страница 27: ...nce with Table 4 8 Disc Holder The surface on the end of the disc holder closest to the disc must be free from steam erosion The two small holes must be open to ensure the passage of steam to the chamber above the disc Make sure the outside diameter is not egg shaped and the surface is smooth If any small indication of galling is present polish the high spots with an emery cloth If serious or larg...

Страница 28: ...ing the lapping plate 10 Seat Bushing a A Consolidated reseating machine should be used to recondition badly worn and out of tolerance bushing seats This machine can be provided by Consolidated s Service Department and eliminates the need to remove a valve from the unit The machine is mounted in place of the yoke and cuts the top face inside diameter and outside of the bushing to establish the cor...

Страница 29: ...of defects such as gray areas or scratches will require a repeat of the whole lapping procedure until a mirror finish is attained v While the finer points of lapping and grinding in may be considered as a mechanical art it is not beyond the ability of the average mechanic to produce good seats with some practice No effort has been made in this manual to establish an exact procedure to cover each a...

Страница 30: ...osition determined during field testing 4 Once the lower adjusting ring is in its correct location lock it in place by installing in the lower adjusting ring pin Verify that the lower ring is capable of a slight movement If the lower ring does not move the pin is too long Should this be the case grind the end of the pin slightly to shorten it while retaining the original tip contour then reinstall...

Страница 31: ...t satisfactory correct the cause before proceeding 16 When disc rock is satisfactory remove the disc and disc holder and secure the disc collar with a stainless steel cotter pin Using side cutters carefully cut off excess cotter pin legs and bend the cotter pin for a neat installation 17 Lubricate the spindle tip and assemble the disc holder and disc to spindle Recheck the rock 18 Remove complete ...

Страница 32: ...he valve is now ready for testing after which the following steps can be taken a After testing the compression screw should be locked firmly in place with the lock nut b Install the release nut onto the spindle Then thread clockwise until the release nut is fully engaged on the spindle thread and the cotter pin hole is aligned For numbers 1 2 3 and 4 orifices run the release nut down enough to all...

Страница 33: ...p by upstream bends Valve inlet nozzle configuration or other internal piping configuration problems 6 High water level in the drum When the valves are subjected to working hydrostatic tests not exceeding the set pressure of the low set valve valves may be gagged rather than using hydrostatic test plugs For higher pressures hydrostatic plugs should be used A common source of safety valve trouble i...

Страница 34: ...ng pressure install gags on all boiler valves not being tested Gags should be installed hand tight no wrenches or mechanical force 4 On the valve to be tested use the following procedure and Table 9 to bring the adjusting ring to seat level a Gag the valve to prevent the disc from accidentally lifting from the seat during adjustment b Remove both service port plugs c Remove the upper ring pin d Mo...

Страница 35: ...e ASME Boiler and Pressure Code Section I or Section XIII UV Valve Operation Standards for more details To determine which standard to use look at the nameplate on the valve The symbol that is present on the nameplate will indicate the proper standard of operation See Table 11 4 If the valve operation is in compliance with the standard proceed to step 7 5 If the valve is not in compliance reduce b...

Страница 36: ...172 37 15N up Level w Holder 20N down 36N down 2501 172 44 2800 193 05 15N up Level w Holder 20N down 36N down 2801 193 12 3000 206 84 15N up Level w Holder 20N down 36N down 5 3 341 21 555 101 6 96 300 20 68 1N down per 600 psig 413 68 barg Max 5N down 8N down 25N down 8N down 25N down 301 20 75 500 34 47 50N up 34N up Seat Level 16N down 501 34 54 900 62 05 40N up 24N up 10N down 26N down 901 62...

Страница 37: ...e set pressure is 301 psig 20 75 barg up to and including 1000 psig 68 75 barg 10 psig 0 69 barg If valve set pressure is 1001 psig 69 02 barg or greater 1 percent of set pressure CODE SYMBOL STAMP ASME Section XIII UV If valve set pressure is less than or equal to 70 psig 4 83 barg 2 psig 0 14 barg After opening the valve must reclose before the system pressure returns to normal operating pressur...

Страница 38: ...ce or the EVT software repeatedly produces exactly the same lifting force Second gauge calibration and vibration in the effective seating area between valves of the same size and type will also affect accuracy With well calibrated gauges and valve seats in good condition accuracy on the order of 1 percent of set pressure may be expected Upon request Baker Hughes will provide pertinent written mate...

Страница 39: ...ncreased to a point where the valve will not leak at one and one half times design boiler pressure It is not necessary to gag the safety valves when hydrostatic plugs are used DRAIN SERVICE PLUG HYDRO PLUG CAUTION DO NOT STEAM TEST UNTIL THE PLUG HAS BEEN REMOVED This safety valve is equipped with an internal plug for hydrostatic test D O N O T R E M O V E THIS TAG UNTIL PLU G I S R E M O V E D Fi...

Страница 40: ... fall from the spindle and become damaged 6 Lap the disc and seat bushing and thoroughly clean the seats with a clean cloth 7 Lubricate the spindle tip with Anti Seize and assemble the disc and disc holder to thr spindle by turning the disc until the dropout threads disengage 8 Reassemble the yoke and spring assembly See Figure 19 into the base being careful not to damage the disc Locate the yoke ...

Страница 42: ...lower spring washer or spindle compression screw spindle straightness etc C Disc has insufficient rock C Disassemble the valve and check the disc rock per Section XIX E of this manual D Discharge stack binding on outlet D Correct as required Hangup or the valve does not close completely A Lower ring too high A Move the lower ring to the left one notch per adjustment and test Repeat until problem i...

Страница 43: ...ium for lapping and polishing the seats and bearing surfaces in Consolidated Series 2700 Safety Valves Gags Lubricant Wrench Sizes XVII Maintenance Tools and Supplies Ring Laps1 Valve Orifice 2 Lap Part No 1 1672806 2 1672807 3 1672808 5 1672810 4 1672809 6 1672811 Q 1672812 Brand Grand Grit Lapping Function Size Container Part No Clover 1A 320 General 4 oz 199 3 Clover C 220 Coarse 4 oz 199 2 Kwi...

Страница 44: ...roper operation of the valve Included are Valve Type ASME and National Board of Boiler and Pressure Vessel Inspectors Approval Stamp Serial Number Set Pressure or Opening Pressure Disc Lift Operating Temperature Capacity The Consolidated 2700 Series Safety Valve nameplate is located on the base of the valve to the left of the Adjusting Ring Pins If the nameplate is missing a duplicate nameplate ca...

Страница 45: ...tWeld Inlet Series Series Orifice Designation Orifice Designation Pressure Class Pressure Class The next time replacement parts are needed keep these points in mind Baker Hughes designed the parts Baker Hughes guarantees the parts Consolidated valve products have been in use since 1879 Baker Hughes has worldwide service Baker Hughes has fast response availability for parts XIX Consolidated Genuine...

Страница 46: ...epairs and product modiﬁcations e g bushing replacements hydroset calibrations electromatic relief valve repairs code welding pilot replacement etc For further information please contact your local Green Tag Center C Maintenance Training Rising costs of maintenance and repair in the utility and process industries indicate the need for trained maintenance personnel Baker Hughes conducts service sem...

Страница 48: ...The Baker Hughes logo Consolidated EVT Thermodisc Thermoflex Hydroset and Green Tag are trademarks of Baker Hughes Company Other company names and product names used in this document are the registered trademarks or trademarks of their respective owners BHCN 2700 IOM 19384F 0222 0 2022 Direct Sales Office Locations valves bakerhughes com Find the nearest local Channel Partner in your area valves b...

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