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XVI. Disassembly of 4900 Series Pilot Valve

A. 49PV07 and 49PV37

(Figures 17 and 18)

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 use Figure 18 to

remove the Lifting Lever assembly. Then return

to Figure 17 to continue disassembly.
a. The Lifting Lever Assembly consists of:

1 – Lever
1 – Drive Pin
1 – Cam Shaft
1 – Bushing

b. Remove Lifting Lever Assembly by turning

Bushing counterclockwise.

c. Turn Cap (Compression Screw)

counterclockwise.

d. Measure distance from Release Lock Nut

to the top of the Lifting Stem for reassembly

later.

e. Remove the Release Lock Nut and Release

Nut by turning counterclockwise.

4. Measure and record Compression Screw height

for later use when resetting.

5. Turn Compression Screw Lock Nut

counterclockwise to loosen.

6. Turn Compression Screw counterclockwise to

remove the load on the Spring.

7. Turn Set Screw counterclockwise to loosen.
8. Bonnet can now be removed by turning

counterclockwise.

9. Spring and Spring Washers can now be

removed.

Note: If Lifting Lever option is equipped, there

is no need to remove Drive Pin from

Bottom Spring Washer assembly.

10. Remove the four Cap Screws (Top Plate)

holding the Top Plate to the Pilot Base. Remove

and discard the Spring Seal (Main Piston) and

O-Ring (Top Plate).

11. Remove Main Piston from Pilot Base.
12. Removing the Insert Assembly:

The Insert Assembly consists of:
1 – Insert Top

1 – Insert Bottom
1 – Spring Seal (Insert)
1 – O-Ring (Insert)
Remove Insert Assembly from the top of the

Pilot Base with tool #4995401 as shown in

Figure 44.
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 Nut by

turningcounterclockwise.

15. Removing the Adjuster Assembly.

The Adjuster Assembly consists of:
1 – Adjuster Top
1 – Adjuster Bottom
1 – O-Ring (Adjuster Top)
1 – O-Ring (Adjuster Bottom)
1 – Spring Seal (Adjuster Top)

16. Turn Adjuster Assembly clockwise counting the

number of flats until assembly stops. Record

number of flats for reassembly.

17. Remove Adjuster Assembly from the Pilot Base

by turning counterclockwise. Remove O-Ring

(Adjuster Top) and O-Ring (Adjuster Bottom)

from adjuster assembly and discard.
a. Disassemble Adjuster Top from the Adjuster

Bottom by turning Adjuster Top

counterclockwise. Remove Spring Seal

(Adjuster Top) from Adjuster Top and discard.

b. Remove Cap Screws counter clockwise to

allow the removal of the Port Adaptor.

c. Remove Ball, O-Ring (Ball Seat), Spring, and

O-Ring (Vent Port Assembly) and discard.

18. 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) Large

2 – O-Ring (Ball Seat)

1 – Pipe Plug (Backflow Preventer)

Consolidated 4900 MPV Series POSRV Manual

| 37

Содержание Consolidated 4900 Series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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