Document G5N0bwLej85L6KepvY6M6EYkn
ABD00200781
CONSOLIDATED
Installation & Maintenance Manual
Safety Relief Valve Type 1900, 1970, 1975,
1980, 1982
INDUSTRIAL VALVE DIVISION
ALEXANDRIA, LOUISIANA REVISED DECEMBER, 1980
ABD00200782
SAFETY NOTICE
PROPER SERVICE AND REPAIR IS IMPORTANTTO THE SAFE, RELIABLE OPERATION OF ALL VALVE PRODUCTS. THE SERVICE PROCEDURES RECOMMENDED BY DRESSER INDUSTRIAL VALVE OPERATIONS (DIVO) AND DESCRIBED IN THIS MAINTENANCE AND SERVICE MANUAL ARE EFFECTIVE METHODS OF PERFORMING THE REQUIRED MAINTENANCE OPERATIONS. SOME OF THESE SERVICE OPERATIONS REQUIRE THE USE OF TOOLS SPECIFICALLY DESIGNED FOR THE PURPOSE. THESE SPECIAL TOOLS SHOULD BE USED WHEN AND AS RECOMMENDED.
IT IS IMPORTANT TO NOTE THAT THIS SERVICE MANUAL CONTAINS VARIOUS WARNINGS AND CAUTIONS WHICH SHOULD BE CAREFULLY READ IN ORDER TO MINIMIZE THE RISK OF PERSONAL INJURY OR THE POSSIBILITY THAT IMPROPER SERVICE METHODS WILL BE FOLLOWED WHICH MAY DAMAGE THE VALVE OR RENDER IT UNSAFE. IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE WARNINGS AND CAUTIONS ARE NOT EXHAUSTIVE. DIVO COULD NOT POSSIBLY KNOW, EVALUATE, AND ADVISE THE CUSTOMER OR UTILITY OF ALL CONCEIVABLE WAYS IN WHICH SERVICE MIGHT BE DONE, OR OF THE POSSIBLE HAZARDOUS CONSQUENCES OF EACH WAY. CONSEQUENTLY, DIVO HAS NOT UNDERTAKEN ANY SUCH BROAD EVALUATION. ACCORDINGLY, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY DIVO MUST SATISFY HIMSELF THOROUGHLY THAT NEITHER HIS OR OTHER PERSONNEL'S SAFETY NOR VALVE SAFETY AND PROPER OPERATION WILL BE JEOPARDIZED BY THE SERVICE METHOD HE SELECTS. CONTACT DIVO IF THERE IS ANY QUESTION ON THE METHOD.
THE TESTING, INSTALLATION, AND REMOVAL OF VALVE AND VALVE PRODUCTS MAY INVOLVE THE USE OF FLUIDS AT EXTREMELY HIGH PRESSURE AND TEMPERA TURE AND/OR ARE CORROSIVE OR EROSIVE. CONSEQUENTLY, EVERY PRECAUTION SHOULD BETAKEN TO PREVENT INJURYTO PERSONNEL DURINGTHE PERFORMANCE OF ANY TEST, INSTALLATION OR REMOVAL SUCH AS, BUT NOT LIMITED TO, EAR DRUM PROTECTION, EYE PROTECTION, AND PROTECTIVE CLOTHING SUCH AS GLOVES, ETC., IN AND AROUND THE TESTING, INSTALLATION, OR REMOVAL AREA. DUE TO THE VARIOUS CIRCUMSTANCES AND CONDITIONS IN WHICH THESE OPERATIONS MAY BE PERFORMED ON OUR PRODUCTS, OR THE POSSIBLE HAZARDOUS CONSEQUENCES OF EACH WAY, DIVO COULD NOT POSSIBLY EVALUATE ALL CONDITIONS THAT COULD INJURE PERSONNEL OR EQUIPMENT, BUT DOES OFFER THESE SAFETY PRECAUTIONS AS AN ASSISTANCE ONLY.
2
ABD00200783
SAFETY PRECAUTIONS
1. DO NOT STAND IN FRONT OFJHE DISCHARGE SIDE OF A PRESSURE RELIEF VALVE WHEN TESTING OR OPERATING.
2. HEARING PROTECTION SHOULD BE USED WHEN TESTING OR OPERATING VALVE.
3. EXERCISE CAUTION WHEN EXAMINING A PRESSURE RELIEF VALVE FOR VISIBLE LEAKAGE.
4. NEVER INSTALL A PRESSURE RELIEF VALVE IN A HORIZONTAL POSITION. PRESSURE RELIEF VALVE INTERNALS ARE DESIGNED TO MOVE VERTICALLY, WHEN INSTALLED HORIZONTALLY, MISALIGNMENT AND GALLING OR HANG UP MAY PREVENT THE VALVE FROM OPENING OR CLOSING PROPERLY.
5. THE BODY DRAIN MUST BE PIPED TO A SAFE AREA.
IF LEFT PLUGGED, CONDENSATE WILL ACCUMULATE INSIDE THE VALVE BODY. IF LEFT OPEN, HOT AND/OR CORROSIVE MEDIUMS WILL ESCAPE AND PRESENT A HAZARD TO PERSONNEL NEAR THE VALVE.
6. PRESSURE RELIEF VALVES SHOULD BE MOUNTED TO PROVIDE ADEQUATE ACCESS, 360 AROUND THE VALVE PLUS OVERHEAD TO PERMIT REMOVAL FOR TESTING AND MAINTENANCE.
7. WHEN REMOVING THE PRESSURE RELIEF VALVE DURING DISASSEMBLY, STAND CLEAR AND/OR WEAR PROTECTIVE CLOTHING TO PREVENT EXPOSURE TO SPLATTER OF ANY CORROSIVE PROCESS MEDIUM WHICH MAY HAVE BEEN TRAPPED INSIDE.
8. ALWAYS GAG A PRESSURE RELIEF VALVE BEFORE MAKING RING ADJUSTMENTS. BE SURE TO REMOVE GAG AFTER ADJUSTMENTS ARE COMPLETED.
3
ABD00200784
TABLE OF CONTENTS
Page No.
SAFETY NOTICE................................................................................................ 2
SAFETY PRECAUTIONS.................................................................................. 3
TABLE OF CONTENTS...................................................................................... 4
NOMENCLATURE/TERMINOLOGY............................................................... 5
INTRODUCTION................................................................................................ 6
DESIGN FEATURES......................................................................................... 6
HANDLING, STORAGE AND PREINSTALLATION........................................ 6
INSTALLATION.................................................................................................. 7
DISASSEMBLY OF FLANGED VALVES......................................................... 7
DISASSEMBLY OF 1970 AND 1975 VALVES.............................................. 9
DISASSEMBLY OF 1980 & 1982 VALVES...................................................... 10
MAINTENANCE OF FLANGED VALVES.......................................................... 10
REPAIR OF FLANGED VALVES........................................................................14
SEAT REPAIRING AND LAPPING TYPES 1970 AND 1975 VALVES.........17
SEAT REPAIR TYPE 1980 VALVE.................................................................... 18
REASSEMBLY OF FLANGED VALVES............................................................18
REASSEMBLY OF TYPES 1970 AND 1975 VALVES....................................19
REASSEMBLY OF TYPE 1980 & 1982 VALVE................................................19
SETTING, TESTING, AND ADJUSTMENTS.....................................................20
CHECKING SEAT TIGHTNESS.................................
20
COLD DIFFERENTIAL SET PRESSURE..........................................................21
HYDRO TEST...................................................................................................... 22
MANUAL POPPING............................................................................................ 22
MAINTENANCE TOOLS AND SUPPLIES........................................................ 23
SERVICE PARTS INVENTORY PLANNING.....................................................25
RECOMMENDED SPARE PARTS....................................................................27
SERVICE CENTER LOCATIONS......................................................................30
MANUFACTURER'S FIELD SERVICE AND REPAIR PROGRAM.................31
4
r
ABD00200785
-\
REF. NO. NOMENCLATURE
NOMENCLATURE/TERMINOLOGY (Ref. Fig. 1)
MATERIAL
1 Base 1905-1918 1920-1928
2 Eductor Tube
3 Nozzle
4 Adjusting Ring
5 Adjusting Ring Pin Ring Pin Head Ring Pin Stem
ASTM A216 Grade WCB Carbon Steel ASTM A217 Grade WC1 Alloy Steel ASTM A479 Type 304 Stainless Steel ASTM A182 Grade F316 Stainless Steel ASTM A296-75 Grade CA15 Stainless Steel
416 Stainless Steel 416 Stainless Steel
6 Adj. Ring Pin Gasket
316 Stainless Steel Asbestos Filled
7 Disc
ASTM A479 Type 316 Stainless Steel
8 Disc Retainer
17-7PH Condition A Stainless Steel
9 Disc Holder
ASTM A479 Type 304 Stainless Steel
10 Guide Guide Sleeve Guide Flange
ASTM A479 Type 430 Stainless Steel ASTM A476 Grade 410 Condition A Stainless Steel
11 Guide Gasket
Soft Iron
12 Bonnet
ASTM A216 Grade WCB Carbon Steel
13 Bonnet Gasket
'Soft Iron
14 Base Stud
ASTM A193 Grade B7 Alloy Steel
15 Stud Nut
ASTM A194 Class 1 Steel
16 Spindle Spindle Head Spindle Stem
ASTM A276 Grade 410 Condition "T" Hardness RC 24-29 416 Stainless Steel
17 Spindle Retainer
17-7PH Condition A Stainless Steel
18 Spring Washer
C1020 Carbon Steel
19 Spring Types 1900 ( )c Types 1900 { )t
Carbon Steel (Phosphated) Tungsten Steel:;!
20 Adjusting Screw
ASTM A276 Grade 410 Condition "T" Hardness RC 24-29
21 Adjusting Screw Nut
416 Stainless Steel
22 Cap
ASTM A216 Grade WCB Carbon Steel
23 Cap Gasket
316 Stainless Steel Asbestos Filled
NOIL 1 ALTERNATE MATERIALS AVAILABLE. SEE CATALOG
-SPRINGS WITH WIRE SIZE >/?" AND SMALLER WILL BE SUPPLIED IN INCONEL
X-750 MATERIAL.
2. DUE TO SPECIAL MANUFACTURING REQUIREMENTS. IT IS HAZARDOUS TO USE VALVE PARTS WHICH HAVE NOT BEEN FACTORY SUPPLIED.
5
INTRODUCTION
ABD00200786
A safety relief valve is an automatic pressure act uated relieving device suitable for use either as a safety valve or relief valve, depending on applica tion.
Safety relief valves are used on hundreds of dif ferent applications, including liquids and hyrdo car bons and, therefore, the valve is designed to meet many requirements. As such, the 1900 series valve can only be used to meet Section VIII requirements. It cannot be used on steam boilers or superheaters, but may be used on process steam.
DESIGN FEATURES
DESIGN SIMPLICITY - Consolidated Safety Relief Valves embody a minimum number of component parts, which results in a savings by minimizing spare parts inventory and simplifying valve main tenance. Contact the Parts Marketing organization, P.0. Box 1430, Alexandria, La. for parts inventory planning assistance.
VALVE INTERCHANGEABILITY - A Consolidated Safety Relief Valve may be converted from the stand ard conventional type valve to the bellows type, or to the "0" ring seat seal type, or vice versa, re quiring a minimum number of new parts. This re sults in lower costs should conversion be required.
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 supplied 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 pres sure be affected when making such a change.
SIMPLE BLOWDOWN ADJUSTMENT - The Consoli dated single blowdown ring design makes it possible to set and test a valve that has been in service when it cannot be set on line and must be taken to the customer's shop. The ring can be positioned so that the set point can be observed although the volume of the testing media is very low. After the set pressure has been established, proper blowdown can be attained by merely positioning the ring in ac cordance with a chart published on Page in this manual.
FIGURE I
HANDLING, STORAGE, AND PREINSTALLATION
1. Flanged valves, either crated or uncrated, should always be kept with the inlet flange down, i.e., never laid on its side, to prevent misalignment and damage to internals.
2. Safety Relief Valves should be stored in a dry environment to protect them from the weather. They should not be removed from the skids or crates until immediately prior to installation.
3. Flange protectors and sealing plugs should not be removed until the valve is ready to be bolted into the installation, i.e., both in let and outlet.
4. Safety Relief Valves, either crated or un crated, should never be subjected to sharp impact. This would be most likely to occur by bumping or dropping during loading or
6
ABD00200787
unloading from a truck or while moving with a power conveyor, such as a fork lift truck. While hoisting to the installation,
care should be exercised to prevent bump ing the valve against steel structures and other objects.
5. Uncrated valves should be moved or hoisted by wrapping a chain or sling around discharge neck, then around upper bonnet structure in such manner as will in sure the valve is in vertical position during lift, i.e., not lifted in horizontal position.
CAUTION: Never lift the full weight of the valve by the lifting lever.
Crated valves should always be lifted with the inlet flange down, i.e., same as installa tion position.
Fig. 2
6. When Safety Relief Valves are uncrated and the flange protectors or sealing plugs re moved immediately prior to installation, meticulous care should be exercised to pre vent dirt and other foreign materials from entering the inlet and outlet ports while bolt ing in place.
INSTALLATION
For conventional valves, the size of the discharge piping should never be less than the valve outlet size, and designed so as to limit variable back pres sure to a maximum of 10% of the valve set pres sure. The arrangement should be as short and direct as possible. For Type 1900-30 bellows valves, variable back pressure may be used within higher limits. (See current Consolidated catalog for capacity performance applicable to existing back pressure conditions.) The outlet system should be
designed and installed to eliminate all possible piping strains on the valve from various sources.
Consolidated Safety Relief Valves are checked, set and adjusted at the factory. Inlet and outlet connec tions are protected for shipment and storage. Ac cumulation of sand, dirt, etc., in relief valve inlet ports will be carried across the seat while the valve is in operation and is frequently the cause of seat leaks and unsatisfactory operation. To prevent
future trouble, store Safety Relief Valves in a clean dry place and do not remove the wooden skid or flange protectors until ready for installation.
DISASSEMBLY OF FLANGED VALVES
DISASSEMBLY OF FLANGED VALVES (For Parts identification refer to Fig. 3, 4, and 5)
The Consolidated Safety Relief Valve can be dis assembled by the procedure outlined below:
Safety Relief Valves must be connected on full sized vessel nozzles as direct and close as possible to the vessel or pipeline (Figure 2). No stop valve should be placed between the pressure vessel and its relief valve except as permitted by code regulations. If a stop valve is located between the pressure vessel and Safety Relief Valve, the stop valve port area should equal or exceed the nominal internal area associated with the pipe size of the safety relief valve inlet. Remove all dirt, sediment, or scale from the relief valve inlet port and vessel. The relief valve should be installed in a vertical position only, (Per API-520. Inlet bolts must be drawn down evenly to prevent distortion of the valve body and inlet nozzle.
7
1. Remove cap (including lifting gear). Remove cap gasket.
2. Remove adjusting ring pin and gasket. If the existing blowdown is to be restored upon re assembly, the position of the adjusting ring with respect to the disc holder should be de termined. Turn the adjusting ring counterclock wise, i.e., move notches on the adjusting ring from left to right. Record the number of notches passing the ring pin hole required for the ring to contact the disc holder. This in formation will be used in setting the ring upon reassembly of the valve.
ABD00200788
3. Loosen adjusting screw nut. Mark or note the position of the adjusting screw and count the number of turns required to barely remove all of the spring compression. This procedure will facilitate later adjustment of the valve to near its original set pressure. When turning the ad justing screw it is good practice to keep the spindle from turning. Channel lock pliers, ap plied to the top of the spindle, may be used for this purpose.
4. Remove the stud nuts and lift off the bonnet. Remove the bonnet gasket.
5. Remove the spring and spring washers. The spring and spring washers should be kept to gether as a unit at all times.
6. All of the upper internal parts can be removed as a unit by lifting out the spindle.' These parts should be removed by lifting straight up. On bellows valves care should be taken so as not to bend or distort the bellows or its flange.
Fig. 4 1900
1902
NOMENCLATURE 1 BASE 2 EDUCTOR TUBE 3 NOZZLE 4 ADJUSTING RING 5 ADJUSTING RING PIN 6 ADJUSTING RING PIN GASKET 7 DISC 8 DISC RETAINER 9 DISC HOLDER 10 GUIDE 11 GUIDE GASKET 12 BONNET
13 BONNET GASKET 14 BASE STUD 15 BASESTUDNUT
16 SPINDLE 17 SPINDLE RETAINER 18 LOWER SPRING WASHfR
19 SPRING 20 UPPER SPRING WASHER 21 ADJUSTING SCREW 22 ADJUSTING SCREW NUT
23 CAP 24 CAP GASKET
Fig. 5
OMENCLATURE
1900-30
BASE NOZZLE
13 GUIDE GASKET 14 BONNET GASKET
ADJUSTING RING
15 BASE STUD
ADJUSTING RING PIN
16 BASE STUD NUT
ADJUSTING RING PIN GASKET
17 SPRING WASHER
DISC
18 SPRING
DISC RETAINER
19 ADJUSTING SCREW
DISC HOLOER
20 ADJUSTING SCREW NUt
SPINDLE RETAINER 0 GUIOE 1 BELLOWS 2 BELLOWS GASKET
21 BONNET
22 SPINDLE
23 CAP 24 CAP GASKET
8
ABD00200789
7. Remove the spindle from the disc holder. Clamp the skirt portion of the disc holder snugly between two wooden V-blocks in a suitable vise. Then compress the spindle retainer with a screwdriver or similar tool through the slots provided, and remove the spindle.
8. Remove guide from the disc holder.
9. The bellows is attached to the disc holder by right-hand threads. Apply a special spanner wrench- to the bellows ring and lossen bellows ring and loosen bellows by turning counter clockwise (Fig. 6). The bellows convolutions are very thin metal and care should be taken lo protect them from damage at all times. Remove bellows gasket.
11. Remove the adjusting ring by turning counter clockwise (left-handed).
12. The nozzle should not be removed from the base unless absolutely necessary. Reference Repair Section.
DISASSEMBLY OF TYPE 1970 AND 1975 (For parts identification refer to Fig. 8 and 9)
1. Remove cap (lifting gear) and cap gasket.
2. Remove guide pin and gasket. If the exist ing valve action is to be restored, the posi tion of the guide should be determined. Work through the valve outlet and turn the guide clockwise until it contacts the base, recording the number of holes turned. Leave in this position during disassembly. Return to the original position upon assembly.
'In instances where valves are i'ouled with for eign materials and/or heavy products, dis assembly may be eased if these parts are given a prior soaking in a suitable solvent. JRev. Maintenance Tools and Supplies section.
10. To remove disc from disc holder, proceed as follows: (See Fig. 7) Clamp stem portion of the disc holder, disc end up, snugly between two V-blocks in a suitable vise. Then start special drift pins3 into the holes in disc holder with tapered portion of pins working against top of disc as indicated. Tap each pin alternately with a light machinist's hammer until disc snaps out of recess in disc holder.
9 1970
ABD00200790
3The special drift pins may be purchased from Industrial Valve Operations, Dresser Industries, Inc., Alexandria, La. 71301. Ref. page 24 for part numbers.
6. Remove spring, spring washers, spindle and disc holder assembly.
7. Remove guide from base.
DISASSEMBLY OF TYPE 1980 & 1982 VALVE (For parts identification refer to Fig. 10)
1. Remove cap (lifting gear). Remove cap gasket.
2. Remove adjusting ring pin and gasket. If the existing valve action is to be restored, the position of the ring should be de termined by turning it counterclockwise un til it contacts the roof of the disc recording the number of notches that the ring is moved. Return to the original position be low the disc upon reassembly.
3. Loosen adjusting screw locknut. Record the number of turns necessary to barely remove all spring compression. Remove compression screw from the bonnet. Re turn to original position when reas sembling.
NOMENCLATURE. (>'**1 Fig 889) 1 BASE ? GUIDE PIN 3 GUIDE PIN GASKET
i OtSC b OISC RETAINER 6 DISC HOLDER 7 RE1AINER LOCK RING
8 GUIDE 9 BONNET
10 BONNET GASKET 11 SPINDLE )2 SPRING WASHER 13 SPRING 1J ADJUSTING SCREW IS ADJUSTING SCREW NUT Hi CAP 17 CAP CASKET
4. With valve base held in vise, loosen the bonnet to base connection (use strap wrench). CAUTION: Do not distort base.
5. Remove bonnet, disc assembly, spindle, spring and spring washer assembly from the base, holding the spindle to be sure that the disc does not drop.
6. Remove disc assembly, spindle, spring and spring washers from bonnet.
3. Loosen the adjusting screw lockout.
4. Remove the adjusting screw. Count the number of turns necessary to barely re move all spring compression and record this figure. Removal of spring compression is indicated when the spindle stops ro tating.
7. Remove disc from spindle by engaging the drop-out threads and turning the disc counterclockwise.
MAINTENANCE OF FLANGED VALVES
VALVE SEAT MAINTENANCE
5. Unscrew bonnet from base.
After the valve has been disassembled, a close inspection should be made of the seating surfaces.
10
ABD00200791
Fig- 10 1980 & 1982
11
Screwed Cap Spindle Adjusting Screw Adjusting Screw Nut Cap Gasket Spring Washer Spring Bonnet Spring Washer Disc Retaining Ring
Disc Disc Guide Disc Holder Adjusting Ring Disc Collar Adjusting Ring Pin Adjusting Ring Pin Gasket Bonnet Gasket Base
ABD00200792
In a majority of cases, a simple lapping of seats is all that is necessary to put the valve in first class working order. If an inspection of the parts shows the valve seating surfaces to be badly damaged, machining will be required before lapping. (For machining of nozzle and disc seating surfaces, see pages 13 and 14.)
The seating surfaces of the Consolidated Safety Relief Valve are flat. The nozzle seat is relieved by a 5 angle on the outside of the flat seat. The disc seat is wider than the nozzle seat; thus, the control of seat width is the nozzle seat (Fig. 11).
^RING LAP
r
LAPPING
Reconditioning of the seating surfaces of the nozzle and disc is accomplished by lapping with a cast iron lap, coated with a lapping compound. To insure that the seating surface is flat, an optical flat and mono chromatic light source should be employed to deter mine if the degree of flatness is adequate. Straight, parallel and equally spaced bands show that the sur face is perfectly flat.
i r r -------1
Fig. 14
LAPPING NOZZLE SEATS
The 5 angle of the nozzle should be lapped first (Fig. 12). Then, invert the nozzle lap and use the flat side as a "starter" lap to insure squareness of the seat (Fig. 13). Finish lapping should be done with a ring lap (Fig. 14). The ring lap is to be used in an eccentric or figure-eight motion. Keep the lap squarely on the flat surface and avoid any tendency to rock the lap which will cause rounding of the seat:
Fig. 12
A wide nozzle seat will induce simmer, especially in the smaller orifice lower pressure valves. For this reason, the seat should be as narrow as practical. Since the seat must be wide enough to carry the bearing load imposed upon it by the spring force, the higher pressure valves must have wider seats than the low pressure valves. The nozzle seat width should conform with the following table.
12
ABD00200793
Orifice 0 i.
r
G
H
J
JC M N 0 R T
Valve Type
Seet Width
Win
19050. 19060. 19100. 191?0. 19?f. 19770
.015 - .02?
19140. 1916D. 19180. 19240. 19260. 19280
.023 - .030
lfoSCBo&s.'lfflSr
---------- .01
1914E. 1916E. 19 3 BE. 1924E. 1926E. 1928E
.MO - .037
19oif. i902fT 1M5F. 1906P, 19!0Fri5Y2r_
1914F. 1916F. 1920F, J922F, 1924F, 1926F
190S-30F, 1906-30F, 1910-30F, 1912-30F 1914-30F. 1916-30F. 1920-30F. 1922-30F
.015 .022
1924-30F. 1926-30F
1918F. 1928F. 19I8-30F. 192R-10F
.oJo - "7537--
1901G. 1902G, 1905G, 19066, 1910G.
1912G, 1914G, 1920G. 19226. 19246.
19266. 190S-30G, 1906-30G. 1910-306, 1912-306. 1914-306. 1920-30G, 1922-30G
.015 - .022
1924-306. 1976-306
39166. 19186, 1928G. 1916-306, 1918-306
1928-30G
.023 - .030
All .023 - .030
19010, 1902J, 19050. 19060, 19100
19110, 19120, 19130. 19140, 19200
19220. 19240. 1905-300. 1906-300, 1910-300
.023 - .030
1911-300, 1912-300. 1913-300. 1914-30J
1920-30J. 1922-30J. 1924-300
19160. 19260. 1916-300. 19?fi-.3fU
------ITTTCT7-
AD ~n5Jo - ,M7 AD M7 All .031 M7
A ___ &
A,
.Mi .837 I .015 .Mr-
.A1 : .MR
AD 45 OM
The seat width can be measured simply and ac curately by the use of a "Measuring Magnifier" (Fig. 15). We recommend the use of Model 81-3435-37 manufactured by Bausch and Lomb Optical Co., Rochester, N.Y. It is a seven power glass with a three-quarter inch scale showing graduations of 0.005 inch. The use of this scale in measuring the nozzle seat width is shown in Fig. 16.
Fig. 16
LAPPING DISC SEAT
The disc seat may be lapped with a ring lap or a lapping plate (Fig. 17). Lapping should be done in an eccentric or figure-eight motion in all directions, applying uniform pressure and rotating the disc or lap slowly.
PRECAUTIONS AND HINTS FOR LAPPING SEATS
If additional lighting is required for measuring the seat, we suggest a goose-neck flashlight similiar to the Type A Lamp Assembly Flashlight manufactured by Standard Molding Corporation, Dayton, Ohio.
13
1. Keep work clean.
2. Always use a fresh lap. If signs of wearing are evident, recondition the lap and verify flatness with an optical flat and monochro-
ABD00200794
matic light source.
3. Apply a very thin layer of compound to the lap. This will prevent rounding off the edges of the seat.
4. Keep the lap squarely on the flat surface and avoid any tendency to rock the lap which cause rounding of the seat.
5. Keep a firm grip on the lap or part to pre vent the possibility of dropping it and damaging the seat.
6. Wipe off old compound and apply new compound frequently.
7. After lapping, the seats should be thoroughly cleaned with kerosene or light oil, using a lint-free cloth.
RECONDITIONING OF LAPS
Ring taps are reconditioned by lapping them on a flat lapping plate. The lapping should be done with a figure-eight motion as indicated in Figure 17. To assure the best results when lapping seats, the ring laps should be reconditioned after each usage and checked with an optical flat.
Nozzle laps must be remachined to recondition the lapping surfaces. Place the nozzle-lap in a lathe be tween centers (Fig. 18). Surfaces marked A and 8 must be running concentric. One lapping surface is 90 and the other is 85. The angle of each surface is marked on the lap. Machine surfaces C and D by taking light cuts at the proper angle until the lapping surfaces are reconditioned.
REPAIR OF FLANGED VALVES
REMACHINING NOZZLE SEATS
The nozzle seat should be machined with the nozzle assembled in the base whenever possible. If it should be necessary to remove the nozzle from the base, see nozzle removal methods in Maintenance, Tools & Supplies Section. The nozzle is assembled to the base with threads and may be removed by turning counter-clockwise (left-handled). To facilitate removal of the nozzle from the base it may be found beneficial to first soak the threaded joint with a suit able penetrating liquid or solvent. In instances where the nozzle is frozen into the base, its removal may be helped by sufficiently heating the base from the outside with a blowtorch in the area of the nozzle threads while dry ice or other cooling medium is ap plied to the inside of the nozzle. CAUTION: Should heat be applied, use care to pre
vent cracking of cast parts. Dye pene trant inspection should be used to check for cracking on cast parts where heat has been applied.
LATHE SET-UP FOR MACHINING OF NOZZLE WHEN ASSEMBLED IN BASE (Fig. 19).
1. Grip the nozzle in a four-jaw independent jaw independent chuck.
2. True up the work so that the top of th*e nozzle at C and the base surface at B run true within .001" on indicator.
LATHE SET-UP FOR MACHINING OF NOZZLE WHEN REMOVED FROM BASE (Fig. 20). 14
ABD00200795
1. Grip the nozzle a four-jaw independent chuck, using a piece of soft material such as copper or fiber between the jaws and the nozzle as shown at A.
2. True up the nozzle so that the surfaces marked B and C run true within .001" on indicator.
MACHINING OF NOZZLE SEAT Tig. 21)
Orifice D E F
H
F 5/16 .035 .954 .831 G 5/16 .035 1.093 .953 H 1/4 .035 1.224 1.123
J 3/8 .035 1.545 1.435 K 7/16 .063 1.836 1.711 L 7/16 .063 2.257 2.132
M 7/16 .063 2.525 2.400 N 1/2 .063 2.777 2.627 P 5/8 .093 3.332 3.182
Q 7/8 .093 4.335 4.185
R1
.093 5.110 4.960
T 3/4 .093 6.234 6.040
2. Cut back the outside surface at G until dimension E is obtained.
3. Cut back inside surface at the angle shown un til dimension E is obtained.
4. The nozzle is now ready for lapping. See pages 11 and 12.
5. When the minimum dimension D is reached the nozzle should be discarded.
MACHINING DIMENSIONS FOR NOZZLE SEATS (Fig. 21)
1. Take light cuts across the surface L at 5 until the damaged areas are removed. Turn to the smoothest possible finish.
15
ABD00200796
REMACHINING THE DISC SEATS (Fig. 22)
The disc seating surface can easily be machined as follows: 1. Grip the disc in a four-jaw independent chuck,
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 surfaces marked B and C run true.
2. Place the spindle in a lathe, using a block, B, to support the point of the spindle.
3. Apply a machinist's indicator at approximately 45 to the outer edge of the spring washer seat at C. Rotate the spindle between the centers, keeping B stationary. At D, spindle passes through the adjusting screw, the total indicator reading should not exceed .007". Straighten if necessary.
MACHINING OF THE DISC SEAT (Fig. 23)
1. Take light cuts across the seating surface L until damaged areas are removed. Turn to smoothest possible finish.
2. The disc is now ready for lapping.
3. When the minimum dimension N is reached, the disc should be discarded.
CHECKING SPINDLE CONCENTRICITY
It is important that the spindle of a safety relief valve be straight in order to transmit the spring load to the disc without laterial binding. Over-gagging is one of the common causes of bent spindles. To check the essential working surfaces of the spindle, either of the following methods is recommended.
CHECKING SPINDLE CONCENTRICITY WITH V-BLOCK .SUPPORT (Fig. 25)
1. The ball pointed spindles should be placed in a piece of material, B, that has been recessed to permit free rotation of the spindle. For hollow spindles, a ball pointed support is required.
2. Support the spindle with a V-block, A, placed near the upper end of the spindle, but below the threads.
3. Apply a machinist's indicator at approximately 45 to the outer edge of the spring washer seat at C. Rotate the spindle. The total indicator read ing should not exceed .007". Straighten if neces sary.
CHECKING SPINDLE CONCENTRICITY IN LATHE (Fig. 24)
The following procedure can be used when checking spindle concentricity in a lathe.
1. Machine center hole A.
16
Fig. 25
ABD00200797
DISC HOLDER FOR SMALL ORIFICE LOW PRESSURE VALVES
The F orifice valves have different disc holders for set pressures 100 psig and below than for set pres sure of 101 psig and above. If an F orifice valve is changed from a set pressure of 100 psig or below to a set pressure of 101 psig or above, a new disc holder should be obtained. If an F orifice valve is changed from a set pressure of 101 psig or above to a set pressure of 100 psig or below, a new disc holder should be obtained or the present disc hold er reworked as shown by Figure 26.
The G through J orifice valves have different disc holders for set pressures 50 psig and below than for pressures 51 psig and above. If a G through J orifice valve is changed from a set pressure of 50 psig or below to a set pressure of 51 psig or above, a new disc holder should be obtained. If a G through J orifice valve is changed from a set pressure of 51 psig or above to a pressure of 50 psig or below a new disc holder should be obtained or the present disc holder reworked as shown by Figure 26.
the large section as shown. If it should be neces sary to grip the disc holder on the small portion. F, extra care should be taken to prevent scarring since this is a guiding surface.
2. Align the part so that surfaces marked D run true.
3. Machine 45 angle to diameter B (designated by dotted line on illustration).
The K through T orifice valve disc holders are the same for both low and high pressure.
SEAT REPAIRING AND LAPPING TYPES 1970 and 1975 VALVES
Reconditioning of the seating surface of the disc and base is accomplished by lapping with a flat cast iron ring lap coated with Grade No. 1000 KWIK-AK-SHUN Silicon-Carbide compound, or equivalent.
Lapping a flat seat is extremely simple. No special skill is required and the technique is readily ap parent after a few minutes of actual lapping.
The following precautions and hints will enable any one to do a "professional" job of lapping seats.
1. Keep the work clean.
2. 3.
Orif'ite D E F G H J
A .714 .858 1.031 1.182 1.393 1.779
B .810 .970 1.166 1.271 1.490 1.928
4. 5. 6.
Fig. 26
7.
1. Grip the disc holder in a four-jaw independent chuck using a piece of soft material between the jaws and the disc holder as shown at E. If possible, the disc holder should be gripped on
17
Always use a fresh lap. If signs of wearing (out of flatness) is evident recondition the lap.
Apply a very thin layer of compound to the lap. This will prevent rounding off the edges of the seat.
Keep the lap squarely on the flat surface and avoid any tendency to rock the lap which will cause rounding of the seat.
When lapping, keep a firm grip on the part to prevent the possibility of dropping it and dam aging the seat.
Lap, using a reciprocating motion in all direc tions, at the same time applying uniform pres sure and rotating the lap slowly.
Replace the compound frequently after wiping off the old compound, and apply more pres sure to speed the cutting action of the com pound.
ABD00200798
8. To check the seating surfaces, remove all com pound from both the seat and the lap. Then shine up 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 is neces sary and only laps known to be fiat should now be used. Only a few minutes will be required to remove the shadows.
9. When the lapping is completed, any lines ap pearing as cross scratches can be removed by rotating the lap, which has been wiped clean of compound, on the seat about its own axis.
10. The seat should now be thoroughly cleaned with kerosene, light oil, or carbon tetra chloride, using a lint-free cloth or tissue paper.
When the seats cannot be repaired by lapping, they can be remachined using dimensions given in Fig. 27.
The disc insert is contained in the disc holder by a Truarc retaining ring. The ring may be removed by using a Truarc Plier #4. After removing the Truarc ring, the disc insert and disc collar can be removed from the disc holder.
The disc insert can now be lapped using the same procedure as used for Type 1970 and 1975 valves.
If the disc is damaged to the extent that machining is necessary, the following procedure can be used:
1. Using a four-jaw chuck, align the disc insert so that it is running true.
2. Take light cuts on the seat surface until all damage is removed. Reestablish dimensions as shown in Fig. 28.
3. When "H" dimension has been reduced to .025, the disc insert should be replaced.
f
1970 USE
19)5 BASC
VALVE
1970 1970 1975
SIZE
H
3/4 & 1 1-1/2 & 2
.576 .854
1/2, 3/4, &1 .389
C '15
7h 10
D(MIN.)
1/2 15/16
3/16
Fig. 27
The following procedure can be used when machin ing the base seat:
to
K
%
i
i-H
2
A .443 .590 .738 1.180 1.511
9 C0E
.487 .525 %, .031
.640 .701 %, .041
.802 .874
Mu
1.294 1.399
.079
1634 1.794 *94.
.111
O*wvm
I960
1991.
FIG. 28
F .516 .669 JO4 1.339 1.880
e
.414 -581 .706 1.139 1.465
H .050 .050 .050 .082 .062
LAPPING TYPE 1980 & 1982 DISCS
Laps are available to allow repair-lapping of discs for 1980 & 1982 valves. The lap diameters neces sary for each 1980 & 1982 valve size are shown in the following Table:
1. Using a four-jaw chuck, align the base so that it is running true.
1980 & 1982 Inlet Size 1/2", 3/4", 1", 1W\ 2"
2. Take light cuts on the seat surface until all damage is removed. Reestablish dimension.
3. Lap the seat. 4. When minimum dimension "D" is exceeded,
the base should be discarded.
SEAT REPAIR, TYPE 1980 VALVE
To recondition the disc seat by lapping, it is neces sary to disassemble the disc assembly. This is done in the following manner:
Lap Diameter
9/16", 13/32", 1", 1-3/4", 2-1/8"
REASSEMBLY OF FLANGED VALVES
(For part identification refer to Fig. 3, 4 and 5)
Before reassembling the valve, all parts should be cleaned. Special attention should be given to guiding surfaces, bearing surfaces, and retainer recesses. Inspect the bellows for corrosion and possible leaks.
18
^
ABD00200799
Reassemble the valve as follows:
1. Thread the adjusting ring into the nozzle. Make sure the ring is low enough on the nozzle to allow sufficient clearance between the disc hold er and the adjusting ring so that the disc will seat on the nozzle.
2. Install the disc into the disc holder. The disc retainer should "snap" into the pocket with moderate finger or hand force. DO NOT USE FORCE TO ASSEMBLE THESE PARTS. Be sure that the disc is free to "wobble" after it is in place.
3. To install the bellows, clamp the large end of the holder between two wooden V-blocks in a vise. Place a new bellows gasket {graphited side down) on the disc holder. Thread the bel lows down to the gasket finger-tight. Then place a spanner wrench around the bellows ring and tighten. It is very important that a pressure tight joint be obtained between the disc holder and the bellows.
4. Place the guide on the disc holder. Do not drop. The weight of the guide will slightly com press the bellows.
5. Place the spindle retainer over the end of the spindle. Apply lubricant to the ball tip of the spindle. Place the spindle in the disc holder and align the spindle retainer so that the gap is midway between the two slots. Compress the spindle retainer and place it in the retaining, groove. Be sure that the spindle turns freely. Slightly grind the ball tip of the spindle into the disc holder pocket to assure a good bearing surface.
6. Place a new guide gasket in the base.
7. Install the disc, disc holder, guide and spindle assembly in the valve base. If a conventional valve, be sure that the hold in the guide flange is located over the small projection of the ed uctor tube.
8- Apply a small quantity of lubricant to the spring washer bearing surface of the spindle. Place the spring assembly on the spindle.
9. Install a new bonnet gasket and the bonnet. Tighten the bonnet stud nuts uniformly.
10. Thread in the adjusting screw (with adjusting screw nut assembled to adjusting screw) until it contacts the top spring washer.
11. When compressing the spring, hold the spindle with channel lock pliers to prevent the spindle point from turning in the disc holder. Turn the adjusting screw clockwise, or right-handed, un til the original number of turns has been re stored. This method of compressing the spring will approximately establish the original set pressure. Be sure that the spindle locates it self centrally within the adjusting screw before proceeding with setting.
19
12. Restore the adjusting ring to its original posi tion with reference to the disc holder and re place the adjusting ring pin. If original posi tion of the adjusting ring is not known, position the ring in accordance with the following table.
Orifice
D,E,F,G H&J
K L M&N P
0 R T
Set Pressures
100 psig and below
4 notches 5 notches 6 notches 6 notches 7 notches 8 notches 10 notches 28 notches 30 notches
Set Pressures
100 psig and above
7 notches 9 notches 14 notches 18 notches 20 notches 24 notches 28 notches 36 notches / 38 notches
Be sure that the pin enters the notch in the ring, but does not bind the ring. The ring should feel free after the pin is installed.
13. The valve is' now ready for setting. After the valve has been set, tighten the adjusting screw nut. Install the cap gasket and cap or lifting gear to the valve.
REASSEMBLY OF TYPES 1970 AND 1975 VALVES (For parts identification refer to Fig. 8 and 9)
Before assembly, all parts should be cleaned.
1. Thread the guide onto the base until it contacts the base shoulder.
2. Apply a small amount of lubricant (Moly-Kote) to the end of the spindle and install it in the disc holder assembly.
3. Insert assembly into guide.
4. Apply a small amount of lubricant to the bear ing surface of the lower spring washer and slip over spindle. Install the spring and upper spring washer.
5. Install a new bonnet gasket on base. Apply a small amount of lubricant to the bonnet thread on the base and install bonnet on base.
6. Apply a small amount of lubricant to the tip of the adjusting screw. Install the adjusting screw in the bonnet, rotating the number of times re quired to restore it to the original position. When the spindle begins to turn, use pliers to hold in position.
7. Restore the guide to the original position and install the guide pin with the guide pin gasket.
8. Valve is now ready for testing.
REASSEMBLY OF TYPE 1980 & 1982 VALVE (For parts identification refer to Fig. 10)
1. Before reassembly, all parts should be clean ed. All burrs on guiding surfaces should be
ABD00200800
carefully removed.
2. Put a small amount of Moly-Kote on the spindle tip and on the lower spring washer bearing. Thread the disc on the spindle and assemble spring and spring washers on the spindle.
3. Insert disc, spindle, spring and spring washer assembly into the bonnet.
4. Assemble adjusting ring to base (top of adjust ing ring to flush with seat). Place a new bonnet gasket on the base.
5. Place a small amount of Moly-Kote on the ball end of the adjusting screw.
6. Holding bonnet and spindle (so that disc will not drop) install bonnet assembly to base. Tighten bonnet on base with strap wrench.
7. Assemble compression screw and reestablish spring compression by first turning down the compression screw to take out all play and then add the same number of turns that it took to relieve the compression when the valve was disassembled.
8. Reestablish position of adjusting ring as follows:
a. Using a pointed tool, turn the adjusting ring to the right slowly, thus raising the ring until it touches the disc.
b. Then, counting the notches, turn the ad justing ring to the left, thereby lowering the ring, until the original position is established.
9. Test valve per instructions outlined under
"Testing."
SETTING, TESTING AND ADJUSTMENTS
SAFETY RELIEF VALVE PERFORMANCE
Satisfactory safety relief valve operation requires that the valve seat shall be satisfactorily tight at the operating pressure (normally about 90/o of the set pressure). Refer to Page 20 for leakage test. On gases and vapors, the valve should pop at set pres sure after the usual slight warning.
BLOWDOWN ADJUSTMENT (Reseating Pressure)
NOTE: UNLESS THE TEST STAND CAPACITY IS EQUAL TO OR GREATER THAN THAT OF THE VALVE, DO NOT ATTEMPT TO SET BLOWDOWN. SIMPLY RETURN THE ADJUSTING RING OR GUIDE TO THE ORIGINAL POSITION.
Blowdown adjustments are made by means of the adjusting ring on the 1900 and 1980 valves and the guide on the 1970 and 1975 valves.
20
If longer or shorter blowdown is required, it can be obtained as follows:
a. To increase blowdown (lower reseating pres sure), the adjusting ring or guide must be raised by moving the notches from left to righi past the ring pin hole.
b. To decrease blowdown (raise reseating pres sure), the adjusting ring or guide must be low ered by moving the notches from right to left past the ring pin hole.
SETTING AND TESTING AFTER RECONDITIONING
Before putting the reconditioned valve in service, it must be set to open at the required set pressure. Al though the valve can be set on the service installa tion, it is more convenient to set the valve and check seat tightness on a test stand.
When using a test stand, the valve should be set to open at the cold differential set pressure as shown on the nameplate. The cold differential set pressure is the set pressure corrected to compensate for back pressure and/or operating temperature. (See Pago 20.)
SETTING THE VALVE
Set the valve on clean air. Before mounting the valve on the test stand, remove all dirt, sediment or scale from the test tank nozzle and the inlet port of the valve. Be sure that the test gauge is accurate and has recently been calibrated on a dead weight gauge tester.
Mount the valve on the test stand. If the adjusting screw of the reconditioned valve has been turned down to its original position, slowly bring the pres sure up in the test tank to the cold differential set pressure. If the valve opens before the desired pres sure is reached, additional compression is required on the spring. Hold the spindle to prevent rotation and turn the adjusting screw down (clockwise or righthanded). If the valve does.not open at the de sired pressure, maintain the. required pressure in the test tank and slowly release the compression on the. spring by turning the adjusting screw counter clockwise or left-handed until the valve opens. Continue adjustment until the valve opens at the de sired pressure. Be sure to hold the spindle when turning the adjusting screw. The spindle should be centrally located within the adjusting screw as hard rubbing of the spindle against the side of the adjust ing screw may cause poor valve action.
After the required set pressure is obtained, tighten the adjusting screw nut and repeat test. At least two repeat openings at the same pressure should be ob tained to be sure that the valve is set accurately.
CHECKING SEAT TIGHTNESS
SCOPE
This standard describes a method of determining seat tightness of safety relief valves. Consolidated "0". ring valves are designed to be bubble tight on air according to Table 1.
ABD00200801
NOTE: The cover plate should be fitted with a suit able device to relieve body pressure in case of ac cidental popping of the valve.
SET PRESSURE PERCENT OF
PSIG
SET PRESSURE
15-60
5 psi below pop point
51-6000 90/o
TABLE 1
PERCENT OF SET PRESSURE (POPPING PRESSURE) AT WHICH VALVE WILL BE TIGHT ON AIR.
TYPE OF VALVE Conventional
8alanced
MANUFACTURER'S ORIFICE SIZE F and smaller G and larger F and smaller G and larger
MAX. LEAKAGE RATE(BURBLES PER MINUTE)
40 20
50 30
APPROX. LEAKAGE RATE (STO. CU. FT. PER 24 HR.)
0-60
0.30
0.75 0.45
COLD DIFFERENTIAL SET PRESSURE
When a Consolidated Safety Relief Valve is to be set on a test stand at room temperature and atmos pheric back pressure and is to operate at a higher temperature and/or a higher back pressure, a set pressure adjustment is required. The adjusted set pressure is designated as the "Cold Differential Set Pressure."
TEMPERATURE ADJUSTMENT
Safety relief valves set on air at atmospheric temper atures and to be used at higher temperatures should have the set pressure adjusted as follows:
Operating Temperature -20F. to 250F. 251F. to 1000F
Set Pressure None 3%
EXAMPLES OF COLD DIFFERENTIAL SET PRESSURE CALCULATIONS
Conventional Valve
(Type 1900 Consolidated Safety Relief Valve) (a) Set pressure 2550 psig, temperature 300F., back pressure atmospheric.
Set Pressure....... 2550 psig plus 3/o or figure from Pressure Adjustment column.......................... 76 psig Cold Differential Set Pressure...................... 2626 psig
TEST APPARATUS
A typical test arrangement for determining seat tight ness for safety relief valves is shown in Fig. 29. Leakage measurement shall be made with use of a 5/16 in. OD tubing with .035 in, wall. The tube end shall be cut square and smooth. It shall be parallel to and 1/2 in. below the surface of the water.
PROCEDURE
With the valve mounted vertically, as shown in Fig. 29, the leakage rate in bubbles per minute shall be determined with pressure at the safety relief valve inlet held at the percent of the set pressure shown in Table 1. The test pressure shall be applied for a minimum of 1 min. for valves of inlet sizes through 2 in.; 2 min. for sizes 2-1/2, 3 and 4 in.1/? 5 min. for sizes 6 in. and 8 in. Air at approximately atmos pheric temperature shall be used as the pressure medium.
"Tightness Standard" the leakage rate in bubbles per minute shall not exceed the following:
21
(b) Set pressure 2550 psig, temperature 300F., constant back pressure 150 psig.
Set Pressure................................................. 2550 psig minus constant back pressure...................... 15Q psig differential pressure.....................................2400 psig plus 3/o or figure from Pressure Adjustment column........... ...........72 psig Cold Differential Set Pressure...................... 2472 psig
(c) Set pressure 2550 psig, temperature 100F., constant back pressure 150 psig.
Set Pressure................................................ 2550 psig minus constant back pressure.......................150 psig Cold Differential Set Pressure..................... 2400 psig
Bellows Valve
(Type 1900-30 Consolidated Safety Relief Valve)
(a) Set pressure 2550 psig, temperature 300^., back pressure atmospheric. Set Pressure............................................... 2550 psig plus 3% or figure from Pressure Adjustment column......................... 76 psig Cold Differential Set Pressure.................... 2626 psig
(b) When constant back pressure or variable back pressure is present, disregard the back pressure and determine the. cold differential set pressure as specified above.
ABD00200802
The following table can be used for set pressure ad justment of valves with operating temperatures from 251F. to 1000F.
Sel Press.
1-16 17-49 50-83 84-117 118-150 151-183 184-217 218-250 251-283 284-317 318-350
351-383 384-417 418-450
451-483 484-517
518-550 551-583 584-617 618-650 651-683 684-717 718-750 751-783 784-817 818-850 851-8S3 884-917 918-950 951-983
984-1017 1018-1050 1051-1083 1084-11 17
1118-1150 1151-1183 1184-1217 1218-1250 1251-1283 1 284-131 7
1318-1350 1351-1383 1384-141 7 1418-1450 1451-1483 1484-1517 1518-1550 1551-1583 1584-1617
1618-1650 1651-1683 1684-i 717
1718-1750
1751-1783 1784-1817 1818-1850
1851-1883 1884-1917 1918-1950 195.1-1983
1984-2017
Press. Adj.
0 1 2 3 4 5 6 7 8
9 10
11 12 13 14
15 16 17 18 19 20 21 22 23 24
25 26 27 28
29 30
31 32
33 34
35 36 37 38 39 40 41 42 43 44
45 46 47 48 49 50 51 52
53 54 55
56 57
58 59 60
Sel Press.
2018-2050 2051-2083 2084-2117 2118-2150 2151-2183 2184-2217 2218-2250 2251-2283 2284-2317 2318-2350 2351-2383 2384-2417 2418-2450 2451-2483 2484-2517 2518-2550 2551-2583 2584-2617 2618-2650 2651-2683 2684-2717 2718-2750 2751-2783 2784-2817 2818-2850
2883 2884-2917 2918-2950 2951-2983 2984-3017 3018-3050 3051-3083 3084-3117 3118-3150 3151-3183 3184-3217 3218-3250 3251-3283 3284-3317 3318-3350 3351-3383 3384-3417 3418-3450 3451-3483 3484-3517 3518-3550 3551-3583 3584-3617 3618-3650 3651-3683 3684-3717 3718-3750 3751-3783 3784-3817 3818-3850 3851-3883 3884-3917 3918-3950 3951-3983 3984-4017
Press. Adj.
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
Set Press.
Press. Adj.
4018-4050
4051-4083 4084-4117 4118-4150 4151-4183 4184-4217 4218-4250 4251-4283 4284-4317 4318-4350
4351-4383 4384-4417 4418-44 50 4451-4483 4484-4517
4518-4550 4551-4583 4584-4617 4618-4650 4651-4683 4684-4717 47 18-4750 4751-4783 4784-4817 4818-4850 4851-4883 4884-4917 4918-4950
4951-4983 4984-5017
5018-5050 5051-5083 5084-5117 5118-5150
5151-5183
5 J 84-521 7 5218-5250
5251-5283 5284-5317 5318-5350 5351-5383 5384-5417 5418-5450 5451-5483 5484-5517
5518-5550 5551-5583 5584-5617 5618-5650 5651-5683 5684-5717
5718-5750
5751-5783 5784-5817
5818-5850 5851-5883 5884-5917
5918-5950
5951-5983 5984-6000
121 122 123 IZ4
125 126 127 128 129
130
131 132 133 134 135
136 137 138 139 140 141 142 143 144 145 146 147 148
149 150 151 152
153 154 155 156 157 158 159 160 161 162 163 164
165 166 167 166
169 170
171 17?
173 174 175
176 177 178
179 180
HYDROSTATIC TEST
When hydrostatic tests are required after installation of the safety relief valve, a test gag must be used (Fig. 30). Very little force (fingertight) on the test gag
is sufficient to hold hydrostatic pressures. Too much force applied to the gag may bend the spindle and damage the seat. After hydrostatic test the gag must be removed and replaced by the sealing plug furnished for this purpose. Test gags for Consoli dated Safety Relief Valves can be furnished for all types of caps and lifting gears.
MANUAL POPPING
After the valve has been installed and is in use, it may be necessary to pop it by hand or by pressure to make sure it has not become fouled by chemical action, such as corrosion, and that it continues to function properly. Consolidated Safety Relief Valves are furnished when so ordered with packed or plain lifting gears for hand popping or with air operated lifting device for remote control (Figs. 30 to 35 incl.).
gag
sealing plug
C GASKET
ABD00200803
FIG. 35
MAINTENANCE TOOLS & SUPPLIES LAPPING TOOLS The following tools are required for proper main tenance of Consolidated Safety Relief Valve seats.
Nozzle Lap4 - 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. A different size lap is required for each valve orifice.
When the valve is opened by hand it is better to have some pressure at the valve inlet, although lift ing levers furnished are heavy enough to permit opening all except very high pressu/e valves with no' pressure on the inlet. Under flowing conditions the valve must be fully lifted from its seat so that dirt, sediment and scale will not become trapped on the seating surfaces. When allowing the valve to close under flowing conditions, completely release the lever from maximum lift to snap the valve back on its seat. Since the dead weight of the lever will have
a tendency to lift the valve, the lever should be hung or supported so that the lifting fork does not contact the release nut.
Ring Lap4 - The ring lap is used for lapping the disc seat and finish lapping of the nozzle seat. The entire line of flanged valves is covered by four ring laps, as follows: (1) Orifice D thru J, (2) Orifice K thru N, (3) Orifice P thru R, (4) Orifice T.
Lapping Plate4 - The lapping plate is used for recon ditioning the ring lap. It may also be used for lapping the disc. One 11" diameter plate is required for the entire line of valves.
Lapping Compound - Lapping compound is used as a cutting medium in lapping the valve seats.
`Nozzle laps, ring laps and lapping plate may be pur chased from Dresser Industrial Valve & Instrument Division, Alexandria, La. 71301
B. Resurfacing Plate - 11" Diameter
For reconditioning all sizes of Ring Laps
The air operated lifting device is designed to fully open the valve with 75/o of set pressure under the valve disc in compliance with ASME Section VIII.
The air operator may be designed to fully open the valve with no pressure at the valve inlet. This liftting device can be operated from a remote point and can be used as a "drop out" valve.
The lifting lever or device is independent of the automatic valve action and may be located in any convenient position on the bonnet.
Part No. VH-272
C. Lapping Compounds
Brand Clover Clover Kwik-Ak-Shun
Grade 1A 3A -
Lapping Grit Function
320 General 500 Finishing
1000 Polishing
Size Container
4 oz.
4 oz.
1 lb.
Part No. 199-3 199-4 199-11
2 oz.
199-12
D. Drift Pins (For removal of Disc from Disc Hold-
er) (Fig. 36)
The air assisted lifting device, Figure 35 may be pur chased to assist the valve to open at pressures from zero to set pressure depending on the requirements.
Orifice F,G,H,J, & K L,M.N, & P
Part No. 0430401 0430402
Qty. Required 2 2
Q Sr R
0430403 2
T 0430404 2
23
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24
\
ABD00200805
"N
Orifice
D, E, F, G, H, J, K L, M, N, P
Q, R T 1970 1975
A 1 - 3/4
2- 1/2 3 3- 1/2 1 - 1/4 1 - 1/4
Drift Pin FIG. 36
B 7/32
3/8 5/8 7/8 1/8 3/64
E. Lubricants
location Noute threads
Noiiie Threads Motile Threads Adjuslint Rini Threads Swndle-SaH Tip
lubricant Led-Plale
Tellon Plate Holy-Hole Holy-Hole
MolyHoie
Material Stainless Nonle Carbon Sll Body Stainless Body Stainless Body All
Temp. All
To S00*F Above S00*F All
FIG. 37 WRENCHES FOR REMOVAL OF BELLOWS*
Valve Orifice F G H J K L M N P
0 R T
Description of Wrench 3/4" Radius-7/32" Pin 3/4" Radius-7/32" Pin 7/8" Radius-15/64" Pin 1-1/8" Radius-17/64" Pin 1-1/4" Radius-9/32" Pin 1-3/8" Radiu$-19/64" Pin 1-5/8" Radius-21/64" Pin 1-7/8" Radius-23/64" Pin 1-7/8" Radius-23/64" Pin 2-1/2" Radius-7/16" Pin 3" Radius-1/2" Pin 3-3/4" Radius-1/2" Pin
Pin Spanner Wrench No. 4451801 4451801 4451802 4451803 4451804 4451805 4451806 4451807 4451807 4451808 ' 4451809 4451810
Purchase from Industrial Valve Operations, Dresser Industries, Inc., Alexandria, La. 71301.
Spindle-Ball Tip lonrer Sprint Wshr. Bearint Surface/ Spindle Adjustmt Screwlower Bearint tnd/Upper Sprint Washer
Holy-Hole Holy-Hole
Holy-Hole
All All
All
All All
All
SERVICE PARTS INVENTORY PLANNING
The basic objective in formulating a service parts inventory philosophy is to provide prompt valve service capability, thus preventing maintenance out age time extensions. To accomplish this, it is neces sary to have immediate availability of the proper in ventory of service parts for optimum valve quan tities. This can be achieved at a minimum of cost by defining the inventory on a frequency of need basis.
NOZZLE REMOVAL METHODS
1. Utilize a 3 or 4 jaw chuck welded vertically to a stand bolted to a concrete floor. Chuck on nozzle flange and break the body loose from the nozzle with a heavy rod or pipe (Fig. 37).
2. Use a large pipe wrench on nozzle flange to re move nozzle from base (Fig. )..
To assist towards this objective, the Field service and Repair Organization of Dresser Industries - In dustrial Valve Operation recommends that the fol lowing guidelines be utilized to establish meaningful inventory levels:
1. Identify the total number of safety valves in service by size, type number, temperature class, and serial number.
2. Identify the frequency of replacement tendency
25
ABD00200806
of specific parts. Class I - Parts Most Frequently Replaced Class II - Parts Less Frequently Replaced, but Critical in the Event of an Emergency Require ment. Class III - Parts Seldom Replaced Class IV - Hardware (e.g. nuts, bolts, pins, cap components, etc.) Class V - Parts Practically Never Requiring Re placement
3. "Need probability coverage" is defined as the probable per cent (/o) of total, uninterupted operational time which can be expected by stocking predetermined valve component classifications.
Determine "need probability coverage" which is compatible with a specific company's opera tional objectives and service parts inventory investment philosophy. Then relate "need probability coverage" to parts classifications which will satisfy that need. Guidelines are as follows:
Parts Classification
Class I Class I, & II Class I, II, &III Class I, II,III,& IV
Need Probability Coverage
70/o 85/o 95/o 99/o
4. Consult recommended spare parts list by valve type to determine quantity of parts for valves to be covered by the inventory plan.
5. Select parts and specify quantities.
IDENTIFICATION AND ORDERING ESSENTIALS
When ordering service parts, please furnish the following information to insure receiving the correct replacement parts:
Identify Valve By:
Specify parts required by:
1. Size
1. Part Name
2. Type
2. Part Number (if known)
3. Temperature Class
3. Quantity
4. Serial Number
Example One: l-l/2"1910Fc
S/NTD-94578
Example Two: 6"1910qc
S/N TD-07961
FIG. 38 The correct part names may be obtained from Figures 1, 8, 9 and 10. All other required informa tion will be found stamped on the nameplate attached to the bonnet of the valve. Typical name plates are shown in Figure 39. Should the nameplate be lost, the valve type and serial number are stamped on the outlet flange.
T*6 FIG. 39
v
26
ABD00200807
RECOMMENDED SPARE PARTS SAFETY RELIEF VALVES 1900 Conventional 1900-30 Bellows
CLASS PART NAME
1. Disc Nozzle Bellows Adj. Ring Pin Disc & Spindle Retainers Gasket (Set) (1) Cap Gasket (1) Bonnet Gasket (1) Guide Gasket (1) Adj. Ring Pin Gasket (1) Bellows Gasket
II. Disc Holder Spindle Studs, Base Nuts, Base Stud
III. Adjusting Ring Spring Assembly (1) Spring (1) Spring Washer (U) (1) Spring Washer (1) Compression Screw
IV. Compression Screw Lock Nut
Cap (Select One): 1. Screwed
2. Plain Lever Assembly (1) Cap Assembly (1) Release Nut (1) Lock Nut
3. Packed Lever Assembly (1) Cap Assembly (4) Cap Bolts (1) Release Nut (1) Lock Nut
C-CONVENTIONAL B-BELLOWS
C&B C&B B C&B C&B
C&B C&B C&B C&B B
C&B C&B C&B C&B
C&B
C&B C&B C&B C&B
C&B
C&B C&B
QTY. PARTS/ NEED SAME VALVES PROBABILITY IN SERVICE COVERAGE
1/3 1/10
1/3 1/3 1 Set/1
70% 70% 70% 70% 70%
1/1 1/1 1/1 1/1 1/1
1/6 1/6 1 Set/6 1' Set/6
1/10
70% 70% 70% 70% 70%
85% 85% 85% 85%
95%
1/10 95% 1/10 95% 1/10 95% 1/10 95%
1/10 99%
1/10 99% 1/10 99%
C&B 1/10 99%
CLASS I
1. Disc 2. Guide Pin 3. Gaskets
3A. Cap 3B. Guide Pin 3C. Bonnet
RECOMMENDED SPARE PARTS 1970 & 1975 CONVENTIONAL
Qty. Parts/Same Size, Type & Material Valves In Service
1/1 1/1 1 Set/1
Need Probability Coverage
70%
27
ABD00200808
CLASS II
5. Disc Holder Assembly 5A. Disc Holder 5B. Lift Nut 5C. Retainer Ring
6. Spindle 7. Guide
CLASS III
8. Spring Assembly 9. Adjusting Screw
CLASS IV
10. Adjusting Screw Nut 11. Cap (Specify Screwed, Packed, Plain) 12. Release Nut (Used on Packed or
Plain Lever Only) 13. Release Lock Nut (Used on Packed or
Plain Lever Only)
*NOTE: Consult Spring Selection Chart before ordering Springs to determine actual quantities required in view of pressure set ting potential in each spring range.
1/5
1/5 1/5
*1/5 1/5
1/5 1/5 1/5 1/5
RECOMMENDED SPARE PARTS 1980 & 1982 PORTABLES
Class 1
1. Disc Assembly 2. Adj. Ring Pin 3. Gaskets
3A. Cap 3B. Adj. Ring Pin 3C. Bonnet
Qty. Parts/Size, Type & Material Valves in Service
1/1 1/1 1 Set/1
CLASS II 5. Spindle 6. Guide
CLASS III
7. Adj. Ring 8. Spring 9. Spring Washers 10. Adj. Screw
CLASS IV
11. Adj. Screw Locknut 12. Cap (Specify Screwed, Packed, Plain) 13. Release Nut (Used on Packed or
Plain Lever Only) 14. Release Locknut (Used on Packed or
Plain Lever Only)
*1/5 1/5
1/5 1/5 1/5 1/5
1/5 1/5 1/5
1/5
' NOTE:
Consult Spring Selection Chart before ordering Springs to determine actual quantities required in view of pressure set ting potential m each spring range.
28
85% 95% 99%
Need Probability Coverage
85% 95% 99%
ABD00200809 TUtu
29
ABD00200810
r
THE OF ;SSER FIELD SERVICE ORGANIZATION IS UNEQUALED.
For proi ipt field service, please call Dresser Industrial Valve Operation Service Department, Alexandria, Louisiana
All Hours. Manager, Field Service (318) 640-6055.
1 Alexandria LA 2 Houston, TX
3 Dallas, TX 4 Tulsa OK 5 Tuscon, AZ
6 Los Angelea CA
LOCATION OF SERVICE MEN
7 Winston-Salem, NC
8 Atlanta GA 9 Charleston, SC 10 Knoxville, TN
11 St Louia MO 12 Chicago, IL
13 Detroit, Ml 14 Charleston, WVA
15 Pittsburgh, PA
16 Philadelphia PA 17 Nashua NH
30
ABD00200811
MANUFACTURER'S FIELD SERVICE & REPAIR PROGRAM
Field Service
Process industries expect and demand service on a moment's notice. CONSOLIDATED Field Service can be depended upon, for prompt response, even in extreme off-hour emergency situations.
Dresser Industrial Valve Operation maintains the largest and most competent field service staff in the industry. Service Engineers are located at strategic points throughout the United States to respond to customer's requirements for service. Each Service Engineer is factory trained and long experienced in servicing Safety Relief Valves. Our Service Engineers restore disc and nozzle critical dimensions which af fect valve performance, and are capable of modern izing valves in the field.
It is highly recommended that the professional talents of a Dresser Field Service Engineer be em ployed to make final adjustments during the initial setting of all CONSOLIDATED Safety Relief Valves.
All Field Service Engineers' activities are coordi nated from the Alexandria, Louisiana, Field Service and Repair Office. Upon receipt of a purchase order number authorizing the trip, the man is dispatched.
Contact: Field Service Department Field Service Manager (318) 640-6055
Factory Repair Facilities
If downtime permits, it may be desirable to return the valves to the factory for repair or modernizing. The factory at Alexandria, Louisiana, maintains a
complete CONSOLIDATED REPAIR CENTER. In addition to factory production parts stock, the repair center maintains its own service parts stock room. Most important, this enables return shipment of re paired valves within forty-eight (48) hours after re ceipt of customer's purchase order.
Contact: Repair Department Repair Manager (318) 640-6058
Pick-Up & Delivery Service
To serve customers emergency requirements, our own pick-up and delivery service is available within a 250 mile radius from Alexandria, La., and Houston, TX.
Service Warrantly
Both factory and field repaired valves carry a war ranty which covers workmanship and new parts in stalled during repair, for a period of one year from date of repair completion. Contact the manager, field service if you suspect a warranty problem.
Product Repair By Unauthorized Sources
Dresser Industrial Valve Operation has authorized no out side repair companied, contractors, nor in dividuals to perform warranty repair service on new products, field or factory repaired products of its manufacture. Therefore, customers contracting such repair service from unauthorized sources must do so at their own risk. Likewise if any Dresser valve product fails to perform within the scope of its design, we must be notified and given the oppor tunity to inspect and correct the product. We will accept no back-charges for unauthorized repair sources performing corrective repairs on our products.
31
ABD00200812
CONSOLIDATED
Division Headquarters 1 2700 Northborough, Suite 620 Houston. Texas 77067 Telephone (713) 580-1 556 Telex 58-6423
Alexandria Operations Highway 71 North P.O. Box 1430 Alexandria. La. 71301 Telephone {318)640-2250 Telex 58-6423
Domestic Sales Headquarters 1 2700 Northborough. Suite 620 Houston. Texas 77067 Telephone (713)580-1556 Telex 58-6423
Northern Region 3201 North Wolf Road Franklin Park, Illinois 60131 Telephone (312) 625-5700 Telex 72-1452
Southern Region Mailing
P.O, Box 1407 Houston, Texas 77001 Telephone (713) 972-5526 Telex 79-4586 Shipping Dresser Center 10205 Westheimer, Suite 961 Houston, Texas 77042
Pacific Region 3931 MacArthur Blvd., Suite 202 Newport Beach, California 92660 Telephone (714) 752-'0455
(213)770-2057 Telex 183-539
INDUSTRIAL VALVE DIVISION
ALEXANDRIA, LOUISIANA
International Sales Headquarters 12700 Northborough. Suite 620 Houston, Texas 77067 Telephone (713) 580-1 556 Telex 58-6423
Canada Dresser Canada. Inc. Industrial Products Division Mississauga Service Centre 6688 Kitimat Road Mississauga, Ontario L5N 1P8 Telephone (416) 826-8411 Telex 97654
Dresser Canada, Inc. Industrial Products Division Cambridge Plant 200 Avenue Road Cambridge, Ontario N1R 5V7 Telephone (519) 621-3200 Telex 59322
Europe Dresser Industrial Valve Operations - Europe Badenerstrasse 1 56 P.O. Box 369 CH-8021 Zurich, Switzerland -Telephone (01) 241-0533 Telex 54389
Japan Dresser Japan, Ltd. 10th Floor-Mori Building No. 20 7-4 Nishi Shinbashi 2-chome Minato-Ku, Tokyo 105 Japan Telephone (03) 501-7781/8 Telex 222-8223 DJTOK
South Africa Dresser South Africa (Pty.), Ltd. Industrial Valve Operations Kelvin & Rigger Roads Spartan Kempton Park 1620 P.O. Box 739 Transvaal, South Africa Telephone 970-1427/8 Telex 8-6425
United Kingdom Dewrance & Company, Ltd. Trevithick Works East Gillibrands Estate P.O. Box 108 Skelmersdale, Lancashire England WN8 9TU Telephone (44) 695-24234 Telex 627039
V