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3900 MPV Series

1. Viton Fluoro Carbon Inlet Size i Orifice Valve Type Material Part No in mm 1 00 25 4 TT Se D E F 3905 10 12 Viton Fluoro Carbon 75 MORK 70V022 1 00 25 4 um T D E F 3905 10 12 Viton Fluoro Carbon 90 MORK 70V005 1 50 38 1 G H 3905 10 12 Viton Fluoro Carbon 75 MORK 71V022 1 50 38 1 G H 3905 10 12 Viton Fluoro Carbon 90 MORK 71V005 2 00 50 8 G H J 3905 10 12 Viton Fluoro Carbon 75 MORK 71V022 2 00 50 8 GH 3905 10 12 Viton Fluoro Carbon 90 MORK 71V005 3 00 76 2 J K L 3905 10 12 Viton Fluoro Carbon 75 MORK 72V022 3 00 76 2 JKA 3905 10 12 Viton Fluoro Carbon 90 MORK 72V005 4 00 101 6 L M N P 3905 10 12 Viton Fluoro Carbon 75 MORK 73V022 4 00 101 6 L M N P 3905 10 12 Viton Fluoro Carbon 90 MORK 73V005 6 00 152 4 Q R 3905 10 12 Viton Fluoro Carbon 75 MORK 74V022 6 00 152 4 Q R 3905 10 12 Viton Fluoro Carbon 90 MORK 74V005 8 00 203 2 T 3905 10 12 Viton Fluoro Carbon 75 MORK 75V022 8 00 203 2 2 3905 10 12 Viton Fluoro Carbon 90 MORK 75V005 1 50 38 1 Full Bore 3905 10 12 Viton Fluoro Carbon 75 MORK 71V022 1 50 38 1 Full Bore 3905 10 12 Viton Fluoro Carbon 90 MORK 71V005 3 00 76 2 Full Bore 3905 10 12 Viton Fluoro Carbon 75 MORK 73V022 4 00 101 6 Full Bore 3905 10 12 Viton Fluoro Carbon 75 MORK 76V022 4 00 101 6 Full Bore 3905 10 12 Viton Fluoro Carbon 90 MORK 76V005 6
2. N Spring Seal Adjuster Top Spring Seal Insert Field Test Connector Vent Assembly Bug Screen Field Test Connection 25 Vent Assembly Bonnet Vent 27 Set Screw Bonnet 34 Top Plate 36 Modulator Base 37 Modulator Stop 56 Modulator Piston Top 39 Modulator Piston Bottom 40 O ring Retainer 41 Lock Screw Retainer 42 Cap Screw Modulator N 1 Main Base Adjuster Cap 5 Adjuster Top 7 j 4 Adjuster Bottom 5 Adjuster Lock Nut 29 6 Compression Screw 7 Compression Screw Lock Nut 8 8 Spring Washer 9 Spring 9 10 Insert Top Lei 11 Insert Bottom 32 S d 12 Main Piston 4 RA 13 Cap Compression Screw 20 lt lt S 14 Cap Screw Top Plate SEP Li e 15 O ring Adjuster Bottom 54 d S 16 O ring Adjuster Top gees 17 O ring Insert 27 32 s a 25 16 O ring Top Plate an J 19 Bonnet __ d 20 Spring Seal Main Piston we Qe SE SSI N CA bi D RA LT H ik STI Z Kee SS y 2 sepe BSNS N EES G OOOH WZ NS e NN 2202 CL Lids 4 AAN NN d N NI WAN NN N ESHOOOOOOO 758 97 45 Socket Head Cap Screw IZ SS E Modulator SHOWN 90 44 O ring Modulator Base SEN 45 O ring Modulator Stop Figure 4 39MVO7 Pilot Valve Construction 46
3. Set Pressure Lapped Seat Width Valve min max min max psig barg psig barg in mm in mm 15 1 03 50 3 45 012 0 30 018 0 46 51 5 52 100 6 89 018 0 46 025 0 64 1 00 25 4 mm 101 6 96 250 17 24 025 0 64 032 0 81 DEF 251 17 51 400 27 58 032 0 81 038 0 97 1 50 38 1 mm 401 27 65 800 55 16 038 0 97 045 1 14 D E F 801 5523 1000 68 95 045 1 14 055 1 40 055 005 13 97 0 13 mm per 100 psig 6 89 bar Bree Waaa 0 005 1 78 Sei Ge 15 1 03 50 3 45 019 0 48 025 0 64 51 3 52 100 6 89 025 0 64 029 0 74 1 50 38 1 mm GH 101 6 96 250 17 24 029 0 74 032 0 81 1 50 38 1 mm 251 17 31 400 27 58 032 0 81 038 0 97 Full Bore 401 27 65 800 55 16 038 0 97 045 1 14 2 00 50 8 mm 801 55 23 1000 68 95 045 1 14 055 1 40 SS 055 005 13 97 0 13 mm per 100 psig 6 89 barg nd La SE 0 070 0 005 1 78 0 13 mm max 32 GE 0il amp Gas XIII Maintenance Instructions Contd Table 3 Approximate Nozzle Seat Width Standard Metal Seat Contd Set Pressure Lapped Seat Valve min max min max psig barg psig barg in mm in mm 15 1 03 50 245 025 0 64 030 0 76 51 3 52 100 6 89 030 0 76 035 0 89 2 00 50 8 mm 101 6 96 250 17 24 035 0 89 040 1 02 Full Bor
4. Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 47 XVI Disassembly of Pilot Valve Contd m d gav 6 Figure 25 39MV22 Disassembly 48 GE Oil 8 Gas XVI Disassembly of Pilot Valve Contd ORO ai Figure 26 39MV72 Disassembly Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 49 XVI Disassembly of Pilot Valve Contd A DANGER D Cleaning 1 Clean parts to remove all rust burrs scale organic matter and loose particles Parts are to be free of any oil or grease except for lubrication as specified in this instruction 2 Cleaning agents used shall be such that effective cleaning is assured without injuring the surface finishes or material properties of the part 3 Acceptable cleaning agents include demineralized water non phosphate detergent acetone and isopropyl alcohol Parts must be blown dry or wiped dry after cleaning 4 If you are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the Follow recommendations solvent s material safety data sheet for safe handling recommendations and for safe handling in the personal protective equipment solvent s Material Safety 5 Data Sheet and observe safe practices for any cleaning method
5. T ET 4 T gt lt er gt 4 lt lt B B w N min P N min N min A C zl zk e d y e Figure 18 Metal and Soft Seat Disc Inspection Areas Table 5 Minimum T and N Dimensions for Standard Disc Inlet Size T min N min Orifice Type in mm in mm in mm 1 00 25 4 D EF 1 179 4 55 010 0 25 1 50 38 1 D EF 1 179 4 55 010 0 25 1 50 38 1 G H 1 394 10 01 020 0 51 2 00 50 8 G H J 1 394 10 01 020 0 51 3 00 76 2 J K L 2 510 12 95 038 0 97 4 00 101 6 L M N P 1 693 17 60 068 1 73 6 00 152 4 QR 3 693 17 60 068 1 73 8 00 203 2 3 905 22 99 068 1 73 1 50 38 1 Full Bore 1 594 10 01 020 0 51 2 00 50 8 Full Bore 2 510 12 95 038 0 97 3 00 76 2 Full Bore 1 693 17 60 068 1 73 4 00 101 6 Full Bore 4 693 17 60 068 1 73 6 00 152 4 Full Bore 3 905 22 99 068 1 73 8 00 203 2 Full Bore 5 1 012 25 70 068 1 73 10 00 254 0 Full Bore 5 1 012 25 70 068 1 73 12 00 304 8 Full Bore N A N A N A N A N A Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 37 XIV Inspection of Main Valve 1 Guide Check ID for galling or scratch marks especially around the guide and seal surface areas Check o ring energize seal contact area for any corrosion or scratched surfaces that might cause a leak Replace the guide if a Visible galling is present on the inside guiding surface as the A min dimension has been
6. PSGKF 51 PSGKF 31V N A 39PV07 1 6S amp LS PSGKF 53B PSGKF 33E PSGKF 33V N A 39PV07 2 GS amp LA PSGK 58B018 PSGK 58E019 PSGK 58V022 Note 2 39PVO7 2 SS PSGK 38E00 N A PSGK 581006 39PV37 1 GS amp LS PSGK 55B018 PSGK 55E019 PSGK 35V022 N A 39PV37 2 GS amp LA N A PSGK 358018 PSGK 55E019 PSGK 35V022 Note 2 39PV37 2 SS 39MVO1 07 amp 37 GS PSGK 32B018 39MVO1 07 37 LS3 N A PSGK 34B018 N A PSGK 32E019 PSGK 54E019 N A PSGK 32V022 PSGK 54V022 PSGK 551006 Note 39MV 07 37 SS N A PSGK 54E002 N A PSGK 34T006 39MV22 LA amp GS PSGK 468018 PSGK 46E019 PSGK 46V022 PSGK 461006 39MV72 LA amp GS PSGK 478008 PSGK 47E002 PSGK 47V005 PSGK 47T005 NOTE 1 For steam service at pressures below 50 psig 3 45 barg the 39PV07 2 SS or 39MVO7 2 SS with EPR O rings should be used E962 90 NOTE 2 For services other than steam consult applications engineering NOTE 3 This kit contains modulator o rings only In addition to this psgk kit the Comparable PV PSGK kit is also required Example 39MV07 2 LS with Viton O rings would require a PSGK 34V022 and a PSGK 38V022 Table 21 Pilot Valve O ring Kit Options Options Buna N Ethylene Propylene Viton Te
7. 0 10 12 999 330 17 3 359 85 32 45 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 31 XIII Maintenance Instructions Contd C Lapped Nozzle Seat Widths A wide nozzle seat will induce leakage especially in the smaller orifice lower pressure valves For this reason the seat of valves other than o ring valves should be as narrow as practical Since the seat must be wide enough to carry the bearing load imposed upon it by the pressure force the higher pressure valves must have wider seats than the lower pressure valves The nozzle seat width should conform to the measurements in Tables 3 or 4 JA yr EH mm Measuring a Magnifier Nozzle A Figure 14a Measuring Magnifier To measure the seat width use a Model S1 34 35 37 Bausch amp Lomb Optical Co measuring magnifier or an equivalent seven power glass with a 750 19 05 mm scale showing graduations of 005 0 13 mm Figures 14a and 14b illustrate the use of this tool in measuring the nozzle seat width If additional lighting is required for measuring use a gooseneck flashlight similar to the Type A Lamp Assembly Standard Molding Corp or equivalent Flat Seat 5 Taper Figure 14b Magnifier Details Figure 14 Measuring Magnifier Table 3 Approximate Nozzle Seat Width Standard Metal Seat
8. 12 EPR Ethylene Propylene 90 MORK 72E002 4 00 101 6 L M N P 3905 10 12 EPR Ethylene Propylene 90 MORK 73E002 6 00 152 4 Q R 3905 10 12 EPR Ethylene Propylene 90 MORK 74E002 8 00 203 2 T 3905 10 12 EPR Ethylene Propylene 90 MORK 75E002 1 50 38 1 Full Bore 3905 10 12 EPR Ethylene Propylene 90 MORK 71E002 3 00 76 2 Full Bore 3905 10 12 EPR Ethylene Propylene 90 MORK 73E002 4 00 101 6 Full Bore 3905 10 12 EPR Ethylene Propylene 90 MORK 76E002 6 00 152 4 Full Bore 3905 10 12 EPR Ethylene Propylene 90 MORK 75E002 8 00 203 2 Full Bore 3905 10 12 EPR Ethylene Propylene 90 MORK 77E002 10 00 254 0 Full Bore 3905 10 12 EPR Ethylene Propylene 90 MORK 78E002 1 00 25 4 DEF 3914 16 EPR Ethylene Propylene 90 MORK 70E002 1 50 38 1 1 50 38 1 G H 3914 16 EPR Ethylene Propylene 90 MORK 71E002 2 00 50 8 G H J 3914 16 EPR Ethylene Propylene 90 MORK 71E002 3 00 76 2 J KL 3914 16 EPR Ethylene Propylene 90 MORK 72E002 4 00 101 6 L M N P 3914 16 EPR Ethylene Propylene 90 MORK 73E002 NOTE 1 Nitrile 70 For Freon 134 Ester Oil Service Neoprene Silicon amp Kalrez Seals are available POA NOTE 2 If repairing a 3900 Metal Seat Design the seat o ring in the above kits will not be used 82 GE Oil amp Gas XXV Recommended Spare Parts Contd Table 19 Main Valve O ring Kits Contd Teflon Inlet Size Orif
9. K L 066 1 68 066 1 68 2 525 002 64 14 0 05 2 400 002 60 96 0 05 2 999 76 17 2 359 59 92 45 4 00 1101 6 ny 095 2 41 095 2 41 3 622 002 92 00 0 05 3 472 002 88 19 0 05 4 374 111 10 2 734 69 44 45 6 00 152 4 Q R 096 2 44 096 2 44 5 795 003 147 19 0 08 5 645 003 143 38 0 08 5 999 152 37 2 859 72 62 45 8 00 203 2 T 096 2 44 096 2 44 6 510 003 165 35 0 08 6 315 003 160 40 0 08 7 249 184 12 3 484 88 49 45 1 50 58 1 1 5 066 1 68 066 1 68 1 836 002 46 63 0 08 1 711 003 43 46 0 08 1 936 49 17 1 984 50 39 45 2 00 50 6 2 0 066 1 68 066 1 68 2 525 005 64 14 0 08 2 400 003 60 96 0 08 2 999 76 17 2 359 59 92 45 3 00 76 2 3 0 095 2 41 095 2 41 3 622 005 92 00 0 08 3 472 003 88 19 0 08 4 374 111 10 2 734 69 44 45 4 00 101 6 4 0 095 2 41 095 2 41 4 195 003 106 55 0 08 4 045 003 102 74 0 08 4 874 123 80 2 734 69 44 45 Full Bore 6 00 152 4 6 0 096 2 44 096 2 44 6 510 003 165 35 0 08 6 315 003 160 40 0 08 7 249 164 1 3 484 88 49 45 8 00 203 2 8 0 127 5 25 12 5 25 8 071 003 205 00 0 08 7 831 003 198 91 0 08 8 499 215 87 2 484 63 09 45 10 00 254 0 10 0 127 3 23 127 3 23 10 260 003 260 60 0 08 10 018 003 254 46 0 08 10 499 266 67 2 859 7
10. Keep work materials clean Always use a fresh lap If signs of wear out of flatness are evident recondition the lap 2 Apply a very thin layer of lapping compound to the lap to prevent rounding off the edges of the seat 3 Keep the lap squarely on the flat surface and avoid rocking the lap which causes rounding of the seat 4 When lapping keep a firm grip on the lapped part to prevent dropping it and damaging the seat 5 Lapin a circular motion while applying a uniform pressure Slowly rotate the lap to evenly distribute the lapping compound Wipe off the old compound and replace it with new compound frequently Apply more pressure to speed the cutting action of the compound To check the seating surfaces remove all compound from the seat and the lap Then shine the seat with the same lap using the lapping method as described above Low sections on the seating surface show up as shadow in contrast to the shiny portion If shadows are present further lapping is necessary Only laps known to be flat can be used It should take only a few minutes to remove the shadows 6 When lapping is complete any lines appearing as cross scratches can be removed by rotating the lap on its axis which has been wiped clean of compound on the seat Thoroughly clean the lapped seat using lint free cloth and a cleansing fluid Before assembly grind the contact surfaces of the nozzle and o ring retainer to provide metal to metal seat
11. XII Disassembly of the 3900 POSRV Contd Figure 11 Soft Seat Valve Disassembly Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 27 XII Disassembly of the 3900 MPV Series POSRV Contd li Start inserting special drift pins into the holes in the disc holder Figure 12 with the tapered portion of the pins working against the top of the disc as indicated See Figure 62 and Table 17 in the Maintenance Tools and Supplies section Section XXII D for drift pin size ii Use q light machinist hammer to tap each pin alternately until the disc snaps out of the recess in the disc holder b For8 and 10 full bore valves remove the disc from the disc holder as follows i Turn the disc holder on its side li Remove the retaining bolts lii Attach the lifting lug to the disc and lift out 9 O ring Disc Disassembly The o ring seat requires the Lock Screw s on the bottom of the Disc to be removed by turning counterclockwise so that the o ring Retainer and Seat o ring can be removed 10 If the nozzle requires rework or replacement remove the nozzle from the base by unscrewing counterclockwise with the appropriate socket or spanner wrench shown in Figure 61 and Table 16 C Cleaning A DANGER this instruction dry after cleaning Follow recommendations for safe handling in the solvent s Material Safety Data Sheet and observe safe practices for any cleaning metho
12. sealing on these surfaces Insert Top Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Insert Bottom Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Adjuster Top Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Adjuster Bottom Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Top Plate Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Bonnet Check for any corrosion or pitting Also check for galling of threads for the compression screw and where it attaches to the pilot base Compression Screw Galling at the spherical bearing surface or in the thread Check for any corrosion or pitting Spring Washer s Galling at the spherical bearing surface Check for any corrosion or pitting Pilot Base Check for any corrosion or pitting Also check for galling of threads Spring Check for any corrosion or pitting Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 51 XVII Part Inspection of Pilot Valve Contd 12 Modula
13. vent and inlet seals never come in contact with the dirty system media The process media pressure still controls the set pressure and blowdown of the POSRV 7 7 SHOWN 90 OUT OF POSITION 1 4 18 NPT Dirty Media Source Figure 43 39PVO7 37 Dirty Service 7S Media M ource 3 1 4 18 NPT AN Dirty Media j N SHOWN 90 Source OUT OF POSITION Figure 44 39MVO7 Dirty Service ZE 5 G SHOWN 90 OUT OF POSITION 1 4 18 NPT Dirty Media Source Clean Media Source v Nomenclature 1 Main Base 2 Adjuster Cap 3 Adjuster Top 10 Insert Top 11 Insert Bottom 12 Main Piston 14 Cap Screw Top Plate 16 O ring Adjuster Top 17 O ring Insert 16 O ring Top Plate 20 Spring Seal Main Piston 21 Spring Seal Adjuster Top 22 Spring Seal Insert 26 Pipe Plug Pilot Valve 29 Piston Retainer Nut 50 Set Screw Piston 31 Vent Seal Adaptor 32 Spring Seal Vent Seal Adaptor 50 Dirty Insert 51 Omni Plug 52 Breather Filer Vent B NSS N NS Yi T 4 CL gt To Main Valve Dome A NNE N NN N Figure 45 39MV22 72 Dirty service Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 67 XXI 3900 MPV Series POSRV Options Contd B Di
14. 3 or Table 4 it does not require machining b To reduce the seat width the 5 angle surface must be machined The nozzle must be replaced if the H dimension is reduced below the minimum as indicated in Tables 2a or 2b Standard Metal Seated Disc This disc Figure 18 can be machined until the T dimension is reduced to the minimum as listed in Table 5 The N min dimension must be maintained as well Thermodisc Metal Seated Disc This disc Figure 19 cannot be machined It can be lapped as long 38 GE Oil amp Gas 2z Z25 Ee View D A VIEW D Figure 19 Thermodisc Design Table 6 Minimum A Dimension for Thermodisc Inlet Size R A min Orifice Type in mm in mm 100 254 DEE 1 006 0 15 150 3841 D E F 1 006 0 15 150 3841 G H 2 008 0 20 2 00 508 G H J 2 008 0 20 3 00 76 2 JK L d 011 0 28 4 00 101 6 L M NP 2 012 0 30 6 00 152 4 QR 2 016 0 41 8 00 203 2 T 2 024 0 61 150 3841 Full Bore 2 008 0 20 2 00 508 Full Bore 2 011 0 28 3 00 76 2 Full Bore 2 012 0 30 4 00 101 6 Full Bore 2 016 041 6 00 1524 Full Bore 2 024 0 61 8 00 203 2 Full Bore 2 022 0 56 10 00 254 0 Full Bore 2 022 0 56 XIV Inspection of Main Valve Contd 9 O ring Seated Disc The o ring retainer cannot instruction Other valve parts may be acceptable with be machi
15. Consolidated Industrial Valve Operation conducts service seminars that can help your maintenance and engineering personnel to reduce these costs Seminars conducted either at your site or at our Alexandria Louisiana manufacturing plant provide participants with an introduction to the basics of preventive maintenance necessary to minimize downtime reduce unplanned repairs and increase valve safety While these seminars do not make instant experts they do provide the participants with Hands On experience with Consolidated Valves The seminar also includes valve terminology and nomenclature component inspection trouble shooting setting and testing with emphasis on the ASME Boiler and Pressure Vessel Code For further information Please contact the Product Training Manager by fax at 318 640 6325 or telephone 518 640 2250 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 87 DIRECT SALES OFFICE LOCATIONS AUSTRALIA TALY SOUTH AFRICA Brisbane Phone 39 081 7892 111 Phone 27 11 452 1550 Phone 61 7 3001 4319 Fax 39 081 7892 208 Fax 27 11 452 6542 Fax 61 7 3001 4399 JAPAN SOUTH amp CENTRAL Perth Chiba AMERICA AND THE CARIBBEAN Phone 61 8 6595 7018 Phone 81 43 297 9222 Phone 55 12 2134 1201 Fax 61 8 6595 7299 Fax 81 43 299 1115 Fax 55 12 2134 1238 Melbourne OREA SPAIN Phone 61 3 8807 6002 Phone 82 2 2274 0748 Phone 34 93 652 6430 Fax 61 3
16. O ring Modulator Seat 47 O ring Modulator Piston Bottom 48 Spring Seal Piston Bottom 49 Spring Seal Piston Top Note 1 Standard material is a filter plug For special materials vent assembly is supplied 18 GE Oil amp Gas IX Consolidated 3900 MPV Series POSRV Contd E 39MV22 MV72 Pilot Valve Standard Service Part No Nomenclature 33 1 Main Base 6 4 2 Adjuster Cap E J 3 Adjuster Top Bebe E 4 Adjuster Bottom 19 Fe i 5 Adjuster Lock Nut 8 6 Compression Screw 9 7 Compression Screw Lock Nut 8 Spring Washer 9 Spring m mar 10 Insert Top 34 25 11 Insert Bottom 27 12 Main Piston S d 13 Cap Compression Screw 23 2 iis gt gt N 14 Cap Screw Top Plate SV N 18 24 jf 2 15 O ring Adjuster Bottom Gr an M N 16 O ring Adjuster Top KY 30 17 O ring Insert Ehe Hy Arda 1 Iq A A 29 18 O ring Top Plate 2 RES Qu KA A 31 19 Bonnet TRAE iG GEI 1 4 i 20 Spring Seal Main Piston 2 A A 21 Spring Seal Adjuster Top a7 A geg D pring Seal Adjuster Top j H A 22 Wyte FE 22 Spring Seal Insert Gy 23 Field Test Connector 16 S YG a5 zu Vent Assembly Bug Screen aj 2 ZA G Field Test Connection A d 3 4
17. Safety Relief Valves H Operating Pressure The gauge pressure to c which the vessel is normally subjected in service A suitable margin is provided between operating pressure and maximum allowable working pressure For assured safe operation the operating pressure should be at least 1096 under the maximum allowable working pressure or 5 psig 0 34 bar whichever is greater Overpressure A pressure increase over the set pressure of the primary relieving device Overpressure is similar to accumulation when the relieving device is set at the maximum allowable working pressure of the vessel Normally overpressure is expressed as a percentage of set pressure Pilot Operated Safety Relief Valve POSRV A pressure relief valve in which the major relieving device is combined with and is controlled by a self actuated auxiliary pressure relief valve Rated Capacity The percentage of measured flow at an authorized percent overpressure permitted by the applicable code Rated capacity is generally expressed in pounds per hour lb hr or kg hr for vapors standard cubic feet per minute SCFM or m3 min for gases and in gallons per minute GPM or Liter min L min for liquids Safety Relief Valve SRV An automatic pressure relieving device used as either a safety or relief valve depending upon application The SRV is used to protect personnel and equipment by preventing excessive overpressure M Set Pressure
18. VERRE P E ed W anda b v aad AS obs 14 B Pilot Valve Introd HO Hi eo yee K i da e a y Sa Say ooo dedi wae g re edd 14 Main Valve Introduction 43 thee cet et EX HERE RERIESE e EE Mo W n enga dd 15 Consolidated 3900 Series POSRV 5 lone x and cede ee a eif ee kk kk kk k ee 16 A Metal Seat Valve sie e ibo k Hin k n ha n RARO rer hee hek ERREUR W ordained arn AAR RE 16 Ee dE 16 C 39PVO7 37 Pilot Valves Standard Service 17 D 39MVO7 Pilot Valve Standard Service 18 E 39MV22 MV72 Pilot Valve Standard Service AWW Wek KK KK kK KK KK eee 19 Operating Principles s s s k kwan 0 20 A 3900 MPV Series Type 39PV Pilot Operational Description 20 B 3900 MPV Series Type 39MVO7 Modulating Pilot Operational Description 22 General Planning for Maintenance cick ieee orbe y Ra e hh eee n 24 Disassembly of the 3900 MPV Series 006055555 5655 5 25 A Removal of Pilot Valve From Main Vale seeds dese ha ban bay n yey ak ale Leia ee he 8 8 4 25 B Bisassembly or Mairi Valves cce ics du het pere EPI y k A4022 ei bd ds DC WAN wate kenl k a n 25 LONE GI so o e OW RE CROIRE 28 Maintenance Instructions See EE ENEE eet RR OR kk lk kk e 29 A GeneralilntOBTidHloL s cge 29 522
19. actuated auxiliary pressure relief valve Note Source ASME Code Section VIII Div 1 Paragraph UG 126 POSRV s are used on hundreds of different applications including liquids and hydro carbons therefore the valve is designed to meet many requirements The Consolidated 3900 MPV Series valves included in this manual may be used to meet the requirements for ASME Section and Section VIII They cannot be used on ASME Section steam boilers or superheaters but may be used on process steam The Consolidated Modular Pilot Valve MPV is designed to provide reliable performance characteristics and stable operation within a pressure range of 15 to 6250 psig 1 03 to 430 92 barg B Pilot Valve Introduction Standard pilot construction consists of 316SS parts with nitrile o rings and nitrile diaphragms only 07 classes with Teflon amp based seals throughout Alternate materials can be provided by contacting the factory Pilot Valve Features One pilot fits all main valves Standard o ring seals Superior seat tightness Accurate adjustment of blowdown and set point Positive closure after blowdown Reduces icing and clogging Dual pilots Dual fillers om NS n PWN Field test connection 10 Remote Sensing 11 Optional sensing line filler 12 Backflow preventer 13 Manual blowdown 14 Pressure differential switch 15 External blowdown adjustments Service and Applications Main valve pressure and te
20. at X until dimension A is obtained c Machine bore diameter G until dimension E is Disc obtained Re establish angle P d The nozzle is now ready for lapping e When the minimum dimension J is reached the nozzle should be discarded 4 Machining Procedure O ring Seat See Figure 13a and Table 2b a Take light cuts across Surface E 50 45 for 12 fullbore until the damaged areas are removed Turn to the smoothest possible finish i M Figure 17 Machining the Disc Seat b Cut back the outside surface X until dimension A is obtained I 1 Grip the disc in a four jaw independent chuck or collet if appropriate using a piece of soft d When the minimum dimension J is reached the material such as copper or fiber between the jaws nozzle should be discarded and the disc as shown at A c Machine radius D 2 True up the disc so that the surface marked B and C run true within 001 0 03 mm TIR 3 Make light cuts across the seating surface L until damaged areas are removed Turn to the smoothest possible finish 4 The disc is now ready for lapping 5 Discard the disc if the minimum dimension N or T Figure 18 Table 5 is reached Do not reestablish surface C Do not remachine a ThermodiscQ or o ring retainer 36 GE 0il amp Gas XIII Maintenance Instructions Contd Figure 18a Figure 18b Figure 18c Figure 18d Figure 18e Type 1 Type 2 Type 3 Type 4 Type 5
21. greater degree of tightness because the increasing operating pressure works to force the o ring against the metal seat When the valve opens there is no pressure build up in the o ring chamber as the slots vent the pressure to a lower pressure area This design features a secondary metal to metal seat which becomes effective if o ring integrity is lost The beveled seat and disc guide the o ring into position eliminating rubbing and abrasion Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 15 IX Consolidated 3900 MPV Series POSRV A Metal Seat Valve e VEINS Pe ON ane Aa S NL N 12 Disc Holder Seal 13 Guide Rings 14 Stud Cap Screw 15 Nut 18 Seat O ring 19 Lock Screw D 10 Disc Retainer 11 Disc Holder 16 Disc Seal 17 O ring Retainer LLP LIL ba Wi Soft Seat 1 N HL NU A NSS AN 11 MISEKS N vT j Metal Seat SE Figure 2 Main Valve Construction Soft Seat Valve Figure 1 Main Valve Construction B 2 2 2 9 Q lt r fin fe 9 16 GE Oil amp Gas IX Consolidated 3900 MPV Series POSRV Contd C 39PV07 37 Pilot Valves Standard Service de Nomenclature 1 Main Base 2 Adjuster Cap 3 Adjuster
22. installing valvels 2 CAUTION Wear hearing protection when testing or operating valves 3 CAUTION Wear appropriate eye and clothing protection 4 CAUTION Wear protective breathing apparatus to protect against toxic media Note Any Service questions not covered in this manual should be referred to GE s Service Department Phone 318 640 6055 Restoring Safety Appropriate service and repair is important to safe reliable operation of all valve products Restoration to original quality and manufacturing specifications will accomplish the desired results Procedures developed by GE as described in the applicable Installation and Maintenance Manual when correctly applied will be effective Il Safety Notice Proper installation and start up is essential to the safe and reliable operation of all valve products The relevant procedures recommended by GE and A CAUTION described in these instructions are effective methods of performing the required tasks It is important to note that these instructions contain various safety messages which should be carefully read in order to minimize the risk of personal injury or the possibility that improper procedures will be followed which may damage the involved GE s Consolidated product or render it unsafe It is also important to understand that these safety messages are not exhaustive GE s Consolidated can not possibly know evaluate and advise any customer of all of t
23. maintained If lapping does not fix damaged area part must be discarded Replace the ThermodiscQ if a Seat defects and damage cannot be lapped out without reducing the A dimension in Figure 19 and listed in Table 6 If the dimension cannot be measured replace the Thermodisc b Cover plate o ring seating areas are pitted and cause the valve to leak between the cover plate and base Base Inspect general condition for cracks or holes Look for any corrosion issues Cover plate Inspect general condition for cracks or holes Look for any corrosion issues O ring Retainer Inspect surface that sits on the disc for any corrosion or defects that might cause the disc not to sit flush with nozzle Spring Check for any corrosion issues that might cause the spring not to operate as designed Nozzle should be replaced if a Dimension from seat to shoulder after remachining and lapping is less than A min on Table 2 3 or 4 b Threads are damaged from pitting and or corrosion C Bottom of flange and intersecting surface are damaged from galling and or tearing d Seat width is outside specification Table 3 and Table 4 Nozzle Seat Width for Metal Seated Valves a Using a measuring magnifying glass see Lapped Nozzle Seat Widths determine whether the finish lapped seat surface must be machined before lapping If the seat can be lapped flat without exceeding the required seat width as indicated in Table
24. minutes for sizes 6 152 4 mm and 8 203 2 mm Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 61 XIX Setting and Testing Contd 4 Theleakage rate in bubbles per minute shall not exceed the values in Table 13 a Main valve equipped with metal seats and water as the test media i Noleakage shall be detected by sight or feel for one minute when pressure is held at 496 below valve set pressure or 2 psig 0 14 barg whichever is greater b Media valve equipped with metal seats and steam as the test media i Leak tightness shall be checked visually using a black background There shall be no visual or audible leakage after the interior or the valve is allowed to dry after popping The leak test pressure shall be when pressure is held at 4 below valve set pressure or 2 psig 0 14 barg whichever is greater c Blowdown is long only consider if system is capable of flowing valve at 10 overpressure d Set point cannot be adjusted to consistently release at 2 of unit ticket set pressure or 2 psig 0 14 barg whichever is greater 5 Repeat set point verification tests 3 times a Inlet pressure ramp guidelines i When set pressure is below or equal to 750 psig 51 7 barg the inlet pressure ramp should not exceed 0 5 psig 0 03 barg per second when test pressure is within 90 of set pressure ii When set pressure is above 750 psig 51 7 barg the inlet pres
25. of pilot operated safety relief valve metal seats and of the disc from the disc holder Refer Figure 62 and may be purchased from GE Table 17 for drift pin specifications 1 Ring Lap The ring lap is used for lapping the disc seat and finish lapping of the nozzle seat n gt 2 Lapping Plate The lapping plate is used for reconditioning the ring lap It may also be used for lapping the disc One 11 279 40 mm diameter plate is required for the entire line of valves Part No 0439004 45 B Diameter Lapping Compound Lapping compound is used as a cutting medium when lapping the valve seats as specified in Table 16 Table 16 Lapping Compound Types P Figure 62 Drift Pin Specifications Brand Grade Grit Lapping Function Size Container Part No Clover 1A 320 General 4 02 199 3 Clover 3A 500 Finishing 4 02 199 4 Kwik Ak Shun 1000 Polishing 1 5 199 11 2 Ib 199 12 A B Orifice Part No in mm in mm D E F G H J 2 50 8 mm 1 5 38 1 mm FB J 3 76 2 mm 2 50 8 mm FB K L 3 76 2 mm 8 203 2 mm FB 2 500 63 50 0 313 7 94 10 254 0 mm FB 3 76 2 mm FB L M N P 4 101 6 mm FB 2 500 63 50 0 438 1141 Q R 6 152 4 mm FB T 1 750 44 45 0 219 5 56 430401 76 GE Oil amp Gas XXIII Replacement Parts Planning A Basic Guidelines The following guidelines should be of assistance i
26. seal adaptor onto the spring spring seal side going in first seal adjuster bottom with flat side up 58 GE Oil amp Gas XVIII NOTE NOTE Lightly lubricate o ring 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 Place o ring insert into groove Final insert assembly is shown in figure 30 Turn insert assembly over and thread into pilot base with t handle groove wrench part 4995401 figure 60 Tighten wrench tight Make sure milled slot is facing up Lubricate main piston stem and cycle main piston through spring seal insert five times For dirty service option please refer to Dirty Service Option Section Section XXI B for assembly instructions Install o ring top plate into groove on top of pilot base for dirty service option o ring top plate is installed into groove on top of the dirty service insert 39MV22 i Lubricate the spring seal main piston and top plate gland Install the spring seal main piston into top plate The spring should be oriented as shown in figure 32 li Lubricate main piston before installing Install the main piston into the top plate with the spring washer bearing point going in first Be careful not to damage the spring seal main piston 39MV72 i Lubricate the backup rings Back up ring upper should be installed first with angle surface facing you when insta
27. the insert assembly a 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 60 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 Remove adjuster cap from the bottom of the pilot base by turning counterclockwise Loosen adjuster lock nut by turning counterclockwise Removing the adjuster assembly a The adjuster assembly consists of 1 Adjuster Top 1 Adjuster Bottom 1 Balance Seal Adaptor 1 O ring Adjuster Top 1 O ring Adjuster Bottom 1 Spring Seal Adjuster Top 1 Spring Seal Adjuster Bottom Turn adjuster assembly clockwise counting the number of flats until assembly stops Record number of flats for reassembly 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 Disassemble adjuster top from the adjuster bottom by turning adjuster top counterclockwise Remove the balance seal adaptor from the adjuster top Remove and discard the spring seal adjuster top and spring seal adjuster bottom Refer to field test connection backflow preventer option Section XXI A for disassembly of field test connection
28. the lock screw Lightly tapping the wrench with a hammer will force the modulator piston assembly into the modulator base Install both o rings modulator stop into grooves on modulator piston stop Insert modulator stop into modulator base with the seat going in first Make sure the side hole in the modulator stop is facing towards the flat side of the modulator base Thread the cap screws modulator through the modulator stop into the modulator base Tighten to 365 30 in lbs 41 2 3 4 N m Do not install modulator assembly at this time Making the Main Pilot Making the main piston assembly d Insert the piston nose into the recess at the threaded end of the piston top b Slide the piston nut over the piston nose and thread it onto the piston top Place the assembly in a vice with soft jaws and torque the piston nut to 30 3 ft lbs 40 624 N m c Install the set screw into the threaded hole of the piston nut and hand tighten Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 57 XVIII Reassembly of Pilot Valve Contd 2 Making the adjuster assembly e Thread adjuster top clockwise onto adjuster This assembly consists of bottom and torque to 27 2 ft lbs 37 2 7 N m 1 Adjuster Bottom f Lubricate main piston stem and cycle main piston through spring seal adjuster top and 1 Adjuster Top spring seal vent seal adaptor five times 1 Balance Seal Adaptor NOTE
29. to receive the dome pressure to atmospheric inlet seal is reopened in the pilot The main valve inlet pressure The main valve disc is allowed to lift off the pressure is again allowed to enter the dome above the seat as the fluid force overcomes the now removed main valve disc As the dome pressure equalizes with pressure load above the main valve disc The valve the inlet pressure the downward force created by the discharges to relieve system pressure differential areas of the disc closes the main valve Figure 7 PV Valve Open Relieving Position Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 21 X Operating Principles Contd B 3900 MPV Series Type 39MVO7 Modulating Pilot Operational Description 39MVO7 Valve Closed Normal Position System pressure from the main valve inlet is fed to the dome by the pilot through interconnecting tubing This equalizes the pressure on the top of the disc with inlet pressure on the seating surface bottom of the disc Since the area on the top of the disc is larger than the area of the seating surface the differential area results in a net download force keeping the main valve tightly closed Figure 8 MVO7 Valve Closed Normal Position 22 GE 0il amp Gas X Operating Principles Contd 39MVO7 Valve Modulating Partial Relieving Position As the inlet pressure increases the pilot pi
30. valves which show leaks in backpressure testing may be attempted by tightening the joint involved to normal tightness while the valve is in the testing area If such procedure does not correct the leak the valve is to be returned to the assembly department with a notation as to cause for rejection The valve is to be examined for cause of failure t Saz corer e lt cx A SOOO lt gt dch SE KEK COO Ze SN RK OX lt 52526 lt lt KX 22 Ge Ke Rex PAL E GC la x jo Figure 39 Field Test Connector Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 63 XIX Setting and Testing Contd D Field Testing of POSRV Assembly area thereby allowing only the pilot to actuate The system shown below is available for remote or local 1 Field Test Connection Figure 39 testing A 250 6 35 mm FNPT field test connection is standard on all pilot valve types This allows the stroking of the valve with an auxiliary media e g air or nitrogen An internal check valve is present in the field test connection isolating the inlet media from the test media and at the same time allowing the valve to open normally in the event of a system overpressurization during a field test 2 Pilot Valve Tester Figure 40 The pilot valve test indicator is available for the modulating and pop action pilot valves The valve tes
31. 00 152 4 Full Bore 3905 10 12 Viton Fluoro Carbon 75 MORK 75V022 6 00 152 4 Full Bore 3905 10 12 Viton Fluoro Carbon 90 MORK 75V005 8 00 203 2 Full Bore 3905 10 12 Viton Fluoro Carbon 75 MORK 77V022 8 00 203 2 Full Bore 3905 10 12 Viton Fluoro Carbon 90 MORK 77V005 10 00 254 0 Full Bore 3905 10 12 Viton Fluoro Carbon 75 MORK 78V022 1 00 25 4 mm DEE 3914 16 Viton Fluoro Carbon 90 MORK 79V005 1 50 38 1 G H 3914 16 Viton Fluoro Carbon 90 MORK 80V005 2 00 50 8 GH 3914 16 Viton Fluoro Carbon 90 MORK 80V005 3 00 76 2 J K L 3914 16 Viton Fluoro Carbon 90 MORK 81V005 4 00 101 6 L M N P 3914 16 Viton Fluoro Carbon 90 MORK 82V005 NOTE 1 Nitrile 70 For Freon 134 Ester Oil Service Neoprene Silicon amp Kalrez Seals are available POA NOTE 2 If repairing a 3900 Metal Seat Design the seat o ring in the above kits will not be used Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 81 XXV Recommended Spare Parts Contd Table 19 Main Valve O ring Kits Contd Ethylene Propylene Inlet Size Orifice Valve Type Material Part No in mm 1 00 25 4 DEF 3905 10 12 EPR Ethylene Propylene 90 MORK 70E002 1 50 38 1 1 50 38 1 GH 3905 10 12 EPR Ethylene Propylene 90 MORK 71E002 2 00 50 8 G H J 3905 10 12 EPR Ethylene Propylene 90 MORK 71E002 3 00 76 2 J K L 3905 10
32. 1 or 32 b Lubricate main piston before installing Install the main piston into the top plate with the spring washer bearing point going in first Be careful not to damage the spring seal main piston 5 Install main piston top plate assembly into pilot base by inserting small diameter end of main piston through insert assembly NOTE For dirty service option install main piston top plate assembly into dirty service Insert instead of pilot base 6 Insert the four cap screws top plate through the top plate and thread into the pilot base Tighten to 25 2 ft lbs 542 7 N m a If removed thread compression screw lock nut clockwise onto compression screw XVIII 10 1 1 1 1 LJ Top Plate Spring Seal Main Piston Figure 31 Top Plate 39PV07 Top Plate Spring Seal Main Piston Figure 32 Top Plate 39PV37 Thread compression screw into top of bonnet until the bearing point begins to protrude through bonnet Place spring washers on the ends of the spring There is not a top or bottom spring washer unless the lifting lever option is installed If pilot has lifting lever option 0 Install the bonnet over the spring and spring washer Place spring over lifting stem and place on bottom spring washer Place top spring washer on top of spring and then place the entire assembly on top of pilot base assembly ensuring that the spherical radius located on the bottom spring
33. 18 022 0 56 5 592 003 142 04 0 08 5 533 003 140 54 0 08 5 999 152 37 2 859 72 62 50 003 0 08 004 0 10 8 00 203 2 T 125 3 18 022 0 56 6 484 164 69 6 420 163 07 7 249 184 121 3 484 88 49 50 004 0 10 003 0 08 001 0 03 1 50 38 1 1 5 089 2 26 022 0 56 1 836 002 46 63 0 05 1 780 45 21 1 936 49 17 1 984 50 39 50 002 0 05 2 00 50 8 2 0 105 2 67 022 0 56 2 479 002 62 97 0 05 2 423 002l 61 54 0 05 2 999 76 17 2 359 59 92 50 002 0 05 4 002 0 05 200 508 20 105 2 67 022 0 56 2 479 88 29 3 42 86 87 4 374 111 10 2 734 69 44 50 003 0 08 003 0 08 002 0 05 4 002 0 05 4 00 101 6 4 0 105 2 67 022 0 56 4 101 104 17 4 045 102 74 4 874 123 80 2 734 69 44 50 Full 003 0 08 003 0 08 Bore 003 0 08 003 0 08 6 00 1524 6 0 125 3 18 022 0 56 6 484 164 69 6 421 163 09 7 249 184 12 3 484 88 49 50 004 0 10 004 0 10 4 003 0 08 003 4 0 08 8 00 203 2 8 0 125 3 18 0220 56 7984 202 79 7921 201 19 8 499 215 87 2 484 63 09 50 004 010 004 0 10 003 0 08 003 0 08 10 00 254 0 10 0 125 3 18 022 0 56 10 234 259 94 10 171 258 34 10 499 266 67 2 859 72 62 50 004 0 10 004 0 10 12 00 304 8 12 0 150 3 81 022 0 56 12 551 004 318 80 0 10 12 305 004 312 55
34. 1B018 1 50 38 1 GH 3905 10 12 Buna N Nitrile 90 MORK 71B008 2 00 50 8 GH 3905 10 12 Buna N Nitrile 70 MORK 71B018 3 00 76 2 JKL 3905 10 12 Buna N Nitrile 70 MORK 72B018 4 00 101 6 L MNP 3905 10 12 Buna N Nitrile 70 MORK 73B018 6 00 152 4 Q R 3905 10 12 Buna N Nitrile 70 MORK 74B018 8 00 203 2 T 3905 10 12 Buna N Nitrile 70 MORK 75B018 1 50 38 1 Full Bore 3905 10 12 Buna N Nitrile 70 MORK 71B018 1 50 38 1 Full Bore 3905 10 12 Buna N Nitrile 90 MORK 71B008 3 00 76 2 Full Bore 3905 10 12 Buna N Nitrile 70 MORK 73B018 4 00 101 6 Full Bore 3905 10 12 Buna N Nitrile 70 MORK 76B018 6 00 152 4 Full Bore 3905 10 12 Buna N Nitrile 70 MORK 75B018 8 00 203 2 Full Bore 3905 10 12 Buna N Nitrile 70 MORK 77B018 10 00 254 0 Full Bore 3905 10 12 Buna N Nitrile 70 MORK 78B018 1 00 25 4 D E F 3914 16 Bunq N Nitrile 90 MORK 79B008 1 50 38 1 1 50 38 1 G H 3914 16 Bunq N Nitrile 90 MORK 80B008 2 00 50 8 GH 3914 16 Buna N Nitrile 90 MORK 80B008 3 00 76 2 JKL 3914 16 Buna N Nitrile 90 MORK 81B008 4 00 101 6 L MNP 3914 16 Buna N Nitrile 90 MORK 82B008 NOTE 1 Nitrile 70 For Freon 134 Ester Oil Service Neoprene Silicon amp Kalrez Seals are available POA NOTE 2 repairing a 3900 Metal Seat Design the seat O ring in the above kits will not be used 80 GE Oil amp Gas XXV Recommended Spare Parts Contd Table 19 Main Valve O ring Kits Contd
35. 2 GE 0il amp Gas XXII Maintenance Tools and Supplies A Adjuster Top Seal Insertion Tool Plunger Cylinder Plunger Funnel Tube ASSEMBLY VIEW OF INSERTION TOOL DETAIL OF PLUNGER CYLINDER A 2 563 14 29 mm 9 53 0 05 mm MEN 156 j 3 97 mm mew 250 e N le wu 6 35 mm lt 1 938 gt 0 79 mm 23 81 mm DETAIL OF FUNNEL TUBE m gt A 380 002 an gt 156 3 97 mm 9 520 002 13 21 0 05 mm 9 465 003 11 85 0 08 mm Y A 1 063 26 99 DETAIL OF PLUNGER E Sep e vy E 145 x 002 375 002 ERA 3 68 0 05 mm 9 53 0 05 mm 10637 ___ iy 26 99 mm Figure 59 Adjuster Top Seal Insertion Tool Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 73 XXII Maintenance Tools and Supplies Contd B Insert Installation Tool ASSEMBLY VIEW OF INSERT INSTALLATION TOOL 3 500 88 90 mm REF 90 Y j 3 76 mm 297 7 54 mm ITEM 1 4 32 250 6 35 mm 2 238 g 002 HEX Note 1 1 500 SRH 0 005mm 38 10 mm 203 3 E o Oy EC 10 i 125 3 18 mm TYP ITEM 2 ITEM 3 lt 250 g 250 19 05mm 6 35mm 2 9375 74 61mm zz __ 313 Figure
36. 2 62 45 12 001504 8 12 0 N A N A N A N A N A N A N A N A N A N A N A N A 45 30 GE 0il amp Gas XIII Maintenance Instructions Contd Table 2a Nozzle Machined Dimensions Metal to Metal x 005 E 005 Valve Inlet 001 P S 0 13 0 13 F G J min Size 0 03 mm 0 5 Bore Orifice mm mm Type in mm in mm in mm in mm in mm in mm in mm a 001 0 03 1 00 25 4 D E F 090 2 29 022 0 56 1 087 001 27 61 0 03 1 041 26 44 1 186 30 12 1 797 45 64 50 002 0 05 001 0 03 1 50 25 4 D E F 090 2 29 022 0 56 1 087 001 27 61 0 03 1 041 26 44 1 186 30 12 1 797 45 64 50 002 0 05 001 0 03 1 50 38 1 GH 089 2 26 02 0 56 1 836 002 46 63 0 05 1 780 45 21 1 936 49 17 1 984 50 39 50 002 0 05 001 0 03 2 00 50 8 G H J 089 2 26 022 0 56 1 836 002 46 63 0 05 1 780 45 21 1 936 49 17 1 984 50 39 50 Std 002 0 05 Bore 3 00 76 2 J K L 105 2 67 0 56 2 479 002 62 97 0 05 2 423 002 61 54 0 05 2 999 76 17 2 359 59 92 50 002 0 05 002 0 05 105 2 67 022 0 56 3 476 88 29 3 420 86 87 4 574 111 10 2 734 69 44 50 003 0 08 003 0 08 us H 4 00 101 6 zur 6 00 152 4 Q R J 125 3
37. 25 Vent Assembly Bonnet Vent 2 CLL 27 Set Screw Bonnet 28 Piston Nose 29 Piston Retainer Nut 30 Set Screw Piston 31 Vent Seal Adaptor 32 Spring Seal Vent Seal Adaptor 7 a 33 Back up Ring 39MV72 Only 34 Top Plate HIGH PRESSURE Note 1 Standard material is a filter plug For special materials vent assembly is supplied Figure 5 39MV22 72 Pilot Valve Construction Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 19 X Operating Principles A 3900 MPV Series Type 39PV Pilot Operational Description PV Valve Closed Normal Position System pressure from the main valve inlet is led to the area of the top of the disc is larger than the area of the dome by the pilot through interconnecting tubing This seating surface the differential area results in a net equalizes the pressure on the top of the disc Since the download force keeping the main valve lightly closed Figure 6 PV Valve Closed Normal Position 20 GE 0il amp Gas X Operating Principles Contd PV Valve Open Relieving Position As inlet pressure increases the pilot position strokes When the discharging main valve reduces the inlet and seals off the main valve inlet pressure from the pressure to the pre set blow down pressure of the pilot dome pressure The pilot simultaneously opens the the pilot piston closes the vent seal Simultaneously the vent seal
38. 3 8 24UNF 245 277 600 1524 QR 6 3 8 24UNF 245 277 8 00 203 2 T 6 3 8 24UNF 245 277 4 00 1016 3 FB 6 3 8 24UNF 245 277 4 00 101 6 4 FB 4 3 8 24UNF 245 277 600 152 6 6 FB 6 3 8 24UNF 245 277 8 00 203 2 8 FB 8 3 8 24UNF 245 277 10 00 254 0 10 FB 8 3 8 24UNF 245 277 12 00 304 81 12 0 FBI 8 3 8 24UNF 245 277 Note 1 For 1 5 and 2 0 FB contact factory 5 Install the seat seal o ring in the disc groove and position the o ring Retainer onto the disc Install the lock screw s and tighten to the torque values listed in Table 8 Note For Teflon seat o rings heat 10 300 F 149 C for ten minutes before installation D Disc to Guide Seal 1 For Teflon seals make sure of the integrity of the Teflon amp seal and seal spring Install disc seal on disc outside diameter on the opposite end of the disc seat as shown in Figure 20 2 Ifan o ring seal is used it is installed in the groove between where the guide ring is installed and 40 GE 0il amp Gas Disc Seal Disc Disc O Ring Figure 20 Disc Seal Installation where a spring energized seal would be installed Figure 10 Install the guide ring s on disc outside diameter If the valve is equipped with two guide rings position the space where the guide ring ends meet 180 apart Guide and Disc Assembly D E F G H J K 8 3 L Make sure the chamfer on the BOTTOM of the gui
39. 60 Insert Installation Tool 74 GE Oil amp Gas XXII Maintenance Tools and Supplies Contd C Main Valve Nozzle Wrench pud lt 015 34 93 mm 7504 BIS d 19 05 20 mm 22 23 mm 9 53 mm B DIA rha 375 e C TYP 9 53 mm A TYP l A A ji R 015 1 2 of C 350 Ke 3 90 19 05 ES 0 00 mm y Figure 61 Main Valve Nozzle Wrench Table 15 Main Valve Nozzle Wrench Tool Dimension Valve Size Tool A B S in mm in mm in mm in mm 1 625 41 28 mm HUS eme Socket Wrench E j 1 250 31 75 mm 1 50 2 00 38 1 50 8 Socket Wrench 3 00 76 2 370 VASO 5 250 8255 SOO 12 7 4 00 101 6 5 250 155 55 4 375 111 13 750 19 05 Spanner Wrench 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 US 24 205022020512 8 00 x 10 00 x 10 00 203 2 x 254 0 x 254 0 375 9 53 mm 10 00 x 10 00 x 10 00 254 0 x 254 0 x 254 0 Hex Key Allen z Wrench 10 00 x 14 00 254 0 x 355 6 12 00 x 16 00 304 8 x 406 4 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 75 XXII Maintenance Tools and Supplies Contd D Lapping Tools The following tools are required for proper maintenance 4 Drift Pins Two drift pins are required for the removal
40. 610 11016 Ree GE 29 C Lapped Nozzle Segt Widths J sss NEEN EIERE kalak es sb a aee ha b E Rr SN SEN RR e re ea s a 32 Dz LAPPING DISC Seats si e suan e chan kel ene den eR eR ar n e k k PELO IRI D Ru Ou n RES 35 E Precautions arid Hints for Lapping S Q S esee kal kk aleke age Pace ed kan ela ka la des 35 E Recoriditionirig G LOGS oe uu deese suni xak nak badeka d ne da handan ga etd e We Waaa uk Bn ad AR e da n n da 35 G ResMachinirig Nozzle Sedts e RIO degree kk k MERI EE eda Shape kl W e ka ka aa dak a a 35 H Re Machir rig the DISC SedE us esos bebes ban n buk Wa k k din d n I eek iMG Pe DDR bn eg 36 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 3 Table of Contents XIV XV XVI XVII XVIII XIX XX XXI Inspection of Main Valve iussus re a Ee mx KK KK KK KK KK kk k ke k e Ea RR e e e e es 38 Reassembly of 3900 MPV Series Main Valve 39 A t bricanis ana Seadlditee Do nee me emn 39 B Assembly Procedure with Metal Get 39 C Assembly Procedure for O ring Seats is kaka yan kel la dasa n ke m e kalek keka waa 39 D DISC to GuideiSegl s5 y4 hte Deeg aad odi er OC Wl nea ob doti On iy n ayan 40 E Guide and Disc Assembly sack a ask xak kk kk ak asan dk a k k RA kk k ee eee 08 enn 40 Disassembly of Pilot V
41. 7 060 1 52 4 00 101 6 mm 301 20 75 800 55 16 060 1 52 070 1 78 L M N P 801 55 23 Above Full Width 15 1 03 100 6 89 040 1 02 050 1 27 4 00 101 6 mm 101 6 96 300 20 68 050 1 27 060 1 52 Full Bore 301 20 75 800 55 16 060 1 52 070 1 78 801 55 23 Above Full Width 15 1 03 100 6 89 040 1 02 050 1 27 6 00 152 4 mm 101 6 96 300 20 68 050 1 27 060 1 52 0 8 301 20 75 800 55 16 060 1 52 070 1 78 801 55 23 Above Full Width 6 00 152 4 mm 15 1 03 100 6 89 050 1 27 060 1 52 Full Bore 101 6 96 300 20 68 060 1 52 075 1 91 8 00 203 2 mm 301 20 75 800 55 16 075 1 91 085 2 16 1 800 55 16 Above Full Width 15 1 03 100 6 89 060 1 52 075 1 91 8 00 203 2 mm 101 6 96 300 20 68 075 1 91 090 2 29 Full Bore 301 20 75 800 55 16 090 2 29 105 2 67 800 55 16 Above Full Width 15 1 03 100 6 89 075 1 91 090 2 29 x k 101 6 96 300 2068 0090 229 105 267 301 20 75 750 5171 Full Width 34 GE 0il amp Gas XIII Maintenance Instructions Contd D Lapping Disc Seats Use a ring lap or lapping plate to lap the disc in a circular motion applying uniform pressure and slowly rotating the disc or lap 1 Apply 1000 lapping compound see Table 16 in Lapping Tools Section Section XXII D Lap disc to a polish finish 2 Remove lapping compound completely from Disc and Disc Holder E Precautions and Hints for Lapping Seats To ensure a quality lapping process observe the following precautions and guidelines 1
42. 70 1 78 080 2 03 r a 251 1731 400 2758 080 203 090 229 401 27 65 800 55 16 090 2 29 100 2 54 801 5523 1000 6895 100 2 54 110 2 79 1001 69 02 Above Full Width 15 1 03 50 3 45 065 1 65 075 1 91 51 3 52 100 6 89 075 1 91 085 2 16 10 00 254 0 mm 101 6 96 250 1724 085 2 16 100 2 54 Full Bore 251 17 31 400 27 58 100 2 54 110 2 79 401 27 65 750 51 71 Full Width Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 33 XIII Maintenance Instructions Contd Table 4 Approximate Nozzle Seat Width Thermodisc Design Set Pressure Lapped Seat Width Valve min max min max psig barg psig barg in mm in mm 100 25 4 mm 15 1 03 100 6 89 020 0 51 035 0 89 DEE 101 6 96 300 20 68 035 0 89 045 1 14 1 50 38 1 mm 301 20 75 800 55 16 045 1 14 055 1 40 D E F 801 55 23 Above Full Width 1 50 38 1 mm 15 1 03 100 6 89 025 0 64 035 0 89 1888 i m 101 6 96 300 20 68 035 0 89 045 1 14 Full Bore 301 2075 800 5516 ous 114 055 140 2 00 50 8 mm G H J 801 55 23 Above Full Width 2 00 50 8 mm 15 1 03 100 6 89 030 0 76 040 1 02 Full Bore 101 6 96 300 20 68 040 1 02 050 1 27 3 00 76 2 mm 301 20 75 800 55 16 050 1 27 060 1 52 J K L 801 55 23 Above Full Width 3 00 76 2 mm 15 1 03 100 6 89 040 1 02 050 1 27 Full Bore 101 6 96 300 20 68 050 1 2
43. 8807 6577 Fax 82 2 2274 0794 Fax 34 93 652 6444 BELGIUM MALAYSIA UNITED ARAB EMIRATES Phone 32 2 344 0970 Phone 60 3 2161 0322 Phone 971 4 8991 777 Fax 32 2 344 1123 Fax 60 3 2163 6312 Fax 971 4 8991 778 BRAZIL MEXICO UNITED KINGDOM Phone 55 11 2146 3600 Phone 52 5 310 9863 Bracknell Fax 55 11 2146 3610 Phone 44 1344 460 500 THE NETHERLANDS Fax 44 1344 460 537 CHINA Phone 31 15 3808666 Phone 86 10 5689 3600 Fax 31 18 1641438 Skelmersdale Fax 86 10 5689 3800 Phone 44 1695 526 00 RUSSIA Fax 44 1695 526 01 FRANCE Veliky Novgorod Courbevoie Phone 7 8162 55 7898 UNITED STATES Phone 33 1 4904 9000 Fax 7 8162 55 7921 Massachusetts Fax 33 1 4904 9010 Phone 1 508 586 4600 Moscow Fax 1 508 427 8971 GERMANY Phone 7 495 585 1276 Ratingen Fax 7 495 585 1279 Corpus Christi Texas Phone 49 2102 108 0 Phone 1 361 881 8182 Fax 49 2102 108 111 SAUDI ARABIA Fax 1 361 881 8246 Phone 966 3 341 0278 INDIA Fax 966 3 341 7624 Deer Park Texas Mumbai Phone 1 281 884 1000 Phone 91 22 8354790 SINGAPORE Fax 1 281 884 1010 Fax 91 22 8354791 Phone 65 6861 6100 Fax 65 6861 7172 Houston Texas New Delhi Phone 1 281 671 1640 Phone 91 11 2 6164175 Fax 1 281 671 1735 Fax 91 11 5 1659635 Consolidated and Green Tag are registered trademarks of the General Electric Company Other company names and product names used in this document are the registered trademarks or trademarks of their respe
44. Do not sand blast internal parts as it can reduce the dimensions of the parts 50 GE Oil amp Gas XVII Part Inspection of Pilot Valve After the valve has been disassembled all parts should be given a visual inspection Some key areas to check with the boundaries for reworking parts are listed blow A 1 10 11 39PV07 37 Main Piston Galling or excessive wear on the small diameter end where it engages the spring seals or on the spherical bearing surface Any corrosion or pitting that appears detrimental to the function of the valve The part can be polished as long as the outside diameter of the stem remains at 243 001 6 18 0 03 mm The stem itself must have a T I R of 001 0 03 mm along its length The upper diameter where the spring seal main piston rides must be 1 495 001 37 97 0 03 mm on 39PVO7 model or 970 001 24 64 0 03 mm on 39PV37 A surface finish of 8 RMS must be maintained for proper sealing on these surfaces Insert Top Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Insert Bottom Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Adjuster Top Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Adjust
45. Do not install adjuster assembly into pilot base 1 Spring Seal Adjuster Top with o rings installed without wrench tightening 1 Spring Seal Adjuster Bottom adjuster top to adjuster bottom together 1 O ring lAdiuster Top Adjuster top can get stuck in pilot base if zeige adjuster top is not tightened properly 1 O ring Adjuster Bottom 9 Install o ring adjuster top into groove on q Check the adjuster top for burrs at the spring adjuster top seal lead in chamfer Remove any burrs using a polishing cloth h Install o ring adjuster bottom into groove on adjuster bottom Install from the opposite end of b Install spring seal adjuster top into adjuster top the square using insertion tool as shown in Figure 59 A i Lightly lubricate both external o rings on adjuster assembly Install adjuster assembly into pilot base with the adjuster top going in i Lubricate spring seal adjuster top with silicone grease i Install Spring Seal adjuster top onto first Rotate the assembly clockwise during plunger cylinder with spring facing away installation until the threads are engaged This from plunger cylinder helps the o rings get by chamfers and holes lii Insert plunger into plunger cylinder j Continue to turn adjuster assembly clockwise until plunger lightly contacts spring seal into pilot base until it stops adjuster top k Turn adjuster assembly counterclockwise iv Insert funnel tube chamfer side
46. GE Oil amp Gas 3900 mpv series GE s Consolidated Pilot Operated Safety Relief Valve Maintenance Manual Conversion Table All the USCS values are converted to metric vqlues using the following conversion fqctors Metric values using the following Conversion Factor Metric Unit conversion factors in 25 mm 0 4535924 kg in 6 4516 cm ft3 min 0 02831685 m min gal min 3 785412 L min lb hr 0 4535924 kg hr psig 0 06894757 barg ft Ib 1 3558181 Nm OF 5 9 F 32 se Note 1 Multiply USCS value with conversion factor to get metric value For valve configurations not listed in this manual please contact your local Green Tag Center for assistance 2 GE 0il Ges Contents VI VII Vill Al XII XIII Product Safety Sign and Label System 6 Safety Alerts cinsan san Re ERE 7 Safety Notice Shee er Ee Er KK kK kk Y k kk k k ke e ee e ee ee ee e e e e ee ele RA 9 Warranty Information iie 29 KN kK kK KK KK Rr kk kk kk kk k kk k l k e e e e 10 Terminology for Pilot Operated Safety Relief Valves SERR 11 Handling dnd 506606 sore kk KK KK KK rs o RR a Rd o coe 12 Pre Installation and Installation Instructions c cece cece eee eee e eens 13 Hir OGUCHON MN E E syne teks eae E ee 14 A General Introduction A ged era Are terze ere re
47. GE P N SP364 AB a Lap disc to disc holder bearing surfaces using c Lubricate standard threads and bearing points lapping compound 1A to lightly grey in with jet lube GE non metallic product code 14613 GE P N4114510 or 4114511 3 Operating temperatures above 505 F 262 7 C b Remove lapping compound completely Install disc retainer into the groove in the disc d Lubricate bearing surfaces of disc disc holder a Lubricate all o rings except silicone spring and retainer ring energized seals and back up rings sparingly with silicone grease GE P N SP505 e Snap disc into disc holder using only moderate b Seal all pipe threads with Teflon tape or pipe Pana fores sealant GE P N SP364 AB f Check to make sure the disc does not bind and C Lubricate standard threads and bearing is free to rock in disc holder points with nickel graphite N5000 GE C Assembly Procedure for O ring Seats P N 4114507 or equivalent 1 Thread sensing tube into the main valve rear B Assembly Procedure with Metal Seats connection making sure the wrench flat which 1 Thread sensing tube into the main valve rear RES Up t position SQ Hpware miter tightening connection making sure the wrench flat which 2 Threqd the tube fitting into the sensing tube reads Up is positioned upward after tightening and tighten 2 Thread the tube fitting into the Sensing Tube Note Install plug filter between tube fitting a
48. Remove insert assembly from the top of the pilot base with tool 4995401 as shown in Figure 60 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 1 CA Remove adjuster cap from the bottom of the pilot base by turning counterclockwise 14 Loosen adjuster lock nut by turning counterclockwise 1 Q Removing the adjuster assembly a 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 1 o Turn adjuster assembly clockwise counting the number of flats until assembly stops Record number of flats for reassembly 1 N 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 Disassemble adjuster top 46 GE Oil amp Gas from the adjuster bottom by turning adjuster top counterclockwise Remove spring seal adjuster top from adjuster top and discard 18 Refer to field test connection backflow preventer option Section XXI A for disassembly of field test connection 19 Remove socket head cap screw 2 Nos to remove modulator assembly from pilot base Remove and discard both o rings modulator base a The modulator assembly consists of 1 Modulator Bas
49. Safety Relief Valve POSRV cast bodies are designed to meet the often specified inlet and outlet connection combinations Sizes range from 1 00 12 00 25 4 mm 304 8 mm pressure ratings from 150 2500 class The main valve o ring dual seating principle is the same design that has been successfully utilized in the Consolidated SRV for over 30 years Capacities are certified by National Board of Boiler and Pressure Vessel Inspectors and published in their NB18 entitled Pressure Relief Device Certifications 1 Main Valve Features orifice controlled capacity N nozzle guided disc 3 superior tightness 4 removable nozzles for replacement or remachining un standard o ring sizes readily available easily replaced 6 meets ASME Section VIII Div 1 N multiple orifices per valve size 8 national Board certified capacities 2 Main Valve Optional Seating Designs Metal Seat Figure 1 Available with a solid metal disc that provides a metal to metal seat This allows the temperature range capabilities of the valve to be expanded to 320 F to 650 F 195 6 C to 343 3 C with the appropriate heat exchanger Soft Seat Figure 2 The o ring retainer has two machined slots in the upper beveled edge allowing system pressure to reach the chamber behind the o ring This exerts pressure against a specially curved metal seating surface on valve nozzle The o ring seat seal design maintains a
50. The gauge pressure at the valve inlet for which the relief valve has been adjusted to open under service conditions In liquid service the inlet pressure at which the valve starts to discharge determines set pressure In gas or vapor service the inlet pressure at which the valve pops determines the set pressure Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 11 VI Handling and Storage A CAUTION Always keep valve in an upright position when handling or storing A CAUTION Do not subject valves to sharp impact 12 GE 01 8 Gas Handling 1 CAUTION Flanged valves either crated or uncrated should always be kept with the inlet flange down in the normal installation position to prevent misalignment and damage to internal parts 2 CAUTION Pressure relief valves either crated or uncrated Should never be subjected to sharp impact Particular care should never be subjected to sharp impact Particular care should be exercised when the valve is being loaded onto or unloaded from a truck and when it is being hoisted into position for installation 3 CAUTION Never attempt to lift the full weight of the valve by the pilot assembly external devices or tubing Lift the valve by the eyebolts shown on figure safety sign Storage Pressure relief valves should be stored in a dry environment and protected from the weather They should not be removed from the weather They shou
51. Top 4 Adjuster Bottom 5 Adjuster Lock Nut 6 Compression Screw 7 Compression Screw Lock Nut 8 Spring Washer 9 Spring 1 4 18 NPT 10 Insert Top VENT Insert Bottom nd Main Piston Cap Compression Screw gt Cap Screw Top Plate m CA Sz O ring Adjuster Bottom AGN Tx NN lt RA MSGS 1 4 18 NPT j DRAIN m ET NN j T O ring Insert SS N A O ring Top Plate Bonnet o O ring Adjuster Top N 2 nd O D A N Spring Seal Main Piston ZZ Z 22 ZIA N e S A N ZZ N nd Spring Seal Adjuster Top a ES N d N NY 22 Spring Seal Insert IN 23 Field Test Connector ES S NN SC 24 Vent Assembly Bug Screen Field N Test Connection 25 Vent Assembly Bonnet Vent 26 Pipe Plug Pilot Valve LL MOGA Z N 27 Set Screw Bonnet 34 Top Plate Note 1 Standard material is a filter plug For special materials vent assembly is supplied HIGH PRESSURE Figure 3 39PV07 37 Pilot Valve Construction Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 17 IX Consolidated 3900 MPV Series POSRV Contd D 39MVO7 Pilot Valve Standard Service Part Nomenclature No
52. age may also contain a more precise definition of the hazard and the consequences of human interaction with the hazard than can be communicated solely by the pictorial 6 A DANGER Do not remove bolts if pressure in line as this will result in severe personal injury or death GE Oil amp Gas A WARNING tf vy RADIATION AREA KEEP OUT RWP REQUIRED FOR ENTRY Know all valve exhaust leakage points to avoid possible severe personal injury or death A CAUTION Wear necessary protective equipment to prevent possible injury product or property damage 4 ATTENTION Do not drop or strike I Safety Alerts Read Understand Practice 1 DANGER High temperature pressure can cause A DANGER injury Be sure all system pressure is absent before repairing or removing valves 2 DANGER Don t stand in front of valve outlet when discharging STAND CLEAR OF VALVE to prevent exposure to trapped corrosive media 3 DANGER When inspecting a pressure relief valve for leakage BE VERY CAREFUL Do not remove bolts if pressure in line as this will result in severe personal injury or death 1 WARNING Allow the system to cool to room temperature before cleaning servicing or repairing A WARNING the system Hot components 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 remo
53. al Insert Adjuster Top Adjuster Bottom Figure 29 Adjuster Top Assembly Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 53 XVIII Note Do not install adjuster assembly into pilot base with o rings installed without wrench tightening adjuster top to adjuster bottom together Adjuster top can get stuck in pilot base if the adjuster top is not tighten properly e Install o ring adjuster top into groove on adjuster top f Install o ring adjuster bottom into groove on adjuster bottom Install from the opposite end of the square wrenching flats g Lightly lubricate both external o rings on adjuster assembly Install adjuster assembly into pilot base with the adjuster top going in first Rotate the assembly clockwise during installation until the threads are engaged This helps the o rings get by chamfers and holes h Continue to turn adjuster assembly clockwise into pilot base until it stops i Turn adjuster assembly counterclockwise the number of flats that was recorded in disassembly instructions Section XVI A Step 16 j Thread the adjuster lock nut clockwise onto the adjuster assembly hand tight k Thread adjuster cap clockwise onto adjuster assembly hand 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 3 The insert assembly of
54. alve eieiei Siet KK KK c de dio feat k kk ek eke le k 42 A S9PVO S7 DISOSSEMDIY s i dosectetur e bes JJ beh erit Poem tror eds 42 Dn a ajjj j r d dg idee ta Ee bd etu tart ie 44 C 39MV22 72 Disassembly nee deman em ee ese e nene 47 D Cleaniligu soror 8 wie E RINIRIQIE oa PERL Reh Pe eNOS E e S E M 50 Part Inspection of Pilot Valve eebe ee ER KK KK K kk od CER 51 DECOR c CE 51 B SIMVOL gereegelt ple whee ae E e 51 EIER 52 Reassembly of Pilot Valve ice vip KK KK KK KK KK KK kk kk kk e k k 53 A LUDKCANLS GNA Sl en EE 55 B Assembly of S9PVOT Sf i ex wO Eh nano bu dln ve UEM dee ees ER AE dei Ben beer end 53 C Assembly of SOMMVOT sess aus sis sects aps saxa ad ku kak e b Ro Rb A a kd adl M ed e abt 55 D Assembly of S9MV 22 72 Lii e ee REI ERG e b gel ai eb d k 57 Setting and Testing dns qu kK kk kk KK KK KK KK KK K K Sad ek d e e ek 60 noD UI Ee 60 B 39MVO7 39MV22 72 esses e e e e e e e e e eres 60 C Troubleshooting Eedkage s lt 3 ii pex bota xan RE P NIAE a ha l ly CREE Wl AA Pu ed 61 Field Testing of POSRV Assembly s cbeneseptre iird Atr RR XP 20355444 nad w W WA WAYA N Ah nb Wr 64 Trouble Shooting iio ar kk kK kK KK KK KK kK k UR CR k k M UO eol 65 3900 Se
55. both external o rings on adjuster assembly Install adjuster assembly into pilot base with the adjuster top going in first Rotate the assembly clockwise during installation until the threads are engaged This helps the o rings get by chamfers and holes Continue to turn adjuster assembly clockwise into pilot base until it stops Turn adjuster assembly counterclockwise the number of flats that was recorded in Disassembly Instructions Section XVI B Step 16 Thread the adjuster lock nut clockwise onto the adjuster assembly hand tight Thread adjuster cap clockwise onto adjuster assembly hand tight Make sure adjuster cap and adjuster lock nut threads freely on adjuster bottom Adjuster asembly may be inadvertently rotated if these two parts do not fit loosely 3 The insert assembly of the pilot consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O ring Insert Press spring seal insert into groove on the insert bottom Make sure spring is facing upwards Install insert top over insert bottom with the spring seal side going in first Lightly lubricate o ring groove now formed by the two insert parts This lubrication is used to 56 GE 01 amp Gas Reassembly of Pilot Valve Contd 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 shown in Figure 30 f Turn insert assembly over and thread into
56. cap screws on the cover plate 4 Lift off the cover plate and bracket 5 Remove the spring from the top of the disc 6 Install a lifting bolt into the drilled and tapped hole in the Disc s center and lift from the Base Note the guide may lift out of the base with the disc If so do not allow the guide to fall and become damaged Also the D orifice through 3 76 20 mm L orifice will lift the guide out with the disc due to its design 7 Remove the guide from the base if it did not come out with the disc 8 Metal Disc Disassembly a For D through T orifice valves and 1 5 38 10 mm through 6 152 40 mm full bore valve remove the disc from the disc holder as follows i Clampthe outside diameter of the disc holder disc end up firmly between two wooden v blocks in a vise 4 DANGER Lower pressure and stand clear of discharge when working on valve to avoid severe personal injury or death A DANGER Do not remove bolts if pressure in line as this will result in severe personal injury or death A CAUTION e Wear necessary protective equipment to prevent possible injury A WARNING Know all valve exhaust leakage points to qvoid possible severe persondl injury or death Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 25 XII Disassembly of the 3900 POSRV Contd Figure 10 Metal Seat Valve Disassembly 26 GE 0il amp Gas
57. ctive owners 2014 General Electric Company All rights reserved GEA30814 12 2014
58. d and equipment 28 GE 0il amp Gas in the Maintenance Tools and Supplies section Section XXII C This applies to all main valve sizes except the 8 10 and 12 full bore valves The latter are disassembled by removing four nozzle cap screws inserting two eyebolts 5 8 11 UNC 180 apart and pulling the nozzle out 11 Discard all o rings guide rings and seals Disc Drift Pin Drift Pin gt ga E Figure 12 Disc Holder Disc Holder 1 Clean parts to remove all rust burrs scale organic matter and loose particles Parts are to be free of any oil or grease except for lubrication as specified in 2 Cleaning agents used shall be such that effective cleaning is assured without injuring the surface finishes or material properties of the part 3 Acceptable cleaning agents include demineralized water nonphosphate detergent acetone and isopropyl alcohol Parts must be blown dry or wiped 4 If you are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations Do not sand blast internal parts as it can reduce the dimensions of the parts XIII Maintenance Instructions A General Information After the valve has been disassembled closely inspect the seating surfaces Usually a lapping of seats is all that is necessary to return a valv
59. d aa de dp 818 8 W A h k W WA EE 72 L Pressure Spike Snubber nnn an ee ee e e e eee ee een 72 ML Remote Pilot MOUM uie pc ton Leid yaxa K n be SWE PAN D b Ey ug BER nak A d 72 IN REFINES SODISIIIG EE 72 Maintenance Tools and Supplies 13 A Adjuster Top Seal Insertion Tool 73 B Insert INStallGtion TOOL s au eee once lal l n xan ag bended Ka bla dE n way ONERE Z na k n n X da 74 Cz Main Valve Nozzle Wrench esisi a yk xaka eicit daw n dl A da be b vede 75 D kapping TOONS s iib ehe M bre er bbc Babe pd d rU RE be geve 76 Replacement Parts Planning cceec cece KK KK KK KK KK een 77 A Basic Guidelines ui aide cate WER Rae bee Q INR n V9 Qale d ka A en W9 Q nk 4u 77 B Identification and Ordering Essentols eene 77 C Positive Identification of Main Valve and Pilot Valve Combinations WWW 78 Genuine Consolidated Portz 79 Recommended Spare Porte 79 Field Service Training and Repair Program 86 2 x DDDD 7 DD DDrDrbrxbbr aZa sra A r_ j j r C seb tir eig 86 B Factory Repair EGCIIIeS s cues de ka 3045 reg bedl ERES X Dd Ea raa kde Xalan w bla 86 C Safety Relief Valve Maintenance Tromimg E ccc een 86 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 5 Product Safety Sign and Label System If and when requi
60. d 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 Valves GE Consolidated Service Engineers restore disc and nozzle critical dimensions which affect valve performance and are capable of modernizing valves in the field It is highly recommended that the professional talents of a GE Field Service Engineer be employed to make final field adjustments during the initial setting of all GE s Consolidated POSRVs All Field Service Engineer s activities are coordinated from the Alexandria Louisiana Field Service Office Upon receipt of a purchase order number authorizing the trip the service engineer is dispatched Contact Field Service Dept Field Service Supervisor 318 640 6055 B Factory Repair Facilities The factory at Alexandria Louisiana maintains a Consolidated Repair Center The Repair Department in conjunction with the manufacturing facilities is equipped to perform specialized repairs and product modifications e g butt weld bushing replacements code welding pilot replacement etc Contact Repair Dept Mgr Valve Repair 318 640 2250 86 GE 0il amp Gas Field Service Training and Repair Program C Safety Relief Valve Maintenance Training Rising costs of maintenance and repair in the Utility and Process Industries indicate the need for trained maintenance personnel
61. de is smooth If any sharp edges exist polish the chamfer since the seal could be damaged during assembly Insert disc seal disc o ring into bottom of guide first Continue pushing disc into guide being careful of not pinching the guide rings Push disc in until shoulder of disc hits bottom of guide Drop guide o ring into top of base for outside diameter of guide Insert guide disc assembly into top of base It will not fit flush The cover plate will force it down during its installation Push disc in until the disc is in contact with the nozzle Use threaded hole on top of disc if necessary to lift assembly Install cover plate o ring into top groove on guide Install spring into dome cavity with smaller coils on bottom When installing the cover plate make sure the spring coils remain in the groove and centered Install cover plate on top of base such that the pilot will be aligned for proper tubing connections Make note of the length of the studs or cap screws The two longer ones will straddle the vertical line of the inlet sensing port on the main base of the pilot valve Install the bracket between the cover plate and the nut or cap screw Torque to the values shown in Table 9 in 15 ft lb 20 N m increments making sure there is a uniform gap between the base and the cover plate Torque in the sequence shown in Figure 21 Be sure that the bracket is aligned so that the two smaller pilot attachment holes are above the h
62. e 1 Modulator Stop 1 Modulator Piston Assembly b The modulator piston assembly consists of 1 Modulator Piston Top 1 Modulator Piston Bottom 1 O ring Retainer 1 Lock Screw 1 O ring Modulator Piston Bottom 1 Spring Seal Piston Top 1 Spring Seal Piston Bottom 1 O ring Modulator Seat 20 Remove cap screws modulator holding modulator stop to modulator base 21 Modulator base can now be removed by rotating the modulator stop enough to be able to push against the ears on the modulator base to remove the modulator stop 22 Remove both o rings modulator stop and discard 23 Disassemble the modulator piston assembly by removing the lock screw 24 Remove and discard o ring modulator piston bottom and o ring modulator seat Be careful not to bend the lip enclosing the o ring modulator seat during its removal 25 Discard spring seal piston bottom and spring seal piston top XVI Disassembly of Pilot Valve Contd C 39MV22 72 Disassembly Figures 25 26 and 23 1 Remove and discard the aluminum seals and sealing wire 2 Remove cap compression screw by turning counterclockwise 3 Ifa lifting lever is installed also use Figure 23 to remove the lifting lever assembly Then return to Figure 25 or 26 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 bush
63. e 251 1731 400 27 58 040 1 02 045 1 14 Sosa ae 27 65 800 55 16 065 1 14 050 1 27 ie 801 5523 1000 68 95 ech Mr 05 un is EN 058 005 1 47 0 13mm per psig 6 arg WW Qj ER EEN 070 005 1 78 0 13 mmmax 15 1 03 50 3 45 030 0 76 0 037 0 94 De 51 3 52 100 6 89 037 0 94 0 045 1 14 Cili Bore 101 6 96 250 1724 045 1 14 0 052 132 251 1731 400 27 58 052 3 32 0 059 1 50 4 00 101 6 mm 01 27 65 800 55 16 059 1 50 0 064 163 L M NP 801 5523 1000 68 95 064 1 63 0 072 1 83 1001 69 02 Above Full Width 15 1 03 50 3 45 030 0 76 0 037 0 94 51 3 52 100 6 89 037 0 94 0 045 1 14 101 6 96 250 17 24 045 1 14 0 052 1 32 MM 251 1731 400 2758 052 132 0 059 1 50 401 2765 800 55 16 059 1 50 0 064 163 801 55 23 1000 6895 064 1 63 0 072 1 83 1001 69 02 Above Full Width 15 1 03 50 3 45 030 0 76 0 037 0 94 51 3 52 100 6 89 037 0 94 0 045 1 14 j 101 6 96 250 1724 045 1 14 0 052 1 32 6 00 mm 551 1731 400 2758 052 132 0 059 150 401 2765 800 55 16 059 1 50 0 064 1 63 801 5523 1000 68 95 064 1 63 0 072 1 83 1001 69 02 Above Full Width 15 1 03 50 3 45 040 1 02 045 1 14 1 362 100 6 89 045 114 053 1 35 Full Bore 101 6 96 250 1724 053 135 061 1 55 251 1731 400 27 58 060 1 52 068 173 8 00 203 2 mm 491 27 65 800 55 16 068 173 076 1 93 T 801 5523 1000 68 95 076 1 93 090 2 29 1001 69 02 Above Full Width 15 1 03 50 3 45 050 1 27 060 1 52 51 3 52 100 6 89 060 152 070 1 78 j 101 6 96 250 17 24 0
64. e by the following nameplate data Size Do not interchange Type parts from one valve to 1 2 3 Pressure Temperature Class Rating another 4 Serial Numbers from both main valve and pilot valve Example Main Valve 3910R 3 CC DA RF GS TL1234M Pilot Valve 39PV07 1 CC B GS TL1234P How to Verify Material of O rings and Seals Kit coding indicates o ring and seals material Examples MORK 60T T Teflon B Buna N PORKF 34E X E Ethylene Propylene PORKF 32V V Viton K Kalrez Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 77 XXII Replacement Parts Planning Contd C Positive Identification of Main Valve and Pilot Valve Combinations POSRV s shipped direct from the factory to the end user probably have main valves and pilot valves with identical serial numbers S N s Those shipped unconnected to the GE Green Tag network may have main valves and pilot valves with different S N s During service and repair the following inspection steps will ensure the proper match of main valves to pilot valves 1 Record main valve and pilot valve S N s of original POSRV s in plant records Inspect S N s for agreement with Step 1 after any disassembly involving removal of pilot valve from main valve Make sure the set pressures of the main valve and pilot valve are identical Check o ring and seals kit material code to ensure they are the same for main valve and
65. e to working order If an inspection shows badly damaged valve seating surfaces machining will be required before lapping o ring seat seal valve nozzles can only be reconditioned by machining not lapping For specific information concerning the machining of nozzle and disc seating surfaces see the Re Machining Nozzle Seats and Bores and Re Machining the Disc Seat sections The seating surfaces of the metal seated Consolidated POSRV 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 Figure 13 A cast iron lap coated with a lapping compound is used for reconditioning the seating surfaces of the nozzle and disc To establish leak free valve seats the nozzle seating surface and the disc seating surface must be lapped flat Figure 13a O ring Seat DA F Zi lg 005 0 13 mm 12 G OJ 004 0 10 m n z B O ring Seqt The nozzle must not have any defects to prohibit the o ring from sealing properly especially the OD of the seat where the surface must maintain a minimum of 32 RMS finish See Figure 13a and Table 2b for reworking o ring nozzle The o ring retainer must also maintain a flat surface for it to sit on the nozzle Only polishing of surface can be done since material removal from this surface will cause the nozzle to over engage o ring Polishing paper or so
66. ed has fast response availability for parts XXV Recommended Spare Parts Table 18 Recommended Spare Parts for 3900 MPV Series POSRV Class Part Name Class Parts should be stocked at the rate of Pilot Valve O ring Kit one 1 per valve Maintaining this level of spare Plug Filter parts will provide replacement parts for 70 of O ring Kit Main Valve possible maintenance requirements Metal Disc Main Piston Tube Fittings 2 Modulator Stop Class parts should be stocked at the rate Pilot Valve of one 1 part per each five 5 valves in O ring Retainer the population Class II parts will provide I Backflow Preventer Seal Kit replacement parts for an additional 1596 of Piston Nose possible maintenance requirements Nozzle Main Valve O ring Retainer Tube Fittings 2 NOTE 1 A combination of Class and parts will satisfy maintenance requirements 85 of the time Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 79 XXV Recommended Spare Parts Contd Table 19 Main Valve O ring Kits Buna N Nitrile Inlet Size Orifice Valve Type Material Part No in mm 1 00 25 4 DEF 3905 10 12 Buna N Nitrile 70 MORK 70B018 1 50 38 1 1 50 38 1 GH 3905 10 12 Buna N Nitrile 70 MORK 7
67. er Bottom Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Top Plate Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads Bonnet Check for any corrosion or pitting Also check for galling of threads for the compression screw and where it attaches to the pilot base Compression Screw Galling at the spherical bearing surface or in the thread Check for any corrosion or pitting Spring Washer s Galling at the spherical bearing surface Check for any corrosion or pitting Pilot Base Check for any corrosion or pitting Also check for galling of threads Spring Check for any corrosion or pitting B 1 10 11 39MVO07 Main Piston Galling or excessive wear on the small diameter end where it engages the spring seals or on the spherical bearing surface Any corrosion or pitting that appears detrimental to the function of the 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 The upper diameter where the spring seal main piston rides must be 1 495 001 37 97 0 03 mm on 39PVO7 model or 970 001 24 64 0 03 mm on 39PV37 A surface finish of 8 RMS must be maintained for proper
68. f Pattern Round Percentage of Required Torque 1 Wrench Tight 2 25 3 60 4 100 5 100 Figure 21 Bolt Tightening Patterns Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 41 XVI Disassembly of Pilot Valve A 39PVO7 37 Disassembly Figures 22 and 23 1 Remove and discard the aluminum seals and sealing wire 2 Remove cop compression screw by turning counterclockwise 3 Ifa lifting lever is installed also use Figure 23 to remove the lifting lever assembly Then return to Figure 22 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 spri
69. first over the number of flats that was recorded in the plunger and spring seal adjuster top disassembly instructions section xvi C Stop when spring seal adjuster top is about Step 16 half way inside the funnel tube as shown in Thread the adjuster lock nut clockwise onto figure 27 the adjuster assembly hand tight v Remove plunger m Thread adjuster cap clockwise onto adjuster vi Insert funnel tube assembly into adjuster assembly hand tight we until kel ww contocts spring seol NOTE make sure adjuster cap and adjuster lock adjuster top gland nut threads freely on adjuster bottom vii Push down on plunger cylinder to insert Adjuster assembly may be inadvertently spring seal adjuster top into adjuster top rotated if these two parts do not fit loosely as shown in figure 28 m 3 The insert assembly of the pilot consists of viii Remove funnel tube assembly 1 Insert top ix Inspect adjuster top to make sure that spring seal adjuster top did not flare out during 1 Insert bottom installation and that the spring 1 Spring seal insert seal adjuster top is oriented as shown 1 O ring insert in figure 29 a Press spring seal insert into groove c Install the spring seal adjuster bottom onto on the insert bottom Make sure spring the adjuster bottom with spring side down as is facing upwards shown in figure 29 9 b Install insert top over insert bottom with the d Place the balance
70. flon amp Field Test Connection Backflow PSGK 57E019 Preventer Seal Kit PSGK 57B018 PSGK 57E0022 PSGK 57V022 PSGK 571006 Line Filter Seal Kit SP540 JKIT NOTE 1 Contact factory for kit number for Dirty Service Option NOTE 2 For steam service at pressures below 50 psig 3 45 barg the 39PV07 2 SS or 39MV07 2 SS with EPR O rings should be used E962 90 84 GE Oil amp Gas XXV Recommended Spare Parts Contd Table 22 Miscellaneous Parts Description Size Part Number Manual Blowdown Valve 250 6 35 mm MNPT SP348 E Male Connector 375 9 53 mm T x 250 6 35 mm MNPT 6000609 Male Elbow 375 9 53 T x 250 6 35 mm MNPT 6000608 Nut and Ferrule Set 375 9 53 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 NOTE 1 The above part numbers are 316 stainless steel material For other material options please contact factory Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 85 XXVI A Field Service Utilities and 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 GE Consolidated maintains the largest and most competent field service staff in the Industry Service Engineers are locate
71. he conceivable ways in which tasks might be performed or of the possible hazardous consequences of each way Consequently GE s Wear necessary Consolidated has not undertaken any such broad evaluation and thus protective equipment anyone who uses a procedure and or tool which is not recommended by GE s to prevent Consolidated or deviates from GE s Consolidated recommendations must possible injury be thoroughly satisfied that neither personal safety nor valve safety will be jeopardized by the method and or tools selected If not so satisfied contact GE s Consolidated at 318 640 6055 if there are any questions relative to tools methods The installation and start up of valves and or valve products may involve proximity to fluids at extremely high pressure and or temperature Consequently every precaution should be taken to prevent injury to personnel during the performance of any procedure These precautions should consist of but are not limited to ear drum protection eye protection and the use of protective clothing i e gloves etc when personnel are in or around a valve work area Due to the various circumstances and conditions in which these operations may be performed on GE s Consolidated products and the possible hazardous consequences of each way GE s Consolidated can not possibly evaluate all conditions that might injure personnel or equipment Nevertheless GE s Consolidated does offer certain Safety Precauti
72. ice Valve Type Material Part No in mm 1 00 25 4 D E F 3905 10 12 Teflon MORK 70T006 1 50 38 1 1 50 38 1 G H 3905 10 12 Teflon MORK 71T006 2 00 50 8 G H J 3905 10 12 Teflon MORK 71T006 3 00 76 2 J K L 3905 10 12 Teflon MORK 72T006 4 00 101 6 L M N P 3905 10 12 Teflon MORK 73T006 6 00 152 4 Q R 3905 10 12 Teflon MORK 74T006 8 00 203 2 T 3905 10 12 Teflon MORK 75T006 1 50 38 1 Full Bore 3905 10 12 Teflon MORK 71T006 3 00 76 2 Full Bore 3905 10 12 Teflon MORK 73T006 4 00 101 6 Full Bore 3905 10 12 Teflon MORK 76T006 6 00 152 4 Full Bore 3905 10 12 Teflon MORK 75T006 8 00 203 2 Full Bore 3905 10 12 Teflon MORK 77T006 10 00 254 0 Full Bore 3905 10 12 Teflon MORK 78T006 1 00 25 4 D E F 3914 16 Teflon MORK 70T006 1 50 38 1 1 50 38 1 G H 3914 16 Teflon MORK 71T006 2 00 50 8 GH 3914 16 Teflon MORK 71T006 3 00 76 2 J KL 3914 16 Teflon MORK 72T006 4 00 101 6 L MNP 3914 16 Teflon MORK 73T006 NOTE 1 Nitrile 70 For Freon 134 Ester Oil Service Neoprene Silicon amp Kalrez amp Seals are available POA NOTE 2 repairing a 3900 Metal Seat Design the seat o ring in the above kits will not be used Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 83 XXV Recommended Spare Parts Contd Pilot Type Table 20 Pilot Valve O ring Kit Buna N Ethylene Propylene Viton Teflon amp 39PV01 1 GS amp LS PSGKF 31B
73. ich may have high frequency pressure spikes The pressure spike snubber is designed to dampen the pressure spikes which could cause unnecessary parts wear or premature valve opening Figure 56 Pilot Valve Tester K Pressure Differential Switch Electrical A pressure differential switch Figure 57 is available which may be wired to an operator station or some other remote location The switch will provide a signal that indicates when the main valve is opening The standard pressure differential switch is a single Figure 58 Pressure Spike Snubber pole double throw rated at 5 amps and 30 volts DC with a NEMA 4 enclosure For other configurations i consult the factory M Remote Pilot Mounting The 39PV and 39MV pilots can be mounted separately from the main valve Remote pilot mounting will allow heating or cooling the pilot in case ambient conditions are outside the scope of the pilot It will also enable the user to group several pilots together for control of ambient conditions in a smaller space In addition this promotes easier maintenance N Remote Sensing The pilot valve inlet may be piped to a location remote from the main valve In this application the customer may pipe the inlet sensing line to some location other than where the main valve is located and where the pressure will be relieved for tubing size and maximum length consult factory for recommendations Figure 57 Pressure Differential Switch 7
74. inal standard configuration for the modulation pilot valves without any options is shown in Figures 36 through 38 Figure 36 39MV07 XIX Setting and Testing Contd Figure 38 39MV72 5 Reasons for failure a Any leakage from pilot at 496 below valve set pressure or 2 psig 0 14 Barg whichever is greater The 39MV22 and 39MV72 may have 50 bubbles per minute at 596 below the set pressures at or above 2251 psig 155 2 barg and none at pressures below 2250 psig 155 1 Barg b Main valve equipped with soft seats i Formain valve equipped with 39MV22 and 39MV72 no leakage 0 bpm is acceptable at 596 below valve set pressure or 2 psig 0 14 barg whichever is greater For set pressures 2250 psig 155 10 barg and above 50 bpm is acceptable for both pilot and main valve i For all other valve types no leakage 0 bpm is acceptable at 496 below valve set pressure or 2 psig 0 14 Psig whichever if greater c Main valve equipped with metal seats and air as test media i initial leakage test of the main valve shall be made using a piece of wet paper placed over the outlet of the valve for one minute with pressure held at 496 below valve set pressure or 2 psig 0 14 barg whichever is greater i Ifleakage from main valve is indicated by a bulging of the wet paper the standard test fixture as described in c iii shall be installed on the outlet flange to determine the extent of the leakage The te
75. ing 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 o ring top plate and back up rings if applicable 11 Remove main piston assembly from pilot base 12 Main piston assembly consists of 1 Main Piston 1 Piston Nose 1 Piston Retainer Nut 1 Set Screw Remove set screw Turn piston retainer nut counterclockwise to remove Remove piston nose NOTE For dirty service option please refer to Dirty 15 14 15 16 17 18 1 20 to Service Option Section XXI B for disassembly instructions Remove spring seal main piston and backup ring if applicable and discard Removing
76. ire assembly on top of pilot base assembly ensuring that the spherical radius located on the bottom spring washer engages with spherical nose on main piston Install the bonnet over the spring and spring washer assembly Thread the bonnet onto the top plate Tighten wrench tight Install and tighten set screw Turn compression screw clockwise until dimension has been reached that was noted during disassembly Tighten compression screw lock nut wrench tight 13 For lifting lever option reinstall release nut and release lock nut onto lifting stem Turn clockwise until it matches the dimension noted during disassembly Install filter plug into bonnet vent hole if removed 15 Install pipe plug pilot valve in port above vent hole if removed Refer to field test connection backflow preventer option section xxi A for reassembly of field test connection Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 59 XIX Setting and Testing A 39PV07 37 Figure 34 39PV07 37 1 Attach pilot to main valve using two socket head cap screws bracket Install the 575 9 53 mm O D tubes refer to Table 12 for sizing of tubing into the fittings for the inlet and dome ports Make sure the tube ends are fully inserted before torquing Begin torquing the fitting about midway down verify that Swagelok gap inspection gauge Swagelok P N MS IG 468 will go Continue to torque down fit
77. ld not be removed from the skids or crates until immediately prior to installation on the system Flange protectors and sealing plugs should not be removed until the valve is to be installed on the system This includes both inlet and outlet protectors VII Pre Installation and Installation Instructions A Pre Installation and Installation A CAUTION CAUTION After the valve is uncrated and protective devices removed exercise care to prevent dirt and other foreign matter from entering either the inlet or the outlet port B Mounting Instructions CAUTION Pressure relief valves should be mounted in a vertical upright position Installing a valve in any other position will adversely affect its operation in varying degrees as a result of induced misalignment of parts Never attempt to lift the No stop valve should be placed between the pressure vessel and its relief valve valve by anything other except as permitted by Code regulations If a stop valves located between the than the eyebolts pressure vessel and pressure relief valve its port area should equal or exceed the nominal internal area of the piping from the vessel to the relief valve must not exceed 3 of the valve set pressure when it is flowing at full capacity A CAUTION Flanges and gasket surfaces must be free from dirt and debris when valves are installed Flange bolts should be tightened evenly to prevent distortion of the valve body and inlet nozzle Before start up be
78. lled ii Back up ring lower should be installed second with angle facing away from you when installed ii Lubricate spring seal main piston and top plate gland Install spring seal main piston into the top plate The spring and back up rings should be oriented as shown in figure 32 iv Lubricate main piston assembly before installing Install main piston into the top plate with spring washer bearing point going in first Be careful not to damage spring seal main piston 5 Reassembly of Pilot Valve Contd Install main piston top plate assembly into pilot base by inserting small diameter end of main piston through insert assembly NOTE For dirty service option install main piston top 10 10 11 12 14 16 plate assembly into dirty service insert instead of pilot base Insert the four cap screws top plate through the top plate and thread into the pilot base Tighten to 25 2 ft lbs 34x2 7 N m If removed thread compression screw lock nut clockwise onto compression screw Thread compression screw into top of bonnet until the bearing point begins to protrude through bonnet Place spring washers on the ends of the spring There is not a top or bottom spring washer unless the lifting lever option is installed If pilot has lifting lever option a Place spring over lifting stem and place on bottom spring washer b Place top spring washer on top of spring and then place the ent
79. ly into guide with the disc seat going in first Continue pushing disc into guide being careful to not pinch the guide rings Push disc in until the disc is in contact with the nozzle 4 L M N P Q R T 3 F B 4 F B 6 F B 4 8 F B 10 F B and 12 F B 1 Make sure the chamfer on the TOP of the guide is smooth If any sharp edges exist polish the chamfer since the seal could be damaged during assembly 5 Install cover plate o ring into top groove on guide 6 Install spring into dome cavity with smaller coils on bottom When installing the cover plate make sure the spring coils remain in the groove and centered 2 Drop guide o ring into top of base for outside diameter of guide 3 Insert guide into top of base It will not fit flush The cover plate will force it down during its installation 7 Install cover plate on top of base such that the pilot will be aligned for proper tubing connections Make note of the length of the studs or cap screws The two longer ones will straddle the vertical line of the inlet sensing port on the main base of the pilot valve Install the bracket between the cover plate and the nut or cap screw Torque to the values found in Table 9 using the torque patterns in Figure 21 and Table 10 Be sure that the bracket is aligned so that the two smaller pilot attachment holes are above the horizontal plane of the cover plate Table 10 Torque Required for Eqch Round o
80. maintenance usually involves e Removal of pilot valve from main valve Disassembly of both the pilot and main valve Cleaning e Component inspection Parts replacement as needed Reassembly Setting testing and resealing the valve Occasionally remachining the seat bushing may be necessary to extend the service life of the valve Keep all parts for each valve separated to ensure replacement in the same valve Note Insure there is no pressure in the inlet of the valve before attempting to remove it from the piping system XII Disassembly of the 3900 MPV Series POSRV A Removal of Pilot Valve From Main Valve Make sure there is no media pressure in the vessel in the valve inlet in the main or in the pilot valve Disconnect the sensing tube and discharge line from the pilot valve Disconnect the filter and remove the manual blow down from the pilot valve if these options exist All other external attachments should be removed to free the pilot valve for disassembly Loosen and remove the two cap bolts holding the pilot valve to the mounting bracket Place parts in the order they are disassembled to facilitate reassembly B Disassembly of Main Valve Note Ifthe pilot valve has not been removed then refer to Section MILA 1 Remove Swagelok tube fitting from sensing tube 2 Remove and discard Plug Filter from sensing tube if applicable 3 Loosen and remove the nuts or
81. me other light abrasive can only be used since the part cannot function properly if its overall dimensions are changed significantly If significant corrosion or damage has occurred on o ring retainer discard and replace Figure 13b Metal Seat MS F 1 00r 10 035 mm Z A 11 0017 005 2 lt lt H H gt Figure 13 Nozzle Seat MS amp DA Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 29 XIII Maintenance Instructions Contd Table 2a Nozzle Machined Dimensions Metal to Metal 005 E x 005 maya Al 0 13 0 13 F G eo Jmin 83 Size Orifice 50 03 mm 0 5 Type mm mm in mm in mm in mm in mm in mm in mm in mm jAngle 1 00 25 4 D E F 092 2 34 032 0 81 1 154 001 29 31 0 03 1 030 001 26 16 0 03 1 186 50 12 1 797 45 64 30 1 50 38 1 D E F 092 2 34 032 0 81 1 154 001 29 31 0 03 1 030 001 26 16 0 03 1 186 30 12 1 797 45 64 30 1 50 58 1 GH 066 1 68 066 1 68 1 836 002 46 65 0 05 1 711 001 43 46 0 03 1 936 49 17 1 984 50 39 45 2 00 50 8 G H 066 1 68 066 1 68 1 836 002 46 65 5 1 711 001 43 46 0 03 1 936 49 17 1 984 50 39 45 Std Bore 3 00 76 2 J
82. ment Do not sand blast internal parts as it can reduce the dimensions of the parts 3 Parts Inspection a Insert Top Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads 68 GE Oil amp Gas Ref No Part 50a Dirty Service Insert 50b Insert Top 50c Insert Bottom 50d O ring Insert 50e Spring Seal Insert 50f O ring Dirty Service Insert 50g Regulator Figure 46 Dirty Service Parts b Insert Bottom Galling or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting Reassembly Instructions Making the insert assembly for dirty service option a Press spring seal insert into groove on the insert bottom Make sure spring is facing upwards b Install insert top over insert bottom with the seal side going in first c Lightly lubricate o ring groove now formed by the two insert parts This lubrication is used to hold the o ring insert in place when it is being inserted into dirty service insert d Place o ring insert into groove e The insert assembly is threaded into the dirty service insert Tighten assembly wrench tight Make sure milled slot is facing up f Install o ring top plate onto groove in pilot base g install dirty service insert assembly on top of pilot base with inlet port facing opposite of vent
83. mperature limitations are combined in pressure class categories according to ANSI Standards Conversely the pressure and temperature limits of the Pilot Valve are presented separately Note When replacing or repairing the main valve and pilot valve assembly pay particular attention to the pressures and temperature limitations for both the main valve and pilot valve to ensure compatibility Table 1 Service and Applications Pressure Range Temperature Range Model Service min max min max psig barg psig barg F 2G OF Me 39PVO7 GS 55 or LA Gas Air Steam or Liquid 15 103 750 51 71 40 400 505 262 8 39MV07 GS or SS Gas Air or Steam 15 1 03 750 51 71 40 40 0 505 262 8 39MVO7 LS Liquid 15 1 03 750 51 71 40 400 505 262 8 39PV37 GS SS orLA Gas Air Steam or Liquid 751 51 78 3750 256 55 40 40 0 505 262 8 39MV22 GS or SS Gas Air or Steam 751 5178 3750 258 55 40 40 0 505 262 8 39MV22 LA Liquid 751 5178 3750 258 55 40 40 0 505 262 8 39MV72 GS SSorLA Gas Air Steam or Liquid 3751 258 62 6250 430 92 40 40 0 505 262 8 Note 195 6 C to 343 3 C 14 GE Oil amp Gas With the installation of the heat exchanger temperature range may be expanded to 320 F to 650 F VIII Introduction Contd C Main Valve Introduction The Consolidated Pilot Operated
84. n developing a meaningful A CAUTION replacement parts plan 1 The total number of valves in service should be classified by size type and temperature class 2 The parts inventory should be classified by the tendency to require replacement Class I Most frequently replaced Class II Less frequently replaced but critical in an emergency 3 Parts for the valve types covered by this manual are classified on Table 18 Oty parts is the number of parts or sets which is recommended to achieve a desired need probability as it relates to the total number of valves in service by size and Always use appropriate type For example a Qty parts of one 1 then five 5 means that 1 part should restoration procedures be stocked for each 5 valves of the same type and size in service 4 When ordering replacement parts please specify in accordance with applicable nomenclature see Figures 1 to 5 Be sure to state the size type and serial number of the valve for which parts are required When ordering pilot parts T CAUTION please state specific pilot type 39PV07 37 etc For ease of maintenance o ring kits are available for each main valve and pilot type A stock of these kits should be kept on hand for maximum operating efficiency See Tables 19 20 and 21 B Identification and Ordering Essentials When ordering service parts please furnish the following information to ensure receiving the correct replacement parts Identify valv
85. n screw into top of bonnet until the bearing point begins to protrude through bonnet 9 Place spring washers on the ends of the spring There is not a top or bottom spring washer unless the lifting lever option is installed XVIII 10 11 12 1 WN 14 1 1 an uU 17 If pilot has lifting lever option a Place spring over lifting stem and place on bottom spring washer b Place top spring washer on top of spring and then place the entire assembly on top of pilot base assembly ensuring that the spherical radius located on the bottom spring washer engages with spherical nose on main piston Install the bonnet over the spring and spring washer assembly Thread the bonnet onto the top plate tighten wrench tight Install and tighten set screw Turn compression screw clockwise until dimension has been reached that was noted during disassembly Tighten compression screw lock nut wrench tight For lifting lever option reinstall release nut and release lock nut onto lifting stem Turn clockwise until it matches the dimension noted during disassembly A Install filter plug into bonnet vent hole if removed Install pipe plug pilot valve in port above vent hole Refer to field test connection backflow preventer option for reassembly of field test connection Making the modulator piston assembly a Install spring seal piston top into groove on modulator piston top Be sure to have the
86. nd and tighten sensing tube if required Note Install plug filter between tube fitting and 3 Installation of nozzle sensing tube if required 4 Install nozzle o ring over threads of nozzle and slide 3 Installation of nozzle until it hits the backside of the flange Install nozzle into base with the appropriate wrench and torque to the value shown in Table 7 Refer to Figure 61 and Table 15 for specifications on appropriate spanner wrench a The nozzle seat must be lapped to a width corresponding to the valve set pressures For seat widths please refer to Table 3 for standard metal seats and Table 4 for Thermodisc seats Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 39 XV Reassembly of 3900 MPV Series Main Valve Contd Table 7 Nozzle Torque Values Valve Inlet Size Nozzle Installation Torque in mm ft lbs 596 N m x 596 1 00 25 4 100 136 1 50 38 1 100 136 2 00 50 8 160 217 3 00 76 2 475 644 4 00 101 6 1070 1451 6 00 152 4 1445 1959 8 00 203 2 1865 2529 Bolted Nozzles 60 81 Inlet Size No W e i Orifice of BoltSize EBIN in mm Bolts An 1 16 1 00 25 4 DEF 1 5 16 18UNC 120 13 6 1 50 38 1 DEF 1 5 16 18UNC 120 13 6 1 50 38 1 GH 1 3 8 24UNF 245 277 2 00 50 8 G H J 1 3 8 24UNF 245 277 3 00 76 2 JKL 4 5 16 18UNC 120 13 6 4 00 101 6 L M N P 6
87. nd blast internal parts as it can reduce the dimensions of the parts 3 Parts Inspection a Shuttle base Galling or excessive wear on the threads Check for any corrosion or pitting b Shuttle plug Galling or excessive wear on the threads Check for any corrosion or pitting 4 Reassembly Instructions Lubricate o rings with silicone grease GE P N SP505 a Assembly of field test connection backflow preventer assembly a Insert one of the small o rings into the shuttle base counter bore b Insert the tube filter into the shuttle base c Insert shuttle ball inside of tube filter d Insert the other small o ring into the shuttle plug counter bore Install larger o ring into groove located on OD of shuttle plug e Thread shuttle plug into shuttle base wrench tighten Shuttle Ball O ring Shuttle Base Shuttle Plug Tube Filter Figure 42 Backflow Preventer Option XXI 3900 MPV Series POSRV Options Contd B Dirty Service Option Severe dirty service precipitation and viscous fluid problems can be solved using the dirty service option offered on the 3900 MPV Series POSRV A dirty service option can be added to the standard pilot valve The kit contains a 316 SS chamber an isolation seal and an extended pilot piston The module is positioned SE at the top of the pilot valve body and below the pilot valve bonnet Crucial valve components such as the modulator dome assembly
88. ned It can be lapped for minor scratches light corrosion pitting or minor damage of other types If lapping does not fix damaged area part must be if it can be determined that it will not affect product discarded performance All o rings and seals should be replaced 10 Disc Holder Should be replaced if the sliding each time the valve is disassembled surface is galled pitted or scratched Refer to Table 18 for a list of recommended spare parts Replace all parts as needed If any damage listed above and Table 19 for a list of o ring repair kits is present the part should be replaced or repaired per XV Reassembly of 3900 MVP Series Main Valve A Lubricants and Sealants b Check seat widths using a measuring magnifier such as Baush amp Lomb Model 81 34 3547 GE 1 0 ting t t below 40 F 40 F It B ERR control number 8003688 or equivalent the Factory c Install nozzle o ring over threads of nozzle and slide until it hits the backside of the flange Install nozzle into base with the appropriate 2 Operating temperatures between 40 and 505 F 40 and 262 7 C a Lubricate all o rings except silicone spring wrench and torque to the value shown in energized seals and back up rings sparingly Table 7 Refer to Figure 61 and Table 15 for with silicone grease GE P N SP505 specifications on appropriate spanner wrench b Seal all pipe threads with Teflon tape or pipe 4 Disc preparation sealant
89. ng 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 Note For dirty service option please refer to Dirty Service Option Section XXI B for disassembly instructions 42 GE Oil amp Gas 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 60 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 1 DB Loosen adjuster lock nut by turning counterclockwise 1 Q 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 1 a Turn adjuster assembly clockwise counting the number of flats until assembly stops Record number of flats for reassembly 1 T Remove adjuster assembly from the pilot base by turning counterclockwise Remove o ring adjuster top and o ring adjuster bottom from adjuster assembl
90. ny corrosion or pitting 11 Spring Washer s Galling at the spherical bearing surface Check for any corrosion or pitting 12 Pilot Base Check for any corrosion or pitting Also check for galling of threads 13 Spring Check for any corrosion or pitting If any damage listed above is present the part should be replaced or repaired per instruction Other valve parts may be acceptable with light corrosion pitting or minor damage of other types if it can be determined that it will not affect product performance All o rings and spring seals should be replaced each time the valve is disassembled Refer to Tables 20 and 21 for o ring spring seal repair kits Recommended spare parts are listed in Table 18 XVIII A Lubricants and Sealants 1 Lubricate all o rings except those made from silicone and spring seals sparingly with silicone grease GE P N SP505 Seal all pipe threads with Teflon tape or pipe sealant GE P N SP364 AB Lubricate standard threads and bearing points with Fluorolube amp GR362 GE P N 4668601 or equivalent Assembly of 39PV07 37 Making the main pilot Making the adjuster assembly This assembly consists of 1 Adjuster Bottom 1 Adjuster Top 1 Spring Seal Adjuster Top 1 O ring Adjuster Top 1 O ring Adjuster Bottom a Check the adjuster top for burrs at the spring seal lead in chamfer Remove any burrs using a polishing cloth b Install spring seal adjuster t
91. one 318 640 6055 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 7 lI Safety Alerts Contd A WARNING All potential hazards may not be covered in this manual A WARNING 7 vy RADIATION AREA KEEP OUT RWP REQUIRED FOR ENTRY Know nuclear health physics procedures if applicable to avoid possible severe personal injury or death A CAUTION Wear necessary protective equipment to prevent possible injury 8 GE 0il amp Gas A WARNING Improper tools or improper use of right tools could result in personal injury or product damage A CAUTION Heed all service manual warnings Read installation instructions before installing valve s A CAUTION Always use appropriate restoration procedures 7 WARNING These WARNINGS are as complete as possible but not all conceivable service methods not evaluate all potential hazards 8 WARNING Use of improper tools or improper use of right tools could result in personal injury or product or property damage 9 WARNING This valve product line is not intended for radioactive nuclear applications Some valve products manufactured by GE may be used in radioactive environments Consequently prior to starting any operation in a radioactive environment the proper health physics procedures should be followed if applicable 1 CAUTION Heed all service manual warnings Read installation instructions before
92. ons for customer information only It is the responsibility of the purchaser or user of GE s Consolidated valves equipment to adequately train all personnel who will be working with the involved valves equipment For more information on training schedules call 318 640 6054 Further prior to working with the involved valves equipment personnel who are to perform such work should become thoroughly familiar with the contents of these instructions Additional copies of these instructions can be purchased at a minimal cost by contacting GE s Consolidated in writing at PO Box 1430 Alexandria LA 71309 1430 or by calling at 318 640 2250 Fax 318 640 6325 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 9 IV Warranty Information 4 CAUTION AN P Defective and nonconforming items must be inspected by GE A CAUTION Removal and or breakage of seal will negate our warranty 10 GE Oil amp Gas Warranty Statement Warranty Statement GE warrants that its products and work will meet all applicable specifications and other specific product and work requirements including those of performance if any and will be free from defects in material and workmanship CAUTION Defective and nonconforming items must be held for GE s inspection and returned to the original F O B point upon request Incorrect Selection or Misapplication of Products GE Consolidated cannot be respon
93. op into adjuster top using insertion tool as shown in Figure 59 i Lubricate spring seal adjuster top with silicone grease ii Install spring seal adjuster top onto plunger cylinder with spring facing away from plunger cylinder ii Insert plunger into plunger cylinder until plunger lightly contacts spring seal adjuster top iv Insert funnel tube chamfer side first over the plunger and spring seal adjuster top Stop when spring seal adjuster top is about half way inside the funnel tube as shown in Figure 27 Plunger a Plunger Cylinder Spring Seal Main Piston Funnel Tube Figure 27 Funnel Tube Reassembly of Pilot Valve v Remove plunger vi Insert funnel tube assembly into adjuster top until funnel tube contacts spring seal adjuster top gland viii Push down on plunger cylinder to insert spring seal adjuster top into adjuster top as shown in Figure 28 Spring Sedl Adjuster Top Adjuster Top Funnel Tube BE Plunger Cylinder Figure 28 Plunger Cylinder viii Remove funnel tube assembly ix Inspect adjuster top to make sure that spring seal adjuster top did not flare out during installation and that the spring seal adjuster top is oriented as shown in Figure 29 c Thread adjuster top clockwise onto adjuster bottom and torque to 27 2 ft lbs 37 2 7 N m d Lubricate main piston stem and cycle main piston through spring seal adjuster top five times Spring Se
94. or excessive wear on the diameter where the spring seals engage Any corrosion or pitting that appears detrimental to the function of the 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 05 mm along its length 3 Insert Top Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads 52 GE Oil amp Gas 4 Insert Bottom Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting 5 Adjuster Top Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads 6 Adjuster Bottom Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads 7 Balance Seal Adaptor Check for any corrosion or pitting 8 Top Plate Galling or excessive wear on the inside diameter that guides the main piston Check for any corrosion or pitting Also check for galling of threads 9 Bonnet Check for any corrosion or pitting Also check for galling of threads for the compression screw and where it attaches to the pilot base 10 Compression Screw Galling at the spherical bearing surface or in the thread Check for a
95. orce on the main valve disc increases allowing the main valve to relieve more pressure The disc obtains full lift full capacity within 1096 of set pressure When the discharging valve reduces the inlet pressure to the pre set blow down pressure of the pilot The pilot piston closes the vent seal Simultaneously the inlet seal is reopened in the pilot The main valve inlet pressure is again allowed to enter the dome above the main valve disc As the dome pressure equalizes with the inlet pressure the downward force created by the differential areas of the disc closes the main valve Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 23 Xl General Planning for Maintenance 4 CAUTION Always use appropriate restoration procedures A CAUTION Do not interchange parts from one valve to another Decontaminate or clean if necessary before pretesting or disassembly Safety and environmental precautions must be taken for the decontamination or cleaning method used 24 GE Oil amp Gas A 12 month maintenance interval is recommended for general service conditions For severe service applications a 3 to 6 month inspection and testing interim may be more appropriate The specific plant s operating and service history will better determine this frequency GE encourages preventive maintenance The 3900 MPV Series Pilot Operated Safety Relief Valve POSRV is easily maintained Normal
96. orizontal plane of the cover plate XV Reassembly of 3900 MPV Series Main Valve Contd Inlet Size 3905 3910 3912 3914 3916 3918 in mm ft lb N m ft lb N m ft lb N m ft lb N m ft lb N m ft lb N m 1 00 25 4 D E F 40 54 40 54 40 54 40 54 40 54 90 122 1 50 3841 D E F 40 54 40 54 40 54 40 54 40 54 340 461 1 50 3841 GH 120 163 120 163 120 163 120 163 120 163 510 691 2 00 50 8 GH J 120 163 120 163 120 163 120 163 120 163 720 976 3 00 762 J K L 210 285 210 285 210 285 210 285 210 285 1015 1376 4 00 101 6 M N P 340 461 340 461 340 461 340 461 340 461 N A N A 6 00 152 4 Q R 340 461 340 461 340 461 N A N A N A N A N A N A 8 00 203 2 T 510 691 510 691 510 691 N A N A N A N A N A N A 1 50 38 1 Full Bore 120 165 120 163 120 163 120 163 120 163 Note 1 Note 1 2 00 50 8 Full Bore 210 285 210 285 210 285 210 285 210 285 Note 1 Note 1 3 00 76 2 Full Bore 340 461 340 461 340 461 340 461 340 461 Note 1 Note 1 4 00 101 6 Full Bore 340 461 340 461 340 461 340 461 N A N A N A N A 6 00 152 4 Full Bore 510 691 510 691 510 691 N A N A N A N A N A N A 8 00 203 2 Full Bore 720 976 720 976 720 976 N A N A N A N A N A N A 10 00 254 0 Full Bore 720 976 720 976 N A N A N A N A N A N A N A N A 12 00 304 8 Full Bore 720 976 720 976 N A N A N A N A N A N A N A N A Insert disc assemb
97. pilot base with t handle groove wrench Part 4995401 Figure 60 Tighten wrench tight Make sure milled slot is facing up g Lubricate main Piston stem and cycle main piston through spring seal insert five times NOTE For dirty service option please refer to assembly instructions included in the dirty service option section 4 nstall o ring top plate into groove on top of pilot base NOTE For dirty service option o ring top plate is installed into groove on top of the dirty service insert a Lubricate the spring seal main piston and top plate gland Install the spring seal main piston into top plate The spring should be oriented as shown in Figure 31 b Lubricate main piston before installing Install the main piston into the top plate with the spring washer bearing point going in first Be careful not to damage the spring seal main piston 5 Install main piston top plate assembly into pilot base by inserting small diameter end of main piston through insert assembly NOTE For dirty service option install main piston top plate assembly into dirty service insert instead of pilot base 6 Insert the four cap screws top plate through the top plate and thread into the pilot base Tighten to 25 2 ft lbs 34 2 7 N m NOTE If removed thread compression screw lock nut clockwise onto compression screw 7 Thread compression screw lock nut clockwise onto compression screw 8 Thread compressio
98. pilot valve Any discrepancies should be promptly reported to the appropriate plant authority Specify parts required by T 2 32 Part Name See Section IX Figures 1 2 3 4 and 5 Part Number if known Quantity Contact Parts Marketing 1 318 640 2250 In addition the main valve serial number is stamped on the top edge of the outlet flange Be sure to include the one or two letters preceding the figures in the serial number Typical valve nameplates are shown in Figures 63 64 and 65 78 GE Oil amp Gas CERTIFIED BY Consolidated SRAL TL1234M Em 112 PSI TEMP 340 F cw 115 979 WATER PT MIN AR CAP CDTP SAT PSI 8 M 9773901 DATE 12 10 Figure 63 Nameplates for Main Valve THIS VALVE CONTAINS TEFLON SEALS AND AN O RING SEAT SEAL BUNA 70 O RING ANS 31018432 Figure 64 Nameplates for Main Valve Consolidated CERTIFIED ALEXANDRIA BY LOUISIANA USA PILOT VALVE MODEL NO 3PVO1 1 CC B GS ARAL TL1234P o RING BUNA TEF PRESS 112 B M 9773901 DATE 12 10 Figure 65 Nameplate for Pilot Valve XX IV Genuine GE Parts The next time replacement parts are needed keep these points in mind e GE s Consolidated designed the parts e GE s Consolidated guarantees the parts Consolidated valve products have been in use since 1879 e GE s Consolidated has worldwide service GE s Consolidat
99. port on pilot base Then install main piston top plate assembly onto base dirty insert by inserting small diameter end of main piston through insert assemblies XXI 3900 MPV Series POSRV Options Contd C Dual Pilots A dual pilot arrangement Figure 47 is available for applications in which the pilot valve soft goods require monitoring and or maintenance more often than the main valve In this installation the pilot valves may be alternated for maintenance without bringing the system down Figure 47 Dirty Service Parts When servicing dual pilots procedures need to be in place to perform a Lock out tag out LOTO of pilots under pressure if they are in service D Field Test Connection A field test connection is standard on all pilot valve types This allows the stroking of the valve with an auxiliary material e g air or nitrogen An internal check valve is present in the field test connection isolating the inlet media from the test media and at the 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 375 9 55 mm tube fitting equipped with a bug screen For all applications on air water over 140 F 60 C or Steam service ASME Section VIII Division 1 requires each pressure relief valve to have a lifting device such as a field test connection or a means of connecting or applying pressure to the pilot to verify
100. pplication of soap solution or equivalent at points of possible leakage Pressure is to be held constant at the test pressure while the valve is being examined for leakage NOTE The letter designation BP designates backflow preventer Field Test Connection Ref No Part 1 Shuttle Ball 2 O ring 3 Shuttle Base 4 Shuttle Plug 5 Tube Filter 2900 bellows 3900 5 MS without backflow preventer backpressure test are to be performed by applying pressure with air or nitrogen to the valve inlet and valve outlet The pressure being applied to the valve inlet should be equal to the pressure being applied to the valve outlet Leakage may be detected by application of soap solution or equivalent at points of possible leakage Pressure is to be held constant at the test pressure while the valve is being examined for leakage NOTE The purpose of applying pressure to the valve inlet and outlet is to prevent the disc and disc holder from separating during the backpressure test e The following points shall be examined for leakage during backpressure testing i Coverplate inlet and outlet joints i Alltube fittings and connections iii Possible point of leakage on the pilot valve When testing steam valves pressure is to be applied through field test connection equal to or greater than the back pressure This is to simulate inlet pressure after valve is taken off of the steam test stand Repair of
101. proximate Leakage per 24 Hours psig barg Bubbles per minute Standard Cubic Feet Bubbles per minute Standard Cubic Feet 15 1000 1 03 68 95 40 0 60 20 0 30 1500 103 42 60 0 90 30 0 45 2000 137 90 80 1 20 40 0 60 2500 172 37 100 1 50 50 0 75 3000 206 84 100 1 50 60 0 90 4000 275 79 100 1 50 80 1 20 5000 344 74 100 1 50 100 1 50 6000 413 69 100 1 50 100 1 50 62 GE 01 amp Gas XIX Setting and Testing Contd If adjustments are necessary adjust compression screw or adjuster and retighten corresponding lock nut Retest beginning at Step 5 Increase pressure from 9096 of set pressure to 496 below set pressure or 2 psig 0 14 barg whichever is greater and check all ports and connections for leakage on pilot and main valve 8 Backpressure testing for leakage q Backpressure is the pressure measured at the valve outlet in pounds per square inch gage psig or barg b Backpressure tests are to be performed after adjustment of set pressure and blowdown on each valve designed for use in a closed system having an inlet size greater than 1 24 5 mm NPS C The pressure at which the valve is to be backpressure tested shall be 30 psig 2 1 barg minimum or system backpressure whichever is higher Air or nitrogen shall be used as the test medium for applying backpressure d Backpressure tests are to be performed by applying pressure with air or nitrogen to the valve outlet Leakage may be detected by a
102. rclockwise 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 Figure 23 Lifting Lever Disassembly 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 44 GE Oil amp Gas XVI Disassembly of Pilot Valve Contd Figure 24 39MV07 Disassembly Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 45 XVI Disassembly of Pilot Valve Contd 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 NOTE For dirty service option please refer to dirty service option Section XXI B for disassembly instructions 12 Removing the insert assembly a The insert assembly consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O ring Insert
103. red appropriate safety labels have been included in the rectangular margin blocks throughout this manual Safety labels are vertically oriented rectangles as shown in the representative examples below consisting of three panels encircled by a narrow border The panels can contain four messages which communicate The level of hazard seriousness The nature of the hazard The consequence of human or product interaction with the hazard The instructions if necessary on how to avoid the hazard DANGER Immediate hazards which WILL result in severe personal injury or death WARNING Hazards or unsafe practices which COULD result in severe personal injury or death The top panel of the format contains a signal word DANGER WARNING 9 CAUTION or ATTENTION which communicates the level of hazard seriousness The center panel contains a pictorial which communicates the nature of CAUTION Hazards or unsafe practices which COULD result in the hazard and the possible consequence of human or product interaction with the hazard In some instances of human hazards the pictorial may instead depict what preventive measures to take such as wearing personal protective equipment PPE The bottom panel may contain an instruction message on how to minor personal injury ATTENTION Hazards or unsafe practices which COULD result in avoid the hazard In the case of human hazard this mess
104. ries POSRV Options cese oo re kk KK kk K k kk k kk k kk ke e eee e ee 66 A Backflow Preventer 0 0 06 jje pmmmmmmmpppmpmpp nm mm 66 1 JDisassembly InistEUCllonS see s ch s z bay n a ch DIR W w OR etd dcr QA Qe b k deed j 66 Ele TE PET 66 JjPartsTnspectlOb usum gee aon Bx Rr Nt AS p ERN PU UR RU ani 66 4 ReassemblyInstr ctlons ci s s k la EEN RER REY E 3005 8 4 98 5 xan IRER IE IN MM ida d 66 Bs DUES SN IES OPIO Ng me y ee e ln cute Se 67 1 JDisassemblylnstructioriss v esset Redeem per oO Rede euer ed 68 NEG e 68 3 SPARS INSPCCHON eene r 2 68 4 Reassembly Instr ctlons x a ieoscbesaee dudit de EP LP 5 A cilkan kak 68 4 GE Oil amp Gas Table of Contents XXII XXIII XXIV XXV XXVI esu e EA E NN T TET T E A ET EE TAE 69 D Field Test COnNNeECtON usen bestie tione n kh ae ade A f now An Ee Ae ak a h A rn n Ok r a 69 E Filter Single Dual or High Capacity n sla a n n n k I e 69 F GOJ 5 A ENEE JM HH ERAN dE dE dE AEN ENEE 70 G e eg Exchange su esie Ye dera ice en eese me aula dac di dita ca aet die PR EL 71 Mig ec 71 I Manual Electrical or Pneumatic Blowdown Valve 6 ccc cece nen enn 71 J Pilot Valve Tester u s deran a ERI PERIERE ae IP PRIEN 72 K Pressure Differential SWItCD acis i ett err ds Gad
105. rty Service Option Contd 1 Disassembly Instructions a C The dirty service option consists of 1 Insert Assembly 1 Dirty Service Insert 1 O ring Dirty Service Insert 1 Regulator The insert assembly consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O ring Insert Remove dirty service insert and discard o ring dirty service insert Remove insert assembly from the dirty service insert with tool 4995401 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 Return to disassembly instructions for pilot Section XVI 2 Cleaning a Clean parts to remove all rust burrs scale organic matter and loose particles Parts are to be free of any oil or grease except for lubrication as specified in this instruction Cleaning agents used shall be such that effective cleaning is assured without injuring the surface finishes or material properties of the part Acceptable cleaning agents include demineralized water nonphosphate detergent acetone and isopropyl alcohol Parts must be blown dry or wiped dry after cleaning If you are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s material safety data sheet for safe handling recommendations and equip
106. sible for customer s incorrect selection or misapplication of our products Unauthorized Repair Work GE Consolidated has not authorized any non GE affiliated 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 service on new products or field repaired products of its manufacture Therefore customers contracting such repair services from unauthorized sources must do at their own risk Unauthorized Removal of Seals All new valves and valves repaired in the field by GE Field Service are sealed to assure the customer of our guarantee against defective workmanship Unauthorized removal and or breakage of this seal will negate our warranty Note 1 Refer to GE s Standard Terms of Sale for complete details on warranty and limitation of remedy and liability V A Accumulation The pressure increase over the maximum allowable working pressure of the vessel during discharge through the Pilot Operated Safety Relief Valve POSRV expressed as a percentage of that pressure or in actual pressure units Backpressure The pressure on the discharge side of the POSRV Built up Backpressure Pressure that develops at the valve outlet as a result of flow after the POSRV has been opened N Superimposed Backpressure Pressure in the discharge header before the POSRV opens Constant Backpres
107. spring in the seal facing up b Install o ring modulator seat into groove on modulator piston bottom c Turn modulator piston bottom over and place o ring modulator piston bottom into inner groove d Install spring seal piston bottom onto modulator piston bottom in outer groove Make sure spring is facing down e Insert modulator piston top into modulator piston bottom through the side with the o ring modulator piston bottom and the spring seal piston bottom f Turn assembly over and install o ring retainer The chamfered outside diameter goes in first g Thread lock screw through the o ring retainer into modulator piston top Tighten 40 5 in Ibs 4 5 0 6 N m h Final modulator piston assembly is shown in figure 33 Modulator Seat 15 16 dee 18 19 20 Assembly of 39MV22 72 Reassembly of Pilot Valve Contd Spring Seal Piston Top Modulator Piston Top Spring Seal Piston Bottom Modulator Piston Bottom O Ring O Ring Retainer Lock Screw Figure 33 Modulator Piston Assembly Lubricate spring seals before inserting into modulator base Insert modulator piston assembly into modulator base with the modulator piston top going in first Push piston in with thumbs until it stops There will be some resistance due to the spring seals compressing to fit into the bore of the modulator base If necessary for installation insert the proper wrench into
108. st fixture is to be connected to the valve outlet in such a manner that no leakage may occur in the connection Per API standard 527 ANSI B147 1 72 a standard test fixture consists of a piece of tubing 313 7 94 mm o D X 032 0 81 mm wall where one end is joined to an adaptor on the valve outlet and other end is immersed 5 12 7 mm below the surface of a reservoir of water C Troubleshooting leakage de To isolate leakage 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 occurring from main valve Leakage from main valve can come from either the main valve seat nozzle seal or dome seal To determine if the leakage is from either the main valve seat or nozzle seal the outlet must be filled with water to above the seat line and checked for bubbles If no bubbles are present then leakage is coming from the dome sedl The leakage rate shall be determined with the valve mounted vertically and using a standard test fixture as described in XIX B c iii The leakage rate in bubbles per minute shall be determined with pressure held at 496 below valve set pressure or 2 psig 0 14 barg whichever is greater The test pressure shall be applied for 1 minute for valves of inlet sizes through 2 50 8 mm 2 minutes for sizes 2 50 63 5 mm 3 76 2 mm and 4 101 6 mm 5
109. ston strikes and stunts off the main valve inlet pressure from the drone pressure The pilot simultaneously opens the vent seat to relieve the dome pressure to the bottom of the modulator piston The modulator piston has a differential area with the smaller area being on top of the modulator piston The top of this always sees the main valve inlet pressure when the dome pressure is applied to the bottom of the modulator piston there is a net upward force This is due to both pressures being Figure 9 MVO7 Valve Open Relieving Position equal at this point and the lower area is larger than the upper area The modulator relieves the pressure from the drone to the atmosphere until force from the inlet pressure on top of the modulator piston is sufficient to move it to the closed position A certain amount of pressure remains in the dome The pressure is controlled by the differential area in the modulator Since the dome pressure has not been dropped to atmospheric pressure the main valve only partially opens at the set point The modulator piston will remain closed until the main valve disc is forced into higher lift by increasing inlet pressure as this occurs the modulator piston may relieve further pressure from the dome as necessary to achieve the required main disc lift within 1096 overpressure 39MVO7 Valve Fully Open Full Relieving Position As inlet pressure increases further the net upward f
110. sure Superimposed backpressure that is constant with time 4 Variable Backpressure Superimposed backpressure that will vary with time C Blowdown The difference between set pressure and reseating pressure of the POSRV expressed as a percentage of the set pressure or in actual pressure units D Cold Differential Set Pressure The pressure ot which the valve is adjusted to open on the test stand This pressure corrects for backpressure when a pop action pilot s vent is piped to the main valve outlet Differential Between Operating and Set Pressures Valves in process service will generally give best results if the operating pressure does not exceed 9096 of the set pressure However on pump and compressor discharge lines the differential required between the operating and set pressures may be greater because of pressure pulsations coming from a reciprocating piston The valve should be set as far above the operating pressure as possible Lift The actual travel of the disc away from the closed position when a valve 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 POSRV is set to open Terminology for Pilot Operated
111. sure it could cause the disc to lift and allow reverse flow through the main valve This situation can be eliminated through the use of the backflow preventer Backflow Preventer Field Test Connection Backflow Preventer Figure 41 Field Test Connection Backflow Preventer Option Note Item 23 in Figures 3 4 and 5 is the same field test connection shown here in Figure 41 Shuttle base 23c can be square or octagon bar stock 1 Disassembly Instructions d Remove shuttle plug from shuttle base by unscrewing counterclockwise b Remove shuttle ball tube filter and o rings and discard 2 Cleaning a If required clean parts to remove all rust burrs scale organic matter and loose particles Parts are to be free of any oil or grease except for lubrication as specified in this instruction b Cleaning agents used shall be such that effective cleaning is assured without injuring the surface finishes or material properties of the part 66 GE 0il amp Gas C Acceptable cleaning agents include demineralized water nonphosphate detergent acetone and isopropyl alcohol Parts must be blown dry or wiped dry after cleaning d Ifyou are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations and equipment e It is not recommended to sa
112. sure all threaded points are tight and secure C Hydrostatic Testing Prior to hydrostatic test of the pressure vessel system the pilot operated safety relief valve should be removed and the mounting flange for the valve blocked Prevent dirt from D Service Considerations entering outlet or For best performance pressure relief valves should be serviced annually unless inlet port maintenance history dictates otherwise They should be located for easy access and removal for service CAUTION E Remote Sensing If the pressure drop between the source of pressure in the equipment to be protected and the pressure at the relief valve inlet exceeds 396 the sensing line to the pilot valve should be connected directly to the equipment being protected rather than to the sensing connection on the main valve inlet neck The main valve sensing port should be plugged with an appropriate sized NPT pipe plug For remote sensing 375 inch 9 53 mm diameter tubing is adequate for distances up to 10 feet 3 048 m For block valve and other special installation features consult API 520 or Always install the factory valve in a vertical upright position Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 13 VIII Introduction A General Introduction A pilot operated safety relief valve is a pressure relief valve in which the major relieving device is combined with and is controlled by a self
113. sure ramp should not exceed 1 0 psig 0 07 barg per second when test pressure is within 90 of set pressure b NOTE NOTE For the 39MV22 and 39MV72 pilots venting will and must begin before the set point The 39MV22 begins venting at 98 of set pressure and the 39MV72 begins venting at 97 of set pressure Drop system to 90 of set pressure between cycles The 3 tests should be within 2 of unit ticket set pressure or 2 psig 0 14 barg whichever is greater If blowdown is being checked the following guidelines are to be followed Blowdown can be set and checked on the main valve only if the system can achieve 1096 over pressure i 39PV model gas steam Less than or equal to 5 or 3 psig 0 20 barg whichever is greater li 39PV model liquid Between 7 and 4 If set pressure is less than 30 psig 2 1 barg 3psig 0 20 barg or less 39MV model gas steam Less than or equal to 496 or 2 psig 0 14 barg whichever is greater iv 39MV model liquid Between 796 and 4 If set pressure is less than 30 psig 2 1 barg 3 psig 0 20 barg or less Customer requirements may note a variation to the standard blowdown Customers request takes priority Table 13 Leakage Rate Effective Orifice Sizes lt 0 307 in Effective Orifice Sizes 0 307 in 15 6 C 1 981 cm D amp E Orifice Only 1 981 cm F Orifice amp Larger Approximate Leakage per 24 Hours Ap
114. t indicator measures the set pressure of the pilot while maintaining pressure on the main valve dome Figure 40 Pilot Valve Tester 64 GE 0il amp Gas XX Trouble Shooting Table 14 Trouble Shooting Chart enough capacity in the discharge system Problem Possible Cause Corrective Action Blowdown incorrect A Incorrect adjuster assembly setting A Re set adjuster assembly see pilot valve setting Leakage around fittings A Fittings are not tightened or are cross A Re install fittings correctly threaded 8 Did not install Teflon tape or pipe sealant B Re install fittings with Teflon tape or pipe sealant Leakage under the cover Cover plate o ring is damaged A Disassemble valve and replace plate when valve is open cover plate o ring B Cap screws or stud nuts on cover plate are B Tighten as required loose Main valve leaks through A Damaged seat o ring A Disassemble valve and replace the seat seat o ring B Damaged metal seat B Disassemble valve and lap metal disc and or nozzle C Metal seat is not lapped in properly to disc C Disassemble disc and disc holder holder to lap two together properly D Seat too wide D Recheck Tables 3 amp 4 Main valve leaks under the A Damaged nozzle o ring A Disassemble main valve and nozzle seat replace damaged nozzle o ring Pilot valve is not opening Wrong set pressure A Readjust the set pressure at set press
115. that the moving parts essential to good operation are free to move Reference UG 136 a 3 The lifting lever or field test connection may be omitted under Code Case 2203 All orders for pressure relief valves without levers or field test connection for steam air and water over 140 F 60 C must state specifically that the valves are being purchased per Code Case 2203 The purchaser is responsible for obtaining jurisdictional authorization for use of Code Case 2203 E Filter Single Dual or High Capacity Filter options are available for dirty applications These filters are installed in the pilot inlet sensing line For the 39PV and 39MV an optional sensing line filter is available Figure 48 This filter has a 316 stainless steel body Teflon seals and a 40 50 micron stainless steel filter element Other high capacity filter options Figure 49 include 1 Acarbon steel cadmium coated filter body with a 35 micron stainless steel element and 2 Anentirely stainless steel filter arrangement These filters may be equipped with a manually operated needle valve which allows for purging the filtered material while the valve is in operation All filter elements are stainless steel and all filters including carbon steel conform to NACE Standard MRO103 and MRO0175 A dual filter arrangement Figure 50 is available for applications in which the customer is unsure of the filter maintenance requirements In these cases a preventi
116. the pilot consists of 1 Insert Top 1 Insert Bottom 1 Spring Seal Insert 1 O ring Insert q Press spring seal insert into groove on the insert bottom Make sure spring is facing upwards b Install insert top over insert bottom with the spring seal side going in first c Lightly lubricate o ring groove now formed by the two insert parts This lubrication is used to hold the o ring in place when it is being inserted into pilot base d Place o ring Insert into groove e Finalinsert assembly is shown in Figure 30 54 GE Oil amp Gas Reassembly of Pilot Valve Contd Spring Seal Insert Top Insert Bottom f O Ring Insert Figure 30 Insert Assembly f Turn insert assembly over and thread into pilot base with t handle groove wrench Part 4995401 Figure 60 Tighten wrench tight Make sure milled slot is facing up g Lubricate main piston stem and cycle main piston through spring seal insert five times NOTE For dirty service option please refer to assembly instructions included in the Dirty Service Option section Section XXI B 4 4 Install o ring top plate into groove on top of pilot base NOTE For dirty service option o ring top plate is installed into groove on top of the dirty service insert a Lubricate the spring seal main piston and top plate gland Install the spring seal main piston into top plate The spring should be oriented as shown in Figure 3
117. tightness in the event of o ring failure F Reconditioning of Laps Ring laps are reconditioned by lapping them on a flat lapping plate in a figure eight motion Figure 15 To ensure the best results recondition the ring laps after each use Use an optical flat to check the quality of the lap LAPPING PLATE RING LAP iG L 7 Figure 15 Lapping Pattern G Re Machining Nozzle Seats Remove the nozzle from the valve to be remachined If it cannot be removed from the base 1 re machine it inside the base Take the following steps to setup the lathe and nozzle 1 Grip the nozzle in a four jaw independent chuck lor collet if appropriate using a piece of soft material such as copper or fiber between the jaws and the nozzle as shown at A Figure 16 2 True up the nozzle so that the surfaces marked B and C run true within 001 0 03 mm on indicator Figure 16 Chuck Jaw Figure 16 Machining Nozzle Seats Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 35 XIII Maintenance Instructions Contd 3 Machining Procedure Metal Seat H Re Machining the Disc Seat See Figure 13b and Table 2a Take the following steps to machine the standard disc a Take light cuts across the surface Y at 5 until seating surface Figure 17 the damaged areas are removed Turn to the smoothest possible finish Chuck Jaw b Cut back the outside surface
118. ting until Swagelok gap inspection gauge will not go After torquing remove to assure the ferrule is in good contact with the tubing Refer to Table 11 and Figure 35 to determine if ferrule has seated itself properly Reinstall the tubing Table 11 Ferrule Wall Thickness Wall Thickness min Pressure Class in mm 150 to 900 035 0 89 1500 049 1 24 2500 065 1 65 Tubing Diameter Tubing Length A in mm in mm 250 6 35 190 4 83 375 9 53 250 6 35 500 12 70 540 8 64 60 GE Oil amp Gas 4 A gt x Figure 35 Tubing Dimensions The vent port of the pilot valve is vented to atmosphere in standard configuration Final standard configuration for a 39PVO7 or 39PV37 without any options is shown in Figure 34 39MVO7 39MV22 72 Attach pilot to main valve using two socket head cap screws bracket Install the tubes into the fittings for the inlet and dome ports Make sure the tube ends are fully inserted before torquing Begin torquing the fitting about midway down verify that Swagelok gap inspection gauge Swagelok P N MS IG 468 will go Continue to torque down fitting until Swagelok gap inspection gauge will not go After torquing remove to assure the ferrule is in good contact with the tubing Reinstall the tubing Install tubing to connect the vent port of the pilot to the outlet of the main valve in the standard configuration F
119. tor Stop Top seating surface for cuts or deformities The surface can be lapped if the distance from the seat to the outside shoulder does not reduce to less than 086 2 18 mm 13 O ring Retainer Seating surface for cuts or deformities The surface can be lapped if the overall height of the part does not reduce to less than 160 4 06 mm Also check the outside diameter for any scratches that might prevent the o ring modulator seat from sealing 14 Modulator Piston Bottom Galling or excessive wear on the outside diameter that rubs against the modulator base Make sure that the lip holding the o ring modulator seat is not deformed Also check the outside diameter of the o ring groove for scratches that might cause the o ring modulator seat not to seal Check for any corrosion or pitting 15 Modulator Base Galling or excessive wear on any inside diameter Any corrosion or pitting C 39MV22 72 1 Main Piston Galling or excessive wear on the diameter where the spring seal main piston engages or on the spherical bearing surface Any corrosion or pitting that appears detrimental to the function of the valve The part can be polished as long as the outside diameter of the where the spring seal main piston rides must be 970 001 24 64 0 03 mm on 39MV22 model or 812 001 20 63 0 03 mm on 39MV72 A surface finish of 8 RMS must be maintained for proper sealing on these surfaces 2 Piston Nose Galling
120. ure and main of the valve valve will not open Main valve does not close A Start up procedures pressurize the valve too A Slowly increase the inlet pressure upon start up P2 chamber rapidly does not load with system 8 Sensing tube is installed upside down B Re install sensing tube correctly pressure C Closed filter C Clear or replace filter D Spring not installed D Install spring Leakage through the pilot A Operating pressure too high A Adjust operating pressure valve B O ring or spring seal degradation B Disassemble and replace o ring or spring seals Main valve opens and A Backpressure is greater than set pressure A Install backflow preventer allows the discharge and forces the main disc up and the media media to flow back into flows backward into the vessel the pressure vessel B Discharging into a closed container or not B Install backflow preventer A WARNING EA Know all valve exhaust Leakage points to avoid possible severe personal injury or deqth Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 65 XXI 3900 Series POSRV Options A Backflow Preventer When the pilot operated safety relief valve is not vented directly to atmosphere it is possible to build up backpressure in the discharge line This is typical in situations where several valves manifold into a common discharge header Should the discharge line pressure exceed the valve inlet pres
121. ve maintenance program may be developed by monitoring the filters without taking the valve off line Figure 48 Dirty Service Parts Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 69 XXI 3900 MPV Series POSRV Options Contd F Gag A manual method of locking a pilot operated relief valve in the closed position for system hydrostatic test 39MV72 limited to 4800 psig 330 9 barg with gag option Figure 51 Figure 49 High Capacity Filter Figure 51 Gag Figure 50 Dual Filter When servicing dual filters procedures need to be in place to perform a Lock out tag out LOTO of pilots under pressure if they are in service 70 GE 0il amp Gas XXI 3900 MPV Series POSRV Options Contd G Heat Exchanger This allows the temperature range for the 3900 POSRV with metal seats to be extended to 320 F to 650 F 195 5 C to 343 3 C Not available above 3750 psig 258 5 barg When the heat exchanger is selected the POSRV shall be piped so that the media enters the heat exchanger first to condition the media s temperature Option s such as line filter canister filter 5 way manifold valve pressure differential switch pressure spike snubber etc shall be piped downstream of the heat exchanger Figures 52 amp 53 Figure 52 Heat Exchanger Hot Service 3 Figure 53 Heat Exchanger Cold Service H Lifting Lever This is an external ph
122. ve 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 leakage or discharge rates of areas i dide j pressurized device may warnings Pressurized fluids gas air injected into or near the result in severe personal body can cause severe personal injury or death injury or death Improper use or repair of Heed all container label 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 can result in severe A WARNING A WARNING personal injury or death 5 WARNING Do not allow anyone under the a influence of intoxicants or narcotics to work on or e around pressurized systems Workers under the influence intoxicants of narcotics are a hazard both to themselves and other employees and can cause severe personal injury or death to themselves or others 6 WARNING Incorrect service and repair could result Provide and use Do not work with in product or property damage or severe personal guarding to prevent valves while under the injury or death contact with heated influence of intoxicants and or pressurized parts or narcotics Note Any Service questions not covered in this manual should be referred to GE s Service Department Ph
123. washer engages with spherical nose on mainpPiston assembly Thread the bonnet onto the top plate Tighten wrench tight Install and tighten set screw Turn compression screw clockwise until dimension has been reached that was noted during disassembly Tighten compression screw lock nut wrench tight For lifting lever option reinstall release nut and release lock nut onto lifting stem Turn clockwise until it matches the dimension noted during disassembly Reassembly of Pilot Valve Contd 14 Install filter plug into bonnet vent hole if removed 15 Install pipe plug pilot valve in port above vent hole if removed 16 Refer to field test connection backflow preventer option Section XXI A for reassembly of field test connection Assembly of 39MV07 1 Making the main pilot 2 Making the adjuster assembly This assembly consists of 1 Adjuster Bottom 1 Adjuster Top Ta T1 1 Spring Seal Adjuster Top O ring Adjuster Top O ring Adjuster Bottom a Check the adjuster top for burrs at the spring seal lead in chamfer Remove any burrs using a polishing cloth b Install spring seal adjuster top into adjuster top using insertion tool as shown in Figure 59 vi viii viii Lubricate spring seal adjuster top with silicone grease Install spring seal adjuster top onto plunger cylinder with spring facing away from plunger cylinder Insert plunger into plunger c
124. y and discard Disassemble adjuster top from the adjuster bottom by turning adjuster top counterclockwise Remove spring seal adjuster top from adjuster top and discard 18 Refer to field test connection backflow preventer option Section XXI A for disassembly of field test connection XVI Disassembly of Pilot Valve Contd T 00 OG OOG Cee e 39PV37 Figure 22 39PV07 37 Disassembly Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 43 XVI Disassembly of Pilot Valve Contd 54 9 T2 Part No Nomenclature 53 Lifting Lever Assembly 53a Cam Bushing 2 53b Cam Shaft 53c Lifting Lever 53d Drive Pin 53e Releqse Nut 53f Release Locknut 54 Gag Bolt 55 Lower Spring Washer Assembly 55g Lower Spring Washer 55b Lifting stem 55c Drive Pin B 39MVO7 Disassembly Figures 23 and 24 1 Remove and discard the aluminum seals and sealing wire 2 Remove cap compression screw by turning counterclockwise 3 Ifa lifting lever is installed also use Figure 23 to remove the lifting Lever assembly Then return to Figure 24 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 counte
125. ylinder until plunger lightly contacts spring seal adjuster top Insert funnel tube chamfer side first over the plunger and spring seal adjuster top Stop when spring seal adjuster top is about half way inside the funnel tube as shown in Figure 27 Remove plunger Insert funnel tube assembly into adjuster top until funnel tube contacts spring seal adjuster top gland Push down on plunger cylinder to insert spring seal adjuster top into adjuster top as shown in Figure 28 Remove funnel tube assembly ix Inspect adjuster top to make sure that spring seal adjuster top did not flare out during installation and that the spring seal adjuster top is oriented as shown in Figure 29 Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 55 XVIII NOTE NOTE Thread adjuster top clockwise onto adjuster bottom and torque to 27 2 ft lbs 37 2 7 N m Lubricate main piston stem and cycle main piston through spring seal adjuster top five times Do not install adjuster assembly into pilot base with o rings installed without wrench tightening adjuster top to adjuster bottom together Adjuster top can get stuck in pilot base if adjuster Top is not tightened properly Install o ring adjuster top into groove on adjuster top Install o ring adjuster bottom into groove on adjuster bottom Install from the opposite end of the square wrenching flats Lightly lubricate
126. ysical means of allowing the pilot valve to relieve dome pressure so that the main valve can open I Manual Electrical or Pneumatic Blowdown Valve Figures 54 amp 55 An optional manual blowdown valve is available for relieving the pilot operated safety relief valve Consult factory for applications requiring a pneumatic or electrical solenoid blowdown valve which may be connected to a distant location such as an operator station for remote actuation The blowdown valve is ported directly to the main dome area so that the media in the dome is vented when the blowdown valve is actuated thus allowing the main valve to open Figure 54 Manual Blowdown Valve Figure 55 Electrical Blowdown Valve Consolidated 3900 MPV Series Pilot Operated Safety Relief Valve Maintenance Manual 71 XXI 3900 MPV Series POSRV Options Contd J Pilot Valve Tester Pneumatic For applications that do not permit an electrical differential switch an option is available to provide pneumatic signal to indicate when the main valve opens The pilot valve test indicator Figure 55 is available for the modulating and pop action pilot valves The valve test indicator measures the set pressure of the pilot while maintaining pressure on the main valve dome L Pressure Spike Snubber area thereby allowing only the pilot to actuate y g ony H GE Consolidated recommends the use of a pressure spike snubber Figure 58 for all applications wh

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