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2700 Series - Maintenance Manual

1. Temp Class ButtWeld Inlet Pressure Class e Dresser Consolidated has worldwide service Dresser Consolidated has fast response availability for parts XIX Manufacturer s Field Service amp Repair Program A Factory Setting vs Field Setting Every Consolidated Safety Valve is set and adjusted on steam before shipment from the factory Ring adjustments are made at the factory However it must be recognized that actual field operating conditions may vary considerably from factory test conditions Conditions beyond the manufacturer s control that affect Safety Valve operation include Improper header nozzle design Quality of media being discharged Discharge piping stresses and back pressure Ambient temperature Shipping or storage damage Improper gagging e Damage due to foreign material in the steam Final Safety Valve adjustments made on the actual installation are the best means of ensuring that the valves perform in compliance with the ASME Boiler Code and or other applicable code requirements B Field Service Utilities and Process Industries expect and demand service at amoment s notice Consolidated Field Service can be depended upon for prompt response even in extreme off hour emergency situations Dresser Consolidated maintains the largest and most competent field service staff in the industry Service Engineers are located at strategic points
2. 11 IX Operation Principles The 2700 Safety Valve operates on the principle that when steam pressure at the valve inlet acting over the area of the disc seat C and bushing seat A generates a force that approaches that produced by the spring the valve opens Minimal leakage into the volume generated by the lower adjusting ring B causes additional force over a larger area acting on the disc holder E causing the valve to pop open Proper adjustment of the upper adjusting ring allows the disc to go into full lift at overpressure When full lift is attained lift stop H rests against the yoke to prevent hunting thus adding stability When the inlet pressure drops to the desired closing pressure the disc C moves downward causing the valve to close The arrangement of the disc and its complement of parts that is disc holder E spindle G disc collar F and lift stop H allow the disc to seek its natural position for tight closure The Thermoflex Disc design by allowing for the rapid equalization of temperature around the valve seat provides a degree of tightness far above that offered by competitive valves DN VLZ2 TASS WN ALY Figure 3 Valve Operation 12 Dresser Consolidated X Recommended Installation Practices A General Requirements ANCHOR DISCHARGE PIPING SOLIDLY TO BLDG STRUCTURE BORE EQUAL TO MINIMUM VALVE OUTLET DIAMETER VERTI
3. 405 900 12 57 0 DOE 6 35 219 5 56 o a eee 900 14 78 90 Q Q wO WUO O0 O00 M ol 250 6 35 281 7 14 Table 4 Allowable Guide Disc Holder Clearance Maximum Clearance Orifice Temp Class In mm m B 005 0 13 D 008 0 20 rs B 008 0 20 D 012 0 30 B 010 0 25 8 D 015 0 38 B 011 0 28 9 D 017 0 43 B 012 0 30 4 D 018 0 46 B 016 0 41 6 D 016 0 41 B 025 0 64 Q D 025 0 64 22 g The desired band width for Type 2700 valves is shown in Table 3 In addition the finished machined size of the spindle nose radius and the flat diameter for each orifice size are also shown in this Table If the required bearing band cannot be obtained by hand grinding then this radius should be checked and remachined if necessary h If the band extends too high on the radius it will be difficult to rock the disc and the disc may lock up under pressure If the band is too narrow the spindle may indent the disc and again the rock will be lost i When the bearing area is re established clean both surfaces Then apply lubricant to the spherical surface of the spindle tio and work it into the surfaces by rotating the disc on the spindle Guide Inspect the guide inside diameter for egging and ensure the inside surface is smooth The threads on the outside must be in good condition to ensure the Dresser Co
4. 10 thd 1 1 4 5 875 9 thd 22 23 9 thd 1 7 16 4 875 9 thd 22 23 9 thd 1 7 16 6 1 125 7 thd 28 58 7 thd 1 13 16 Q 1 125 7 thd 28 58 7 thd 1 13 16 XVII Replacement Parts Planning A Basic Guidelines The basic objectives in formulating a replacement parts plan are e PROMPT AVAILABILITY Part Replacement Predicted e MINIMUM DOWNTIME Classification Frequency Availability e SENSIBLE COST CLASS Most Frequent 70 e SOURCE CONTROL CLASS II Less Frequent But Critical 85 Consult the Recommended Spare Parts CLASS III Seldom Replaced 95 list to define the parts to be included in the inventory plan CLASS IV Hardware 99 Select parts and specify quantities CLASS V Practically Never 400 Replaced Guidelines for establishing meaningful inventory levels Parts Classification B Identification and Ordering Essentials Explanation of Name Plate The valve nameplate contains several necessary pieces of information necessary to the proper operation of the valve Included are e Valve Type e ASME and National Board of Boiler and Pressure Vessel Inspectors Approval Stamp e Serial Number e Set Pressure or Opening Pressure e Disc Lift e Operating Temperature e Capacity 2700 Valve Series nameplate is located on the base of the valve to the left of the Adjusting Ring Pins If the nameplate is missing a duplicate nameplate can be supplied by Dresser Flow Control To order th
5. 19 Prior to installing the spindle assembly into the valve base wipe the disc seat with a soft lint free cloth 12 Verify that the spindle bearing has been ground to the disc pocket as specified in Section XII B 6 e of this manual Then carefully install the spindle assembly into the guide Note This step must be accomplished before proceeding 20 Lubricate the ee ee threads with Fel with re assembly Pro Nickel Ease and thread into the yoke Install the lower washer on the spring and then install the 13 If the lift stop was removed from the spindle lubricate upper washer on the spring Lubricate the bearing the threads and install the lift stop Do not install the assembly with Fel Pro Nickel Ease and install on cotter pin at this time the upper spring washer 14 If the disc collar was removed lubricate the threads 21 For orifice sizes 5 Q next place the compression and install on the spindle Do not install the cotter pin at this time Then carefully lower the disc holder onto screw adaptor on top of the bearing Table 8 Required Lift for Capacity Verification ae Capacity Lift Sa aA Total Lift in mm in mm in mm 1 281 7 14 020 0 51 301 7 65 Approx 31 Notches 2 338 8 59 020 0 51 358 9 09 Approx 36 Notches 3 450 11 43 030 0 76 480 12 19 Approx 48 Notches 5 516 13 11 050 1 27 566 14 38 Approx 62 Notches 4 563 14 30 040 1 02
6. Move the lower adjusting ring up until it contacts the disc holder j After referring to Table 9 lower the adjusting ring the number of notches indicated in Column A This setting will place the lower adjusting ring at seat level Z Once the lower adjusting ring is at seat level it can be preset to the beginning test position by moving the adjusting ring down one notch for each 600 psi 41 37 bar or part thereof Example 1 000 psi 68 95 bar Set Pressure 2 notches Replace the adjusting ring pin in the valve to hold the lower adjusting ring in position without binding Wire the adjusting ring pins together to prevent them from loosening and vibrating out under pressure Replace the service port plugs Remove the gag from the valve to be tested and reinstall the cap and lever assembly on the valve Now the valve is ready for steam testing Steam Testing Instructions Attach a rope to the lifting lever on the valve to be tested Increase the boiler pressure at a rate not to exceed 2 psi 0 14 barg per second Note and record the pressure indicated on the pressure gauge when the valve pops open After the valve pops open reduce the fire in the boiler and lower the pressure until the valve closes note and record the pressure when the valve closes If in raising the boiler pressure the valve doesn t open within 3 overpressure for ASME Section valves or 10 overpressure for ASME Section VI
7. They should not be removed from the skids or crates until immediately prior to installation Flange protectors and sealing plugs should remain installed until just prior to installation Safety valves either crated or uncrated should never be subjected to sharp impact This would be most likely to occur by bumping or dropping during loading or unloading from a truck or while moving with a power conveyor such as a fork lift truck The valve either crated or uncrated should always be kept with the inlet down i e never laid on its side to prevent misalignment and damage to internals Even crated valves should always be lifted with the inlet down Uncrated valves should be moved or hoisted by wrapping a chain or sling around the discharge neck then around the upper yoke structure in such manner as will insure that the valve is in vertical position during lift i e not lifted in horizontal position Never lift the full weight of the valve by the lifting lever Never hook to the spring to lift When safety valves are uncrated and the flange protectors removed prior to installation meticulous care should be exercised to prevent dirt from entering the outlet port while bolting in place While hoisting to the installation care should be exercised to prevent bumping the valve against steel structures and other objects VII Introduction The safety valve is the final safeguard between a controlled boiler and a catastrophic explos
8. 603 15 32 Approx 56 Notches 6 750 19 05 060 1 52 810 20 57 Approx 81 Notches Q 987 25 07 070 1 78 1 057 26 85 Approx 106 Notches Note 1 For full lift valves only Note 2 Total lift tolerance is 949 6 81 mm Per the ASME Section code the valve lift must be mechanically verified and shall meet or exceed the required lift 26 Dresser Consolidated XIII Re Assembly Contd 22 23 24 Place the spring and bearing assembly into the yoke Lubricate the yoke studs with Fel Pro Nickel Ease Carefully lower the yoke spring assembly over the spindle while aligning the yoke as shown in Figure 17 of Section XIV Ensuring that the yoke vent hole is on the side of the valve opposite the inspection port make certain that the yoke does not bind on the lift stop Care should then be taken to tighten down the yoke evenly so as to prevent distortion and misalignment Raise the lift stop until it contacts the yoke Then lower the lift stop to achieve the proper dimension shown in Table 8 or the restricted lift identified on the valve nameplate Note Do Not Deviate From Stamped Nameplate Lift The lift stop must be adjusted to the rated lift marked on the nameplate plus an additional amount as indicated The additional lift is to compensate for heated condition of the lower spindle when the valve is in operation Note For all Type 2700 valves one revolution of the lift 25 stop equals 063 1 59
9. amp Repair Program ereere 41 A Factory Setting vs Field Setting icsacscrtdecnctacuceanecte skiing cqubedenceeatuadmneeeles eaeestthineaceedemerah 41 Bi Fiel SaNi C Erria eia aaa a E aE EEEa 41 C Factory Repair Facilite Seyran uane en A EEEE EEEE RA 41 D Safety Valve Maintenance Training i irrssirsriissrrosrissrinisnrnseiririiassres sirintina rnani annen 41 Sales Office LOGAS minirerinnndiniasoie nai saned leans tetatesessbuossaubbepheesedsauehddedeh ananin aoi 42 2700 Series Safety Relief Valve July 2011 3 I Product Safety Sign and Label System If and when required 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 left and below consisting of three panels encircled by a narrow boarder The panels can contain four messages Which communicate e The level of hazard seriousness e The nature of the hazard e The consequence of human or product interaction with the hazard e The instructions if necessary on how to avoid the hazard The top panel of the format contains a signal word DANGER WARNING CAUTION or ATTENTION which communicates the level of hazard seriousness The center panel contains a pictorial which communicates the nature of the hazard and the possible consequence of human or product interaction with the hazard In some instances of human hazards t
10. contact area of disc and nozzle lower spring washer or spindle compression screw spindle straightness etc C Disc has insufficient rock C Disassemble valve and check disc rock per Section XIX E of this manual Discharge stack binding on outlet Correct as required Hangup or valve A Lower ring too high Move lower ring to the left one notch per does not close adjustment and test Repeat until problem is completely eliminated B Foreign material B Disassemble valve and correct any abnormal condition Inspect system for cleanliness Excessive A Upper ring too low A Decrease blowdown as outlined in Section blowdown XV C 3 of this manual B Exhaust pressure too high B Decrease exhaust pressure by increasing discharge stack area Chatter or short A Upper ring too high A Lower upper ring blowdown B Inlet piping pressure drop too high B Reduce inlet pressure drop to less than one half of required valve blowdown by redesigning inlet piping C Yoke vent is plugged C Clear yoke vent 2700 Series Safety Relief Valve July 2011 37 XVI Maintenance Tools and Supplies Lapping Tools The following tools are required for proper maintenance of Consolidated Type 2700 Safety Valve seats Ring Lap The ring lap is used for lapping the nozzle and disc seats Ring Laps Valve Orifice Lap Part NO 1 1672806 2 1672807 3 1672808 5 1672810 4 1672809 6 1672811 Q 1672812 Note 1 One set
11. lowered capacity as well as damage to the seating surface of the valve Severe chattering can cause damage to other parts of the valve The following recommendations will assist in eliminating the factors that produce chatter 1 The downstream corner of the header nozzle must be rounded to a radius of not less than 250 6 35 mm of the opening diameter See Figure 5 2 Pressure drop due to friction flow to the inlet of the valve should not be greater than 50 of the expected blowdown of the safety valve To decrease the effects of a phenomenon known as sonic vibrations or flow induced vibrations the following recommendations are made 1 Safety valves should be installed at least eight to ten pipe diameters downstream from any bend in a 2700 Series Safety Relief Valve July 2011 13 X Recommended Installation Practices Contd steam line This distance should be increased when the valve is installed on the horizontal section of a header which is preceded by an upward section 2 Safety valves should not be installed closer than eight to ten pipe diameters either upstream or downstream from a diverging or a converging Y 3 In cases where a piping configuration renders the above two recommendations impractical or impossible the downstream corner of the header nozzle inlet should be rounded to a greater extent than the upstream corner The header nozzle entrance should be rounded so the radiu
12. need to remove a valve from the unit The machine is mounted in place of the yoke and cuts the top face inside diameter and outside of the bushing to establish the correct height angles and diameters b The use of a reseating machine is suggested for reconditioning badly worn seats or for re establishing Dimension E per Figure 15 Dimension E should be re established when it is less than 010 0 25 mm for orifices 1 2 3 5 and 4 and less than 030 0 76 mm for orifices 6 and Q c To lap the bushing seat Note If the bushing seat surface requires extensive lapping or reconditioning a reseating machine should be used prior to lapping i Cover the seat lap face with a light coating of 1 A Clover Compound and gently place the lap on the valve bushing seat Note A heavy coat of lapping compound tends to round off the edges of the seat ii Lap using an oscillating motion in various directions while holding the lap loosely in the fingers and allowing the weight of the lap to rest on the seat surface Control the motion of the lap to prevent either the inside or outside edge of the lap from crossing the bushing seat surface If either edge touches the seat surface the seat can become scratched and or rounded Note Care should be used not to run off the seating surface with the lap as this will cause the seat to become uneven ii Do not lap excessively with a ring lap without resurfacing on a la
13. of 2 Ring Laps is recommended for each orifice valve in service to assure ample flat laps are available at all times Note 2 Valve orifice number is third digit of valve type number e g a 2737A valve has a 8 orifice Lapping Plate The lapping plate is used for reconditioning the ring laps Only one 11 279 40 mm diameter plate is required for all sizes of ring laps Resurfacing Plate 11 279 40 mm Diameter Part No 0439004 Lapping Compound Lapping compound is used as a cutting medium for lapping and polishing the seats and bearing surfaces in Type 2700 Safety Valves Lapping Size Brand Grand Grit Fiinetion Container Part No Clover 1A 320 General 4 oz 199 3 Clover C 220 Coarse 4 oz 199 2 oe 1 Ib 199 11 Kwik Ak Shun 1000 Polishing 2 Oz 199 12 38 Dresser Consolidated Gags Valve Orifice Gag Part No 1 Oo oK OW PD VJ5920 VJ5920 4363001 4363001 4363001 4363001 4363001 Lubricant Location Lubricant Bearing Points 1 Spindle Disc 2 Compression Screw Top Spring Washer 3 Spindle Bottom Spring Washer All Threads All Nut Contact Faces Fel Pro Nickel Ease Wrench Sizes 2700 Yoke Stud Size Wrench Size Orifice in mm in 1 625 11 thd 15 88 11 thd 1 1 16 2 625 11 thd 15 88 11 thd 1 1 16 3 750 10 thd 19 05
14. set screw and lift off cap and drop lever assembly Do not disassemble valve with pressure in drum or 3 Remove the cotter pin which retains the release nut and then remove the header as this will result release nut in severe personal injury or death 4 Refer to Figure 6 and measure and record Dimension A as this information will be required to correctly re assemble the valve 5 Loosen the compression screw locknut and the compression screw to remove tension from the spring 6 Loosen and remove the yoke stud nuts DEPTH DISC COLLAR MICROMETER Ay DISC HOLDER SPINDLE LIFT STOP COMPRESSION SCREW COMPRESSION SCREW LOCKNUT SOFT METAL VISE a Figure 6 Yoke Disassembly Figure 7 Spindle Disassembly 18 Dresser Consolidated XI Disassembly of 2700 Series Safety Valve Contd a 10 Carefully lift the yoke and spring assembly over the spindle and away from the valve Remove the thrust bearing assembly and the spring washer assembly Mark the spring to indicate the top of the spring as this formation will be used in reassembly Remove the spindle disc and disc holder assembly from the valve by lifting the spindle Take care to ensure that the disc seating surface is not damaged from improper handling To remove the disc and disc holder from the spindle first insert the spindle into a vise see Figure 7 being careful not to damage the threaded end of the spindle T
15. steps until the subject valve is in compliance with the appropriate standard After one pop has been determined to be in compliance test the valve two more times for consistency of set pressure and blowdown Allow a minimum of 10 minutes between pops If the operation remains in compliance with the standard reduce the boiler pressure to approximately 85 of the set pressure and seal the valve cap and adjusting ring pins Proceed to the next valve to be tested When all valve have been tested and sealed return the boiler to normal operating pressure See Table 12 XIV Setting and Testing Contd Table 10 Adjusting Ring Presetting Information a Saturated Steam Superheated Steam Orifice Area Set Pressure Range M Orifice l Lower Ring Temp Class B Temp Class D in ene min max Position Upper Ring Upper Ring Upper Ring Upper Ring psig barg psig barg Seat Disc Holder Seat Disc Holder 101 6 96 300 20 68 Seat Level 10N down Seat Level 10N down 301 20 75 500 34 47 20N up 10N up Seat Level 10N down 501 34 54 900 62 05 1N down per 20N up 10N up Seat Level 10N down 1 0 994 6 413 901 6212 150
16. which the low set valve is adjusted 3 Apply the gag load by turning the gag screw clockwise If the gag on any valve has not been tightened sufficiently the valve will leak On steam service the leakage is accompanied by a Sizzling sound XIV Setting and Testing Contd If this occurs the hydrostatic test pressure or steam pressure should be reduced until the valve becomes tight and then the gag should be tightened still further This procedure must be followed exactly since it is very difficult to stop the leak by additional gagging once it has started Any attempt to stop the leakage through the valve without first lowering the system pressure could result in damage to the valve seats 4 After the hydrostatic test or steam test is completed the gags should be removed when the hydrostatic pressure has been reduced to 80 to 90 of the pressure of the low set valve Note Under no circumstances should the gags be left on the valves during normal boiler operation C Presetting Adjusting Rings 1 Remove the caps on all valves to be set on the steam drum and main steam line 2 Install a currently calibrated pressure gauge on the drum near the valve being set When main steam valve are to be set install the calibrated gauge upstream from the valves on the main steam line to read line pressure 3 After the pressure in the boiler has increased to 80 of operating pressure install gags on all boiler valves not b
17. 0 103 42 ers TN up BN up 5N down 15N down 1501 103 49 2500 172 37 Max 5N down 10N up 3N down 10N down 23N down 2501 172 44 2800 193 05 10N up 3N down 10N down 23N down 2801 193 12 3000 206 84 5N up 8N down 15N down 28N down 101 6 96 300 20 68 Seat Level 12N down Seat Level 12N down 301 20 75 500 34 47 20N up 8N up Seat Level 12N down 501 34 54 900 62 05 1N down per 20N up 8N up Seat Level 12N down 2 1 431 9 232 901 6212 1500 103 42 eran TN up 3N up 5N down 17N down 1501 103 49 2500 172 37 Max 5N down 10N up Level w Holder 10N down 22N down 2501 172 44 2800 193 05 10N up Level w Holder 10N down 22N down 2801 193 12 3000 206 84 5N up 7N down 15N down 27N down 101 6 96 300 20 68 Seat Level 16N down Seat Level 16N down 301 20 75 500 34 47 25N up 9N up Seat Level 16N down 501 34 54 900 62 05 1N down per 25N up ON up Seat Level 16N down 3 2545 16 419 901 62 12 1500 103 42 TEn 20N up AN up JON down 26N down 1501 103 49 2500 172 37 Max 5N down 15N up Level w Holder 20N down 36N down 2501 172 44 2800 193 05 15N up Level w Holder 20N down 36N down 2801 193 12 3000 206 84 15N up Level w Holder 20N down 36N down 101 6 96 300 20 68 8N down 25N down 8N down 25N down 301 20 75 500 34 47 50N up 34N up Seat Level 16N down 501 34 54 900 62 05 1N down pe
18. CAL CLEARANCE REQUIRED WHEN VALVE IS OPERATING RADIAL CLEARANCE REQUIRED WHEN VALVE IS OPERATING VENT SEE FIGURE 5 BODY DRAIN FLANGED INLET SHOWN WELDED INLET SIMILAR BORE EQUAL TO MINIMUM OF VALVE INLET DIAMETTER Figure 4 2700 Valve Installation Table 1 Maximum Dimension Inlet Size X max Class in mm in mm 3 00 76 2 150 7 250 184 15 6 00 152 4 150 12 500 317 50 8 00 203 2 150 16 000 406 40 3 00 76 2 300 7 625 193 68 6 00 152 4 300 12 875 327 03 8 00 203 2 300 16 375 415 93 The valve should be installed to meet all the requirements of Figure 4 The safety valve shall be connected to the header independent of any other connection and attached as close as possible to the header without any unnecessary intervening pipe or fitting Necessary intervening pipe or fittings shall not be longer than the face to face dimension of the corresponding tee fitting of the same diameter and pressure per ANSI ASME Standards No valve of any description should be placed between the safety valve and the header nor on the discharge pipe between the safety valve and the atmosphere In no case may the inlet piping to the valve have a flow area less than the area of the valve inlet Excessive pressure loss at the inlet of the safety valve will cause extremely rapid opening and closing of the valve which is known as chattering Chattering may result in
19. DRESSER YE Consolidated Pressure Relief Valves 2700 Series Maintenance Manual Consolidated Safety Valve Conversion Table All the USCS values in the Manual is converted to Metric values using following conversion factors USCS Unit Conversion Factor Metric Unit in 25 4 mm b 0 4535924 kg in 6 4516 cm ft min 0 02831685 m3 min gal min 3 785412 L min lb hr 0 4535924 kg hr psig 0 06894757 barg ft Ib 1 3558181 Nm F 5 9 F 32 C Note 1 Multiply USCS value with Conversion Factor to get Metric value NOTICE For valve configurations not listed in this manual please contact your local Greentag Center for assistance 2 Dresser Consolidated Table of Contents Section Subject Page No l Product Safety Sign and Label System esssesiisssssssetttttttttt ttnt tatt ttEEEEEEEEEEEEEEEEEEEEEEE EEEE En EEEE 4 Il Safty AISI S idana ai ian anaE whos shor aia an anaE EN 5 Ill Safety NOCE pensarien nan paiia Au Desa o vba a EO a OAE NAA OEEO n 6 IV Warranty IMfOrmation scsi insiies stnasasuasnasradens sSpeestes saanaaedesanndandand supaa ddan aaae es saani AAA PATENN NAA 7 V Vake Term Olo nororiente E E EAE 7 VI HANGING and STOP GS set vitacasndewacaee ated vieeyesteb bananas EE r EEEE ENEE EE EEEE EES 9 VIL Mtro JUGON arasinda aana nes aeaa EE aaa Aaa aa ATRAGE ATENEA EaR 9 VIII Consolidated Safety Relief Valve Type 2700 neee 10 Ay Flanged Inleteisstin hive ais
20. II valves reduce the fire in the boiler and pull the rope to open the valve 30 Dresser Consolidated 3 Determine if the valve popping point and reseating points comply with the ASME requirements for valve operation as recorded in Table 10 Gee ASME Boiler and Pressure Code Section I or Section VIII Valve Operation Standards for more details To determine which standard to use look at the nameplate on the valve The symbol that is present on the nameplate will indicate the proper standard of operation See Table 11 If the valve operation is in compliance with the standard proceed to step 7 If the valve is not in compliance reduce boiler pressure to approximately 85 of valve set pressure GAG the safety valve being adjusted a If set pressure is out of compliance turn the compression screw one sixth of a turn clockwise to raise set pressure and counterclockwise to lower set pressure Retest and note the change in set pressure for one sixth turn then calculate the number of turns needed to bring the set pressure to the desired pressure Adjust as necessary 2 If the blowdown is excessive raise the upper adjusting ring 5 to 10 notches If the blowdown is insufficient lower the upper adjusting ring 5 to 10 notches Re test as in step 2 if the blowdown is not within specification repeat step 5 Remove the gag and repeat Step 2 raising the pressure until the valve pops then proceed with the following
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22. ag the safety valves when hydrostatic plugs are used These plugs must of course be removed from the valves prior to placing the boiler in service However they should be retained and reinstalled whenever a hydrostatic test is conducted which exceeds the low set valve pressure Before starting to disassemble the valve be sure that there is no steam pressure in the drum or header XIV Setting and Testing Contd F 2 Domestic Plugs To remove the domestic plug the following steps must be followed 1 Remove the cap assembly adjust release nut to 2nd hole from the top of the spindle and install cotter pin Back off the yoke stud nuts uniformly until compression screw engages release nut Now remove yoke stud nuts Yoke and spring assembly See Figure 20 from base being careful not to damage the disc Remove the hydrostatic test plug from the seat bushing This may be accomplished by inserting a threaded rod into the tapped hole in the plug and lifting up until free from bushing Care should be taken as not to damage the seat bushing Remove the disc from the disc holder by turning clockwise until it is disengaged from spindle threads Note Hold the disc holder against the disc adjusting collar 10 11 12 during this step otherwise the disc holder will fall from the spindle and become damaged Lap the disc and seat bushing and thoroughly clean the seats with a clean cloth Lubricate the spindl
23. ally requests otherwise All flanged inlet valves shipped within the continental United States are shipped without a hydroplug unless one is specifically requested by the customer Valves shipped with either type of hydroplug are identified by a Red on White CAUTION TAG which is attached to the valve by wires extending through the drain hole in the valve body See Figure 18 2700 Series Safety Relief Valve July 2011 33 XIV Setting and Testing Contd ee el cm VA WSS TEN Gi SS gt E JeF Y I I f 70 5 n HYDRO PLUG CAUTION This safety valve is equipped with an internal plug for hydrostatic test o0Oo DO NOT STEAM TEST UNTIL THE PLUG HAS BEEN REMOVED US Tag UN Vv SERVICE Figure 17 Hydrostatic Test Plug Hydrostatic test plugs must be removed prior to firing boiler The hydrostatic plugs are placed in the bore of the valve inside the seating surface Their purpose is twofold First they effect closure at a point differing from the seating surface of the valve so that if the valve is lifted on hydrostatic test the seating surface is not as likely to be damaged Second by raising the disc of the valve off its seat and increasing spring compression the set pressure of the valve is increased to a point where the valve will not 34 Dresser Consolidated leak at one and one half times design boiler pressure It is not necessary to g
24. confirm that all adjustment components i e 16 Dresser Consolidated ring pins cap etc are properly locked and sealed as required by the ASME Code For operational hydrostatic tests at the valve inlet which do not exceed valve set pressure the valve should be gagged Refer to the final Field Testing portion of this manual for proper techniques Ensure that the gag is removed upon completion of the inlet hydrostatic test Prior to startup of the unit on steam the sections of this manual which specify requirements for set pressure testing should be reviewed For conditions where the valve is subjected to high steam pressures i e those exceeding normal operating conditions preparations should be made to gag the valves These preparations should then be cleared with the boiler manufacturer and Dresser Consolidated Engineering Refer to Section XIV B 3 of this manual for the proper gagging techniques The safety valve should be tested with full steam pressure to ensure that the safety valve installation has been properly accomplished In some cases this is not practical thus the use of the Consolidated Hydroset or the Electronic Valve Tester EVT should be considered For valves being tested for set pressure by using a Hydroset or EVT only the set pressure is being verified Other factors such as blowdown lift reaction force proper discharge stack sizes and effects of thermal expansion cannot be determined
25. d outer edge of the nozzle seat and mechanic to produce good seats with some disc seat The purpose of this is to remove any practice No effort has been made in this small metal particles or fins attached to the sharp manual to establish an exact procedure to corner surfaces Do not exceed 002 0 05 mm cover each and every case because different chamfer for this purpose persons can get the same results using their e Seat Bushing should be replaced if D dimension own techniques is below the values mentioned in Table 6 Table 6 Seat Bushing Replacement Criteria Orifice l Dinin In mm H 125 3 18 2 208 5 16 3 250 6 35 5 313 7 95 4 313 7 95 6 500 12 70 Q 438 11 13 24 Dresser Consolidated XIII Re Assembly of 2700 Series Safety Valve A General Information The Type 2700 Safety Valve can be easily re assembled after required inspection maintenance of internal parts has been performed All parts should be clean prior to assembly See Section XVI for recommended compounds lubricants and tools B Specific Steps 1 Prior to reinstalling the lower adjusting ring lubricate the threads of the lower adjusting ring pin and partially insert the pin into the valve body Now the pin can again serve as a pointer or reference point as previously described in Section XI B of Disassembly Lubricate the threads of the lower adjusting ring and install the ring in the valve body Th
26. djusting ring must be lowered Refer to Table 7 to determine the number of notches that the ring is to be lowered the spindle allowing it to sit on the face of the disc collar The disc onto the spindle ensuring that the disc is free to rock on the spindle tip as specified in 9 Once the upper adjusting ring guide assembly is Section XII B 6 f of this manual If disc rock is not properly set lubricate the guide seating surface in the satisfactory correct the cause before proceeding vale Pane e essen mio me pae 16 When disc rock is satisfactory remove the disc and then lubricate the threads of the upper adjusting ring d lose hennad DETTI 3 disc holder and secure the disc collar with a stainless a a a S nng JUE ASSA y I aS By steel cotter pin Using side cutters carefully cut off SANJ NS REN excess cotter pin legs and bend the cotter pin for a 10 Verify that the upper ring is capable of a slight neat installation movement we Upper ring does not move the pin 17 Lubricate the spindle tio and assemble the disc is too long Should this be the case grind the end 3 i 3 iz holder and disc to spindle Recheck the rock of the pin to shorten it while retaining the original tip contour then reinstall the pin 18 Remove complete assembly from the vise being sure to protect the disc seat surface at all times 11 Clamp the spindle in a padded vise with the ball j end of the spindle upward
27. e installed in a vertical position Nominal tolerance on vertical installation is plus or minus 1 degree The discharge area of the outlet piping from a safety valve should not be less than the area of the outlet connection Where more than one safety valve is connected to a common outlet pipe the area of the pipe should not be less than the combined area of the outlet connections to the safety valves All safety valve discharges should be piped so that the effluent is discharged clear from walkways or platforms Ample provision for gravity drain should be made in the discharge pipe at or near each safety valve where water or condensation may collect Each valve has an open gravity drain through the body below the level of the valve seat and this drain should be piped to a safe discharge area If a silencer is used on a safety valve it should have sufficient outlet area to prevent back pressure from interfering with the proper operation and discharge capacity of the valve The silencer or other piping components should be constructed so as to avoid the possibility of creating corrosion deposit restrictions in the steam passages Exhausts drains and vents must be installed so that they will not impose undue stresses on the safety valve Any such stresses can produce body distortion and leakage Therefore the following recommendations are provided 1 Discharge piping should not be supported by the valve The maximum weight on t
28. e located in a manner that allows for easy access Sufficient working space should be provided around and above the valve to permit access to adjusting rings If two or more valves are ANCHOR DISCHARGE PIPING SOLIDLY TO BUILDING STRUCTURE FABRICATED DRIP PAN YOKE VENT SCHEDULE 40 PIPE UNION M ANONS AS CLOSE SECTION A A POSSIBLE Figure 5 Valve Installation 14 Dresser Consolidated X Recommended Installation Practices Contd located close together the outlets should be parallel so as to offer as much protection as possible to personnel repairing or working close to the safety valve Because foreign material passing into and through a safety valve is damaging the system on which the valve is installed must also be inspected and cleaned New systems are prone to contain welding beads pipe scale and other foreign materials which are inadvertently trapped during construction and destroy the valve seating surfaces the first few times the valve opens With regard to weld end inlet valves completely assembled valves may be installed without disassembly being necessary at the time of welding During welding the valve neck should be insulated to reduce thermal stresses When stress relieving insulation should also be utilized to reduce thermal stresses In service the valve neck should be insulated at least to the point of the inlet neck valve body bowl juncture Safety valves should b
29. e replacement nameplate call the Dresser Consolidated Field Service Supervisor at 318 640 6055 with the valve serial number as stamped on the top of the discharge flange of the valve Table 14 Standard Valve Connection Pressure Class Temperature Class Inlet Size Area Orifice Designation Class Designation Range in mm in cm 1 5 38 10 1 0 994 6 41 nae B TO 750 F 398 89 C 900 o o 2 0 50 80 2 1 431 9 23 ANSI D TO 1050 F 565 56 C 1500 2 5 63 50 3 2 545 16 42 ANSI 3 0 76 20 5 3 341 21 55 3 0 76 20 4 3 976 25 65 4 0 101 60 6 7 070 45 61 6 0 152 40 7Q 12 250 79 03 2700 Series Safety Relief Valve July 2011 39 XVII Replacement Parts Planning Contd CERTIFIED BY LW gt Consolidated NB TYPE 2749 WB 2 S sze 3 mo Br 23514 N SET 464900 LBS HR AT 9259201 Figure 21 Valve Identification VALVE TYPE CODING Flanged Inlet 27 3 7 B Series L T Temp Class Orifice Designation Buttweld Inlet 27 3 7 W B Series L T L Orifice Designation XVIII Genuine Dresser Parts The next time replacement parts are needed keep these points in mind Dresser Consolidated designed the parts Dresser Consolidated guarantees the parts Consolidated valve products have been in use since 1879 40 Dresser Consolidated Pressure Class
30. e required to correctly reassemble the valve Remove both the lower adjusting ring pin and the lower adjusting ring from the valve base The valve is now ready to be cleaned and the parts inspected for proper size and condition ADJUSTING SEAT BUSHING Figure 9 Placing a Ring Lap on Top of the Seat Bushing 2700 Series Safety Relief Valve July 2011 19 XII Inspection and Part Replacement A General Once the valve is disassembled appropriate parts can be inspected for damage and their suitability for reuse B Specific Components 1 Lift Lever and Cap Assembly Visually inspect the lift lever and cap assembly for damage from improper handling or severe corrosion Components should be replaced if damage interferes with proper function or manual lifting of the valve Compression Screw and Locknut The compression screw must be replaced if the threads are damaged to the point that spring adjustment is affected The wrench flats should not be worn or rounded or distorted due to the improper use of an adjusting wrench on either the compression screw or locknut The spring washer bearing surface or compression screw adapter surface 5 through Q orifice only should not be pitted or torn and should have a 32 RMS finish Thrust Bearing The aligning washer must match evenly to the lower thrust bearing spherical surface such that full face contact is achieved between the parts Therefore grind t
31. e tip with Anti Seize and assemble the disc and disc holder to spindle by turning the disc until the dropout threads disengage Reassemble yoke and spring assembly See Figure 20 into base being careful not to damage the disc Locate the yoke vent to the side of the valve The lug on the top spring washer should be on the right side of the valve when facing the outlet Replace the yoke and the stud nuts Tighten the stud nuts according to Table 13 Remove cotter pin from release nut and position release nut so that 125 3 17 mm of clearance is visible between lifting fork and release nut then install cotter pin Install cap and lever assembly Valve is now ready for the initial field test on steam in order to check valve set point and blowdown SPINDLE H NY ZLI LLA ZZ SSS 7A ASSAN S Z LL NNG Y DISC HOLDER N Z Z A HYDROPLUG SEAT BUSHING Figure 18 Domestic hydrostatic plug Table 13 Yoke Nut Torque Values Orifice Nut Torque Designation ft lbs Ni 1 60 81 35 2 60 81 35 3 110 149 14 51 170 230 49 4 375 508 43 6 375 508 43 7Q 375 508 43 Note 1 5 is a smaller orifice than 4 2700 Series Safety Relief Valve July 2011 35 XIV Setting and Testing Contd F 3 Export Plugs When hydrostatic plugs are installed in 2700 Valves scheduled for shipment to foreign countries the disc is removed and di
32. e to the bottom of disc holder Note 4 If valve is to be tested on superheated steam set lower ring at seat level 2700 Series Safety Relief Valve July 2011 31 XIV Setting and Testing Contd Table 11 Nameplate Symbols ASME Boiler and Pressure Vessel Code Section and Symbol Set Pressure Tolerance The valve must POP open within the range indicated below Blowdown Requirements If valve set pressure is less than or equal to 70 psig 4 83 barg 2 psig 0 14 barg If valve set pressure is 71 psig 4 90 barg up to and including 300 psig 20 68 barg 3 of set pressure If valve set pressure is 301 psig 20 75 barg up to and After opening the valve must reclose within a range of 98 to 96 however if the valve set pressure is 100 psig 6 89 barg or less the valve must CODE SYMBOL l reclose within a range of 2 to 4 TAE including 1000 psig 68 75 barg psig 0 14 to 0 28 barg below ASME Section I 10 psig 0 69 baro set pressure If valve set pressure is 1001 psig 69 02 barg or greater 1 of set pressure If valve set pressure is less than or equal to 70 psig 4 83 barg 2 psig 0 14 barg After opening the valve must reclose before the system pressure returns to normal CODE SYMBOL If valve set pressure is 71 psig 4 90 barg or greater operating pressure STAME 3 of set pressure ASME Section VIII B p Table 12 Recommended Operating Gap B
33. eing tested Gags should be installed hand tight no wrenches or mechanical force 4 Onthe valve to be tested use the following procedure and Table 9 to bring the adjusting ring to seat level a Gag the valve to prevent the disc from accidentally lifting from the seat during adjustment cS Remove both service port plugs Q Remove the upper ring pin 2 Move the upper ring until it is level with the disc holder From this point move the upper adjusting ring down from right to left as viewed through the service plug hole counting the number of notches A WARNING until the number in Column B in Table 9 appropriate to the orifice size is reached This will establish the upper adjusting ring at seat level Q Table 9 Adjusting Ring Seat Level Lower Ring Seat Level Upper Ring Seat Level Orifice Adjustment in Notches Adjustment in Notches Column A Column B 1 7 10 2 8 12 3 12 16 5 12 16 Gag safety valve during 4 12 16 ring adjustments to avoid 6 30 45 possible severe personal 7Q 30 45 injury or death 2700 Series Safety Relief Valve July 2011 29 XIV Setting and Testing Contd f Adjust the upper adjusting ring as indicated in the upper ring Column of Table 10 use either the Saturated Column or Superheated Column as conditions warrant g Replace the ring pin in the valve to hold the upper adjusting ring in position without binding h Remove the lower ring pin i
34. en turn the lower adjusting ring clockwise until the top of the ring clears the seat The lower adjusting ring is to be installed in the position it originally held prior to disassembly To effect this relocation place a clean ring lap on the nozzle seat and turn the lower adjusting ring in a counterclockwise direction until it makes contact with the ring lap If the original location of the adjusting ring was recorded simply lower the ring by turning it clockwise the same number of notches as was recorded in Step XI B of Disassembly If information on the original lower ring position is not available the ring should be lowered by turning it clockwise one notch for every 600 psig 20 7 barg of set pressure This position represents a staring position See Note below Note For a valve set pressure of 1200 psig 81 6 barg the ring will have to be lowered two 2 notches below the bushing seat This will be the starting position with the final position being determined during field testing Once the lower adjusting ring is in its correct location lock it in place by installing in the lower adjusting ring pin Verify that the lower ring is capable of a slight movement If the lower ring does not move the pin is too long Should this be the case grind the end of the pin slightly to shorten it while retaining the original tio contour then reinstall the pin If the upper adjusting ring has been removed from the gu
35. er label warnings A WARNING Do not work with valves while under the influence of intoxicants or narcotics A WARNING Rig Improper tools or improper use of right tools could result in personal injury or product damage Read Understand Practice Warning Alerts Allow the system to cool to room temperature before cleaning servicing or repairing the system Hot components or fluids can cause severe personal injury or death Always read and comply with safety labels on all containers Do not remove or deface the container labels Improper handling or misuse could result in severe personal injury or death Never use pressurized fluids gas air to clean clothing or body parts Never use body parts to check for leaks or flow rates or areas Pressurized fluids gas air injected into or near the body can cause severe personal injury or death 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 personal injury or death Do not allow anyone under the influence of intoxicants or narcotics to work on or around pressurized systems Workers under the influence of intoxicants or narcotics are a hazard both to themselves and other employees and can cause severe personal injury or death to themselves or others Incorrect service and repair could result in product or property damage or severe p
36. ersonal injury or death These WARNINGS are as complete as possible but not all inclusive Dresser cannot know all conceivable service methods nor evaluate all potential hazards Use of improper tools or improper use of right tools could result in personal injury or product or property damage This valve product line is not intended for radioactive nuclear applications Some valve products manufactured by Dresser Consolidated 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 2700 Series Safety Relief Valve July 2011 5 ll Safety Alerts Contd Caution Alerts e Heed all service manual warnings Read installation instructions before installing valve s e Wear hearing protection when testing or operating valves e Wear appropriate eye and clothing protection e Wear protective breathing apparatus to protect against toxic media Note Any service questions not covered in this manual should be referred to Dresser s Service Department Phone 318 640 6055 lll Safety Notice Proper installation and start up is essential to the safe and reliable operation of all valve products The relevant procedures recommended by Dresser Consolidated and described in these instructions are effective methods of performing the required tasks It is important to note that these instructi
37. fety systems in critical applications around the world www dresser com Dresser Inc 15455 Dallas Parkway Addison TX 75001 T 972 361 9800 F 972 361 9903 2009 Dresser Inc All rights reserved About Dresser Inc Dresser Inc is a leader in providing highly engineered infrastructure products for the global energy industry The company has leading positions in a broad portfolio of products including valves actuators meters switches regulators piping products natural gas fueled engines retail fuel dispensers and associated retail point of sale systems and air and gas handling equipment Leading brand names within the Dresser portfolio include Dresser Wayne retail fueling systems Waukesha natural gas fired engines Masoneilan control valves Consolidated pressure relief valves and Roots blowers It has manufacturing and customer service facilities located strategically worldwide and a sales presence in more than 100 countries Consolidated www consolidatedvalve com 2700_MM
38. for approximately 15 seconds then check the spindle tip and disc pocket to determine progress See Figure 11 XII Inspection and Part Replacement Contd SPINDLE NOSE me SEAT STEP BEARING BAND WIDTH R FLAT DIAMETER Figure 12 Disc to Spindle Lapping Figure 13 e The spindle nose should be ground into the disc pocket until the bearing is clearly marked The band position is shown in Figure 12 f Place the disc holder on the spindle allowing it to rest on the face of the disc collar as previously shown in Figure 7 on Section XI B Then assemble the disc holder and new disc The disc should be free enough to rock on the spindle tip If there is no freedom lower the disc collar until the disc is free to rock slightly initially approximately 001 to 002 0 25 to 05 mm rock The disc collar must then be lowered two additional notches from this initial position and secured with a stainless steel cotter pin See Figure 13 Note Failure to provide the recommended disc rock at assembly will result in a leaking valve 2700 Series Safety Relief Valve July 2011 21 XII Inspection and Part Replacement Contd Orifice Table 3 Disc to Spindle Lapping Information e Flat Bearing Wes Scie Diameter Band Width in mm in mm in mm 1 277 tooa 7 04 o 000 Q 125 3 18 125 3 18 000 0 2 377 tooa 9 42 t O 313 7 94 125 3 18 po
39. gags should be applied only hand tight During setting over gagging will also cause damage to the seating surface and result in seat leakage The gag load applied should be only enough to ensure that the valves do not lift at the expected overpressure During start up gags should never be applied when the boiler is cold The spindle of the safety valve expands considerably with the temperature increase If it is not free to expand with this temperature change it may become seriously overstressed and bent Except for hydrostatic tests boiler pressure should be brought up to within 80 of the pressure of the low set valve before applying gags Tighten the gags of drum and superheater valves finger tight When adjusting the ring positions of a valve the valve must be gagged to prevent accidental lifting and personal danger If testing the set pressure of a valve the other valves in the system should also be gagged B Application of Test Gags All Pressures 1 Refer to Figure 17 Remove top lever pin and top lever then loosen the cap screw Remove cap and drop lever as an assembly The release nut is fixed to the spindle by means of a cotter pin Note that the release nut does not quite engage top of compression screw 2 Center the test gag in the exposed end of the SPINDLE and hook the legs of gag under the sides of the YOKE Do not apply the gag load until the system steam pressure is equal to 80 of the pressure to
40. he outlet of the valve should not exceed the weight of a flange and short radius elbow plus a twelve 12 inch 804 8 mm straight length of standard weight thickness pipe with drip pan 2 Clearance between the valve exhaust piping and the discharge stack should be sufficient to prevent contact when considering thermal expansion of the header valve and discharge stack Movements due to vibration temperature changes and valve reaction forces should also be considered to ensure adequate clearance between the exhaust piping and the discharge stack 3 Flexible metal hoses are not generally recommended but if used to connect valve outlets to discharge stacks they must be of sufficient length and be configured installed in such a manner that they will not become solid in any one position Better results are obtained if the hoses are installed so that they will permit movement by bending rather than by stretching and compressing along their length The yoke can be vented to the atmosphere as in Figure 4 Precautions should be taken to vent the yoke in such a manner that it will exhaust into a safe area to prevent injury to personnel near the valve The yoke vent piping must not be connected to the body drain piping Do not plug the yoke vent hole or reduce vent hole pipe size Reference Table 2 as this could lead to valve malfunction and damage Precautions should be taken to prevent accumulations of foreign material
41. he pictorial may instead depict what preventive measures to take such as wearing protective equipment The bottom panel may contain an instruction message on how to avoid the hazard In the case of human hazard this message may 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 Know all valve exhaust leakage points to avoid possible severe personal injury or death Do not remove bolts if pressure in line as this will result in severe personal injury or death 4 Dresser Consolidated Wear necessary protective equipment to prevent possible injury 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 CAUTION Hazards or unsafe practices which COULD result in minor personal injury ATTENTION Hazards or unsafe practices which COULD result in product or property damage A ATTENTION Do not drop or strike ll Safety Alerts A WARNING Improper use or repair of pressurized media or steam device may result in severe personal injury or death A WARNING Provide and use guarding to prevent contact with heated and or pressurized parts A WARNING All potential hazards may not be covered in this manual A WARNING _N Heed all contain
42. heetiiieianiia dairies aie EE 10 Bv BUMWEIG IMICT Firacaccsthessenassiecentessiapandessstpuscetesibsaabamasinenadan a SENE n EAEE ANNE AEEA EEN 10 IX Operating PHNCIPICS ssassn anana a E thieaneennatens 12 X Recommended Installation Practices 0 ccccccccceeeeeee teens ceecneceeeeeeeeeeeeeetneennaeees 13 A General Requirements c cect eee eee ee ttt tt attat tAE EAnAEEASANEAEEEEEEEAEEEANEERREEEEEEEEEEE AREER EEE 13 B Outdoor Safety Valve Installation ssssssssissiessssestktttt inttr rrtt ttt tEEEEEEEEEEREEEEEEEEEE EEEE EEEn nt 17 C Indoor Safety Valve Installation sssssesseissririissttettttt ktkt rtnn AnEEEAEEEEEEEEEEEEEEE RENEE 17 xI Disassembly of 2700 Series Safety Valve ccc eee cteeceeeeeeeeeeeeeeeeeeeneea 18 A General Normat ORs ierpenar ierann a a aa aa baa aie EAN ENE eE ea 18 Bi Specifi Steps e t a aiana a a aE EE AE ADA aana 18 xII Inspection and Part Replacement 0 cece treet eee enti eeeeeeeeeeeeteeteeeea 20 As GONG E stiitecedatunndians et E E E sagt nasaventea 20 Be Specifi GOMPONENMS sisistscccacatnssaanciinauestacdtnenssaztalnssnedacsensesndnnisanassadinds aE AEE 20 XIII Re Assembly of 2700 Series Safety Valves nnee rererere r eereerreir nnen 25 A General Normat O raiirninusi nann ie bina a ERAN EEEa EEE ANE 25 B Specifi SISOS srira aaan eaa tiana a AED aAA T AEE REENEN 25 XIV Setting and Testing sie iieccscavavatcsns snsnnsen
43. hen lift up on the disc holder and turn the disc disc holder counterclockwise to engage the drop thru threads Once the threads are engaged release the disc holder and continue to unthread and remove the disc After the disc is removed lift disc holder from the spindle Note Removal of the lift stop and or the disc collar from the 11 spindle is usually unnecessary unless the spindle is to be replaced Measure from the top of the guide to the bushing seat Dimension B Figure 8 with a depth UPPER ADJ RING PIN LOWER ADJ RING PIN Figure 8 Bushing Seat 12 15 16 micrometer or other suitable measuring device Record Dimension B Place a scale or other thin flat metal surface against the lower face of the upper adjusting ring and measure from the top of the guide to the face of the upper adjusting ring Dimension C Figure 8 Record Dimension C Remove the upper adjusting ring pin from the valve base Loosen the lower adjusting pin until the pin is slightly clear of the notches in the lower adjusting ring Being careful not to move the lower adjusting ring place a ring lap on top of the bushing seat See Figure 9 Then using the ring pin as a pointer or reference point rotate the lower adjusting ring counterclockwise and count the number of notches that pass in front of the pointer until contact is made with the ring lap Record this information as it will b
44. id possible severe personal injury or death Warranty Statement Dresser warrants that its products and work will meet all applicable specification and other specific product and work requirements including those of performance if any and will be free from defects in material and workmanship Defective and nonconforming items must be held for Dresser s inspection and returned to the original F O B point upon request Incorrect Selection or Misapplication of Products Dresser Consolidated cannot be responsible for customer s incorrect selection or misapplication of our products Unauthorized Repair Work Dresser Consolidated has not authorized any non Dresser 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 services from unauthorized sources must do so at their own risk Unauthorized Removal of Seals All new valves and valves repaired in the field by Dresser 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 Refer to Dressers Standard Terms of Sale for complete details on warranty and limitation of remedy and liability V Valve Terminology e Accumulation Accumulation is the pressure increase over the maximum allowable working pressure of the ves
45. ide lubricate the ring threads and re install the ring on the guide Install the adjusting ring and guide assembly into the valve base such that the scribe marks will be visible from the valve outlet or the inspection port Measure the overall length of the upper ring and guide assembly Adjust the upper ring to the Dimension C recorded in Step 12 of Section XI B Disassembly Observe the marks made on the ring and guide and adjust the ring to align the marks Recheck the overall length of the adjusting ring and guide assembly to assure that the upper ring is in its original position Measure from the top of the guide to the bushing seat with a depth micrometer Subtract Dimension B as measured in Step 11 Section XI B of Disassembly Table 7 General Adjusting Ring Information Total Number of Number of Notches Disc Vertical Ring Travel for each N Pressure E Holder to Seat oa of ey Ring Ring Lower Ring Upper Ring ae A a 1 All 18 22 7 10 0035 0 089 0025 0 064 2 All 21 31 8 12 0030 0 076 0020 0 051 3 All 31 41 12 16 0020 0 051 0015 0 038 5 All 31 37 12 17 0020 0 051 0015 0 038 4 All 31 47 12 16 0020 0 051 0015 0 038 6 All 41 56 30 45 0015 0 038 0010 0 025 Q All 48 62 30 45 0015 0 038 0010 0 025 2700 Series Safety Relief Valve July 2011 25 XIII Re Assembly Contd from the dimension previously measured The difference is the distance the upper a
46. ion In an over pressure situation the pressure in the valve inlet increases until the force on the disc exerted by the system pressure equals the force exerted by the spring This causes the safety valve to pop or lift relieving the excess steam until the system pressure is reduced to the desired level The Consolidated Safety Valve has been a leader in the industry since 1879 thus offering over a century of experience in design engineering and product manufacturing Dresser s history of dependable and reliable valve service assures that today s products and designs are consistent with industry s current requirements Rigid manufacturing standards controlled by an ASME approved Quality Control Program insure that each valve will be manufactured in accordance with established design criteria and tested for functional performance This quality controlled manufacturing and test program assures that each valve manufactured will provide long and reliable service 2700 Series Safety Relief Valve July 2011 9 Vill Consolidated Safety Relief Valve Type 2700 A Flanged Inlet Ate ISSS 2737 THRU 2777Q 3 SSN Taa aan RSS 5 pA i d K 4 x PERMA YLZZZ R7 2747 THRU 2777Q VENT 90 OUT OF POSITION DO NOT PLUG iJ ij S SESS LHH A N A f M p gt com PSP UP j N AGE a N SAS A Z ONE Figure 1 2700 Safety Valve Construction Flanged Inle
47. irely they can be reduced by using a hydraulic or electronic device that allows the set pressure to be checked while the system pressure remains below the set pressure Accuracy of results obtained by the use of either of these devices depends on several factors First friction must be reduced as a source of error so that for a given pressure the Hydroset or the EVT repeatedly produces exactly the same lifting force Second gauge calibration and vibration in the effective seating area between valves of the same size and type will also affect accuracy With well calibrated gauges and valve seats in good condition accuracy on the order of 1 of set pressure may be expected Upon request Dresser Consolidated will provide pertinent written material concerning the Dresser Consolidated Hydroset Device or the EVT This material specifies all required information necessary to ensure proper usage of these devices F Hydrostatic Test Plug Removal Domestic amp Export F 1 General Information Flanged inlet safety valves shipped without Hydrostatic Test Plugs should be removed from the boiler during hydrostatic tests and boiler nozzles blanked off to prevent possible valve damage All valves shipped outside the continental United States are shipped with an export hydroplug See Figure 20 All welded inlet valves shipped within the continental United States are shipped with a domestic hydroplug See Figure 19 unless the customer specific
48. ixed portion of the seat closure 8 Dresser Consolidated Operating Pressure The operating pressure is the gauge pressure to 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 10 under the maximum allowable working pressure or 5 psi 0 34 barg whichever is greater Overpressure Overpressure is 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 Rated Capacity Rated capacity is 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 for vapors standard cubic feet per minute SCFM or m min for gases and in gallons per minute GPM for liquids Relief Valve A relief valve is an automatic pressure relieving device actuated by static pressure upstream from the valve a relief valve is used primarily for liquid service Safety Relief Valve A safety relief valve is an automatic pressure relieving device which may be used as either a safety or relief valve depending upon application A safety relief valve is used to protect pe
49. lutions P O Box 2234 16 Edendale Road Eastleigh Edenvale 1610 Republic of South Africa Telephone 27 11 452 1550 Fax 27 11 452 2903 SPAIN Dresser Italia S r l Via Cassano 77 80020 Casavatore Naples Italy Telephone 39 081 7892 111 Fax 89 081 7892 308 SWITZERLAND Dresser Valves Europe GmbH Windenboden 23 CH 6345 Neuheim Switzerland Telephone 41 41 755 27 03 Fax 41 41 755 28 13 UNITED ARAB EMIRATES Dresser International Inc Middle East Operations P O Box 61302 R A 8 Blue Sheds JA01 amp JA02 Jebel Ali Free Zone Dubai United Arab Emirates Telephone 971 4 8838752 Fax 971 4 8838038 UNITED KINGDOM Dresser U K Limited Dresser House East Gillibrands Skelmersdale Lancashire England WN8 9TU United Kingdom Telephone 44 1695 52600 Fax 44 1695 52601 FOR YOUR GREEN TAG CENTER IN USA CANADA Visit www dresser com or contact the locations listed above for international service Dresser and Consolidated are registered trademarks of Dresser Inc Copyright 2007 Dresser Inc 2700 Series Safety Relief Valve July 2011 43 About Dresser Consolidated Dresser Consolidated headquartered in Houston Texas has been an international leader in dependable pressure relief valves and solutions for more than 100 years A business segment of Dresser Inc the company delivers the trusted expertise to provide and service reliable flow sa
50. mm of lift There are six 6 notches on the lift stop so each notch of adjustment represents approximately 010 0 25 mm lift Secure the lift stop with a cotter pin SPINDLE COMPRESSION COMPRESSION SCREW LOCKNUT Figure 16 26 27 28 29 Refer to Figure 16 and establish Dimension A to that previously recorded in Section XI B 4 of Disassembly Ensure that the too washer arms do not remain in contact with the yoke after each compression screw adjustment The valve is now ready for testing after which the following steps can be taken a Following testing the compression screw should be locked firmly in place with the lock nut b Install the release nut onto the spindle then thread clockwise until the release nut is fully engaged on the spindle thread and the cotter pin hole is aligned For numbers 1 2 3 and 4 orifices run the release nut down enough to allow the lock nut to fully engage and then loosely install the lock nut c Install the cap over the release nut and seat the cap firmly into place on the yoke Install the top lever in the cap and then insert the top lever pin through the top lever and cap holes d Adjust the release nut until it clears top lever by 125 3 20 mm Remove the lever pin top lever and cap Next insert a cotter pin through the release nut slots and the spindle and spread the cotter pin ends Re assemble the cap with the dr
51. mp a dial indicator onto the railing and locate at point C The total indicator reading should not exceed 007 0 18 mm when the spindle is rotated If it does the spindle must be straightened prior to reuse b To straighten the spindle place the unthreaded portion of the small and large end in padded V blocks with the point of maximum indicator readout upward and then apply a downward force with a padded press or jack as required until the spindle is within the specifications c Other parts of the spindle not used as working surfaces may run out considerably more than Section X X Figure 10 SPINDLE FLAT SU RFACE Figure 11 007 0 18 mm but this should not be regarded as unacceptable Although the upper thread end is not a working surface excessive bending in this area could effect the accuracy of the Dresser Consolidated Hydroset device and or the Dresser Consolidated Electronic Valve Tester if either of these devices is used to verify valve set pressure d Apply a small amount of lapping compound 1A on the tip of the spindle Install the disc without the disc holder onto the spindle tip turning it clockwise until the disc threads drop out Place a ring lap on a table or similar flat surface and wipe the exposed surface of the lap clean Insert the disc nose into a ring lap so that the seat contacts the lap surface Oscillate the spindle using 360 degree oscillations
52. n Table 5 the disc should be replaced iii It may not be necessary to use all the laps at any one time but having a sufficient supply on hand will save reconditioning time The laps should be reconditioned on a flat lapping plate A lap should not be used on more than one valve without being reconditioned Laps must be checked for flatness prior to use and at frequent intervals during use A lap that is flat within one half light band is considered satisfactory Information on XII Inspection and Part Replacement Contd BEARING SURFACE X Figure 14 Table 5 Minimum Seat Relief M min Orifice in mm 1 004 0 10 2 005 0 13 3 006 0 15 5 007 0 18 4 008 0 20 6 010 0 25 Q 012 0 30 the Monochromatic Light and optical flat is available upon request from the Dresser Consolidated Field Service Department iv To recondition a ring lap wipe all compound from the lapping plate and ring lap then move the ring lap in a figure eight motion on a lapping plate If the lap is not flat a shadow will be apparent To remove the shadow coat the lapping plate with 1000 Grit Compound and lap the ring with figure eight motions covering the lapping plate 10 Seat Bushing a A Dresser Consolidated reseating machine should be used to recondition badly worn out of tolerance bushing seats This machine can be provided by the Dresser Consolidated Service Department and eliminates the
53. n each stud nut Increase the torque progressively until the final torque is applied Upon completion recheck each stud nut s torque Required torque will vary with bolting material and gaskets used See your company engineering or specification department for details on torquing sequence and torque values As an extra precaution the gap between the two mating flanges should be checked during the torquing process to ensure that the flanges are being pulled together evenly A final inspection and review should be made to ensure that all of the requirements for bolting the valve inlet have been implemented 4 The outlet piping may now be installed A complete inspection of components and their cleanliness is to be made prior to further work Studs are to be lubricated with an appropriate lubricant 5 Install the outlet gasket studs and nuts Stud nuts are to be pulled down finger tight An initial value of torque is to be applied The additional procedures outlined in Step 3 are also to be followed After being assured that the valve is properly installed the drainage piping from the valve body bowl is to be connected This line also must be flexible so it will not create stress on the valve under operating conditions Prior to completing the installation a visual check should be made to ensure that the valve lifting lever has room and is free to operate At the time of installation an inspection of the valve should be made to
54. nsolidated upper ring will adjust even when the valve is hot If serious galling is present the guide should be replaced a Clearance The maximum clearance between the disc holder and guide should be in accordance with Table 4 Disc Holder The surface on the end of the disc holder closest to the disc must be free from steam erosion The two small holes must be open to ensure the passage of steam to the chamber above the disc Make sure the outside diameter is not egg shaped and the surface is smooth If any small indication of galling is present polish the high spots with an emery cloth If serious or large scale galling is present the disc holder should be replaced Disc Inspect the disc seat for steam cuts nicks or other damage If the seat step measures less than dimensions specified in Table 5 this indicates that the thermal lip has been lapped to the minimum thickness Do not machine any ThermoDisc however a disc which is not below minimum relief can be lapped to remove minor damage a To Lap Disc Seat i The above lapping method is also used on the disc seat When lapping the disc seat the disc should be held stationery but not rigidly and the lap moved as above Use care not to strike the cone of the disc as this would cause the seat to be high on the inside i The ThermoDisc can not be machined If after lapping Dimension M in Figure 14 does not meet the minimum specified i
55. ogether or replace the entire thrust bearing as necessary Top and Bottom Spring Washers The lower spring washer bearing surface must be ground to the spindle To grind the lower spring washer a 320 grit Clover 1A lapping compound is used for roughing in and then finish lap with 1000 grit Kwik Ak Shun lapping compound until a satisfactory bearing band is obtained The bearing width should be 1 800 8 20 mm min to 3 160 4 80 mm max Clean lower spring washer and spindle when complete Spring Visually inspect for pitting and corrosion of coils that will reduce the coil diameter When this condition is found replace the spring Inspect for end parallelism in the free height and any obvious unevenness in coils collapse of coils or general distortion Spindle It is important that the spindle be kept very straight in order to transmit the spring force to the disc without 20 Dresser Consolidated lateral binding Overgagging is one of the common causes of bent spindles A method to check the essential working surfaces of the spindle is illustrated in Figure 10 This may be performed either with or without the disc collar and lift stop on the spindle a Using Figure 10 as a reference clamp a V block A made of wood fiber or other suitable material onto the platform railing Imbed the ball end of the spindle in a piece of soft wood B and place the top of the Spindle below the threads in the V block A Cla
56. oiler Design Pressure Minimum Differential as a Percent of Boiler Design Pressure Over 15 to 300 psig 1 03 to 20 68 barg 10 but not less than 7 psi 0 48 baro Over 300 to 1000 psig 20 68 to 68 95 barg 7 but not less than 30 psi 2 07 barg Over 1000 to 2000 psig 68 95 to 137 90 barg 5 but not less than 70 psi 4 83 barg 32 Dresser Consolidated XIV Setting and Testing Contd A DANGER Improper lift adjustment may result in severe personal injury or death A DANGER Do not disassemble valve with pressure in drum or header as this will result in severe personal injury or death E Hydroset Electronic Valve Testing EVT Periodic tests may be required for verification of valve set pressure Both the Dresser Consolidated Hydroset Test Device and EVT provide for this capability however set pressure is the only factor which can be verified Valves should be initially set using full system pressure as outlined in sections XIV A through XIV C of this manual The Hydroset or EVT used for subsequent checks of set pressure Setting safety valves by the recommended method of lifting valves under steam pressure presents a number of problems In high pressure conventional boilers superheater tubes may be damaged if the turbine is not operating Also the expense of feed water fuel and personnel involved is considerable Although these problems cannot be eliminated ent
57. ons 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 Dresser Consolidated product or render it unsafe It is also important to understand that these safety messages are not exhaustive Dresser Consolidated can not possibly know evaluate and advise any customer of all of the conceivable ways in which tasks might be performed or of the possible hazardous consequences of each way Consequently Dresser Consolidated has not undertaken any such broad evaluation and thus anyone who uses a procedure and or tool which is not recommended by Dresser Consolidated or deviates from Dresser Consolidated recommendations must be thoroughly satisfied that neither personal safety nor valve safety will be jeopardized by the method and or tools selected Contact Dresser 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 a
58. op lever top lever and top lever pin Install a cotter pin to lock the top lever pin in place A final check should be made to ensure the proper clearance exists between the release nut and the top lever Finally tighten the cap set screw to secure the cap After testing the valve for proper set point and blowdown the ring pins top lever pin and lift stop shall be sealed Run a continuous wire through the sealing wire holes leaving both ends in such a manner that a lead seal may be threaded to them Before crimping the seal assure that the parts being sealed can not be tampered with without removing the seal 2700 Series Safety Relief Valve July 2011 27 XIV Setting and Testing A General Information Upon completion of hydrostatic testing of the boiler but prior to placing the boiler in service ENSURE THAT THE HYDROSTATIC TEST PLUGS ARE REMOVED FROM ALL VALVES All Type 2700 Safety Valves are steam tested at the factory to verify set pressure adjust ability and seat tightness Every valve is set to have a clean popping action and to reseat tightly However because the boiler used in setting the valves has a small capacity compared to the capacities of the Type 2700 Valves the valves are factory set with a long blowdown to prevent chattering under initial start up conditions Final adjustments should be made on the operating system with conditions approximately those that will be realized under actual operating condi
59. or water in the vent pipe This vent is a critical part of the valve system for controlling valve blowdown and lift All face surfaces which require gaskets to seal pressure shall be inspected for cleanliness or any defects that can cause leakage Burrs mashed serrations uneven surfaces etc are all possible leakage producing defects Proper gasket sizes and pressure ratings should be checked prior to starting valve installation It is of utmost importance that the gaskets used be dimensionally correct for the specific flange and that they fully clear the valve inlet and outlet openings Gaskets flange facings and bolting should meet the service requirements for the pressure and temperature involved Other valve installation considerations include 1 Install the inlet gasket if required on the header mounting flange Check for cleanliness surface alignment condition gasket condition etc When possible inlet studs on the mounting flange should be used to guide the valve on the header mounting flange Inlet studs should be lubricated with the appropriate lubricant 2700 Series Safety Relief Valve July 2011 15 X Recommended Installation Practices Contd 2 When installing flanged valves the flange bolts must be pulled down evenly to prevent body distortion misalignment and leakage 3 With valve in position screw on the stud nuts until all nuts are finger tight An initial torque shall be placed in turn o
60. ork and release nut then install cotter pin 11 Install cap and lever assembly 12 Valve is now ready for the initial field test on steam in order to check valve set point and blowdown 36 Dresser Consolidated SPINDLE DISC HOLDER EXPORT HYDROPLUG SLL i SEAT BUSHING LLL Z S PATA Figure 19 Export Hydrostatic Plug A Ses ZA eZ ZZ LL N A ESS S GF G PANASSS 4 aN N 7 TR SSN K Oy gt J L S f Eg S gt Ib idi EEZ ZZZ CZA 6 SS rt ll lk ee ZANNE ETT Z Y lt gt CH Y Figure 20 Yoke and Spring Assembly XV Trouble Shooting The 2700 Valves Possible Cause Corrective Action No Action Valve A Upper ring too high A Increase blowdown as outline in Section does not go into XV C 4 of this manual full lift B Foreign material trapped between disc B Disassemble valve and correct any holder amp guide abnormality as outline in Section XI of this manual Inspect system for cleanliness Simmer A Lower ring too low A Adjust per Section XV C 2 of this manual B Steam line vibrations B _ Investigate and correct cause Valve Leaking and A Damaged seat A Disassemble valve lap seating surfaces or exhibits erratic replace disc if required as outlined in popping actions Section XIX B of this manual B Part misalignment B Disassemble valve inspect
61. pped in preservative then packed in a box The package is then inserted into the valve outlet To remove the special export plug the following steps must be followed 1 Remove the cap assembly adjust release nut to 2 hole from the top of the spindle and install cotter pin 2 Back off the yoke stud nuts uniformly until compression screw engages release nut Now remove yoke stud nuts 38 Remove yoke and spring assembly See Figure 20 from base 4 Remove hydrostatic plug by turning until it is disengaged from spindle threads Note Hold the disc holder against the disc adjusting collar during this step otherwise the disc holder will fall from the spindle and become damaged 5 Remove the seal peel preservative from the disc 6 Lap the disc and seat bushing thoroughly clean the seats with a clean cloth 7 Lubricate the spindle tip with Anti Seize and assemble the disc and disc holder to spindle by turning the disc until the dropout threads disengage 8 Reassemble yoke and spring assembly See Figure 20 into base being careful not to damage the disc Locate the yoke vent to the side of the valve The lug on the top spring washer should be on the right side of the valve when facing the outlet 9 Replace the yoke and the stud nuts Tighten the stud nuts according to Table 13 10 Remove cotter pin from release nut and position release nut so that 125 3 17 mm of clearance is visible between lifting f
62. pping plate Use a new ring lap if further lapping is required to remove Figure 15 2700 Series Safety Relief Valve July 2011 23 XII Inspection and Part Replacement Contd any defect in the seat To finish lapping the vi The following precautions and hints will be of bushing seat apply a light coating of 1000 assistance when lapping nozzle and or disc Grit Compound to the face of the new lap seats and repeat the lapping motion described e Two 2 ring laps per valve previously e 1A Clover Grinding Compound per tool iv Remove the ring lap and wipe the lap surface d j list with a clean lint free cloth leaving compound on the bushing seat Replace the ring lap e 1000 Grit Kwik Ak Shun Grinding on the seat and lap as above but without Compound per tool list adding compound Repeat this operation until the seat has a mirror finish Any evidence of defects such as gray areas or scratches will require a repeat of the whole lapping d Before lapping the nozzle and disc seat the procedure until a mirror finish is attained leading edges inside diameter of seats of both must be slightly chamfered as follows e Clean lint free cotton rags Note 1 This tool list is located on Section XV of this manual v While the finer points of lapping and grinding in may be considered as a mechanical art Use a fine grade sandpaper to lightly break the it is not beyond the ability of the average inner edge an
63. r 40N up 24N up 10N down 26N down 5 3 341 21 555 901 62 12 1500 103 42 nee 40N up 24N up 10N down 26N down 1501 103 49 2500 172 37 Max 5N down 40N up 24N up 15N down 31N down 2901 172 44 2800 193 05 45N up 29N up 25N down 41N down 2801 193 12 3000 206 84 45N up 29N up 25N down 41N down 101 6 96 300 20 68 9N down 25N down 9N down 25N down 301 20 75 500 34 47 55N up 38N up Seat Level 17N down 501 34 54 900 62 05 1N down per 50N up 33N up 10N down 27N down 4 3 976 25 652 901 62 12 1500 103 42 Poin 45N up 28N up 15N down 32N down 1501 103 49 2500 172 37 Max 5N down __45N up 28N up 20N down 37N down 2501 172 44 2800 193 05 45N up 28N up 25N down 42N down 2801 193 12 3000 206 84 45N up 28N up 25N down 42N down 101 6 96 300 20 68 1N down per Seat Level 45N down Seat Level 45N down 6 7 070 45 613 301 20 75 500 34 47 600 psig 7ON up 25N up Seat Level 45N down i 501 3454 900 62 05 413 68 barg 65N up 20N up 10N down 55N down 901 6212 1100 75 84 Max SN down Gon up 15N up 20N down 65N down 1N down per a 12 250 79 032 All Pressures neues Seat Level 45N down Jem Below Bin down Max 3N down Note 1 For pressures over those listed in this table use the same ring setting as the highest listed pressures Note 2 Position reference to seat level Note 3 Position referenc
64. rect 4841 Leopard Street Corpus Christi TX 78408 Telephone 1 361 881 8182 Fax 1 361 881 8246 BRAZIL Dresser Industria E Comercio Ltda Rod Presidente Dutra KM 154 7 Predio 18 Pq Industrial CEP 12240 420 San Jose dos Campos Sau Paulo Brazil Telephone 55 11 2146 3600 Fax 65 11 2146 3610 CHINA Dresser Machinery Suzhou Co Ltd 81 Suhong Zhong Road Suzhou Industrial Park Suzhou P R China 215021 Telephone 86 512 6258 6500 Fax 86 512 6258 8590 Dresser Inc Suite 1708 Capital Mansion 6 Xinyuan S Road Chaoyang District Beijing 100004 P R China Telephone 86 10 8486 4515 Fax 86 10 8486 5305 42 Dresser Consolidated FRANCE Dresser Flow Technology Europe Energy 5 180 190 Bd de Verdun 92413 Courbevoie Cedex France Tel 83 1 49 04 90 00 Fax 33 1 49 04 90 10 GERMANY Dresser Valves Europe GmbH Heiligenstrasse 75 41751 Viersen Germany Tel 49 2162 8170 0 Fax 49 2162 8170 280 INDIA Dresser Valve India Pvt Ltd 305 306 Midas Sahar Plaza Mathuradas Vasanji Road J B Nagar Andheri East Mumbai India 400 059 Telephone 91 22 2 835 4790 838 1134 Fax 91 22 2 835 4791 ITALY Dresser Italia S r l Via Cassano 77 80020 Casavatore Naples Italy Telephone 39 081 7892 111 Fax 89 081 7892 308 JAPAN Dresser Japan Ltd DJL 20th Floor Marive East Tower WBG 2 6 Nakase Mihama ku Chib
65. round a valve work area Due to the various circumstances and conditions in which these operations may be performed on Dresser Consolidated products and the possible hazardous consequences of each way Dresser Consolidated can not possibly evaluate all conditions that might injure personnel or equipment Nevertheless Dresser Consolidated does offer certain Safety Alerts listed in Section Il for customer information only It is the responsibility of the purchaser or user of Dresser 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 Dresser Consolidated in writing at PO Box 1430 Alexandria LA 71309 1430 or by calling at 818 640 2250 Fax 318 640 6325 6 Dresser Consolidated A CAUTION Heed all service manual warnings Read installation instructions before installing valve s A CAUTION Wear necessary protective equipment to prevent possible injury IV Warranty Information A WARNING tf vy RADIATION AREA KEEP OUT RWP REQUIRED FOR ENTRY Know nuclear health physics procedures if applicable to avo
66. rsonnel and equipment by preventing excessive overpressure Safety Valve A safety valve is an automatic pressure relieving device actuated by the static pressure upstream of the valve and characterized by rapid opening or pop action It is used for steam gas or vapor service Seat A seat is the pressure containing contact between the fixed and moving portions of the pressure containing elements of a valve Set Pressure Set pressure is the gauge pressure at the valve inlet for which the relief valve has been adjusted to open under service conditions In liquid service set pressure is determined by the inlet pressure at which the valve V Valves Terminology Contd A CAUTION Prevent dirt from entering outlet or inlet port A ATTENTION A Lift only in vertical upright position A ATTENTION Handle valve carefully Do not drop or strike starts to discharge In gas or vapor service the set pressure is determined by the inlet pressure at which the valve pops e Simmer Simmer is characterized by the audible passage of a gas or vapor across the seating surfaces just prior to pop The difference between this start to open pressure and the set pressure is simmer and is generally expressed as a percentage of set pressure e Valve Trim Valve trim includes the nozzle and disc VI Handling and Storage Safety valves should be stored in a dry environment to protect them from the weather
67. s at the downstream corner will be equal to a minimum of 1 4 of the nozzle diameter The radius should be reduced gradually leaving only a small portion of the upstream corner with a smaller radius See Figure 5 4 Safety valves should never be installed in a steam line in a position directly opposite to a branch line Excessive line vibrations are known to produce shifts in safety valve set pressures Vibrations may possibly introduce chatter causing damage to the valve and reduce its capacity This vibration also contributes to increased incidents of seat leakage Considerations should be given to eliminating this problem prior to installing the valve on the unit Table 2 2700 Yoke Vent Sizes Orifice Yoke Vent Size NPT Designation fim ae 1 50 12 7 2 50 12 7 3 50 12 7 5 75 19 0 4 75 19 0 6 1 00 25 4 7Q 1 00 25 4 Note 1 5 is a smaller orifice than 4 Steam flowing vertically out of a discharge elbow produces a downward reaction on the elbow Effects of reaction force vibration and seismic loads on all valve components and discharge piping should be considered when designing the valve system Refer to ANSI B 31 1 Non Mandatory Appendix Il Dresser Product Information Sheet SV PI 15 and Dresser Bulletin SV 5 for further information For optimum performance safety valves must be serviced regularly and otherwise maintained So that servicing can be properly performed valves should b
68. s 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 preventative maintenance These seminars help to minimize downtime reduce unplanned repairs and increase valve safety While they 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 818 640 6325 or telephone 318 640 6054 2700 Series Safety Relief Valve July 2011 41 Sales Office Locations UNITED STATES Dresser Consolidated Dresser Inc LA Hwy 3225 US Hwy 167N P O Box 1480 Alexandria LA 71309 1430 Telephone 1 318 640 2250 Fax 1 318 640 6325 Dresser Consolidated Headquarters 10343 Sam Houston Park Drive Suite 210 Houston TX 77064 Telephone 1 281 671 1640 Fax 1 281 671 1735 Dresser Direct 1250 Hall Court Deer Park TX 77536 Telephone 1 281 884 1000 Fax 1 281 884 1010 Dresser Direct 905A Industrial Road Clute TX 77531 Telephone 1 979 265 1309 Fax 1 979 265 2514 Dresser Di
69. sel during discharge through the pressure relief valve expressed as a percentage of that pressure or actual pressure units e Back Pressure Back pressure is the pressure on the discharge side of a safety relief valve 1 Superimposed Back Pressure Superimposed back pressure is the pressure in the discharge header before the safety relief valve opens a Constant Specify single constant back pressure e g 20 psig 1 38 barg b Variable Specify variable back pressure range using min and max limits e g O to 20 psig 1 38 barg 2 Built up Back Pressure Built up back pressure is pressure which develops at the valve outlet as a result of flow after the safety relief valve has been opened e Blowdown Blowdown is the difference between set pressure and reseating pressure of a pressure relief valve expressed as a percentage of the set pressure or actual pressure units 2700 Series Safety Relief Valve July 2011 7 V Valves Terminology Contd Cold Differential Set Pressure Cold differential set pressure is the pressure at which the valve is adjusted to open on the test stand This pressure includes the corrections for back pressure and or temperature service conditions Chatter Chatter is abnormal rapid reciprocating motion of the moveable parts of a safety valve in which the disc contacts the seat Differential Between Operating and Set Pressures Valves in process service will generally give best res
70. t 10 Dresser Consolidated a Nomenclature Disc Holder Guide Base Yoke Upper Adjusting Ring Upper Adjusting Ring Pin Lower Adjusting Ring Lower Adjusting Ring Pin Spring Top Spring Washer Bottom Spring Washer Seat Bushing Disc Disc Collar Lift Stop Spindle Compression Screw Compression Screw Adaptor 4 to 7_Q Orifices Only Thrust Bearing Lifting Gear Studs Studded Inlet Nuts Compression Screw Locknut Cotter Pins Not Shown VIII Contd B Buttweld Inlet a a ZDA 4 Xe NSS LX 2735W THRU 2775QW Gamer SEs KSSSS Z NDAN aye Yat x RK CSS Sp i Z KS Ne EXE Sse YLLLLZ Z 2745W THRU 2775QW VENT 90 OUT OF POSITION DO NOT PLUG U iy LY Be eS si A KS Figure 2 2700 Safety Valve Construction Buttweld Inlet Part No 3 ON Oa RR OOD i i 4 i k N O A gt O N Co 20 21 22 23 24 Nomenclature Disc Holder Guide Base Yoke Upper Adjusting Ring Upper Adjusting Ring Pin Lower Adjusting Ring Lower Adjusting Ring Pin Spring Top Spring Washer Bottom Spring Washer Seat Bushing Disc Disc Collar Lift Stop Spindle Compression Screw Compression Screw Adaptor 4 to 7_Q Orifices Only Thrust Bearing Lifting Gear Studs Studded Inlet Nuts Compression Screw Locknut Cotter Pins Not Shown 2700 Series Safety Relief Valve July 2011
71. 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 Dresser Consolidated Service Engineers restore disc and seat bushing 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 Dresser Consolidated Field Service Engineer be employed to make final field adjustments during the initial setting of all Consolidated Safety Valves All Field Service Engineers activities are coordinated from the Alexandria Louisiana Field Service Office Upon receipt of a purchase order number authorizing the trip the engineer is dispatched Reference www consolidatedvalve com to locate your local Field Service representative C 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 bushing replacements hydroset calibrations electromatic relief valve repairs etc Contact Valve Repair Department at 318 640 6057 D Safety Valve Maintenance Training Rising costs of maintenance and repair in the Utility and Process Industries indicate the need for trained maintenance personnel Dresser Industrial Valve Operation conduct
72. tions Note Dresser Consolidated recommends full flow steam testing upon initial start up Adjusting ring settings are initial adjustments only and are not intended to be final adjustments The use of a Dresser Consolidated Hydroset or EVT unit can serve to establish set pressure but cannot be used for verifying blowdown lift etc For additional information see Section X Recommended Installation Practices of this manual It is recommended that the safety valves be tested and adjusted with the boiler isolated Factors which can affect valve operation and which should be considered when initially setting a valve are as follows 1 Ambient temperature near the valve and valve temperature stabilization 2 Line vibration 3 Valve capacity versus rated flow through the line on which the valve is mounted 4 Discharge stack or drain piping binding 5 Flow induced vibrations or pressure pulsations set up by upstream bends Valve inlet nozzle configuration or other internal piping configuration problems 6 High water level in the drum When the valves are subjected to working hydrostatic 28 Dresser Consolidated tests not exceeding the set pressure of the low set valve valves may be gagged rather than using hydrostatic test plugs For higher pressures hydrostatic plugs should be used A common source of safety valve trouble is over gagging During hydrostatic testing and during safety valve setting
73. ults if the operating pressure does not exceed 90 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 It is recommended that the valve be set as high above the operating pressure as possible Disc A disc is the pressure containing moveable member of a safety valve which effects closure Leak Test Pressure Leak test pressure is the specified inlet static pressure at which a quantitative seat leakage test is performed in accordance with a standard procedure Lift Lift is the actual travel of the disc away from the closed position when a valve is relieving Lifting Lever A lifting lever is a device for manually opening a safety valve by the application of external force to lessen the spring loading which holds the valve closed Maximum Allowable Working Pressure Maximum allowable working pressure is 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 safety relief valve is set to open Nozzle Seat Bushing A nozzle is the pressure containing element which constitutes the inlet flow passage and includes the f
74. ures this insulation will effectively reduce thermal stresses due to high temperature gradients through the walls of the safety valve nozzle Spring covers should be used to stabilize as nearly as possible the temperature of the spring to prevent the accumulation of snow and ice between the coils of the spring and to prevent dirt and fly ash from accumulating between the coils of the spring Lifting gear covers should be installed to prevent ice dirt and fly ash from accumulating in areas inside the safety valve cap C Indoor Safety Valve Installation Indoor valve installations should have inlet necks insulated only up to the underside of the valve body Considerations should be given to ambient temperature changes greater than 100 F 37 8 C because of possible set point changes which may occur 2700 Series Safety Relief Valve July 2011 17 XI Disassembly of 2700 Series Safety Valve A General Information The Type 2700 Safety Valve can be easily disassembled for inspection reconditioning A DAN G ER seats or replacing internal parts The initial spring load can be established after reassembly Refer to Figure 1 and 2 for parts nomenclature NOTES e Before starting to disassemble the valve be sure that there is no steam pressure in the drum or header e Parts from one valve should not be interchanged with parts from another valve B Specific Steps 1 Remove the top lever pin and top lever 2 Loosen cap
75. using these setting devices Full flow steam testing is recommended at initial start up to adjust blowdown and verify proper installation Proper adjusting ring position can then be recorded and maintained when valves are serviced Vent and drain piping should have a union connection to facilitate valve removal or servicing in place See Figure 4 X Recommended Installation Practices Contd A WARNING Know all valve exhaust leakage points to avoid possible severe personal injury or death B Outdoor Safety Valve Installation Safety valves operating under the best possible conditions i e of favorable operating gap relatively stable ambient temperatures the absence of dirt and in relatively still air will provide the maximum degree of safety tightness and dependability When a safety valve is installed in an outdoor location it may be exposed to wind rain snow ice dirt and varying temperatures Therefore the following recommendations are made for proper protection and to ensure that operational dependability can be restored to a level near that of the valve installed under ideal conditions The inlet neck of the safety valve and safety valve body up to the top of the base should be insulated The exterior surface of any such insulation should be made weather proof by any suitable means In addition to maintaining a more even temperature within the valve body especially during widely fluctuating ambient temperat
76. veensiadawnsanssaneasbeded tadesantintauansentidauneenesdaameaamand intended 28 Az General Informati ON inei srira eai aaa ea ieaiai ATONE 28 B Application of Test Gags sssssssssssesttttrrtttttt erent ttt ee eee ee eet ee ten aaesaeeeeeeeeenetenicenaaeeas 28 O Presetting AGJUStING RINGS recseg iaa a Ea 29 D Steam TEStinGlNSIUCION eseis a N EA 30 E Hydroset Electronic Valve Testing EVT e ssssssssssserseitrrrrinrestrettnrtiinritnrttttttrttrrnrennnnent 33 F Hydrostatic Test Plug Removal Domestic amp EXPO ssissssessesreerriirrieneteetterrtinrennnnent 33 F1 General IniormatiO i assests naiaiae Aaaa 33 F2 Domesie PIUS earns enin aa EE EEN EEEE E 34 FS EPO PIUG S airesin knne Ina a UN iE i Eain E PINDE NANDE AE S ANED RIDETAS 36 XV Trouble Shooting the Type 2700 Valve oo cece cectctetee eee ee ester teetaaaeaeeeeeeeeeettetieeneaaeaeeees 37 XVI Maintenance Tools amp Supplies 2 2 eect eter e reece eerie eee ee eee ee tected aeeaeeeeeeeeteetenneea 38 XVII Replacement Parts Planning ses nssessitsnieenrrrierrtrtrninrinrinnnnnrinnrntrennrnrrnnrrnnenerenene 39 A Basic Guidelines iiisii cicsaiedtativsasttearsasaadiaw E an EAA EEEE Eni AEE 39 B Identification and Ordering Essentials sssteissssrsirinirnsiinneei ninenin iaee nnna 39 XVIII Genuine Dresser Parts ssssssssssseseetttnrrtttttt attt ttt tr tAn Anat AAEEEEEEEAEAAEREARAEAEEEEEEEREEEEREEEREEEEEEEEEEEE 40 XIX Manufacturer s Field Service

2700 Series - Maintenance Manual

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