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3500 EBV Series - Maintenance Manual

1. Figure 14 Contd Schematic Wiring Diagram Electromatic Valve 120VAC 240VAC 24VDC amp 125VDC 3500 EBV Series Safety Valve March 2011 27 XIII Maintenance Instructions Contd Solenoid CONTROL VOLTAGE Voltage Supplied 3539 Kal By Customer CONTROLLER SOLENOID VOLTAGE INRUSH CURRENT HOLDING CURRENT Control Voltage Supplied By Customer d 25387 Control 7 ar ae E vc ET E Station SURE Roa Ur Por E Ganga cuc ECC Ee Yir TEREA 10 T9 T8 T7 T6 T5 T4 T2 1 ow BLOCK zm 0 NE f N es a e 6 e o o E 18 T7 T6 T5 T4 T2 T1 E RESISTOR 16 AWG 2 34mm Move To Be au 5 a ra 9 a m E 6 o 6 o 16 AWG 2 34mm co PSH Io E e Indicating Indicating 2 a 5 z Lamp Open L CI d o Ele 22 g amp Closed g No Nc No Ele ET lt lt 2 _ 85 2 Relay a d SIS Contacts CR3 D CR2 CRI 5 2 1
2. Control Voltage Supplied by Customer TTT BUSY a Tux EHE NI CNN 2537 Control pee LEE EN T EE E Pd dE 1 iTERMINAL qo POR p Us BLOCK Dx a T Terminal Block Terminal Block o 4 n e i 6 T7 T6 T5 T3 T2 Move To Be Same As Control Voltage 2 34mm e E 5 oc S 5 g E E een mum lt Bi Indicating Indicating EN Lamp Open Lamp Closed lt lt 2 Relay 2 Contacts CR3 16 awae samm RED OR BLACK 2537 CONTROL STATION SWITCH LAYOUT Relay Aux MAN MAN MAN SE PL e Ki l 3 L i 29 JN CR4 Indicating b d OFF OFF 16 AWG2 34mm Lamp AUTO el SN S EE AUTO Valve Shown in Closed Position SWITCHIN SWITCHIN SWITCH IN AUTO OFF MAN POSITION POSITION POSITION Normally Closed 8316G64 Normally Open 8316G66 DE ENERGIZED ENERGIZED DE ENERGIZED ENERGIZED EXHAUST CYLINDER EXHAUST CYLINDER EXHAUST CYLINDER EXHAUST SOLENOID CYLINDER LENOID 2 SOLENOID SOLENOID p SOLENO E A Pressure P Pressure P Pressure
3. m L lt 4 D D 2 Heater Thermostat Notes amp T10 15 1 T7 T6 15 14 T3 T2 Ti 2 The Figure shown is a section view from the 3539 Controller showing placement and RESISTOR cc wiring of the Heater THERMOSTAT Thermostat Components RESISTOR Figure 17 Optional DCS Control Interface 220 VDC amp 250 VDC 32 Dresser Consolidated XIII Maintenance Instructions Contd aa OPTIONAL DCS CONTROL INTERFACE To 2537 Control Station Required Terminals For Direct Contact Control Open closed Dry Con tact Control From DCS Voltage Supplied By Customers ASTI CR3 12AWG 3 15mm RED 16 AWG 2 34mm 2 S Sief ZS 4 S4 T10 T9 T8 T7 T6 T4 T2 Ti 8 bal o o 9 D E d ey a tc gt Resistor MOV to Be H Same As Control Resistor Voltage e m E lt 16 2 34 z 5 T BROWN g Wha E 2 PSL PSH Eg 5 zl y 5 _ EIE z o E x lt Relay a Contacts e w o T lt T RELAY COIL 16AWG 2 34mm YELLOW o z lt 16 AWG 2 34mm RED a RED Valve Shown in Closed Position DCS NOTES 1 All interface with DCS System occurs in 3539 Controller For any other configuration consult factory Figure 17 Contd Option
4. KEEN 48 Recommended Spare Partei 48 XXII Manufacturer s Field Service amp Repair 49 Factory Setting vs Field Setting rete Epi Ex Red be 49 Ej euo d 49 CG Factory Repair 49 D Safety Valve Maintenance mme 49 Dales ee EE 50 4 Dresser Consolidated 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 below consisting of three panels encircled by a narrow border 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 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 the pictorial may instead depict what preventive measures to take such as wearing protective equ
5. S 3 4 N BO e I Loader N ES 4D Belleville Washer E Wf 4E Split Spacer Ring UA LM NS A Gasket 778 2 Stem Stem Nut Packing Gland Flange 5 6 7 8 Bearing Washer Figure 2 3500 Valve Typical Flange Inlet 9 0 Packing Gland 11 Packing Ring 12 Packing Stop Washer Discharge Collar Studs Discharge Collar Nuts 4 my 15 Stud Packing Gland en A 6 Nut Packing Gland 7 Cap Screw Yoke Body 18 Lock Washer Z9 G 9 99 Q d 19 Drive Bushing 20 Screw Yoke Actuator CN Lock Washer Yoke NN NY 21 Actuator NYY 9 22 Key Stem 23 Set Screw N WN Op 24 Drain 48 4E 4D E 25 Actuator Assembly Figure 3 3500 Valve Typical Buttweld Inlet 25 Actuator 3500 EBV Series Safety Valve March 2011 15 IX Consolidated 3500 Series Safety Valves Contd Part No 25B Solenoid Open Nomenclature 25C Solenoid Closed 25D Position Switch 25E Bracket Cap Screw Bracket Actuator Lock Washer Bracket Actuator Cap Screw Bracket Switch Lock Washer Bracket 234 Switch 25K Close Nipple Pipe 1 2 14F NPT 25 25 25G 25H 25B Flush Bushing Conduit Fitting Straight 25N Pipe Plug 25M 25P Tee
6. Actuator assembly for Ledeen GS amp SY Series Actuators Refer to Figures 21 and 22 1 Slide the Actuator Drive Bushing into the Drive 5 Remove the Actuator Drive bushing and the Yoke Sleeve of the Actuator Alignment Tool from the yoke and Actuator 2 Insert the yoke alignment tool Figure 20 through 6 Place the Key into the milled Keyway on the stem the bottom of the yoke and into the Bushing Guide 7 Align the Key in the Keyway of the Actuator Drive Bore of the Actuator Yoke Figure 20 Bushing With the key on the Stem of the Ball 3 For proper alignment assemble the Yoke to the Valve Actuator with the Yoke Alignment Tool with the 8 Slide the Actuator Drive Bushing on the Stem Actuator Drive Bushing in place until it is about 125 3 18 mm from the Packing 4 Fasten the Yoke to the Actuator using the Cap Gland Studs Bolts provided and torque to the values in Table 3 Figure 21a Top View of GS620 amp GS628 Series Actuator Elbow _ Pipe Normally Closed Energize to Open Solenoid Valve B Tube Fitting Elbow 2 Tube Fitting Elbow Tube Fitting racke itti Elbow Screw amp Washer Tube Fitting Elbow Cap Screw amp Washer Flush Bushing Pipe Closed Nipple Pipe Flush Bushing Pipe Closed Nipple Pipe Normally Closed Energize to Open Solenoid Valve Tubing Tube Fittin
7. Conversely by turning Screw B clockwise the closing point will be decreased lengthening the blowdown TO GROUND LUG ON DOOR Figure 24 3539 Controller 42 Dresser Consolidated Example with the valve set at a pressure of 2000 psi 137 90 bar the set point can be increased to 2010 psi 138 58 bar by turning Screw a counterclockwise To reduce the set point to 1990 psi 137 21 bar Screw A must be turned clockwise The type 3539 Controller is capable of being adjusted to an extremely short differential or blowdown setting It is not always possible however to take full advantage of this short blowdown adjustment if the pressure connection to the sensing elements is connected to the superheater due to an additional pressure drop Therefore if this additional pressure drop under any load condition exceeds the closing point setting of the valve the valve will chatter Accordingly it is absolutely essential that the pressure connection from the leader be at lease 8 10 pipe diameters upstream from the Electromatic Ball Valve inlet A DANGER AVOID ELECTRICAL SHOCK Touch only Screw A and Screw B XVI Setting and Testing Contd A 4 Minimum Blowdown setting A DANGER The DFC recommended blowdown settings for the valve are shown in Table 4 Table 4 Recommended Blowdown for ASME and Non ASME Applications Set Point Min Blowdown All Pressures 2 0 of Set Pressure Make sure there is
8. Regulator amp Filter Figure 8 Auxiliary Supply Manifold Figure 6 Valve Actuator Assembly VA123 Actuator 18 Dresser Consolidated X Operating Principles Electrical System The Electromatic Ball Valve is a 90 degree turn open to close electrically controlled pneumatically actuated relief valve Automatic actuation at a predetermined set pressure is accomplished by a 3539 controller The Field Wiring must have insulation suitable for at least 600 volts The Type 3539 Controller is actuated by the pressure in any vessel to which it is connected The construction of the Controller is such that it will make and break electrical contact with a difference in pressure of 1 1 2 of the set pressure Within the Controller See Figure 9 is the Dual Control Pressure Switch Adjusting Screws A and B determine the operating point TO GROUND LUG ON DOOR Figure 9 3539 Controller When the pressure reaches the predetermined point at which the valve is set to open contact is made in the Type 3539 Controller resulting in the relay closing Accordingly the solenoid valves are energized and the valve opens At this time the red light in the Type 2537 Control Station turns on which indicates that the valve is open When the pressure decreases below the adjusted closing point of the valve the relay de energi
9. 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 Direct 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 55 11 2146 3610 CHINA Dresser Machinery Suzhou Co Ltd 81 Suhong Zhong Road Suzhou Industrial Park Suzhou China 215021 Telephone 86 512 6258 6500 Fax 86 512 6258 8590 Dresser Inc Suite 1703 Capital Mansion 6 Xinyuan S Road Chaoyang District Beijing 100004 P R China Telephone 86 10 8486 4515 Fax 86 10 8486 5305 50 Dresser Consolidated FRANCE Dresser Flow Technology Europe Energy 5 130 190 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 GimbH 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 Casav
10. checked The valve must be isolated from system pressure before it can be disassembled Using the procedures outlined in the disassembly section of this manual remove the Adapter Flange and Ball and Seat assembly Inspect the spherical radius in the seat for cutting or flaking of the chrome carbide Inspect the spherical radius of the ball for cutting or flaking of the chrome carbide Very light flaking at the edge of the bore is acceptable If the seat is damaged and the ball has galling or flaking of the carbide coating the entire ball and seat and loader assembly must be replaced Remove the old gasket and clean the gasket surfaces of the body and the busing Reassemble the valve using the procedures outlined in the assembly section of this manual Pressurize and actuate the valve Check for leakage 3 If a new ball seat and loader assembly has been installed and the valve still leaks the stem bearing 24 Dresser Consolidated pad must be replaced Refer to the disassembly and assembly section of this manual for disassembly and assembly instruction The valve must be isolated from System pressure when removing and replacing the stem bearing pad New packing must be installed each time the stem is removed B Packing Leakage Should packing leakage occur tighten the two packing nuts in the quarter turn increments Check after each quarter turn adjustment to see if leakage has stopped The packing should be tightened only enough t
11. 34mm WHITE YELLOW 16 AWG 2 34mm WHITE ORANGE 16 AWG 2 34mm YELLOW 16 AWG 2 34mm ORANGE 16AWG 2 34mm BROWN 16 AWG 2 34mm RED WHITE 16 AWG 2 34mm BLUE WHITE NC 16 AWG 2 34mm Che BLACK WHITE TERMINAL 16 AWG 2 34mm BLUE Limit BLOCK NC S Switch 16 AWG 2 34mm BLACK Ie 16 AWG 2 34mm RED NO NC Md 1 ell NC SWITCH e NO Heus Contact Open Contact Closed Opening Cycle Closing Cycle Valve Mid Valve Valve Mid Valve Contact Relay Closed Open Open Open Closed Closed CRI r CRR 2 EE Cee ee Ss ee CR3 2 CR4 CR5 m en che nenn be en cken NC CONTACT Le 4 CR6 NO CONTACT L Figure 15 Contd Schematic Wiring Diagram Electromatic Valve 220 VDC amp 250 VDC 3500 EBV Series Safety Valve March 2011 29 XIII Maintenance Instructions Contd 3 OPTIONAL DCS CONTROL INTERFACE Required Terminals For Dry Contact Control Open Closed Dry Solenoid Voltage Contact Control Supplied From DCS By Customer To To 2537 Controller Control i Assy Station E E g S a a 6 a c a a 6 o s m E 9 T10 9 T8 T7 T6 T5 T3 T2 E a o
12. ATTENTION Do not position inlet flange horizontally or lift value by tubing assembly or external devices A WARNING Improper tools or improper use of right tools could result in personal injury or product damage A CAUTION Do not allow dirt or foreign matter to enter the inlet or outlet points The valve either crated or un crated should always be kept with the inlet down i e never laid on its side Never attempt to lift the full weight of the valve by the actuator tubing solenoid valve junction box etc Electromatic Ball valves should be stored in their original shipping crates in a dry environment to protect them from the weather They should not be removed from the crates until immediately prior to installation The inlet and outlet protectors should not be removed until the valves are ready for installation into the system Electromatic Ball valves either crated or un crated should never be subjected to sharp impact This would 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 or while hoisting during installation care should be exercised to prevent bumping the valve against structures or other objects When Electromatic Ball valves are un crated and the inlet and outlet protectors are removed immediately prior to the installation meticulous care should be exercised to prevent dirt or other
13. P Figure 14 Schematic Wiring Diagram Electromatic Valve 120VAC 240VAC 24VDC amp 125VDC 26 Dresser Consolidated XIII Maintenance Instructions Contd OPTIONAL b Feed Back Signal to Customers DCS CONTROLLER NOTE DCS Supplied by Customer ASSY 1 Broken lines indicate field wiring by customer 16 AWG 2 34mm gt 55 5 16 AWG 2 34mm E225 GREEN 5929 Zog a 16 AWG 2 34mm 08a RED ee lt 16 AWG 2 34mm YELLOW BER oS 16 AWG 2 34mm g GREEN 9 59 2850 16 AWG 2 34mm 5509 YELLOW o9 16 AWG 2 34mm WHITE BROWN 16 AWG 2 34mm WHITE YELLOW 16 AWG 2 34mm WHITE ORANGE 16 AWG 2 34mm YELLOW 16 AWG 2 34mm ORANGE 16AWG 2 34mm BROWN 16 AWG 2 34mm RED WHITE 16 AWG 2 34mm BLUE WHITE CR5 We TERN NAL BLACK WHITE BLOCK 16 AWG 2 34mm BLUE Limit Switch NS 16 AWG 2 34mm RED NO Sets Contact Open Contact Closed Opening Cycle Closing Cycle Valve Mid Valve Valve Mid Valve Contact Relay Closed Open Open Open Closed Closed CRI r CR4 CR5 n alin eds el NC CONTACT CR6 NO CONTACT
14. Pipe 25Q Nipple Pipe 6 Length 25R Elbow Pipe 255 Tubing Tube Fitting Union Elbow 25U Tube Fitting Union 25T 25V Male Branch Tee 25W Male Run Tee 26 Pressure Regulator 27 Filter 28 Nipple Pipe 3 Length 29 Check Valve 30 Cross Pipe 31 Hex Nipple Pipe Figure 4 Valve Actuator Assembly GS620 GS628 Actuator 32 Thread Protector NOTE The Drive Bushing that connects the Ledeen GS620 and 628 Actuators with the Stem of the Ball Valve 33 Rupture Disc may float up inside the Actuator during re assembly A temporary application during disassembly of duct tape or a 4 hose clamp will hold it in position with about 34 of an inch of bushing showing below the actuator Following re assembly remove any duct tape or hose clamp from the drive bushing and insure that the drive bushing set screw is tight 16 Dresser Consolidated IX Consolidated 3500 Series Safety Valves Contd AN d IN PE mum QUEE le T d SA KE Figure 5 Valve Actuator Assembly SY1032 SY1043 Actuator 3500 EBV Series Safety Valve March 2011 17 IX Consolidated 3500 Series Safety Valves Contd Figure 7 Pressure
15. Training Rising costs of maintenance and repair in the Utility and Process Industries indicate the need for trained maintenance personnel Dresser Industrial Valve Operation conducts service seminars that can help your maintenance and engineering personnel to reduce these costs Seminars conducted either at your site or at our Alexandria Louisiana manufacturing plant provide participants with an introduction to the basics of 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 318 640 6325 or telephone 318 640 6054 3500 EBV Series Safety Valve March 2011 49 Sales Office Locations UNITED STATES Dresser Consolidated Dresser Inc LA Hwy 3225 US Hwy 167N P O Box 1430 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
16. Voltage yao a o E ba 5 Se 5 o 2 lt Coq 2 0 E E a 5 Relay Contacts 9 CR3 lt 16AWG 2 34mm RED or BLACK 16 AWG 2 34mm YELLOW Indicating Lamp 16 AWG 2 34mm RED 16 AWG 2 34mm RED Valve Shown in Closed Position DCS NOTES 1 All interface with DCS System occurs in 3539 Controller For any other configuration consult factory Figure 16 Contd Optional DCS Control Interface 120 VAC 240 125 VDC amp 24VDC 3500 EBV Series Safety Valve March 2011 31 XIII Maintenance Instructions Contd 7 N OPTIONAL DCS CONTROL INTERFACE Required Terminals For Dry Contact Control Open closed Dry Contact Voltage Supplied Control From DCS By Customers poem To To Control x E Assy Station 5 4 1 EEN 1 D D e e e e 2724218 e 11079 T8 T7 T6 T4 T8 T2 T1 Q o o 9 o Cen a E E pun E f Resistor MOV to Be E Same As E Control eil H Resistor Voltage O a 5 t o 16 AWG 2 34mm BROWN a E 9 E 2 2 Relay 9 Contacts 16 AWG 2 34mm YELLOW CLAN Indicating Lamp 16AWG 2 34mm RED Required Terminals for Optional Heater Thermostat
17. a a o 1 5 MOV to Be E E Same As E 5 Control ee 3 NS Voltage E e Ola 5 iD lt om Sw lt Ele ge gu a lt c a NO KE a Relay 90 SIN a 1 Contacts 5 lt lt e 16 AWG 2 34mm 16 AWG 2 34mm YELLOW PL Indicating Lamp RED Valve Shown in Closed Position Required Terminals for penis Se PRESSE SHADERS OSH ES Optional Heater Thermostat i Wo NS Supe T4 T2 Terminal Block Heater Thermostat Notes The Figure shown is a section view from the 3539 Controller HEATER THERMOSTAT showing placement and wiring of the Heater Control w Voltage I Thermostat Components Figure 16 Optional DCS Control Interface 120 VAC 240 VAC 125 VDC amp 24VDC 30 Dresser Consolidated XIII Maintenance Instructions Contd 2537 Control Station OPTIONAL DCS CONTROL INTERFACE Required Terminals For Direct Contact Control EE Open Closed Direct Control Voltage Supplied From DCS By Customer iulii p EE ndi nd eur A To Controller Assy T7 T D D e T4 T2 1 No LI T10 T9 T8 T7 T6 T5 40422 AA Terminal Block Terminal Block MOV to Be Ka Same As E E Control E
18. body b Lower the bushing until it rests on the ball c Rotate the seat bushing back and forth to insure it is not binding d Without exerting downward force on the bushing use a depth micrometer and measure the distance from the top of the bushing to the top of the body Remove the bushing from the body Place the bushing gasket in the gasket recess of the body Install the bushing in the body On the Ledeen GS620 and GS628 actuators insure that the Drive Bushing has not slipped up into the actuator when assembling the actuator and Yoke to the stud nuts on the ball valve body If the Yoke has been removed from the actuator a special guide must be used to align the Yoke the Drive Bushing and the actuator Remove the Alignment tool prior to re assembly to Ball Valve Stud nuts Align the bolt holes of the discharge collar with the discharge collar studs and place the discharge collar onto the body Screw the discharge collar stud nuts onto the studs of the body Using the sequence in Figure 20 torque to the values in Table 3 Part No Actuator Type 7530243 VA123 7530249 GS620 amp GS628 7530250 SY1032 amp SY1043 EN Alignment Tool Actuator Ball Valve Yoke Alignment Tool Installed In Yoke Figure 19 Yoke Alignment Tool Figure 20 Yoke Alignment Tool Installed In Yoke 36 Dresser Consolidated XV Reassembly of 3500 Series Safety Valve Contd D
19. corrosive process medium which may have been trapped inside the valve Ensure the valve is isolated from system pressure before valve is removed Exercise care when examining a power operated safety relief valve for audible or visible leakage to avoid possible personal injury Prior to each actuation ensure that no personnel are near the valve exhaust point Media escaping from the valve during actuation can possibly cause personal injury Never tamper with the valve when system pressure is near the valve set pressure Before performing any machining on valve parts consult Dresser Consolidated or its authorized representative All valves require periodic inspection and tests by qualified persons to insure that the valves are in proper working condition and will function as designed by Dresser Consolidated The Owner operator of the valves must be aware of usage condition and must bear the responsibility for determining the appropriate frequency of examination of the valves Do not attempt to repack a power actuated relief valve while it is pressurized Use care when making wiring connections on electrical components and when making valve setting adjustments to avoid electrical shock A DANGER Avoid Electric Shock 8 Dresser Consolidated A DANGER Eliminate pressure and stand clear of discharge when working on valve to avoid severe personal injury or death A CAUTION Wear necessary protective equipment to prevent pos
20. end of the stem 4 nsert the stem bearing washer and stem nut assembly into the stuffing box opening of the body Screw the stem nut into the body and torque to the value specified in Table 3 5 Place the packing stop ring over the stem and slide it down into the stuffing box until it contacts the stem nut 6 Place the packing rings over the stem and slide them down into the stuffing box 7 Install the packing gland to the stem with the larger spherical radius facing away from the valve 8 Place the packing gland flange onto the stem and align the two holes with the packing gland studs Slide it down until it contacts the packing gland Screw the packing gland nuts onto the packing gland studs until they contact the gland flange Tighten hand tight 9 Rotate the stem so that the Tang of the stem head is perpendicular with the valve center line With the small tapered end of the Belleville Washer up Insert the first Belleville Washer into the guide bore at the top of the body It should rest flat at the bottom of the guide bore Install the spring spacer with the tapered end of the second Belleville Washer down insert it into the guide bore It should seat on the spacer 10 Rotate the seat loader so that the bore center line is perpendicular to the body center line Lower the loader into the bore until the lower edge is below the Tang of the stem Rotate the loader under the Tang until it rests flat on the Belleville Wa
21. foreign materials from entering the inlet and outlet ports while installing the valves 3500 EBV Series Safety Valve March 2011 13 Vil Design Features and Nomenclature Figure 1 illustrates the relationship of the various elements of the Power Actuated Relief Valve System The Type 3539 Controller consists of a pressure sensing element i e a bourdon tube an electrical relay and control box which houses the electrical relay and sensing element The Type 2537 Control Station is a 3 position selector which allows Selection of Manual actuation Off or Automatic actuation It consist of a box selector switch and two indicator lights red and amber The Pneumatic Actuator Assembly consists of a double acting pneumatic actuator two three way solenoid valves one normally open and one normally closed and one actuator mounted Westlock Switch which contains two SPDT limit switches The electrical supply system consists of a control circuit and a solenoid circuit The solenoid circuit provides the voltage needed for the Solenoid The solenoid power supply wiring must be Sized so that the voltage drop due to the solenoid inrush current does not exceed 596 3539 Controller Shut Off Valve From Steam Header Solenoid Voltage Supply Drain amp Test Valve 2537 Control Station Control Voltage Supply Pneumatic Level The field wiring must have insulation suitable for at least 600 volts The s
22. no pressure in the valve before disassembly Note Due to some systems having vibrations or pulsations It may be necessary to increase the blowdown of the valve B Hydrostatic Testing When conducting a hydrostatic test involving the Electronic Ball valve the sensing line to the bourdon tube should be disconnected or isolated to prevent damage to the bourdon tube in the Controller Be sure to reconnect the sensing line after the hydrostatic test is completed The hydrostatic test may be conducted with the Isolating Gate Valve closed unless the Electromatic Ball Valve is to be subjected to the hydrostatic test In such case either the isolating Gate Valve or the By Pass Valve should be opened 3500 EBV Series Safety Valve March 2011 43 XVII Troubleshooting Table 5 is provided as a guideline to be followed should the actuator fail to function properly If all the steps listed in Table 5 are followed and the actuator still does not function the factory should be consulted Note The valve should be isolated from system pressure while trouble shooting of the actuation system Accidental actuation of the valve could occur Table 5 Actuation System Trouble Shooting Problem Possible Cause Corrective action Valve will not open when over pressure occurs 3539 pressure switch CR1 amp CR2 not properly set Check CR1 amp CR2 Settings f not correct Reset pressure switches f co
23. to the exhaust position D The Normally Open solenoid valve is also de energized as limits witch 5 is still in the NC position until the actual or cylinder fully closes the ball valve E When the ball valve is fully closed limit switch CR5 goes to the NO position and the Normally Open solenoid valve is energized and goes to the exhaust position F The limit switch CR6 returns to the NC position and the Closed indicating lamp goes on and the Open indicating lamp goes off Control station Manual Mode 1 To operate the valve manually electrical current is in produced to terminals T5 and T6 in the controller to energize the relay and subsequently open the ball valve When a control station is supplied with the ball valve the manual switch can be used to open the valve Relay Auxiliary Switch CR4 The purpose of the relay auxiliary switch is to provide the valve with an adjustable blow down This switch keeps the relay coil energized after the PSH CR1 switch has opened until the system pressure has dropped to ball valve close point and the PSL CR2 switch has opened Controller Indicating Lamp This lamp is used when adjusting the pressure switches CR1 and CR2 to accurately set the valve blowdown Additional limit switches Up to two additional limit switches are available Valves is shown with additional double pole double throw limit switch XIV Inspection and Part Replacement Visually in
24. to verify actuator is in closed position Loosen the packing gland nuts and retighten hand tight The valve is now ready to test to insure it will open and close at the correct pressures See Section XVI for instructions for setting and testing the valve Actuator and Accessory Assembly for Ledeen Models VA123 Actuators Refer to Figures 23a amp 23b Rotate the stem until the milled keyway is located 90 1 4 turn to the left of the valve center line and temporarily tighten the Packing Gland Nuts to prevent the stem from moving Slide the Actuator Drive Bushing into the Drive Sleeve of the Actuator Insert the Yoke Alignment Tool Figure 20 through the bottom of the yoke into the Bushing Guide Bore of the Actuator Yoke Figure 20 For proper alignment assemble the Yoke to the Actuator with the Yoke Alignment Tool with the Actuator Drive Bushing in place Fasten the Yoke to the Actuator using the Cap Bolts provided and torque to the values in Table 3 Remove the Actuator Drive Bushing and the Yoke Alignment Tool from the Yoke and Actuator Place the key in the limited Keyway on the Ball Valve Stem Align the small diameter end of the Actuator Drive Bushing Keyway with the Key in the Ball Valve Stem Slide the Drive Valve Bushing onto the Ball Valve Stem Position the Actuator Drive Bushing on the Stem so that the small diameter end is about 375 9 53 mm below the Yoke Install and tighten the Actuat
25. 1 26 19 3 000 76 20 1 141 28 98 563 14 29 3517 27 37 2 750 69 85 1 375 34 93 3 875 98 43 1 687 42 85 688 17 46 3547 38 3 625 92 08 3 625 92 08 5 000 127 00 2 062 52 37 938 23 81 Table 8 Machining Dimensions for Yoke Alignment Tools Part Actuator 016 0 40 mm 001 0 02 mm C 016 0 40 mm D 016 0 40 mm E 001 0 02 mm Number Type in mm in mm in mm in mm in mm 7530243 Ledeen 2250 57 15 1 755 4458 1 313 33 34 1 000 25 40 1 868 47 45 VA123DA i i i Ledeen 7530249 05620 amp 3 250 82 55 2 505 63 63 1 313 33 34 1 000 25 40 2 620 66 55 GS628 Ledeen 7530250 SY1032 amp 5 125 130 18 4 505 114 43 1 313 33 34 1 000 25 40 4 666 118 52 SY1043 46 Dresser Consolidated XIX Replacement Parts Planning A General Information The importance of maintenance planning is the key to good plant operations Part of that planning involves making sure that replacement parts needed to repair valves are available at the job site when required Developing and implementing a standard valve maintenance plan will quickly pay for itself by eliminating costly downtime unscheduled outages etc B Inventory Planning Replacement Parts List The basic objectives in formulating a replacement part plan are PROMPT AVAILABILITY MINIMUM DOWN TIME SENSI
26. 500 Series Safety Valve Figure 12 Ball Placement and Removal Tool 22 Dresser Consolidated CAUTION Make sure that no pressure is in the valve prior to disassembly If equipped with an isolation valve close the isolation valve and actuate the EBV valve open closed to remove all pressure If not equipped with an isolation valve the unit must be shut down prior to disassembly A Ball Seat and Loader Assembly Removal Refer to Figure 2 and 3 1 If the ball seat and loader assembly is to be removed while on the unit and the installation is equipped with an isolation valve close the isolation valve Actuate the EBV from open to close to relieve any pressure between the EBV and the isolation valve if not equipped with an isolation valve the unit must be shut down prior to disassembly 2 If disassembling on the unit remove the discharge stack If the valve is not in the closed position CAUTION Do not actuate the valve with the collar removed Damage to the ball may result 3 Loosen and remove the body stud nuts 4 Lift the discharge collar off the valve 5 Two threaded holes are provided so that a bolt or all thread can be used to remove the seat The 1 5 38 1 mm and 2 50 8 mm size valves are tapped with a 10 32 thread The 2 5 63 5 size valves are tapped with a 0 25 6 35 mm 20 thread Screw two bolts or two pieces of all thread into the threaded holes Lift the seat out of t
27. 6 AWG 2 34mm 16 AWG 2 34mm YELLOW RED OR BLACK 2537 CONTROL STATION SWITCH LAYOUT Relay Aux E ER gE Switch MAN MAN MAN SE 8 no nc PL EL E oat 7 JV CR4 Indicating lud OFF 16 AWG 2 34mm RED Se 16 AWG 2 34mm Lamp elt HE eh S RED AUTO AUTO AUTO Sa AUTO Valve Shown in Closed Position SWITCH IN SWITCH IN SWITCH IN AUTO OFF MAN POSITION POSITION POSITION Normally Closed 8316G64 Normally Open 8316G66 DE ENERGIZED ENERGIZED DE ENERGIZED ENERGIZED EXHAUST CYLINDER EXHAUST CYLINDER EXHAUST CYLINDER EXHAUST SOLENOID CYLINDER LENOID Z SOLENOID ne SOLENO IO D ee gt 3 a Pressure P Pressure P Pressure P Pressure P Figure 15 Schematic Wiring Diagram Electromatic Valve 220 VDC amp 250 VDC 28 Dresser Consolidated XIII Maintenance Instructions Contd OPTIONAL Feed Back Signal To Customer s DCS NOTE DCS Supplied By Customer CONTROLLER 1 Broken lines indicate ASSY field wiring by customer 16 AWG 2 34mm c9 o RED gt 5 16 AWG 2 34mm 8055 SW Oo GREEN ogg 16 AWG 2 34mm RED lt 16 AWG 2 34mm oS c YELLOW 52 oS 16 AWG 2 34mm go S I REHEEM E o q GREEN E 950 OD oC zoo 16 AWG 2 34mm YELLOW lt 16 AWG 2 34mm WHITE BROWN 16 AWG 2
28. BLE COST SOURCE CONTROL Having parts immediately available from plant storeroom inventory is obviously the best way to accomplish those objectives Since it is impractical to have very part that might be needed to accomplish a given repair in stock at all times guidelines for establishing meaningful inventory levels are summarized in the Table 9 Note Genuine Dresser Parts The next time replacement parts are needed keep these points in mind e Dresser Consolidated designed the parts e Dresser Consolidated guarantees the parts e Dresser Consolidated valve products have been in service since 1877 e Dresser Consolidated has worldwide service e Dresser Consolidated has fast response availability for parts Table 9 Guidelines for Establishing Meaningful Inventory Part Description Quantity Parts Number of Valves Predicted Availability CLASS 1 Packing Set 1 1 70 2 Gasket 1 1 3 Parking stop Washer 1 1 CLASS II 4 Ball Loader Push Ring Split spacer Ring 1 4 Belleville Washer Assembly 70 5 Bearing Washer 1 1 CLASS III 6 Drive Bushing Set Screw 1 1 99 Predicted availability means that percentage of time the user plant will have the right parts to make the proper repair on the product i e if Class parts are stocked at the owners facility the parts needed to repair valve in question will be immediately available in 70 of all instances 3500 EBV
29. DRESSER YE Consolidated Pressure Relief Valves ok 3500 EBV Series Maintenance Manual Consolidated Electromatic Ball Valve System Conversion Table All the USCS values in the Manual is converted to USCS Unit Conversion Factor 25 4 0 4535924 6 4516 0 2831685 3 785412 0 4535924 0 6894757 1 3558181 5 9 F 32 Metric values using following conversion factors Metric Unit m min L min kg hr barg Nm C Note 1 Multiply USCS value with Conversion Factor to get Metric value 2 Dresser Consolidated For valve configurations not listed in this manual please contact your local Greentag Center for assistance NOTICE Table of Contents Section Subject Page No l Product Safety Sign amp Label System 22 5 Il SINE 6 Ill Dalely te 9 Wartarnity deren 10 V WAIVE engl ee KEE 11 VI Manding and oo icio m 13 Design Features and Nomenclature irm etre ENEE Se RR Red rrr ERR Red 14 m 14 IX Consolidated 3500 Series Safety Valves AA 15 X Operating Principles ee 19 Xl Recommended Installation Dractces AAA 20 EUR cl M 20 B Type3599 ee EE 20 Reguired Wire auge E 21 Disassembly of 3500 Series Safety Valve eee emm 22 A B
30. Drive Bushing to prevent it 4947001 3517 3527 3537 from floating up into the actuator Approximately 75 4946901 3538 3547 19 mm of the drive bushing should show below the actuator 2 Loosen the allen head set screw in the drive bushing Slide the bushing off the stem and remove the drive key LS 3 Loosen and remove the two packing gland stud Cp CD nuts Remove the packing gland flange and the packing gland 4 Using a wire hook or screw driver dig out the 316 Stainless Steel with Flexible Graphite Fillers Spiral Wound packing The packing stop washer is drilled l and tapped with two 10 32 threaded holes Screw 1 apiece of all thread 10 32 screw approximately 3 76 2 mm long into one of the holes in the packing stop ring Slide the packing stop ring off the stem The stem nut can now be removed using the stem nut wrench illustrated in Figure 13a amp 13b Rotate Cleaning the nut counterclockwise to remove it The 3500 Electronic Ball Valve parts may normally be cleaned with wire brushes and low pressure air Whatever method is used clean the parts safely and use 5 Remove the stem and bearing washer from the body care to prevent damage to the environment If internal Stem Nut Removal Tool parts are cleaned with industrial solvents or cleaning Part No Used On solutions take precautions to protect yourself from 4948901 3515 3516 3525 3526 potential danger of br
31. Series Safety Valve March 2011 47 XIX Replacement Parts Planning Contd C Identification and Ordering Essentials When it becomes necessary to order a replacement part the order should state e Hart name e Valve Size e Valve Type e Serial Number of Valve e Valve Seat Bore Full Bore or Reduced Bore as designated by FB or RB in valve code Example 3515F 1 X1 FB0875 Indicates Bore Diameter 0 875 Indicates Bore Type FB Full Bore or RB Reduced Bore XX 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 All other information will be found stamped on the nameplate attached to the body of the valve See Figure 28 In addition the serial number is stamped on the top edge of the outlet flange Be sure to include the one or two letters preceding the figures in the serial number f N CONSOLIDATED POWER RELIEF BALL VALVE BORE DIA PRESSURE amp TEMPRATURE LIMITS SER NO B M ES Consolidated Figure 28 Valve Nameplate e Dresser Consolidated has worldwide service Dresser Consolidated has fast response availability for parts Recommended Spare Parts Consult the Replacement Parts Lis
32. WARNING Do not work with valves while under the influence of intoxicants or narcotics All potential hazards may not be covered in this manual 6 Dresser Consolidated Y Il Safety Alerts Read Understand Practice 1 DANGER High temperature pressure can cause injury Be sure all system pressure is absent before repairing or removing valves 2 DANGER Don t stand in front of valve outlet when discharging Stand Clear of Valve to prevent exposure to trapped corrosive media 3 DANGER when inspecting a pressure relief valve for leakage Be Very Careful 1 WARNING 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 WARNING Always read and comply with safety labels on all containers Do not remove or deface the container labels Improper handling or misuse could result on severe personal injury or death WARNING 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 result in severe personal injury or death WARNING It is the responsibility of the owner to Specify and provide guarding to protect persons from pressurized or heated parts Contact with pressurized or heated parts can result in sever personal injury or death WARNING Do not allow an
33. a minimal cost by contacting Dresser Consolidated in writing at P O Box 1430 Alexandria LA 71309 1430 or by calling at 318 640 2250 Fax 318 640 6325 3500 EBV Series Safety Valve March 2011 9 IV Warranty Information Warranty Statement Dresser warrants that its products and work will meet all applicable specifications and other specific product and work requirements including those of performance if any and will be free from defects in material and workmanship Refer to Dresser s Standard Terms of Sale or specific contract for complete details on warranty and limitation of remedy and liability 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 workmanshi
34. al DCS Control Interface 220 VDC amp 250 VDC RED or BLACK To Controller Assy 3500 EBV Series Safety Valve March 2011 33 XIII Maintenance Instructions Contd Electromatic Ball Valve Operation Principles Automatic Mode 1 System pressure below valve set pressure The ball valve is closed A Pressure switches CR1 and CR2 are in NC position B Switch CR4 is in the NC position Note the indicating lamp next to switch CR4 is only for setting the close point of the valve during bench testing of the controller It is enclosed in the controller box and is not visible during normal operation C The relay contacts are open D The Normally Closed solenoid valve is not energized and in the exhaust position E The Closed indicating lamp control station is on The power is through the NC contact of limits witch CR6 The Open indicating lamp control station is off System pressure begins to increase A When system pressure reaches the valve close off point PSL CR2 goes to the NO position This turns on the indicating lamp next to CR4 B When system pressure reached the valve set point pressure switch PSH CR1 goes to the NO position C The relay coil is energized and closes the relay contacts and relay AUX Switch D The Normally Closed solenoid is energized and starts to introduce air pressure to the actuator cylinder to open the ball valve The ac
35. all Seat and Loader Assembly Demoval menn 22 B Actuator Assembly removal i a corte d EUER 22 tem le EE 23 M M 23 Maintenance 24 EE EE ee 24 Packing Eeakage EE 24 EE 25 XIV Inspection and Part Replacement 35 XV Reassembly of 3500 Series Safety Valve 35 E E cct 35 Oli Ee UE 35 TEE TE 35 D Actuator and Accessory Assembly for Ledeen GS amp SY Series Achators 37 E Actuator and Accessory Assembly for Ledeen Models VA123 Actuators 39 3500 EBV Series Safety Valve March 2011 3 Table of Contents Section Subject Page No Setting and Testing TTT 41 En le RRE ME 41 PhOrto Ri de 41 A 2 System Start UD EE 41 Adjusting the Set Pressure and Blowdown 41 4 Minimum Blowdown 2 43 blydrostatic TOSNO EET 43 THOUBIESMOOUNG MEE 44 ANIL Maintenance 45 XIX Replacement Parts Planning 47 A Genra teg le E 47 B Inventory Planning Replacement Parts List 47 C dentification and Ordering MEET 48 XX Genuine Dresser Parts ss idc dite Dec Ene Egeria e eripe dede ka ku
36. and seat This WILL RESULT on seat leakage Isolation valves equipped with by pass valves may be closed during start up provided the by pass valve is OPEN A 3 Adjusting the Set Pressure and Blowdown To adjust the Bourdon tube for set point and blowdown refer to Figure 24 Open door on controller Only make contact with Screw and Screw B Figure 24 for adjustment purposes DO NOT make contact with any other terminal or screw due to live voltage and risk of electric shock Screw A is used to adjust the set point By turning screw A counter clockwise the set point will be increased Conversely by turning Screw A clockwise the set point will be decreased 3500 EBV Series Safety Valve March 2011 41 XVI Setting and Testing Contd The Low Pressure Switch indicating Light E is to be utilized in adjusting the blowdown Accordingly as the system pressure is increased the indicating light E will come on indicating actuation of the Low Pressure Switch D Since the Low Pressure Switch Controls the closing pressure of the valve the closing pressure of the valve is known before the valve opens As the pressure decreases the actual closing point of the valve is indicated when light E goes out Screw B is used to adjust the closing point of the valve which establishes the blowdown of the valve By turning Screw B counterclockwise the closing point will be increased thus shortening the blowdown
37. atore Naples Italy Telephone 39 081 7892 111 Fax 39 081 7892 308 JAPAN Dresser Japan Ltd DJL 20th Floor Marive East Tower WBG 2 6 Nakase Mihama ku Chiba shi Chiba 261 7120 Japan Telephone 81 48 297 9211 Fax 81 43 299 1115 KOREA Dresser Korea Inc Hyundai Swiss Tower 17 Floor 143 40 Samsun don Kangham ku Seoul 135 090 Korea Telephone 82 2 2274 0748 Fax 82 2 2274 0720 Sales Office Locations MALAYSIA Dresser Inc Asia Pacific Headquarters Business Suite 19A 9 1 Level 9 UOA Centre No 19 Jalan Pinang 50450 Kuala Lumpur West Malaysia Telephone 60 3 2161 0322 Fax 60 3 2163 6312 MEXICO Dresser De Mexico S A de C V Henry Ford 114 Esq Fulton Fraccionamiento Industrial San Nicolas 54030 Tlalnepantla Estado de Mexico Telephone 52 55 5310 9863 Fax 52 55 5310 4279 THE NETHERLANDS Dresser Valves Europe GmbH Steenhouwerstraat 11 NL 3194 AG Hoogvliet The Netherlands Telephone 31 10 866 6538 Fax 31 79 361 8995 RUSSIA Dresser Europe Derbenevskaya Ulitsa 1 Bldg 3 Office 17 Moscow Russian Federation 115 114 Telephone 7 4955 851276 Fax 7 4955 851279 SAUDI ARABIA Dresser Al Rushaid Valve amp Inst Co Ltd DARVICO 10145 Jubail Industrial City 31961 Kingdom of Saudi Arabia Telephone 966 3 341 0278 Fax 966 3 341 7624 SINGAPORE Dresser Singapore Pte Ltd Dresser Flo
38. ccordance with a standard procedure Lift Lift is the actual travel of the disc away from closed position when a valve is relieving Lifting Device A lifting device 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 Back Pressure Back pressure is the static pressure existing at the outlet of a safety valve device due to pressure in the discharge system Blowdown Blowdown is the difference between actual popping pressure of a safety valve and actual reseating pressure expressed as a percentage of set pressure or in pressure units Bore Area Bore area is the minimum cross sectional area of the seat bushing Bore Diameter Bore diameter is the minimum diameter of the seat bushing Built Up Back Pressure Pressure existing at the outlet of a safety valve while it is open and flowing through a discharge system Chatter Chatter is abnormal rapid reciprocating motion of the moveable parts of a safety valve in which the disc contacts the seat Closing Pressure Closing pressure is the value of decreasing inlet static pressure at which the valve disc re establishes contact with the seat or at which lift becomes zero Disc A disc is the pressure containing moveable member of a safety valve which effects closure Inlet Size Inlet size is the nominal pipe size of the inlet of a safety valve unless otherwise desig
39. ction should be mounted at least eight to ten pipe diameters upstream from the Electronic Ball Valve in order to provide a stable pressure signal Finally if the Controller may be subjected to freezing temperatures a heating element should be added to prevent freezing of the bourdon tube C Required Wire Gauge The electrical supply to the controller solenoid voltage should have stranded wiring The wire should be no smaller than 12 AWG If necessary the wire should be larger than 12 AWG to prevent more than a 596 voltage drop to the solenoid inrush current Table 1 Optional Voltage Type Voltage Frequency Amperage 100 240 AC 50 60 HZ 3 3500 Ball Valve 24 48 100 240 DC N A 1 0 WELDING CAUTION This valve contains a ball amp seat assembly that has been coated for wear resistance and may be damaged if exposed to elevated temperatures associated with welding and post weld heat treatment Welding interpass temperatures should be in compliance with ASME B amp PV Code Section IX but should not exceed 570 F 299 C Local post weld heat treatment of the weld and heat affected zone is recommended If this entire valve body is to receive post weld heat treatment the hall and seat assembly should be removed The bushing gasket must not be reused after disassembly Refer to Valve service manual of disassembly and assembly instructions 3500 EBV Series Safety Valve March 2011 21 XII Disassembly of 3
40. d hole in the side of the Actuator Drive Bushing Tighten to secure the Actuator Drive Bushing to the Ball Valve Stem Temporarily tighten the packing gland nuts to prevent forcing the stem against the ball when assembling the actuator to the valve Align the stem keyway 90 degrees to the left of the valve center line for GS Series actuators and 90 degrees to the right for SY Series actuators Make sure the actuator is stroked to the closed location The keyway will be 45 degrees to the right of the center line when viewing the actuator from the top Slide the actuator and yoke over the stem and seat the actuator yoke over the raised guide face and against the body Install and tighten the yoke cap bolts to the torque specified in Table 3 Remove the actuator output shaft cover Rotate the actuator if required to align the keyway Install the 13 key into the keyway Replace the actuator output shaft cover With the valve closed check adjustment of limit switch CR6 Refer Figure 21 wired to the solenoid piped to close the valve Use a continuity tester or volt ohm meter across terminal 5 and 6 to verify that the switch contacts are closed With the valve open verify that the port hole through the ball is perfectly aligned with the valve ports If it is not make adjustments using the open side travel stop Now check if limit switch CR5 is in open position Refer Figures 14 amp 15 Check continuity across terminals 2 amp 3
41. dable 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 safety 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 p Consolidated www consolidatedvalve com 3500_MM
42. eathing fumes chemical burns or 4947101 3517 3527 3537 explosion See the Manufactures Safety Data Sheet for safe handling instructions 4945701 3538 3547 and information about 2253 protective clothing and equipment for use A MH SZ when working with the chemical The outside surfaces of the Actuator 2537 Control Station and 3539 Controller Box be cleaned by wiping with damp cloth Follow recommendations for Lt safe handling in the solvent s Material Safety Data Sheet and observe safe practices for Figure 13a Stem Nut Removal Tool any cleaning method 3500 EBV Series Safety Valve March 2011 23 XIII Maintenance Instructions A Seat leakage If leakage should occur use the following procedure to determine and correct the cause 1 Verify that the normally closed solenoid valve is energized and vented To accomplish this check the voltage across terminal 2 and 3 in the actuator junction box There should be voltage at these terminals when the valve is closed If no voltage is present check continuity across terminals 3 and 4 There should be continuity across these terminals when the valve is closed If there is no continuity adjust the closed side actuator switch lever cam until the circuit is closed Actuate the valve and check for leakage 2 Iftheswitchis properly adjusted and leakage continues the ball and seat assembly must be removed and
43. ed 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 1 CAUTION Heed all service manual warnings Read installation instructions before installing valve s 2 CAUTION Wear hearing protection when testing or operating valves 3 CAUTION Wear appropriate eye and clothing protection 4 CAUTION Wear protective breathing apparatus to protect against toxic media Note Any service questions not covered in this manual should be referred to Dresser s Service Department Phone 318 640 6055 3500 EBV Series Safety Valve March 2011 7 Safety Alerts Contd Read Understand Practice Safety Precautions Follow all plant regulations but be sure to observe the following Always eliminate the working pressure before making any valve adjustments or repairs This will preclude severe personal injury or death Do not stand in front of the discharge of a valve when testing or operating Hearing protection should always be used when testing or operating a valve Wear protective clothing Hot water can burn and super heated steam is not visible When removing a power operated safety relief valve from a system stand clear and or wear protective clothing to prevent exposure to spatter or any
44. 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 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
45. g Union Tubing TEE Pipe Tubing Pipe Plug Conduct Fitting Straight Figure 21b Front View of GS620 amp GS628 Series Actuator Figure 21 Actuator Assembly for Ledeen GS620 amp GS628 3500 EBV Series Safety Valve March 2011 37 Tube Fitting Union XV Reassembly of 3500 Series Safety Valve Contd Actuator assembly for Ledeen GS amp SY Series Actuators N Figure 22a Front View of SY1032 amp SY1043 Series Actuators Note 4 Discharge TIR E d z Collar Stud Packing Discharge Discharge Collar Collar Nuts Ring Voke Studs Bearing vent Washer Packing Gland Flange Packing Stud Packing Discharge Gland Gland Collar Studs Figure 22b Top View of SY1032 amp SY1043 Series Actuators Actuator EH Elbow Pipe Normally Closed Energize to Open Solenoid Valve 2 Tube Fitting Elbow ae aS Tube Fitting Elbow L Cap Screw Tube Fitting Elbow amp Washer Bracket Westlock Cap Screw Switch amp Washer Figure 22 Actuator Assembly for Ledeen SY1032 amp SY1043 38 Dresser Consolidated XV Reassembly of 3500 Series Safety Valve Contd 9 10 11 12 9 10 Thread the Socket Head Set Screw into the threade
46. he body 6 Usingtwolifting hooks illustrated in Figure 12 remove the ball This is accomplished by inserting the hooked end into the flow port of the ball and lifting upward 7 Insert the hock end of one of the lifting hooks under the sear loader and rotate the loader until it s bore is perpendicular to the body bore Lift the loader up and out of the body 8 Remove the Belleville washer and the split ring spacer B Actuator Assembly Removal Refer to Figures 4 5 or 6 1 Shutoff the service air line and disconnect it from the actuator 2 Shutoffthe electrical supply to the actuator mounted westlock switch Disconnect electrical wires and conduit coming from the controller to the westlock switch 3 Attach a strap sling around the cylinder portion of the actuator at the end near the housing NOTE Do not connect a lifting device to the westlock switch solenoid valves or tubing Hook a chain hoist or other suitable lifting device to the strap sling Adjust the hoist until no slack is in the line Loosen and remove the four actuator mounting bolts connecting the yoke to the valve body Slide the actuator and yoke assembly away from the valve until the mounting yoke is clear of the drive bushing XII Disassembly of 3500 Series Safety Valve Contd ee Refer to Figures 2 and 3 Used 1 Apply a temporary piece of duct tape or a 4 101 6 4949001 3515 3516 3525 3526 mm hose clamp to the
47. inal adjustment must be made after the valve is pressurized Tighten just enough to prevent leakage Table 2 Split Ring Service Packing Valve Type Part Number Quantity 3515 3516 3525 amp 3526 4960902 3 3517 3527 amp 3537 4960901 3 3538 amp 3547 4960903 3 C Electrical System To inspect for proper wiring of the Controller Control Station and the actuator refer to Figure 14 and 15 If trouble is encountered in the Controller the Control Station or the actuator refer to the Trouble Shooting Chart shown in Table 5 Each block in the chart identifies a particular piece of equipment Le the Controller the Control Station the actuator assembly etc and the terminal to check when the system is malfunctioning Therefore when numbers and letters such as T7 or T8 are encountered in the Trouble Shooting Chart these refer to specific terminals Such as 7 or 8 in a particular piece of equipment Note Supply wiring should be large enough to prevent more than a 596 voltage drop to the solenoid in rush current A voltage drop may cause the solenoid to fail WIRE AWG DIA mm 16 1 52 12 2 66 Note A 5 AMP circuit breaker should be Installed to protect the controller 3500 EBV Series Safety Valve March 2011 25 XIII Maintenance Instructions Contd 6 Solenoid CONTROL VOLTAGE 4 3539 SOLENOID VOLTAGE INRUSH CURRENT E HOLDING CURRENT eee ee elaine
48. ipment 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 DANGER 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 Wear necessary protective equipment to prevent possible injury DANGER Immediate hazards which WILL result in severe personal injury or death 2 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 4 ATTENTION Hazards or unsafe practices which COULD result in product or property damage ATTENTION PN Handle valve carefully Do not drop or strike 3500 EBV Series Safety Valve March 2011 5 A WARNING A DANGER Improper use or repair of pressurized device may result in severe personal injury or death Do not remove bolts if pressure in line as this will result in severe personal injury or death A WARNING 6 WARNING Need all container label warnings Provide and use guarding to prevent contact with heated and or pressurized parts A WARNING A
49. ly necessary to push the Control Station Switch to the off position Note Remember that when the switch Is In the automatic position the valve will open at the predetermined pressure for which it is set 3500 EBV Series Safety Valve March 2011 19 XI Recommended Installation Practices A Main Valve The power actuated Relief Valve is customarily installed either on a superheater or on a manifold fed by two or more boilers To facilitate servicing an Isolation Valve should be installed directly below the Main Valve as shown in Figure 11 Refer to ASME Code Restrictions for code stamped valves Care should taken to ensure that mechanical strains from the discharge piping are not transmitted to the Electronic Ball Value Such Strains are detrimental to good valve performance The discharge pipes should have adequate steam capacity and should be of a size to provide for movement caused by thermal expansion Discharge piping should be drained to prevent the accumulation of water in the valve outlet At no time should the discharge piping bear against the drip pan or the nipple therein The riser piping should be securely anchored to the building Structure and never to the valve in order for it to resist the reactive forces of the discharged steam The Drains should be piped in such a manner as to prevent the unnecessary escape of steam into any enclosure and to keep foreign material from being blown back into the valve from other
50. mber A pressure retaining member of a safety valve is a part which is stressed due to its function in holding one or more pressure containing members in position 12 Dresser Consolidated Rated Lift Rated lift is the design lift at which a valve attains its rated relieving capacity Safety Valve A safety valve is a pressure relief valve actuated by inlet static pressure and characterized by rapid opening or pop action Set Pressure Set pressure is the value of increasing inlet static pressure at which a safety valve displays the operational characteristics as defined under Popping Pressure It is one value of pressure stamped on the safety valve Seat A seat is the pressure containing contact between the fixed and moving portions of the pressure containing elements of a valve Seat Diameter Seat diameter is the smallest diameter of contact between the fixed and moving members of the pressure containing elements of a valve Seat Tightness Pressure Seat tightness pressure is the specific inlet static pressure at which a quantitative seat leakage test is performed in accordance with a standard procedure Simmer Simmer is the audible or visible escape of fluid between the seat and disc at an inlet static pressure below the popping pressure and at no measurable capacity It applies to safety valves on compressible fluid service Warn See Simmer definition above Handling and Storage A
51. nated 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 3500 EBV Series Safety Valve March 2011 11 V Valve Terminology Contd Lift Lift is the actual travel of the disc away from closed position when a valve is relieving Lifting Device A lifting device 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 Seat Bushing A seat bushing is the pressure containing element which constitutes the inlet flow passage and includes the fixed portion of the seat closure Outlet Size Outlet size is the nominal pipe size of the outlet passage of a safety valve unless otherwise designated Overpressure Overpressure is a pressure increase over the set pressure of a safety valve usually expressed as a percentage of set pressure Popping Pressure Popping pressure is the value of increasing inlet static pressure at which the disc moves in the opening direction at a faster rate as compared with corresponding movement at higher or lower pressures It applies only to safety or safety relief valves on compressible fluid service Pressure Containing Member A pressure containing member of a safety valve is a part which is in actual contact with the pressure media in the protected vessel Pressure Retaining Me
52. o stop the leakage If the leakage can not be stopped by tightening the gland nuts the valve should be repacked with new packing The valve can be repacked without removing the actuator and actuator yoke if split ring service ring packing is used Refer to Table 2 for part numbers The EBV can also be repacked with 316 Stainless Steel rubber pack If the electronic Ball valve is equipped with an isolator valve it must be closed to isolate the EBV Open the EBV from open to closed to relieve pressure with an isolation valve the unit must be shut down Loosen the packaging gland bolts one full turn Wait approximately two minutes to verify that the gland and flange does not move and reload the packing gland nuts Loosen the actuator drive bushing lock screw and move the bushing away form the packing gland flange enough to slow removal of the packing gland slud nuts Move XIII Maintenance Instructions Contd the packing gland flange and packing gland away from the stuffing box until the flange contacts the yoke Using a wire hook similar to the one illustrated in Figure 12 or a packing remover remove the 316 Stainless Steel packing from the stuffing box Place the split ring packing around the stem below the packing gland Use the gland Note 1 with Flexible Graphite Fillers Spiral Wound to position the packing in the stuffing box The correct number of rings is specified in Table 2 Install the packing gland nuts and tighten F
53. olenoid insulation is Class F Environmental Conditions e Indoor or outdoor use e Elevation maximum 2000 M Operating ambient temperature maximum 140 F 60 C CE certified at 40 C maximum Pollution Degree 2 Over voltage category Ill Main supply voltage fluctuations 70 of the nominal voltage Protection Classification 2537 Control Station Nema IP e 3539 Controller Nema 4 IP Top mount Controller Assy Nema IP 3500 Series Electromatic Ball Valve Isolating Gate Valve Header Figure 1 Consolidated Electronic Ball Valve Systems Vill Introduction The Consolidated Electromatic Ball Valve is an electrically controlled pneumaticaly actuated pressure relief device It may be manually operated by closing a Switch or automatically operated at specified opening and closing pressure The application provides the plant operator with a means of instantaneously opening and closing a relief valve at a remote location 14 Dresser Consolidated When the pressure element is set to open the Electronic Ball Valve at a pressure slightly below the lowest set spring loaded safety valves it will prevent the safety valves from opening except during major overpressure excursions IX Consolidated 3500 Series Safety Valves Part Nomenclature No 1 Body 2 Yoke 3 Discharge Collar 4 amp Seat Assembly CANS 1 PANN Seat Ke re EA p
54. or Drive Bushing Lock Screw Slide the Actuator yoke over the stem and raised guide diameter of the body seat until it seats against the body Install the Yoke Cap Bolts and tighten to the value specified in Table 3 With the valve closed check adjustment of limit switch CRS Ref Figure 14 amp 15 wired to the Solenoid to close the valve Use a continuity tester or volt ohm meter across terminals 5 and 6 to verify that the switch contacts are closed With the Valve open verify that the port hole through the ball is perfectly aligned with the valve ports If it is not make adjustments using the open side travel stop Check continuity across terminals 2 amp 3 to verify adjustment of CR5 in closed position Loosen the Packing Gland Stud Nuts and retighten hand tight The valve is now ready to test To ensure it will open and close at the correct pressures see Section XVI for instructions for setting and testing the valve 3500 EBV Series Safety Valve March 2011 39 XV Reassembly of 3500 Series Safety Valve Contd Tube Fitting Flush Bushing Pipe Closed Nipple Pipe Figure 24a Front View of VA123 DA Actuators Tube Fitting Elbow Flush Bushing Pipe Tube Fitting Tube Fitting Male Branch Tee Normally Closed Energize to Open Solenoid Valve Elbow Pipe Nipple Pipe Tee Pipe Male Run Tee Closed Nipple 5 S T
55. p Unauthorized removal and or breakage of this seal will negate our warranty 10 Dresser Consolidated V Valve Terminology Paraphrased from ASME s PTC 25 Back Pressure Back pressure is the static pressure existing at the outlet of a safety valve device due to pressure in the discharge system Blowdown Blowdown is the difference between actual popping pressure of a safety valve and actual reseating pressure expressed as a percentage of set pressure or in pressure units Bore Area Bore area is the minimum cross sectional area of the seat bushing Bore Diameter Bore diameter is the minimum diameter of the seat bushing Built Up Back Pressure Pressure existing at the outlet of a safety valve while it is open and flowing through a discharge system Chatter Chatter is abnormal rapid reciprocating motion of the moveable parts of a safety valve in which the disc contacts the seat Closing Pressure Closing pressure is the value of decreasing inlet static pressure at which the valve disc re establishes contact with the seat or at which lift becomes zero Disc A disc is the pressure containing moveable member of a safety valve which effects closure Inlet Size Inlet size is the nominal pipe size of the inlet of a safety valve unless otherwise designated Leak Test Pressure Leak test pressure is the specified inlet static pressure at which a quantitative seat leakage test is performed in a
56. ring E DIA dimensions These tools are available from Dresser Valve and Controls Aftermarket Support at 318 640 6044 or you may manufacture your own using the dimensions supplied Drill E Dia through D 2 places as shown Figure 26 Stem Nut Removal Tool Retainer Plate Figure 27 Yoke Alignment Tool Machine Drawing 3500 EBV Series Safety Valve March 2011 45 XVIII Maintenance Tools Contd 6 Machine Dimensions for Stem Nut Removal Tool Valve Type in mm in mm in mm in mm in in mm in mm in mm in mm 3515 25 16 26 3 375 85 73 1 000 25 40 1 313 33 35 200 5 08 1 250 31 75 220 5 59 1 125 28 58 1 000 25 40 688 17 48 3517 27 37 5 000 127 00 1 016 0 40 2 500 63 50 312 7 92 1 875 47 63 360 9 14 11 625 41 28 1 500 38 10 1 188 30 18 3547 38 5 750 146 05 1 000 25 40 2 500 63 50 200 5 08 2 350 59 69 360 9 14 1 906 48 41 1 813 46 05 1 531 38 89 Note For use with Stem Nut Removal Tool Assemblies over the removal tool and is held in place by the packing gland stud bolts and loosely tightened nuts Table 7 Machining Dimensions for Stem Nut Removal Tool Retainer Plate Valve Type in mm in mm in mm in mm in mm 3515 25 16 26 2 063 52 40 1 03
57. rrect go to possible cause 2 No air supply pressure to the solenoid valves Re establish air supply pressure to the solenoid valves Solenoid valve coil burnt out Check solenoid coil Burnt coil Replace coil No Go to possible cause 4 Loss of electrical power supply Check voltage No voltage Re establish electric power Has voltage Go to possible cause 6 Damaged On OFF AUTO selector switch in 2537 control station Check continuity of contacts No continuity Replace switch Has continuity Go to possible cause 6 Defective high and or low pressure Switch CR1 amp CR2 in 3539 controller Check voltage at 3539 terminal T5 amp T7 Has voltage Go to possible cause 8 No voltage Replace pressure switch Relay CRS 3539 failure Check voltage at 3539 terminals with Relay Coil energized T3 to T2 amp T3 to T1 Has voltage Replace relay No voltage Go to possible cause 8 Wiring or terminal plug failure Check all wire and terminal connections Replace as required Valve will not open with the control station selector in the manual mode or recluse when put in automatic No air supply pressure to the solenoid valves Re establish air supply pressure to the solenoid valves Solenoid valve coil burnt out Check solenoid coil Burnt Coil Replace coil No Go to possible cause 3 Lose of electric po
58. sher The 45 degree seat angle and 15 degree tapered angle must be facing the top of the body zech zech Rotate the stem until the Tang of the stem is in line with the valve center line When viewing the stem from the top the milled keyway must face to the left on VA A GS series and to the right for SY series actuator With Table 3 Bolting Torque FT LBS Discharge Collar Packing Gland Valve St Nut Yoke Bolts Actuator Bolts EE Stud Nuts Stud Nuts rads dase jae 3515 3516 3525 j 90 35 50 50 50 amp 3526 3517 3527 amp 3537 200 50 100 75 75 3538 amp 3547 275 50 125 100 100 3500 EBV Series Safety Valve March 2011 35 XV Reassembly of 3500 Series Safety Valve Contd the flow port perpendicular to the body center line use two wire hooks to lower the ball into the body The slot in the ball must align with the stem Tang and rest on the seat loader 12 Insert a flat blade screw driver between the ball and the body at a location 1800 from the Tang slot e D Figure 18 Discharge Collar Torquing Pattern Yoke Alignment Tool 14 15 16 to prevent the stem from moving the ball Tighten packing by torquing to the values in Table 3 Remove the screw driver 13 Prior to assembly of the seat bushing and bushing gasket the bushing stand off must be checked Follow the steps below to check stand off a Install the seat bushing into the
59. sible injury A WARNING Know all valve exhaust leakage points to avoid possible severe personal injury or death 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 A AUTION and described in these instructions are effective methods of performing the required tasks It is important to note that these instructions contain various safety messages which should be carefully read in order to minimize the risk of personal injury or the possibility that improper procedures will be followed which may damage the involved 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 Wear necessary protective f equipment to prevent nor valve safety will be jeopardized by the method and or tools selected If not possible injury so sa
60. sources Refer to Figure 1 1 Cover the main valve outlet during system shut downs when the valve is not in Service or is not pressurized to prevent foreign matter from entering into the main valve B Type 3539 Controller Care must be taken in mounting the Controller since it will not operate properly if subjected to vibration It is recommended that the Controller be mounted directly to the building structure and depending on the installation it may even be advisable to mount the Controller on some type of shock absorbing material in order to isolate it from the any vibration in the building structure Since the sensing line from the pressure vessel may also transmit vibrations to the controller precautions should be Ball Valve Figure 11 Recommended Exhaust Stack Installation 20 Dresser Consolidated A ATTENTION Support 5 8500 Valve Wear necessary protective equipment to prevent possible injury Before disassembling the valve ensure there is no media pressure in the vessel A DANGER Valve caps and bonnets can trap fluids Use caution when removing to prevent injury or environmental damage Recommended Installation Practices Contd taken to eliminate this possibility Dresser Consolidated suggests that several loops of high pressure tubing be used to accomplish this task Further the pressure sensing conne
61. spect all parts for cleanliness and the presence of foreign materials Clean and reinspect as necessary Inspect the carbide coating of the ball seat loader stem and bearing washer for cracking or flaking Replace if damaged Check electrical wires for cracking or other damage to the insulation Replace as necessary Inspect solenoid valves and regulator for obstructions in their parts Clean or replace as necessary XV Reassembly of 3500 Series Safety Valve A Lubrication Acceptable lubricants are Molykote GN paste and Sentry s Twist antisieze compound All threaded fasteners except pipe threads and tube fittings are to be lubricated Pipe threads must be sealed with pipe thread sealant or Teflon tape Care must be taken not to get lubricant on any other valve surfaces B Tools Required 1 Stem nut wrench see Figures 13a amp 13b 2 Two hooks for installation removal of the ball See Figure 12 3 Torque wrench or torque adjustable impact wrench 4 Various size open x boxed end wrenches 5 Screw drivers 6 Wire cutter stripper and lug crimper combination tool C Valve Assembly Refer to Figures 2 and 3 1 Place the valve body in a vise or other suitable holding fixture with the seat bushing opening facing up 2 Place the bearing washer onto the stem and slide against the bearing shoulder of the stem 3 Place the stem nut onto the stem with the milled wrench slots facing away from the large
62. t see Section XIX B of this manual to define the parts to be included in the inventory plan Select the desired parts and determine those required for proper maintenance of the valve population in the plant 48 Dresser Consolidated Dresser Valve and Controls recommends keeping class Il amp Ill spare parts available based on the number of valves in the population XXII Manufacturer s Field Service amp Repair Program A Factory Setting vs Field Setting Every Consolidated9 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 a moment s notice Consolidated Field Service can be depended upon for prompt response even in
63. tisfied 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 e gloves etc when personnel are in or around a valve work area Due to the various circumstances and conditions in which these operations may be performed on 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 Precautions 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
64. tuator cylinder starts moving through the power stroke opening the ball valve E The Normally Open solenoid valve remains energized to exhaust the opposite side of the actuator cylinder F By means of a cam located on the valve stem limit switch CR5 goes to the NC position and limit switch CR6 goes to the NO position G The Closed indicating lamp goes out and the Open indicating lamp turns on Control station When the actuator cylinder completes its full stroke the ball valve is fully open and relieving system pressure The cylinder remains pressurized on the open side to hold the ball valve open System pressure is being vented and drops down below the ball valve set point A Switch CR1 changes to the NC position B Switches CR2 and CR4 remain in the NO position to keep the relay coil energized until the system 34 Dresser Consolidated pressure reaches the predetermined valve closing point C The Normally Closed solenoid remains energized to keep pressure in the actuator cylinder and keep the ball valve open D The Normally Open solenoid valve is also energized to exhaust any pressure on the vent side of the cylinder System pressure drops down to the predetermined ball valve closing point A CR2 switch PSL goes to the NC position which de energizes the relay coil The relay contacts and relay AUX Switch CR4 open C The Normally Closed solenoid valve is de energized and goes
65. ubing Pipe Plug Conduct Tube Fitting Fitting Straight Union Figure 24b Top View of VA123 DA Actuators Note 4 Body Discharge Collar Nuts 40 Dresser Consolidated Eh AS e EM C Ball amp Seat Discharge Gasket E Assembly Collar Nuts Figure 23 Actuator assembly for Ledeen VA123DA XVI Setting and Testing A Start up of the System A ATTENTION Wear necessary protective equipment to prevent possible injury A DANGER Before disassembling the valve ensure there is no media pressure in the vessel A 1 Prior To Start Up Checks Open the isolation valve if it is closed Turn on the power and set the Type 2537 Control Station switch to the Automatic position if the electrical system is on the amber light will be turned on Set the Control Station switch to the Manual position Observe to verify that the valve rotated to the open position The red light will be turned on at this point Return the Control Station switch to the automatic position The valve should close the red light go out and the amber light will be turned on A 2 System Start Up 1 If the Power Actuated Relief valve is equipped with an isolation valve this valve MUST BE OPEN during system start up Bringing the system online and then opening the isolation valve WILL RESULT the damage to the coating on the ball
66. w Solutions 16 Tuas Avenue 8 Singapore 639231 Telephone 65 6861 6100 Fax 65 6861 7197 SOUTH AFRICA Dresser International Ltd South Africa Branch Dresser Flow Solutions 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 61302 R A 8 Blue Sheds JAO1 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 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 3500 EBV Series Safety Valve March 2011 51 About Dresser Consolidated Dresser Consolidated headquartered in Houston Texas has been an international leader in depen
67. wer supply properly set or has failed Check voltage No voltage Re establish electric power Has Voltage Go to possible cause 4 Check continuity between junction box terminals 5 amp 6 No Continuity Replace switch Has continuity Go to possible cause 6 Damaged ON OFF AUTO selector switch in 2537 control station Check continuity of contacts No continuity Replace switch Has continuity Go to possible cause 6 Relay 3539 failure Check voltage at 3539 terminals with Relay Coil energized to T2 amp T3 to T1 No voltage Replace relay Has voltage Go to possible cause 7 Wiring or terminal plug failure Check all wire and terminal connections Replace as required 44 Dresser Consolidated XVIII Maintenance Tools Disassembly and Reassembly i require the following tools A Stem Nut Removal Tool see Figure 13a for Dresser u Sa Drill J Dia part number For manufacturing dimensions see J through Figure 25 and Table 6 aaa B Stem Nut Remover Retainer Plate see Figure 13b for Dresser part number For manufacturing dimensions see Figure 26 and Table 7 A C Two wire S hook about 6 152 4 mm to 8 203 2 GDIA mm long see Figure 12 to shape wire D Yoke Alignment Tool see Figures 19 20 amp 25 Y A gt e D F for identification and Table 6 for manufactu
68. yone 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 WARNING Incorrect service and repair could result in product or property damage or severe personal injury or death Refer XII C WARNING These Warnings are as complete as possible but not all inclusive Dresser cannot know all conceivable service methods nor evaluate all potential hazards WARNING Use of improper tools or improper use of right tools could result in personal injury or product or property damage A WARNING Improper tools or improper use of right tools could result in personal injury or product damage A WARNING hf vy RADIATION AREA KEEP OUT RWP REQUIRED FOR ENTRY Know nuclear health physics procedures if applicable to avoid possible severe personal injury or death A CAUTION Wear necessary protective equipment to prevent possible injury A WARNING bf Vd RADIATION AREA KEEP OUT RWP REQUIRED FOR ENTRY Know nuclear health physics procedures if applicable to avoid possible severe personal injury or death A CAUTION Need all Service Manual warnings Read Installation instructions before installing valve s A CAUTION Wear necessary protective equipment to prevent possible injury Il Safety Alerts Contd Read Understand Practice 9 WARNING This valve product is not indent
69. zes and this in turn de energizes the solenoid valves and causes the valve to close The red light in the Type 2537 Control Station will then go off and the amber light will go of each switch When the pressure increases to the set point High Pressure Switch C is actuated and completes the relay circuit that energizes the valve solenoid The Low Pressure Switch D then provides for relay control below the actuation value of the High Pressure Switch thereby allowing an adjustable blow down for the Electromatic Valve This action makes extremely sensitive regulation possible The Type 2537 Control Station which includes a switch and two lights Is a small unit that can be mounted in a control panel The Control Station is electrically connected to the Type 3539 Controller With the Control Station Switch in the automatic position see Figure 10 the amber light turns on and remains on until the valve is opened ELECTROMATIC RELIEF VALVE TYPE 2537 CONTROL STATION e VALVE VALVE OPEN CLOSED e MAN H AUTO o e Ez Consolidated ALEXANDRIA LOUISIANA 71301 Figure 10 Control Station 2537 on The lights on the control station are controlled by a position switch on the actuator When it is desirable to open the valve manually this can be accomplished by simply pushing the Control Station Switch to the manual position To close the valve it is on

3500 EBV Series - Maintenance Manual

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