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Consolidated® - Allied Valve Inc.

1. 13 B 2900 Series with Type 39 MV Modulating 15 XI Cross Sectional Drawings and 17 Ac 39 PV BIIORVaAWe ssim be ave Mca ce Rum a ae Trio b eod qe eto AUG pea fa a 17 gt 39V See age es Oe casa 18 C 39 PV Dirty Service Option 19 D 2900 Malia Va D toe HT tco CDS yu cies a ta telus 20 XII 6 21 XIII General Planning for 21 XIV Disassembly of the 2900 Pilot Operated Safety Relief Valve 22 A Removal of the Pilot Valve from the Main 22 B Disassembly of the Main Valve 23 Cs Cleaning aa CURT De add Net tS 25 DY Parts Inspectlofi zu at es NEA Uo ena sawa case Het 26 ey am ce o IOS RE ou Dura al EXE ENT aU ee UE 25 25 7 DISC eu tud Glen ee N e 27 9 scs eR ES DER REA REP ESSERE Baader 28 4 Dise Holder Junt 28 gt G de ee e Ee PER eine yx s Ree eee 28 Gaskets Sus ans ham ce eee ear Seg 28 eii ETE 28 7 5 don nons erate QOL T RC ETE 28 2 Con 29 Contents Section XVI XVII XVIII XIX XX XXI XXII Con 29 Subject Page Maintenance I
2. OZ v L 108 1 e esr S9 0ON 867 i 9716 99110 JO JOO sn pey sn pey el el el el el el quiessesiq Ov 34Nd14 s 13Q d SQIvauHL 2 les 1001 Ajquiessy pue pue 2611172 SECTION XXVII Replacement Parts Kits 39PV 2 PILOT VALVE SEAL KITS Material Class CC per configuration PILOT VALVE SEAL KITS PILOT MATERIAL PART NO Pilot valve seal kits consist of o rings in materials shown above spring energized Teflon seals one 9 32 ball one tube filter grease and instruction sheet TABLE 14 39MPV 2 PILOT VALVE MODULATOR SERVICE 1 PART NO With Spring Energized Teflon Seals and Buna Nitrile 70 O rings 4985001 iqui 5040301 With Spring Energized Teflon Seals and Viton Fluoro Carbon 75 O rings Gs 4985002 liquid 5040302 With Spring Energized Teflon Seals and E P R Ethylene Propylene 70 O rings With Spring Energized Teflon Seals and E P R Ethylene Propylene 90 O rings 5040307 Note For repair or replacement of 39MV or conversion of Pop Pilot 39PV to Modulating Pilot 39MV The pilot valve modulator listed is a complete assembly including necessary mounting screws TABLE 15 Con 29 65 66 39MPV 2 PILOT VALVE MODULATOR SEAL KITS FOR MODULATOR CONVERSION OR REPAIR KIT CONTAINS SPRING ENE
3. 035 j 1 124 035 j 1 436 __ 035 4 960 6 040 6 315 8 336 10 458 METRIC UNITS MM a t 002 000 O RING SEAL NOZZLE FIGURE 14B J 005 14 55 18 62 9 22 05 26 92 30 89 96 00 08 08 00 10 46 69 56 08 00 00 15 00 129 41 158 42 47 282 70 19 L O Ring Seat Seal dius O Ring Seat Seal 2 2900 2900 30 Standard Metal Seated Disc Inspection Areas A Disc should be replaced if 1 The disc has been machined or lapped to remove damage from seat surface L and the N dimension as indicated in Figure 14 measures less than N minimum as indicated in Table 3 2 The dimension See Figure 15 is reduced by machining or lapping seat surface L and measures less than T minimum indicated in Table 3 Note See Section X for information concerning re establishing the disc seating surface I N MIN N MIN L seat surface 1 2 cC TYPE 3 D H J T FOR 2900V AND 2900W ONLY FIGURE 15 TABLE 3 DISC ORIFICE MILLIMETERS aL millimeters in millimeters 2 i ll Er KE 73 gt 3 05 VEE S ye Le aoe es Minimum Allowable Dimensions after Machining of the Disc Seat lt H UIOTZSTRC IT Con 29 27 3 2900 Series Thermodisc Replacement Criteria If seat defects and damage can not be lapped out without reducing the A dimension below that shown on Table 4 the Thermodi
4. 14B a Take light cuts across surface A 45 until the damaged areas are removed Turn to the smoothest possible finish b Cut back the outside surface M until dimension J is obtained c Machine radius B d The nozzle is now ready for grinding e When the minimum dimension D is reached the nozzle should be replaced Con 29 33 Lapping Disc Seats The disc seat may be lapped with a ring lap or a lapping plate Lapping should be done in an eccentric or Figure eight motion in all directions applying uniform pressure and rotating the disc or lap slowly H Machining the Disc Seat The standard disc seating surface L see Figure 21 can easily be machined as follows 1 Grip the disc in a four jaw independent chuck or collet if appropriate using a piece of soft material such as copper or fiber between the jaws and the disc as shown at A 2 True up the disc so that the surface marked B and C run true within 001 0 025 mm TIR 3 Take light cuts across the seating surface L until damaged areas are removed Turn to smoothest possi ble finish 4 The disc is now ready for lapping 5 When the minimum dimension N or T see Table 3 is reached the disc should be discarded Do not re establish surface C CHUCK JAW FIGURE 21 Note Thermodisc and O Ring discs are not to be machined If the involved valve has an O Ring seat seal refer to the tag plate mounted on the valve see Figure 36 to determine O
5. by machining not lapping For specific information concerning the machining of als e a nozzle and disc seating surfaces see Paragraphs F and G which follow FIGURE 17 SEAT WIDTH NOZZLE The seating surfaces of the metal seated Consolidated Safety Relief Valve are flat The nozzle seat is relieved by a 5 angle on the outside of the flat seat The disc seat is wider than the nozzle seat thus the control of seat width is the nozzle seat see Figure 17 Reconditioning of the seating surfaces of the nozzle and disc is accomplished by lapping with a cast iron lap and lapping compound Anytime the V or W orifice valve is disassembled be sure to inspect the guide rings for wear If worn replace before reassembly NOTE In order to establish leak free valve seats the nozzle seating surface and the disc seating surface must be lapped flat B Nozzle Seat Widths Lapped Awide nozzle seat will induce leak especially in the smaller orifice lower pressure valves For this reason the seat on non O Ring valves should be as narrow as practical Since the seat must be wide enough to carry the bearing load imposed upon it by the piston and system pressure the higher pressure valves must have wider seats than the lower pressure valves The nozzle seat width should conform with those listed in Table 6 or 7 The seat width can be measured by the use of a Measuring Magnifier Figure 18 shows its use to determine seat width Measuring Ma
6. in place when it is being inserted into base Place small main O Ring into groove Thread the insert assembly into base with T handle groove wrench part 4995401 Tighten wrench tight Make sure milled slot is facing up Cycle main piston through Teflon seat seal 10 times 17A Forthe Dirty Service option see Figure 7A use steps 11 through 17 to build up the insert assembly for the dirty insert Place large O Ring in groove on top of base 18A For the Dirty Service option install the o ring in the groove on the dirty insert Install the Teflon seal into yoke The energizer spring should be facing you down toward the pressure when installed Install main piston yoke with the spring washer bearing point going in first Install main piston and yoke assembly into base by inserting small diameter end of piston through insert assembly Line up the yoke arms with the dome port and the inlet port 21A For the dirty service option install the dirty insert on to the main valve base with the dirty insert inlet port facing opposite the vent on the main pilot base Con 29 21B Forthe dirty service option insert the small end of the piston into the insert assembly in the dirty insert and through to the pilot valve base 22 Lubricate and insert the four cap screws through the yoke and thread into the main base Tighten to 300 in Ibs 30 in Ibs 23 Lubricate and thread locknut onto compression screw 24 Thread compres
7. moderate finger or hand force DO NOT USE EXCESSIVE FORCE TO ASSEM BLE THESE PARTS Be sure that the Disc is free to wobble after it is in place For V and W orifice discs place Disc into Disc Holder and secure disc retaining bolts C For O Ring disc sizes K thru T reassemble the disc using a new O Ring O Ring retainer and new screws Assemble the disc into the disc holder as described in b above d For O Ring disc sizes D thru J reassemble the disc holder using a new O Ring O Ring retainer and new screw s These disc holders are ready for the next step 3 Forbellows valves D through place a new bellows gasket on the disc holder Thread the bellows fin ger tight down to the gasket on the disc holder Use a pin spanner wrench or special cable type wrench to turn the bellows ring down until a pressure tight joint is obtained For bellows valves V and W place a new bellows gasket on the disc holder Bolt down using proper torque as found in the assembly instructions 4 Setthe disc holder disc side down on the work surface Place a small amount of 1000 grit grinding com pound onto the ball end of the piston and place it in the disc holder pocket Turn the piston clockwise and then counter clockwise to seat the piston Clean all grinding compound from parts 5 Place the guide over the disc holder DO NOT DROP If bellows is present the weight of the guide will slightly compress the bellows 6 Place
8. parts of an Disc Holder additional 1596 of possible maintenance require ments A combination of Class and parts will satisfy maintenance requirements 85 of the time Note Depending on service either an O ring or Spring Energized Teflon Seal is required TABLE 12 Con 29 61 XXVI Special Tools A Insert Installation Tool 2 Ik ASSEMBLY Y 238 002 DIA 080 DIA u 250 HEX NOTE 1 i 0 SS SS KU 32 10 Xem 125 ITEM Ji 4 gt e 516 SQ 250 DIA SABE STEMS FIGURE 38 62 Con 29 B Adjuster Top Seal Insertion Tool ASSEMBLY VIEW OF INSERTION TOOL Plunger DETAIL OF PLUNGER CYLINDER gt At 95 32 1 15 32 DETAIL OF FUNNEL TUBE 5 32 520 002 4 DETAIL OF PLUNGER p ape T 375 002 L 1 9 16 TL FIGURE 39 Con 29 63 L 318V1 29 sued eui 810016 ui Buu o pezis ejyeudoudde ue esf 910 11 8 9 INN prepueis asn PU 91 8 INN prepueis e asn 91 8 INN prepueis e asn Put 02 P L INN prepueis asn 2 1 X PY LL 8 S og e 3 1 e esr p Z L pul 91 8 uog eA3 1 e esr 2 1 X pul 91 8 uog eA3 1 e esr Z L
9. pilot valves 1 Record main valve and pilot valve S N s of original POSRV s in plant records 2 Inspect S N s for agreement with Step 1 after any disassembly involving removal of pilot valve from main valve 3 Make sure the set pressures of the main valve and pilot valve are identical 4 Check O Ring and Seals Kit material code to ensure they are the same for main valve and pilot valve Any discrepancies should be promptly report to the appropriate plant authority Specify parts required by 1 Name See Nomenclature See Figures 1 2 amp 3 2 Part Number if known 3 Quantity Contact Parts Marketing 1 318 640 2250 In addition the main valve serial number is stamped on the top edge of the outlet flange Be sure to include the one or two letters preceding the figures in the serial number Typical valve nameplates are shown in Figures 35 36 and 37 60 Con 29 D Recommended Spare Parts PILOT OPERATED SAFETY RELIEF VALVES POSRV FOR 2900 1 MAIN VALVE Guide Ring on Piston Class 1 parts should be stocked at the rate of one Disc 1 per valve Maintaining this level of spare parts Retainer Ring on Disc will provide replacement parts for 7096 of possible O Ring maintenance requirements Spring Energized Teflon Seal Gasket 1 Gasket 2 Class parts should be stocked at the rate of one Stud 2 1 part per each five 5 valves in the population Nozzle Class parts will provide replacement
10. 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 equip ment 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 defini tion of the hazard and the conse quences of human interaction with the hazard than can be communi cated solely by the pictorial Improper use or repair of pressurized media or steam device may result in severe personal injury or death Heed all container label warnings Do not work with valves while under the influence of intoxicants or narcotics Provide and use guarding to prevent contact with heated and or pressurized parts Improper tools or improper use of right tools could result in personal injury or product damage All potential hazards may not be covered in this manual SECTION IV Safety Alerts Read Understand Practice 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 2 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 in severe personal injury or death 3 WARNING Never
11. the guide gasket in the base Con 29 35 COVER PLATE NUT TORQUE FT LBS 2912 2941 2916 2918 2920 2921 2922 2923 2924 2926 2928 60 60 120 55 55 co 60 t1 80 120 55 55 eo 60 115 70 70 115 55 55 70 70 115 26 ss o eo s ya 1 20 25 1 e 65 oo 75 8 EAE 6o 6 90 l o o o o 60 140 90 130 eso gt z a 150 mE N O1 O1 Ns lo le In o o SS o O1 1 o mv lo le o o NIG o a e _ par lt iz iz o 6 k _ J C1 O1 RT Oo D EM w ESSI EH wa i s Bee REX s TABLE 9A 7 Install disc guide assembly Use the same lifting tool see Figure 9 as was used during disassembly then car
12. 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 4 WARNING It is the responsibility of the owner to specify and provide guarding to protect per sons from pressurized or heated parts Contact with pressurized or heated parts can result in severe personal injury or death 5 WARNING Do not allow anyone under the influ ence of intoxicants or narcotics to work on or around pressurized systems Workers under the influence of intoxicants or narcotics are a haz ard both to themselves and other employees and can cause severe personal injury or death to themselves or others 6 WARNING Incorrect service and repair could result in product or property damage or severe personal injury or death 7 WARNING This valve product line is not intend ed for radioactive nuclear applications Some valve products manufactured by Dresser Inc 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 8 WARNING Use of improper tools or improper use of right tools could result in personal injury or product or property damage Con 29 9 WARNING These WARNINGS are as complete as possible but not all inclu sive Dresser cannot know
13. with fluorolube GR362 or equivalent SECTION XX Assembly of 39MPV Pilot Valve and Components Note 39 07 and 39MV37 are assembled identically to the 39PV except for the final addition of the mod ulator after the Pilot Valve is calibrated and tested A Assembly of the 39PV Pilot Valve Adjuster Plug 1 Assemble the following parts 1 Adjuster Bottom 1 Adjuster Top 1 Teflon Seat Seal 2 Small main O rings Install first small main O Ring into groove in the Adjuster Top Install second O Ring in to the groove on adjuster bottom Install on the opposite end of the square wrench ing flats Use the special seal insertion tool pictured in Figure 39 to correctly insert the vent seal into the Adjuster Top prior to assembly on the Adjuster Bottom a Place the seal with the energizer spring facing you onto the smaller end of the Plunger Cylinder b Place the male part of the Plunger through the seal and into the Plunger Cylinder c Insert the small end of the Plunger Seal Plunger Cylinder assembly in to the larger opening of the Funnel Tube and press the seal through the funnel tube until it is about 1 4 of an inch 5 or 6 mm from exiting the smaller end of the tube d Remove the Plunger from the assembly leaving the seal and female part of the insertion assembly in the Funnel Tube e Seatthe seal plunger and funnel into the end of the Adjuster Top f Press the plunger to seat the seal in the recessed area in the Adju
14. with the modulator piston top going in first Push piston in with thumbs until it stops There will be some resistance due to the Teflon seals compressing to fit into the bore of the modulator base If necessary for installation insert the proper wrench into the lock screw Lightly tapping the wrench with a hammer will force the piston into the modulator base Lubricate and install both large modulator O Rings into grooves on modulator piston stop Insert modulator stop into modulator base with the seat going in first Make sure the side hole in the modula tor stop is facing towards the flat side of the modulator base Lubricate and thread the cap screws through the modulator stop into the pilot modulator Tighten to 365 in lbs 30 in Ibs Con 29 SECTION XXI Assembly of Pilot to the Main Valve WITH STANDARD OPTIONS NOTE Seal all pipe threads with a non organic sealant or Teflon tape 1 Assemble the 1 2 NPT x 3 8 ferrule to the main valve cover plate Tighten wrench tight 2 Assemble the pilot mounting bracket to the main valve using cover plate stud nuts Torque nuts to the value listed in Table 9a or 9b Assemble the pilot to the mounting bracket using the two cap bolts 30 provided Do not tighten gt Connect the dome sensing line 28 to the dome port of the pilot and the ferrule fitting in the main valve cover Tighten wrench tight Connect the inlet sensing line 27 to the pilot inlet port 23
15. 11 SECTION IX B Main Valve Introduction The CONSOLIDATED 2900 Pilot Operated Safety Relief Valve POSRV cast bodies are designed to meet the API 526 spring loaded specified inlet and outlet connection combinations API orifice sizes range from 1 10 pressure ratings from 150 1500 class The standard metal seat is the same design that has been successfully utilized in the CONSOLIDATED SRV for over 50 years Capacities are certified by National Board of Boiler and Pressure Vessel Inspectors and published in their NB18 entitled Pressure Relief Device Certifications Main Valve Features Orifice controlled capacity Superior tightness Removable nozzles for replacement or remachining Standard O Ring sizes readily available easily replaced Meets ASME Section VIII Div 1 National Board certified capacities Uses many parts standard on 1900 Series SRV SAN T A 9 000000 FIGURE 1 12 REF NO NOMENCLATURE 1 BASE 1905 1916 1920 1926 BASE PLUG 1905 1916 1920 1926 NOZZLE DISC DISC RETAINER DISC HOLDER GUIDE GUIDE GASKET COVER PLATE COVER PLATE GASKET BASE STUD STUD NUT MAIN VALVE PISTON MAIN VALVE PISTON O RING GUIDE RING PLUG ADAPTER PLUG ADAPTER GASKET Con 29 SECTION X 2900 Series MPV Operational Descriptions SECTION X A 2900 Series with Type 39PV Pop Pilot Operational Descriptions PV VALVE
16. CLOSED Normal Position System pressure from the main valve inlet is fed to the dome by the pilot through interconnecting tubing This equalizes the pressure on the top of the piston with inlet pressure on the seating surface bottom of the disc Since the area of the top of the piston is larger than the area of the seating surface the differential area results in a net downward force keeping the main valve tightly closed FIGURE 2 Con 29 13 SECTION Continued PV VALVE OPEN Relieving Position As inlet pressure increases the pilot piston strokes and seals off the main valve inlet pressure from the dome pres sure The pilot simultaneously opens the vent seal to relieve the dome pressure to atmospheric pressure The main valve disc is allowed to lift off the seat as the fluid force overcomes the now removed pressure load above the main valve piston The valve discharges to relieve system pressure When the discharging main valve reduces the inlet pressure to the pre set blowdown pressure of the pilot the pilot piston closes the vent seal Simultaneously the inlet seal is reopened in the pilot The main valve inlet pressure is again allowed to enter the dome above the main valve piston As the dome pressure equalizes with the inlet pres sure the downward force created by the differential areas of the piston and disc closes the main valve FIGURE 3 14 Con 29 SECTION X B 2900 Series 39 MV Modulating Pilot Ope
17. Consolidated INSTALLATION OPERATION AND MAINTENANCE MANUAL Consolidated Pilot Operated Safety Relief Valve Type 2900 Series P O Box 1430 Alexandria Louisiana 71309 1430 USA Modular Pilot Valve Types 39MV07 2 39MV37 2 39PV07 2 39PV37 2 Series 2900 Backflow Preventer Filter Manual Blowdown Pressure Differential i Switch High Temperature Low Temperature Dirty Service 29 March 2003 Contents Section Subject Page RD CUPRUM 1 Contents da rc 2 Product Safety Sign and Label 5 IV Safety Alerts Read Understand 6 V Warranty Information us z are eate 8 VI angling ane Storage es i veu ge paw 9 VII Pre installation and 1 lt 10 VIII Hydrostatic Testing and Service Considerations 10 IX General 10 A s Qus 11 B Main Valve 12 2900 Series MPV 13 2900 Series with Type 39 PV Pop
18. F Heat Exchanger used on Cryogenic Service Pilot valves are traditionally limited to the service ranges its elastomers and Teflon products The 2900 series valve metal seat design is able to operate at a design temperature that is above 505 F and below 40 F with the use of an air cooled or air e m 2 warmed Heat Exchanger For temperatures 41 enden and below as well as those 506 F and above consult the factory The Heat exchanger located upstream of s the pilot valve in order to condition the temperature of the process fluid within the acceptable range of SENSING L TE the pilot valve and soft goods see figure 7A The mE w Heat exchanger must be sized and selected to meet e 7 the service conditions for each application and valve SENSING size P RING SENSING WARNING Medium may freeze if ambient tem A TUBE perature drops below the freezing point of the bibis ar T media when a heat exchanger is installed SYSTEM SENSING SING PRESSURE OPTIONAL CONNECT TO FIELD TEST SERVICE SOONE RRS E AES FIGURE 32 56 Con 29 Heat Exchanger for Steam and Hot Service ka HEAT EXCHANGER SENSING LINE BRACKET f k L x i E SENSING HUU LINE 2 3 TT E SENSING RING ri SENSING TUBE SYSTEM SENSING RING PRESSURE GP TIONAL CONNECT TO F
19. F O B point upon request Incorrect Selection or Misapplication of Products Dresser Inc cannot be responsible for customer s incorrect selection or misapplication of our products Unauthorized Repair Work Dresser Inc 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 service 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 Hefer to Dresser s Standard Terms of Sales for complete details on warranty and limitation of remedy and liability Con 29 SECTION VI HANDLING 1 CAUTION Flanged valves either crated or uncrated should always be kept with the inlet flange down in the normal installation position to prevent mis alignment and damage to internal parts 2 CAUTION Pressure relief valves either crated or uncrated should never be subjected to sharp impact Particular care should be exercised when the valve is being loaded onto or unloaded from a truck and when it is being hoisted into position for installation 3 CAUTION Never attempt to lift the full weight of the
20. IELD TEST CONNECTOR TO ESTABLISH SYSTEM PRESSURE IN PILOT FIGURE 33 H Optional Line Filter Standard with Steam Option Filter TEST Additional protection for the standard filtered pilot valve is provided by an optional sensing line pilot filter See Fig LINE 34 Greater filter capacity will boost FILTER removal of unusual amounts of scale _ deposits or foreign particles which oth SENSING SENSING Bi Ji erwise may obstruct the sensing line LINE RNa causing malfunction of the pilot SENSING 4 TUBE AN iN r PIPE TO PRESSURE OPTIONAL CONNECT TO FIELD TEST CONNECTOR TO ESTABLISH SYSTEM PRESSURE IN PILOT FIGURE 34 Con 29 57 Assembly of Options and Alternative Piping Additional information concerning the installation and appropriate piping designs is available in the Consolidated 2900 Series Pilot Operated Safety Relief Valve Catalog Suggested References begin on page 2900 42 and con tinue through 2900 62 SECTION XXIV Troubleshooting 58 Problem Pilot valve is not open at set A pressure and main valve will not open Main valve does not close upon start up P2 chamber does not load with system Possible Cause Wrong set Pressure A Start up procedures pres surize the valve too rapid ly Sensing tube is installed upside down Closed filter Operating pressure too Leakage through the Pilot Valve Back
21. II 2900 Pilot Valve Options A Available Options Backflow preventer Auxiliary Canister Filter Manual Blowdown Dirty Service with Auxiliary Canister Filter Heat Exchanger used on Cryogenic Service Heat Exchanger used on Steam and Hot Service Optional Line Filter B Backflow Preventer REF PART LAW pue NO E spl PAIN LHP Shuttle Ball ef gt DISCHARGE T LINE Shuttle Base 4 Shuttle Plug j SENSING W Tube Filter xl PIPE TO SYSTEM OPTIONAL i LE PRESSURE u CONNECT TO FIELD TEST CX T j 1 CONNECTOR TO ESTABLISH SYSTEM PRESSURE IN PILOT ip ri Au J BACKFLOW PREVENTOR oe al i BACKFLOW PREVENTER Note The backflow preventer is the same part as the field test connection FIGURE 28 When pilot operated relief valve is not vented directly to atmosphere it is possible to build up a back pressure in the discharge line This is typical in applications where several valves manifold into a common discharge head er Should the discharge line back pressure exceed the valve inlet pressure it could cause the main valve piston to lift and allow reverse flow through the main valve This trouble can be avoided by use of the Backflow Preventer optional feature Con 29 53 Backflow Preventer Maintenance Backflow Preventer DISASSEMBLY Ref Figure 28 Remove plug located near the valve discharge flange from body by unscrewing counterclockwise Remove b
22. NCH NOZZLE BASE FIGURE 13 10 Remove the Nozzle from the Valve Base as suggested in Figure 12 or by using a Hex wrench or a pipe wrench on the flange as indicated in Figure 13 Note Exercise care not to damage the Nozzle when inserting a rod or pipe in the outlet to remove the Nozzle 11 The Main valve is ready for cleaning inspection and refurbishing 24 Con 29 SECTION XIV C Cleaning Parts are to be free of any oil or grease except for lubrication as specified in this instruction Cleaning agents used should be such that effective cleaning is assured without injuring the surface finishes or material properties of the part Acceptable cleaning agents include demineralized water non phosphate deter gent acetone or isopropyl alcohol Parts must be blown dry or wiped dry after cleaning If you are using cleaning solvents take precautions to protect yourself from poten tial danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations and equipment It is not recommended to sand blast internal parts as it can reduce the dimen sions of the parts The base may be sand blasted with care not to erode internal surfaces or damage machined surfaces SECTION XIV D Parts Inspection See Figure 8 for a cross sectional drawing and designated parts nomencla ture 1 2900 2900 30 Nozzle Inspection Criteria A Nozzle should
23. OP ADJUSTER BOTTOM ADJUSTER LOCK NUT COMPRESSION SCREW COMPRESSION SCREW LOCK NUT SPRING WASHER SPRING INSERT TOP INSERT BOTTOM MAIN PISTON CAP COMPRESSION SCREW CAP SCREW YOKE O RING ADJUSTER BOTTOM O RING ADJUSTER TOP O RING INSERT O RING MAIN BASE YOKE SPRING SEAL MAIN PISTON SPRING SEAL ADJUSTER TOP SPRING SEAL INSERT FIELD TEST CONNECTOR BUG SCREEN VENT ASSY PIPE PLUG PILOT VALVE Con 29 39PV37 2 HIGH PRESSURE SHOWN 90 OUT OF POSITION 39PV07 2 FIGURE 6 17 Section 39MV Cross Sectional Drawing and Nomenclature Af Ju ORT Q z 5 ge d OT show so faz 39 07 2 39MV37 2 HIGH PRESSURE BENNETOETION FIGURE 7 18 REF NO NOMENCLATURE MAIN BASE ADJUSTER CAP ADJUSTER TOP ADJUSTER BOTTOM ADJUSTER LOCK NUT COMPRESSION SCREW COMPRESSION SCREW LOCK NUT SPRING WASHER SPRING INSERT TOP INSERT BOTTOM MAIN PISTON CAP COMPRESSION SCREW CAP SCREW YOKE O RING ADJUSTER BOTTOM O RING ADJUSTER TOP O RING INSERT O RING MAIN BASE YOKE SPRING SEAL MAIN PISTON SPRING SEAL ADJUSTER TOP SPRING SEAL INSERT FIELD TEST CONNECTOR BUG SCREEN PLUG FILTER MODULATOR BASE MODULATOR STOP MODULATOR PISTON TOP MODULATOR PISTON BOTTOM O RING RETAINER LOCK SCREW CAP SCREW MODULATOR O RING MODULATOR BASE O RING MODULATOR STOP O RING MODULATOR SEAT O RING MODULATOR PISTON BOTTOM SPRING SEAL PISTON BOTTOM SPRING
24. RGIZED TEFLON SEALS AND O RINGS AS INDICATED PSGK 34B018 PSGK 34V022 PSGK 32E019 Buna N Nitrile 70 Viton Fluoro Carbon 75 Liquid E P R Ethylene Propylene 70 PSGK 34E019 Teflon PSGK 32T006 PSGK 34T006 PSGK 34T006 Steam E P R Ethylene Propylene 90 PSGK 34E002 Note A modulating valve requires both a pilot valve seal conversion or repair TABLE 16 kit and a seal kit for modulator Il d 39 2 PILOT VALVE MODULATOR BACKFLOW PREVENTER FIELD TEST CONNECTION 39PV 2 BACKFLOW PREVENTER KIT EACH KIT CONSISTS OF DESCRIPTION OTY Fitting Fitting Reducing Bushing TABLE 17 PART NO PAP79B018 PAP79E019 PAP79V022 PAP79T006 PAP79E002 PART NO AND ONE OF THE FOLLOWING SHUTTLE VALVE ASSEMBLIES SEAL MATERIAL PART NO Buna N Nitrile 70 5040101 TABLE 18 Con 29 39MV 2 BACKFLOW PREVENTER Material Class per configuration MATERIAL PART NO Buna N Nitrile 70 79 018 Viton Fluoro Carbon 75 PAP79V022 E P R Ethylene Propylene 70 79 019 Teflon PAP79TO06 E PR Ethylene Propylene 90 79 002 EACH KIT CONSISTS OF DESCRIPTION QTY PART NO Fitting 6000622 TABLE 19 AND ONE OF THE FOLLOWING SHUTTLE VALVE ASSEMBLIES Note Field Test Connector Consist of one of the Select Shuttle Valve Assemblies Shown Above Fittings are Swagelok other brands available SP561 Q replaced by 6000609 SP561 R replaced by 6000608 SP468 G replac
25. Ring material and as built part number Coverplate Beyond cleaning and inspection no maintenance is required for the coverplate Note Do not machine the inside of the coverplate dome J Bearing Point The bearing point on the piston should be ground into the piston pocket of the disc holder 34 Con 29 SECTION XVI Assembly of the 2900 Main Valve A Lubrication Use a nickel based anti seize lubricant on all threads and bearing surfaces Note O rings except silicone and energized seals should be lightly lubricated with silicone grease supplied with o ring kits B Specific Steps 1 Ifthe valve nozzle was removed apply thread lubricant to the nozzle threads before reinstalling in the valve base Insert it into the inlet flange of the base and torque to the correct value listed in Table 8 2 Assemble the disc disc holder as follows a Prior to assembly of the Disc into the Disc Holder remove the spring clip from the back of the disc Use 1000 grit grinding compound on the bearing surface to grind the disc into the disc holder to properly establish the bearing surface b For all orifices metal to metal discs place the disc retainer into the groove in the disc The disc with the retainer should snap into the disc Nozzle Torque Values 10 0 Orifice Required Torque ft lbs 00 100 1020 TABLE 8 F 1 EET mo Required Torque nm 129 224 holder pocket with
26. SEAL PISTON TOP SPRING SHIELD NOT SHOWN NEEDLE VALVE MANUAL BLOWDOWN NOT SHOWN PILOT SUPPLY FILTER NOT SHOWN CANISTER FILTER NOT SHOWN CANISTER FILTER NOT SHOWN W FLUSH VALVE NOT SHOWN BACKFLOW PREVENTER NOT SHOWN BACKFLOW PREVENTER LINE NOT SHOWN VENT ASSY TOP PLATE SET SCREW BONNET Con 29 Section 39PV Dirty Service Option COMPRESSION SCREW COMPRESSION SCREW LOCKNUT YOKE m SPRING WASHER SPRING SPRING WASHER 7777277777 SHOWN 90 T OF POSITION SCREW DIRTY INSERT E dA El BASE i ADJUSTER TOP EN MAIN PISTON INSERT INSERT INSERT BOTTOM ADJUSTER LOCKNUT 7 ADJUSTER BOTTOM ADJUSTER DC e PC T SHOWN 90 OUT OF POSITION A NN ITA FIGURE 7A DIRTY SERVICE OPTION Note Dirty Service Option can be applied to the following pilot valves 39PV07 39PV37 39 07 and 39MV37 Con 29 19 REF Section XI D NO 1 BASE 2900 Main Valve Cross Section and Nomenclature 0000 OOQQOGQ 1905 1916 1920 1926 1A BASE PLUG NOT SHOWN 05 1916 1920 1926 NOZZLE DISC DISC RETAINER za gt SY 7 2 4 NJ D U EU ROK SS 2900 MAIN VALVE FIGURE 8 SECTION XII Restoring
27. Safety Appropriate service and repair are important to safe reliable operation of all valve products Restoration to original quality and manufacturing specifications will accomplish the desired results Procedures developed by Consolidated as described in the applicable Installation and Maintenance Manual when correctly applied will be effective SECTION XIII General Planning for Maintenance A 12 month maintenance interval is recommended for general service conditions For severe service applications a 3 to 6 month inspection and test interim may be more appropriate The specific plant s operating and service history will better determine this frequency Dresser encourages preventive maintenance The 2900 series Pilot Operated Safety Relief Valve POSRV is easily maintained Normal maintenance usually involves Removal of pilot valve from main valve e Disassembly of both the pilot and main valve Cleaning Component Inspection Parts Replacement as Needed Reassembly Setting Testing and Resealing the Valve Occasionally remachining the nozzle may be necessary to extend the service life of the valve Keep all parts for each valve separated to ensure replacement in the same valve Note Insure there is no pressure in the inlet of the valve before attempting to remove it from the piping system Con 29 Always use appropriate restoration procedures Do not interchange parts from one valve to another De
28. Uxbridge Middlesex England UB8 2GH Telephone 44 1895 454900 Fax 44 1895 454919 Telex 851 627039 FoR YouR GREEN TAG CENTER IN USA CANADA CALL 1 800 245 VALV or contact the locations listed above for international service Consolidated is a registered Trademark of Dresser Inc all other referenced Brands or trade Names are Trademarks of their respective companies Copyright 2000 Dresser Inc Con 29
29. ached For 39PV Set at 196 to 226 BELOW S P or 1 psig whichever is greater For 39MV Set at 0 to 196 BELOW S P or 1 psig whichever is greater FOR EXAMPLE S P 150 psig The following valves would be set at 39PV01 amp 39PV07 147 0 psig Closing point 144 1 psig Pilot 0 BPM 144 psig Pilot lt 40 BPM 165 psig Con 29 49 30 01 amp 39 07 148 5 psig Closing point 145 5 psig Pilot 0 BPM 144 psig Pilot 0 BPM 165 psig S P 1000 psig The following valves would be set at 39PV37 1000 0 psig closing point 2 970 psig Pilot 0 BPM 960 psig Pilot 0 BPM 1100 psig 22 After adjustments have been made tighten locknut on compression screw and tighten adjuster cap to secure settings 23 Re Verify Settings 24 Lower inlet pressure so that inlet and dome pressures are equal Approximately 9096 of set pressure 25 Slowly increase pressure to verify that pilot is tight O Bubbles per minute at 496 below set point or 2 psig whichever is greater 26 Increase inlet pressure to 196 or 1 psig above set point whichever is greater and hold for a couple of seconds to make sure dome pressure is dropping If dome pressure is dropping continue to increase to 1096 over pres sure or 3 psig whichever is greater Dome pressure should drop to 0 psig If dome pressure is not dropping adjust as noted in 15 or 16 Retest beginning with 24 27 Check rate of leakage from pilot at 1096 or 3 psig which
30. all and filter MAINTENANCE AND REASSEMBLY Remove and discard O Rings Clean all parts and inspect for damage and wear Lubricate O Rings with silicone grease or equivalent Reassemble with new O Rings Ref Table VIII O Ring kit information WITH BACKFLOW PREVENTER Refer to Figure 28 for location of Backflow Preventer Pilot Valve Mounting Plate Tubing etc 1 2 54 Insert bushing into cover plate and tighten Insert threaded end of backflow preventer into bushing and tighten Make sure that the 1 4 FNPT threads are facing 90 degrees from pilot When viewed from the outlet of the valve the right side is piped to the dome port of the pilot The left side is piped to the outlet of the main valve Install the pilot valve and sensing lines as described above Install the sensing line between the main valve outlet and the backflow sensing port Con 29 C Auxiliary Canister Supply Filter The supply filter is an option available and is used to prevent foreign material from entering the pilot valve 1 The filter is connected to the main valve See Figure 29 2 Connect and tighten the inlet sensing line to the inlet of the filter and the sensing fitting at the inlet of the main valve 3 Connect and tighten the pilot sensing line to the outlet of the filter and the pilot valve inlet sens ing port D Manual Blowdown Manual Blowdown An optional manual blowdown valve is available for ope
31. all conceivable service methods nor evaluate all potential hazards Cautions Concerning Product Warning Labels 1 CAUTION Heed all service manual warnings Read installation instructions before installing valve s CAUTION Wear hearing protection when testing or operating valves CAUTION Wear appropriate eye and clothing protection CAUTION Wear protective breathing apparatus to protect against toxic media Bom NOTE Any service questions not covered in this manual should be referred to Dresser s Service Department Phone 318 640 6055 Con 29 hf 9 RADIATION AREA KEEP OUT RWP REQUIRED FOR ENTRY Know nuclear health physics procedures if applicable to avoid possible severe personal injury or death Heed all service manual warnings Read installation instructions before installing valve s Wear necessary protective equipment to avoid possible personal injury Defective and nonconforming items must be inspected by Dresser Removal and or breakage of seal will negate our warranty SECTION V Warranty Information Warranty Statement Dresser Inc warrants that its products and work will meet all applicable specifications and other specific product and work require ments including those of performance if any and will be free from defects in material and workmanship CAUTION Defective and nonconforming items must be held for Dresser s inspec tion and returned to the original
32. alling or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting 4 Adjuster Top Galling or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting Also check for galling of threads 5 Adjuster Bottom Galling or excessive wear on the inside diameter that guides the Main Piston Check for any corrosion or pitting Also check for galling of threads 6 Yoke Galling or excessive wear on the inside diameter that guides the Main Piston Assembly Any corrosion or pitting Check for any galling on the threads for the compression screw 7 Compression Screw Galling at the spherical bearing surface or in the thread Check for any corrosion or pitting 8 Spring Washers Galling at the spherical bearing surface Check for any corrosion or pitting B Field Test Connection Parts Inspection 1 Field Test Connection Base Galling or excessive wear in the threads 2 Field Test Connection Plug Galling or excessive wear in the threads C Modulator Parts Inspection 1 Modulator Stop Top seating surface for cuts or deformities The surface can be lapped if the distance from the seat to the outside shoulder does not reduce to less than 0 086 inches 2 O Ring Retainer Seating surface for cuts or deformities The surface can be lapped if the overall height of the part does not reduce to less than 0 160 inches Also check the outs
33. and the inlet sensing fitting Tighten wrench tight Tighten the two pilot to bracket Allen 30 cap bolts wrench tight Assemble remaining options See Section XXIII Tighten all tubing connections wrench tight o Connect the inlet sensing line 27 to the system pressure or to the sensing tube 38 if the sensing ring option 39 is used WITH SENSING RING OPTION Remote sensing is the standard pressure connection to the pilot valve used on the 2900 Pilot Operated Safety Relief Valve However with the Sensing Ring Option the pilot valve pressure can be picked up just before the inlet of the main valve The center to face dimensions for a 1900 valve being replaced or converted should be reviewed The 2900 Center to Outlet dimension remains the same as a 1900 valve However the Center to Inlet dimen sion increases by 1 1 2 inches due to the Sensing ring and two inlet gaskets to be supplied by the customer The gaskets are to be inserted between the Valve Nozzle and the Sensing Ring and between the Sensing Ring and the system flange Pipe in System Pressure Sensing Ring optional FIGURE 25 Note 38 Sensing Tube must be used with 39 Sensing Ring if used on 2900 MPV valve Con 29 45 SECTION XXII General Information General Information on Testing Set Pressure and Blowdown on Pilot Operated Valves If testing is to be accomplished while the valve is installed on a pressurized syste
34. ate the Pilot Valve on a calibration stand prior to testing it on the main valve on a shop test facility Blowdown may also be established using this method 2 The complete valve main and pilot can be tested in the field through the use of the Field Test Connection and a pressure source that can attain set pressure This method will also measure blowdown and will cause the Main Valve to Open and discharge media 46 Con 29 A Pilot Valve Calibration Strand The pilot test stand should consist of the following equipment refer to Figure 26 for recommended set up All equipment must be rated for at least 4200 psi 264 kg cm psig pressure Suitable pressure source with regulator 1 2 cubic foot 14 liter inlet side accumulator 1 30 cubic foot 1 liter dome simulator Inlet and dome pressure gauges Inlet supply throttle valve Inlet supply vent throttle valve DUX Gr Se oom Inlet supply and dome simulator pressure gauges The inlet accumulator and dome simulator should be fitted with a drain valve at the lowest point in the vessel to allow draining moisture before testing SOURCE eT 39MPV PILOT VALVE SUPPLY THROTTLE VALVE yENT THROTTLE INLET VALVE GAUGE ACCUMULATOR 1 7 4 EL dd DRAIN VALVE FIGURE 26 NOTE Do not attempt to adjust blowdown when testing the pilot main assembly The 39PV and 39MV can only be tested for set pressure and tightne
35. be replaced if 1 The seat width requires adjustment and the Dimension from the seat to the first thread is less than D minimum on Table 5 2 Thread sections are damaged from pitting and or corrosion 3 Top of the nozzle flange and intersecting surface are damaged from galling and or tearing 4 The nozzle flange thickness can change center to face Dimensions The minimum dimension for orifices D through P is 43 64 672 or 16 5 mm and Q through W orifices are 51 64 797 or 20 2 mm Note See Table 5A or 5B for information concerning reestablishing the Seat width and other critical dimensions of the nozzle seat area Con 29 Follow recommendations for safe handling the solvent s Material Safety Data Sheet and observe safe practices for any cleaning method A DANGER 25 METAL SEATED NOZZLE Fa F FIGURE 14 Nozzle Metal To Metal D Min 13 32 15 32 5 16 5 16 1 4 3 8 Orifice 015 020 030 035 035 035 02 093 093 250 350 om lt 1 5 8 Nozzle 26 Et red 788 955 1 094 1 225 1 546 7 16 063 1 836 1 711 063 7 16 063 2 257 2 132 063 7 16 063 2 525 2 400 063 1 2 063 2 777 2 627 063 5 8 093 3 332 3 182 093 7 8 093 4 335 4 185 093 5 110 6 234 6 510 8 816 11 058 Metal To Metal TABLE 5A ENGLISH UNITS INCH 002 005 H 000 N 000 R P 1 2 B 30 832 035 954
36. conditions PILOT OPERATED PRESSURE RELIEF VALVE a pressure relief valve in which the major relieving device is combined with and is controlled by a self actuated auxiliary pressure relief valve DISC the pressure containing movable element of a pressure relief valve which effects closure NOZZLE a pressure containing element which constitutes the inlet flow passage and includes the fixed portion of the seat closure SEAT the pressure containing contact between the fixed and moving portions of the pressure containing elements of a valve BORE AREA the minimum cross sectional flow area of a nozzle LIFT the actual travel of the disc away from the closed position when a valve is relieving 70 29 Operational Characteristics SET PRESSURE the gauge pressure at the valve inlet for which the PRV has been adjusted to open under service conditions In liquid service set pressure is determined by the inlet pressure at which the valve starts to discharge a continuous stream of liquid In gas or vapor service the set pressure is determined by the inlet pressure at which the valve pops OPERATING PRESSURE 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 1096 under the maximum allowable working pressure or 5 psi 34 bar whichever is g
37. contaminate or clean if necessary before pretesting or disassembly Safety and environmental precautions must be taken for the decontamination or cleaning method used DANGER Lower pressure and stand clear of discharge when working on valve to avoid severe personal injury or death Wear necessary protective equipment to prevent possible injury DANGER Do not remove bolts if valve is under pressure as this will result in severe personal injury or death 22 SECTION XIV Disassembly of the 2900 Pilot Operated Safety Relief Valve SECTION XIV A Removal of Pilot Valve from Main Valve 1 Make sure there is no media pressure in the vessel in the valve inlet in the main or in the pilot valve 2 Disconnect the Sensing Tube Dome Tube and Discharge Line from the Pilot Valve 3 All other external attachments should be removed to free the Pilot Valve for Disassembly 4 Loosen and remove the two cap bolts holding the pilot valve to the mounting bracket 5 Place parts in the order they are disassembled to facilitate reassembly Know all valve exhaust leakage points to avoid possible severe personal injury or death Con 29 SECTION XIV B Disassembly of the Main Valve To disassemble the main valve see Figure 8 for a cross sectional drawing and designated parts nomenclature Follow these specific steps 1 Loosen and remove the stud nuts or cap screws on the Cover Plate 2 Lift off the Co
38. d the discharge flange 2 Close the vent valve and isolation valve in Figure 27 3 Connect the isolation valve to the pilot valve through the test port labeled Test DO NOT REMOVE ANY OTHER PLUGS 4 Open the valve at the inlet neck of the nitrogen tank 5 Turn the regulator control knob clockwise gradually until a pressure of 10 psi is indicated on the test gauge attached to the regulator 6 Open the vent valve to purge the test system 7 Close the vent valve 8 Increase the test pressure by turning the control knob on the regulator clockwise until the pilot valve begins to vent Con 29 51 9 Note the test gauge reading when the pilot valve vents The pilot opening pressure should be within tolerances referenced in Section XXII B NOTE The main valve will open using field test connection 10 After the set pressure is noted turn the control knob counterclockwise to reduce the pressure in the pilot valve and close the main valve 11 Confirm the pilot valve opening pressure by repeating the above test twice more for a total of three tests test results should be within the proper set pressure tolerance Testing on Installation PRESSURE ISOLATION VALVE GAUGBi r 4 CONNECTION TO NITROGEN VALVE TEST PLUG REGULATOR x NITROGEN BOTTLE A VALVE VENT VALVE NITROGEN BOTTLE TYPICAL FIELD TEST ARRANGEMENT __ Field Test Connection FIGURE 27 52 Con 29 SECTION XXI
39. ection 40 Pilot Valve Lubrication 41 Assembly of the 39 MPV Pilot 41 A Assembly of the Pilot Valve 41 B Assembly of the Field Test Connector 43 C Assembly of the Liquid or Gas Modulator 44 Assembly of the Pilot to the Main Valve 45 Testing General Information 46 A Calibration of the Pilot Valve Prior to mounting on the main valve 47 1 Pilot Calibration and Test 48 2 Definitions shox 48 3 Pilot Calibration and Test Procedure PV and 4222222 Q nh 24 2 eee en 48 Contents Section XXIII XXIV XXV D XXVI XXVII XXVIII XXIX XXX Subject Page 4 Final Set Pressure 51 5 Final Seat Tightness and Leakage 51 B Testing on the Installation 51 2900 Pilot Valve Options 53 A Available options s Ea qe e ab ee dun 53 Backflow Preventi esse aei ee reor a enu gear eee tds 53 C Auxiliary Canister Supply Filter 55 D Man
40. ed by 6000622 TABLE 20 39MV 2 PILOT VALVE MODULATOR SEAL KITS FOR REPAIR OR CONVERSION OF BACKFLOW PREVENTER OR FIELD TEST CONNECTION BACKFLOW PREVENTER SEAL KITS TABLE 21 MANUAL BLOWDOWN MANUAL BLOWDOWN VALVE ASSEMBLY Material Class CC per configuration PART NO PAP72 TABLE 22 Con 29 Note PAP72 is listed above PAP75 shown in the bill of materials is identi cal to PAP72 PAP75 and PAP72 are interchangeable MANUAL BLOWDOWN VALVE ASSEMBLY CONSIST OF DESCRIPTION PART NO 1 Needle Valve 2 42 24 SP348 E 62000622 Fitting is Swagelok other brands available SP468 AE replaced by 6000622 TABLE 23 II PILOT VALVE OPTIONS LINE FILTER Material Class CC per configuration SP540 J Kit Line filter kit consists of filter element and two Teflon o rings only TABLE 24 HIGH CAPACITY FILTER 9465 1851 HIGH CAPACITY FILTER REPLACEMENT PARTS NO REQUIRED DESCRIPTION PART NO PER VALVE FILTER ELEMENT 6027301 O RINGS 31006131 TABLE 25 SPRING COVER SPRING COVER MATERIAL PART NO PEEK 4982901 BONNET METAL COVER KIT 9999742 BONNET 5039701 CLOTH SOCK TO GO OVER YOKE 9999740 TABLE 26 PILOT VALVE HARDWARE MOUNTING BRACKET SCREWS NO REQUIRED DESCRIPTION PART NO PER VALVE Sssonew 2210180 TABLE 27 68 TUBING TUBING DESCRIPTION PART NO Low Pressure Tubing 531607310004 High Pressure Tubi
41. efully lower it into the valve base On V and W sizes use the same lifting lugs as were used during disassembly 8 Using a small amount of Silicone Grease supplied with soft goods replacement kit rub a small amount on the seals and O rings prior to assembly 9 Take the piston and measure and cut diagonally the proper length of Guide Ring material to fit in the groove of the piston Allow 1 16 of an inch gap between the ends for proper fit 10 Install energized seal onto see note below piston with the exposed spring facing upwards For o ring seals install the o ring onto the piston Locating it in the groove below the energized seal groove Note Spring energized seal on piston is only for Teflon o ring material option All other o ring material 36 options will include an o ring for the piston For valve sizes D E F G H J K L M N amp P and set pressure below 50 psig remove and discard the spring in the energize seal before installing 11 Install the guide ring s onto the piston If there is more than one guide ring stagger the cut locations 180 apart 12 To prevent seal damage during assembly check the chamfer on the bottom of the coverplate for burrs If any sharp edges exist polish the chamfer 13 Insert piston energize seal o ring side first into bottom of coverplate Continue pushing piston into cov erplate being careful not to pinch the guide rings Push piston in until bottom of piston is even with
42. ephone 55 11 453 5511 Fax 55 11 453 5565 CANADA DI Canada Inc 5010 North Service Road Burlington Ontario L7L 5R5 Canada Telephone 1 905 335 3529 Fax 1 905 336 7628 DI Canada Inc 333 5th Ave SW Suite 1100 Calgary Alberta T2P 3B6 Canada Telephone 1 403 290 0001 Fax 1 403 299 1526 72 CHINA Dresser Valve Division Suite 2403 Capital Mansion 6 Xinyuannan Road Cho Yang District Beijing China 100040 Telephone 86 10 6466 1164 Fax 86 10 6466 0195 FRANCE Dresser Produits Industrials 4 Place de Saverne 92971 Coabevoie Telephone 33 1 49 04 9000 Fax 33 1 49 04 9020 GERMANY Dresser Valve Europe Klein Kollenburg Strasse 78 80 Box 1208 47871 Willich Germany Telephone 49 2156 91890 Fax 49 2156 41058 ITALY Dresser Italia S p A Masoneilan Operation Via Cassano 77 P O Box 123 80020 Casavatore Naples Italy Telephone 39 81 789 2111 Fax 39 81 789 2259 JAPAN Nigata Masoneilan Co Ltd Dresser Valve Division 20th Floor Marive East Tower WBG 2 6 Nakase Mihama Ku Chiba shi Chiba 261 7120 Japan Telephone 81 43 297 9222 Fax 81 43 299 1115 KOREA Dresser Korea Inc 2107 Dong Building 60 1 3 Ka Choongmu ro Chung Ku Seoul Korea Telephone 82 2 274 0792 Fax 82 2 274 0794 DRESSER MALAYSIA Dresser Valve Division Far East Regional Office Business Suite 19A 9 1 Level 9 UOA Centre No 19 Jalan Pinang 50450 Kuala Lumpur West Malaysia Te
43. er to the pilot base Remove and discard the O ring and Teflon seal from the Bonnet adapter 5B For dirty service option remove the yoke or bonnet remove the dirty service insert and throw away the o ring Remove the insert assembly from the dirty insert using procedure in step 7 6 Remove main piston from the base 38 Con 29 7 Remove Insert Assembly from the top of the base with tool 4995401 See Section XXVI for construction drawing Remove and discard the O Ring on the bottom of the insert Disassemble Insert Assembly by remov ing Insert Bottom from the Insert Top Discard Teflon seal 8 Loosen the Adjuster Plug Lock Nut 9 Turn the Adjuster Plug to the right and count the number of Flats until the Adjuster Plug stops against the Pilot Valve Base Record the number of flats of adjustment for use when reassembling the pilot 10 Remove Adjuster Plug Cap from the bottom of the base 11 Loosen Adjuster Plug Lock Nut 12 Remove Adjuster Assembly from the base Remove both O Rings from Adjuster Assembly and discard Disassemble Adjuster Top from the Adjuster Bottom Discard Teflon seal C Disassembly of the Field Test Connection 1 Remove Shuttle Plug from the Field Test Connector DANGER 2 Remove and discard O Rings ball and filter D Cleaning Parts are to be free of any oil or grease except for lubrication as specified in this instruction Cleaning agents used shall be such that effect
44. ever is greater above set point It should be less than 40 BPM 28 Slowly drop inlet pressure to note the closing point 29 Final Test of Modulator Remove pipe plug on flat modulator surface of main base Check to verify that no Teflon tape has been left in vent port or the port above it 30 Place two small modulator O Rings into grooves on flat surface of main pilot 31 Attach modulator to main base with two hollow head cap screws with 95 in Ibs 10 in Ibs of torque 32 Re pop pilot five times then check for the following 33 Do not re adjust compression screw or adjuster 34 Pilot should be tight O Bubbles Per Minute up to 496 below set pressure or 2 psig whichever is greater 35 Pilot should be tight O Bubbles Per Minute at 1096 above set pressure or 3 psig whichever is greater 36 When set pressure is above or equal to 75 psig at 1096 over pressure or 3 psig whichever is greater the dome pressure should drop to the following level GAS 45 to 60 of S P LIQUID 15 TO 35 OF S P 37 When set pressure is below 75 psig at 1096 over pressure the dome pressure should drop to the following level GAS 0 to 60 of S P LIQUID 0 to 35 of S P 50 Con 29 4 Final Set Pressure Adjustment Once the pilot valve set pressure and blowdown are calibrated on the pilot valve calibration stand and the pilot valve is installed on the main valve increase the pressure on the main valve and check to see that
45. f pressure in the equipment to be pro tected and the pressure at the relief valve inlet exceeds 396 the sensing line to the pilot valve should be connected directly to the equipment being protected The optional sensing ring should not be installed For remote sensing 3 8 inch diam eter tubing is adequate for distances up to 10 feet 3 048 m For block valve and other special installation features consult API 520 or the fac tory SECTION IX General Introduction A pilot operated pressure relief valve is a pressure relief valve in which the major relieving device is combined with and is controlled by a self actuated auxiliary pressure relief valve Source ASME Code Section VIII Div 1 Paragraph UG 126 The CONSOLIDATED Modular Pilot Valve MPV is designed to provide reliable performance characteristics and stable operation within a pressure range of 15 to 3750 psig Con 29 SECTION IX A Pilot Valve Introduction Standard pilot construction consists of 316SS parts with nitrile o rings with Teflon based seals throughout Standard Steam and High Temperature Pilot Construction consists of 316SS parts with Teflon o rings and seals Alternate materials can be provided by contacting the factory Pilot Valve Features One pilot fits all main valves Reduces icing and clogging Standard o ring seals Field test connection Superior seat tightness Remote sensing Accurate adjustment of blowdown and set point Ex
46. flow at an authorized percent overpressure permitted by the applic able code Rated capacity is generally expressed in pounds per hour Ib hr for vapors standard cubic feet per minute SCFM or m min for gases and in gallons per minute GPM for liquids 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 BACK PRESSURE pressure on the discharge side of a pressure relief valve distinguished as follows 1 Superimposed Back Pressure which occurs prior to valve opening a Constant consistent back pressure on the outlet e g 20 psig b Variable fluctuating back pressure e g 0 to 35 psig 2 Built up back pressure which occurs as or after the valve opens e g builds to 25 psig Con 29 71 Sales Offices UNITED STATES Dresser Flow Control Dresser Inc LA Hwy 3225 9 U S Hwy 167 N P O Box 1430 Alexandria Louisiana 71309 1430 Telephone 1 318 640 2250 Fax 1 318 640 6222 Northern Region Dresser Flow Control Dresser Inc 85 Bodwell Street Avon Massachusetts 02322 Telephone 1 508 586 4600 Fax 1 508 941 5497 Southern Region Dresser Flow Control Dresser Inc 11100 West Airport Blvd Stafford TX 77477 3014 Telephone 1 281 568 2211 Fax 1 281 568 6731 BRAZIL Dresser Industria E Comercio Ltda Rua Senador Verqueiro 433 09521 320 Sao Caetano Do Sul Sao Paulo Brazil Tel
47. gnifiers are available through Industrial Machinists Supplies MEASURING MAGNIFIER NOZZLE FIGURE 18 Con 29 29 STANDARD METAL SEAT DESIGNS APPROXIMATE NOZZLE SEAT WIDTH VALVE SET PRESSURE PSIG LAPPED SEAT WIDTH IN 2900D G 15 50 012 51 100 018 101 250 025 251 400 032 401 800 038 801 038 2900 H J 019 025 029 032 038 ADD 005 PER 100 LBS 2900 N 025 030 035 040 045 ADD 005 PER 100 LBS 2900 P R 2900 T 15 50 51 100 101 250 251 250 2900 V 15 50 51 100 101 250 251 250 2900 W 15 50 51 100 101 250 251 250 NOT EXCEED 070 005 IN TABLE 6 Con 29 THERMODISC DESIGN APPROXIMATE NOZZLE SEAT WIDTH VALVE SET PRESSURE PSIG LAPPED SEAT WIDTH IN 2900D F 020 030 035 045 045 055 FULL WIDTH 2900 G J 020 030 035 045 045 055 FULL WIDTH 2900 K N 035 045 045 055 055 065 FULL WIDTH 2900 P R 040 050 050 065 060 070 FULL WIDTH 2900 T 15 100 050 065 101 300 060 075 2900 V 15 100 075 100 101 300 095 130 2900 W 15 100 100 125 101 300 120 160 TABLE 7 C Precautions and Hints for Lapping Seats The following precautions and hints will enable maintenance personnel to do a professional job of lapping sets 1 2 Keep work materials clean Always use fresh lap If signs of wearing out of flatness are evident reconditi
48. ide diameter for any scratches that might prevent the O Ring from sealing 3 Modulator Piston Bottom Galling or excessive wear on the outside diameter that rubs against the modulator base Make sure that the lip holding the O Ring for the seat is not deformed Also check the outside diame ter of the O Ring groove for scratches that might cause the O Ring not to seal Check for any corrosion or pit ting 4 Modulator Piston Top Galling or excessive wear on the outside diameter that rubs against the modulator base Check for any corrosion or pitting 5 Modulator Base Galling or excessive wear on any inside diameter Any corrosion or pitting 6 If any damage listed above is present the part should be replaced or repaired per instruction Other valve parts may be acceptable with light corrosion pitting or minor damage of other types if it can be determined that it will not affect product performance All O Rings and seals should be replaced each time the valve is disas sembled Refer to Tables 14 through 28 for a list of Parts and O Ring repair kits Recommended spare parts are listed in Table 12 40 Con 29 SECTION XIX Pilot Valve Lubrication 1 Lightly lubricate all O Rings except Silicone O Rings with Silicone Grease as provided in the kit 2 Lubricate and Seal pipe threads with a Teflon thread compound such as Dresser SP 364 AB pipe sealant or Teflon tape 3 Lubricate standard threads and bearing points
49. ing should be done with a figure eight motion as indicated in Figure 19 To assure the best results when lapping seats the ring laps should be reconditioned after each usage and checked with an optical flat FIGURE 19 32 Con 29 F Machining Nozzle Seats The nozzle should be removed from the valve to be machined see NOZZLE Figure 20 See Nozzle Removal Instructions in Section XIV B and sD Figures 12 and 13 If it can not be removed from the base it should be machined inside the base 1 Lathe Set Up Nozzle Removed CHUCK JAW a Grip the nozzle in a four jaw independent chuck using a piece of soft material such as copper or fiber between the jaws and the nozzle as shown at A in Figure 20 FIGURE 20 b True up the nozzle so that the surfaces marked B C and D run true within 001 on indicator 2 Machining Procedure Metal to Metal Seat See Figure 14A a Take light cuts across the surface L at 5 until the damaged areas are removed See Figure 15 Turn to the smoothest possible finish b Cut back the outside surface at G until dimension N is obtained The surface at G is common to all nozzles except the D 1 Omit this step on the D 1 orifice nozzles c Machine bore diameter H until dimension E is obtained Re establish angle P d The nozzle is now ready for lapping e When the minimum dimension D is reached the nozzle should be replaced 3 Machining Procedure O Ring Seat Seal See Figure
50. ingful replacement parts plan A The total number of valves in service should be classified by size type and temperature class B The parts inventory should be classified by the tendency to require replacement Class Most frequently replaced Class Less frequently replaced but critical in an emergency C Parts for the valve types covered by this manu al are classified on Table 12 Qty parts is the num ber of parts or sets which is recommended to achieve a desired need probability as it relates to the total number of valves in service by size and type For example a Qty parts of 1 for Valves in service of 5 means that 1 part should be stocked for each 5 valves of the same type and size in service D When ordering replacement parts please spec ify in accordance with applicable nomenclature see Figures 6 7 or 8 Be sure to state the size type and serial number of the valve for which parts are required When ordering pilot parts please state specific pilot type 39 07 37 etc For ease of maintenance O Ring kits are avail able for each main valve and pilot type A stock of these kits should be kept on hand for maximum operating efficiency See Section XXVII B Identification and Ordering Essentials Identification and Ordering Essentials When ordering service parts please furnish the fol lowing information to ensure receiving the correct replacement parts Con 29 Identify valve by
51. ive cleaning is assured without injuring the surface finishes or material properties of the part Follow recommendations for safe handling in the Acceptable cleaning agents include demineralized water non phosphate deter solvent s Material Safety gent acetone and isopropyl alcohol Parts must be blown dry or wiped dry after Data Sheet and observe safe practices for any cleaning cleaning method If you are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations and equipment SECTION XVIII Inspection and Part Replacement A Pilot Valve Parts Inspection After the pilot valve has been disassembled all parts should be given a visual inspection Some key areas to check with the boundaries for reworking parts are listed below 1 Main Pilot Valve Piston Galling or excessive wear on the small diameter end where it engages the seals or on the spherical bearing surface Any corrosion or pitting The part can be polished as long as the outside diameter of the stem remains at 0 243 001 inches The stem itself must have TIR of 0 001 inches along its length Con 29 39 2 Insert Top Galling or excessive wear on the inside diameter that guides the Piston Check any cor rosion or pitting Also check for galling of threads 3 Insert Bottom G
52. lephone 60 3 2163 2322 Fax 60 3 2163 6312 MEXICO Dresser Valve de Mexico S A de C V Av Henry Ford No 114 Esq Fulton Fraccionamiento Ind San Nicholas 54030 Tlalnepantla Estado de Mexico Telephone 52 5 310 9863 Fax 52 5 310 5584 SAUDI ARABIA Dresser Al Rushaid Valve amp Instrument Co Ltd Box 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 Valve Division 16 Tuas Ave 8 Singapore 639231 Telephone 65 861 6100 Fax 65 861 7172 SOUTH AFRICA Dresser Limited South Africa Branch Valve Division P O Box 2234 16 Edendale Road Eastleigh Edenvale 1610 Republic of South Africa Telephone 27 11 452 1550 Fax 27 11 452 2903 Dresser Valve Division Plot 90 Ajose Adeogun Street Victoria Island Lagoe Lagos Nigeria Telephone 23 41 2620765 Fax 23 41 2620768 SPAIN Dresser Valve Division Masoneilan S A C Murcia 39 C 08830 Sant Boi de Barcelona Spain Telephone 34 93 652 6430 Fax 34 93 652 6444 UNITED ARAB EMIRATES Dresser Valve Division Middle East Operations P O Box 61302 Jebel Ali Free Zone United Arab Emirates Courier Units Nos JA01 JA02 Roundabout 8 Jebel Ali Free Zone United Arab Emirates Telephone 971 4 838752 Fax 971 4 838038 UNITED KINGDOM DI UK Ltd Unit 4 Suite 1 1 Nobel House Grand Union Office Park Packet Boat Ln
53. m in the field it is possible to adjust the blowdown as well as the set pressure as indicated in the field testing Section XXII B If the valve has been removed from the installation for servicing an extra precaution should be taken to prevent an artificial indication of a long blowdown There is a maximum time delay of about 4 of a second as the plow of pressure from the dome flows through the tubing that connects the pilot and it to the Main Valve The greater the dome volume the more time it takes for the evacuation of the dome Like wise the reverse is true when the valve is closing It take time for the system pressure to flow through the sensing line to fill up the dome and close the valve During this period of time the main valve is open and dis charging pressure from the test vessel The test vessel is still decreasing in pressure while Dome pressure builds up to close the valve The pressure gauge measuring the pressure in the test vessel after the valve has closed shows an artificially long blowdown DO NOT ATTEMPT TO SET THE BLOWDOWN ON A 2900 SERIES POSRV IF THE PILOT VALVE DOME CON NECTION IS CONNECTED TO THE MAIN VALVE DOME AND THE VALVE IS TO BE TESTED ON A SHOP TEST STAND ATTEMPTING TO REDUCE BLOWDOWN IN THIS TEST SITUATION WILL RESULT IN RAPID CYCLING OF THE MAIN VALVE UNDER NORMAL OPERATING CONDITIONS The 2900 Series Pilot Operated Pressure Relief Valve may be tested for set pressure as follows 1 The first is to calibr
54. n product or property damage Know all valve exhaust leakage points to avoid possible severe personal injury or death WARNING Hazards or unsafe prac tices which COULD result in severe personal injury or death Wear necessary protective equipment to prevent possible injury CAUTION Hazards or unsafe practices which COULD result in minor personal injury Con 29 SECTION Iil Product Safety Sign and Label System If and when required appropriate safety labels have been included in the rectan gular 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 border The panels can contain four mes sages which communicate level of hazard seriousness nature of the hazard The consequence of human or product interaction with the hazard instructions if necessary on how to avoid the hazard Do not remove bolts if pressure in line as this will result in severe personal injury or death DANGER Immediate hazards which WILL result in severe personal injury or death The top panel of the format con tains a signal word DANGER WARNING CAUTION or ATTEN TION which communicates the level of hazard seriousness The center panel contains a pictor ial which communicates the nature of the hazard and the
55. ner Spring Seal Piston Bottom 1 Lock screw gt Spring Seal Piston Top 1 Small modulator O Ring Modulator Base Modulator Stop Modulator Piston Top 1 Teflon inlet seal 1 Teflon balance seal SIS Modulator Piston Bottom 1 Medium modulator O Ring O Ring Retainer j Lock Screw Install Teflon inlet seal into groove on modulator pis LKA Cap Screw Modulator ton top Be sure to have the spring in the seal facing up top Steam service requires a liquid modulator FIGURE 24 3 Install the piston seat O Ring into groove on modu lator piston bottom 4 Turn modulator piston bottom over and place small modulator piston O Ring into inner groove 5 Install spring energized Teflon seal onto modulator piston bottom in outer groove Make sure spring opening is facing down 6 Insert modulator piston top into modulator piston bottom through the side with the small modulator O Ring and the Teflon balance seal 7 Turn assembly over and install O Ring retainer The chamfered outside diameter goes in first 8 Lubricate and thread lock screw through O Ring retainer into modulator piston top Tighten 40 in Ibs 5 in Ibs 9 Lubricate Teflon seals before inserting into modulator base NOTE Make sure that the proper service is stamped on the top of the modulator base and it matches what is stamped on modulator piston top 10 11 12 44 Insert modulator piston assembly into modulator base
56. ner are to be lightly ground together during the assembly process to minimize leakage in the event of a O ring failure After assembling the reconditioned Nozzle in to the base according to instruction in Section XVI place a small amount of 1000 grit lapping compound on the 45 angled surface Then for the D J orifice fasten the o ring retainer without installing the o ring into Disc Holder and placing into the guide Install the guide and Disc Holder together in the valve base and gently allow the Disc Holder and retainer to come in contact with the nozzle Turn the Disc Holder within the Guide 15 to 20 rotations and remove disassemble and clean lapping compound from the Nozzle Disc Holder and O ring Retainer For ori fices K and larger the process does not require assembling the nozzle in to the base and it does not require the use of the Disc Holder Assemble the O ring retainer into the O ring Disc and placing a small amount of 1000 grit Lapping Compound on the 45 angled surface of the nozzle place the disc and retainer on the nozzle lightly grind the o ring retainer into the nozzle About 15 to 20 rotations are recommended to establish full contact between the O ring retainer and the nozzle Remove the retainer screw s and retainer and thoroughly clean the retainer retainer screws and disc holder or disc E Reconditioning of Laps LAPPING PLATE pier RING LAP Ring laps are reconditioned by lapping them on a flat lapping plate The lapp
57. ng 531607310124 Tubing is sold in 4 foot sections 2916 requires high pressure tubing TABLE 28 Con 29 SECTION XXVIII Manufacturer s Field Service Repair and Training Program A Field Service Utilities and Process Industries expect and demand service on a moment s notice CONSOLIDATED Field Service can be depended upon for prompt response even in extreme off hour emergency situations Dresser Inc maintains the largest and most competent field service staff in the Industry Service Engineers are located at strategic points throughout the United State to respond to customer s requirements for service Each Service Engineer is factory trained and long experienced in servicing Safety Valves Dresser Service Engineers restore disc and nozzle critical dimensions which affect valve performance and are capable of modernizing valves in the field It is highly recommended that the professional talents of a Dresser Inc Field Service Engineer be employed to make final field adjustments during the initial setting of all CONSOLIDATED POSRV s All Field Service Engineer s activities are coordinated from the Alexandria Louisiana Field Service Office Upon receipt of a purchase order number authorizing the trip the service engineer is dispatched Contact Field Service Dept Field Service Supervisor 318 640 6055 B Factory Repair Facilities The factory at Alexandria Louisiana maintains a CONSOLIDATED Repair Center The Repair Depar
58. ning the main valve See Figure 30 When open the manual blowdown valve reduces the pressure above the main valve Know all valve disc head allowing the main valve to open Con 29 exhaust leakage points to avoid possible severe personal injury or death th mn B TE T CANISTER LH FILTER jir 1 u T s Lau le re l i 1 1 F3 FT XXL SENSING 1 RING SENSING amp TUBE m PIPE TO 1 SYSTEM l I PRESSURE I OPTIONAL CONNECT TO FIELD TEST CONNECTOR TO ESTABLISH SYSTEM PRESSURE IN PILOT FIGURE 29 ncm EEE DOME LINE FIELD j TEST MANUAL n IR BLOWDOWN r T EP E 1 ml ber 1 mL cam SENSING gt mE LINE N n SENSING Bi RING us Lm SENSING 1 s TUBE NE H gt pe 1 T PIPE TO SYSTEM PHESSUHE OPTIONAL CONNECT TO FIELD TEST CONNECTOR TO ESTABLISH SYSTEM PRESSURE IN PILOT MANUAL BLOWDOWN FIGURE 30 55 E Auxiliary Canister and Dirty Service Option REGULATOR CANTER Si Ehe roan e TOC MEDIA SOURCE TO DIRTY L cx MEDIA SOURCE SENSING 1 RING 2 1 SENSING r3 r TUBE d1 OPTIONAL CONNECT TO FIELD TEST CONNECTOR TO ESTABLISH SYSTEM PRESSURE IN PILOT FIGURE 31
59. nstructions 29 A General Maintenance Information 29 B Nozzle Seat Width Lapped 29 C Precautions and hints for Lapping Seats 31 D Grinding O ring Metal seating surfaces 32 E Hecoriditiobihng des esu 32 F Machining Nozzle DOSE d uae oum OE EE ERREUR E EET 33 Ge Lapping i DISC u 34 H Machining the Disc 34 k BoVerplate eur ass ee ye 34 Ji Bearing Point 2 i arbo RU ER ass ripa e En sa Eres acids 34 Assembly of 2900 Main 35 MM 6 91 9 pa ire Siete A E 35 Specifi Steps Ta pha tha a piqa PN a 35 Disassembly of the 9 38 A Removal and Disassembly of the Liquid or Gas Modulator 38 B Disassembly of the 39 MPV Pilot Valve 38 C Disassembly of the Field Test Connection 39 Doe GIG a A EM 39 Inspection and Part 39 A Pilot Valve Parts 39 Field Test Connection Parts Inspection 40 C Modulator Parts Insp
60. on the base Only turn adjuster when there is less than 125 psig in dome Long Blowdown Turn adjuster out Pilot flowing and dome not dropping at 196 or 1 psig over pressure whichever is greater Turn adjuster in Adjusting Blowdown Lower inlet pressure so that inlet and dome pressures are equal approximately 9096 of Set Pressure Slowly increase pressure to note the set point Increase inlet pressure to 196 or 1 psig above set point whichever is greater and hold for a couple of seconds to make sure dome pressure is dropping If dome pressure is dropping continue to increase to 1096 over pres sure or 3 psig whichever is greater Dome pressure should drop to 0 psig If dome pressure is not dropping adjust as noted in 16 Slowly drop inlet pressure to note the closing point Use the following guidelines when setting blowdown For Gas Service S P is 15 to 75 psig 0 to 1 5 psig blowdown S P is 76 to 750 psig 096 to 2 blowdown S P is 751 to 3750 psig 096 to 396 blowdown For Liquid Service S P is 15 to 30 psig 1 to 3 psig blowdown S P is 31 to 75 psig 2 to 4 psig blowdown S P is 76 to 3750 psig 396 to 6 blowdown If blowdown adjustments are necessary increase inlet pressure to release dome pressure to less than 125 psig Make adjustments as noted in 14 or 15 and retest beginning with 16 If adjustments are not necessary continue with 20 Adjust compression screw for set pressure without modulator att
61. on the lap Apply a very thin layer of compound to the lap This will prevent rounding off the edges of the seat Keep the lap squarely on the flat surface and avoid any tendency to rock the lap which causes rounding of the seat Con 29 31 5 When lapping keep a firm grip on the part to prevent the possibility of dropping it and damaging the seat 6 Lap using eccentric or figure eight motion in all directions at the same time applying uniform pressure and rotating the lap slowly See Paragraph G for further information 7 Replace the compound frequently after wiping off the old compound and apply more pressure to speed the cutting action of the compound 8 To check the seating surfaces remove all compound from both the seat and the lap Then shine the seat with the same lap using the lapping motion described above Low sections on the seating surface will show up as a shadow in contrast to the shiny portion If shadows are present further lapping is necessary and only laps known to be flat should now be used Only a few minutes will be required to remove the shadows 9 When the lapping is completed any lines appearing as cross scratches can be removed by rotating the lap which has been wiped clean of compound on the seat about its own axis 10 The seat should now be thoroughly cleaned using a lint free cloth and a cleansing fluid D Grinding O Ring Metal Seating Surfaces The contact surfaces of the nozzle and O ring Retai
62. pressure is greater Main Valve opens and allows the discharge media to flow back into the pressure ves sel B Blowdown incorrect Leakage around fittings Leakage under the cover plate when valve is open Main valve leaks through the A seat high O ring or seal degradation than the set pressure and forces the main disc up and the media flows back ward into the vessel Discharging into a closed container or not enough capacity in the discharge system Incorrect Adjuster Plug Setting Fittings are not tightened or are cross threaded Guide or coverplate gasket A is damaged Cap screws or stud nuts on coverplate are loose Damaged seat O Ring Damaged metal seat TABLE 11 orrective Action Readjust the set pressure valve of the valve Slowly increase the inlet pressure Re install the sensing tube correctly Clear or replace Adjust operating pressure Disassemble and replace O Ring or seals Install backflow preventer Install backflow preventer Re set Adjuster Plug See Pilot Valve Settings Re install fittings correctly Disassemble valve and replace gasket Tighten as required Disassemble valve and replace O Ring Disassemble valve and replace seating surfacer Con 29 SECTION XXV Replacement Parts Planning A Basic Guidelines The following guidelines should be of assistance in developing a mean
63. rational Description MV VALVE CLOSED Normal Position System pressure from the main valve inlet is fed to the dome by the pilot through interconnecting tubing This equalizes the pressure on the top of the piston with inlet pressure on the seating surface bottom of the disc Since the area of the top of the piston is larger than the area of the seating surface the differential area results in a net downward force keeping the main valve tightly closed Con 29 SHOWN 90 OUT OF POSITION FIGURE 4 15 SECTION Continued MV VALVE MODULATING Partial Relieving Position As inlet pressure increases the pilot piston strokes and seals off the main valve inlet pressure from the dome pres sure The pilot simultaneously opens the vent seal to relieve the dome pressure to the bottom of the modulator pis ton The modulator piston has a differential area with the smaller area being on top of the modulator piston The top of this piston always sees the main valve inlet pressure When the dome pressure is applied to the bottom of the modulator piston there is a net upward force This is due to both pressures being equal at this point and the lower area is larger than the upper area The modulator relieves the pressure from the dome to the atmosphere until force from the inlet pressure on top of the modulator pis ton is sufficient to move it to the closed position A certain amount of pressure remains in the dome This p
64. reater OPERATING AND SET PRESSURE DIFFERENTIAL valves in process service will generally give best results if the operating pressure does not exceed 90 of the set pressure On pump and compressor discharge lines however the differential required between the operating and set pres sures 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 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 pri mary pressure safety relief valve is set to open ACCUMULATION pressure increase over the maximum allowable working pressure of the vessel during discharge through the pres sure relief valve expressed as a percentage of that pressure or pounds per square inch 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
65. ressure is controlled by the differen tial area in the modulator Since the dome pressure has not been dropped to atmospheric pressure the main valve only partially opens at the set point The modulator piston will remain closed until the main valve disc is forced into higher lift by increasing inlet pressure As this occurs the modulator piston may relieve further pressure from the dome as necessary to achieve the required main disc lift within 1096 overpressure MV FULLY OPEN Full Relieving Position As the inlet pressure increases fur ther the net upward force on the main valve disc increases allowing the main valve to relieve more pres sure The disc obtains full lift full capacity within 1096 of set pressure SHOWN 90 OUT OF POSITION When the discharging valve reduces the inlet pressure to the pre set blow down pressure of the pilot the pilot piston closes the vent seal Simultaneously the inlet seal is reopened in the pilot The main valve inlet pressure is again allowed to enter the dome above the main valve piston As the dome pressure equal izes with the inlet pressure the downward force created by the differ ential areas of the piston and disc closes the main valve FIGURE 5 16 Con 29 Section Cross Sectional Drawings and Nomenclature SECTION 39PV Pilot Valve Cross Sectional Drawings and Nomenclature REF NO NOMENCLATURE MAIN BASE ADJUSTER CAP ADJUSTER T
66. sc may not be machined and must be replaced Note A dimension on D through H orifices is difficult to measure If you cannot measure the 006 min imum thickness of the thermal lip replace the Thermodisc 4 2900 2900 30 Disc Holder should be replaced if the sliding surface of the Holder is galled pitted or scratched 5 2900 2900 30 Guide should be replaced if the sliding surface is galled pitted or scratched or the machined gasket surfaces are damaged 6 Solid Metal Gaskets may be re used unless they are corroded pitted or crimped 7 The Coverplate should be reused if a The sliding surface in the dome area is not galled scratched corroded or pitted b The Gasket surface is not scratched corroded or pitted 8 The Piston should be re used if there is no indication of galling scratched corroded or pitted on any surface of the piston TABLE 4 IZE Thermodisc Thermodisc Design J W Orifices D H Orifices FIGURE 16 28 Con 29 SECTION XV Maintenance Instructions A General Maintenance Information After the valve has been disassembled a close inspection should be made of the seating surfaces In a majority of cases a simple lapping of seats is all that is nec essary to put the valve in first class working order If an inspection of the parts shows the valve seating surfaces to be badly damaged machining will be required before lapping O Ring seat seal valve nozzles can only be reconditioned
67. set pressure is within the popping pressure tolerance allowed for the set pressure of the valve The Compression Screw may be adjusted to fine tune the Set Pressure if necessary NOTE The blowdown cannot be successfully adjusted in the shop when the pilot valve is installed on the main valve The pilot valve must be set on the pilot valve calibration stand A 5 Seat Tightness and Leakage Test After the set point and blowdown have been set the valve must be checked for seat tightness Pressurize the valve to 96 or within two psig of set pressure whichever is greater Use a bubble cup filled with water to check for leakage Check all fittings and ports for leakage B Testing on Installation DANGER Field testing may be used to verify the valve opening point repaired valves or to periodically check the function of valves in service A test set up similar to that shown in Figure 27 should be used The set pressure of the 2900 series is defined as the pressure at which the main valve opens The following table indicates the allowable set pressure tolerances according to the ASME Boiler and Pressure Vessel Code Required Set Point Tolerance 15 70 psig 2 psig Do not stand or place 1 05 4 92 kg cm 14 kg cm hand In front of inis 71 psig and greater 4 99 kg cm 3 of the set pressure discharge flange if valve is under pressure 1 Loosen and remove the tubing connecting the pilot valve an
68. sion screw into top of yoke until the bearing point begins to protrude through yoke 25 Place spring washers on the ends of the spring 26 Place spring and spring washer assembly into the yoke and on top of main piston Hold this assembly in place while turning compression screw down to the top spring washer 27 Tighten compression screw and locknut hand tight 28 The pilot valve is ready to be calibrated prior to assembly on the main valve B Assembly of Field Test Connector Field Test Connection 1 Install shuttle seat O Ring into shuttle base 2 Install tube filter into shuttle base 3 Drop ball into tube filter 4 Install shuttle new seat O Ring into shuttle plug 5 Install shuttle new plug O Ring over threads on shuttle plug 6 Place new tube filter and ball in shuttle base 7 Lubricate and thread Shuttle Plug into Shuttle Base and tighten to en dd 350 in Ibs 35 in Ibs f R Shuttle Base Shuttle Plug Tube Filter 8 The field test connector is ready for test on 39MPV FIGURE 23 Con 29 43 1 2 NOTE sure that the proper service gas or liq uid is stamped on the top of the modulator piston Gas or Liquid Modulator Assembly Making the modulator piston assembly HERTEN This assembly consists of 38 NOMENCLATURE 1 Modulator piston top O Ring Modulator Stop O Ring Modulator Seat 1 Modulator piston bottom O Ring Modulator Piston 1 O Ring retai
69. ss when the pilot main valve assembly is tested together NOTE The in line accumulator must be at least 1 2 cubic foot 14 liters in volume NOTE A suitable dome simulator may be made out of a short length of stainless steel tubing tubing fittings and a suitable pressure gauge The dome simulator will increase in pressure as the pilot valve inlet increases in pressure Set pressure is indicated when the dome simulator pressure gauge drops off in pressure As inlet pressure is decreased in the pilot valve to 95 of the set pressure or 3 psig 21 kg cm whichever is greater the dome simulator should show an increase in pressure to match the inlet pressure Con 29 47 A1 Pilot Calibration and Test Procedure NOTE The pilot should be adjusted for both set point and blowdown on a suitable test stand prior to mounting on a main valve 1 Mount the pilot on the stand 2 Connect dome chamber to pilot 3 Connect sensing line to pilot inlet A2 Definitions 1 Set Point Point where vent pressure is felt from port 2 Closing Point Point where dome pressure begins to reload 3 Blowdown Set point minus closing point 4 Notch Any peak or valley on bottom of main pilot which is used for adjustment A3 Specific Steps 1 Pre setting the Blowdown Remove Adjuster Cap and install NPT pipe plug into top hole on flat surface of pilot 2 Turn Adjuster into base until it stops Turn out 1 turn 3 Adjust compression screw un
70. ster Top g Remove the insertion tool leaving the seal in the Adjuster Top with the energizer spring oriented toward the four small holes in the Adjuster Top Note Do not install adjuster assembly into main base with O Rings installed without wrench tightening adjuster top and adjuster bottom together Adjuster top can get stuck in base Con 29 41 8 9 10 Cycle piston through Teflon seat seal the Adjuster Plug top 10 times Lightly lubricate both O Rings Install assembly into base with the adjuster top going in first Rotate the assem bly at the same time as it is being inserted until the threads are engaged This helps the O Rings get by the chamfers and holes Continue to thread adjuster assembly into base until it stops Do not tighten Thread adjuster lock nut on to adjuster plug Hand tighten Lock nut Thread adjuster cap onto adjuster assembly Hand tighten NOTE Make sure cap threads freely on adjuster bottom 11 12 13 14 15 16 17 18 19 20 21 42 Making the insert assembly This assembly consists of 1 Insert top 1 Insert bottom 1 Teflon seat seal 2 Small main o ring Press Teflon seat seal into groove on the insert bottom Make sure spring is facing upwards Install insert top over insert bottom with the seal side going in first Lightly lubricate O Ring groove now formed by the two insert parts This lubrication is used to hold the O Ring
71. ternal blowdown adjustments Positive closure after blowdown Service and Applications Model Service Pressure Range Temperature Range 39 07 Gas Air Steam 15 psig to 750 psig 40 F to 505 F GS SS or Liquid 1 05 kg cm to 52 7 40 C to 262 C or LS kg cm 39 07 Gas Air or 15 psig to 750 psig 40 F to 505 F GS or SS Steam 1 05 kg cm to 52 7 40 C to 262 kg cm 39MVO07 Liquid 15 psig to 750 psig 40 F to 505 F LS 1 05 kg cm to 52 7 40 C to 262 C kg cm 39PV37 Gas Air Steam 751 psig to 3750 psig 40 F to 505 F GS SS or Liquid 52 8 kg cm to 263 6 40 C to 262 C or LS kg cm 39MV37 Gas Air or 751 psig to 3750 psig 40 F to 505 F GS or SS Steam 52 8 kg cm to 263 6 40 C to 262 C kg cm 39MV37 Liquid 751 psig to 3750 psig 40 F to 505 F LS 52 8 kg cm to 263 6 40 C to 262 C kg cm TABLE Note With the installation of the heat exchanger temperature range may be expanded to 450 F to 1200 F Main Valve pressure and temperature limitations are combined in pressure class categories according to ANSI Standards Conversely the pressure and temperature limits of the Pilot Valve are presented separately NOTE WHEN REPLACING OR REPAIRING THE MAIN VALVE AND PILOT VALVE ASSEMBLY PAY PARTICULAR ATTENTION TO THE PRESSURE AND TEMPERATURE LIMITATIONS FOR BOTH THE MAIN VALVE AND PILOT VALVE TO ENSURE COMPATIBILITY Con 29
72. the bottom of the coverplate 14 Install coverplate gasket Place the coverplate on the main valve base and replace the stud nuts Con 29 15 Torque to the values found in Table 9 using the torque patterns in Figure 22 and Table 10 16 Once the Main Valve is assembled before any tubing is connected reach through the hole in the center of the Coverplate and force the Piston down until it contacts the Disc Holder Failure to complete this proce dure will prevent the main valve from loading and closing when pressure is applied to the valve 17 The Main Valve is ready to receive the pilot and finished assembly 2912 2914 2016 2918 2020 2921 2922 2923 2924 2926 2026 FW usw ice eo eo e iss je e Le 15 io mo a ro Ts T La iso ise i 6 ea L e T TABLE 9B TABLE 10 Torque required for each round of pattern FIGURE 22 Con 29 37 SECTION XVII Disassembly of the 39MPV Pilot Valve A Removal and Disassembly of the Liquid or Gas Modulator 1 Remove the seal and seal wire 2 Remove socket head cap screws holding the modulator to the main pilot 3 Remove and discard the 2 O Rings between the modulator and the main pilot 4 Remove both cap screws from the bottom of modulator 5 Remove mod
73. the following nameplate data Size Type Pressure Temperature Class Rating Serial Numbers from both main valve and pilot valve com Example POSRV IDENTIFICATION NAMEPLATES 2 FOR MAIN VALVE CONSOLIDATED CERTIFIED ALEXANDRIA Flow Control LOUISIANA USA SERIAL NO SET PRESS PSI CDTP PSI BACK PRESS TEMP LBS HR STD CU FT SAT STEAM MIN AIR GPM STD CU 7 AP WATER MIN N G FIGURE 35 THIS VALVE CONTAINS TEFLON SEALS AND SEAT SEAL O RING PART NO FIGURE 36 NAMEPLATE FOR PILOT VALVE CONSOLIDATED DRESSERY ALEXANDRIA Flow Control LOUISIANA USA GEM PILOT VALVE 5 22 FIGURE 37 59 How to verify materials of O Rings and Seals Kit coding indicates O Ring and seals material Examples PSGK 38B018 B018 Buna N 70 B008 Buna N 90 PSGK 35V022 V022 Viton 75 V005 Viton 90 006 Teflon PSGK 32E019 E002 Ethylene Propylene E019 Propylene 70 Note For Kalrez material contact factory C Positive Identification of Main Valve and Pilot Valve Combinations POSRV s shipped direct from the factory to the end user probably have main valves and pilot valves with identical serial numbers S N s Those shipped unconnected to the Dresser Green Tag network may have main valves and pilot valves with different S N s During service and repair the following inspection steps will ensure the proper match of main valves to
74. til dome pressure stops increasing between 75 and 125 psig If set point is below 75 psig use any dome pressure between 15 and 75 psig NOTE If vent pressure is felt and dome pressure has not stopped drop inlet pressure until it is not felt and raise adjuster clockwise 1 flat 4 Raise inlet pressure 0 5 to 5 psig above pressure found in step 8 3 2 Keep in mind the blowdown that is required for the given set point NOTE If pilot vents continue with 5 5 With finger over vent port turn adjuster out slowly until the vent pressure is felt NOTE If pressures become equal while adjusting increase inlet pressure again until a differential pres sure occurs Continue 6 Lower inlet pressure until it equals dome pressure 7 Increase inlet pressure Dome pressure should have started dropping with 1 or 1 psig over pressure whichever is greater of the point the vent pressure was felt NOTE If dome pressure does not drop adjuster has been turned out too far Turn in raise 1 flat and repeat steps 3 through 7 8 Check pilot for leakage at 1096 or 5 psig below set point whichever is greater 9 Final Setting of Seals Adjust compression screw to approximately 10 of set point of pilot Final setting will be done later 48 Con 29 10 11 12 13 14 15 16 17 18 19 20 21 Make adjustments in 2 notches less Match any corner the square on the bottom of the adjuster to a notch
75. tions If a stop valve is located between the pressure vessel and pressure relief valve its port area should equal or exceed the nominal internal area of the piping to the relief valve inlet Pressure drop in the piping from the vessel to the relief valve must not exceed 3 of the valve set pres sure when it is flowing at full capacity Flanges and gasket surfaces must be free from dirt and debris when valves are installed Flange bolts should be tightened evenly to prevent distortion of the valve body and inlet nozzle The length size and maximum change in height of the remote sensing line should be verified through analysis taking into account the requirement to re charge the dome through the pilot valve On request Dresser will assist in the analysis to determine the appropriate length size and maximum change in height for the sensing line and to determine the correct capacity of the pressure relief valve Before start up be sure all threaded joints are tight and secure SECTION VIII Hydrostatic Testing Prior to hydrostatic test of the pressure vessel system the pilot operated safety relief valve should be removed and the mounting flange for the valve blocked Service Considerations For best performance pressure relief valves should be serviced annually unless maintenance history dictates otherwise They should be located for easy access and removal for service Remote Sensing If the pressure drop between the source o
76. tment in con junction with the manufacturing facilities is equipped to perform specialized repairs and product modifications e g butt weld bushing replacements code welding pilot replacement etc Contact Repair Dept Mgr Valve Repair 318 640 6057 Safety Relief Valve Maintenance Training Rising costs of maintenance and repair in the Utility and Process Industries indicate the need for trained mainte nance personnel Dresser Flow Control conducts service seminars that can help your maintenance and engineer ing personnel to reduce these costs Seminars conducted either at your site or at our Alexandria Louisiana manufacturing plant provide participants with an introduction to the basics of preventive maintenance necessary to minimize downtime reduce unplanned repairs and increase valve safety While these seminars do not make instant experts they do provide the partic ipants with Hands On experience with CONSOLIDATED Valves The seminar also includes valve terminology 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 6041 or telephone 318 640 6054 Con 29 69 SECTION XXIX Glossary General PRESSURE RELIEF DEVICE a device designed to prevent internal fluid pressure from rising above a predetermined maximum pressure in a pressure vessel exposed to emergency or abnormal
77. ual BIloWdoWIXY siasa am 55 E Dirty Service with Auxiliary 56 F Heat Exchanger used on Cryogenic Service 56 Heat Exchanger used on Steam and Hot 57 H Optional Line Filter Standard with Steam Service 57 Assembly of Options and Alternative 0 58 Troubleshooting dte Spek He Pete tee ee 58 Replacement Parts Planning 59 A Basic Guidelines ee ae hha eek 59 B Identification and Ordering Essentials 59 C Positive Identification of Main Valve and Pilot Valve CIOTTID IG HOTIS arts see Seas DLL LO Aa 60 Recommended Spare lt 61 just rp 62 Insert Installation sua DERE 62 B Adjuster Seal Insertion 63 C Disc Holder and Guide Removal and Assembly 64 Replacement Parts 65 Manufacturer s Field Service Repair and Training Programs 69 Glossary Ol Tens e tree uu m E 70 Office Locations and Contacts 72 Con 29 A ATTENTION 4 Do not drop or strike ATTENTION Hazards or unsafe prac tices which COULD result i
78. ulator stop from modulator base This can be done by rotating the modulator stop enough to be able to push against the ears on the modulator base to remove the modulator stop 6 Remove both O Rings from modulator stop and discard 7 Remove modulator piston from the modulator base by hitting the base on a firm surface Make sure surface is clean so that when the piston comes out the seat does not hit any object that might damage it 8 Disassemble the modulator piston by removing the lock screw 9 Remove and discard both O Rings Be careful not to bend the lip enclosing medium modulator O Ring seat during removal of the O Ring 10 Discard both Teflon seals B Disassembly of the 39MPV Pilot Valve 1 Remove the compression screw cap 2 Measure and record compression screw height for later use when resetting 3 Loosen compression screw locknut 4 Turn compression screw counterclockwise to remove it from the yoke The spring spring washers and spring cover if present can now be removed 5 Remove the 4 cap screws holding the yoke to the base and remove the yoke Remove and discard the O Ring if present and the Teflon seal if present from the yoke 5A If the Pilot Valve has a Bonnet instead of a Yoke loosen the bonnet set screw then remove the Bonnet counterclockwise using a wrench on the wrenching flats near the top of the Bonnet Then remove the spring spring washers and the four cap screws that hold the bonnet adapt
79. valve by the pilot assem bly external devices or tubing Lift the valve by the eyebolts shown on figure safety sign STORAGE Pressure relief valves should be stored in a dry environment and protected from the weather They should not be removed from the skids or crates until immedi ately prior to installation on the system This includes both inlet and outlet protec tors FLANGE PROTECTORS Flange protectors and sealing plugs should not be removed until the valve is to be installed on the system This includes both inlet and outlet protectors Con 29 Always keep valve in an upright position when handling or storing Do not subject valves to sharp impact Never attempt to lift the valve by anything other than the eyebolts 10 Prevent dirt from entering outlet or inlet port Always install valve ina vertical upright position SECTION VII PRE INSTALLATION AND INSTALLATION CAUTION After the valve is uncrated and protective devices removed exercise care to prevent dirt and other foreign matter from entering either the inlet or the outlet port Mounting Instructions CAUTION Pressure relief valves should be mounted in a vertical upright posi tion Installing a valve in any other position will adversely affect its operation in varying degrees as a result of induced misalignment of parts No stop valve should be placed between the pressure vessel and its relief valve except as permitted by Code regula
80. ver Plate 3 Remove the piston from the Cover Plate using a dowel pressed through the center hole in the top of the Cover Plate 4 Remove the Cover Plate Gasket 5 Install the Disc Holder Removal tool in the top of the Disc Holder Use the tool indicated in Table 2 and Figure 9 On V and W Orifice Valves Thread two 5 8 11 NC Standard Eye Bolts into the top of the Disc Holder as shown in Figure 10 Disc Holder Removal Tool Toc Number 4464601 D through construction plans 4464602 H K and L 4464603 4464604 P Q R and T Supplied 5 8 11NC TABLE 2 2 LIFTING TOOL EYE BOLTS DISC HOLDER f DISC HOLDER GUIDE s GUIDE TOP OF BASE D THROUGH ORIFICE VALVES See Section XXVI V AND W ORIFICE VALVES FIGURE 9 FIGURE 10 6 Lift out and remove the Guide and Disc holder together 7 Remove the Lifting tool or Eye Bolts from the top of the Disc holder 8 Liftthe Guide off the Disc Holder If the valve has a bellows avoid damage to the gasket seating surfaces and if present the convolutions or the flange section of the Bellows 9 Using the Drift Pins as illustrated in Figure 11 remove the Disc from the Disc Holder Use care to avoid scar ring the bearing surface on the back of the Disc Con 29 23 DRIFT PIN 4 8 10 LONG ROD OR HEAVY PIPE LL BASE NOZZLE EPI JAW CHUCK LL cucs FIGURE 12 PIPE WRE

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Consolidated® - Allied Valve Inc.