Baker Hughes Consolidated 1982 Series Manual de usuario

Consolidated™

1982 Series

Safety Relief Valves

Instruction Manual (Rev. B)

Baker Hughes Data Classification : Public

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT

PROJECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/

OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE

OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BAKER HUGHES (AND

ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC

PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS

CREATED BY THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL

UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL

AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS.

THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED

IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT

THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER

EQUIPMENT AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS

IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET

IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD

FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE

WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S

PURPOSES THE MATTER SHOULD BE REFERRED TO BAKER HUGHES.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE

CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED

IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL

REPRESENTATIONS OR WARRANTIES BY BAKER HUGHES REGARDING THE

EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE

INSTRUCTIONS.

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY

TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE

OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED

IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.

NOTICE!

For any service questions not covered

in this manual, please contact your local

Green Tag™ Center (GTC).

Consolidated 1982 Series Safety Relief Valve Manual | c

All the USCS values are converted to

metric values using the following conversion factors:

USCS Units Conversion Factor Metric Unit

in. 25.4 mm

lb. 0.4535924 kg

in26.4516 cm2

ft3/min 0.02831685 m3/min

gal/min 3.785412 L/min

lb/hr 0.4535924 kg/hr

psig 0.06894757 barg

ft lb 1.3558181 Nm

°F 5/9 (°F-32) °C

Conversion Table

Note: Multiply USCS value with conversion factor to get metric value.

Table of Contents

I. Warranty Information ................................................1

II. Safety Notice .......................................................2

III. Product Safety Sign and Label System..................................3

IV. Safety Alerts .......................................................4

V. Handling and Storage ................................................6

VI. Pre-installation and Mounting .........................................6

VII. General Planning for Maintenance .....................................7

VIII. Terminology for Pressure Relief Valves .................................8

IX. Design Features and Nomenclature ....................................9

X. Introduction ........................................................9

IX. Consolidaed 1982 Series Safety Relief Valve ............................10

X. Disassembly.......................................................12

XI. Inspection and Part Replacement .....................................14

A. Base .........................................................................14

B. Disc Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

C. Disc Retainer ..................................................................15

D. Guide ........................................................................16

E. Adjusting Ring .................................................................16

F. Adjusting Screw ................................................................16

XII. Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

XIII. Setting and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

A. Setting and Testing after Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

B. Setting the Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

C. Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

D. ColdDi󰀨erentialSetPressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

E. Temperature Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

F. Seat Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

G. Hydrostatic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

H. Manual Popping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

XIV. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

XV. Maintenance Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

A. Lapping Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

B. Lap Resurfacing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C. Lapping Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

D. Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Consolidated 1982 Series Safety Relief Valve Manual | e

XVI. Replacement Parts Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Basic Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. IdenticationandOrderingEssentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

XVII. Genuine Consolidated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

XVIII. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

XIX. Manufacturer’s Service, Repair and Training Program ....................26

A. Field Service.................................................................. 26

B. Repair Facilities ............................................................... 26

C. Maintenance Training ........................................................... 26

I. Warranty Information

Removal or breakage

of seal will negate

our warranty.

Defective and

nonconforming items

must be inspected

by Baker Hughes

Warranty Statement

Warranty Statement(1) - Baker Hughes warrants that its products and services

will meet all applicable specifications and other specific product and service

requirements (including those of performance), if any, and will be free from

defects in material

and workmanship.

CAUTION: Defective and nonconforming items must be held for Baker

Hughes’sinspectionandreturnedtotheoriginalF.O.Bpointuponrequest.

Incorrect Selection or Misapplication of Products - Baker Hughes cannot be

responsible for customer’s incorrect selection or misapplication of our products.

Unauthorized Repair Work - Baker Hughes has not authorized any non-Baker

Hughes affiliated repair companies, contractors or individuals to perform

warranty repair service on new products or field repaired products of its

manufacture. Therefore customers contracting such repair services from

unauthorized sources must do at their own risk.

Unauthorized Removal of Seals - All new valves and valves repaired in the

field by Baker Hughes 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.

1. Refer to the Baker Hughes Standard Terms of Sale for complete details on

warranty and limitation of remedy and liability.

SEALED

Consolidated 1982 Series Safety Relief Valve Manual | 2

Proper installation and start-up is essential to the safe and reliable

operation of all valve products. The relevant procedures recommended by

Baker Hughes, and described in these instructions, are effective methods

of performing the required tasks.

It is important to note that these instructions contain various “safety

messages” which should be carefully read in order to minimize the risk

of personal injury, and/or the possibility that improper procedures will be

followed which may damage the involved Baker Hughes product, or render

it unsafe. It is also important to understand that these “safety messages”

are not exhaustive. Baker Hughes can not possibly know, evaluate, and

advise any customer of all of the conceivable ways in which tasks might

be performed, or of the possible hazardous consequences of each

way. Consequently, Baker Hughes has not undertaken any such broad

evaluation and, thus, anyone who uses a procedure and/or tool, which

is not recommended by Baker Hughes, or deviates from Baker Hughes

recommendations, must be thoroughly satisfied that neither personal

safety, nor valve safety, will be jeopardized by the procedure and/or tools

selected. If not so satisfied, contact your local Green Tag Center (GTC) if

there are any questions relative to procedures and/or tools.

The installation and start-up of valves and valve products may involve

proximity to fluids at extremely high pressure and/or temperature.

Consequently, every precaution should be taken to prevent injury to

personnel during the performance of any procedure. These precautions

should consist of, but are not limited to, ear drum protection, eye protection,

and the use of protective clothing, (i.e., gloves, etc.) when personnel are in,

or around, a valve work area.

It is the responsibility of the purchaser or user of Baker Hughes valves/

equipment to adequately train all personnel who will be working with the

involved product. For more information on training schedules, please

contact your local Green Tag Center (GTC). Prior to working with the

involved valves/equipment, personnel who are to perform such work should

become thoroughly familiar with the contents of these instructions.

Wear necessary

protective equipment

to prevent

possible injury.

II. Safety Notice

III. Product Safety Sign and Label System

If and when required, appropriate safety labels have been included in

the rectangular margin blocks throughout this manual. Safety labels

are vertically oriented rectangles as shown in the representative

examples (below), consisting of three panels encircled by a narrow

border. The panels can contain four messages which communicate:

• The level of potential harm from the hazard

• The nature of the hazard

• The consequence of human and/or product interaction with the

hazard.

• The instructions, if necessary, on how to avoid the hazard.

The top panel of the format contains a signal word (DANGER,

WARNING, CAUTION or ATTENTION) which communicates the level

of potential harm from the hazard.

The center panel contains a pictorial which communicates the nature

of the hazard, and the possible consequence of human and/or product

interaction with the hazard. In some instances of risk to human health

and safety the pictorial may, instead, depict what preventive measures

to take, such as wearing wearing the appropriate personal protective

equipment (PPE).

The bottom panel may contain instructions on how to avoid the hazard.

If there is a risk to human health and safety this message may also

contain a more precise definition of the hazard, and the consequences

of human and/or product interaction with the hazard, than can be

communicated solely by the pictorial.

DANGER — Immediate hazards

which WILL LIKELY result in

severe personal injury or death.

WARNING — Hazards or unsafe

practiceswhichCOULDresultin

severe personal injury or death.

CAUTION — Hazards or unsafe

practiceswhichCOULDresultin

minor personal injury.

ATTENTION — Hazards or

unsafepracticeswhichCOULD

result in product or property

damage.

Do not remove bolts

if pressure is in the

line, as this will

likely result in severe

personal injury or

death.

Know all valve

exhaust/leakage

points to avoid possible

severe personal injury

or death.

Wear

necessary protective

equipment to prevent

possible injury

Do not drop

or strike.

Consolidated 1982 Series Safety Relief Valve Manual | 4

IV. Safety Alerts

Read – Understand – Practice

1. DANGER: High temperature/pressure can

cause injury. Be sure all system pressure is

absent before repairing or removing valves.

2. DANGER: Don’t stand in front of valve outlet

whendischarging.STANDCLEAROFVALVE

to prevent exposure to potentiality trapped,

corrosive media.

3. DANGER: When inspecting a pressure relief

valve for leakage. BE VERY CAREFUL!

Improper use or repair of

a pressurized device may

result in severe personal

injury or death.

Stand clear of valve

when outlet is

discharging.

Be sure all system

pressure is absent

before repairing or

removing valves.

Heed all container

label warnings.

XXX

Provide and use

guarding to prevent

contact with heated

and/or pressurized parts.

Do not work with

valves while under the

influence of intoxicants

or narcotics.

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. Do not remove or deface the

container labels. Improper handling or misuse

could result in severe personal injury or death.

3. WARNING: Never use pressurized fluids/gas/air

to clean clothing or body parts. Never use body

parts to check for leakage and/or discharge rates

of valve 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 persons

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

influence of intoxicants or narcotics to work on

or around pressurized systems. Workers under

the influence of intoxicants or narcotics are a

hazard both to themselves and other employees

and can cause severe personal injury or death to

themselves and/or others.

6. WARNING: Incorrect service/repair could result

in product/property damage and/or severe

personal injury or death.

7. WARNING: The misuse of a tool or the use of an

improper tool could result in personal injury and/

or product/property damage.

IV. Safety Alerts (Cont.)

Heed all service

manual warnings.

Read installation

instructions before

installing valve(s).

Know nuclear "health

physics" procedures,

if applicable, to avoid

possible severe

personal injury or

death.

All potential hazards

may not be covered

in this manual.

Improper tools or

improper use of right

tools could result in

personal injury or

product damage.

Wear necessary

protective equipment

to prevent

possible injury

Always use

appropriate restoration

procedures.

1. CAUTION: Heed all service manual warnings.

Read installation instructions before installing

valve(s).

2. CAUTION: Wear the appropriate hearing

protection when testing or operating valves.

3. CAUTION: Wear the appropriate eye and

clothing protection.

4. CAUTION: Wear the appropriate self-contained

breathing apparatus (SCBA) to protect against

toxic media.

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