Baker Hughes Consolidated 2478 Series Manual de usuario

Consolidated™

2478 Series

Pressure Relief Valves

Instruction Manual (Rev. C)

Baker Hughes Data Classification : Public

Consolidated 2478 Series Pressure Relief Valve Manual | 1

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.

Conversion Table

USCS Unit 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

Note: Multiply USCS value with Conversion Factor to get Metric value.

All the United States Customary System (USCS)

values in the Manual are converted to Metric values using

the following conversion factors:

NOTICE!

For valve congurations not listed in this

manual, please contact your local Green

Tag™ Center (GTC) for assistance.

Consolidated 2478 Series Pressure Relief Valve Manual | 3

Table of Contents

I. Product Safety Sign and Label System ................................................................................. 4

II. Safety Precautions................................................................................................................. 5

III. Safety Notice ......................................................................................................................... 6

IV. Warranty Information ............................................................................................................. 7

V. Valve Terminology.................................................................................................................. 7

VI. Handling and Storage ............................................................................................................ 9

VII. Pre-Installation and Installation Instructions .......................................................................... 9

VIII. Introduction ............................................................................................................................ 9

IX. Consolidated 2478 Series Relief Valve................................................................................ 10

X. Operating Principle ...............................................................................................................11

XI. Disassembly of 2478 Series Relief Valve .............................................................................11

XII. Inspection and Part Replacement........................................................................................ 12

XIII. Reassembly of 2478 Series Relief Valve............................................................................. 13

XIV. Setting and Testing .............................................................................................................. 14

XV. Trouble Shooting ................................................................................................................. 14

XVI. Replacement Parts Planning ............................................................................................... 15

A. Basic Guidelines ............................................................................................................ 15

B. Identication and Ordering Essentials ........................................................................... 15

XVII. Genuine Consolidated Parts................................................................................................ 15

XVIII. Recommended Spare Parts ................................................................................................ 16

XIX. Manufacturer’s Field Service & Repair Program ................................................................ 17

A. Field Service .................................................................................................................. 17

B. Factory Repair Facilities ................................................................................................ 17

C. Relief Valve Maintenance Training................................................................................. 17

DANGER — Immediate hazards

which WILL result in severe

personal injury or death.

WARNING — Hazards or unsafe

practices which COULD result

in severe personal injury or

death.

CAUTION — Hazards or unsafe

practices which COULD result

in minor personal injury.

ATTENTION — Hazards or

unsafe practices which COULD

result in product or property

damage.

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 hazard seriousness

• The nature of the hazard

• The consequence of human, or product, interaction with the hazard.

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

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

CAUTION or ATTENTION) which communicates the level of hazard

seriousness.

The center panel contains a pictorial which communicates the nature of

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

with the hazard. In some instances of human hazards the pictorial may,

instead, depict what preventive measures to take, such as wearing

protective equipment.

The bottom panel may contain an instruction message on how to avoid

the hazard. In the case of human hazard, this message may also contain

a more precise denition of the hazard, and the consequences of human

interaction with the hazard, than can be communicated solely by the

pictorial.

I. Product Safety Sign and Label System

Do not remove bolts

if pressure in line, as

this will 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

Handle valve carefully.

Do not drop or strike.

1234

Consolidated 2478 Series Pressure Relief Valve Manual | 5

Lower pressure and stand

clear of discharge when

working on valve to avoid

severe personal injury or

death.

Know all valve exhaust/

leakage points to

avoid possible severe

personal injury or death.

II. Safety Precautions

Follow all plant safety regulations, but be sure to observe the following:

• Always lower the working pressure before making any valve adjustment. When

making ring adjustments, always gag the valve before making the adjustment. This

will avoid possible personal injury.

• Do not stand in front of the discharge side of a safety valve when testing or

operating.

• Hearing and eye protection should be used when testing or operating a valve.

• Wear protective clothing. Hot water can burn and superheated steam is not visible.

• When removing the safety valve during disassembly, stand clear and/or wear

protective clothing to prevent exposure to splatter, or any corrosive process medium,

which may have been trapped inside the valve. Ensure the valve is isolated from

system pressure before the valve is removed.

• Exercise care when examining a safety valve for leakage.

• Prior to each actuation, assure that no personnel are near the valve. Steam

escaping from the valve during actuation can possibly cause personal injury.

• When popping a safety valve for the rst time, or after refurbishment, always be

prepared to actuate the valve with the lever while standing in a safe place away from

the valve. This may be done by xing a rope to the lever for actuating the valve from

a distance.

• Striking a valve which is under pressure can cause premature actuation. Never

tamper with the valve when system pressure is near the valve set pressure.

• Before performing any machining on valve parts, consult Baker Hughes or its

authorized representative. Deviation from critical dimensions can adversely a󰀨ect

valve performance.

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 e󰀨ective methods of performing the required

tasks.

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

which should be carefully read in order to minimize the risk of personal injury,

or the possibility that improper procedures will be followed which may damage

the involved 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 satised that neither personal safety, nor

valve safety, will be jeopardized by the method and/or tools selected. Contact your

local Green Tag Center (GTC) if there are any questions relative to tools/methods.

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

to uids at extremely high pressure and/or temperature. Consequently, every

precaution should be taken to prevent injury to personnel during the performance

of any procedure. These precautions should consist of, but are not limited to, ear

drum protection, eye protection, and the use of protective clothing, (i.e., gloves,

etc.) when personnel are in, or around, a valve work area. Due to the various

circumstances and conditions in which these operations may be performed on

Baker Hughes products, and the possible hazardous consequences of each way,

Baker Hughes can not possibly evaluate all conditions that might injure personnel

or equipment. Nevertheless, Baker Hughes does o󰀨er certain Safety Precautions,

listed in Section II, for customer information only.

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 valves/

equipment. For more information on training schedules, please contact your

local Green Tag Center (GTC). Further, prior to working with the involved valves/

equipment, personnel who are to perform such work should become thoroughly

familiar with the contents of these instructions.

III. Safety Notice

Wear necessary

protective equipment to

prevent possible injury

Consolidated 2478 Series Pressure Relief Valve Manual | 7

• Back Pressure

Back pressure is the static pressure existing at the

outlet of a safety valve device due to pressure in the

discharge system.

• Blowdown

Blowdown is the di󰀨erence between actual popping

pressure of a safety valve and actual reseating

pressure expressed as a percentage of set pressure,

or in pressure units.

• Bore Area

Bore area is the minimum cross-sectional area of the

seat bushing.

• Bore Diameter

Bore diameter is the minimum diameter of the seat

bushing.

• Built-Up Back Pressure

Pressure existing at the outlet of a safety valve while it

is open and owing through a discharge system.

• Chatter

Chatter is abnormal, rapid reciprocating motion of the

moveable parts of a safety valve, in which the disc

contacts the seat.

• Closing Pressure

Closing pressure is the value of decreasing inlet static

pressure at which the valve disc re-establishes contact

with the seat, or at which lift becomes zero.

• Disc

A disc is the pressure containing moveable member of

a safety valve which a󰀨ects closure.

• Inlet Size

Inlet size is the nominal pipe size of the inlet of a

safety valve, unless otherwise designated.

• Leak Test Pressure

Leak test pressure is the specied inlet static pressure

at which a quantitative seat leakage test is performed

in accordance with a standard procedure.

• Lift

Lift is the actual travel of the disc away from closed

position when a valve is relieving.

• Lifting Device

A lifting device is a device for manually opening a

safety valve, by the application of external force

to lessen the spring loading which holds the valve

closed.

• Seat Bushing

A seat bushing is the pressure containing element

which constitutes the inlet ow passage and includes

the xed portion of the seat closure.

• Outlet Size

Outlet size is the nominal pipe size of the outlet

passage of a safety valve, unless otherwise

designated.

V. Valve Terminology (Paraphrased from ASME’s PTC 25)

IV. Warranty Information

Warranty Statement: Baker Hughes warrants that its

products and work will meet all applicable specications

and other specic product and work requirements

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

free from defects in material and workmanship. Refer

to Baker Hughes’s Standard Terms of Sale, or specic

contract for complete details on warranty and limitation

of remedy and liability.

Defective and nonconforming items must be held

for Baker Hughes’s inspection and returned to the

manufacturer 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 a󰀩liated repair

companies, contractors or individuals to perform

warranty repair service on new products or eld repaired

products of its manufacture. Therefore, customers

contracting such repair services from unauthorized

sources must do so at their own risk.

Unauthorized Removal of Seals: All new valves and

valves repaired in the eld 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.

V. Valve Terminology (Cont.)

• Overpressure

Overpressure is a pressure increase over the set

pressure of a safety valve, usually expressed as a

percentage of set pressure.

• Popping Pressure

Popping pressure is the value of increasing inlet

static pressure at which the disc moves in the

opening direction at a faster rate as compared

with corresponding movement at higher or lower

pressures. It applies only to safety or safety relief

valves on compressible uid service.

• Pressure Containing Member

A pressure containing member of a safety valve is a

part which is in actual contact with the pressure media

in the protected vessel.

• Pressure Retaining Member

A pressure retaining member of a safety valve is a part

which is stressed due to its function in holding one or

more pressure containing members in position.

• Rated Lift

Rated lift is the design lift at which a valve attains its

rated relieving capacity.

• Safety Valve

A safety valve is a pressure relief valve actuated

by inlet static pressure and characterized by rapid

opening or pop action.

• Set Pressure

Set pressure is the value of increasing inlet static

pressure at which a safety valve displays the

operational characteristics as dened under “Popping

Pressure.” It is one value of pressure stamped on the

safety valve.

• Seat

A seat is the pressure containing contact between the

xed and moving portions of the pressure containing

elements of a valve.

• Seat Diameter

Seat diameter is the smallest diameter of contact

between the xed and moving members of the

pressure containing elements of a valve.

• Seat Tightness Pressure

Seat tightness pressure is the specic inlet static

pressure at which a quantitative seat leakage test is

performed in accordance with a standard procedure.

• Simmer

Simmer is the audible or visible escape of uid

between the seat and disc at an inlet static pressure

below the popping pressure and at no measurable

capacity. It applies to safety valves on compressible

uid service.

• Warn

See “Simmer” (denition above).

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