Baker Hughes Consolidated Generation II 2900 Series Manual de usuario

Consolidated™

2900 Series Generation II

Pilot-Operated Safey Relief Valves

Instruction Manual (Rev. E)

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 valve congurations not listed in this

manual, please contact your local Green

Tag™ Center (GTC) for assistance.

All the United States Customary System (USCS) units are

converted to metric units using the following conversion factors:

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

Conversion Table

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

Consolidated 2900 Series Generation II POSRV Instruction Manual | 3

Table of Contents

I. Product Safety Sign and Label System..................................7

II. Safety Precautions ..................................................8

Restoring Safety .................................................................. 9

III. Safety Notice ......................................................10

IV. Warranty Information ...............................................11

V. Terminology for Pilot Operated Safety Relief Valves ......................12

VI. Handling and Storage ...............................................13

VII. Pre-Installation and Installation Instructions ............................14

VIII. Introduction .......................................................16

A. General Introduction ............................................................16

B. Main Valve Introduction ..........................................................16

C. Pilot Valve Introduction ..........................................................16

IX. 2900 Series Pilot Operated Safety Relief Valves .........................17

A. Metal Seat Valve ...............................................................17

B. Soft Seat Valve ................................................................17

C. Integral Sense..................................................................17

D. D-U Orice (with Bellows) ........................................................18

E. V & W Orice (with Bellows) ......................................................18

F. Metal Seat Valve for Section I Liquid Service (LA1) .....................................19

G. Soft Seat Valve for Section I Liquid Service (LA1) .................................... 20

H. 39PV07/37 Pilot Valves (Standard Service) ...........................................21

I. 39MV07 Pilot Valve (Standard Service)............................................. 22

J 39MV22/72 Pilot Valve (Standard Service) .......................................... 23

X. Operating Principles ................................................24

A. 2900 Series with Type 39PV (Pop) Pilot Operational Descriptions .........................24

B 2900 Series 39MV07 (Modulating) Pilot – Operational Description ....................... 26

XI. General Planning for Maintenance ....................................28

XII. Recommended Installation Practices ..................................28

A. Mounting Position ............................................................. 28

B. Inlet Piping ................................................................... 29

C. Outlet Piping.................................................................. 30

D. Integral Sensing ............................................................... 30

E. Remote Sensing................................................................31

F. Freeze Protection ...............................................................31

Table of Contents (Cont.)

XIII. Disassembly of the 2900 POSRV ......................................33

A. Removal of Pilot Valve from Main Valve ............................................ 33

B. Disassembly of Main Valve ...................................................... 33

B.1 Nozzle Removal.............................................................37

C. Cleaning ..................................................................... 39

XIV. Maintenance Instructions ............................................40

A. General Maintenance Information ................................................. 40

B. O-Ring Seat .................................................................. 40

C. Lapping Nozzle Seats (Metal Seat, Non-O-Ring Styles).................................42

D. Lapped Nozzle Seat Widths.......................................................42

E. Lapping Disc Seats ............................................................ 44

F. Precautions and Hints for Lapping Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

G. Reconditioning of Laps ......................................................... 44

H. Re-Machining Nozzle Seats ..................................................... 45

I. Re-Machining the Disc Seat ..................................................... 45

XV. Inspection and Part Replacement .....................................47

XVI. Reassembly of the 2900 Main Valve ...................................51

A. Lubricants and Sealants .........................................................51

B. Assembly Procedure with Metal Seats ..............................................51

B.2.1 Integral Sensing Ring Assembly.............................................. 52

B.3 Disc/Disc Holder Assembly ................................................... 52

C. Assembly Procedure with O-Ring Seats ............................................ 52

XVII. Disassembly of Pilot Valve ...........................................57

A. 39PV07/37 Disassembly ........................................................ 57

B. 39MV07 Disassembly .......................................................... 60

C. 39MV22/72 Disassembly........................................................ 63

D. Cleaning ..................................................................... 66

XVIII. Part Inspection of Pilot Valve .........................................67

A. 39PV07/37 ................................................................... 67

B. 39MV07 ..................................................................... 67

C. 39MV22/72 .................................................................. 68

XIX. Reassembly of Pilot Valve ...........................................69

A. Lubricants and Sealants ........................................................ 69

B. Assembly of 39PV07/37......................................................... 69

C. Assembly of 39MV07 ............................................................71

D. Assembly of 39MV22/72 ........................................................ 73

Consolidated 2900 Series Generation II POSRV Instruction Manual | 5

Table of Contents (Cont.)

XX. Setting and Testing .................................................76

A. General Information .............................................................76

B. With Standard Options...........................................................76

C. Integral Sensing Ring........................................................... 77

D. Troubleshooting Leakage.........................................................78

E. Conversions between Conventional and Bellows Type ................................. 80

F. Field Testing of POSRV Assembly ..................................................81

XXI. Troubleshooting....................................................85

XXII. 2900 Series POSRV Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

A. Backow Preventer ............................................................ 86

B. Dirty Service Option.............................................................87

C. Dual Pilots ................................................................... 89

D. Field Test Connection .......................................................... 89

E. Sensing Line Filter (Standard) ................................................... 89

F. Single, Dual and High Capacity Filters (Optional) ..................................... 90

G. Gag .........................................................................91

H. Heat Exchanger ................................................................91

I. Lifting Lever .................................................................. 92

J. Manual, Electrical, or Pneumatic Blowdown Valve .................................... 92

K. Pressure Di󰀨erential Switch...................................................... 92

L. Pressure Spike Snubber ........................................................ 92

M. Remote Pilot Mounting.......................................................... 93

N. Remote Sensing............................................................... 93

O. Sensing Ring Options .......................................................... 93

XXIII. Maintenance Tools and Supplies ......................................94

A. Adjuster Top Seal Insertion Tool .................................................. 94

B. Insert Installation Tool .......................................................... 95

C. Lapping Tools................................................................. 96

D. Disc Holder and Guide Removal and Assembly Tool ..................................97

E. 2900 IS Torquing Tool Insert...................................................... 98

XXIV. Replacement Parts Planning .........................................99

A. Basic Guidelines .............................................................. 99

B. Identication and Ordering Essentials .............................................. 99

C. Positive Identication of Main Valve and Pilot Valve Combinations ....................... 100

XXV. Genuine Consolidated Parts ........................................100

XXVI.Recommended Spare Parts .........................................101

XXVII. Field Service, Repair and Training Program ...........................110

A. Field Service .................................................................110

B. Repair Facilities ...............................................................110

C. Maintenance Training...........................................................110

I. Product Safety Sign and Label System

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 definition of the hazard, and the consequences

of human interaction with the hazard, than can be communicated solely

by the pictorial.

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

Do not drop

or strike.

Consolidated 2900 Series Generation II POSRV Instruction Manual | 7

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.

II. Safety Precautions

Improper use or repair

of pressurized media or

steam device may result

in severe personal

injury or death.

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.

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. 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 or discharge rates of

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. Contact with

pressurized or heated parts can result in severe

personal injury or death.

5. WARNING: Do not allow anyone under the

influence or intoxicants or narcotics to work on or

around pressurized systems. Workers under the

influence intoxicants or narcotics are a hazard

both to themselves and other employees and

can cause severe personal injury or dearth 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

intended for radioactive nuclear applications.

Some valve products Manufactured by

Baker Hughes 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.

9. WARNING: These WARNINGS are as complete

as possible but not all-inclusive. Baker Hughes

cannot know all conceivable service methods nor

evaluate all potential hazards.

II. Safety Precautions (Cont.)

Wear necessary

protective equipment

to prevent possible

injury.

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.

Cautions Concerning Product

Warning Labels

1. CAUTION: Heed all service manual warnings.

Read installation instructions before installing

valve(s).

2. CAUTION: Wear hearing protection when

testing or operating valves.

3. CAUTION: Wear appropriate eye and clothing

protection.

4. CAUTION: Wear protective breathing

apparatus to protect against toxic media.

Note: Any Service questions not covered in

this manual should be referred to your

local Green Tag™ Center (GTC).

Restoring 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 Baker Hughes as

described in the applicable installation and

Maintenance Manual, when correctly applied, will

be effective.

Always use

appropriate

restoration

procedures.

Consolidated 2900 Series Generation II POSRV Instruction Manual | 9

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, or the possibility that improper procedures will be followed

which may damage the involved Baker Hughes Consolidated 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 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 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. Due to the various circumstances and

conditions in which these operations may be performed on Consolidated

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 offer certain Safety

Precautions for customer information only.

It is the responsibility of the purchaser or user of Baker Hughes's

Consolidated valves/equipment to adequately train all personnel who will

be working with the involved valves/equipment. For more information on

training schedules, call 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.

Wear necessary

protective equipment

to prevent possible

injury.

III. Safety Notice

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