Baker Hughes Consolidated 2900 Maintenance Manual

BHGE Data Classication : Public

Consolidated* 2900 Series Pilot-Operated Safety Relief Valves

Maintenance Manual (Rev.B)

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, BHGE (BAKER HUGHES, A GE COMPANY 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 BHGE.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE 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 BHGE 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 BHGE.

2 | BHGE

NOTICE!

For valve congurations not listed in this manual, please contact your local Green Tag* Center for assistance.

All the USCS values are converted to

metric values using the following conversion factors:

Metric values using

the following

conversion factors:

Conversion Factor Metric Unit

in. 25.4 mm

lb. 0.4535924 kg

6.4516 cm

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

Consolidated 2900 Series POSRV Maintenance Manual | 3

Table of Contents

I. Product Safety Sign and Label System .............................................6

II. Safety Precautions ................................................................7

Restoring Safety ...........................................................................................8

III. Safety Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

IV. Warranty Information ............................................................10

V. Terminology for Pilot Operated Safety Relief Valves ..............................11

VI. Handling and Storage .............................................................12

VII. Pre-Installation and Installation Instructions .....................................13

VIII. Introduction .....................................................................14

A. General Introduction ..................................................................................14

B. Main Valve Introduction ..............................................................................14

C. Pilot Valve Introduction ...............................................................................14

IX. Consolidated 2900 Series Pilot Operated Safety Relief Valves .....................15

A. Metal Seat Valve ......................................................................................15

B. Soft Seat Valve ........................................................................................15

C. D - U Orice (with Bellows) ............................................................................16

D. V & W Orice (with Bellows) ...........................................................................16

E. 39PV07/37 Pilot Valves (Standard Service) .............................................................17

F. 39MV07 Pilot Valve (Standard Service) .................................................................18

G. 39MV22/72 Pilot Valve (Standard Service) .............................................................19

X. Operating Principles ..............................................................20

A. 2900 Series with Type 39PV (Pop) Pilot Operational Descriptions ......................................20

B 2900 Series 39MV07 (Modulating) Pilot – Operational Description .....................................22

XI. General Planning for Maintenance ................................................24

XII. Recommended Installation Practices .............................................24

A. Mounting Position ....................................................................................24

B. Inlet Piping ............................................................................................25

C. Outlet Piping ..........................................................................................26

D. Remote Sensing .......................................................................................26

E. Freeze Protection .....................................................................................27

XIII. Disassembly of the 2900 POSRV ..................................................28

A. Removal of Pilot Valve from Main Valve ................................................................28

B. Disassembly of Main Valve ............................................................................28

C. Cleaning ..............................................................................................33

4 | BHGE

Table of Contents (Cont'd)

XIV. Maintenance Instructions ........................................................34

A. General Maintenance Information .....................................................................34

B. O-Ring Seat ...........................................................................................34

C. Lapping Nozzle Seats (Metal Seat, Non-O-Ring Styles) .................................................36

D. Lapped Nozzle Seat Widths ...........................................................................36

E. Lapping Disc Seats ....................................................................................38

F. Precautions and Hints for Lapping Seats ..............................................................38

G. Reconditioning of Laps ................................................................................38

H. Re-Machining Nozzle Seats ............................................................................39

I. Re-Machining the Disc Seat ...........................................................................39

XV. Inspection and Part Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

XVI. Reassembly of the 2900 Main Valve ...............................................44

A. Lubricants and Sealants ..............................................................................44

B. Assembly Procedure with Metal Seats .................................................................44

C. Assembly Procedure with O-Ring Seats ...............................................................45

XVII. Disassembly of Pilot Valve ........................................................48

A. 39PV07/37 Disassembly ...............................................................................48

B. 39MV07 Disassembly .................................................................................51

C. 39MV22/72 Disassembly ..............................................................................54

D. Cleaning ..............................................................................................57

XVIII. Part Inspection of Pilot Valve .....................................................58

A. 39PV07/37 ............................................................................................58

B. 39MV07 ..............................................................................................58

C. 39MV22/72 ...........................................................................................59

XIX. Reassembly of Pilot Valve ........................................................60

A. Lubricants and Sealants ...............................................................................60

B. Assembly of 39PV07/37 ...............................................................................60

C. Assembly of 39MV07 ..................................................................................62

D. Assembly of 39MV22/72 ..............................................................................65

A. General Information ..................................................................................67

B. With Standard Options ................................................................................67

C. With Sensing Ring Option .............................................................................68

D. Troubleshooting Leakage ..............................................................................69

E. Conversions between Conventional and Bellows Type .................................................71

F. Field Testing of POSRV Assembly ......................................................................71

XXI. Troubleshooting ..................................................................72

Consolidated 2900 Series POSRV Maintenance Manual | 5

Table of Contents (Cont'd)

XXII. 2900 Series POSRV Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

A. Backow Preventer ...................................................................................73

B. Dirty Service Option ..................................................................................74

B. Dirty Service Option (Contd.) ..........................................................................75

C. Dual Pilots ............................................................................................76

D. Field Test Connection .................................................................................76

E. Filter (Single, Dual, or High Capacity) ..................................................................77

F. Ga g ...................................................................................................78

G. Heat Exchanger .......................................................................................78

H. Lifting Lever ..........................................................................................79

I. Manual, Electrical, or Pneumatic Blowdown Valve .....................................................79

J. Pilot Valve Tester .....................................................................................80

K. Pressure Dierential Switch ...........................................................................80

L. Pressure Spike Snubber ...............................................................................81

M. Remote Pilot Mounting ................................................................................81

N. Remote Sensing .......................................................................................81

O. Sensing Ring ..........................................................................................81

XXIII. Maintenance Tools and Supplies ..................................................82

A. Adjuster Top Seal Insertion Tool .......................................................................82

B. Insert Installation Tool ................................................................................83

C. Lapping Tools .........................................................................................84

D. Disc Holder and Guide Removal and Assembly Tool ...................................................85

XXIV. Replacement Parts Planning ......................................................87

A. Basic Guidelines ......................................................................................87

B. Identication and Ordering Essentials ..................................................................87

XXV. Genuine Consolidated Parts ......................................................88

C. Positive Identication of Main Valve and Pilot Valve Combinations ....................................88

XXVI. Recommended Spare Parts .......................................................89

XXVII. Field Service, Repair and Training Program .......................................98

A. Field Service ..........................................................................................98

B. Factory Repair Facilities ...............................................................................98

C. Safety Relief Valve Maintenance Training ..............................................................98

6 | BHGE

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 denition 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 POSRV Maintenance 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 BHGE 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. BHGE cannot know all conceivable service methods nor evaluate all potential hazards.

8 | BHGE

II. Safety Precautions (Contd.)

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 BHGE’s Service Department. Phone: (318) 640-6255.

Restoring Safety

Appropriate service and repair are important to safe, reliable operation of all valve products. Restoration to original quality and manufacturing specications will accomplish the desired results. Procedures developed by BHGE as described in the applicable installation and Maintenance Manual, when correctly applied, will be eective.

Always use

appropriate

restoration

procedures.

Consolidated 2900 Series POSRV Maintenance Manual | 9

Proper installation and start-up is essential to the safe and reliable operation of all valve products. The relevant procedures recommended by BHGE, 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 BHGE Consolidated product, or render it unsafe. It is also important to understand that these “safety messages” are not exhaustive. BHGE 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, BHGE has not undertaken any such broad evaluation and, thus, anyone who uses a procedure and/or tool, which is not recommended by BHGE, or deviates from BHGE 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 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 Consolidated products, and the possible hazardous consequences of each way, BHGE can not possibly evaluate all conditions that might injure personnel or equipment. Nevertheless, BHGE does oer certain Safety Precautions for customer information only.

It is the responsibility of the purchaser or user of BHGE'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 (318) 640-6054. Further, prior to working with the involved valves/equipment, personnel who are to perform such work should become thoroughly familiar with the contents of these instructions.

Wear necessary

protective equipment

to prevent possible

injury.

III. Safety Notice

10 | BHGE

S E A L E D

Removal and/or

breakage of seal will

negate our warranty.

IV. Warranty Information

Defective and nonconforming items must be inspected by

BHGE

Warranty Statement

Warranty Statement1- BHGE 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.

CAUTION: Defective and nonconforming items must be held for BHGE’s inspection and returned to the original F.O.B. point upon request.

Incorrect Selection or Misapplication of Products – BHGE cannot be responsible for customer’s incorrect selection or misapplication of our products.

Unauthorized Repair Work – BHGE has not authorized any non-BHGE 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 or performing such repair service from unauthorized sources do so at their own risk.

Unauthorized Removal of Seals – All new valves and valves repaired in the eld by BHGE 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.

Note 1: Refer to BHGE’s Standard Terms of Sale for complete details on warranty

and limitation of remedy and liability.

Consolidated 2900 Series POSRV Maintenance Manual | 11

V. Terminology for Pilot Operated Safety Relief Valves

• Accumulation: The pressure increase over the maximum allowable working pressure of the vessel during discharge through the POSRV, expressed as a percentage of that pressure or in actual pressure units.

• Backpressure: The pressure on the discharge side of the POSRV:

– Built-up Backpressure: Pressure that develops

at the valve outlet as a result of flow, after the POSRV has been opened.

– Superimposed Backpressure: Pressure in the

discharge header before the POSRV opens.

– Constant Backpressure: Superimposed

backpressure that is constant with time.

– Variable Backpressure: Superimposed

backpressure that will vary with time.

• Blowdown: The difference between set pressure and reseating pressure of the POSRV, expressed as a percentage of the set pressure or in actual pressure units.

• Cold Differential Set Pressure: The pressure at which the valve is adjusted to open on the test stand. This pressure corrects for backpressure when a pop action pilot’s vent is piped to the main valve outlet.

• Differential Between Operating and Set Pressures: Valves in process service will generally

give best results if the operating pressure does not exceed 90% of the set pressure. However, on pump and compressor discharge lines, the differential required between the operating and set pressures may be greater because of pressure pulsations coming from a reciprocating piston. The valve should be set as far above the operating pressure as possible.

• Lift: The actual travel of the disc away from the closed position when a valve is relieving.

• Maximum Allowable Working Pressure: 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 primary pressure

POSRV is set to open.

• 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 10% under the maximum allowable working pressure or 5 psig (0.34 bar), whichever is greater.

• Overpressure: 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.

• Pilot Operated Safety Relief Valve (POSRV):

A pressure relief valve in which the major relieving device is combined with, and is controlled by, a self-actuated auxiliary pressure relief valve.

• Rated Capacity: The percentage of measured flow at an authorized percent overpressure permitted by the applicable code. Rated capacity is generally expressed in pounds per hour (lb/hr) or kg/hr for vapors, standard cubic feet per minute (SCFM) or m³ /min for gases, and in gallons per minute (GPM) or Liter/min (L/min) for liquids.

• Safety Relief Valve (SRV): An automatic pressure- relieving device used as either a safety or relief valve, depending upon application. The SRV is used to protect personnel and equipment by preventing excessive overpressure.

• Set Pressure: The gauge pressure at the valve inlet, for which the relief valve has been adjusted to open under service conditions. In liquid service, the inlet pressure at which the valve starts to discharge determines set pressure. In gas or vapor service, the inlet pressure at which the valve pops determines the set pressure.

12 | BHGE

VI. Handling and Storage

Never attempt to lift the

valve by anything other

than theeyebolts.

Do not subject valves

to sharp impact.

Always keep valve in an

upright position when

handling or storing.

Handling

Always keep the inlet ange down on a crated or uncrated ange valve to prevent misalignment and damage to valve internals.

Pilot Operated Safety Relief Valves should be handled carefully. The internal parts of a pilot operated safety relief valve are precision machined and tted together to maintain perfect alignment. Rough handling may damage the external tubing, pilot, and main valve seats or may cause misalignment sucient to incur leakage or erratic operation. POSRVs are shipped with a protective covering over the inlet and the outlet anges. This is to prevent damage to the anged surfaces and to prevent entry of foreign material into the valve.

ATTENTION!

Never lift the full weight of the valve by the pilot

assembly, external devices or tubing.

ATTENTION!

Do not rotate the valve horizontally or lift/carry using the pilot assembly.

ATTENTION!

Only lift the valve by the eyebolts inserted into the cover plate.

ATTENTION!

Handle carefully. Do not drop or strike the valve.

Storage

Store POSRVs in a dry environment and protect them from the weather. Do not remove the valve from the skids or crates until immediately before installation. Do not remove ange protectors and seating plugs until the valve is ready to be bolted into place during the installation, i.e., both inlet and outlet.

Consolidated 2900 Series POSRV Maintenance Manual | 13

VII. Pre-Installation and Installation Instructions

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

position. Installing a valve in any other position will adversely aect 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 regulations. 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 from the vessel to the relief valve must not exceed 3% of the valve set pressure when it is owing at full capacity.

Flanges and gasket surfaces must be free from dirt and debris when valves are installed. The length, size and maximum change in height of the remote sensing line should be veried through analysis, taking into account the requirement to re-charge the dome through the pilot valve. On request, BHGE 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.

Hydrostatic Testing

Prior to hydrostatic test of the pressure vessel system, the pilot-operated safety relief valve should be removed and the mounting ange 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 of pressure in the equipment to be protected and the pressure at the relief valve inlet exceeds 3%, 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, .375” (9.53 mm) diameter 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 factory.

Always install valve

in a vertical, upright

position.

Prevent dirt from entering outlet or

inlet port.

Decontaminate or

clean if necessary

before pretesting or

disassembly. Safety

and environmental

precautions must

be taken for the

decontamination or

cleaning method used.

14 | BHGE

VIII. Introduction

A. 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.

Note 1: 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 6250 psig (10.34 to 430.92 barg)

B. Main Valve Introduction

The Consolidated Pilot Operated Safety Relief Valve (POSRV) cast bodies are designed to meet the often specied inlet and outlet connection combinations. Sizes range from 1” - 12” (25.4 mm - 304.80 mm); pressure ratings from 150 - 2500 class. The standard metal seat is the same design that has been successfully utilized in the Consolidated SRV for over 50 years.

Capacities are certied by National Board of Boiler and Pressure Vessel Inspectors and published in their NB18 entitled “Pressure Relief Device Certications”.

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

Service and Applications

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 pressures and temperature limitations for both the main valve and pilot valve to ensure compatibility.

C. 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

• Standard O-Ring seals

• Superior seat tightness

• Accurate adjustment of blowdown and set point

• Positive closure after blowdown

• Reduces icing and clogging

• Field test connection

• Remote Sensing

• External blowdown adjustments

Table 1: Service and Applications

Model Service

Pressure Range Temperature Range

min. max. min. max.

psig barg psig barg °F °C °F °C

39PV07, GS, SS, or LA Gas, Air, Steam or Liquid 15 1.03 750 51.71 -40 -40.0 505 262.8

39MV07 GS or SS Gas, Air or Steam 15 1.03 750 51.71 -40 -40.0 505 262.8

39MV07 LS Liquid 15 1.03 750 51.71 -40 -40.0 505 262.8

39PV37 GS, SS, or LA Gas, Air, Steam or Liquid 751 51.78 3750 258.55 -40 -40.0 505 262.8

39MV22 GS or SS Gas, Air or Steam 751 51.78 3750 258.55 -40 -40.0 505 262.8

39MV22 LA Liquid 751 51.78 3750 258.55 -40 -40.0 505 262.8

39MV72 GS, SS or LA Gas, Air, Steam or Liquid 3751 258.62 6250 430.92 -40 -40.0 505 262.8

Note: With the installation of the heat exchanger, temperature range may be expanded to -450°F to 1200°F. ( -267.8°C to 648.9°C)

Consolidated 2900 Series POSRV Maintenance Manual | 15

IX. Consolidated 2900 Series Pilot Operated Safety

Relief Valves

Part

No.

Nomenclature

1 Base

2 Nozzle

3 Coverplate

4 Coverplate Gasket

5 Main Valve Piston

6 Main Valve Piston O-Ring

7 Disc

8 Disc Retainer

9 Disc Holder

10 Guide

11 Guide Gasket

12 Guide Ring(s)

13 Stud (Base)

14 Nut (Base)

15 Plug Adaptor

16 Plug Adaptor Gasket

17 O-Ring Retainer Lock Screw

18 O-Ring Retainer

19 O-Ring Seat Seal

Figure 1: Main Valve Construction - Metal Seat

A. Metal Seat Valve

B. Soft Seat Valve

D Thru J Orifice

K Thru U Orifice

Figure 2: Main Valve Construction - Soft Seat

16 | BHGE

IX. (Contd.)

C. D - U Orifice (with Bellows)

Figure 3: Main Valve Construction - Bellows (D-U orifices)

D. V & W Orifice (with Bellows)

1A 1/2” NPT DRAIN

Figure 4: Main Valve Construction - Bellows (V&W orifices)

Part

No.

Nomenclature

20 Bellows Assembly

21 Bellows Gasket

8A Disc Retainer Screws

8B Retainer Screw Lock Washer

9 Disc Holder Assembly

20 Bellows Assembly

21 Bellows Gasket

22 Bellows Bolts

23 Bellows Bolts Lock Washers

24 Guide Ring (Guide)

25 Bug Screen (Not Shown)

Consolidated 2900 Series POSRV Maintenance Manual | 17

E. 39PV07/37 Pilot Valves (Standard Service)

1/4”-

18 NPT

SHOWN 90°

OUT OF POSITION

1/4” - 18 NPT

VENT

1/4” - 18 NPT

DRAIN

HIGH PRESSURE

Figure 5: 39PV07/37 Pilot Valve Construction

IX. (Contd.)

Part

No.

Nomenclature

1 Main Base

2 Adjuster Cap

3 Adjuster Top

4 Adjuster Bottom

5 Adjuster Lock Nut

6 Compression Screw

7 Compression Screw Lock Nut

8 Spring Washer

9 Spring

10 Insert Top

11 Insert Bottom

12 Main Piston

13 Cap (Compression Screw)

14 Cap Screw (Top Plate)

15 O-Ring (Adjuster Bottom)

16 O-Ring (Adjuster Top)

17 O-Ring (Insert)

18 O-Ring (Top Plate)

19 Bonnet

20 Spring Seal (Main Piston)

21 Spring Seal (Adjuster Top)

22 Spring Seal (Insert)

23 Field Test Connector

Vent Assembly/Bug Screen (Field Test Connection)

25 Vent Assembly (Bonnet Vent)

26 Pipe Plug (Pilot Valve)

27 Set Screw (Bonnet)

34 Top Plate

Plug Filter (Used in Sensing Tube When Equipped) (Not Shown)

Note 1: Standard material is a filter plug. For special materials, vent assembly is supplied.

18 | BHGE

F. 39MV07 Pilot Valve (Standard Service)

1/4” -18 NPT

1/4”

18 NPT

SHOWN 90°

OUT OF POSITION

4544 42

Figure 6: 39MV07 Pilot Valve Construction

IX. (Contd.)

Part

No.

Nomenclature

1 Main Base 2 Adjuster Cap 3 Adjuster Top 4 Adjuster Bottom

5 Adjuster Lock Nut 6 Compression Screw

7 Compression Screw Lock Nut 8 Spring Washer

9 Spring 10 Insert Top 11 Insert Bottom 12 Main Piston 13 Cap (Compression Screw) 14 Cap Screw (Top Plate) 15 O-Ring (Adjuster Bottom) 16 O-Ring (Adjuster Top) 17 O-Ring (Insert) 18 O-Ring (Top Plate) 19 Bonnet 20 Spring Seal (Main Piston) 21 Spring Seal (Adjuster Top) 22 Spring Seal (Insert) 23 Field Test Connector

Vent Assembly/Bug Screen (Field Test Connection)

25 Vent Assembly (Bonnet Vent)

27 Set Screw (Bonnet) 34 Top Plate

Plug Filter (Used in Sensing Tube

When Equipped) (Not Shown) 36 Modulator Base 37 Modulator Stop 38 Modulator Piston Top 39 Modulator Piston Bottom 40 O-Ring Retainer 41 Lock Screw (Retainer) 42 Cap Screw (Modulator)

Socket Head Cap Screw

(Modulator) 44 O-Ring (Modulator Base) 45 O-Ring (Modulator Stop) 46 O-Ring (Modulator Seat)

O-Ring (Modulator Piston

Bot tom) 48 Spring Seal (Piston Bottom)

49 Spring Seal (Piston Top)

Note 1: Standard material is a filter plug. For special materials, vent assembly is supplied.

Consolidated 2900 Series POSRV Maintenance Manual | 19

G. 39MV22/72 Pilot Valve (Standard Service)

HIGH PRESSURE

1/4”-18 NPT

VENT

1/4”-

18 NPT

Figure 7: 39MV22/72 Pilot Valve Construction

IX. (Contd.)

Part

No.

Nomenclature

1 Main Base

2 Adjuster Cap

3 Adjuster Top

4 Adjuster Bottom

5 Adjuster Lock Nut

6 Compression Screw

7 Compression Screw Lock Nut

8 Spring Washer

9 Spring

10 Insert Top

11 Insert Bottom

12 Main Piston

13 Cap (Compression Screw)

14 Cap Screw (Top Plate)

15 O-Ring (Adjuster Bottom)

16 O-Ring (Adjuster Top)

17 O-Ring (Insert)

18 O-Ring (Top Plate)

19 Bonnet

20 Spring Seal (Main Piston)

21 Spring Seal (Adjuster Top)

22 Spring Seal (Insert)

23 Field Test Connector

Vent Assembly/Bug Screen (Field Test Connection)

25 Vent Assembly (Bonnet Vent)

27 Set Screw (Bonnet)

28 Piston Nose

29 Piston Retainer Nut

30 Set Screw (Piston)

31 Vent Seal (Adaptor)

32 Spring Seal (Vent Seal Adaptor)

33 Back-up Ring (39MV72 Only)

34 Top Plate

Plug Filter (Used in Sensing Tube When Equipped) (Not Shown)

Note 1: Standard material is a filter plug. For special materials, vent assembly is supplied.

20 | BHGE

X. Operating Principles

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

PV 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 dierential area results in a net downward force keeping the main valve tightly closed.

Figure 8: PV Valve Closed (Normal Position)

Consolidated 2900 Series POSRV Maintenance Manual | 21

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

PV Valve OPEN (Relieving Position)

As inlet pressure increases, the pilot piston strokes and seals o the main valve inlet pressure from the dome pressure. The pilot simultaneously opens the vent seal to relieve the dome pressure to atmospheric pressure. The main valve disc is allowed to lift o the seat as the uid 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 preset 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 pressure, the downward force created by the dierential areas of the piston and disc closes the main valve.

X. Operating Principles (Contd.)

Figure 9: PV Valve OPEN (Relieving Position)

22 | BHGE

X. Operating Principles (Contd.)

Shown

out of

Position

Dome

Figure 10: MV07 Valve Closed (Normal Position)

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

MV07 Valve Closed (Normal Position)

Consolidated 2900 Series POSRV Maintenance Manual | 23

X. Operating Principles (Contd.)

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

MV07 Valve Modulating (Partial Relieving Position)

As inlet pressure increases, the pilot piston strokes and seals o the main valve inlet pressure from the dome pressure. The pilot simultaneously opens the vent seal to relieve the dome pressure to the bottom of the modulator piston. The modulator piston has a dierential 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 being 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 piston is sucient to move it to the closed position. A certain amount of pressure remains in the dome. This pressure is controlled by the dierential 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 10% overpressure.

MV07 Fully Open (Full Relieving Position)

As the inlet pressure increases further, the net upward force on the main valve disc increases, allowing the main valve to relieve more pressure. The disc obtains full lift (full capacity) within 10% of set pressure. When the discharging valve reduces the inlet pressure to the preset 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 pressure, the downward force created by the dierential areas of the piston and disc closes the main valve.

Shown

out of

Position

Dome

Figure 11: MV07 Valve Modulating (Partial Relieving Position)

24 | BHGE

XI. 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 specic plant's operating and service history will better determine this frequency. BHGE 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

• 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.

XII. Recommended Installation

Practices

A. Mounting Position

The POSRVs should be mounted in a vertical upright position (in accordance with API RP 520). Installing a pilot operated safety relief valve in any position other than vertical (±1 degree) will adversely aect its operation as a result of induced misalignment of moving parts.

A stop valve may be placed between the pressure vessel and its relief valve only as permitted by code regulations. If a stop valve is located between the pressure vessel and POSRV, the stop valve port area should equal or exceed the nominal internal area associated with the pipe size of the POSRV inlet. The pressure drop from the vessel to the POSRV shall not exceed 3% of the valve’s set pressure, when owing at full capacity.

Ensure the anges and sealing faces of the valve and connective piping are free from dirt, sediment, and scale.

Ensure all ange bolts are drawn evenly to prevent distortion of the valve body and the inlet nozzle.

Position the POSRVs for easy access and/or removal so that servicing can be properly performed. Ensure sucient working space is provided around and above the valve.

Decontaminate or

clean if necessary

before pretesting or

disassembly. Safety

and environmental

precautions must

be taken for the

decontamination or

cleaning method used.

Do not interchange

parts from one valve

to another.

Consolidated 2900 Series POSRV Maintenance Manual | 25

XII. Recommended Installation Practices (Contd.)

Vessel

Stop Valve

The pressure drop (P.D.) between the source of pressure in the protected equipment and the pressure relief valve inlet is not to exceed 3% of the valve set pressure.

P.D.

From Protected Equipment

P.D.

Figure 12: Pressure Drop on the Inlet Piping

B. Inlet Piping

The inlet piping (Figure 12) to the valve should be short and direct from the vessel, or equipment, being protected. The radius of the connection to the vessel should permit smooth ow to the valve. Avoid sharp corners. If this is not practical, then the inlet should be at least one additional pipe diameter larger. The pressure drop from the vessel to the valve shall not exceed 3% of valve set pressure when the valve is allowing full capacity ow. The inlet piping should never be smaller in diameter than the inlet connection of the valve. Excessive pressure drop in gas, vapor, or ashing- liquid service at the inlet of the POSRV will cause extremely rapid opening and closing of the valve, which is known as “chattering”. Chattering will result in lowered capacity and damage to the seating surfaces. The most desirable installation is that in which the nominal size of the inlet piping is the same as, or greater than, the nominal size of the valve inlet ange; and in which the length does not exceed the face-to-face dimensions of a standard tee of the required pressure class.

Do not locate POSRV inlets where excessive turbulence is present, such as near elbows, tees, bends, orice plates or throttling valves.

Section VIII of the ASME Boiler and Pressure Vessel Code requires the inlet connection design to consider stress conditions during valve operation, caused by external loading, vibration, and loads due to thermal expansion of the discharge piping.

The determination of reaction forces during valve discharge is the responsibility of the vessel and/or

piping designer. BHGE publishes certain technical information about reaction forces under various uid ow conditions, but assumes no liability for the calculations and design of the inlet piping.

External loading, by poorly designed discharge piping and support systems, and forced alignment of discharge piping can cause excessive stresses and distortions in the valve as well as the inlet piping. The stresses in the valve may cause a malfunction or leak. Therefore, discharge piping must be independently supported and carefully aligned.

Vibrations in the inlet piping systems may cause valve seat leakage and/or fatigue failure. These vibrations may cause the disc seat to slide back and forth across the nozzle seat and may result in damage to the seating surfaces. Also, vibration may cause separation of the seating surfaces and premature wear to valve parts. High-frequency vibrations are more detrimental to POSRV tightness than low-frequency vibrations. This eect can be minimized by providing a larger dierence between the operating pressure of the system and the set pressure of the valve, particularly under high frequency conditions.

Temperature changes in the discharge piping may be caused by uid owing from the discharge of the valve or by prolonged exposure to the sun or heat radiated from nearby equipment. A change in the discharge piping temperature will cause a change in the length of the piping, which may cause stresses to be transmitted to the POSRV and its inlet piping. Proper support, anchoring or provision for exibility of the discharge piping can prevent stresses caused by thermal changes. Do not use xe supports.

26 | BHGE

C. Outlet Piping

Alignment of the internal parts of the POSRV is important to ensure proper operation (see Figure 13). Although the valve body will withstand a considerable mechanical load, unsupported discharge piping consisting of more than a companion ange long-radius elbow, and a short vertical pipe is not recommended. Use spring supports to connect outlet piping to prevent thermal expansion from creating strains on the valve. The discharge piping should be designed to allow for vessel expansion as well as expansion of the discharge pipe itself. This is particularly important on long distance lines.

A continual oscillation of the discharge piping (wind loads) may induce stress distortion in the valve body. The resultant movement of the valve’s internal parts may cause leakage.

Where possible, use properly supported drainage piping to prevent the collection of water or corrosive liquid in the valve body.

In every case, the nominal discharge pipe size should be at least as large as the nominal size of the POSRV outlet ange In the case of long discharge piping, the nominal discharge pipe size must sometimes be much larger.

D. Remote Sensing

ATTENTION!

Change in elevation between relief valve and source

of sensing line may cause set pressure changes.

For block valve and other special installation features consult API 520 or the factory.

Long-Radius Elbow

Pan Drain

Drain

Pan

Stack

Long-Radius Elbow

WRONG

Cap may be

required

for weather

protection

Attach stack rigidly to structure. Do not connect

to drain pan or the discharge piping.

For a closed system, specific care must be taken to keep piping strains away from the pressure relief valve under all conditions of process operation and temperature.

Vessel Vessel Vessel

Figure 13: POSRV Parts Alignment

XII. Recommended Installation Practices (Contd.)

Consolidated 2900 Series POSRV Maintenance Manual | 27

E. Freeze Protection

Type of Applications:

1. Applications where the process media, in the liquid state, has a freezing point between the ambient temperature limits of the local region.

2. Steam service applications where the pilot operated valve is exposed to the climate, extreme cold ambient temperatures.

Example: the condensed steam in the pilot

and tubing may become frozen.

3. Applications where the process media is temperature sensitive to thick formations.

Example: Hydrocarbon applications where the

possibility of hydrate formation may occur.

Reasons for Freeze Protection:

1. If the pilot sensing line becomes clogged or frozen, then system pressure can be isolated from the pilot valve. This will not allow the pilot to detect system pressure, open and relieve the overpressure situation.

Recommendations for insulating and heat tracing

pilot operated safety relief valve:

Types of freeze protection:

a. Insulation by fiberglass blankets or wrap.

b. Heat tracing with electrical heat tape.

c. Radiant heat sources, such as a heat lamp.

For applications where heat tracing or radiant heaters are used, the temperature should be limited to approximately 200ºF (93.3ºC) so that the elastomers are not damaged. Higher temperatures may be allowed upon review of the application.

Valve illustrations showing acceptable locations for insulation are shown in Figures 14 and 15. Figure 14 shows a standard pilot operated relief valve. Figure 15 shows a pilot operated relief valve equipped with a heat exchanger.

XII. Recommended Installation Practices (Contd.)

Pilot Valve

Base

All Tubing

Insulation

not required

for Bonnet

and Cap

Main Valve

Base

Accessories

(I.E. Filters)

Figure 14: Pilot Operated Safety Relief Valve

Insulation

not required

for Bonnet

and Cap

Do not insulate

or cover

Heat Exchanger

top or bottom

Outside perimeter

of Heat Exchanger

may be insulated.

Cover Plate

Pilot

Valve

Main Valve

Base

Figure 15: POSRV with Heat Exchanger

28 | BHGE

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 valve, 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.

B. Disassembly of Main Valve

Note: If the pilot valve has not been removed,

then refer to Section XIII.A.

1. If applicable, remove sensing tube fitting from Sensing Tube

2. Remove and discard Plug Filter from Sensing Tube (if applicable).

3. Loosen and remove the Stud Nuts on the Cover Plate.

4. Remove the Bracket.

5. Install 1/4” MNPT pipe plug into Cover Plate where dome line is installed. Pipe plug will prevent Main Valve Piston from falling out of Cover Plate when the assembly is removed.

6. Remove Cover Plate and Main Valve Piston assembly from Base.

ATTENTION!

If Main Valve Piston O-Ring or Spring Energize

Seal is damaged, then Main Valve Piston may

fall out of Cover Plate during disassembly.

7. Remove pipe plug from Cover Plate.

8. Remove the Main Valve Piston from the Cover Plate using a dowel pressed through the center hole in the top of the Cover Plate.

XIII. Disassembly of the 2900 POSRV

Wear necessary

protective

equipment to

prevent possible

injury

Lower pressure

and stand clear of

discharge when

working on valve to

avoid severe personal

injury or death.

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

Consolidated 2900 Series POSRV Maintenance Manual | 29

XIII. Disassembly of the 2900 POSRV (Contd.)

Figure 16: Conventional Metal Seat Valve Disassembly

30 | BHGE

15 16

Figure 17: Bellows Metal Seat Valve Disassembly

XIII. Disassembly of the 2900 POSRV (Contd.)

Consolidated 2900 Series POSRV Maintenance Manual | 31

9. Remove the Cover Plate Gasket.

10. For “D” through “N” orifice, removed Disc Holder and Guide.

For “P” through “U” orifices, install the Disc Holder

Removal Tool (BHGE P/N 4464604) in the top of the Disc Holder as shown in Figure 21. Lift out and remove the Guide and Disc Holder. Remove the Lifting Tool from the top of the Disc Holder.

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 22. Lift out and remove the Guide and Disc Holder. Remove the Eye Bolts from the top of the Disc Holder.

11. Lift the 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.

Eye BoltsDisc Holder Guide

Top of Base

Lifting Tool

Guide

Disc Holder

Top of Base

Figure 21: Disc Holder Removal Tool (P-U)

Disc Holder

Disc Retainer

Thermodisc

Figure 18: Thermodisc

Disc Holder

O-Ring Seat Seal

O-Ring Retainer

Retainer Lockscrew

Figure 19: O-Ring Seat (D-J Orifices)

Disc Holder

Disc Retainer

O-Ring Seat Seal

Disc

O-Ring Retainer

Retainer Lockscrew

Figure 20: O-Ring Seat (K -W Orifices)

Figure 22: Disc Holder Removal Tool (V & W)

XIII. Disassembly of the 2900 POSRV (Contd.)

32 | BHGE

12. For D through U orifice bellows valves, the bellows is attached to the disc holder by right-hand threads. Use a special spanner wrench on the bellows ring to remove it by turning counterclockwise (Figure 23).

For V and W orifice bellows valves, the bellows is

bolted to the disc holder. Remove these bolts to disassemble the bellows from the disc holder.

ATTENTION!

The bellows convolutions are very thin and

fragile. Take care to protect them from damage.

13. Remove the bellows gasket.

14. Follow the procedure appropriate to the orifice valve type:

• For D through U orifice valves, remove the

disc from the disc holder as follows:

– Clamp the stem portion of the disc holder,

disc end up, firmly between two wooden V-blocks in a vise.

– Start inserting special drift pins into the

holes in the disc holder (Figure 24) with the tapered portion of the pins working against the top of the disc, as indicated. See Figure 82 and Table 19 in the Maintenance Tools and Supplies section for drift pin size.

– Use a light machinist hammer to tap each

pin alternately until the disc snaps out of the recess in the disc holder.

• For V and W orifice valves, remove the disc from the disc holder as follows:

– Turn the disc holder on its side.

– Remove the retaining bolts.

– Attach the lifting lug to the disc and lift out.

15. For O-Ring seat seal valves only, remove the Retainer Lock Screw(s), O-Ring Retainer, and O-Ring Seat Seal.

16. The nozzle is threaded onto the base and is removed by turning it counterclockwise (from right to left). Before removing the nozzle, soak the threaded joint with a suitable penetrating liquid or solvent. If the nozzle is frozen to the base, apply dry ice or other cooling medium to the inside of the nozzle and heat the base from the outside with a blowtorch in the area of the nozzle threads.

ATTENTION!

Should heat be applied, use care to

prevent cracking of cast parts.

17. Using a three- or four-jaw chuck welded vertically to a stand bolted to a concrete floor, clamp the nozzle into the chuck and break the body loose with a heavy rod or pipe (Figure 26).

ATTENTION!

Exercise care when inserting a rod or pipe

in the outlet. Ensure the valve nozzle is

not damaged during the operation.

Vise

Bellows Ring

Disc Holder

Bellows

Convolutions

Spanner Wrench

Soft Material

Bellows Gasket

Figure 23: Removal of Bellows Ring

Drift PinDrift Pin

Disc Holder

Disc

Figure 24: Removing the Disc with Drift Pins

XIII. Disassembly of the 2900 POSRV (Contd.)

Consolidated 2900 Series POSRV Maintenance Manual | 33

18. Use a large pipe wrench on the nozzle flange to remove the nozzle from the base (Figure 25).

ATTENTION!

The nozzle is normally removed for

routine maintenance and service.

19. Remove the Nozzle from the Valve Base as suggested in Figure 25, or by using a Hex wrench or a pipe wrench on the flange as indicated in Figure 26.

20. The Main valve is ready for cleaning, inspection and refurbishing.

21. Discard all O-Rings, guide rings, and seals.

C. Cleaning

1. Clean parts to remove all rust, burrs, scale, organic matter, and loose particles. Parts are to be free of any oil or grease except for lubrication as specified in this instruction.

2. Cleaning agents used shall be such that effective cleaning is assured without injuring the surface finishes or material properties of the part.

3. Acceptable cleaning agents include demineralized water, nonphosphate detergent, acetone, and isopropyl alcohol. Parts must be blown dry or wiped dry after cleaning.

4. 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.

5. Do not “sand blast” internal parts as it can reduce the dimensions of the parts.

Base

Nozzle

3 Jaw Chuck

Chuck Stand

8' (2.4 m)-10' (3 m)

Long Rod or

Heavy Pipe

Figure 25: Loosening the Nozzle from the Base

Base

Nozzle

Pipe Wrench

View From Top

View From Side

Figure 26: Removing the Nozzle from the Base

recommendations

for safe handling in

the solvent's Material

Safety Data Sheet

and observe safe practices for any

cleaning method

XIII. Disassembly of the 2900 POSRV (Contd.)

34 | BHGE

XIV. 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 necessary to put the valve in rst 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 by machining, not lapping. (For specic information concerning the machining of nozzle and disc seating surfaces, see The Re-Machining Nozzle Seats and Bores and Re-Machining the Disc Seat sections.)

The seating surfaces of the metal seated Consolidated Safety Relief Valve are at. The nozzle seat is relieved by a 5° angle on the outside of the at seat. The disc seat is wider than the nozzle seat; thus, the control of seat width is the nozzle seat (see Figure 27).

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 orice valve is disassembled, be sure to inspect the Guide Rings for wear. If worn, replace before reassembly.

ATTENTION!

In order to establish leak free valve seats,

the nozzle seating surface and the disc

seating surface must be lapped at..

B. O-Ring Seat

The nozzle must not have any defects to prohibit the O-Ring from sealing properly, especially the OD of the seat where the surface must maintain a minimum of 32 RMS nish. See Figure 27 and Table 2 for reworking O-Ring Nozzle.

The O-Ring Retainer must also maintain a at surface for it to sit on the Nozzle. Only polishing of surface can be done since material removal from this surface will cause the Nozzle to over engage O-Ring. Polishing paper or some other light abrasive can only be used since the part cannot function properly if its overall dimensions are changed signicantly. If signicant corrosion or damage has occurred on O-Ring retainer, discard and replace.

45°

Nozzle

Bore

5°

Nozzle

Bore

Figure 27a: Metal Seat Nozzle Figure 27b: Soft Seat Nozzle

Figure 27: Main Valve Nozzle Critical Dimensions

Consolidated 2900 Series POSRV Maintenance Manual | 35

XIV. Maintenance Instructions (Contd.)

Note 1: Do not remachine threaded areas of the nozzle to reestablish “D” Dimension. Once “D” minimum is

reached, replacement of nozzle is necessary.

Table 2: Nozzle Critical Dimensions

Orice

Nozzle Bore

D min.1

E ± .005”

(0.13 mm)

F H

min. max.

in. mm in. mm in. mm in. mm in. mm. in. mm.

D .402 10.21 .409 10.39 .313 7.95 .030 0.76 .954 ± .001 24.23 ± 0.03 .831 ± .001 21.11 ± 0.03

E .539 13.69 .544 13.82 .31 3 7.95 .030 0.76 .954 ± .001 24 .23 ± 0.03 .831 ± .001 21.11 ± 0.03

F .674 17.12 .679 17. 25 .313 7.9 5 .030 0.76 .954 ± .001 24.23 ± 0.03 . 831 ± .001 21.11 ± 0.03

G .864 21.95 .869 22.07 .313 7.9 5 .035 0.89 1.093 ± .001 2 7.76 ± 0.03 .953 ± .001 24.21 ± 0.03

H 1.078 27.38 1.083 27. 51 .250 6.35 .035 0.89 1. 224 ± .001 31.09 ± 0.03 1.123 ± .001 28.52 ± 0.03

J 1.380 35.05 1.385 35.18 .375 9.53 .035 0.89 1.545 ± .001 39.24 ± 0.03 1.435 ± .001 36.45 ± 0.03

K 1.650 41.91 1.655 42.04 .438 11.13 .063 1.60 1.836 ± .002 46.63 ± 0.05 1.711 ± .002 43.46 ± 0.05

L 2.055 52.20 2.060 52.32 .438 11.13 .063 1.60 2.257 ± .002 57.33 ± 0.05 2.133 ± .002 54.18 ± 0.05

M 2.309 58.65 2.314 58.78 .438 11.13 .063 1.60 2.525 ± .002 64.14 ± 0.05 2.400 ± .002 60.96 ± 0.05

N 2.535 64.39 2.540 64.52 .500 12.70 .063 1.60 2.777 ± .002 70.54 ± 0.05 2.627 ± .002 66.73 ± 0.05

P 3.073 78.05 3.078 78.18 .625 15.88 .093 2.36 3.332 ± .002 84.63 0.05 3.182 ± .002 80.82 ± 0.05

Q 4.045 102.74 4.050 102.87 .875 22.23 .093 2.36 4.335 ± .003 110.11 ± 0.08 4.185 ± .003 106.30 ± 0.08

R 4.867 123.62 4.872 123.75 1.000 25.40 .093 2.36 5.110 ± .003 129.79 ± 0.08 4.960 ± .003 125.98 ± 0.08

T 6.202 1 57.53 6.208 157. 6 8 .750 19.05 .093 2.36 6.510 ± .003 165.35 ± 0.08 6 .315 ± .003 160.40 ± 0.08

U 6.685 169.80 6.691 169.95 .750 19.05 .093 2.36 6.993 ± .003 177. 62 ± 0.08 6.798 ± .003 172.67 ± 0.08

V 8.000 203.20 8.005 203.33 1.250 31.75 .250 6.35 8.816 ± .005 223.93 ± 0.13 8.336 ± .005 211.73 ± 0.13

W 10.029 2 54.74 10.034 254.86 1.750 44.45 .350 8.89 11.058 ± .005 280.87 ± 0.13 10.458 ± .005 265.63 ± 0.13

Table 2: Nozzle Critical Dimensions (Contd.)

Orice

±0.5°

Radius B

± .001” (0.03 mm)

J ± .005”

(0.13 mm)

K L

in. mm in. mm in. mm in. mm in. mm

D .038

+-.002

.003

0.97

+-0.05

0.08

30° .016 0.41 .079 2.01 0.867 ± .001 22.02 ± 0.03 . 813 ± .001 20.65 ± 0.03

E .038

+-.002

.003

0.97

+-0.05

0.08

30° .016 0.41 .079 2.01 0.867 ± .001 22.02 ± 0.03 . 813 ± .001 20.65 ± 0.03

F .038

+-.002

.003

0.97

+-0.05

0.08

30° .016 0.41 .079 2.01 0.867 ± .001 22.02 ± 0.03 . 813 ± .001 20.65 ± 0.03

G .038

+-.002

.003

0.97

+-0.05

0.08

30° .022 0.56 .090 2.29 1.058

+-.002

.001

26.87

+-0.05

0.03

.998 ± .001 25.35 ± 0.03

H .035

+-.002

.003

0.89

+-0.05

0.08

45° .022 0.56 .060 1.52 1.214

+-.002

.001

30.84

+-0.05

0.03

1.165

+-.002

.001

29.59

+-0.05

0.03

J .035 ± .005 0.89 ± 0.13 45° .022 0.56 .074 1.88 1.532

+-.002

.001

38.91

+-0.05

0.03

1.479

+-.002

.001

37. 57

+-0.05

0.03

K .063 ± .005 1.60 ± 0.13 45° .022 0.56 .126 3.20 1.836 ± .002 46.63 ± 0.05 1.780

+-.001

.002

45.21

+-0.03

0.05

L .063 ± .005 1.60 ± 0.13 45° .017 0.43 .126 3.20 2.206 ± .002 56.03 ± 0.05 2.156 ± .002 54.76 ± 0.05

M .063 ± .005 1.60 ± 0.13 45° .022 0.56 .126 3.20 2.534 ± .002 64.36 ± 0.05 2.478 ± .002 62.94 ± 0.05

N .063 ± .005 1.60 ± 0.13 45° .022 0.56 .101 2.57 2.706 ± .002 68.73 ± 0.05 2.650 ± .002 67. 31 ± 0.05

P .093 ± .005 2.36 ± 0.13 45° .022 0.56 .150 3.81 3.332 ± .002 84.63 ± 0.05 3.277

+-.002

.003

83. 24

+-0.05

0.08 Q .093 ± .005 2.36 ± 0.13 45° .022 0.56 .188 4.78 4.335 ± .003 110.11 ± 0.08 4.281 ± .003 108 .74 ± 0.08 R .093 ± .005 2.36 ± 0.13 45° .022 0.56 .215 5.46 5.092 ± .003 129.34 ± 0.08 5.033 ± .003 1 27.84 ± 0.08

T .093 ± .005 2.36 ± 0.13 45° .022 0.56 .142 3.61 6.510

+-.003

.004

165.35

+-0.08

0.10

6.420

+-.004

.003

163.07

+-0.10

0.08

U .093 ± .005 2.36 ± 0.13 45° .022 0.56 .142 3.61 6.992 ± .003 177.60 ± 0.08 6.902 ± .0 03 175.31 ± 0.08

V .275 ± .005 6.99 ± 0.13 30° .020 0.51 .275 6.99 9.125 ± .005 231.78 ± 0.13 8.336 ± .003 211.73 ± 0.08

W .353 ± .005 8.97 ± 0.13 30° .020 ± .005 0.51±0.13 .353 8 .97 11.125 ± .005 282.58 ± 0.13 10.458 ± .005 265.63 ± 0.13

36 | BHGE

C. Lapping Nozzle Seats (Metal Seat,

Non-O-Ring Styles)

ATTENTION!

Nozzle laps as illustrated in Figure 28 are available

from BHGE. Do not use these laps if the valve

nozzle can be removed and machined to the seat

dimensions described in Table 3 and Table 4.

Lap the 5º angle of the nozzle rst (Figure 28, View A). Then, invert the nozzle lap and use the at side as a “starter” lap to ensure the seat is square (Figure 28, View B). Use a ring lap in a circular motion to nish lapping (See Figure 28, View C and Reconditioning of Laps). Keep the lap squarely on the at surface and avoid rocking the lap, which will cause rounding of the seat.

D. Lapped Nozzle Seat Widths

A wide nozzle seat will induce leakage, especially in the smaller-orice, lower-pressure valves. For this reason, the seat of valves other than 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 pressure force, the higher pressure valves must have wider seats than the lower pressure valves. The nozzle seat width should conform to the measurements in Table 3 and Table 4.

To measure the seat width, use a Model S1-34-35-37 Bausch and Lomb Optical Co. measuring magnier or an equivalent seven-power glass with a 3/4” (19.05 mm) scale showing graduations of 0.005” (0.13 mm). Figure

29a and 29b illustrate the use of this tool in measuring the nozzle seat width. If additional lighting is required for measuring, use a gooseneck ashlight similar to the Type A Lamp Assembly (Standard Molding Corp.), or equivalent.

XIV. Maintenance Instructions (Contd.)

Nozzle Lap

90˚

85˚

Ring Lap

View A

View C

View B

Nozzle Lap

85˚

90˚

Figure 28: Lapping Nozzle Seats

Figure 29: Measuring Magnifier

Figure 29a: Measuring Magnifier

Measuring Magnifier

Nozzle

Figure 29b: Magnifier Details

Consolidated 2900 Series POSRV Maintenance Manual | 37

XIV. Maintenance Instructions (Contd.)

Note 1: Seat widths for set pressures below 15 psig (1.03

barg) should be approximately the same as those shown for 15 psig (1.03 barg).

Note 2: 042” + .005" (1.07 + 0.13 mm) per 100 psig (6.89 barg). Not to exceed .070 ± .005" (1.78±0.13 mm).

Note 3: 040” + .005” (1.02 + 0.13 mm) per 100 psig (6.89 barg). Not to exceed .070 ± .005” (1.78±0.13 mm).

Note 4: 048” + .005” (1.22 + 0.13 mm) per 100 psig (6.89 barg). Not to exceed .070 ± .005” (1.78±0.13 mm).

Table 3: Approximate Nozzle Seat Width

(Std. Metal Seat Designs)

Orice

Set Pressure Range1Lapped Seat Width

min. max. min. max.

psig barg psig barg in. mm in. mm

D - G

1 0.07 50 3.45 .012 0.30 .015 0.38

51 3.52 10 0 6.89 .015 0.38 .022 0.56 101 6.96 250 17. 24 .022 0.56 .028 0.71 251 17.31 400 27.58 .028 0.71 .035 0.89

401 27. 65 800 55.16 .035 0.89 .042 1.07 801 55.23 Above Note 2 Note 2

H - J

1 0.07 50 3.45 .019 0.48 .022 0.56

51 3.52 10 0 6.89 .022 0.56 .027 0.69 101 6.96 250 17. 24 .027 0.69 .031 0.79 251 17.31 400 27.58 .031 0.79 .035 0.89

401 27. 65 800 55.16 .035 0.89 .040 1.02 801 55.23 Above Note 3 Note 3

K - N

1 0.07 50 3.45 .025 0.64 .028 0.71

51 3.52 10 0 6.89 .028 0.71 .033 0.84 101 6.96 250 17. 24 .033 0.84 .038 0.97 251 17.31 400 27.58 .038 0.97 .043 1.09

401 27. 65 800 55.16 .043 1.09 .048 1.22 801 55.23 Above Note 4 Note 4

P - R

1 0.07 50 3.45 .030 0.76 .034 0.86

51 3.52 10 0 6.89 .034 0.86 .041 1.04 101 6.96 251 17.31 .041 1.04 .049 1.24 251 17.31 400 27.58 .049 1.24 .056 1.42

401 27. 65 800 55.16 .056 1.42 .062 1.57 801 55.23 Above .062 1.57 .064 1.63

1 0.07 50 3.45 .040 1.02 .043 1.09

51 3.52 10 0 6.89 .043 1.09 .049 1. 24 101 6.96 250 17. 24 .049 1.24 .057 1.45 251 17.31 300 20.68 .057 1.45 .060 1.52

1 0.07 50 3.45 .040 1.02 .043 1.09

51 3.52 10 0 6.89 .043 1.09 .049 1. 24 101 6.96 250 17. 24 .049 1.24 .057 1.45 251 17.31 300 20.68 .057 1.45 .060 1.52

1 0.07 50 3.45 .075 1.91 .083 2.11

51 3.52 10 0 6.89 .083 2.11 .103 2.62 101 6.96 250 17. 24 .103 2.62 .123 3.12 251 17.31 300 20.68 .123 3.12 .130 3.30

1 0.07 50 3.45 .100 2.54 .110 2.79

51 3.52 10 0 6.89 .110 2.79 .130 3.30 101 6.96 250 17. 24 .130 3.30 .150 3.81 251 17.31 300 20.68 .150 3.81 .160 4.06

Table 4: Approx. Nozzle Seat Width

(Thermodisc Designs)

Orice

Set Pressure Range1Lapped Seat Width

min. max. min. max.

psig barg psig barg in. mm in. mm

D - F

1 0.07 100 6.89 .020 0.51 .035 0.89

101 6.96 300 20.68 .035 0.89 .045 1.14

301 20.75 800 55.16 .045 1.14 .055 1.40

801 55.23 Above Full Width

G - J

1 0.07 100 6.89 .025 0.64 .035 0.89

101 6.96 300 20.68 .035 0.89 .045 1.14

301 20.75 800 55.16 .045 1.14 .055 1.40

801 55.23 Above Full Width

K - N

1 0.07 100 6.89 .035 0.89 .045 1.14

101 6.96 300 20.68 .045 1.14 .055 1.40

301 20.75 800 55.16 .055 1.40 .065 1.65

801 55.23 Above Full Width

P - R

1 0.07 100 6.89 .040 1.02 .050 1.27

101 6.96 130 8.96 .050 1.27 .060 1.52

131 9.03 800 55.16 .060 1.52 .070 1.78

801 55.23 Above Full Width

1 0.07 100 6.89 .050 1.27 .060 1.52

101 6.96 300 20.68 .060 1.52 .075 1.91

1 0.07 100 6.89 .050 1.27 .060 1.52

101 6.96 300 20.68 .060 1.52 .075 1.91

1 0.07 100 6.89 .075 1.91 .100 2.54

101 6.96 300 20.68 .100 2.54 .130 3.30

1 0.07 100 6.89 .100 2.54 .125 3.18

101 6.96 300 20.68 .125 3.18 .160 4.06

Note 1: Seat widths for set pressures below 15 psig (1.03 barg) should be approximately the same as those shown for 15 psig (1.03 barg).

Note 2: Not to exceed .070 ± .005" (1.78±0.13 mm).

38 | BHGE

E. Lapping Disc Seats

Use a ring lap or lapping plate to lap the disc in a circular motion, applying uniform pressure and slowly rotating the disc or lap.

• Apply 1000 lapping compound (see Table 18 in Lapping Tools Section XXIII.C. Lap disc to a polish finish.

• Remove lapping compound completely from Disc and Disc Holder.

F. Precautions and Hints for

Lapping Seats

To ensure a quality lapping process, observe the following precautions and guidelines:

Keep work materials clean. Always use a fresh lap. If signs of wear (out of atness) are evident, recondition the lap.

Apply a very thin layer of lapping compound to the lap to prevent rounding o the edges of the seat.

Keep the lap squarely on the at surface, and avoid rocking the lap, which causes rounding of the seat.

When lapping, keep a rm grip on the lapped part to prevent dropping it and damaging the seat.

Lap in a circular motion while applying a uniform pressure. Slowly rotate the lap to evenly distribute the lapping compound. Wipe o the old compound and replace it with new compound frequently. Apply more pressure to speed the cutting action of the compound. To check the seating surfaces, remove all compound from the seat and the lap. Then, shine the seat with the same lap using the lapping method as described above. Low sections on the seating surface show up as shadow in contrast to the shiny portion. If shadows are present, further lapping is necessary. Only laps known to be at can be used. It should take only a few minutes to remove the shadows.

When lapping is complete, any lines appearing as crossscratches can be removed by rotating the lap on its axis (which has been wiped clean of compound) on the seat. Thoroughly clean the lapped seat using lint free cloth and a cleansing uid.

ATTENTION!

Before assembly, grind the contact surfaces of the nozzle and O-Ring retainer to provide metal-to-metal seat tightness in the event of O-Ring failure.

G. Reconditioning of Laps

Ring laps are reconditioned by lapping them on a at lapping plate in a gure-eight motion (Figure 30). To ensure the best results, recondition the ring laps after each use. Use an optical at to check the quality of the lap.

Nozzle laps must be re-machined to recondition the lapping surfaces. Place the nozzle lap in a lathe between centers (Figure 31). The surfaces marked A and B must be running concentric.

Lapping Plate

Ring Lap

Figure 30: Lapping Pattern

Lathe Center Lathe Center

85°90°

Figure 31: Nozzle Lap in a Lathe

XIV. Maintenance Instructions (Contd.)

Consolidated 2900 Series POSRV Maintenance Manual | 39

H. Re-Machining Nozzle Seats

1. Remove the nozzle from the valve to be

remachined. If it cannot be removed from the base, re-machine it inside the base.

2. Take the following steps to setup the lathe and

nozzle:

a. Grip the nozzle 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 nozzle as shown at A (Figure 32).

b. True up the nozzle so that the surfaces marked

B and C run true within .001” (0.03 mm) on indicator (Figure 32).

3. Take the following steps to re-machine the

metal-to-metal nozzle (Figure 27a and Table 2):

a. Make light cuts across the surface L at 5º until

the damaged areas are removed. Turn to the smoothest possible finish.

b. The nozzle is now ready for lapping.

c. When the minimum dimension H is reached,

discard the nozzle.

4. Take the following steps to re-machine the O-Ring

seat seal (Figure 27b and Table 2):

a. Make light cuts across surface A (45º) until

the damaged areas are removed. Turn to the smoothest possible finish.

b. Re-machine radius R.

c. The nozzle is now ready for lapping.

d. When the minimum dimension H is reached,

discard the nozzle.

I. Re-Machining the Disc Seat

Take the following steps to machine the standard disc seating surface (Figure 33):

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” (0.03 mm), TIR.

3. Make light cuts across the seating surface L until damaged areas are removed. Turn to the smoothest possible finish.

4. The disc is now ready for lapping.

5. Discard the disc if the minimum dimension N or T (Figure 34, Table 5) is reached. Do not reestablish surface C.

ATTENTION!

Do not remachine a Thermodisc or O-Ring Retainer.

Figure 32: Nozzle Positioned in a Jaw

90°

Disc

Chuck Jaw

Figure 33: Standard Disc Seating Surface

XIV. Maintenance Instructions (Contd.)

40 | BHGE

XIV. Maintenance Instructions (Contd.)

Table 5: Metal Seat Disc Machining Dimensions

Disc Type Orice Size

T min. N min.

in. mm in. mm

Type 1

D .174 4.42 .010 0.25

E .174 4.42 .010 0.25

F .174 4.42 .010 0.25

G .174 4.42 .010 0.25

H .335 8 .51 .010 0.25

Type 2

J .369 9.37 .010 0.25

K .432 10.97 .038 0.97

L .467 11.86 .038 0.97

M .467 11.86 .038 0.97

N .495 12.57 .038 0.97

P .620 15.75 .068 1.73

Q .620 15.75 .068 1.73

R .620 15.75 .068 1.73

T .832 21.13 .068 1.73

U .833 21.16 .068 1.73

Type 3

V 1.230 31 .24 .120 3.05

W 1.855 47.12 .168 4.27

Figure 34: Metal and Soft Seat Disc Inspection Areas

Figure 34b: Type 2

J - U Orifice

Figure 34d:

Disc O-Ring Soft Seat (K-U Orifices Only)

Figure 34a: Type 1

D - H Orifice

Figure 34c: Type 3

V&W Orifice

Consolidated 2900 Series POSRV Maintenance Manual | 41

XV. Inspection and Part Replacement

1. Guide Replacement Criteria:

2900 Series Guide should be replaced:

a. if the sliding surface is galled, pitted or scratched

or the machined gasket surfaces are damaged.

b. The “A” dimension (See Figures 35, 36) exceeds

A max. in Table 6.

Table 6: Guide Critical Dimension

Orice

A max.

Orice

A max.

in. mm in. mm

D .455 11.56 N 1.876 47.65

E .455 11.56 P 2. 314 58.78

F .455 11.56 Q 2.314 58.78

G .500 12.70 R 2.314 58.78

H .688 17.48 T 2.313 58.75

J 1.001 25.43 U 2.313 58.75

K 1.251 31.78 V 6.446 163.73

L 1.376 34.95 W 8.446 214.53

M 1.751 44.48

2. Base: Inspect general condition for cracks or holes. Look for any corrosion issues.

3. Bellows: Inspect general condition for cracks, holes or deformation of convolutions. Check for any corrosion or pitting.

4. Cover Plate: Cover Plate 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.

5. O-Ring Retainer: Inspect surface that sits on the disc for any corrosion or defects that might cause the disc not to sit flush with nozzle.

Figure 35b: V & W Orifice

Figure 35: Guide Critical Dimensions

(Metal Seat)

Figure 35a: D-U Orifice

Figure 36: Guide Critical Dimensions

(Bellows)

Figure 36b: H-U Orifice

Figure 36a: D-G Orifice

Figure 36c: V&W Orifice

42 | BHGE

6. Nozzle: Nozzle should be replaced if:

a. The seat width requires adjustment, and the

Dimension from the seat to the first thread is less than “D” minimum on Table 2.

b. Thread sections are damaged from pitting

and/or corrosion.

c. Top of the nozzle flange and intersecting surface

are damaged from galling and/or tearing.

d. The nozzle flange thickness can change center

to face Dimensions. The minimum dimension for orifices “D” through “P” is .672” (16.50 mm) and “Q” through “W” orifices is .797” (20.20 mm).

Nozzle Seat Width: Using a measuring magnifying

glass, (see Lapped Nozzle Seat Widths), determine whether the finish lapped seat surface must be machined before lapping. If the seat can be lapped flat without exceeding the required seat width, as indicated in Table 3 or 4, it does not require machining.

To reduce the seat width, the 5º angle surface

must be machined. The nozzle must be replaced if the D min is reduced below the minimum as indicated in Table 2.

7. Spring: Check for any corrosion or pitting.

8. Standard Metal Seated Disc: This disc (Figure 34) can be machined until the T dimension is reduced to the minimum, as listed in Table 5. The “N” minimum dimension must be maintained as well.

9. Thermodisc* Metal Seated Disc: This disc (Figure

37) cannot be machined. It can be lapped as long as the “A” minimum dimension has been maintained. If lapping does not fix damaged area, part must be discarded.

The Thermodisc must be replaced if:

a. Seat defects and damage cannot be lapped out

without reducing the “A” dimension in Figure 37 that is listed in Table 7.

b. If the dimension cannot be measured, replace

the Thermodisc.

10. O-Ring Seated Disc: The O-Ring Retainer cannot

XV. Inspection and Part Replacement (Contd.)

Figure 37: Thermodisc Design

Figure 37b: J-U Orifices

Figure 37c: V&W Orifices

Figure 37a: D-H Orifices

Table 7: Thermodisc Replacement Criteria

Orice

A min.

in. mm

D .006 0.15

E .006 0.15

F .006 0.15

G .006 0.15

H .006 0.15

J .013 0.33

K .014 0.36

L .014 0.36

M .014 0.36

N .014 0.36

P .017 0.43

Q .015 0.38

R .015 0.38

T .025 0.64

U .025 0.64

V .035 0.89

W .035 0.89

Consolidated 2900 Series POSRV Maintenance Manual | 43

be machined. It can be lapped for minor scratches. If lapping does not fix damaged area, part must be discarded.

11. Disc Holder: Disc Holder should be replaced if the sliding surface of the Holder is galled, pitted, or scratched.

12. Solid Metal Gaskets: Solid Metal Gaskets can be reused unless they are corroded, pitted, or crimped.

13. Main Valve Piston Replacement Criteria:

The Piston should be re-used if:

a. There is no indication of galling, scratched,

corroded or pitted on any surface of the piston.

b. The “B” & “E” dimensions (See Figure 38) are less

than “B” minimum and “E” minimum, indicated in Table 8.

Replace all parts as needed. 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 aect product performance. All o-rings and seals should be replaced each time the valve is disassembled.

Refer to Tables 23 for a list of recommended spare parts and Table 24 for a list of O-Ring repair kits.

XV. Inspection and Part Replacement (Contd.)

Figure 38: Main Valve Piston

Figure 38a:

D-G Orifice

(Bellows)

Figure 38b:

H-W Orifice (Bellows),

D-W Orifice

(Conventional)

Table 8: Piston Critical Dimensions

Orice

B min. E min.

in. mm in. mm

D .989 25.12 .74 8 19.00

E .989 25.12 .74 8 19.00

F .989 25.12 .74 8 19.00

G 1.114 28.30 .873 22.17

H 1.365 34.67 .998 25.35

J 1.677 42.60 1.310 33.27

K 1.990 50.55 1.623 41.22

L 2.490 63.25 2.123 53.92

M 2.867 72.82 2.498 63.45

N 3.117 79.17 2.748 69.80

P 3.741 95.02 3.372 85.65

Q 4.861 123.47 4.498 114.25

R 5.735 145.67 5.372 136.45

T 7.360 186.94 6.997 177.72

U 8.110 205.99 7.747 196.77

V 9.662 245.41 9.500 241.30

W Contact BHGE Engineering Department.

44 | BHGE

A. Lubricants and Sealants

1. Operating temperatures below -40°F (-40°C), consult the Factory.

2. Operating temperatures between -40 and +505°F (-40 and 262.7°C)

a. Lubricate all o-rings, except silicone, spring

energized seals, and back-up rings sparingly with silicone grease (BHGE P/N SP505).

b. Seal all pipe threads with Teflon tape or pipe

sealant (BHGE P/N SP364-AB).

c. Lubricate standard threads and bearing points

with Jet-Lube, BHGE non-metallic, product code #14613 (BHGE P/N4114510 or 4114511).

3. Operating temperatures above +505°F (262.7°C)

a. Lubricate all o-rings, except silicone, spring

energized seals, and back-up rings sparingly with silicone grease (BHGE P/N SP505).

b. Seal all pipe threads with Teflon tape or pipe

sealant (BHGE P/N SP364-AB).

c. Lubricate standard threads and bearing points

with nickel graphite N5000 (BHGE P/N 4114507) or equivalent.

B. Assembly Procedure with Metal

Seats

1. If the valve Nozzle was removed, apply thread lubricant to the nozzle threads before reinstalling in the Base. Insert it into the inlet flange of the Base, and torque to the correct value listed in Table 9.

2. Assemble the disc/disc holder as follows:

a. Prior to assembly of the Disc into the Disc

Holder, remove the Disc Retainer 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 “D” through “U” orifice valves, place the

Disc Retainer into the groove in the disc. The Disc with the Disc Retainer should “snap” into the Disc Holder pocket with moderate finger or hand force. Do not use excessive force to assemble 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.

XVI. Reassembly of the 2900 Main Valve

Table 10: Disc Holder Torque Values

Orice

No. of

Bolts

Bolt Size

Torque

in-lbs N-m

D, E, F 1 1/4-28UNF 75 ± 3 8.5 ± 0.3

G 1 1/4-28UNF 75 ± 3 8.5 ± 0.3

H 1 1/4-28UNF 75 ± 3 8.5 ± 0.3

J 3 #10 -32UNF 30 ± 2 3.4 ± 0.2

K 3 #8-32NC 18 ± 1 2.0 ± 0.1

L 3 #8-32NC 18 ± 1 2.0 ± 0.1

M 4 #8-32NC 18 ± 1 2.0 ± 0.1

N 4 #8-32NC 18 ± 1 2.0 ± 0.1

P 4 1/4-28UNF 75 ± 3 8.5 ± 0.3

Q 4 1/4-28UNF 75 ± 3 8.5 ± 0.3

R 4 1/4-28UNF 75 ± 3 8.5 ± 0.3

T 4 1/4-28UNF 75 ± 3 8.5 ± 0.3

U 4 1/4-28UNF 75 ± 3 8.5 ± 0.3

V - - - -

W - - - -

Table 9: Nozzle Torque Values +10% - 0%

Orice

Required Torque

ft-lbs Nm

D, E & F 165 224

G 145 197

H 165 224

J 335 454

K 430 583

L 550 746

M 550 746

N 640 868

P 1020 1383

Q 1400 1898

R 1070 1451

T 1920 2603

U 1920 2603

V 1960 2657

W 2000 2712

Note: DO NOT USE impact wrench on “D” through “K”

orifice Nozzles.

Consolidated 2900 Series POSRV Maintenance Manual | 45

C. Assembly Procedure with O-Ring

Seats

2. Assemble the disc/disc holder as follows:

a. For disc sizes “D” thru “J”, reassemble the Disc

Holder using a new O-Ring, O-Ring Retainer, and new Lock Screw(s). Refer to Table 10 for the proper torque. These Disc Holders are ready for the next step.

b. For disc sizes “K” thru “W”, reassemble the

Disc using a new O-Ring, O-Ring Retainer, and new Lock Screws. Refer to Table 10 for the proper torque.

(i) Prior to assembly of the Disc into the Disc

Holder, remove the Disc Retainer 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.

(ii) Place the Disc Retainer into the groove

in the disc. The Disc with the Disc Retainer should “snap” into the Disc Holder pocket with moderate finger or hand force. Do not use excessive force to assemble 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.

3. Set the Disc Holder (disc side down), on the work surface. Place a small amount of 1000 grit grinding compound onto the ball end of the Main Valve Piston and place it in the disc holder pocket. Turn the Main Valve Piston clockwise, and then counter clockwise, to seat the Main Valve Piston. Clean all grinding compound from parts.

4. a. For bellows valves “D” through “U”, place a new Bellows Gasket on the Disc Holder. Thread the Bellows, finger-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.

b. 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.

c. For Spring Assist valves, place the Spring down

onto the Disc Holder.

5. a. For D through U orifice valves:

Place the Guide over the Disc Holder. (DO NOT

DROP.) If Bellows is present, the weight of the Guide will slightly compress the Bellows.

b. For V and W orifice valves:

Install guide rings into the grooves located inside

the guide ID. Make sure the space where the upper and lower guide ring ends meet is positioned 180° apart. Mark both the guide and disc holder at the point where the bottom guide ring ends meet. This mark must be faced 180° away from the outlet when the assembly is place into the valve. Gently lower the guide down onto the disc holder ensuring that guide rings remain in their respective groove.

6. Place the Guide Gasket in the Base.

7. Install disc guide assembly. Use the same lifting tools (see Figure 21 and Figure 22) as was used during disassembly, then carefully lower it into the 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 Main Valve Piston and measure and cut diagonally the proper length of Guide Ring material to fit in the groove of the Main Valve Piston. Allow 1/16 of an inch gap between the ends for proper fit.

10. For Teflon seals make sure of the integrity of the Teflon seal and seal spring. Install Disc Seal on Disc outside diameter on the opposite end of the disc seat as shown in Figure 39.

XVI. Reassembly of the 2900 Main Valve (Contd.)

Main Valve Piston

Main Valve Piston O-Ring

Guide Ring

Figure 39: Main Valve Piston

46 | BHGE

XVI. Reassembly of the 2900 Main Valve (Contd.)

Table 11: Cover Plate Nut Torque

Orice

2905 2906 2910 2912 2914 2916 2918

ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm

D 55 75 55 75 55 75 60 81 60 81 60 81 120 163

E 55 75 55 75 55 75 60 81 60 81 60 81 120 163

F 55 75 55 75 55 75 60 81 70 95 70 95 115 156

G 55 75 55 75 55 75 60 81 70 95 70 95 75 102

H 90 122 90 122 60 81 75 102 65 88 65 88 — —

J 60 81 60 81 75 102 100 136 100 136 100 136 — —

K 65 88 65 88 60 81 60 81 135 183 145 197 — —

L 75 102 75 102 90 122 90 122 140 190 140 190 — —

M 95 129 95 129 110 149 95 129 95 129 — — — —

N 105 142 105 142 130 176 85 115 85 115 — — — —

P 120 163 120 163 145 197 125 169 125 169 — — — —

Q 105 142 105 142 125 169 150 203 — — — — — —

R 115 156 115 156 115 156 135 183 — — — — — —

T 95 129 95 129 95 129 125 169 — — — — — —

U 95 129 95 129 95 129 125 169 — — — — — —

V 130 176 130 176 130 176 — — — — — — — —

W 130 176 130 176 130 176 — — — — — — — —

Table 11: Cover Plate Nut Torque (Contd.)

Orice

2920 2922 2923 2924 2926 2928

ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm

D 55 75 55 75 — — 60 81 60 81 115 156

E 55 75 55 75 — — 60 81 60 81 115 156

F 55 75 55 75 — — 70 95 70 95 115 156

G 55 75 60 81 — — 70 95 70 95 75 102

H 60 81 60 81 — — 75 102 85 115 — —

J 75 102 75 102 — — 100 136 100 136 — —

K 60 81 60 81 — — 60 81 140 190 — —

L 90 122 90 122 — — 140 190 140 190 — —

M 90 122 95 129 — — 95 129 — — — —

N 130 176 85 115 — — 85 115 — — — —

P 145 197 — — 125 169 125 169 — — — —

Q 105 142 150 203 — — — — — — — —

R 115 156 135 183 — — — — — — — —

T 125 169 — — — — — — — — — —

U 125 169 — — — — — — — — — —

V 130 176 — — — — — — — — — —

W 130 176 — — — — — — — — — —

Consolidated 2900 Series POSRV Maintenance Manual | 47

If an O-Ring seal is used, it is installed in the groove between where the Guide Ring is installed and where a Spring Energized Seal would be installed (Figure 16).

11. Install the Guide Ring(s) onto the Main Valve 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 Cover Plate for burrs. If any sharp edges exist, polish the chamfer.

13. Insert Main Valve Piston (energize seal/o-ring side first) into bottom of Cover Plate. Continue pushing Main Valve Piston into Cover Plate, being careful not to pinch the guide rings. Push Main Valve Piston in until bottom of Main Valve Piston is even with the bottom of the Cover Plate.

14. Install 1/4” MNPT pipe plug into Cover Plate where dome line connects.

15. Install Cover Plate Gasket. Install Cover Plate on top of Base such that the pilot will be aligned for proper tubing connections. Make note of the length of the studs. The two longer ones will straddle the vertical line of the inlet sensing port on the Main Base of the pilot valve. Install the bracket between the Cover Plate and the Nut or Cap Screw. Be sure that the bracket is aligned so that the two smaller pilot attachment holes are above the horizontal plane of the Cover Plate.

16. Remove pipe plug from Cover Plate.

17. Torque to the values found in Table 11 using the torque patterns in Figure 40 and Table 12.

18. Once the Main Valve is assembled before any tubing is connected reach through the hole in the center of the Cover Plate and force the Main Valve Piston down until it contacts the Disc Holder. Failure to complete this procedure will prevent the Main Valve from loading and closing, when pressure is applied to the valve.

19. The Main Valve is ready to receive the pilot and finished assembly.

Table 12: Torque Required for Each Round of Pattern

Round Percentage of Required Torque

1 Wrench Tight

2 25

3 60

4 100

5 100

Holes

Figure 40: Bolt Tightening Patterns

XVI. Reassembly of the 2900 Main Valve (Contd.)

48 | BHGE

XVII. Disassembly of Pilot Valve

A. 39PV07/37 Disassembly

Figures 41 and 42

1 Remove and discard the aluminum seals and

sealing wire.

2. Remove Cap (Compression Screw) by turning counterclockwise.

3. If a lifting lever is installed, also use Figure 42 to remove the Lifting Lever assembly. Then return to Figure 41 to continue disassembly.

a. The Lifting Lever Assembly consists of:

1 – Lever

1 – Drive Pin

1 – Cam Shaft

1 – Bushing

b. Remove Lifting Lever Assembly by turning

Bushing counterclockwise.

c. Turn Cap (Compression Screw)

counterclockwise.

d. Measure distance from Release Lock Nut to the

top of the Lifting Stem for reassembly later.

e. Remove the Release Lock Nut and Release Nut

by turning counterclockwise.

4. Measure and record Compression Screw height for later use when resetting.

5. Turn Compression Screw Lock Nut counterclockwise to loosen.

6. Turn Compression Screw counterclockwise to remove the load on the Spring.

7. Turn Set Screw counterclockwise to loosen.

8. Bonnet can now be removed by turning counterclockwise.

9. Spring and Spring Washers can now be removed.

Note: If Lifting Lever option is equipped, there is

no need to remove Drive Pin from Bottom Spring Washer assembly.

10. Remove the four Cap Screws (Top Plate) holding the Top Plate to the Pilot Base. Remove and discard the Spring Seal (Main Piston) and O-Ring (Top Plate).

11. Remove Main Piston from Pilot Base.

Note: For Dirty Service Option, please refer to

“Dirty Service Option” (Section XXII.B) for disassembly instructions.

12. Removing the Insert Assembly.

The Insert Assembly consists of:

1 - Insert Top

1 - Insert Bottom

1 - Spring Seal (Insert)

1 - O-Ring (Insert)

Remove Insert Assembly from the top of the Pilot

Base with tool #4995401 as shown in Figure 81. Remove and discard the O-Ring (Insert) on the bottom of the Insert Assembly. Disassemble Insert Assembly by removing the Insert Bottom from the Insert Top. Discard Spring Seal (Insert).

13. Remove Adjuster Cap from the bottom of the Pilot Base by turning counterclockwise.

14. Loosen Adjuster Lock Nut by turning counterclockwise.

15. Removing the Adjuster Assembly.

The Adjuster Assembly consists of:

1 – Adjuster Top

1 – Adjuster Bottom

1 – O-Ring (Adjuster Top)

1 – O-Ring (Adjuster Bottom)

1 – Spring Seal (Adjuster Top)

16. Turn Adjuster Assembly clockwise counting the number of flats until assembly stops. Record number of flats for reassembly.

17. Remove Adjuster Assembly from the Pilot Base by turning counterclockwise. Remove O-Ring (Adjuster Top) and O-Ring (Adjuster Bottom) from adjuster assembly and discard. Disassemble Adjuster Top from the Adjuster Bottom by turning Adjuster Top counterclockwise. Remove Spring Seal (Adjuster Top) from Adjuster Top and discard.

18. Refer to Field Test Connection / Backflow Preventer Option (Section XXII.A) for disassembly of Field Test Connection

Consolidated 2900 Series POSRV Maintenance Manual | 49

XVII. Disassembly of Pilot Valve (Contd.)

39PV37

Figure 41: 39PV07/37 Disassembly

50 | BHGE

53b

53a

53d

53c

55c

55a

53f

53e

55a

Figure 42: Lifting Lever Disassembly

XVII. Disassembly of Pilot Valve (Contd.)

Part

No.

Nomenclature

1 Main Base

2 Adjuster Cap

3 Adjuster Top

4 Adjuster Bottom

5 Adjuster Lock Nut

6 Compression Screw

7 Compression Screw Lock Nut

8 Spring Washer

9 Spring

10 Insert Top

11 Insert Bottom

12 Main Piston

13 Cap (Compression Screw)

14 Cap Screw (Top Plate)

15 O-Ring (Adjuster Bottom)

16 O-Ring (Adjuster Top)

17 O-Ring (Insert)

18 O-Ring (Top Plate)

19 Bonnet

20 Spring Seal (Main Piston)

21 Spring Seal (Adjuster Top)

22 Spring Seal (Insert)

23 Field Test Connector

Vent Assembly/Bug Screen (Field Test Connection)

25 Vent Assembly (Bonnet Vent)1

27 Set Screw (Bonnet)

34 Top Plate

53 Lifting Lever Assembly

53a Cam Bushing

53b Cam Shaft

53c Lifting Lever

53d Drive Pin

53e Release Nut

53f Release Locknut

54 Gag Bolt

55 Lower Spring Washer Assembly

55a Lower Spring Washer

55b Lifting Stem

55c Drive Pin

Note 1: Standard material is a filter plug. For

special materials, vent assembly is supplied.

Consolidated 2900 Series POSRV Maintenance Manual | 51

XVII. Disassembly of Pilot Valve (Contd.)

B. 39MV07 Disassembly

Figures 42 and 43

1 Remove and discard the aluminum seals and

sealing wire.

2. Remove Cap (Compression Screw) by turning counterclockwise.

3. If a lifting lever is installed, also use Figure 42 to remove the Lifting Lever assembly. Then return to Figure 43 to continue disassembly.

a. The Lifting Lever Assembly consists of:

1 – Lever

1 – Drive Pin

1 – Cam Shaft

1 – Bushing

b. Remove Lifting Lever Assembly by turning

Bushing counterclockwise.

c. Turn Cap (Compression Screw)

counterclockwise.

d. Measure distance from Release Lock Nut to the

top of the Lifting Stem for reassembly later.

e. Remove the Release Lock Nut and Release Nut

by turning counterclockwise.

4. Measure and record Compression Screw height for later use when resetting.

5. Turn Compression Screw Lock Nut counterclockwise to loosen.

6. Turn Compression Screw counterclockwise to remove the load on the Spring.

7. Turn Set Screw counterclockwise to loosen.

8. Bonnet can now be removed by turning counterclockwise.

9. Spring and Spring Washers can now be removed.

Note: If Lifting Lever option is equipped, there is

no need to remove Drive Pin from Bottom Spring Washer assembly.

10. Remove the four Cap Screws (Top Plate) holding the Top Plate to the Pilot Base. Remove and discard the Spring Seal (Main Piston) and O-Ring (Top Plate).

11. Remove Main Piston from Pilot Base.

Note: For Dirty Service Option, please refer to Dirty

Service Option (Section XXII.B) for disassembly instructions.

12. Removing the Insert Assembly.

The Insert Assembly consists of:

1 - Insert Top

1 - Insert Bottom

1 - Spring Seal (Insert)

1 - O-Ring (Insert)

Remove Insert Assembly from the top of the Pilot

13. Remove Adjuster Cap from the bottom of the Pilot Base by turning counterclockwise.

14. Loosen Adjuster Lock Nut by turning counterclockwise.

15. Removing the Adjuster Assembly.

The Adjuster Assembly consists of:

1 – Adjuster Top

1 – Adjuster Bottom

1 – O-Ring (Adjuster Top)

1 – O-Ring (Adjuster Bottom)

1 – Spring Seal (Adjuster Top)

16. Turn Adjuster Assembly clockwise counting the number of flats until assembly stops. Record number of flats for reassembly.

18. Refer to Field Test Connection / Backflow Preventer Option (Section XXII.A) for disassembly of Field Test Connection.

52 | BHGE

Figure 43: 39MV07 Disassembly

XVII. Disassembly of Pilot Valve (Contd.)

Consolidated 2900 Series POSRV Maintenance Manual | 53

XVII. Disassembly of Pilot Valve (Contd.)

Part

No.

Nomenclature

1 Main Base 2 Adjuster Cap 3 Adjuster Top 4 Adjuster Bottom

5 Adjuster Lock Nut 6 Compression Screw

7 Compression Screw Lock Nut 8 Spring Washer

9 Spring 10 Insert Top 11 Insert Bottom 12 Main Piston 13 Cap (Compression Screw) 14 Cap Screw (Top Plate) 15 O-Ring (Adjuster Bottom) 16 O-Ring (Adjuster Top)

17 O-Ring (Insert) 18 O-Ring (Top Plate) 19 Bonnet 20 Spring Seal (Main Piston) 21 Spring Seal (Adjuster Top) 22 Spring Seal (Insert) 23 Field Test Connector

Vent Assembly/Bug Screen (Field Test Connection)

25 Vent Assembly (Bonnet Vent)1 27 Set Screw (Bonnet) 34 Top Plate 36 Modulator Base 37 Modulator Stop 38 Modulator Piston Top 39 Modulator Piston Bottom 40 O-Ring Retainer

41 Lock Screw (Retainer) 42 Cap Screw (Modulator) 43 Socket Head Cap Screw (Modulator) 44 O-Ring (Modulator Base) 45 O-Ring (Modulator Stop) 46 O-Ring (Modulator Seat)

47 O-Ring (Modulator Piston Bottom) 48 Spring Seal (Piston Bottom) 49 Spring Seal (Piston Top)

Note 1: Standard material is a filter plug. For special

materials, vent assembly is supplied.

19. Remove Socket Head Cap Screw (2 Nos.) to remove Modulator Assembly from Pilot Base. Remove and discard both O-Rings (Modulator Base).

The Modulator Assembly consists of:

1 – Modulator Base

1 – Modulator Stop

1 – Modulator Piston Assembly

The Modulator Piston Assembly consists of:

1 – Modulator Piston Top

1 – Modulator Piston Bottom

1 – O-Ring Retainer

1 – Lock Screw

1 – O-Ring Modulator Piston Bottom

1 – Spring Seal (Piston Top)

1 – Spring Seal (Piston Bottom)

1 – O-Ring (Modulator Seat)

20. Remove Cap Screws (Modulator) holding Modulator Stop to Modulator Base.

21. Modulator Base can now be removed by rotating the Modulator Stop enough to be able to push against the ears on the Modulator Base to remove the Modulator Stop.

22. Remove both O-Rings (Modulator Stop) and discard.

23. Disassemble the Modulator Piston Assembly by removing the Lock Screw.

24. Remove and discard O-Ring (Modulator Piston Bottom) and O-Ring (Modulator Seat). Be careful not to bend the lip enclosing the O-Ring (Modulator Seat) during its removal.

25. Discard Spring Seal (Piston Bottom) and Spring Seal (Piston Top).

54 | BHGE

C. 39MV22/72 Disassembly

Figures 44, 45 and 42

1 Remove and discard the aluminum seals and sealing

wire.

2. Remove Cap (Compression Screw) by turning counterclockwise.

3. If a lifting lever is installed, also use Figure 42 to remove the Lifting Lever assembly. Then return to Figure 44 or 45 to continue disassembly.

a. The Lifting Lever Assembly consists of:

1 – Lever

1 – Drive Pin

1 – Cam Shaft

1 – Bushing

b. Remove Lifting Lever Assembly by turning

Bushing counterclockwise.

c. Turn Cap (Compression Screw)

counterclockwise.

d. Measure distance from Release Lock Nut to the

top of the Lifting Stem for reassembly later.

e. Remove the Release Lock Nut and Release Nut

by turning counterclockwise.

4. Measure and record Compression Screw height for later use when resetting.

5. Turn Compression Screw Lock Nut counterclockwise to loosen.

6. Turn Compression Screw counterclockwise to remove the load on the Spring.

7. Turn Set Screw counterclockwise to loosen.

8. Bonnet can now be removed by turning counterclockwise.

9. Spring and Spring Washers can now be removed.

Note: If Lifting Lever option is equipped, there is no

need to remove Drive Pin from Bottom Spring Washer assembly.

10. Remove the four Cap Screws (Top Plate) holding the Top Plate to the Pilot Base. Remove and discard the Spring Seal (Main Piston), O-Ring (Top Plate) and back-up rings (if applicable).

11. Remove Main Piston Assembly from Pilot Base.

12. Main Piston Assembly consists of:

1 – Main Piston

1 – Piston Nose

1 – Piston Retainer Nut

1 – Set Screw

Remove Set Screw. Turn Piston Retainer Nut

counterclockwise to remove. Remove Piston Nose.

Note: For Dirty Service Option, please refer to “Dirty

Service Option” (Section XXII.B) for disassembly instructions.

13. Remove Spring Seal (Main Piston) and Backup Ring (if applicable) and discard.

14. Removing the Insert Assembly.

The Insert Assembly consists of:

1 - Insert Top

1 - Insert Bottom

1 - Spring Seal (Insert)

1 - O-Ring (Insert)

Remove Insert Assembly from the top of the Pilot

15. Remove Adjuster Cap from the bottom of the Pilot Base by turning counterclockwise.

16. Loosen Adjuster Lock Nut by turning counterclockwise.

17. Removing the Adjuster Assembly.

The Adjuster Assembly consists of:

1 – Adjuster Top

1 – Adjuster Bottom

1 – Vent Seal Adaptor

1 – O-Ring (Adjuster Top)

1 – O-Ring (Adjuster Bottom)

1 – Spring Seal (Adjuster Top)

1 – Spring Seal (Adjuster Bottom)

18. Turn Adjuster Assembly clockwise counting the number of flats until assembly stops. Record number of flats for reassembly.

19. Remove Adjuster Assembly from the Pilot Base by turning counterclockwise. Remove O-Ring (Adjuster Top) and O-Ring (Adjuster Bottom) from adjuster assembly and discard. Disassemble Adjuster Top from the Adjuster Bottom by turning Adjuster Top counterclockwise. Remove the Vent Seal Adaptor from the Adjuster Top. Remove and discard the Spring Seal (Adjuster Top) and Spring Seal (Adjuster Bottom).

20. Refer to Field Test Connection / Backflow Preventer Option (Section XXII.A) for disassembly of Field Test Connection.

XVII. Disassembly of Pilot Valve (Contd.)

Consolidated 2900 Series POSRV Maintenance Manual | 55

Figure 44: 39MV22 Disassembly

XVII. Disassembly of Pilot Valve (Contd.)

56 | BHGE

Figure 45: 39MV72 Disassembly

XVII. Disassembly of Pilot Valve (Contd.)

Consolidated 2900 Series POSRV Maintenance Manual | 57

XVII. Disassembly of Pilot Valve (Contd.)

Note 1: Standard material is a filter plug. For special

materials, vent assembly is supplied.

D. Cleaning

1. Clean parts to remove all rust, burrs, scale, organic matter, and loose particles. Parts are to be free of any oil or grease except for lubrication as specified in this instruction.

2. Cleaning agents used shall be such that effective cleaning is assured without injuring the surface finishes or material properties of the part.

3. Acceptable cleaning agents include demineralized water, nonphosphate detergent, acetone, and isopropyl alcohol. Parts must be blown dry or wiped dry after cleaning.

5. Do not “sand blast” internal parts as it can reduce the dimensions of the parts.

recommendations

for safe handling in

the solvent's Material Safety Data Sheet and observe safe practices

for any cleaning

method

Part

No.

Nomenclature

1 Main Base

2 Adjuster Cap

3 Adjuster Top

4 Adjuster Bottom

5 Adjuster Lock Nut

6 Compression Screw

7 Compression Screw Lock Nut

8 Spring Washer

9 Spring

10 Insert Top

11 Insert Bottom

12 Main Piston

13 Cap (Compression Screw)

14 Cap Screw (Top Plate)

15 O-Ring (Adjuster Bottom)

16 O-Ring (Adjuster Top)

17 O-Ring (Insert)

18 O-Ring (Top Plate)

19 Bonnet

20 Spring Seal (Main Piston)

21 Spring Seal (Adjuster Top)

22 Spring Seal (Insert)

23 Field Test Connector

Vent Assembly/Bug Screen (Field Test Connection)

25 Vent Assembly (Bonnet Vent)1

27 Set Screw (Bonnet)

28 Piston Nose

29 Piston Retainer Nut

30 Set Screw (Piston)

31 Vent Seal (Adaptor)

32 Spring Seal (Vent Seal Adaptor)

33 Back-up Ring (39MV72 Only)

34 Top Plate

58 | BHGE

XVIII. Part Inspection of Pilot Valve

After the 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 blow.

A. 39PV07/37

1. Main Piston: Galling or excessive wear on the small diameter end where it engages the spring seals or on the spherical bearing surface. Any corrosion or pitting that appears detrimental to the function of the valve. The part can be polished as long as the outside diameter of the stem remains at .243 ± .001” (6.18 ± 0.03 mm). The stem itself must have a T.I.R of .001” (0.03 mm) along its length. The upper diameter where the Spring Seal (Main Piston) rides must be 1.495 ± .001 (37.97 ± 0.03 mm) on 39PV07 model or .970 ± .001” (24.64 ± 0.03 mm) on 39PV37. A surface finish of 8 RMS must be maintained for proper sealing on these surfaces.

2. Insert 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.

3. Insert Bottom: Galling 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. Top Plate: 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.

7. Bonnet: Check for any corrosion or pitting. Also, check for galling of threads for the compression screw and where it attaches to the Pilot Base.

8. Compression Screw: Galling at the spherical bearing surface or in the thread. Check for any corrosion or pitting.

9. Spring Washer(s): Galling at the spherical bearing surface. Check for any corrosion or pitting.

10. Pilot Base: Check for any corrosion or pitting. Also, check for galling of threads.

11. Spring: Check for any corrosion or pitting.

B. 39MV07

1. Main Piston: Galling or excessive wear on the small diameter end where it engages the spring seals or on the spherical bearing surface. Any corrosion or pitting that appears detrimental to the function of the valve. The part can be polished as long as the outside diameter of the stem remains at .243 ± .001” (6.17 ± 0.03 mm). The stem itself must have a T.I.R of .001” (0.03 mm) along its length. The upper diameter where the Spring Seal (Main Piston) rides must be 1.495 ± .001 (37.97 ± 0.03 mm) on 39PV07 model or .970 ± .001” (24.64 ± 0.03 mm) on 39PV37. A surface finish of 8 RMS must be maintained for proper sealing on these surfaces.