Baker Hughes Consolidated 1511 Series User manual

Consolidated™
1511 Series
Safety Valves
Instruction Manual (Rev. E)
Baker Hughes Data Classification : Public

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THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT
PROJECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/
OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE
OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BAKER HUGHES (AND
ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC
PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS
CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL
UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL
AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS.
THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED
IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT
THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER
EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS
IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET
IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD
FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE
WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S
PURPOSES THE MATTER SHOULD BE REFERRED TO BAKER HUGHES.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE
CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED
IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL
REPRESENTATIONS OR WARRANTIES BY BAKER HUGHES REGARDING THE
EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE
INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY
TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE
OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED
IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.

Consolidated 1511 Series Safety Valve Instruction Manual | 3
© 2020 Baker Hughes Company. All rights reserved.
NOTICE!
For valve configurations not listed in this
manual, please contact your local
Green Tag™ Center for assistance.
All the United States Customary System (USCS) values
are converted to metric values using
the following conversion factors:
USCS Unit Conversion Factor Metric Unit
in. 25.4 mm
lb. 0.4535924 kg
in26.4516 cm2
ft3/min 0.02831685 m3/min
gal/min 3.785412 L/min
lb/hr 0.4535924 kg/hr
psig 0.06894757 barg
ft lb 1.3558181 Nm
°F 5/9 (°F-32) °C
Conversion Table
Note: Multiply USCS value with conversion factor to get metric value.

4 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
Table of Contents
I. Product Safety Sign and Label System................................................................................. 5
II. Safety Alerts .......................................................................................................................... 6
III. Safety Notice ......................................................................................................................... 7
IV. Warranty Information ............................................................................................................. 8
V. Valve Terminology ................................................................................................................. 8
VI. Storage and Handling Prior to Installation........................................................................... 10
VII. Introduction.......................................................................................................................... 10
VIII. Consolidated Safety Valve Type 1511 ..................................................................................11
IX. Recommended Installation Practices
A. General Requirements.................................................................................................... 12
B. Outdoor Safety Valve Installation .................................................................................... 13
X. Disassembly of 1511 Series Safety Valve ........................................................................... 14
XI. Maintenance Instructions
A. General Information ....................................................................................................... 14
B. Machining....................................................................................................................... 15
C. Lapping Procedures....................................................................................................... 15
D. Reconditioning a Ring Lap............................................................................................. 16
E. Spindle Runout .............................................................................................................. 16
F. Spring and Spring Washers ........................................................................................... 17
G. Lift Restrictor.................................................................................................................. 17
XII. Inspection and Part Replacement
A. General Information ....................................................................................................... 17
 B. SpecicSteps ................................................................................................................ 17
XIII. Reassembly......................................................................................................................... 20
XIV. Setting and Testing
A. Steam Testing Procedures ............................................................................................. 21
B. Hydrostatic Testing & Gagging....................................................................................... 23
B.1 General Information ................................................................................................ 23
B.2 Application of Test Gags (All Pressures) ................................................................. 24
C. Presetting the Adjusting Rings ....................................................................................... 24
D. Electronic Valve Testing (EVT)....................................................................................... 25
XV. Trouble Shooting the 1511 Series Safety Valve .................................................................. 26
XVI. Maintenance Tools and Supplies......................................................................................... 27
XVII. Replacement Parts Planning
A. Basic Guidelines ............................................................................................................ 28
 B. IdenticationandOrderingEssentials ........................................................................... 28
XVIII. Consolidated Genuine Parts ............................................................................................... 29
XIX. Recommended Spare Parts ................................................................................................ 30
XX. Manufacturer’s Field Service, Repair and Training Program
A. Field Service .................................................................................................................. 31
B. Repair Facilities ............................................................................................................. 31
C. Maintenance Training..................................................................................................... 31

Consolidated 1511 Series Safety Valve Instruction Manual | 5
© 2020 Baker Hughes Company. All rights reserved.
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.
1
2
3
4
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 that 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 depict what
preventive measures to take, such as wearing protective equipment.
The bottom panel may contain an instruction message on how to avoid the
hazard. In the case of human hazard, this message may also contain a more
precisedenitionofthehazard,andtheconsequencesofhumaninteraction
with the hazard, than can be communicated solely by the pictorial.
I. Product Safety Sign and Label System
Do not remove bolts
if pressure in line, as
this will result in severe
personal injury or
death.
Know all valve
exhaust/leakage points
to avoid possible
severe personal injury
or death.
Wear necessary
protective equipment to
prevent possible injury.
Handle valve carefully.
Do not drop or strike.
1234

6 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
Follow all plant safety regulations, but be sure to observe the following:
• Always lower the working pressure before making any valve adjustment. When
making ring adjustments, always gag the valve before making the adjustment.
This will avoid possible personal injury.
• Do not stand in front of the discharge side of a safety valve when testing or
operating.
• Hearing and eye protection should be used when testing or operating a valve.
• Wear protective clothing. Hot water can burn and superheated steam is not
visible.
• When removing the safety valve during disassembly, stand clear and/or wear
protective clothing to prevent exposure to splatter or any corrosive process
medium, which may have been trapped inside the valve. Ensure the valve is
isolated from system pressure before the valve is removed.
• Exercise care when examining a safety valve for leakage.
• Prior to each actuation, assure that no personnel are near the valve. Steam
escaping from the valve during actuation can possibly cause personal injury.
• Whenpoppingasafetyvalveforthersttimeorafterrefurbishment,alwaysbe
prepared to actuate the valve with the lever while standing in a safe place away from
thevalve.Thismaybedonebyxingaropetotheleverforactuatingthevalvefrom
a distance.
• Striking a valve which is under pressure can cause premature actuation. Never
tamper with the valve when system pressure is near the valve set pressure.
• Before performing any machining on valve parts, consult Baker Hughes or its
authorizedrepresentative.Deviationfromcriticaldimensionscanadverselya󰀨ect
valve performance.
Lower pressure and stand
clear of discharge when
working on valve to avoid
severe personal injury or
death.
Know all valve exhaust/
leakage points to
avoid possible severe
personal injury or death.
II. Safety Alerts

Consolidated 1511 Series Safety Valve Instruction Manual | 7
© 2020 Baker Hughes Company. All rights reserved.
Proper installation and startup is essential to the safe and reliable operation of
all valve products. The relevant procedures recommended by Baker Hughes and
describedintheseinstructionsaree󰀨ectivemethodsofperformingtherequired
tasks.
It is important to note that these instructions contain various “safety messages”
which should be carefully read in order to minimize the risk of personal injury or the
possibility that improper procedures will be followed which may damage the involved
product or render it unsafe. It is also important to understand that these “safety
messages” are not exhaustive. Baker Hughes cannot possibly know, evaluate,
and advise any customer of all of the conceivable ways in which tasks might be
performed, or of all possible hazardous consequences. Consequently, Baker
Hughes has not undertaken any such broad evaluation and, thus, anyone who uses
a procedure and/or tool that is not recommended by Baker Hughes, or deviates from
BakerHughesrecommendationsmustbethoroughlysatisedthatneitherpersonal
safety, nor valve safety, will be jeopardized by the method and/or tools selected. If
notsosatised,contactBakerHughes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, Baker Hughes
cannot possibly evaluate all conditions that might injure personnel or equipment.
Nevertheless,BakerHughesdoeso󰀨ercertainSafetyPrecautions,listedinSection
II, for customer information only.
It is the responsibility of the purchaser or user of Baker Hughes valves/equipment
to adequately train all personnel who will be working with the involved valves/
equipment. For more information on training schedules, contact your local Green
Tag Center. 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

8 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
IV. Warranty Information
Warranty Statement - Baker Hughes warrants that its
productsandworkwillmeetallapplicablespecications
andotherspecicproductandworkrequirementsand
will be free from defects in material and workmanship.
Refer to Baker Hughes’s Standard Terms of Sale, or
speciccontractforcompletedetailsonwarrantyand
limitation of remedy and liability.
Defective and nonconforming items must be held for Baker
Hughes’s inspection and returned to the original F.O.B. point
upon request.
Incorrect Selection or Misapplication of Products
- Baker Hughes cannot be responsible for customer ’s
incorrect selection or misapplication of our products.
Unauthorized Repair Work - Baker Hughes has not
authorizedanynon-BakerHughesa󰀩liatedrepair
companies, contractors or individuals to perform
modicationsorservicesonnewproductsoreldrepaired
products of its manufacture. Therefore, customers
contracting for such services or performing such services
on their own do so at their own risk.
Unauthorized Removal of Seals - All new valves and
valvesrepairedintheeldbyBakerHughes’sa󰀩liated
repair companies are sealed to assure the customer
of our guarantee against defective workmanship.
Unauthorized removal and/or breakage of this seal will
negate our warranty.
• Back Pressure
Back pressure is the static pressure existing at the
outlet of a safety valve device due to pressure in the
discharge system.
• Blowdown
 Blowdownisthedi󰀨erencebetweenactualpopping
pressure of a safety valve and actual reseating
pressure expressed as a percentage of set pressure,
or in pressure units.
• Bore Area
Bore area is the minimum cross-sectional area of the
seat bushing.
• Bore Diameter
Bore diameter is the minimum diameter of the seat
bushing.
• Built-Up Back Pressure
Pressure existing at the outlet of a safety valve while
itisopenandowingthroughadischargesystem.
• Chatter
Chatter is abnormal, rapid reciprocating motion of the
moveable parts of a safety valve, in which the disc
contacts the seat.
• Closing Pressure
Closing pressure is the value of decreasing inlet
static pressure at which the valve disc re-establishes
contact with the seat, or at which lift becomes zero.
• Disc
A disc is the pressure containing moveable member
ofasafetyvalvewhiche󰀨ectsclosure.
• Inlet Size
Inlet size is the nominal pipe size of the inlet of a
safety valve, unless otherwise designated.
• Leak Test Pressure
 Leaktestpressureisthespeciedinletstatic
pressure at which a quantitative seat leakage test is
performed in accordance with a standard procedure.
• Lift
Lift is the actual travel of the disc away from closed
position when a valve is relieving.
• Lifting Device
A lifting device is a device for manually opening a
safety valve, by the application of external force
to lessen the spring loading which holds the valve
closed.
V. Valve Terminology
(Paraphrased from ASME’s PTC 25)

Consolidated 1511 Series Safety Valve Instruction Manual | 9
© 2020 Baker Hughes Company. All rights reserved.
• Seat Bushing
A seat bushing is the pressure containing element
whichconstitutestheinletowpassageandincludes
thexedportionoftheseatclosure.
• Outlet Size
Outlet size is the nominal pipe size of the outlet
passage of a safety valve, unless otherwise
designated.
• Overpressure
Overpressure is a pressure increase over the set
pressure of a safety valve, usually expressed as a
percentage of set pressure.
• Popping Pressure
Popping pressure is the value of increasing inlet
static pressure at which the disc moves in the
opening direction at a faster rate as compared
with corresponding movement at higher or lower
pressures. It applies only to safety or safety relief
valvesoncompressibleuidservice.
• Pressure Containing Member
A pressure containing member of a safety valve is
a part which is in actual contact with the pressure
media in the protected vessel.
• Pressure Retaining Member
A pressure retaining member of a safety valve is a
part which is stressed due to its function in holding
one or more pressure containing members in
position.
• Rated Lift
Rated lift is the design lift at which a valve attains its
rated relieving capacity.
• Safety Valve
A safety valve is a pressure relief valve actuated
by inlet static pressure and characterized by rapid
opening or pop action.
• Set Pressure
Set pressure is the value of increasing inlet static
pressure at which a safety valve displays the
operationalcharacteristicsasdenedunder“Popping
Pressure.” It is one value of pressure stamped on the
safety valve.
• Seat
A seat is the pressure containing contact between the
xedandmovingportionsofthepressurecontaining
elements of a valve.
• Seat Diameter
Seat diameter is the smallest diameter of contact
betweenthexedandmovingmembersofthe
pressure containing elements of a valve.
• Seat Tightness Pressure
 Seattightnesspressureisthespecicinletstatic
pressure at which a quantitative seat leakage test is
performed in accordance with a standard procedure.
• Simmer
 Simmeristheaudibleorvisibleescapeofuid
between the seat and disc at an inlet static pressure
below the popping pressure and at no measurable
capacity. It applies to safety valves on compressible
uidservice.
• Warn
 See“Simmer”(denitionabove).
V. Valve Terminology

10 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
Safety valves should be stored in a dry environment
to protect them from the weather. They should not be
removed from the skids or crates until immediately
prior to installation. Flange protectors and sealing plugs
should remain installed until just prior to installation.
Safety valves, either crated or uncrated, should never be
subjected to sharp impact. This would be most likely to
occur by bumping or dropping during loading or unloading
from a truck or while moving with a power conveyor, such
as a fork lift truck. The valve, either crated or uncrated,
should always be kept with the inlet down (i.e., never
laid on its side), to prevent misalignment and damage to
internals. Even crated valves should always be lifted with
the inlet down.
Uncrated valves should be moved or hoisted by
wrapping a chain or sling, around the discharge neck,
then around the upper yoke structure, in such manner
as will ensure that the valve is in vertical position during
lift, (i.e., not lifted in horizontal position). Never lift the
full weight of the valve by the lifting lever. Never hook
to the spring to lift. When safety valves are uncrated
andtheangeprotectorsremoved,immediatelyprior
to installation, meticulous care should be exercised to
prevent dirt from entering the outlet port while bolting in
place.
While hoisting to the installation, care should be
exercised to prevent bumping the valve against steel
structures and other objects.
Do not lift valve
horizontally, or hook to
lifting lever or spring.
Prevent dirt from
entering valve outlet
port.
Handle valve carefully.
Do not drop or strike.
VI. Storage and Handling Prior to Installation
The“safetyvalve”isthenalsafeguardbetweena
controlled boiler and a catastrophic explosion. In an
over-pressure situation, the pressure in the valve inlet
increases until the force on the disc exerted by the
system pressure equals the force exerted by the spring.
This causes the safety valve to pop, or lift, relieving the
excess steam until the system pressure is reduced to the
desired level.
Baker Hughes’s Consolidated safety valves have been
aleaderintheindustrysince1879,thuso󰀨eringovera
century of experience in the valve industry.
Baker Hughes’s history of dependable and reliable
valve service assures that today’s products and designs
are consistent with industry’s current requirements.
Rigid manufacturing standards controlled by an
ASME-approved Quality Control Program ensure that
each valve will be manufactured in accordance with
established design criteria and tested for functional
performance. This quality controlled manufacturing and
test program assures that each valve manufactured will
provide long and reliable service.
VII. Introduction

Consolidated 1511 Series Safety Valve Instruction Manual | 11
© 2020 Baker Hughes Company. All rights reserved.
1
2
4
1/2” - NPT
Drain
5
7
3
6
9
11
17
18
15
19
29
14
16
13
11
8
10
12
27
20
21
22
VIII. Consolidated 1511 Series Safety Valve
Part
No. Nomenclature
1 Base
2 Seat Bushing
3 Disc
4Lower Adj. Ring
5 Lower Adj. Ring Pin
6Upper Adj. Ring
7 Upper Adj. Ring Pin
8 Yoke
9 Yoke Cap Screws
10 Spindle Assembly
11 Spring Washer
12 Spring
13 Compression Screw
14 Compression Screw Nut
15 Cap
16 Cap Set Screw
17 Lever
18 Release Nut
19 Lever Pin
20 Spring Cover
21 Cover Bolt
22 Cover Nut
23 Top Lever
24 Drop Lever
25 Top Lever Pin
26 Drop Lever Pin
27 Floating Washer
28 Lift Stop(1)
29 Spindle Locknut
26
24
23 25
Figure 1: 1511 Series Safety Valve
Figure 2:
Cap and Lifting Lever Assembly
1. Not Shown. Required for
5-26 psi (0.34-1.79 bar).

12 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
A. General Requirements
The safety valve shall be connected to the boiler in a vertical position independent
of any other steam connection and attached as close as possible to the boiler.
Interveningpipeorttingsshallbenolongerthantheface-to-facedimension
ofthecorrespondingteettingofthesamediameterandpressureunderthe
corresponding American Standard as set forth by the ASME.
Thoroughly clean the inlet of the valve before installation and be sure that the proper
gasketisused.Tightenboltsevenly.For1510and1511Series,theangebolting
shall be ASTM A307 Grade B per ASME B16.1, and shall be torqued not to exceed
the values shown in Table 1.
The safety valve shall be free from external stresses transmitted from the discharge
piping. Figure 3 illustrates a recommended design allowing for ample clearance
to take care of thermal expansion. The riser pipe should be large enough to
accommodate the full capacity of the valve without causing steam to escape by
owingbackwardthroughthedrippan.Innocaseshouldthepipeconnectedtothe
valve be of a smaller size than the valve outlet.
Know all valve exhaust/
leakage points to
avoid possible severe
personal injury or death.
IX. Recommended Installation Practices
Table 1: 1510 & 1511 Series Safety Valve Inlet Flange Bolting Torque
Orifice
Inlet Flange
Size
Inlet Flange
Bolt Size Bolting Torque (ft-lbs) Bolting Torque (Nm)
inches mm inches mm Dry Lubricated Dry Lubricated
H
1 1/2 38.1 3/4 19.1 110 85 149 115
2 50.8 5/8 15.9 60 45 81 61
2 1/2 63.5 3/4 19.1 110 85 149 115
3 76.2 3/4 19.1 110 85 149 115
J
1 1/2 38.1 3/4 19.1 110 85 149 115
2 50.8 5/8 15.9 60 45 81 61
2 1/2 63.5 3/4 19.1 110 85 149 115
3 76.2 3/4 19.1 110 85 149 115
K
2 50.8 5/8 15.9 60 45 81 61
2 1/2 63.5 3/4 19.1 110 85 149 115
3 76.2 3/4 19.1 110 85 149 115
3 1/2 88.9 3/4 19.1 110 85 149 115
4 101.6 3/4 19.1 110 85 149 115
L
2 1/2 63.5 3/4 19.1 110 85 149 115
3 76.2 3/4 19.1 110 85 149 115
3 1/2 88.9 3/4 19.1 110 85 149 115
4 101.6 3/4 19.1 110 85 149 115
M
3 76.2 3/4 19.1 110 85 149 115
3 1/2 88.9 3/4 19.1 110 85 149 115
4 101.6 3/4 19.1 110 85 149 115
4 1/2 114.3 3/4 19.1 110 85 149 115
N4 101.6 3/4 19.1 110 85 149 115
P4 101.6 3/4 19.1 110 85 149 115
Q6 152.4 3/4 19.1 110 85 149 115

Consolidated 1511 Series Safety Valve Instruction Manual | 13
© 2020 Baker Hughes Company. All rights reserved.
When a safety valve is installed on an outdoor unit, it is
advisable to insulate the valve body, including the inlet
ange,uptothebottomoftheyoke.Theinsulationwill
stabilize the valve body temperature preventing variation
in the set pressure.
Valves must be readjusted if insulation is installed.
Weather shielding should be used to protect the spring
and to minimize rain or snow from entering the valve
body.
Riser supported overhead
Drain Pipe Open
To Safe Place
1/2” - NPT Drain Pipe
Open To Safe Place
(Valves manufactured
prior to 1987 may have
other size drain holes)
Make short as possible
3/4” std. pipe &
ttings
Figure 3: Recommended Installation for Discharge and Vent Piping
B. Outdoor Safety Valve Installation

14 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
Do not disassemble valve
with pressure in drum or
header, as this will result
in severe personal injury
or death.
Before removing the valve, be sure there is no steam pressure in the drum or
header, then proceed as follows:
1. Remove the lower ring pin.
2. Turn the lower ring upwards counting the number of notches moved until contact
is made with the disc. Record this information for use during reassembly.
3. Remove the lever pin and lever.
4. Loosen the cap screw(s) and remove the cap.
5. Remove the release nut and lock nut or cotter pin.
6. Measure the distance from the top of the spindle to the top of the compression
screw. Record this for use in reassembly to restore the correct spring
compression.
7. Loosen the compression screw lock nut and remove the compression screw.
8. Remove the cap screws or stud nuts holding the yoke to the base and raise the
yoke over the spindle.
9. Remove the spring and spring washer assembly, record the spring number
stamped in the spring. Mark the spring and washers top and bottom.
10. Lift the disc and spindle straight up to remove the disc from the valve body.
Engage the drop through threads of the disc and unscrew it from the spindle.
11. Measure from the top of the combination guide and upper ring to the top of the
bushing seat. Record this measurement for reassembly.
12. Remove the upper ring pin.
13. Remove the combination guide and upper ring by turning it upwards until the
threads disengage.
14. Remove the lower adjusting ring. The valve is now completely disassembled.
X. Disassembly of 1511 Series Safety Valve
A. General Information
The 1511 safety valves are easily maintained. Normal
maintenance usually involves:
• Disassembly
• Cleaning
• Component Inspection
• Lapping the Seats
• Reassembly
• Setting, Testing and Resealing the Valve
Occasionally, remachining the seat bushing may be
necessary to extend the service life of the valve. In any
case, keep all parts for each valve together or marked to
ensure that they are replaced in the same valve.
The following tools are recommended for normal
maintenance and following remachining:
1. Flat lapping plate, (for resurfacing ring laps) - Part
Number 0439004(1)
2. Grinding Compounds(1)
3. High temperature thread lubricant(1) - (Fel-Pro, Nickel
Ease, or equivalent)
4. Two (2) ring laps per valve size and type(1)
1. See maintenance Tools and Supplies in Section XVI.
XI. Maintenance Instructions

Consolidated 1511 Series Safety Valve Instruction Manual | 15
© 2020 Baker Hughes Company. All rights reserved.
XI. Maintenance Instructions (Cont’d)
After the parts have been determined to be reusable,
proper machining technique must be employed in
reestablishing disc and seat bushing dimensions.
On 1511 Series safety valves, the seat bushing should
be machined in the valve base to ensure proper parts
alignment. When chucking the valve base or disc into
a lathe, alignment must be within .001” (0.03 mm) total
indicator runout at the points indicated in Figure 4 as “A”,
“B”, and “C”.
Figure 4
A
A
B
B
C
C
Chuck Jaws
Chuck Jaws
Note: See Section XII.B for rework dimensions for the Seat Bushing and Flat Solid Discs.
B. Machining
All of the above tools can be purchased from Baker
Hughes,withpricesine󰀨ectatthetimeofdelivery.
It may not be necessary to use all of the ring laps at
anyonetime,buthavingasu󰀩cientsupplyonhand
will save reconditioning time during a boiler outage.
After the boiler is back in operation, the ring laps can
bereconditionedontheatlappingplate.Lapping
compound,whenusedwithringlaps,wearso󰀨theseat
surfaceonthediscorseatbushing,butitalsowearso󰀨
theatsurfaceoftheringlap.Alapshouldnotbeused
on more than one valve without being reconditioned.
Lapping procedure for reconditioning the seating
surfaces of the disc and seat bushing is outlined in
Section XI.C.
C. Lapping Procedures
1. General:
 Whilethenerpointsoflappingmaybeconsidered
a mechanical art, it is possible for the average
mechanic to produce satisfactory results with some
practice.Noe󰀨orthasbeenmadeinthismanual
to establish an exact procedure to cover each and
everycasebecausedi󰀨erentpeoplecanachievethe
same results using their own techniques.
The following materials will be of assistance when
lapping bushing and/or disc seats:
a. Two ring laps per valve
b. 1-A Clover Grinding Compound
c. 1000 grit Kwik-Ak-Shun Grinding Compound
d. Lint free wipers for cleaning
2. Lapping the seat bushing or Disc Seat:
Before lapping the seat bushing and disc, use a
negradesandpapertolightlybreaktheinner
edge and outer edge of the bushing and disc seats.
This chamfer should not exceed .002” (0.05mm).
If the seating surfaces require extensive lapping or
reconditioning, machining should be considered prior
to lapping. See Inspection Section XII.B for criteria.
Coveroneatsurfaceofaringlapwithathincoating
of Clover 1-A Grinding Compound and gently set the
lap on the seat surface. Thick coatings tend to round
o󰀨edgesoftheseat. Lap using a slight oscillating
motion in various directions. Control the motion of the
lap to prevent the inside edge or outside edge of the
lapfromrunningo󰀨theseatingsurface,asthismay
cause the seat to become scratched or uneven.

16 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
3. Polishing or Finish Lapping:
 Wipeo󰀨allusedcompoundfromthebushingor
disc.Thenuseaat,reconditionedringlap,and
light coating of Kwik-Ak-Shun™ 1000 Grit Grinding
Compound to lap the seat. After lapping the seat
forsometime,wipeo󰀨allgrindingcompoundfrom
theringlap(donotwipeo󰀨thecompoundonthe
bushing or disc seat). Using only the compound
remaining on the seat, and the clean ring lap,
continuetolapuntilitbecomesdi󰀩culttomovethe
ringlapontheseat.Again,wipeo󰀨thegrinding
compound from the ring lap only, and using the
remaining compound on the seat continue to lap.
The seating surface will become mirror like as the
grinding compound is further broken down. Inspect
the seat for cuts and scratches, repeat procedures
as necessary to eliminate damage.
 Oncetheseatsurfaceisat,clearandmirror-like,wipe
all traces of grinding compound from the part and begin
reconditioning the other seat.
Note: Do not place the disc in a vice to accomplish
lapping procedures, as damage can occur to
disc surfaces and distortion to the seating
surface.
D. Reconditioning a Ring Lap
To recondition a ring lap, use Clover 1-A Compound on
thelappingplate,andmovetheringlapina“gure8”
motion as shown in Figure 5. Continue lapping until all
indications of wear (on both sides), are removed from
the ring lap and a uniform grey surface is achieved. The
ringlapisreadytouseonthenextvalve.Alapthatisat
within one light band is considered satisfactory for use.
Informationonthemonochromaticlightandopticalat
is available upon request from the Baker Hughes Field
Service Department.
A
C
45
0
A
B
Figure 6: Spindle Check Stand
Table 2: Spindle Critical Dimensions
Orifice
C max.
in. mm
H.004 0.10
J.004 0.10
K.007 0.18
L.007 0.18
M.007 0.18
N.007 0.18
P.007 0.18
Q.007 0.18
Lapping Plate Ring Lap
Figure 5
XI. Maintenance Instructions (Cont’d)

Consolidated 1511 Series Safety Valve Instruction Manual | 17
© 2020 Baker Hughes Company. All rights reserved.
E. Spindle Runout
It is important that the spindle be kept very straight in
order to transmit the spring force to the disc without lateral
binding. Overgagging is one of the common causes of
bent spindles. A method to check the essential working
surfaces of the spindle is illustrated in Figure 6.
Using a spindle check stand (see Figure 6 as a
reference), place the ball end of the spindle into a
depression at the base “B” of the stand. Lean the upper
portion of the spindle against the “V” block. It should be
touching the spindle just below the threads on the upper
portion of the spindle. Using a machinists indicator on a
45° angle at spindle shoulder "C", rotate the spindle and
read the Total Indicator Run out on the indicator. If the
T.I.R is less than values shown in Table 2, the spindle may
be returned to service. If the T.I.R is greater than these
values, straighten the spindle using "V" blocks and a
hydraulic press until the T.I.R is found to be acceptable.
Other parts of the spindle not used as working surfaces
may run out considerably more than .007” (0.18 mm), but
this should not be regarded as unacceptable. Although
the upper thread end is not a working surface, excessive
bendinginthisareacoulda󰀨ecttheaccuracyofthe
Consolidated Hydroset device, and/or the Consolidated
Electronic Valve Tester (EVT™), if either of these devices is
used to verify valve set pressure.
F. Spring and Spring Washers
Spring wire that is irregularly spaced, or the ends are
notparallel,aresu󰀩cientcausesforreplacement.The
springwashersaremachinedtottheendsofthe
spring - there should be no more than a .030” (0.76 mm)
clearance between the spring and the spring washer. If
aspringisbadlydamagedbycorrosion(aking,pitting,
or reduction in wire diameter), replace the spring with
theproperspring.Ifthespringisunabletobeidentied
contact your local Green Tag Center.
G. Lift Restrictor
On 1511 valves with set pressures of 26 psig (1.79 barg)
and below will have a Lift Restrictor installed on the
spindle stem, located inside the spring. Measure to verify
minimumlengthfortheappropriateoriceasperTable3.
If under the minimum length, replace the Lift Restrictor.
XI. Maintenance Instructions (Cont’d)
Table 3: Lower Pressure Lift Stop
Orifice L min
in. mm
H2.25 57.0
J2.25 57.0
K3.50 88.8
L3.50 88.8
M3.50 88.9
N3.50 88.9
P3.94 100.0
Q5.00 127.0
A. General Information
Once the valve is disassembled, the appropriate parts can be inspected for damage and
their suitability for reuse.
B. Specic Steps
1. Inspect the guide inside diameter for egging, and ensure the inside surface is
smooth. The threads on the outside must be in good condition to ensure the
adjusting ring/guide will adjust when the valve is hot. If serious, large scale galling
or ridges corresponding to the grooves in the disc are present, the part should be
replaced.
2. Disc :
The 1511 Safety Valve is designed with a Flat Solid Disc (FSD) in either a low
pressure (LP) or high pressure (HP) version (Refer to Table 4).
Disc
1511
FSD
(LP) (HP)
Table 4
XII. Inspection and Part Replacement

18 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
1511 Series Flat Solid Disc Machining Dimensions
G
JH
F
Figure 7: HP Flat Solid Disc
1. When (F) dimension is reduced to .015” (0.38 mm) for H
–Norices,or.026”(0.66mm)forP–Qorices,restore
the dimensions indicated in Table 5b. Do not re-machine
once minimum (H or J) dimensions are reached. Disc is
to be discarded at this point.
D
C
N
150
45
0
Figure 8: LP Flat Solid Disc
All Orices - 124 psig & below 1. All other dimensions identical to values found in Tables 5a & 5b
Table 5a: Replacement Criteria
Orifice H min. J min.
in. mm in. mm
H1.140 28.96 .303 7.70
J1.359 34.52 .348 8.84
K1.453 36.91 .380 9.65
L1.797 45.64 .412 10.46
M1.859 47.22 .474 12.04
N2.109 53.57 .536 13.61
P2.739 69.57 .645 16.38
Q3.547 90.09 .714 18.14
Table 5b: Rework / Inspection Dimensions
Orifice
F +.002/-.003 in.
(+0.05/-0.08 mm) (1) G
in. mm in. mm
H.028 0.71 .062 ±.007 1.57 ±0.18
J.028 0.71 .062 ±.005 1.57 ±0.13
K.028 0.71 .062 ±.007 1.57 ±0.18
L.028 0.71 .062 ±.007 1.57 ±0.18
M.028 0.71 .062 ±.007 1.57 ±0.18
N.028 0.71 .062 ±.007 1.57 ±0.18
P.039 0.99 .078 ±.007 1.98 ±0.18
Q.039 0.99 .107 +
-
.003
.002 2.72 + -
0.08
0.05
Table 6: Rework Inspection Dimensions (1)
Orifice C D N
in. mm in. mm in. mm
H1.552 ±.005 39.42 ±0.13 1.349 ±.002 34.26 ±0.05 .053 ±.002 1.35 ±0.05
J1.983 ±.005 50.37 ±0.13 1.683 ±.002 42.75 ±0.05 .056 +
-.002 .003 1.42 + -0.05 0.08
K2.372 ±.005 60.25 ±0.13 1.977 ±.002 50.22 ±0.05 .079 ±.002 2.01 ±0.05
L2.948 ±.005 74.88 ±0.13 2.418 ±.002 61.42 ±0.05 .096 ±.002 2.44 ±0.05
M3.307 ±.005 84.00 ±0.13 2.722 ±.002 69.14 ±0.05 .102 ±.002 2.59 ±0.05
N3.639 ±.005 92.43 ±0.13 3.011 ±.003 76.48 ±0.08 .111 ±.002 2.82 ±0.05
P4.206 ±.005 106.83 ±0.13 3.608 ±.003 91.64 ±0.08 .116 ±.002 2.95 ±0.05
Q5.795 ±.005 147.19 ±0.13 4.682 ±.003 118.92 ±0.08 .149 ±.002 3.78 ±0.05
Note: Once a minimum dimension is
met, disc is to be discarded.
XII. Inspection and Part Replacement (Cont’d)

Consolidated 1511 Series Safety Valve Instruction Manual | 19
© 2020 Baker Hughes Company. All rights reserved.
XII. Inspection and Part Replacement (Cont’d)
4. Adjusting rings:
If damage is present on the lower surface of the upper
adjusting ring, or on the upper surfaces of the lower
adjusting ring, the damaged part must be replaced.
Thread damage may also be a cause for replacement,
if it prevents adjustments when the valve is heated.
5. Bushing Seat:
Seat bushings are normally treated as part of the
valve body and should be machined when necessary,
inside the valve body. (See Seat Bushing Machining
3. Clearance between the disc and upper ring/guide:
Measure the I.D. of the guide and the O.D. of the disc;
subtracttondthecoldclearance.
The maximum clearance should not be greater than
the value indicated in Table 7. Greater clearances can
indicate wear and can generate alignment problems
and cause the valve not to reseat properly.
F
E
G
BC
Figure 9: Bushing Seat
1. Once clearance exceeds table values, further inspection is required for the disc and
upper adjusting ring.
Instructions, Section XI.B) When the “E” dimension
is reduced by machining or lapping to the minimum
given in Table 8b, the valve seat bushing should be
remachined to the given dimension. The bushing seat
can be remachined until the limiting Dimension “G” is
reached as per Table 8a. See instructions concerning
the “G” dimension in Table 8b. The bushing seat
mustbelappedtoamirrornishtodetermineifthey
areatandfreeofnicks,cutsandscratches.(See
Section XI.C for Lapping Instructions.)
Table 7: Allowable Clearance Between
Upper Adjusting Ring and Disc (1)
Orifice
Clearance Disc Outside
Diameter
Upper Adjusting
Ring (Inside
Diameter)
min max
in. mm in. mm in. mm in. mm
H.007 0.18 .014 0.36 1.905 48.39 1.919 48.74
J.007 0.18 .014 0.36 2.445 62.10 2.459 62.46
K.006 0.15 .013 0.33 2.930 74.42 2.939 74.65
L.007 0.18 .014 0.36 3.638 92.41 3.652 92.76
M.007 0.18 .014 0.36 4.079 103.61 4.093 103.96
N.012 0.30 .019 0.48 4.483 113.87 4.502 114.35
P.008 0.20 .017 0.43 5.448 138.38 5.465 138.81
Q.010 0.25 .019 0.48 7.137 181.28 7.156 181.76
Table 8a: Seat Bushing
Replacement Criteria
Orifice G min
in. mm
H.937 23.80
J.937 23.80
K1.187 30.15
L1.375 34.93
M1.375 34.93
N1.500 38.10
P1.750 44.45
Q2.187 55.55

20 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
1. When(E)dimensionisreducedto.020”(0.51mm)forH–Norices,or.025”(0.64mm)forP–Qorices,
restore the dimensions to those indicated in Table 8b. Seat Bushing is re-machinable until minimum (G)
dimension is reached, then must be discard.
Table 8b: Seat Bushing Rework/Inspection Dimensions
Orifice B max C E (1) F
in. mm in. mm in. mm in. mm
H1.182 30.02 1.304 +
-
.000
.003 33.12 + -
0.00
0.08 .028 + -
.002
.003 0.71 + -
0.05
0.08 .079 + -
.002
.003 2.01 + -
0.05
0.08
J1.513 38.43 1.635 +
-
.000
.003 41.53 + -
0.00
0.08 .025 + -
.005
.000 0.64 + -
0.13
0.00 .098 + -
.005
.000 2.49 + -
0.13
0.00
K1.809 45.95 1.931 +
-
.000
.003 49.05 + -
0.00
0.08 .025 + -
.005
.000 0.64 + -
0.13
0.00 .117 + -
.005
.000 2.97 + -
0.13
0.00
L2.248 57.10 2.400 +
-
.000
.003 60.96 + -
0.00
0.08 .028 + -
.002
.003 0.71 + -
0.05
0.08 .149 + -
.002
.003 3.78 + -
0.05
0.08
M2.523 64.08 2.676 +
-
.000
.003 67.97 + -
0.00
0.08 .028 + -
.002
.003 0.71 + -
0.05
0.08 .167 + -
.002
.003 4.24 + -
0.05
0.08
N2.773 70.43 2.950 +
-
.006
.000 74.93 + -
0.15
0.00 .025 + -
.005
.000 0.64 + -
0.13
0.00 .179 + -
.005
.000 4.55 + -
0.13
0.00
P3.364 85.45 3.547 +
-
.000
.004 90.09 + -
0.00
0.10 .036 + -
.005
.000 0.91 + -
0.13
0.00 .217 + -
.005
.000 5.51 + -
0.13
0.00
Q4.424 112.37 4.615 +
-
.000
.003 117.22 + -
0.00
0.08 .036 + -
.005
.000 0.91 + -
0.13
0.00 .285 + -
.005
.000 7.24 + -
0.13
0.00
During reassembly, three items are of extreme
importance. They are:
1) Alignment
2) Cleanliness
3) Lubrication
To achieve the correct alignment, the bearing surfaces
of the compression screw/upper spring washer, spindle/
lower spring washer and spindle to disc pocket should
each be ground together to attain a perfect match. This
is done by applying a lapping and grinding compound
of about 500 grit on one of the surfaces and rubbing the
surfaces together until a smooth unbroken contact point
is established on both surfaces.
All bearing surfaces and threaded areas must be
lubricated using a high quality high temperature lubricant.
At the factory, Nickel-Ease®is used and is recommended.
For environments where corrosion is a problem, contact
thefactoryeldservicedepartmentforsuggestionson
special coating or plating procedures which will protect the
parts.
1. Thread the lower ring onto the seat bushing and
turn it down until it is below the seating surface.
(This allows the disc to rest on the bushing without
interference from the ring).
2. Thread the upper ring/guide into the valve body
reestablishing its original relationship to the bushing,
as measured in Section X, Disassembly of 1511
Series Safety Valve, step 2. Insert the upper
adjusting ring pin into the valve and tighten. The ring
should now be able to rock back and forth but not
turn. If position is not known, refer to Section XIV.C.
3. After inspecting both the disc and bushing seat for
cleanliness, thread the spindle into the disc and
insert the disc gently into the valve until it rests on the
bushing.
4. Place the spring and spring washers onto the
spindle.
5. Place the yoke over the spindle and replace the
cap screws or nuts. Care must be taken to tighten
the yoke down evenly to prevent distortion and
misalignment.
XIII. Reassembly
XII. Inspection and Part Replacement (Cont’d)