Baker Hughes Consolidated 1811 Series User manual

Consolidated™
1811 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 1811 Series Safety Valve Instruction Manual | 3
© 2020 Baker Hughes Company. All rights reserved.
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:
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................................................................................. 4
II. Safety Alerts .......................................................................................................................... 5
III. Safety Notice ......................................................................................................................... 6
IV. Warranty Information ............................................................................................................. 7
V. Valve Terminology ................................................................................................................. 7
VI. Storage and Handling Prior to Installation............................................................................. 9
VII. Introduction............................................................................................................................ 9
VIII. Consolidated Safety Valve Type 1811 ................................................................................. 10
IX. Recommended Installation Practices
A. General Requirements.....................................................................................................11
B. Outdoor Safety Valve Installation .....................................................................................11
X. Disassembly of 1811 Series Safety Valve ........................................................................... 12
XI. Maintenance Instructions
A. General Information ....................................................................................................... 13
B. Machining....................................................................................................................... 13
C. Lapping Procedures....................................................................................................... 14
D. Reconditioning a Ring Lap............................................................................................. 14
E. Spindle Runout .............................................................................................................. 15
F. Spring and Spring Washers ........................................................................................... 15
XII. Inspection and Part Replacement
A. General Information ....................................................................................................... 16
B. Specic Steps ................................................................................................................ 16
XIII. Reassembly......................................................................................................................... 20
XIV. Setting and Testing
A. Steam Testing Procedures ............................................................................................. 20
B. Hydrostatic Testing & Gagging....................................................................................... 22
B.1 General Information ................................................................................................ 22
B.2 Application of Test Gags (All Pressures)................................................................. 23
C. Presetting the Adjusting Rings ....................................................................................... 23
D. Electronic Valve Testing (EVT)....................................................................................... 24
XV. Trouble Shooting the 1811 Valve......................................................................................... 25
XVI. Maintenance Tools and Supplies......................................................................................... 26
XVII. Replacement Parts Planning
A. Basic Guidelines ............................................................................................................ 26
B. Identication and Ordering Essentials ........................................................................... 27
XVIII. Consolidated Genuine Parts ............................................................................................... 27
XIX. Recommended Spare Parts ................................................................................................ 28
XX. Manufacturer’s Field Service, Repair and Training Program
A. Field Service ................................................................................................................... 29
B. Repair Facilities .............................................................................................................. 29
C. Maintenance Training ..................................................................................................... 29

Consolidated 1811 Series Safety Valve Instruction Manual | 5
© 2020 Baker Hughes Company. All rights reserved.
If and when required, appropriate safety labels have been included in
the rectangular margin blocks throughout this manual. Safety labels are
vertically oriented rectangles as shown in the representative examples
(below), consisting of three panels encircled by a narrow border. The
panels can contain four messages which communicate:
• The level of hazard seriousness
• The nature of the hazard
• The consequence of human, or product, interaction with the hazard
• The instructions, if necessary, on how to avoid the hazard
The top panel of the format contains a signal word (DANGER, WARNING,
CAUTION or ATTENTION) which communicates the level of hazard
seriousness.
The center panel contains a pictorial which communicates the nature of
the hazard, and the possible consequence of human or product interaction
with the hazard. In some instances of human hazards the pictorial may,
instead, depict what preventive measures to take, such as wearing
protective equipment.
The bottom panel may contain an instruction message on how to avoid
the hazard. In the case of human hazard, this message may also contain
a more precise denition of the hazard, and the consequences of human
interaction with the hazard, than can be communicated solely by the
pictorial.
I. Product Safety Sign and Label System
Do not remove bolts
if pressure in line, as
this will result in severe
personal injury or
death.
Know all valve
exhaust/leakage points
to avoid possible
severe personal injury
or death.
Wear necessary
personal protective
equipment to prevent
possible injury
Handle valve carefully.
Do not drop or strike.
1
1 2 3 4
2
3
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
4

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 1811 Series Safety Valve Instruction Manual | 7
© 2020 Baker Hughes Company. All rights reserved.
Wear necessary
personal protective
equipment to prevent
possible injury
Proper installation and start-up is essential to the safe and reliable operation of
all valve products. The relevant procedures recommended by Baker Hughes, and
described in these instructions, are e󰀨ective methods of performing the required
tasks.
It is important to note that these instructions contain various “safety messages”
which should be carefully read in order to minimize the risk of personal injury,
or the possibility that improper procedures will be followed which may damage
the involved Baker Hughes product, or render it unsafe. It is also important to
understand that these “safety messages” are not exhaustive. Baker Hughes can
not possibly know, evaluate, and advise any customer of all of the conceivable
ways in which tasks might be performed, or of the possible hazardous
consequences of each way. Consequently, Baker Hughes has not undertaken
any such broad evaluation and, thus, anyone who uses a procedure and/or tool,
which is not recommended by Baker Hughes, or deviates from Baker Hughes
recommendations, must be thoroughly satised that neither personal safety, nor
valve safety, will be jeopardized by the method and/or tools selected. Contact
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 circumstances and conditions in which these operations may be performed
on Consolidated products, and the possible hazardous consequences of each
way, Baker Hughes can not possibly evaluate all conditions that might injure
personnel or equipment. Nevertheless, Baker Hughes does o󰀨er certain Safety
Allerts, listed in Section II, for customer information only.
It is the responsibility of the purchaser or user of Baker Hughes valves/equipment
to adequately train all personnel who will be working with the involved valves/
equipment. For more information on training schedules, please contact your local
Green Tag Center. Further, prior to working with the involved valves/equipment,
personnel who are to perform such work should become thoroughly familiar with
the contents of these instructions.
III. Safety Notice

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 (including those of performance), if
any, and will be free from defects in material and
workmanship. Refer to Baker Hughes’s Standard
Terms of Sale, or specic contract for complete details
on warranty and limitation of remedy and liability.
Defective and nonconforming items must be held
for Baker Hughes’s inspection and returned to the
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-a󰀩liated repair companies,
contractors or individuals to perform warranty repair
service on new products or eld repaired products
of its manufacture. Therefore, customers contracting
such repair services from unauthorized sources must
do so at their own risk.
Unauthorized Removal of Seals - All new valves and
valves repaired in the eld by Field Service are sealed
to assure the customer of our guarantee against
defective workmanship. Unauthorized removal and/or
breakage of this seal will negate our warranty.
V. Valve Terminology for Safety Valves
(Paraphrased from ASME’s PTC 25)
• Backpressure
Backpressure 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.
• 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.

Consolidated 1811 Series Safety Valve Instruction Manual | 9
© 2020 Baker Hughes Company. All rights reserved.
• 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 for Safety Valves (Cont.)

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 insure 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.
The Consolidated Safety Valve has been a leader
in the industry since 1879, thus o󰀨ering over a
century of experience in design, engineering and
product manufacture. ’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 insure 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 1811 Series Safety Valve Instruction Manual | 11
© 2020 Baker Hughes Company. All rights reserved.
1/2”-14 NPT
Drain
19
24
20
12
6
3
7
5
4
2
1
9
10
17
16
18
15
14
8
11
13
21
VIII . Consolidated Safety Valve Type 1811
22
23
Figure 1: 1811 Consolidated Safety Valve
Part
No. Nomenclature
1 Base
2 Seat Bushing
3 Disc
4Lower Adjusting Ring
5 Lower Adjusting Ring Pin
6Upper Adjusting Ring
7 Upper Adjusting Ring Pin
8 Yoke
9 Base Stud
10 Stud Nut
11 Spindle
12 Bottom Spring Washer
13 Spring
14 Top Spring Washer
15 Compression Screw
16 Compression Screw
Locknut
17 Cap
18 Cap Set Screw
19 Lever
20 Release Nut
21 Lever Pin
22 Top Lever (4” & 6” Sizes)
23 Drop Lever (4” & 6” Sizes)
24 Release Locknut
Figure 2: Cap and Lifting Lever
Assembly for 4” and 6” Sizes
Figure 3: Flat Solid Disc
(Optional)
Figure 4:
Thermodisc

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. Care should be taken when fastening
bolts on cast iron anges as cracking may result.
The valve shall be free from external stresses transmitted from the discharge
piping. Figure 5 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.
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.
Know all valve exhaust/
leakage points to
avoid possible severe
personal injury or death.
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 5: Recommended Installation for Discharge and Vent Piping
IX. Recommended Installation Practices
B. Outdoor Safety Valve Installation

Consolidated 1811 Series Safety Valve Instruction Manual | 13
© 2020 Baker Hughes Company. All rights reserved.
X. Disassembly of 1811 Series Safety Valve
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 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.

14 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
A. General Information
The 1811 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 insure 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
2. Grinding Compounds
3. High temperature thread lubricant - (Fel-Pro, Nickel
Ease, or equivalent)
4. Two (2) ring laps per valve size and type
Note: See maintenance Tools and Supplies in
Section XVI.
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.
XI. Maintenance Instructions
After the parts have been determined to be reusable,
proper machining technique must be employed in
reestablishing disc and seat bushing dimensions.
On 1811 valves, the seat bushing should be machined
in the valve base to insure 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 on Figure 6 as
“A”, “B”, and “C”.
A
A
B
B
C
C
Chuck Jaws
Chuck Jaws
Figure 6
B. Machining
Note: Thermodisc™ Discs can not be machined without damaging the lip thickness.
See section XII.B for rework dimensions for the seat bushing and Flat Solid Discs.

Consolidated 1811 Series Safety Valve Instruction Manual | 15
© 2020 Baker Hughes Company. All rights reserved.
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 7. 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
Consolidated Field Service Department.
Lapping Plate Ring Lap
Figure 7
XI. Maintenance Instructions (Cont.)
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” (.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.
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. 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.

16 | Baker Hughes © 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 8 below.
Using a spindle check stand (see Figure 8 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 TIR is less than values shown in Table 1, the
spindle may be returned to service. If the TIR is greater
than these values, straighten the spindle using "V"
blocks and a hydraulic press until the TIR 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
e󰀨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 the Baker Hughes Field
Service Department.
A
C
450
A
B
Figure 8
Spindle Check Stand
XI. Maintenance Instructions (Cont.)
Table 1: Spindle Critical Dimensions
Orice C max
in. mm
H .004 0.10
H .004 0.10
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

Consolidated 1811 Series Safety Valve Instruction Manual | 17
© 2020 Baker Hughes Company. All rights reserved.
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
insure the inside surface is smooth. The threads
on the outside must be in good condition to insure
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 Flat Solid Disc (FSD) and the Thermodisc Disc
(TD). Each of these disc designs is available in
either a low pressure (LP) or high pressure (HP)
version.
Disc
1811
(LP) (LP)
FSD TD
(HP) (HP)
Table 2
XII. Inspection and Part Replacement
1811-HP Flat Solid Disc Machining Dimensions
Figure 9: HP Flat Solid Disc
Table 3a: Flat Seat Disc Replacement Criteria1
Orice H min J min
in. mm in. mm
F1.609 40.87 .308 7.82
G1.547 39.29 .308 7.82
H1.609 40.87 .406 10.31
J1.578 40.08 .402 10.21
K1.859 47.22 .475 12.07
L2.266 57.56 .497 12.62
M2.359 59.92 .558 14.17
N2.922 74.22 .621 15.77
P3.313 84.15 .762 19.35
Q3.922 99.62 .840 21.34
Table 3b: Flat Seat Disc Rework/Inspection
Dimensions
Orice
F +.002/-.003 in.
(+0.05/-0.08 mm) G
in. mm in. mm
F .028 0.71 .062 ± .007 1.57 ± 0.18
G .028 0.71 .062 ± .007 1.57 ± 0.18
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 .105 ± .005 2.67 ± 0.13
1. Once a minimum dimension is met, disc is to be
discarded.

18 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
XII. Inspection and Part Replacement (Cont.)
Figure 10: HP Thermodisc 1. Once a minimum dimension is met, disc is to be discarded.
1811-HP Thermodisc Machining Dimensions
Table 4: Thermodisc Replacement Criteria1
Orice F min
in. mm
F .020 0.51
G .020 0.51
H .020 0.51
J .020 0.51
K .020 0.51
L .020 0.51
M .020 0.51
N .020 0.51
P .030 0.76
Q .030 0.76
Note: Due to the thin seat lip, Thermodisc can not be machined. Damage, if present, may be removed
by lapping unit “F” (min.) is exceeded. The Thermodisc requires replacement when the “F” (min.)
dimension is exceeded
If you nd exible seating congurations di󰀨erent from those shown in Figures 9 & 11,
replacement with the current, improved design Thermodisc is recommended.
The 1811-HP & LP Thermodisc is designed for
steam service, and are standard on all new 1811
Safety Valves. The Thermodisc prevents most seat
damage by maintaining a tight seal at higher operating
pressures than the Flat Solid Disc. Inspect the disc
seat for steam cuts, nicks, or other damage. If minor
damage has occurred, the seat may be restored by
lightly lapping seat area G, as indicated in Figures 9 &
10. Do not machine Thermodisc.
If dimension F is reduced to the minimum indicated
in Table 4, the disc should be replaced. Other
replacement criteria include thread damage, spindle
bearing surface damage and severe galling. Egging
caused by vibration and wear also require replacement
to maintain “like new” valve performance.
D
C
N
150
45
0
Figure 11: LP Flat Solid Disc & Thermodisc

Consolidated 1811 Series Safety Valve Instruction Manual | 19
© 2020 Baker Hughes Company. All rights reserved.
1. All other dimensions identical to values found in table 3b
Table 5: Low Pressure Disc Rework Inspection Dimensions (1)
Orice C Flat Seat D Thermodisc D N
in. mm in. mm in. mm in. mm
F - - .834 ± .002 21.18 ± 0.05 .860 ± .002 21.84 ± 0.05 - -
G - - 1.076 ± .002 27.33 ± 0.05 1.092 ± .002 27.74 ± 0.05 - -
H - - 1.349 ± .002 34.26 ± 0.05 1.344 ± .002 34.14 ± 0.05 - -
J 1.983 ± .005 50.37 ± 0.13 1.680 ± .002 42.67 ± 0.05 1.670 ± .002 42.42 ± 0.05 .056 +
-
.002
.003 1.42 + -
0.05
0.08
K 2.372 ± .005 60.25 ± 0.13 1.977 ± .002 50.22 ± 0.05 1.990 ± .002 50.55 ± 0.05 .079 ± .002 2.01 ± 0.05
L 2.948 ± .005 74.88 ± 0.13 2.418 ± .002 61.42 ± 0.05 2.466 ± .003 62.64 ± 0.08 .096 ± .002 2.44 ± 0.05
M 3.307 ± .005 84.00 ± 0.13 2.722 ± .002 69.14 ± 0.05 2.750 ± .003 69.85 ± 0.08 .102 ± .002 2.59 ± 0.05
N 3.639 ± .005 92.43 ± 0.13 3.060 ± .003 77.72 ± 0.08 3.040 ± .005 77.22 ± 0.13 .111 ± .002 2.82 ± 0.05
P 4.418 ± .005 112.22 ± 0.13 3.700 ± .003 93.98 ± 0.08 3.680 ± .005 93.47 ± 0.13 .116 ± .002 2.95 ± 0.05
Q 5.795 ± .005 112.22 ± 0.13 4.800 ± .003 121.92 ± 0.08 4.780 ± .005 121.41 ± 0.13 .149 ± .002 3.78 ± 0.05
XII. Inspection and Part Replacement (Cont.)
3. Clearance between the disc and upper ring/
guide:
Measure the inside diameter of the guide and the
outside diameter of the disc; subtract to nd the
cold clearance.
The maximum clearance should not be greater
than the value indicated in Table 6. Greater
clearances can indicate wear and can generate
alignment problems and cause the valve not to
reseat properly.
Note: Once clearance exceeds table values, further inspection is required for the disc and adjusting ring.
Table 6: Allowable Clearance Between Upper Adjusting Ring and Disc
Orice
Clearance Disc Outside
Diameter
Upper Adjusting Ring
(Inside Diameter)
min max
in. mm in. mm in. mm in. mm
F .004 0.10 .011 0.28 1.189 30.20 1.200 30.48
G .008 0.20 .015 0.38 1.521 38.63 1.536 39.01
H .007 0.18 .014 0.36 1.905 48.39 1.919 48.74
J .009 0.23 .014 0.36 2.445 62.10 2.459 62.46
K .006 0.15 .013 0.33 2.926 74.32 2.939 74.65
L .011 0.28 .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

20 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
1. Seat prole must be reestablished when Dimension (E) is .020” (0.51 mm) for Orice F - N, or .030” (0.76 mm) for P – Q
Orice. Once (Z max.) has been reached, discard. Do not remachine the head ange to reestablish (Z).
Table 7: Base and Seat Bushing Assembly Rework/Inspection Dimensions
Orice B max C E1F Z max
in. mm in. mm in. mm in. mm in. mm
F .740 18.80 .839 +
-
.001
.002 21.31 + -
0.03
0.05 .028 + -
.002
.003 0.71 + -
0.05
0.08 .113 + -
.002
.003 2.87 + -
0.05
0.08 2.083 52.91
G .947 24.05 1.069 +
-
.001
.002 27.15 + -
0.03
0.05 .028 + -
.002
.003 0.71 + -
0.05
0.08 .089 + -
.002
.003 2.26 + -
0.05
0.08 2.083 52.91
H 1.182 30.02 1.353 +
-
.001
.002 34.37 + -
0.03
0.05 .028 + -
.002
.003 0.71 + -
0.05
0.08 .103 + -
.002
.003 2.62 + -
0.05
0.08 2.203 55.96
J 1.513 38.43 1.677 +
-
.002
.001 42.60 + -
0.05
0.03 .028 + -
.002
.003 0.71 + -
0.05
0.08 .126 + -
.002
.003 3.20 + -
0.05
0.08 2.271 57.68
K 1.809 45.95 1.999 +
-
.001
.002 50.77 + -
0.03
0.05 .028 + -
.002
.003 0.71 + -
0.05
0.08 .145 + -
.002
.003 3.68 + -
0.05
0.08 2.645 67.18
L 2.248 57.10 2.479 +
-
.001
.002 62.97 + -
0.03
0.05 .028 + -
.002
.003 0.71 + -
0.05
0.08 .174 + -
.002
.003 4.42 + -
0.05
0.08 3.083 78.31
M 2.523 64.08 2.779 +
-
.001
.002 70.59 + -
0.03
0.05 .028 + -
.002
.003 0.71 + -
0.05
0.08 .192 + -
.002
.003 4.88 + -
0.05
0.08 3.458 87.83
N 2.773 70.43 3.073 +
-
.003
.003 78.05 + -
0.08
0.08 .028 + -
.002
.003 0.71 + -
0.05
0.08 .206 + -
.002
.003 5.23 + -
0.05
0.08 3.958 100.53
P 3.364 85.45 3.718 +
-
.002
.002 94.44 + -
0.05
0.05 .039 + -
.002
.003 0.99 + -
0.05
0.08 .245 + -
.002
.003 6.22 + -
0.05
0.08 4.458 113.23
Q 4.424 112.37 4.818 +
-
.001
.002 122.38 + -
0.03
0.05 .039 + -
.002
.003 0.99 + -
0.05
0.08 .312 + -
.002
.003 7.92 + -
0.05
0.08 5.333 135.46
H
X
.001” (0.03 mm)B
B
J
C
E
FB
Ø.005” (0.13 mm)
Z
H
Figure 13: Base and Seat Bushing AssemblyFigure 12: Base and Seat Bushing Assembly
XII. Inspection and Part Replacement (Cont.)
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 Instructions, Section
XI.B). When the “E” dimensions are reduced by
machining or lapping to a minimum given in Table
7, the valve seat bushing should be remachined
to the given dimensions. The bushing seat can
be remachined in 1811 Safety Valves until the
limiting dimensions are reached. See instructions
concerning the “Z” dimension in Table 7. 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).