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