Baker Hughes Consolidated 19000 Series User manual

Consolidated™
19000 Series
Safety Relief Valve
Instruction Manual (Rev. E)
Baker Hughes Data Classification : Public

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

2 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
NOTICE!
For valve congurations not listed in this manual,
please contact your local Consolidated 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.

Consolidated 19000 Series Safety Relief Valve Instruction Manual | 3
© 2020 Baker Hughes Company. All rights reserved.
Conversion Table .................................................................................................................................. 2
I. Product Safety Sign and Label System .............................................................................................. . 5
II. Safety Alerts ........................................................................................................................................ 6
III. Safety Notice......................................................................................................................................... 7
IV. Warranty Information............................................................................................................................. 8
V. Terminology for Safety Relief Valves..................................................................................................... 8
VI. Handling, Storage, and Pre-Installation ................................................................................................ 9
VII. Pre-Installation and Installation Instructions ......................................................................................... 10
VIII. Design Features and Nomenclature................................................................................................. 10
A. General Information ....................................................................................................................... 10
B. Design Options .............................................................................................................................. 10
C. Nomenclature.................................................................................................................................. 10
IX. Introduction ..........................................................................................................................................11
A. 19000 MS & DA Safety Relief Valves...............................................................................................11
B. 19096M-DA-BP Safety Relief Valves ...............................................................................................11
X. Consolidated 19000 Series SRV ........................................................................................................ 12
A Metal Seat Valve ............................................................................................................................. 12
B. Standard Cap Types ....................................................................................................................... 13
C. Soft Seat Valve................................................................................................................................ 14
D. The 19096M-DA-BP Valve .............................................................................................................. 15
XI. Recommended Installation Practices .............................................................................................. 16
A. Mounting Position ......................................................................................................................... 16
B. Inlet Piping .................................................................................................................................... 16
C. Outlet Piping ................................................................................................................................. 17
XII. Disassembly of Consolidated 19000 Series SRV............................................................................... 18
A. General Information ...................................................................................................................... 18
B. Disassembly................................................................................................................................... 19
C. Cleaning......................................................................................................................................... 19
XIII. Maintenance ....................................................................................................................................... 20
A. Metal Seat Valves (MS)................................................................................................................... 20
B. O-Ring Seat Seal Valves (DA) ........................................................................................................ 25
C. Checking Spindle Concentricity .................................................................................................... 26
XIV. Inspection and Part Replacement .................................................................................................... 27
A. Base............................................................................................................................................... 27
B. Metal Seat Disc.............................................................................................................................. 27
C. O-Ring Seat Seal Assembly........................................................................................................... 27
D. Bonnet............................................................................................................................................ 27
E. O-Ring Disc Holder ........................................................................................................................ 27
F. Guide ............................................................................................................................................. 28
G. Spindle ........................................................................................................................................... 28
G.1 MS & DA ................................................................................................................................ 28
G.2 DA - BP ................................................................................................................................. 28
Table of Contents

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H. Spring............................................................................................................................................. 29
I. Spring Washers ............................................................................................................................. 29
J. Adjusting Screw ............................................................................................................................. 29
K. Bonnet Top ..................................................................................................................................... 29
L. Bonnet Bottom ................................................................................................................................ 30
M. Backup Plate................................................................................................................................... 30
N. Spindle O-Ring................................................................................................................................ 30
O. Backup Plate O-Ring ...................................................................................................................... 30
P. Seat O-Ring .................................................................................................................................... 30
XV. Reassembly of Consolidated 19000 Series SRV.............................................................................. 30
A. Metal Seat Valves (MS)................................................................................................................... 30
B. O-Ring Seat Seal Valves (DA) ........................................................................................................ 31
C. 19096M-DA-BP O-Ring Seat Seal Valves ...................................................................................... 31
XVI. Setting and Testing ............................................................................................................................. 33
A. General Information ........................................................................................................................ 33
B. Test Equipment ............................................................................................................................... 33
C. Test Media....................................................................................................................................... 33
D. Setting the Valve ............................................................................................................................. 33
E. Set Pressure Compensation ........................................................................................................... 33
F. Blowdown........................................................................................................................................ 34
G. Simmer............................................................................................................................................ 35
H. Seat Leakage.................................................................................................................................. 35
I. Back Pressure Testing (MS & DA) .................................................................................................. 35
J. Hydrostatic Testing and Gagging .................................................................................................... 37
K. Manual Popping of the Valve ......................................................................................................... 37
XVII. Trouble Shooting Guide ........................................................................................................................ 37
XVIII. Maintenance Tools and Supplies .......................................................................................................... 38
XIX. Replacement Parts Planning.............................................................................................................. 39
A. General Information ........................................................................................................................ 39
B. Inventory Planning .......................................................................................................................... 39
C. Replacement Parts List................................................................................................................... 39
D. Identication and Ordering Essentials ............................................................................................ 39
XX. Genuine Consolidated Parts ............................................................................................................. 39
XXI. Recommended Spare Parts.................................................................................................................. 40
XXI. Field Service, Training, and Repair Program.................................................................................... 41
A. Field Service ................................................................................................................................... 41
B. Repair Facilities .............................................................................................................................. 41
C. SRV Maintenance Training ............................................................................................................. 41
Table of Contents

Consolidated 19000 Series Safety Relief 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
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
personal 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.
1
2
3
4
1234

6 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
II. Safety Alerts
Read - Understand - Practice
Danger Alerts
A DANGER alert describes actions that may cause
severe personal injury or death. In addition, it may provide
preventive measures to avoid severe personal injury or
death.
DANGER alerts are not all-inclusive. Baker Hughes cannot
know all conceivable service methods nor evaluate all
potential hazards. Dangers include:
• High temperature/pressure can cause injury. Ensure all
system pressure is absent before repairing or removing
valves.
• Do not stand in front of a valve outlet when discharging.
STAND CLEAR OF VALVE to avoid exposure to trapped,
corrosive media.
• Exercise extreme caution when inspecting a pressure
relief valve for leakage.
• Allow the system to cool to room temperature before
cleaning, servicing, or repairing. Hot components or
uids can cause severe personal injury or death.
• Always read and comply with safety labels on all
containers. Do not remove or deface container labels.
Improper handling or misuse could result in severe
personal injury or death.
• Never use pressurized uids/gas/air to clean clothing
or body parts. Never use body parts to check for leaks,
ow rates, or areas. Pressurized uids/gas/air injected
into or near the body can cause severe personal injury
or death.
• It is the owner’s responsibility to specify and provide
personal protective wear to protect persons from
pressurized or heated parts. Contact with pressurized
or heated parts can result in severe personal injury or
death.
• Do not work or allow anyone under the inuence of
intoxicants or narcotics to work on or around pressurized
systems. Workers under the inuence of intoxicants
or narcotics are a hazard to themselves and other
employees. Actions taken by an intoxicated employee
can result in severe personal injury or death to
themselves or others.
• Always perform correct service and repair. Incorrect
service and repair can result in product or property
damage or severe personal injury or death.
• Always use the correct tool for a job. The misuse of a
tool or the use of an improper tool can result in personal
injury, damage to product or property.
• Ensure the proper “health physics” procedures are
followed, if applicable, before starting operation in a
radioactive environment.
Caution Alerts
A CAUTION alert describes actions that may result in a
personal injury. In addition, they may describe preventive
measures that must be taken to avoid personal injury.
Cautions include:
• Heed all service manual warnings. Read installation
instructions before installing valve(s).
• Wear hearing protection when testing or operating
valves.
• Wear appropriate eye and clothing protection.
• Wear protective breathing apparatus to protect against
toxic materials.

Consolidated 19000 Series Safety Relief Valve Instruction Manual | 7
© 2020 Baker Hughes Company. All rights reserved.
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 cannot 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 various circumstances and conditions in
which these operations may be performed on Baker Hughes 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 Alerts, listed in Section II, for customer information only.
It is the responsibility of the purchaser or user of Consolidated 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.
Wear necessary personal
protective equipment to
prevent possible injury
III. Safety Notice

8 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
V. Terminology for Safety Relief
Valves (SRV)
1. Accumulation
The pressure increase over the maximum allowable working
pressure of the vessel during discharge through the SRV,
expressed as a percentage of that pressure or in actual
pressure units.
2. Backpressure
The pressure on the discharge side of the SRV:
a. Built-up Backpressure - the pressure that develops at the
valve outlet, after the SRV has been opened, as a result
of ow.
b. Superimposed Backpressure - the pressure in the
discharge header before the SRV is opened.
3. Constant Backpressure
The superimposed backpressure that is constant with time.
4. Variable Backpressure
The superimposed backpressure that varies with time.
5. Blowdown
The di󰀨erence between set pressure and re-seating
pressure of the SRV, expressed as a percentage of the set
pressure or in actual pressure units.
6.ColdDi󰀨erentialSetPressure
The pressure at which the valve is adjusted to open on the
test stand. This pressure
includes the corrections
for backpressure and/
or temperature service
conditions.
Di󰀨erential Between Operating and Set Pressures Valves- in
installed process services will generally give best results if
the operating pressure does not exceed 90 percent of the
set pressure. However, on pump and compressor discharge
lines, the di󰀨erential required between the operating and set
pressures may be greater because of pressure pulsations
coming from a reciprocating piston. The valve should be set
as far above the operating pressure as possible.
7. Lift
The actual travel of the disc away from the closed position
when a valve is relieving.
8. Maximum Allowable Working Pressure
The maximum gauge pressure permissible in a vessel
at a designated temperature. A vessel may not be
operated above this pressure, or its equivalent, at any
metal temperature other than that used in its design.
Consequently, for that metal temperature, it is the highest
pressure at which the primary pressure SRV is set to open.
IV. Warranty Information
Warranty Statement(1): 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.
CAUTION: Defective and nonconforming items must be held for Baker Hughes’s
inspection and returned to the manufacturer upon request.
Incorrect Selection or Misapplication of Products: Baker Hughes cannot be responsible
for customers’ 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 warranty repair service
on new products or eld repaired products of its manufacture. Therefore, customers
contracting such repair services from unauthorized sources do so at their own risk.
Unauthorized Removal of Seals: All new valves and valves repaired in the eld by Baker
Hughes 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.
1. Refer to Baker Hughes’s Standard Terms of Sale for complete details on warranty and limitation of
remedy and liability.
Defective and
nonconforming items
must be inspected by
Baker Hughes
SEALED
Removal and/or
breakage of seal will
negate our warranty.