Baker Hughes Consolidated 1900/P Series User manual

Consolidated™
1900/P Series
Safety Valves
The Eductor Tube Advantage™
Instruction Manual (Rev.C)
Baker Hughes Data Classification : Public

2 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
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 1900/P Series Safety Valves 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 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
Section Subject Page No
I. Product Safety Sign and Label System................................................................................................6
II. Safety Alerts .........................................................................................................................................7
III. Safety Notice ........................................................................................................................................8
IV. Warranty Information ............................................................................................................................9
V. Terminology for Safety Valves ....................................................................................................... 9-10
VI. Handling and Storage ........................................................................................................................11
VII. Pre-Installation and Installation Instructions.......................................................................................12
VIII. Introduction.........................................................................................................................................12
IX. Consolidated 1900/P Series Safety Valves.....................................................................................13
A. Conventional Valve .......................................................................................................................13
B. Standard Cap Types .....................................................................................................................13
C. Bellows Valve (P1 only).................................................................................................................14
X. General Planning for Maintenance.....................................................................................................16
XI. Recommended Installation Practices ................................................................................................16
XII. Disassembly of 1900/P Series Safety Valves ....................................................................................17
XIII. Maintenance Instructions ................................................................................................................18
A. Machining of Seat Nozzle .............................................................................................................18
B. Lapping .........................................................................................................................................19
C. Reconditioning of Ring Laps ........................................................................................................19
D. General Lapping Comments ........................................................................................................19
E. Nozzle Lapping ............................................................................................................................19
F. Thermodisc™ Disc Lapping..........................................................................................................20
XIV. Inspection and Part Replacement ............................................................................................... 20-22
XV. Reassembly 1900/P Series Safety Valves ......................................................................................23
A. Reassembly of the Valve......................................................................................................... 23-24
B. Checking Lift on D and E Valves............................................................................................. 25-26
C. Limit Washer Length .....................................................................................................................26
XVI. Setting and Testing ..........................................................................................................................27
A. Setting the Valve ...........................................................................................................................27
B. Back Pressure Compensation ......................................................................................................27
C. Blowdown......................................................................................................................................27
D. Seat Leakage................................................................................................................................28
E. Recommended Back Pressure Testing .........................................................................................28
F. System Hydrostatic Testing...........................................................................................................28
G. Adjusting Ring Settings.................................................................................................................29
XVII. Troubleshooting Guide for Safety Valve .............................................................................................30

Consolidated 1900/P Series Safety Valves Instruction Manual | 5
© 2020 Baker Hughes Company. All rights reserved.
Section Subject Page No
Table of Contents
XVIII. 1900/P Series SV Options.......................................................................................................... 30-31
A. Cap and Weather Shield Options............................................................................................ 30-31
XIX. Maintenance Tools and Supplies ....................................................................................................32
A. Pin Spanner Wrenches .................................................................................................................32
B. Inside Snap Ring Pliers.................................................................................................................32
C. Lap Rings......................................................................................................................................33
D. Lap Plate.......................................................................................................................................33
E. Lapping Compounds.....................................................................................................................33
XX. Replacement Parts Planning...........................................................................................................34
A. Service Parts Inventory Planning..................................................................................................34
B. Ordering Essentials................................................................................................................. 34-35
XXI. Genuine Consolidated Parts ..............................................................................................................35
XXII. Recommended Spare Parts ...............................................................................................................36
XXIII. Manufacture's Field Service, Repair and Training Program.........................................................37
A. Field Service .................................................................................................................................37
B. Factory Repair Facilities ...............................................................................................................37
C. Maintenance Training....................................................................................................................37

6 | Baker Hughes © 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
Make sure there is no
pressure in the valve
before disassembly.
1
Know all valve exhaust/
leakage points to avoid
possible severe personal
injury or death.
2
Wear necessary
protective equipment
to prevent possible
injury
3
Handle carefully. Do
not drop or strike.
4
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

Consolidated 1900/P Series Safety Valves Instruction Manual | 7
© 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 safety
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
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 media.

8 | Baker Hughes © 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 effective 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 your local GTC™ (Green Tag Center )if there
are any questions relative to tools/methods.
The installation and start-up of valves and/or valve products may involve proximity
to uids at extremely high pressure and/or temperature. Consequently, every
precaution should be taken to prevent injury to personnel during the performance of
any procedure. These precautions should consist of, but are not limited to, ear drum
protection, eye protection, and the use of protective clothing, (i.e., gloves, etc.) when
personnel are in, or around, a valve work area. Due to the various circumstances
and conditions in which these operations may be performed on Baker Hughes
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 offer 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, please contact your local GTC (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
avoid possible personal
injury.
Improper tools or
improper use of right
tools could result in
personal injury or
product damage.
All potential hazards
may not be covered in
this manual.
III. Safety Notice

Consolidated 1900/P Series Safety Valves Instruction Manual | 9
© 2020 Baker Hughes Company. All rights reserved.
SEALED
Removal and/or
breakage of seal will
negate our warranty.
IV. Warranty Information
Defective and
nonconforming items
must be inspected by
Baker Hughes
Warranty Statement:1Baker 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
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-af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 Baker Hughes Field Service team are sealed to assure the customer of our
guarantee against defective workmanship. Unauthorized removal and/or breakage
of this seal will negate our warranty.
Note 1 Refer to Baker Hughes Standard Terms of Sale for complete details on
warranty and limitation of remedy and liability.
V. Terminology for Safety Valves
The basic denitions of safety valves are given in ANSI B95.1, Terminology for
Safety Valve Devices; ASME PTC 25.3, Performance Test Code for Safety and
Relief Valves; and API RP 520, Design and Installation of Pressure Relieving
Systems in Reneries.
• Accumulation
See Overpressure
• Back Pressure
The pressure at the discharge side of the valve.
• Superimposed Back Pressure
The pressure in the discharge header before the valve opens
- Constant Superimposed: This type of back pressure remains essentially
at a xed value (constant) and exists (superimposed) continuously prior to
and during the opening of the valve.
- Variable Superimposed: This type of back pressure varies or changes over
a range from a minimum to a maximum, or vice versa. The actual back
pressure at any specic time depends on conditions in the piping system to
which the outlet of the valve is connected.
• Built-up Back Pressure
The pressure which develops at the valve outlet as a result of ow after the
valve is opened.
(paraphrased from PTC 25.3)

10 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
V. Terminology for Safety Valves (Contd.)
• Blowdown
Blowdown is the difference between set pressure
and resetting pressure. It is generally expressed as a
percentage of set pressure.
• Chatter
Chatter is abnormal, rapid reciprocating motion of the
movable parts of a safety valve in which the disc contacts
the seat.
• Closing pressure
Closing pressure is the point at which the valve recloses.
• ColdDi󰀨erentialSetPressure(CDS)
This is the test pressure at which the valve is adjusted
to open on the test stand. This pressure includes the
corrections for temperature and/or back pressure service
conditions. Nameplate shows “cold set press” (see Figure
31).
• Disc
A disc is the pressure containing movable element of a
valve which affects closure.
• Flutter
Flutter is abnormal, reciprocating motion of the movable
parts of a valve in which the disc does not contact the seat.
• Leakage
See “Seat Leakage”.
• Lift
Lift is the disc rise when a valve is open.
• Maximum Allowable Working Pressure (MAWP)
The maximum pressure permissible in a vessel at the
design temperature.
• Nozzle
A nozzle is the pressure-containing element which consists
of the inlet ow passage (orice) and includes the xed
portion of the seat.
• Operating Pressure
The normal pressure required to operate the vessel or
system. A suitable margin must be provided between the
operating and the valve set pressure.
• OperatingandSetPressure-Di󰀨erential
Valves in process service will generally give best results
if the operating pressure does not exceed 90 percent of
the set pressure. On pump and compressor discharge
lines, however, the differential required between the
operating and set pressures may be greater because of
pressure pulsations coming from a reciprocating piston. It
is recommended that the valve be set as high above the
operating pressure as possible.
• Orice
The orice is the minimum cross-sectional area of the
controlling nozzle bore.
• Overpressure
Overpressure is any pressure in excess of the set pressure,
usually expressed as a percentage of set pressure. For
certication, accumulation is the percent of overpressure
at which the valve is to be fully open as specied by the
ASME Code.
• Safety Valve
A safety valve is an automatic pressure relieving device
actuated by upstream pressure. A safety valve is designed
to open to prevent a rise of system pressure above a
specied value and to reclose after normal conditions have
been restored.
A safety valve is a two-chamber component having primary
and secondary zones. Each chamber has different design
criteria (i.e., pressure and temperature). The nozzle and
disc are the primary members. The base and bonnet are
the secondary members.
• Rated Capacity
This is the rated ow at an authorized percent
accumulation permitted by the applicable Code. Rated
capacity is generally expressed in pounds per hour (lbs/hr)
or kg/hr for vapors; standard cubic feet per minute (SCFM)
or m3/min for gases; and in gallons per minute (GPM) or L/
min for liquids.
• Relief Valve
A safety valve which opens in proportion to overpressure. A
relief valve is used primarily for liquid service.
• Reseating Pressure
See closing pressure.
• Safety Valve
A safety valve characterized by rapid full opening or pop
action. It is used for gas or vapor service.
• Safety Relief Valve
A safety valve that may be used as either a safety or relief
valve, depending upon the application.

Consolidated 1900/P Series Safety Valves Instruction Manual | 11
© 2020 Baker Hughes Company. All rights reserved.
V. Terminology for Safety Valves (Contd.)
Prevent dirt from
entering outlet port.
Make sure there is no
pressure in the valve
before disassembly.
• Seat
The seat is the junction between the nozzle which is xed and the disc which
moves against the nozzle to obtain closure.
• Seat Leakage
Seat leakage test pressure is the specied inlet static pressure at which a
quantitative seat leakage test is performed in accordance with a standard
procedure.
• Set Pressure
Set pressure is the inlet pressure at which the valve has been adjusted to
open under service conditions.
For gas and vapor service - when the valve pops.
For liquid service - when the valve begins to discharge a continuous stream.
• Simmer
Characterized by the audible/visual passage of a uid across the seating
surfaces just prior to opening. The difference between this start to open
pressure and the set pressure is simmer.
For gas service valves, simmer is leakage just prior to opening.
For liquid service valves, simmer is the noncontinuous ow (drops) just prior
to becoming continuous.
• Valve Trim
Includes the disc and nozzle.
VI. Handling and Storage
1. Each valve should be carefully inspected after uncrating to be sure the valve
has not been damaged during transit.
2. Flanged valves, either crated or skidmounted, should always be kept with the
inlet ange down, i.e. never laid on their side, to prevent misalignment and
damage to internals.
3. 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.
Handle carefully.
Do not drop or strike.

12 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
VII. Pre - Installation and Installation Instructions
1. Flange protectors and sealing plugs should not be removed until the valve is ready
to be bolted into the installation, both inlet and outlet. Meticulous care should be
exercised to prevent dirt and other foreign materials from entering the inlet and
outlet ports before installation.
2. Valves, either crated or uncrated, should never be subjected to sharp impact. This
would be most likely to occur while unloading or otherwise moving with a fork
lift truck. While hoisting to the installation, care should be exercised to prevent
bumping valve.
3. Uncrated valves should be moved or hoisted by wrapping chain or sling around
discharge neck, then around upper bonnet structure in such manner as will ensure
the valve is in vertical position during lift, i.e., not lifted in horizontal position.
Caution: Never lift the full weight of the valve by the lifting lever (if so equipped).
Design Features
Baker Hughes's Consolidated 1900/P Series Steam Internals (conventional or
bellows) safety valve is a precision machined device and operates on the force
balance principle.
Types 1900/P1 closed bonnet and P3 slotted bonnet valves have been designed for
steam service in accordance with ASME Code Section I and VIII. Both types come
ready for application and should be handled carefully through receiving, handling,
storage and installation.
Safety valves in organic uid vaporizer service are totally enclosed and do not have a
lifting lever.
Reliable performance and easy maintenance procedures are characteristics of those
valves when properly installed in applications suitable for their design.
Seat Tightness - Thermodisc™
When the valve closes, a Thermodisc seat compensates for temperature gradient
around the seating surface.
High Nozzle Guide
Nozzle is guided in the base as close as possible to the nozzle seat.
Low Spindle Bearing
Valve has a low spindle bearing point, assuring proper alignment and load distribution
at the seating surface. This prevents the disc from sliding across the seat on opening
and closing.
Simple Blowdown Adjustment
Single blowdown ring design permits ease of adjustment. Proper blowdown can be
attained by positioning the ring in accordance with Table 11 (Section XVII)
VIII. Introduction
Mount safety valve
only in a vertical
upright position.
Do not lift or
carry valve by
the lifting lever.

Consolidated 1900/P Series Safety Valves Instruction Manual | 13
© 2020 Baker Hughes Company. All rights reserved.
IX. Consolidated 1900/P Series Safety Valves
Part No. Nomenclature
1 Base
2 Nozzle
3 Adjusting Ring
4 Adjusting Ring Pin
5 Adjusting Ring Pin Gasket
6 Disc
7 Disc Holder
8 Holder Ring
9 Holder Ring Retainer
10 Guide
11 Guide Gasket
12 Bonnet
13 Bonnet Gasket (P1 Only)
14 Base Stud
15 Stud Nut
16 Spindle
17 Spring Washer
18 Spring
19 Adjusting Screw
20 Adjusting Screw Nut
22 Plain Cap
24 Cap Set Screw
26 Release Nut
27 Release Locknut
33 Top Lever
33A Top Lever Pin
34 Drop Lever
34A Drop Lever Pin
42 Eductor Tube (P1 Only)
43 Bonnet Plug
44 Limit Washer (D-2 & E-2)
33A
1
2
5
3
4
6
8
7
10
11
13
16
17
12
18
17
26
43
14
15
44
42
9
1A
1/2” NPT
DRAIN
34A
33
34
24
20
19
27
22
A. Conventional Valve
Figure 1: Conventional Valve Construction

14 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
IX. (Contd.)
Part
No. Nomenclature
Packed Cap Assembly
21 Packed Cap
23 Cap Screw
25 Cap Gasket (P1 Only)
26 Release Nut
27 Release Locknut
28 Lever
29 Lifting Fork
30 Lever Shaft
31 Packing
32 Packing Nut
Plain Cap Assembly
22 Plain Cap
24 Cap Set Screw
26 Release Nut
27 Release Locknut
33 Top Lever
33A Top Lever Pin
34 Drop Lever
34A Drop Lever Pin
Bolted Cap Assembly
35 Bolted Cap
23 Cap Screw
25 Cap Gasket (P1 Only)
Gag Assembly
38 Gag Bolt
39 Sealing Plug
40 Sealing Plug Gasket
Screwed Cap Assembly
41 Screwed Cap
25 Cap Gasket (P1 Only)
29
21
27
26
28
23
25
32
31
30
24
33A
26
22
27
33
34A
34
35
23
25
38
39
40
41
25
B. Standard Cap Types
Figure 2: Packed Cap Assembly
Figure 3: Plain Cap Figure 4: Bolted Cap
Figure 6: Screwed Cap
Figure 5: Cap with Gag

Consolidated 1900/P Series Safety Valves Instruction Manual | 15
© 2020 Baker Hughes Company. All rights reserved.
IX. (Contd.)
1A
1/2” NPT
DRAIN
47
45
46
Part
No. Nomenclature
45 Bellows
Bellows Nut
Bellows Flange
46 Bellows Gasket
47 Seal Plate
C. Bellows Valve (P1 Only)
Bellows
Flange Bellows
Bellows
Ring
Figure 7: Bellows Metal Seat Valve Construction
Figure 8: Bellows Assembly

16 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
Vessel C
Expansion Joint
Recommended
Not
Recommended
In closed systems,
avoid piping strains to
pressure relief valve.
*
Attach vent pipe
rigidly to structure.
Do not connect to drip pan
or the discharge piping.
Vent Pipe
Drip Pan
Pan Drain
Elbow Drain
Vessel B
Long Radius
Elbow
*
Cap may be required
for weather protection.
Vessel A
Long Radius
Elbow
(1)
The pressure drop between the source of pressure in the protected equipment and the valve inlet
(1)
should not exceed 3% of the valve set pressure.
Consolidated Safety valves are checked, set and adjusted at
the factory.
Piping (systems) is the responsibility of the user. One source of
information is ANSI B31.1 Power Piping, Appendix II, “Non-
mandatory Rules for the Design of Safety Valve Installations” in
steam service.
Valves in organic uid vaporizer service require a closed
discharge piping system.
Piping should be as short as possible and in perfect alignment.
Safety valves should be mounted to provide adequate access
360° around the valve plus overhead room to permit removal
for testing and maintenance. A safety valve must never be
installed in any position except the vertical position and
preferably never on the outlet side of an elbow. No stop valve
should be placed between the pressure vessel and its safety
valve except as permitted by applicable Codes. If a stop valve
is located between the pressure vessel and a safety valve, the
stop valve shall have a minimum inside diameter equal to or
greater than the nominal inside diameter of the safety valve
inlet. The inlet piping must be clean before installation.
The discharge piping size must never be less than the valve
outlet size.
For conventional valves, Baker Hughes recommends that the
discharge piping be designed to limit the back pressure to 10
percent of the set pressure. Baker Hughes recommends a
bellows valve (see Consolidated SRV-1 for applicable capacity
factor).
When gags are used in conjunction with setting valves installed
on the boiler, they should be installed after the boiler is at
operating temperature.
When a valve is equipped with a lifting lever, the lever should
be positioned to avoid accidental contact by other equipment or
personnel, which might cause valve to lift accidentally.
Steam service valve body drain must be piped to a safe area. If
left plugged, condensate will collect inside the valve body. If left
open, hot water can escape and present a hazard to personnel
near the valve. Preferably the drain connections (body, elbow
and drip pan) should be piped separately - not main-folded -
because of the tendency of small pipes to plug with rust.
When installing bellows valves, the bonnet vent plug must be
removed and vented (piped) to a safe area.
XI. Recommended Installation Practices
X. General Planning for Maintenance
This manual provides plans for inspection and repair of
Consolidated 1900/P series steam internals safety valves. The
requirements of this manual are considered minimum and do
not relieve the user of the responsibility of applicable codes,
standards and guides, including all safety regulations having
jurisdiction over the installation.
Preventative maintenance should be practiced. At regular
intervals each valve should be removed, disassembled,
inspected, refurbished and tested to the customer’s
requirements.
Figure 9: Installation

Consolidated 1900/P Series Safety Valves Instruction Manual | 17
© 2020 Baker Hughes Company. All rights reserved.
Notes:
A. It’s a good policy to keep parts together by valve serial
number. Serial number and valve type number are
stamped into the top edge of the outlet ange and on the
valve nameplate.
B. For parts identication refer to Figures 1-8
The Consolidated 1900/P series safety valve can be
disassembled by following the procedure outlined below:
1. Remove cap (including lifting gear) and cap gasket.
2. Remove adjusting ring pin and gasket. If the existing
blowdown is to be restored upon reassembly, the
position of the adjusting ring with respect to the disc
holder must be determined. Turn the adjusting ring
counterclockwise, i.e., move notches on the adjusting
ring from left to right. Record the number of notches
passing the ring pin hole required for the ring to contact
the disc holder. This information will be used in setting
the ring upon reassembly of the valve.
3. Use dial caliper or depth micrometer to measure and
record dimension "A" of Figure 10 from the top of the
spindle to the top of the adjusting screw. This will be
used later for adjustment of the valve to near its original
set pressure. Loosen the adjusting screw lock nut. Turn
adjusting screw counter-clockwise to remove the spring
load. When turning the adjusting screw use Vise-Grip®
pliers to hold the spindle.
4. Remove the stud nuts and lift off the bonnet or yoke.
Remove bonnet gasket.
5. Remove the spring and spring washers. The spring and
spring washers should be kept together as a unit at all
times.
6. All the upper internal parts can be removed as a unit by
lifting out the spindle(1). These parts should be removed
by lifting straight up. On bellows valves care should be
taken not to bend or distort the bellows or its ange.
Care should be taken to ensure that disc and spindle
assembly are fully engaged before removal.
7. Remove the spindle from the disc holder. In valves as
shown in Figures 1 to 7, it is necessary to rotate the
spindle counter-clockwise only, while pulling up. This
engages the drop-out thread.
8. Remove guide from the disc holder.
9. On D and E valves, remove the limit washer and tag
with the valve serial number. If bellows D or E, tilt the
disc holder bellows assembly and slide out the limit
washer. The bellows is attached to the disc holder by
right-hand threads. Apply a pin spanner wrench to the
bellows ring and loosen bellows by turning counter-
clockwise (Figure 11). The bellows convolutions are
very thin metal and care should be taken to protect
them from damage at all times. Remove bellows gasket.
10. Remove disc holder retainer ring using inside snap ring
pliers (see Figure 29).
11. Separate disc holder, disc and holder ring.
12. Remove the adjusting ring from the nozzle by turning
counter-clockwise and tag with valve serial number.
13. The nozzle should not be removed from the base
unless necessary due to damage.
(1) In instances where valves are fouled with foreign materials
and/or heavy products, disassembly may be eased if
these parts are given a prior soaking in a suitable solvent.
XII. Disassembly of 1900/P Series Safety Valves
Depth
Micrometer
Dimension
A
Adjusting
Screw
Spindle
Vise
Bellows Ring
Disc Holder
Bellows
Convolutions
Spanner Wrench
Soft Material
Bellows Gasket
Figure 10 Figure 11: Removing the Bellows Ring

18 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
A. Machining of Nozzle Seat
All damaged parts, as determined by inspection, must be
replaced with the exception of the valve nozzle, which may be
machined as follows:
The nozzle seat should be machined with the nozzle
assembled in the base whenever possible. If it should be
necessary to remove the nozzle from the base, use the
methods shown in Figure 12 or 13.
Use a hex wrench or pipe wrench as appropriate on nozzle
ange to remove nozzle from base, or use a three-jaw chuck
welded vertically to a stand bolted to the oor (see Figure 12).
Lathe set-up for machining of nozzle: grip the inlet ange of the
valve in a four-jaw independent chuck (see Figure 14).
True up the work so that the top of the nozzle at “C” and
the base surface at "B” run true within .001" (0.03 mm) on
indicator.
If the nozzle has been removed, grip the nozzle in a fourjaw
independent chuck using a piece of soft material such as
copper or ber between the jaws and the nozzle as shown at
“A” (Figure 15).
True up the nozzle so that the surfaces marked “B”, “C” and “D”
run true within .001" (0.03 mm). on indicator.
Thermodisc™: because of the critical shape of the disc,
because of the critical shape of the disc, Baker Hughes does
not recommend machining of the disc. However, careful
lapping may be done so long as dimensions in Figure 16 and
Table 1 are maintained.
XIII. Maintenance Instructions
Base
Nozzle
3 Jaw Chuck
Chuck Stand
8' (2.4 m)-10' (3 m)
Long Rod or
Heavy Pipe
Base
Nozzle
Pipe Wrench
View From Top
View From Side
A
Chuck Jaw
Nozzle
C
BD
Chuck Jaw
B
C
Base
Nozzle
Figure 12: Loosening the Nozzle from the Base Figure 13: Removing the Nozzle from the Base
Figure 14: Lathe set-up for machining of nozzle Figure 15: Nozzle Positioned in a Jaw

Consolidated 1900/P Series Safety Valves Instruction Manual | 19
© 2020 Baker Hughes Company. All rights reserved.
B. Lapping
Lapping is required to obtain the surface nish necessary
for proper seating. Prior to lapping, Lap Ring must be
reconditioned to ensure proper results.
C. Reconditioning of Ring Laps
Lap Rings are reconditioned by lapping them on a at
lapping plate. The lapping should be done with gure-eight
motions as indicated in Figure 17. To obtain the best results,
the Lap Rings must be reconditioned before each use.
Always run the outer edge of the lap beyond the edge of the
plate to even wear.
Lapping Plate(1): The lapping plate is used for reconditioning
Lap Rings. One 11" (279.40 mm) diameter cast iron plate is
required for the entire range of valve sizes.
Lap Rings(1): Laps are at cast iron rings.
Lapping Compound(1): Lapping compound is used as the
cutting medium in lapping valve seats.
(1)See Maintenance Tools and Supplies (Section XIX).
D. General Lapping Comments
Seat lapping is an art and comes with practice and
experience. To obtain the best results, the Lap Rings must
be reconditioned before each use.
At rst the parts will slide easily; however, as the seat becomes
smooth and at, the lap will drag noticeably. Clean the seat
periodically for examination. When the seat is fully lapped, it
will have a uniform dull light grey appearance. At this point,
clean and apply 1000 grit and lap to a mirror nish. When
lapping has been completed, any lines appearing as cross
scratches can be removed by rotating the lap which has been
wiped clean of compound - on the seat faces - about its own
axis. With practice a quarter turn on #4/0 emery polishing
paper accomplishes the same result. Clean with alcohol or
other suitable cleaner.
A Surface Finish Comparator is used to determine surface
nish number (microinch). For full details on surface nish
numbers refer to ANSI B46.1 and/or Machinery’s Handbook.
In many cases a 1000 grit lap may be adequate. Both nozzle
and disc seat surfaces must be 8 RMS nish or better.
Table 2: Typical Seat Lapping Recommendations
Seat Finish RMS Repair Oper. Grit
over 250 machine -
over 125 - 250 grinding 320
over 16 - 125 grinding 500
16 and under lapping 1000
E. Nozzle Lapping
When using the Lap Ring uniformly, coat the lap with a small
amount of lapping compound. Keep the lap squarely on the
nozzle seat and avoid any tendency to rock the lap, which will
result in rounding of the seat. Keep a rm grip on the lap to
prevent the possibility of dropping it and damaging the seat.
Use an oscillating motion while applying very light force and if
possible occasionally rotate the nozzle. (Do not turn the lap in
just one direction.)
F. Thermodisc™ Disc Lapping
XIII. Maintenance Instructions (Contd.)
Lapping
Plate
Lap
Ring
Disc
A
Table 1: Minimum A Dimensions (Thermodisc)
Orice A min.
in. mm
D thru M .003 0.08
N thru T .005 0.13
Figure 17: Lapping Pattern
Figure 16: Thermodisc™

20 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
XIII. Maintenance Instructions (Contd.)
Uniformly coat the disc with a small amount of lapping
compound and place it on the Lap Ring. The operation is
basically the same as the nozzle except that the disc must be
moved on the Lap Ring.
Now all parts should be cleaned. First remove grease and
sealants, then remove rust and scale. Inspect the internal parts
to ensure they are not damaged by galling. Look especially at
the rubbing surfaces of the guide and disc holder.
Inspect the spindle to ensure concentricity. Over-gagging is
one of the common causes of bent spindles.
Inspect the spring and washer assembly for excess clearance
[greater than .031” (0.79 mm)] and inspect the bearing surfaces
for galling.
1. Between the upper spring washer and the adjusting screw
2. The lower spring washer and the spindle shoulder
3. Spring - look for corrosion pits. Replace the spring if
severe corrosion or pitting is present. If the spring has
been in service a long time, measure the free length of the
spring. Contact Baker Hughes and give this dimension, the
spring number, and the valve set pressure to obtain their
recommendations.
On all disc holders, inspect the bearing surface between the
spindle pocket of the disc holder.
Inspect all bearing parts for concentricity, apply a very thin layer
of Clover 3A grinding compound to the actual bearing surfaces,
and grind together to determine if smooth, uninterrupted
contact is made. If grinding does not restore the original
condition or very close to it, then the parts should be replaced.
Spherical surfaces should have a 63 RMS or better surface
nish and their radius must be continuous. Each corresponding
bearing surface should be conical and smooth with a 63 RMS
or better surface nish. All traces of lapping compound must be
carefully and totally removed prior to reassembly.
A surface nish comparator is required to obtain these
readings. See Maintenance Tools and Supplies on Section XX.
The bellows (if present) should be visually inspected and
perhaps reassembled to the disc holder with a good gasket,
lled with water, and allowed to set for an hour or two to show
any leakage. At conclusion, if a successful test, then dump the
water and remove the gasket and allow the bellows to dry out.
(Make sure bellows is dry when valve is reassembled).
If conventional valve with eductor tube, push a wire through the
tube to check for plugging.
Nozzle - The nozzle seating surface must be inspected for
nicks, cuts or grooves. Minor steam cuts can be lapped out.
See dimensions in (Figure 19) and Tables 3 and 4.
Thermodisc™ - If surface defects cannot be lapped out, the
disc must be replaced. If after lapping, “A” in (Figure 16 in
Section XIII) is less than “A min.” (Table 1), replace the disc.
Adjusting Ring - The adjusting ring must have undamaged
threads. Both surfaces “A” and “B” must be undamaged (see
Figure 20).
Adjusting Ring Pin - Pin must be inspected to ensure that it is
long enough to keep the Adjusting Ring from turning yet without
touching the bottom of the notch (See Figure 20).
Gasket Surfaces - All gasket surfaces should be inspected for
cleanliness and be without radial scratches. Be sure all pieces
of the old gasket have been completely removed.
XIV. Inspection and Part Replacement
At a 450angle
an indicator reading
should not exceed
.007” (0.18 mm) runout
Ball Bearing
Top View
Figure 18: V-Block Support Setup