Baker Hughes Consolidated 1982 Series User manual

Consolidated™
1982 Series
Safety Relief Valves
Instruction Manual (Rev. B)
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.
b | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

NOTICE!
For any service questions not covered
in this manual, please contact your local
Green Tag™ Center (GTC).
Consolidated 1982 Series Safety Relief Valve Manual | c
© 2020 Baker Hughes Company. All rights reserved.
All the USCS values are converted to
metric values using the following conversion factors:
USCS Units 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.

d | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
Table of Contents
I. Warranty Information ................................................1
II. Safety Notice .......................................................2
III. Product Safety Sign and Label System..................................3
IV. Safety Alerts .......................................................4
V. Handling and Storage ................................................6
VI. Pre-installation and Mounting .........................................6
VII. General Planning for Maintenance .....................................7
VIII. Terminology for Pressure Relief Valves .................................8
IX. Design Features and Nomenclature ....................................9
X. Introduction ........................................................9
IX. Consolidaed 1982 Series Safety Relief Valve ............................10
X. Disassembly.......................................................12
XI. Inspection and Part Replacement .....................................14
A. Base .........................................................................14
B. Disc Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
C. Disc Retainer ..................................................................15
D. Guide ........................................................................16
E. Adjusting Ring .................................................................16
F. Adjusting Screw ................................................................16
XII. Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
XIII. Setting and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. Setting and Testing after Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
B. Setting the Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
C. Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
D. ColdDi󰀨erentialSetPressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
E. Temperature Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
F. Seat Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
G. Hydrostatic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
H. Manual Popping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
XIV. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XV. Maintenance Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
A. Lapping Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
B. Lap Resurfacing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
C. Lapping Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
D. Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Consolidated 1982 Series Safety Relief Valve Manual | e
© 2020 Baker Hughes Company. All rights reserved.
XVI. Replacement Parts Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
A. Basic Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
B. IdenticationandOrderingEssentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
XVII. Genuine Consolidated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
XVIII. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
XIX. Manufacturer’s Service, Repair and Training Program ....................26
A. Field Service.................................................................. 26
B. Repair Facilities ............................................................... 26
C. Maintenance Training ........................................................... 26

1 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
I. Warranty Information
Removal or breakage
of seal will negate
our warranty.
Defective and
nonconforming items
must be inspected
by Baker Hughes
Warranty Statement
Warranty Statement(1) - Baker Hughes warrants that its products and services
will meet all applicable specifications and other specific product and service
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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 affiliated repair companies, contractors or individuals to perform
warranty repair service on new products or field repaired products of its
manufacture. Therefore customers contracting such repair services from
unauthorized sources must do at their own risk.
Unauthorized Removal of Seals - All new valves and valves repaired in the
field 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 the Baker Hughes Standard Terms of Sale for complete details on
warranty and limitation of remedy and liability.
SEALED

Consolidated 1982 Series Safety Relief Valve Manual | 2
© 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, and/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 satisfied that neither personal
safety, nor valve safety, will be jeopardized by the procedure and/or tools
selected. If not so satisfied, contact your local Green Tag Center (GTC) if
there are any questions relative to procedures and/or tools.
The installation and start-up of valves and valve products may involve
proximity to fluids 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.
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 product. For more information on training schedules, please
contact your local Green Tag Center (GTC). Prior to working with the
involved valves/equipment, personnel who are to perform such work should
become thoroughly familiar with the contents of these instructions.
Wear necessary
protective equipment
to prevent
possible injury.
II. Safety Notice

3 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
III. Product Safety Sign and Label System
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 potential harm from the hazard
• The nature of the hazard
• The consequence of human and/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 potential harm from the hazard.
The center panel contains a pictorial which communicates the nature
of the hazard, and the possible consequence of human and/or product
interaction with the hazard. In some instances of risk to human health
and safety the pictorial may, instead, depict what preventive measures
to take, such as wearing wearing the appropriate personal protective
equipment (PPE).
The bottom panel may contain instructions on how to avoid the hazard.
If there is a risk to human health and safety this message may also
contain a more precise definition of the hazard, and the consequences
of human and/or product interaction with the hazard, than can be
communicated solely by the pictorial.
DANGER — Immediate hazards
which WILL LIKELY 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
Do not remove bolts
if pressure is in the
line, as this will
likely result in severe
personal injury or
death.
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
Do not drop
or strike.
4

Consolidated 1982 Series Safety Relief Valve Manual | 4
© 2020 Baker Hughes Company. All rights reserved.
IV. Safety Alerts
Read – Understand – Practice
1. DANGER: High temperature/pressure can
cause injury. Be sure all system pressure is
absent before repairing or removing valves.
2. DANGER: Don’t stand in front of valve outlet
whendischarging.STANDCLEAROFVALVE
to prevent exposure to potentiality trapped,
corrosive media.
3. DANGER: When inspecting a pressure relief
valve for leakage. BE VERY CAREFUL!
Improper use or repair of
a pressurized device may
result in severe personal
injury or death.
Stand clear of valve
when outlet is
discharging.
Be sure all system
pressure is absent
before repairing or
removing valves.
Heed all container
label warnings.
XXX
Provide and use
guarding to prevent
contact with heated
and/or pressurized parts.
Do not work with
valves while under the
influence of intoxicants
or narcotics.
1. WARNING: Allow the system to cool to room
temperature before cleaning, servicing or
repairing the system. Hot components or fluids
can cause severe personal injury or death.
2. WARNING: Always read and comply with safety
labels on all containers. Do not remove or deface
the container. Do not remove or deface the
container labels. Improper handling or misuse
could result in severe personal injury or death.
3. WARNING: Never use pressurized fluids/gas/air
to clean clothing or body parts. Never use body
parts to check for leakage and/or discharge rates
of valve areas. Pressurized fluids/gas/air injected
into or near the body can cause severe personal
injury or death.
4. WARNING: It is the responsibility of the owner to
specify and provide guarding to protect persons
from pressurized or heated parts. Contact with
pressurized or heated parts can result in severe
personal injury or death.
5. WARNING: Do not allow anyone under the
influence of intoxicants or narcotics to work on
or around pressurized systems. Workers under
the influence of intoxicants or narcotics are a
hazard both to themselves and other employees
and can cause severe personal injury or death to
themselves and/or others.
6. WARNING: Incorrect service/repair could result
in product/property damage and/or severe
personal injury or death.
7. WARNING: The misuse of a tool or the use of an
improper tool could result in personal injury and/
or product/property damage.

5 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
IV. Safety Alerts (Cont.)
Heed all service
manual warnings.
Read installation
instructions before
installing valve(s).
Know nuclear "health
physics" procedures,
if applicable, to avoid
possible severe
personal injury or
death.
All potential hazards
may not be covered
in this manual.
Improper tools or
improper use of right
tools could result in
personal injury or
product damage.
Wear necessary
protective equipment
to prevent
possible injury
Always use
appropriate restoration
procedures.
1. CAUTION: Heed all service manual warnings.
Read installation instructions before installing
valve(s).
2. CAUTION: Wear the appropriate hearing
protection when testing or operating valves.
3. CAUTION: Wear the appropriate eye and
clothing protection.
4. CAUTION: Wear the appropriate self-contained
breathing apparatus (SCBA) to protect against
toxic media.

Consolidated 1982 Series Safety Relief Valve Manual | 6
© 2020 Baker Hughes Company. All rights reserved.
V. Handling and Storage
VI. Pre-installation and Mounting
Do not subject valves
to impact.
Always keep valve in
an upright position.
Pressure relief valves should be stored in a dry environment and protected
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.
Pressure relief 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 internal components. Crated valves should always be lifted with the
inlet down.
Uncrated valves should be moved or hoisted by wrapping a chain or sling
around the discharge neck, then around the upper yoke structure, in such
manner as will ensure the valve is in a vertical position during lift. Never lift
the full weight of the valve by the pilot assembly, tubing, lifting lever or other
external device.
When a valve is uncrated and the flange protectors removed, prior to
installation, meticulous care should be exercised to prevent dirt from entering
the outlet port.
While hoisting a valve to the installation area, care should be exercised to
prevent bumping the valve against steel structures and other objects
Pressure relief valves should be mounted in a vertical, upright position.
Installing a valve in any other position will adversely affect its operating in
varying degrees as a result of induced misalignment of parts.
Flanges and gasket surfaces must be free from dirt and debris when valves are
installed. Flange bolts should be tightened evenly to prevent distortion of the
valve body and inlet nozzle. Before start-up be sure all threaded points are tight
and secure.
Prevent dirt from
entering the outlet or
inlet port.

7 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
VII. General Planning for Maintenance
A 12-month maintenance interval is recommended for general service conditions.
For severe service applications, a 3 to 6 month inspection and testing interim may
bemoreappropriate.Thespecicplant’soperatingandservicehistorywillbetter
determine this frequency. Baker Hughes encourages preventive maintenance.
Occasionally,remachiningmaybenecessarytoextendtheservicelifeofavalve.
Keep all parts for each valve separated to ensure replacement in the same valve.
DANGER: Insure there is no pressure in the inlet of the valve before attempting
to remove it from the piping system.
Note: For maintenance questions not covered in this manual, please
contact your local Green Tag Center (GTC).
Decontaminate or
clean if necessary
before pretesting or
disassembly. Safety
and environmental
precautions must
be taken for the
decontamination or
cleaning method used.
Do not interchange
parts from one valve
to another.
Always use
appropriate restoration
procedures.

Consolidated 1982 Series Safety Relief Valve Manual | 8
© 2020 Baker Hughes Company. All rights reserved.
VIII. Terminology for Pressure Relief Valves
A. Accumulation: The pressure increase over
the maximum allowable working pressure of
the vessel during discharge through the valve,
expressed as a percentage of that pressure or in
actual pressure units.
B. Backpressure: The static pressure existing on
the discharge side of a pressure relief valve:
1. Built-up Backpressure: Pressure that
develops at the valve outlet as a result of
flow, after the valve has opened.
2. Superimposed Backpressure: Pressure
in the discharge header before the valve
opens.
3. Constant Backpressure: Superimposed
backpressure that is constant with time.
4. Variable Backpressure: Superimposed
backpressure that will vary with time.
C. Blowdown: The difference between set
pressure and reseat pressure of a valve,
expressed as a percentage of the set pressure
or in actual pressure units.
D. Cold Differential Set Pressure: The pressure
at which the valve is adjusted to open on a test
stand. This pressure corrects for backpressure
when a pop action pilot’s vent is piped to the
main valve outlet.
E. Differential Between Operating and Set
Pressures: Valves in process service will
generally give best results if the operating
pressure does not exceed 90% of the set
pressure. However, on pump and compressor
discharge lines, the differential 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.
F. Lift: The actual travel of the disc away from the
closed position when a valve is relieving.
G. 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 relief valve is set to
open.
H. Operating Pressure: The gauge pressure to
which the vessel is normally subjected in
service. A suitable margin is provided between
operating pressure and maximum allowable
working pressure. The suitable margin depends
on the type of pressure relief valve in service.
I. Overpressure: A pressure increase over the
set pressure of the primary relieving device.
Overpressureissimilartoaccumulationwhen
the relieving device is set at the maximum
allowable working pressure of the vessel.
Normally, overpressure is expressed as a
percentage of set pressure.
J. Rated Capacity: The percentage of measured
flow at an authorized percent overpressure
permitted by the applicable code. Rated
capacity is generally expressed in pounds per
hour (lb/hr) or kg/hr for vapors, standard cubic
feet per minute (SCFM) or m³ /min for gases,
and in gallons per minute (GPM) or Liter/min (L/
min) for liquids.
K. Set Pressure: The inlet static pressure at which
a pressure relief valve begins to operate under
service conditions. In liquid service, the inlet
pressure at which a valve starts to discharge
determines the set pressure. In gas or vapor
service, the inlet pressure at which the valve
pops or starts to leak, determines the set
pressure.
L. Simmer: The audible passage of a gas or
vapor across the seating surfaces just before
a “pop”. The difference between this start-to-
open pressure and the set pressure is called
“simmer”. Simmer is generally expressed as a
percentage of set pressure.

9 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
IX. Design Features and Nomenclature
X. Introduction
Design Simplicity: Consolidated Safety Relief
Valves embody a minimum number of component
parts, which results in a savings by minimizing spare
parts inventory and simplifying valve maintenance.
ContactthePartsMarketingorganization,P.O.Box
1430, Alexandria, La. for parts inventory planning
assistance.
Cap and Lever Interchangeability: Many times it is
necessary to change the type of cap or lever in the
eldafteravalvehasbeeninstalled.Consolidated
Safety Relief Valves are supplied so they can be
converted to any type of lever or cap desired.
Simple Blowdown Adjustment: The Consolidated
single blowdown ring design makes it possible to
set and test a valve that has been in service when
it cannot be set on line and must be taken to the
customer’s shop. The ring can be positioned so
that the set point can be observed although the
volume of the testing media is very low. After the set
pressure has been established, proper blowdown
can be attained by merely positioning the ring to its
original position.
The safety relief valve is an automatic, pressure
actuated relieving device suitable for use either as a
safety valve or relief valve, depending on application.
Safetyreliefvalvesareusedonhundredsofdi󰀨erent
applications, including liquids and hydrocarbons
and therefore, the valve is designed to meet many
requirements. However the valve cannot be used or
steam boilers or super heaters, but may be used on
process steam.

Consolidated 1982 Series Safety Relief Valve Manual | 10
© 2020 Baker Hughes Company. All rights reserved.
IX. Consolidated 1982 Series Safety Relief Valve
A. Metal Seat Valve
2
5
3
4
6a
6b
6c
6d
7
8
9
10
8
11
12
13
14
15
1
Liquid Trim
6c
6b
6a
45
1
7
Part
No. Nomenclature
1 Base
1a Inlet Flange
(When Applicable)
2Bonnet Gasket
3Adjusting Ring Pin Gasket
4Adjusting Ring Pin
5Adjusting Ring
6Disc Assembly
6a Disc Collar
6b Disc Holder
6c Disc
6d Disc Retainer
7 Guide
8Spring Washer
9 Bonnet
10 Spring
11 Cap Gasket
12 Adjusting Screw Locknut
13 Adjusting Screw
14 Spindle Assembly
15 Screwed Cap
Figure 1: Conventional Metal Seat Valve Construction

11 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
IX. Consolidated 1982 Series Safety Relief Valve
Part
No. Nomenclature
16 Plain Cap
17 Release Locknut
18 Release Nut
19 Lever Pin
20 Plain Lever
21 Cap Screw
22 Packed Cap
23 Packed Lever
24 O-Ring
25 Bushing
26 Cam Shaft
27 Drive Stud
28 Lever Gasket
29 Gag
30 Sealing Plug
31 Sealing Plug Gasket
28
27
26
25
23
24
22
17
18
14
11
20 17
18
19
14
21
16
29
30
31
Figure 2: Packed Cap
Figure 3: Plain Cap Figure 4: Screwed Cap with Gag

Consolidated 1982 Series Safety Relief Valve Manual | 12
© 2020 Baker Hughes Company. All rights reserved.
X. Disassembly
(ForthepartsidenticationrefertoFigures1to4)
1. Remove cap (lifting gear). Remove cap gasket.
2. Remove adjusting ring pin and gasket. If the
existing valve action is to be restored, the
position of the ring should be determined by
turning it counterclockwise until it contacts the
roof of the disc recording the number of notches
that the ring is moved. Return to the original
position below the disc upon reassembly.
3. Loosen adjusting screw locknut. Record the
number of turns necessary to barely remove all
spring compression. Remove adjusting screw
from the bonnet. Return to original position when
reassembling.
4. With valve base held in vise, loosen the bonnet
to base connection (use strap wrench).
CAUTION: Do not distort base.
5. Remove bonnet, disc assembly, spindle, spring
and spring washer assembly from the base,
holding the spindle to be sure that the disc does
not drop.
6. Remove disc assembly, spindle, spring and
spring washers from bonnet.
7. Remove disc from spindle by engaging
the drop-out threads and turning the disc
counterclockwise.
Seat Repairing and Lapping
Reconditioning of the seating surface of the disc
andbaseisaccomplishedbylappingwithaatcast
iron ring lap coated with Grade No. 1000 KWIK-AK-
SHUN™ Silicon-Carbide compound, or equivalent.
Lapping tools are listed in Section XVI (Maintenance
Tools and Supplies).
The following method is recommended for lapping
seats.
1. Keep the work clean.
2. Always use a fresh lap. If signs of wearing (out
ofatness)isevidentreconditionthelap.
3. Apply a very thin layer of compound to the lap.
Thiswillpreventroundingo󰀨theedgesofthe
seat.
4. Keepthelapsquarelyontheatsurfaceand
avoid any tendency to rock the lap which will
cause rounding of the seat.
5. Whenlapping,keeparmgriponthepart
to prevent the possibility of dropping it and
damaging the seat.
6. Lap using a reciprocating motion in all directions,
at the same time apply uniform pressure and
rotating the lap slowly.
7. Replace the compound frequently after wiping
o󰀨theoldcompound,andapplymorepressure
to speed the cutting action of the compound.
8. To check the seating surfaces, remove all
compound from both the seat and the lap. Then
shine up the seat with the same lap using the
lapping motion described above. Low sections
on the seating surface will show up as a shadow
in contrast to the shiny portion. If shadows are
present, further lapping is necessary and only
lapsknowntobeatshouldnowbeused.Only
a few minutes will be required to remove the
shadows.
9. When the lapping is completed, any lines
appearing as cross scratches can be removed
by rotating the lap, which has been wiped clean
of compound, on the seat about its own axis.
10. The seat should now be thoroughly cleaned.
When the seats cannot be repaired by lapping,
they can be remachined using dimensions given
in Figure 5 and Table 1. The following procedure
can be used when machining the base seat:
a. Using a four-jaw chuck, align the base so
that it is running true.
b. Take light cuts on the seat surface until
all damage is removed. Reestablish the
.028” (0.71 mm) and B dimension per
Figure 6 and Table 2.
c. Lap the seat.
d. When minimum dimension “D” is
exceeded (Table 2), the base should be
discarded.

13 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
X. Disassembly (Cont.)
Disc Seat Repair
To recondition the disc seat by lapping, it is
necessary to disassemble the disc assembly. This is
done in the following manner: The disc is contained
in the disc holder by a Truarc retaining ring; the ring
may be removed by using a Truarc Plier #4; after
removing the Truarc ring, the disc and disc collar can
be removed from the disc holder.
The disc can now be lapped using the same
procedure as described above.
If the disc is damaged to the extent that machining is
necessary, the following procedure can be used:
a. Using a four-jaw chuck, align the disc insert so
that it is running true.
b. Take light cuts on the seat surface until all
damage is removed. Reestablish dimensions as
shown in Figure 5 and Table 1.
c. When “C” dimension has been reduced to .025”
(0.64 mm), the disc insert should be replaced.
D
F
H
T
E
RETAINING
RING
X
C
BZ
A
DISC
F
T
E
DISC
COLLER
DISC
HOLDER
G
C
G
J
D
H
Figure 5: Disc Assembly
Table 1: Disc Assembly Rework Dimensions
Valve Size A
±.002”(±0.05 mm)
B
±.002”(±0.05 mm) C min. D min. H min. J +.000”/-.003” (+0.00/-0.08 mm)
in. mm in. mm in. mm in. mm in. mm in. mm in. mm
.50 12.70 .518 13.16 .412 10.46 .025 0.64 .715 18.16 .092 2.34 N/A N/A
.75 19.05 .669 16.99 .561 14.25 .025 0.64 .953 24.21 .117 2.97 .700 17.78
1.00 25.40 .834 21.18 .706 17.93 .025 0.64 1.192 30.28 .147 3.73 .873 22.17
1.50 38.10 1.339 34.01 1.139 28.93 .025 0.64 1.909 48.49 .222 5.64 1.400 35.56
2.00 50.80 1.680 42.67 1.465 37.21 .025 0.64 2.449 62.20 .284 7.21 1.803 45.80
Figure 5a:
Gas/Air Service: .5” to 2”(12.7 to 50.8 mm)
Liquid Service: .5” (12.7 mm)
Figure 5b:
Liquid Service: .75” to 2”
(19.1 to 50.8 mm)

Consolidated 1982 Series Safety Relief Valve Manual | 14
© 2020 Baker Hughes Company. All rights reserved.
XI. Inspection and Part Replacement
1. Base Replacement Criteria
Base should be replaced if:
a. Seat (Surface X) is nicked, or dimension D
minimum has been exceeded. (See Table 2).
b. Threads (T) are torn, galled or stripped.
c. Gasket surface (G) is nicked or experiencing
leakage.
d. Exceeds other dimensions in Table 2 and
Figure 6.
2. Disc Holder Replacement criteria, Figure 5 and
Table 1
Disc Holder should be replaced if:
a. Outsidediameter(D)isgalledorexceeds
minimum dimension. It requires 32 RMS
nish.
b. Retainer ring shoulder (G) is worn.
c. Exceeds dimensions mentioned in Table 1
and Figure 5.
30˚
E
A
B
C
A
VIEW - A
Z
DY
X
T
G
5˚
.028”
(0.71mm)
.010”
(0.25mm)
Figure 6: Threaded Base
1. Base to be discarded once D minimum is exceeded. Do not reestablish D.
Table 2: Base Rework Dimensions
Valve Size A +.003”/-.000”
(0.08/-0.00 mm)
B +.000”/-.003”
(0.00/-0.08 mm)
C +.000”/-.002”
(0.00/-0.05 mm) D min.(1) E +.005”/-.000” (0.13/-0.00 mm)
in. mm in. mm in. mm in. mm in. mm in. mm
.50 12.7 .442 11.23 .488 12.40 .527 13.39 .219 5.56 .033 +
-
.002
.000 0.84 +
-
0.05
0.00
.75 19.1 .589 14.96 .641 16.28 .702 17.83 .219 5.56 .038 0.97
1.00 25.4 .737 18.72 .803 20.40 .875 22.23 .359 9.13 .047 1.19
1.50 38.1 1.179 29.95 1.295 32.89 1.400 35.56 .406 10.32 .076 1.93
2.00 50.8 1.510 38.35 1.635 41.53 1.795 ± .002 45.59 ± 0.05 .484 12.30 .098 2.49

15 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.
XI. Inspection and Part Replacement (Cont.)
3. Disc Replacement Criteria, Figure 5 and Table 1
Disc should be replaced if:
a. Seat surface (Z) is nicked, or dimension (C)
is reduced to .025” (0.64 mm).
b. Spindle pocket surface (F) is pitted or galled,
itrequires63RMSnish.
c. Threads (T) are torn, galled or stripped.
d. Retainer Ring groove (E) is worn.
e. Disc height (H) exceeds minimum dimension.
f. Exceeds dimensions mentioned in Table 1
and Figure 5.
4. Disc Retainer Replacement criteria, Figure 5
Disc Retainer should be replaced if:
a. Overallconditionissprungorsignsof
corrosion.
5. Guide Replacement Criteria, Figure 7 and
Table 3
Guide should be replaced if:
a. Inside diameter (A) exceeds maximum.
dimension or galled. It requires 32 RMS
nish.
b. Threads (T) should be replaced if torn, galled
or stripped.
c. Overallconditionisdistortedoregged.
d. Guide weld (W) is cracked weld or loose
guide.
Note: Guide is tack welded to the bonnet, do not
attempt to remove from bonnet.
Table 3: Guide Critical Dimensions
Valve Size A max.
in. mm in. mm
.50 12.70 .722 18.34
.75 19.05 .960 24.38
1.00 25.40 1.200 30.48
1.50 38.10 1.917 48.69
2.00 50.80 2.459 62.46
W
A
T
Figure 7: Bonnet Assembly (For Guide)