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.