Baker Hughes Consolidated 2700 Series User manual

Consolidated™
2700 Series
Safety Valve
Instruction Manual (Rev. F)
Baker Hughes Data Classification : Public

ii | Baker Hughes © 2022 Baker Hughes Company. All rights reserved.

Consolidated 2700 Series Safety Valve Instruction Manual | iii
© 2022 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/
OPERATORARESTRICTLYLIMITEDTOTHOSEEXPRESSLYPROVIDEDINTHECONTRACT
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.

iv | Baker Hughes © 2022 Baker Hughes Company. All rights reserved.
All the United States Customary System (USCS) values are
converted to metric values using the following conversion factors:
USCS Unit Conversion Factor Metric Unit
in. 25.4 mm
lb. 0.4535924 kg
in26.4516 cm2
ft3/min 0.02831685 m3/min
gal/min 3.785412 L/min
lb/hr 0.4535924 kg/hr
psig 0.06894757 barg
ft lb 1.3558181 Nm
°F 5/9 (°F-32) °C
Conversion Table
Note: Multiply USCS value with conversion factor to get metric value.

Consolidated 2700 Series Safety Valve Instruction Manual | v
© 2022 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. Consolidated 2700 Series Safety Valve...................................................................................................9
A. Flanged Inlet ..........................................................................................................................................9
B. Buttweld Inlet .........................................................................................................................................9
X. Operating Principles .................................................................................................................................. 11
XI. Recommended Installation Practices....................................................................................................12
A. General Requirements.........................................................................................................................12
B. Outdoor Safety Valve Installation.........................................................................................................16
C. Indoor Safety Valve Installation............................................................................................................16
XII. Disassembly Instructions ..................................................................................................................... 17
A. General Information ............................................................................................................................ 17
 B. SpecicSteps ..................................................................................................................................... 17
XIII. Inspection and Part Replacement......................................................................................................... 19
A. General ...............................................................................................................................................19
 B. SpecicComponents ...........................................................................................................................19
XIV. Re-Assembly Instructions .................................................................................................................... 24
A. General Information ............................................................................................................................ 24
 B. SpecicSteps ..................................................................................................................................... 24
XV. Setting and Testing .................................................................................................................................27
A. General Information .............................................................................................................................27
B. Application of Test Gags ......................................................................................................................27
C. Presetting Adjusting Rings ...................................................................................................................28
D. Steam Testing Instruction.....................................................................................................................29
E. Consolidated Hydroset Test Device/Electronic Valve Tester (EVT) Software .................................... 32
F. Hydrostatic Test Plug Removal ........................................................................................................... 32
F.1 General Information ......................................................................................................................32
F.2 Hydrostatic Test Plugs...................................................................................................................34
XVI. Troubleshooting the Consolidated 2700 Series Safety Valve ................................................................... 36
XVII. Maintenance Tools and Supplies ..............................................................................................................37
XVIII. Replacement Parts Planning..................................................................................................................38
A. Basic Guidelines ................................................................................................................................. 38
 B. IdenticationandOrderingEssentials ................................................................................................ 38
XIX. Consolidated Genuine Parts .................................................................................................................... 38

vi | Baker Hughes © 2022 Baker Hughes Company. All rights reserved.
XX. Manufacturer’s Service Repair and Training Program ........................................................................40
A. Field Service ........................................................................................................................................40
B. Repair Facilities ...................................................................................................................................40
C. Safety Valve Maintenance Training......................................................................................................40

Consolidated 2700 Series Safety Valve Instruction Manual | 1
© 2022 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 Statement1 - 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.
Note: Refer to Baker Hughes’s Standard Terms of Sale for complete details on
warranty and limitation of remedy and liability.
SEALED

2 | Baker Hughes © 2022 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 Consolidated 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 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’s
Consolidated products to adequately train all personnel who will be working
with the involved product. For more information on training schedules,
please, contat your local Green Tag Center. Further, prior to working with
the involved product, 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

Consolidated 2700 Series Safety Valve Instruction Manual | 3
© 2022 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

4 | Baker Hughes © 2022 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
inuence 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.