Baker Hughes Consolidated 2900-40 Series User manual

Consolidated™
2900-40 Series
Pilot-Operated Safey Relief Valves
Instruction Manual (Rev. D)
Baker Hughes Data Classification : Public

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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 2900-40 Series POSRV 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.
Conversion Table
Note: Multiply USCS value with conversion factor to get metric value.
All the United States Customary System (USCS) units are
converted to metric units 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

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Table of Contents
I. Product Safety Sign and Label System .....................................................................................................................7
II. Safety Alerts...............................................................................................................................................................8
III. Safety Notice............................................................................................................................................................10
IV. Warranty Information ............................................................................................................................................... 11
V. Terminology for Pilot Operated Safety Relief Valves ...............................................................................................12
VI. Handling and Storage ..............................................................................................................................................13
VII. Pre-Installation and Installation Instructions ............................................................................................................14
VIII. Introduction............................................................................................................................................................15
A. General Introduction .........................................................................................................................................15
B. Main Valve Introduction.....................................................................................................................................15
C. Pilot Valve Introduction......................................................................................................................................15
IX. Consolidated 2900-40 Series Safety Relief Valves .............................................................................................16
A. 2900-40 Main Valve (Metal Seat)......................................................................................................................16
B. 2900-40 Main Valve (Soft Seat) ........................................................................................................................17
C. 39PV Pilot Valve................................................................................................................................................18
X. Operating Principles..............................................................................................................................................19
A. PV Valve Closed (Normal Position)...................................................................................................................19
B. PV Valve Open (Relieving Position)..................................................................................................................20
XI. General Planning for Maintenance ..........................................................................................................................21
XII. Recommended Installation Practices ..................................................................................................................21
A. Mounting Position .............................................................................................................................................21
B. Inlet Piping ........................................................................................................................................................22
C. Outlet Piping .....................................................................................................................................................22
D. Remote Sensing ...............................................................................................................................................23
E. Freeze Protection..............................................................................................................................................23
XIII. Disassembly of the 2900-40 POSRV ....................................................................................................................25
A. Removal of the Pilot Valve from the Main Valve ...............................................................................................25
B. Disassembly of the Main Valve .........................................................................................................................25
C. Cleaning............................................................................................................................................................29
XIV. Maintenance Instructions......................................................................................................................................30
A. General Maintenance Information.....................................................................................................................30
B. O-Ring Seat ......................................................................................................................................................30
C. Lapping Nozzle Seats (Metal Seat - Non-O-Ring Styles) .................................................................................30
D. Lapped Nozzle Seat Widths..............................................................................................................................32
E. Lapping Disc Seats ...........................................................................................................................................32
F. Precautions and Hints for Lapping Seats..........................................................................................................34
G. Reconditioning of Laps .....................................................................................................................................34
H. Re-Machining Nozzle Seats..............................................................................................................................34
I. Re-Machining the Disc Seat .............................................................................................................................35

Consolidated 2900-40 Series POSRV Instruction Manual | 5
© 2020 Baker Hughes Company. All rights reserved.
XV. Inspection and Part Replacement .............................................................................................................................37
1. Guide ................................................................................................................................................................37
2. Base..................................................................................................................................................................37
3. Cover Plate .......................................................................................................................................................37
4. O-Ring Retainer ................................................................................................................................................37
5. Nozzle ...............................................................................................................................................................37
6. Spring................................................................................................................................................................37
7. Standard Metal Seated Disc .............................................................................................................................37
8. Thermodisc™ Metal Seated Disc .....................................................................................................................37
9. O-Ring Seated Disc ..........................................................................................................................................38
10. Disc Holder .......................................................................................................................................................38
11. Solid Metal Gaskets ..........................................................................................................................................38
12. Main Valve Piston..............................................................................................................................................38
XVI. Reassembly of 2900-40 Main Valve......................................................................................................................39
A. Lubricants and Sealants ...................................................................................................................................39
B. Assembly Procedure with Metal Seats .............................................................................................................39
C. Assembly Procedure with O-Ring Seats...........................................................................................................39
XVII. Disassembly of Pilot Valve....................................................................................................................................43
A. 39PV07/37 Disassembly..................................................................................................................................43
B. Cleaning ...........................................................................................................................................................43
XVIII. Part Inspection of Pilot Valve................................................................................................................................46
A. 39PV07/37 ........................................................................................................................................................46
XIX. Reassembly of Pilot Valve.....................................................................................................................................47
A. Lubricants and Sealants ...................................................................................................................................47
B. Assembly of 39PV07/37....................................................................................................................................47
XX. Setting and Testing................................................................................................................................................50
A. General Information ..........................................................................................................................................50
B. With Standard Options......................................................................................................................................50
C. With Sensing Ring Option.................................................................................................................................51
D. Functional Testing .............................................................................................................................................51
E. Field Testing of POSRV Assembly ...............................................................................................................53-54
E.1 Mitigation of Main Valve Instatility During Startup .....................................................................................55
E.2 Articial Actuation of Pilot and Main Valve ................................................................................................56
E.2.1 Articial Actuation of Pilot Only ..............................................................................................................56
E.3 Hydrostatic Testing and Gagging ..............................................................................................................57
XXI. Troubleshooting .......................................................................................................................................................58
XXII. 2900-40 Series POSRV Options............................................................................................................................59
A. Backow Preventer ...........................................................................................................................................59
A.1 Disassembly Instructions ...........................................................................................................................59
A.2 Cleaning.....................................................................................................................................................59
A.3 Parts Inspection .........................................................................................................................................59
A.4 Reassembly Instructions............................................................................................................................59

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B. Dual Pilots.........................................................................................................................................................60
C. Field Test Connection .......................................................................................................................................60
D. Single, Dual and High Capacity Filters (optional) ............................................................................................60
E. Sensing Line Filter (standard)...........................................................................................................................61
F. Gag ...................................................................................................................................................................62
G. Heat Exchanger ................................................................................................................................................62
H. Lifting Lever ......................................................................................................................................................63
I. Manual, Electrical, or Pneumatic Blowdown Valve ...........................................................................................63
J. Pilot Valve Tester...............................................................................................................................................64
K. Pressure Di󰀨erential Switch ..............................................................................................................................64
L. Pressure Spike Snubber ...................................................................................................................................65
M. Remote Pilot Mounting......................................................................................................................................65
N. Remote Sensing ...............................................................................................................................................65
O. Sensing Ring.....................................................................................................................................................65
XXIII. Maintenance Tools and Supplies .........................................................................................................................66
A. Adjuster Top Seal Insertion Tool........................................................................................................................66
B. Insert Installation Tool ......................................................................................................................................67
C. Lapping Tools ...................................................................................................................................................68
D. Disc Holder and Guide Removal and Assembly Tool...................................................................................69-70
XXIV. Replacement Parts Planning ................................................................................................................................71
A. Basic Guidelines ...............................................................................................................................................71
B. Identication and Ordering Essentials ..............................................................................................................71
C. Positive Identication of Main Valve and Pilot Valve Combinations ..................................................................72
XXV. Genuine Consolidated Parts....................................................................................................................................72
XXVI. Recommended Spare Parts................................................................................................................................73-78
XXVII. Manufacture's Field Service, Repair, and Training Programs ...........................................................................79
A. Field Service .....................................................................................................................................................79
B. Repair Facilities ................................................................................................................................................79
C. Safety Relief Valve Maintenance Training.........................................................................................................79

Consolidated 2900-40 Series POSRV Instruction Manual | 7
© 2020 Baker Hughes Company. All rights reserved.
I. Product Safety Sign and Label System
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
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.
Do not remove bolts
if pressure in line, as
this will result in severe
personal injury or death.
Know all valve exhaust/
leakage points to avoid
possible severe personal
injury or death.
Wear necessary
protective equipment to
prevent possible injury
Do not drop
or strike.
123 4

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XXX
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.
Provide and use
guarding to prevent
contact with heated and/
or pressurized parts.
Improper use or repair
of pressurized media or
steam device may result
in severe personal injury
or death.
Heed all container
label warnings.
Do not work with
valves while under the
inuence of intoxicants
or narcotics.
II. Safety Alerts
1. WARNING: Allow the system to cool to room
temperature before cleaning servicing or repairing the
system. Hot components or uids 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 uids/gas/air to
clean clothing or body parts. Never use body parts
to check for leakage or discharge rates of areas.
Pressurized uids/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. Contact with pressurized or heated parts
can result in severe personal injury or death.
5. WARNING: Do not allow anyone under the inuence
or intoxicants or narcotics to work on or around
pressurized systems. Workers under the inuence
intoxicants or narcotics are a hazard both to themselves
and other employees and can cause severe personal
injury or dearth to themselves or others.
6. WARNING: Incorrect service and repair could result in
product or property damage or severe personal injury or
death.
7. WARNING: This valve product line is not intended
for radioactive nuclear applications. Some valve
products Manufactured by Baker Hughes may be used
in radioactive environments. Consequently, prior to
starting any operation in a radioactive environment, the
proper “health physics” procedures should be followed,
if applicable.
8. WARNING: Use of improper tools or improper use of
right tools could result in personal injury or product or
property damage.
Read – Understand – Practice

Consolidated 2900-40 Series POSRV Instruction Manual | 9
© 2020 Baker Hughes Company. All rights reserved.
II. Safety Alerts (Cont.)
1. CAUTION: Heed all service manual warnings. Read
installation instructions before installing valve(s).
2. CAUTION: Wear hearing protection when testing or
operating valves.
3. CAUTION: Wear appropriate eye and clothing
protection.
4. CAUTION: Wear protective breathing apparatus to
protect against toxic media.
Wear necessary
protective equipment to
prevent possible injury
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.
Note: Any Service questions not covered in this
manual should be referred to your local Green
Tag Center (GTC)
Cautions Concerning Product Warning Labels
Appropriate service and repair important to safe, reliable
operation of all valve products. Restoration to original
quality and manufacturing specications will accomplish the
desired results. Procedures developed by Baker Hughes
as described in the applicable installation and Maintenance
Manual, when correctly applied, will be e󰀨ective.
Always use appropriate
restoration procedures.
Restoring Safety
9. WARNING: These WARNINGS are as complete as
possible but not all-inclusive. Baker Hughes cannot
know all conceivable service methods nor evaluate all
potential hazards.

10 | 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 e󰀨ective methods of performing the required tasks.
It is important to note that these instructions contain various “safety messages” which
should be carefully read in order to minimize the risk of personal injury, or the possibility
that improper procedures will be followed which may damage the involved Baker
Hughes 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's recommendations, must be thoroughly satised that neither
personal safety, nor valve safety, will be jeopardized by the method and/or tools selected.
Please contact your local Green Tag Center (GTC) 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 Consolidated 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 o󰀨er certain Safety Precautions, listed in Section IV, for customer information only.
It is the responsibility of the purchaser or user of Baker Hughes's Consolidated valves/
equipment to adequately train all personnel who will be working with the involved valves/
equipment. For more information on training schedules, please contact your local Green
Tag Center. Further, prior to working with the involved valves/equipment, personnel who
are to perform such work should become thoroughly familiar with the contents of these
instructions.
Wear necessary
protective equipment to
prevent possible injury
III. Safety Notice