Baker Hughes Consolidated 2900 series User manual

BHGE Data Classication : Public
Consolidated*
2900 Series Pilot-Operated
Safety Relief Valves
Maintenance Manual (Rev.B)

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, BHGE (BAKER HUGHES, A GE COMPANY
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 BHGE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE 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 BHGE 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 BHGE.
2 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.

NOTICE!
For valve congurations not listed in this
manual, please contact your local Green Tag*
Center for assistance.
All the USCS values are converted to
metric values using the following conversion factors:
Metric values using
the following
conversion factors:
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 1: Multiply USCS value with conversion factor to get metric value.
Consolidated 2900 Series POSRV Maintenance Manual | 3
© 2018 Baker Hughes, a GE company. All Rights Reserved.

Table of Contents
I. Product Safety Sign and Label System .............................................6
II. Safety Precautions ................................................................7
Restoring Safety ...........................................................................................8
III. Safety Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
IV. Warranty Information ............................................................10
V. Terminology for Pilot Operated Safety Relief Valves ..............................11
VI. Handling and Storage.............................................................12
VII. Pre-Installation and Installation Instructions .....................................13
VIII. Introduction .....................................................................14
A. General Introduction ..................................................................................14
B. Main Valve Introduction ..............................................................................14
C. Pilot Valve Introduction ...............................................................................14
IX. Consolidated 2900 Series Pilot Operated Safety Relief Valves.....................15
A. Metal Seat Valve ......................................................................................15
B. Soft Seat Valve ........................................................................................15
C. D - U Orice (with Bellows) ............................................................................16
D. V & W Orice (with Bellows) ...........................................................................16
E. 39PV07/37 Pilot Valves (Standard Service) .............................................................17
F. 39MV07 Pilot Valve (Standard Service) .................................................................18
G. 39MV22/72 Pilot Valve (Standard Service) .............................................................19
X. Operating Principles..............................................................20
A. 2900 Series with Type 39PV (Pop) Pilot Operational Descriptions ......................................20
B 2900 Series 39MV07 (Modulating) Pilot – Operational Description .....................................22
XI. General Planning for Maintenance ................................................24
XII. Recommended Installation Practices .............................................24
A. Mounting Position ....................................................................................24
B. Inlet Piping ............................................................................................25
C. Outlet Piping ..........................................................................................26
D. Remote Sensing .......................................................................................26
E. Freeze Protection .....................................................................................27
XIII. Disassembly of the 2900 POSRV ..................................................28
A. Removal of Pilot Valve from Main Valve ................................................................28
B. Disassembly of Main Valve ............................................................................28
C. Cleaning ..............................................................................................33
4 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.

Table of Contents (Cont'd)
XIV. Maintenance Instructions ........................................................34
A. General Maintenance Information .....................................................................34
B. O-Ring Seat ...........................................................................................34
C. Lapping Nozzle Seats (Metal Seat, Non-O-Ring Styles) .................................................36
D. Lapped Nozzle Seat Widths ...........................................................................36
E. Lapping Disc Seats ....................................................................................38
F. Precautions and Hints for Lapping Seats ..............................................................38
G. Reconditioning of Laps ................................................................................38
H. Re-Machining Nozzle Seats ............................................................................39
I. Re-Machining the Disc Seat ...........................................................................39
XV. Inspection and Part Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
XVI. Reassembly of the 2900 Main Valve ...............................................44
A. Lubricants and Sealants ..............................................................................44
B. Assembly Procedure with Metal Seats .................................................................44
C. Assembly Procedure with O-Ring Seats ...............................................................45
XVII. Disassembly of Pilot Valve........................................................48
A. 39PV07/37 Disassembly ...............................................................................48
B. 39MV07 Disassembly .................................................................................51
C. 39MV22/72 Disassembly ..............................................................................54
D. Cleaning ..............................................................................................57
XVIII. Part Inspection of Pilot Valve.....................................................58
A. 39PV07/37 ............................................................................................58
B. 39MV07 ..............................................................................................58
C. 39MV22/72 ...........................................................................................59
XIX. Reassembly of Pilot Valve ........................................................60
A. Lubricants and Sealants ...............................................................................60
B. Assembly of 39PV07/37 ...............................................................................60
C. Assembly of 39MV07 ..................................................................................62
D. Assembly of 39MV22/72 ..............................................................................65
A. General Information ..................................................................................67
B. With Standard Options ................................................................................67
C. With Sensing Ring Option .............................................................................68
D. Troubleshooting Leakage ..............................................................................69
E. Conversions between Conventional and Bellows Type .................................................71
F. Field Testing of POSRV Assembly ......................................................................71
XXI. Troubleshooting..................................................................72
Consolidated 2900 Series POSRV Maintenance Manual | 5
© 2018 Baker Hughes, a GE company. All Rights Reserved.

Table of Contents (Cont'd)
XXII. 2900 Series POSRV Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
A. Backow Preventer ...................................................................................73
B. Dirty Service Option ..................................................................................74
B. Dirty Service Option (Contd.) ..........................................................................75
C. Dual Pilots ............................................................................................76
D. Field Test Connection .................................................................................76
E. Filter (Single, Dual, or High Capacity) ..................................................................77
F. Gag ...................................................................................................78
G. Heat Exchanger .......................................................................................78
H. Lifting Lever ..........................................................................................79
I. Manual, Electrical, or Pneumatic Blowdown Valve .....................................................79
J. Pilot Valve Tester .....................................................................................80
K. Pressure Dierential Switch ...........................................................................80
L. Pressure Spike Snubber ...............................................................................81
M. Remote Pilot Mounting ................................................................................81
N. Remote Sensing .......................................................................................81
O. Sensing Ring ..........................................................................................81
XXIII. Maintenance Tools and Supplies ..................................................82
A. Adjuster Top Seal Insertion Tool .......................................................................82
B. Insert Installation Tool ................................................................................83
C. Lapping Tools .........................................................................................84
D. Disc Holder and Guide Removal and Assembly Tool ...................................................85
XXIV. Replacement Parts Planning......................................................87
A. Basic Guidelines ......................................................................................87
B. Identication and Ordering Essentials ..................................................................87
XXV. Genuine Consolidated Parts ......................................................88
C. Positive Identication of Main Valve and Pilot Valve Combinations ....................................88
XXVI. Recommended Spare Parts.......................................................89
XXVII. Field Service, Repair and Training Program .......................................98
A. Field Service ..........................................................................................98
B. Factory Repair Facilities ...............................................................................98
C. Safety Relief Valve Maintenance Training ..............................................................98
6 | BHGE © 2018 Baker Hughes, a GE 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.
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.
1
2
3
4
Do not remove bolts
if pressure in line,
as this will 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 2900 Series POSRV Maintenance Manual | 7
© 2018 Baker Hughes, a GE company. All Rights Reserved.

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.
II. Safety Precautions
Improper use or repair
of pressurized media or
steam device may result
in severe personal
injury or death.
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.
Read – Understand – Practice
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 or discharge rates of 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. Contact
with pressurized or heated parts can result in
severe personal injury or death.
5. WARNING: Do not allow anyone under the
influence or intoxicants or narcotics to work on
or around pressurized systems. Workers under
the influence 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 BHGE 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.
9. WARNING: These WARNINGS are as complete as
possible but not all-inclusive. BHGE cannot know
all conceivable service methods nor evaluate all
potential hazards.
8 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.

II. Safety Precautions (Contd.)
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.
Cautions Concerning Product
Warning Labels
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.
Note: Any Service questions not covered in this
manual should be referred to BHGE’s Service
Department. Phone: [phone].
Restoring Safety
Appropriate service and repair are 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 BHGE as described in the applicable
installation and Maintenance Manual, when correctly
applied, will be eective.
Always use
appropriate
restoration
procedures.
Consolidated 2900 Series POSRV Maintenance Manual | 9
© 2018 Baker Hughes, a GE 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 BHGE, 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 BHGE Consolidated product, or render it unsafe. It is also important
to understand that these “safety messages” are not exhaustive. BHGE 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, BHGE has not undertaken any such broad evaluation
and, thus, anyone who uses a procedure and/or tool, which is not recommended
by BHGE, or deviates from BHGE recommendations, must be thoroughly
satised that neither personal safety, nor valve safety, will be jeopardized by the
method and/or tools selected. Contact your local Green Tag Center ifthere are
any questions relative to tools/methods.
The installation and start-up of valves and/or valve products may involve
proximity to uids at extremely high pressure and/or temperature.
Consequently, every precaution should be taken to prevent injury to personnel
during the performance of any procedure. These precautions should consist
of, but are not limited to, ear drum protection, eye protection, and the use of
protective clothing, (i.e., gloves, etc.) when personnel are in, or around, a valve
work area. Due to the various circumstances and conditions in which these
operations may be performed on Consolidated products, and the possible
hazardous consequences of each way, BHGE can not possibly evaluate all
conditions that might injure personnel or equipment. Nevertheless, BHGE does
oer certain Safety Precautions for customer information only.
It is the responsibility of the purchaser or user of BHGE's Consolidated valves/
equipment to adequately train all personnel who will be working with the
involved valves/equipment. For more information on training schedules, call
[phone]. 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
10 | BHGE © 2018 Baker Hughes, a GE company. All Rights Reserved.