Baker Hughes Consolidated 4900 Series User manual

Consolidated™
4900 MPV Series
Pilot Operated Safety Relief Valve
Instruction Manual (Rev. B)
Baker Hughes Data Classification : Public

2 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

Consolidated 4900 MPV Series POSRV Manual | 3
© 2020 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/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.

NOTICE!
For any service questions not covered
in this manual, please contact your local
Green Tag™ Center (GTC).
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.
4 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

Contents
I. Product Safety Sign and Label System..................................7
II. Safety Precautions ..................................................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 ............................13
VIII. Introduction .......................................................13
IX. Consolidated 4900 Series POSRV .....................................14
A. 4900 Series Main Valve Construction ...............................................14
B. 49PV07/37 Pilot Valve Construction ................................................15
C. 49MV07 Pilot Valve Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
D. 49MV22/72 Pilot Valve Construction ................................................21
X. General Planning for Maintenance ....................................24
XI. Recommended Installation Practices ..................................25
A. Mounting Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
B. Inlet Piping ................................................................... 25
C. Outlet Piping.................................................................. 26
D. Remote Sensing............................................................... 27
E. Freeze Protection.............................................................. 27
XII. Disassembly of the 4900 POSRV ......................................28
A. Removal of Pilot Valve From Main Valve ............................................ 28
B. Disassembly of Main Valve ...................................................... 28
C. Cleaning ..................................................................... 30
XIII. Maintenance Instructions ............................................31
A. General Information .............................................................31
B. O-Ring Seat ...................................................................31
C. Re-Machining Nozzle Seats ......................................................31
D. Machining Procedure: O-Ring Seat .................................................31
XIV. Inspection and Part Replacement .....................................33
1. Guide: ...................................................................... 33
2. Base: ....................................................................... 33
3. Coverplate: .................................................................. 33
4. O-Ring Retainer: .............................................................. 33
5. Spring: ...................................................................... 33
6. Nozzle ...................................................................... 33
7. O-Ring Seated Disc: ........................................................... 33
8. Disc Holder: ................................................................. 33
XV. Reassembly of 4900 Series Main Valve.................................34
A. Lubricants and Sealants ........................................................ 34
B. Assembly Procedure for O-Ring Seats ............................................. 34
B.1 Installation of Nozzle ........................................................ 34
B.2 Disc to Guide seal .......................................................... 35
B.3 Guide and Disc Assembly (D, E, F, G, H, J, K, & 3” L) .............................. 35
B.4 Guide and Disc Assembly (4” L, M, N, P, Q, R, T, 3” F.B., 4” F.B, 6” F.B., 8” F.B., & 10” F.B.) 36
Consolidated 4900 MPV Series POSRV Manual | 5
© 2020 Baker Hughes Company. All rights reserved.

XVI. Disassembly of 4900 Series Pilot Valve ................................37
A. 49PV07 and 49PV37 ............................................................37
B. 49MV07 ......................................................................41
C. 49MV22/72 .................................................................. 45
D. Cleaning ..................................................................... 50
XVII. Inspection and Part Replacement of Pilot Valve .........................51
A. 49PV07/37 ....................................................................51
B. 49MV07 ......................................................................51
C. 49MV22/72 .................................................................. 52
XVIII. Reassembly of 4900 Series Pilot Valve .................................53
A. Lubricants and Sealants ........................................................ 53
B. Assembly of 49PV07/37......................................................... 53
C. Assembly of 49MV07 ........................................................... 56
D. Assembly of 49MV22/72 ........................................................ 60
XIX. Setting and Testing .................................................63
A. Pilot Valve Testing ............................................................. 63
B. Pilot Valve Test Stand .......................................................... 63
C. Pilot Valve Test Procedure ....................................................... 63
D. Pilot/Main Valve Assembly Testing ................................................ 66
D.1 49PV07/37 ................................................................ 66
D.2 49MV07, 49MV22 and 49MV72 ............................................... 66
D.3 Reasons for failure: ......................................................... 67
E. Troubleshooting Leakage........................................................ 67
F. Field Testing of POSRV Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F.1 Field Test Connection........................................................ 69
F.2 Pilot Valve Tester ........................................................... 69
G. Hydrostatic Testing and Gagging .................................................. 69
XX. Trouble Shooting ...................................................70
XXI. 4900 Series POSRV Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
A. BackowPreventer .............................................................71
B. Field Test Connection ...........................................................71
C. Filter (High Capacity) ........................................................... 72
D. Gag ........................................................................ 72
E. Lifting Lever .................................................................. 72
F. Manual,ElectricalorPneumaticBlowdownValve ..................................... 72
G. Pilot Valve Tester .............................................................. 73
H. PressureDi󰀨erentialSwitch...................................................... 73
I. Remote Sensing............................................................... 73
XXII. Maintenance Tools and Supplies ......................................74
A. Adjuster Top Seal Insertion Tool ...................................................74
B. Insert Installation Tool ...........................................................75
C. Main Valve Nozzle Wrench .......................................................76
XXIII. Replacement Parts Planning .........................................77
A. Basic Guidelines .............................................................. 77
B. IdenticationandOrderingEssentials .............................................. 77
C. PositiveIdenticationofMainValveandPilotValveCombinations.........................78
XXIV. Genuine Consolidated Parts .........................................78
XXV. Recommended Spare Parts ..........................................79
XXVI.Field Service, Repair and Training Program .............................82
A. Field Service ................................................................. 82
B. Factory Repair Facilities......................................................... 82
C. Safety Valve Maintenance Training ................................................ 82
6 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

I. 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 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 definition of the hazard, and the consequences of human
interactionwiththehazard,thancanbecommunicatedsolelybythe
pictorial.
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
Do not remove bolts
if pressure in line, as
this will result in
severe
personal injury
or death.
1
Know nuclear “health
physics” procedures,
if applicable, to avoid
possible severe
personal injury
or death.
2
Wear necessary
protective equipment
to prevent possible
injury
3
Handle valve
carefully. Do not
drop or strike.
4
Consolidated 4900 MPV Series POSRV Manual | 7
© 2020 Baker Hughes Company. All rights reserved.

II. Safety Precautions
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 trapped, corrosive media.
3. DANGER: When inspecting a pressure relief
valveforleakage.BEVERYCAREFUL!
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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 or others.
6. WARNING: Incorrect service and repair could
result in product or property damage or severe
personal injury or death.
Note: Any Service questions not covered in this
manual should be referred to your local Green
Tag Center (GTC).
Improper use or repair
of pressurized device
may result in severe
personal injury
or death.
Provide and
use guarding to
prevent contact
with heated and/or
pressurized parts.
XXX
Do not work
with valves while
under influence
of intoxicants or
narcotics.
Heed all
container label
warnings
Do not remove bolts
if pressure in line, as
this will result in
severe personal injury
or death.
8 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

II. Safety Precautions (Cont.)
7. 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.
8. WARNING: Useofimpropertoolsorimproper
use of right tools could result in personal injury
or product or property damage.
9. 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.
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 your local Green
Tag Center (GTC).
Restoring Safety
Appropriate service and repair important to safe,
reliable operation of all valve products. Restoration
to original quality and manufacturing specifications
willaccomplishthedesiredresults.Procedures
developed by Baker Hughes as described in the
applicable installation and Maintenance Manual,
whencorrectlyapplied,willbeeffective.
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.
Wear necessary
protective equipment
to prevent
possible injury.
Always use
appropriate
restoration
procedures.
Improper tools or
improper use of right
tools could result in
personal injury or
product damage.
Consolidated 4900 MPV Series POSRV Manual | 9
© 2020 Baker Hughes Company. All rights reserved.

III. Safety Notice
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,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 method and/or tools selected. 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 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.Duetothevariouscircumstancesand
conditionsinwhichtheseoperationsmaybeperformedonBakerHughes
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 offer certain Safety
Precautions, listed in Section II, for customer information only.
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 valves/equipment. For more information on training schedules
pleasecontactyourlocalGreenTagCenter(GTC).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
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