Baker Hughes Consolidated Generation II 2900 Series User manual

Consolidated™
2900 Series Generation II
Pilot-Operated Safey Relief Valves
Instruction Manual (Rev. E)
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.
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NOTICE!
For valve congurations not listed in this
manual, please contact your local Green
Tag™ Center (GTC) for assistance.
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
Conversion Table
Note: Multiply USCS unit with conversion factor to get metric value.
Consolidated 2900 Series Generation II POSRV Instruction Manual | 3
© 2021 Baker Hughes Company. All rights reserved.

Table of Contents
I. Product Safety Sign and Label System..................................7
II. Safety Precautions ..................................................8
Restoring Safety .................................................................. 9
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 .......................................................16
A. General Introduction ............................................................16
B. Main Valve Introduction ..........................................................16
C. Pilot Valve Introduction ..........................................................16
IX. 2900 Series Pilot Operated Safety Relief Valves .........................17
A. Metal Seat Valve ...............................................................17
B. Soft Seat Valve ................................................................17
C. Integral Sense..................................................................17
D. D-U Orice (with Bellows) ........................................................18
E. V & W Orice (with Bellows) ......................................................18
F. Metal Seat Valve for Section I Liquid Service (LA1) .....................................19
G. Soft Seat Valve for Section I Liquid Service (LA1) .................................... 20
H. 39PV07/37 Pilot Valves (Standard Service) ...........................................21
I. 39MV07 Pilot Valve (Standard Service)............................................. 22
J 39MV22/72 Pilot Valve (Standard Service) .......................................... 23
X. Operating Principles ................................................24
A. 2900 Series with Type 39PV (Pop) Pilot Operational Descriptions .........................24
B 2900 Series 39MV07 (Modulating) Pilot – Operational Description ....................... 26
XI. General Planning for Maintenance ....................................28
XII. Recommended Installation Practices ..................................28
A. Mounting Position ............................................................. 28
B. Inlet Piping ................................................................... 29
C. Outlet Piping.................................................................. 30
D. Integral Sensing ............................................................... 30
E. Remote Sensing................................................................31
F. Freeze Protection ...............................................................31
4 | Baker Hughes © 2021 Baker Hughes Company. All rights reserved.

Table of Contents (Cont.)
XIII. Disassembly of the 2900 POSRV ......................................33
A. Removal of Pilot Valve from Main Valve ............................................ 33
B. Disassembly of Main Valve ...................................................... 33
B.1 Nozzle Removal.............................................................37
C. Cleaning ..................................................................... 39
XIV. Maintenance Instructions ............................................40
A. General Maintenance Information ................................................. 40
B. O-Ring Seat .................................................................. 40
C. Lapping Nozzle Seats (Metal Seat, Non-O-Ring Styles).................................42
D. Lapped Nozzle Seat Widths.......................................................42
E. Lapping Disc Seats ............................................................ 44
F. Precautions and Hints for Lapping Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
G. Reconditioning of Laps ......................................................... 44
H. Re-Machining Nozzle Seats ..................................................... 45
I. Re-Machining the Disc Seat ..................................................... 45
XV. Inspection and Part Replacement .....................................47
XVI. Reassembly of the 2900 Main Valve ...................................51
A. Lubricants and Sealants .........................................................51
B. Assembly Procedure with Metal Seats ..............................................51
B.2.1 Integral Sensing Ring Assembly.............................................. 52
B.3 Disc/Disc Holder Assembly ................................................... 52
C. Assembly Procedure with O-Ring Seats ............................................ 52
XVII. Disassembly of Pilot Valve ...........................................57
A. 39PV07/37 Disassembly ........................................................ 57
B. 39MV07 Disassembly .......................................................... 60
C. 39MV22/72 Disassembly........................................................ 63
D. Cleaning ..................................................................... 66
XVIII. Part Inspection of Pilot Valve .........................................67
A. 39PV07/37 ................................................................... 67
B. 39MV07 ..................................................................... 67
C. 39MV22/72 .................................................................. 68
XIX. Reassembly of Pilot Valve ...........................................69
A. Lubricants and Sealants ........................................................ 69
B. Assembly of 39PV07/37......................................................... 69
C. Assembly of 39MV07 ............................................................71
D. Assembly of 39MV22/72 ........................................................ 73
Consolidated 2900 Series Generation II POSRV Instruction Manual | 5
© 2021 Baker Hughes Company. All rights reserved.

Table of Contents (Cont.)
XX. Setting and Testing .................................................76
A. General Information .............................................................76
B. With Standard Options...........................................................76
C. Integral Sensing Ring........................................................... 77
D. Troubleshooting Leakage.........................................................78
E. Conversions between Conventional and Bellows Type ................................. 80
F. Field Testing of POSRV Assembly ..................................................81
XXI. Troubleshooting....................................................85
XXII. 2900 Series POSRV Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
A. Backow Preventer ............................................................ 86
B. Dirty Service Option.............................................................87
C. Dual Pilots ................................................................... 89
D. Field Test Connection .......................................................... 89
E. Sensing Line Filter (Standard) ................................................... 89
F. Single, Dual and High Capacity Filters (Optional) ..................................... 90
G. Gag .........................................................................91
H. Heat Exchanger ................................................................91
I. Lifting Lever .................................................................. 92
J. Manual, Electrical, or Pneumatic Blowdown Valve .................................... 92
K. Pressure Di󰀨erential Switch...................................................... 92
L. Pressure Spike Snubber ........................................................ 92
M. Remote Pilot Mounting.......................................................... 93
N. Remote Sensing............................................................... 93
O. Sensing Ring Options .......................................................... 93
XXIII. Maintenance Tools and Supplies ......................................94
A. Adjuster Top Seal Insertion Tool .................................................. 94
B. Insert Installation Tool .......................................................... 95
C. Lapping Tools................................................................. 96
D. Disc Holder and Guide Removal and Assembly Tool ..................................97
E. 2900 IS Torquing Tool Insert...................................................... 98
XXIV. Replacement Parts Planning .........................................99
A. Basic Guidelines .............................................................. 99
B. Identication and Ordering Essentials .............................................. 99
C. Positive Identication of Main Valve and Pilot Valve Combinations ....................... 100
XXV. Genuine Consolidated Parts ........................................100
XXVI.Recommended Spare Parts .........................................101
XXVII. Field Service, Repair and Training Program ...........................110
A. Field Service .................................................................110
B. Repair Facilities ...............................................................110
C. Maintenance Training...........................................................110
6 | Baker Hughes © 2021 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.
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.
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 Generation II POSRV Instruction Manual | 7
© 2021 Baker Hughes 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
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.
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.
8 | Baker Hughes © 2021 Baker Hughes Company. All rights reserved.

II. Safety Precautions (Cont.)
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 your
local Green Tag™ Center (GTC).
Restoring Safety
Appropriate service and repair are 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.
Always use
appropriate
restoration
procedures.
Consolidated 2900 Series Generation II POSRV Instruction Manual | 9
© 2021 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, 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 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 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 offer certain Safety
Precautions 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, call 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.
III. Safety Notice
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