Dresser Consolidated 1900 User manual

Consolidated
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
Consolidated Safety Relief Valve
Type 1900
Industrial Valve Operation
Dresser Valve and Controls Division
Alexandria, Louisiana 71309-1430 (USA)
®
Design Options
Include:
Bellows
(-30),
O-Ring Seat
(DA),
Liquid Trim
(LA)
and
Thermodisc
®
(TD)
®
CON-2
Revised 7/97

CON-2
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),consistingofthreepanelsencircled
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, or CAUTION) which
communicates the level of hazard seriousness.
The center panel contains a pictorial which
communicatesthenatureofthehazard,andthepossible
consequence of human or product interaction with the
hazard.Insomeinstancesofhumanhazardsthepictorial
may,instead,depictwhatpreventivemeasurestotake,
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
Do not remove bolts if
pressure in line,as this
will result in severe
personal injury or death.
Know nuclear health
physics procedures, if
applicable, to avoid
possible severe per
sonal
injury or death.
WARNING
Wear necessary
protective equipment
to prevent possible
injury.
CAUTION
SAFETY ALERTS!
READ –UNDERSTAND –PRACTICE
1. DANGER: High temperature/pressure can
causeinjury. Be sure all systempressureisabsent
before repairing or removing valves.
2. DANGER: Don’t stand in front of valve
outletwhendischarging.STANDCLEAROFVALVE
to prevent exposure to trapped, corrosive media.
3. DANGER: When inspecting a pressure
relief valve for leakage, BE VERY CAREFUL!
DANGER
Do not remove bolts if
pressure in line,as this
will result in severe
personal injury or death.

CON-2
Page 1
Contents
Section Subject Page
Product Safety Sign and Label System..................................................................... Inside Front Cover
I. Safety Alerts .................................................................................................................................. 2
II. Terminology for Safety Relief Valves ............................................................................................ 4
III. Introduction ................................................................................................................................... 5
IV. Design Features and Nomenclature .............................................................................................5
V. Handling, Storage and Pre-Installation ......................................................................................... 8
VI. Recommended Installation Practices ............................................................................................ 9
A. Mounting Position ................................................................................................................ 9
B. Inlet Piping ........................................................................................................................... 9
C. Outlet Piping ........................................................................................................................ 11
VII. Disassembly Instructions .............................................................................................................. 12
A. General Information ............................................................................................................. 12
B. Specific Steps ...................................................................................................................... 12
VIII. Cleaning ........................................................................................................................................ 14
IX. Parts Inspection ............................................................................................................................ 14
A. Nozzle.................................................................................................................................. 14
B. Nozzle Seat Width ............................................................................................................... 16
C. Nozzle Bore ......................................................................................................................... 16
D. 1900, 1900-30 Standard Disc .............................................................................................. 16
E. 1900 Series Thermodisc...................................................................................................... 17
F. Disc Holder .......................................................................................................................... 18
G. Guide ................................................................................................................................... 21
H. Spindle................................................................................................................................. 21
I. Spring .................................................................................................................................. 21
X. Maintenance Instructions .............................................................................................................. 22
A. General Information ............................................................................................................. 22
B. Lapping Nozzle Seats (Non O-Ring Styles) ........................................................................ 22
C. Nozzle Seat Widths-Lapped ................................................................................................ 22
D. Lapping Disc Seats.............................................................................................................. 24
E. Precautions and Hints for Lapping Seats ............................................................................ 24
F. Lapping O-Ring Seating Surfaces ....................................................................................... 24
G. Reconditioning of Laps ........................................................................................................25
H. Remachining Nozzle Seats and Bores ................................................................................ 25
I. Remachining the Disc Seat ................................................................................................. 26
J. Checking Spindle Concentricity ........................................................................................... 27
K. Set Pressure Change-Disc Holder ...................................................................................... 28
L. Checking Lift on Restricted Lift Valves ................................................................................ 28
XI. Reassembly................................................................................................................................... 29
A. General Information ............................................................................................................. 29
B. Lubrication ........................................................................................................................... 30
C. Specific Steps ...................................................................................................................... 30
XII. Setting and Testing ....................................................................................................................... 35
A. General Information ............................................................................................................. 35
B. Test Equipment ................................................................................................................... 35
C. Test Media ........................................................................................................................... 35
D. Setting the Valve ................................................................................................................. 35
E. Set Pressure Compensation................................................................................................ 35
F. Seat Tightness Testing ........................................................................................................37
XIII. Hydrostatic Testing and Gagging .................................................................................................. 38
XIV. Manual Popping of the Valve ........................................................................................................ 39
XV. Conversion of Type 1900 Flanged Safety Relief Valves
From Conventional to Bellows Type, and Vice Versa ................................................................... 40
A. General Information ............................................................................................................. 40
B. Conversion From Conventional to Bellows Type................................................................. 41
C. Conversion From Bellows to Conventional Type................................................................. 41
XVI. Trouble Shooting Type 1900 Valves ............................................................................................. 42
XVII. Maintenance Tools and Supplies .................................................................................................. 42
XVIII. Replacement Parts Planning......................................................................................................... 44
A. Basic Guidelines .................................................................................................................. 44
B. Replacement Parts List ....................................................................................................... 44
C. Identification and Ordering Essentials ................................................................................. 44
XIX. Genuine Dresser Parts.................................................................................................................. 45
XX. Recommended Spare Parts for the 1900 Safety Relief Valves .................................................... 46
XXI. Manufacturer's Warranty, Field Service & Repair Program .......................................................... 48
A. Warranty Information ........................................................................................................... 48
B. Field Service ........................................................................................................................ 48
C. Factory Repair Facilities ...................................................................................................... 48
D. Safety Relief Valve Maintenance Training........................................................................... 48
Appendix RE: Optional Glide-Alloy® Parts ................................................................................... A.1
Service Engineers and Sales Office Locations ......................................................... Back Cover

CON-2
Page 2
SAFETY ALERTS!
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 labels. Improper handling or
misuse could result in severe personal injury or
death.
3. WARNING: Never use pressurized
fluids/gas/airtocleanclothingorbodyparts.Never
use body parts to check for leaks or flow rates or
areas. Pressurized fluids/gas/air injected into or
nearthebodycancauseseverepersonalinjuryor
death.
4. WARNING: It is the responsibility of the owner
tospecifyandprovideguardingtoprotectpersons
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
theinfluenceofintoxicants ornarcoticstoworkon
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.
WARNING
All potential hazards may
not be covered in this
manual.
WARNING
Improper tools or
improper use of right
tools could result in
personal injury or
product damage.
WARNING
Improper use or repair of
pressurized media or
steam device may result
in severe personal injury
or death.
WARNING
Heed all container label
warnings.
WARNING
Provide and use guarding
to prevent contact with
heated and/or
pressurized parts
WARNING
Do not work with valves
while under the
influence of intoxicants
or narcotics.
7. WARNING: These WARNINGS are as
complete as possible but not all-inclusive. Dresser
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:Somevalveproductsmanufacturedby
DVCD may be used in radioactive environments.
Consequently, prior to starting any operation in a
radioactiveenvironment,theproper“healthphysics”
procedures should be followed, if applicable.

CON-2
▲
Page 3
Know nuclear health
physics procedures, if
applicable, to avoid
possible severe per
sonal
injury or death.
WARNING
Wear necessary
protective equipment
to prevent possible
injury.
CAUTION
CAUTION
Heed all service manual
warnings.Read
installation instructions
before installing valve(s).
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
shouldbereferredtoDresser’sServiceDepartment,
Phone [phone].

CON-2
Page 4
II. Terminology for Safety
Relief Valves
•Accumulation
Accumulation is the pressure increase over the
maximum allowable working pressure of the
vessel during discharge through the pressure
relief valve, expressed as a percentage of that
pressure, or actual pressure units.
•Back Pressure
Back pressure is the pressure on the discharge
side of a safety relief valve:
1. Superimposed Back Pressure
Superimposedbackpressureisthepressure
in the discharge header before the safety
relief valve opens.
a) Constant-Specifysingleconstantback
pressure (e.g., 20 psig/1.38 bar).
b) Variable - Specify variable back
pressure range using min. and max.
limits (e.g., 0 to 20 psig/1.38 bar).
2. Built-up Back Pressure
Built-up back pressure is pressure which
develops at the valve outlet as a result of
flow, after the safety relief valve has been
opened.
•Blowdown
Blowdownisthedifferencebetweensetpressure
andreseatingpressureofapressurereliefvalve,
expressedasapercentageofthesetpressure,or
actual pressure units.
•Cold Differential Set Pressure
Cold differential set pressure is the pressure at
which the valve is adjusted to open on the test
stand. Thispressure includesthecorrections for
back pressure and/or temperature service
conditions.
•Differential Between Operating and Set
Pressures
Valvesin processservicewill generallygivebest
resultsiftheoperatingpressuredoesnotexceed
90%of theset pressure. However, onpump and
compressor discharge lines, the differential
requiredbetweentheoperatingandsetpressures
may be greater because of pressure pulsations
coming from a reciprocating piston. It is
recommended that the valve be set as high
above the operating pressure as possible.
•Lift
Lift is the actual travel of the disc away from the
closed position when a valve is relieving.
•Maximum Allowable Working Pressure
Maximum allowable working pressure is the
maximumgaugepressurepermissibleinavessel
at a designated temperature. A vessel may not
beoperatedabovethispressure,oritsequivalent,
at any metal temperature other than that used in
its design. Consequently, for that metal
temperature, it is the highest pressure at which
the primary pressure safety relief valve is set to
open.
•Operating Pressure
The operating pressure is the gauge pressure to
whichthevesselisnormallysubjectedinservice.
A suitable margin is provided between operating
pressure and maximum allowable working
pressure. For assured safe operation, the
operatingpressure shouldbeat least10% under
themaximumallowableworkingpressureor5psi
(.34 bar), whichever is greater.
•Overpressure
Overpressureisapressureincreaseover theset
pressure of the primary relieving device.
Overpressure is similar to accumulation when
the relieving device is set at the maximum
allowable working pressure of the vessel.
Normally, overpressure is expressed as a
percentage of set pressure.
•Rated Capacity
Rated capacity is the percentage of measured
flow at an authorized percent overpressure
permittedbytheapplicablecode. Ratedcapacity
is generally expressed in pounds per hour (lb/hr)
forvapors;standardcubicfeetperminute(SCFM)
or m3/min for gases; and in gallons per minute
(GPM) for liquids.
•Relief Valve
A relief valve is an automatic pressure-relieving
device, actuated by static pressure upstream
from the valve, a relief valve is used primarily for
liquid service.
•Safety Relief Valve
A safety relief valve is an automatic pressure-
relieving device which may be used as either a
safetyorreliefvalve,dependinguponapplication.
A safety relief valve is used to protect personnel
and equipment by preventing excessive
overpressure.

CON-2
Page 5
II. (Continued)
•Safety Valve
Asafety valve is an automatic pressure-relieving
device actuated by the static pressure upstream
ofthevalve,andcharacterized by rapid opening
or pop action. It is used for steam, gas or vapor
service.
•Set Pressure
Set pressure is the gauge pressure at the valve
inlet,forwhichtherelief valve has been adjusted
toopenunderserviceconditions. Inliquidservice,
set pressure is determined by the inlet pressure
at which the valve starts to discharge. In gas or
vapor service, the set pressure is determined by
the inlet pressure at which the valve pops.
•Simmer
Simmer is characterized by the audible passage
ofagasorvaporacrosstheseating surfacesjust
prior to "pop". The difference between this "start
toopenpressure"andthesetpressureissimmer,
andisgenerallyexpressedasapercentageofset
pressure.
•Valve Trim
Valve trim includes the nozzle and disc.
III. Introduction
A safety relief valve is an automatic pressure actuated
relievingdevicesuitableforuseeither asa safetyvalve
or relief valve, depending on application.
Safety relief valves are used on hundreds of different
applications, including liquids and hydrocarbons;
therefore, the valve is designed to meet many
requirements. The 1900 series valves included in this
manual can only be used to meet Section VIII
requirements. It cannot be used on ASME Code
Section I steam boilers or superheaters, but may be
used on process steam.
IV. Design Features and
Nomenclature
•Cap and Lever Interchangeability
Many times it is necessary to change the type of
cap or lever in the field after a valve has been
installed. All flanged Consolidated®Safety Relief
Valves are designed so they can be converted to
anytypeofleverorcapdesired. Itisnotnecessary
to remove the valve from the installation, nor will
the set pressure be affected when making such a
change.
•Design Simplicity
ConsolidatedSafetyReliefValveshaveaminimum
number of component parts. This results in a
savings by minimizing spare parts inventory and
simplifies valve maintenance.
•Nomenclature Related to Design Features
Applicable nomenclature of the components of
Type 1900 valves, including those with design
optionsforbellowsO-Ringseat,andliquidtrimand
Thermodisc, is identified in Figures 1 thru 6 on
pages 6 and 7.
•Simple Blowdown Adjustment
The Consolidated single blowdown ring design
makes it possible to set and test a valve that has
been in service when it cannot be set on line and
mustbetakentothecustomer'sshop. Theringcan
bepositionedsothatthesetpointcanbeobserved
although the volume of the testing media is very
low. After the set pressure has been established,
proper blowdown can be attained by merely
positioningtheringinaccordancewiththeadjusting
ringpositionshowninTables12-14(asappropriate),
on page 34 of this manual.
•Valve Interchangeability
A Standard Consolidated Safety Relief Valve may
be converted to the bellows type, the O-Ring seat
seal type, etc. and vice versa. This requires a
minimumnumberofnewparts,andresultsinlower
costs should conversion be required.

CON-2
Page 6
Part
No. Nomenclature
1 Base
2 Nozzle
3 Adjusting Ring
4 Adjusting Ring Pin
5 Adj. Ring Pin Gasket
6 Disc
7 Disc Retainer
8 Disc Holder
9 Guide
10 Guide Gasket
11 Bonnet
12 Bonnet Gasket
13 Base Stud
14 Stud Nut
15 Spindle
16 Spindle Retainer
17 Spring Washer
18 Spring
19 Adjusting Screw
20 Adjusting Screw Nut
21 Screwed Cap
*22 Bolted Cap
*23 Packed Cap
*24 Plain Cap
*25 Cap Bolt
*26 Cap Set Screw
27 Cap Gasket
*28 Release Nut
*29 Release Locknut
*30 Lever
*31 Lifting Fork
*32 Lever Shaft
*33 Packing
*34 Packing Nut
*35 Top Lever
*36 Drop Lever
40 Eductor Tube
41 Bonnet Vent Plug
* Shown in Figures 38-42 on
page 39 of this manual.
FIGURE 1
CONSOLIDATED SAFETY RELIEF VALVE
TYPE 1900 - CONVENTIONAL

CON-2
NOTE:
A combination of the O-Ring seat
sealandliquidtrimdesignoptionsis
designated as DA-LA.
FIGURE 4
FIGURE 6
V & W Orifice Only
FIGURE 2
Page 7
DESIGN OPTIONS
THERMODISC (TD)
DESIGN
FIGURE 3
THERMODISC
FIGURE 5
LA Liquid Trim Design
(See Fig. 20)
DISC RETAINER
DISC
GUIDE
ADJUSTING RING
NOZZLE
DISC HOLDER
PART INTEGRITY
ESPECIALLY DESIGNED
FOR SHORT BLOWDOWN
AND SMOOTH CHATTER-
FREE OPERATION
AT MAXIMUM CAPACITY.

CON-2
Page 8
V. Handling, Storage and
Pre-Installation
•Handling
A flanged valve, either crated or uncrated, should
always be kept with the inlet flange down (i.e., in
ordertopreventpossiblemisalignmentanddamage
to internals).
Uncrated valves
should be moved or
hoisted by wrapping
a chain or sling
around discharge
neck, then around
upper bonnet
structure in such
manner as will
ensurethevalveisin
a vertical position
during lift, i.e. not
lifted in horizontal
position.
NOTE:
Never lift the full
weight of the valve
by the lifting lever.
Crated valves should always be lifted with the
inlet flange down, i.e., same as installation
position.
Safety relief valves,
either crated or
uncrated, should
never be subjected
tosharpimpact. This
would be most likely
to occur by bumping
or dropping during
loading or unloading
from a truck. While
hoisting to the
installation, care
should be taken to
prevent bumping the
valve against steel
structures and other
objects.
Do not lift horizontally,
or hook to lifting lever.
WARNING
Handle carefully. Do
not drop or strike.
WARNING
•Storage
Safety relief valves should be stored in a dry
environment to protect them from the weather.
They should not be removed from the skids or
crates until immediately prior to installation.
Flangeprotectorsandseatingplugsshouldnotbe
removed until the valve is ready to be bolted into
the installation, i.e., both inlet and outlet.
•Pre-installation
When safety relief
valves are uncrated,
and the flange
protectors or sealing
plugs removed
immediately prior to
installation,
meticulous care
should be exercised
to prevent dirt and
other foreign
materials from
enteringtheinletand
outlet ports while
bolting in place.
Prevent dirt from
entering outlet or inlet
port.
WARNING