Emerson Anderson Greenwood 500 Series User manual

ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
© 2017 Emerson. All Rights Reserved.Emerson.com/FinalControl
1 GENERAL VALVE DESCRIPTION AND
START-UP
1.1 Operation
The Anderson Greenwood pilot operated
safety-relief valves utilize the principle
of
pressurizing the top, or large area,
of a differential area piston with line
pressure to hold the piston closed up to set
pressure. At set pressure the pilot valve
relieves, partially evacuating the dome
(volume above piston) and the piston lifts
permitting discharge from the main valve.
When the pilot reseats, line pressure is diverted
to the dome closing the main valve.
The set pressure range is 15 to 720 psig
(1to 51 bar).
Before installation, these instructions must be carefully read and understood
Engineering Doc. #05.9040.272 Rev. H
VCIOM-06022-EN 19/06
Installation and maintenance instructions for
Anderson Greenwood Series 500 Pilot Operated
Safety Relief Valves (POSRV).
The intent of these instructions is to acquaint
the user with the installation and maintenance
of this product.
TABLE OF CONTENTS
1. General valve description and start-up ....... 1
2. Main valve maintenance ............................... 2
3. Pilot maintenance ......................................... 6
4. Pilot set pressure adjustment...................... 9
5. Testing complete valve assembly .............. 10
6. Pilot set pressure field test procedure...... 11
7. Soft goods repair kits.................................. 13
8. Pilot accessories ......................................... 13
9. Pilot conversion kits.................................... 13
1.2 Installation
Either or both inlet and outlet may be standard
ANSI/ASME flanges and the valve should be
installed in accordance with accepted piping
practices.
When remote pressure pick-up is used the
pilot supply tube is connected to a remote
location rather than to the inlet neck of the
valve. If a block valve for shut-off is used in the
remote pilot supply line, be sure it is opened
before pressurizing the system or opening the
isolating block valve, where installed.
NOTE
Remote pressure pick-up piping must have the
equivalent flow area of ½” (12.7 mm) tubing for
lengths up to 20feet (6 m). For lengths greater than
20feet (6 m), larger tubing or pipe should be used.

2
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
1.4 Storage and handling
Valves are often on hand at the job site months
before they are installed. Unless stored properly
and protected, valve performance may be
affected adversely.
Rough handling and dirt may damage or
cause misalignment of the valve parts. It is
recommended that the valves be left in their
original shipping containers and that they be
stored in a warehouse or at a minimum on a dry
surface with a protective covering until they are
used. Consult factory for soft goods shelf life.
2 MAIN VALVE MAINTENANCE
2.1 Disassembly
Remove the cap from the body. Remove the
piston and liner. A cap bolt may be threaded
into hole in top of piston to aid in removal.
Through holes in seat retainers 2, 3 and 4 in.
(50.8, 76.2 and 101.6 mm) sizes are threaded to
assist in disassembly. Remove the soft goods
from the piston. If the piston is equipped with
a wedge ring, clean and retain it for use during
assembly. The dipper tube is swaged in place
and no attempt should be made to remove
it. Refer to Figure 1 for parts description and
location. The nozzle and nozzle seal should not
be removed unless the nozzle is damaged or
the seal is leaking.
2.1.1 Nozzle and nozzle seal disassembly
Refer to Figure 2 for parts description and
location.
1. Place liner in body and piston, without seat
or seat retainer, into liner and on top of
nozzle.
2. Place appropriate spacer (see Table 1)
on top of piston and then the cap over the
spacer.
3. Thread the appropriate number of cap bolts
(see Table 1) into threaded holes on top
of body. If two bolts are used, they should
be 180° apart. When using four bolts, they
should be 90° apart.
4. Tighten cap bolts evenly to the torque listed
in Table 1 to compress nozzle seal.
5. Use a punch or bar with a light hammer
and tap on the nozzle retainer teeth to
loosen the nozzle retainer. Unthread nozzle
retainer approximately ½ turn.
6. Loosen cap bolts to remove load from
nozzle. Remove components from main
valve.
1.3 Startup
There must be pressure at the valve inlet to
establish a differential in force across the
piston and “load” it in the closed position.
Pressure must pass through the pilot supply
tube and pilot, and exert force on the top of
the piston. On normal plant start-up, the valve
loads itself without incident as plant pressure
increases. It is not uncommon that slight
leakage past the main seat occurs until system
pressure reaches five to ten pounds. This
amount of pressure is sometimes needed to
form the PTFE seat to nozzle surface.
Block valves are often used under safety valves
in order to isolate them when maintenance
is required. When putting the safety valve in
service be sure the block valve is fully opened.
If the block valve is opened after system
start-up, the safety valves may briefly vent to
the atmosphere past the main seat before the
dome gets pressurized-it will then close off
positively. To minimize this venting, open the
block valve slowly.

3
32
32
.010
R.020
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
2.3 Assembly
2.3.1 Nozzle and nozzle seal installation
1. Place nozzle seal and nozzle in body.
2. Place nozzle retainer over nozzle and thread
into body until it stops on nozzle shoulder.
Do not lubricate nozzle retainer threads or
mating body threads.
3. Repeat steps 1 through 4 of disassembly
procedure to compress nozzle seal.
Valve size and type
Min. nozzle projection height
in. mm
1½” Series 546 .045 1.143
2” Series 546 .055 1.397
3” Series 546 .055 1.397
4” Series 546 .055 1.397
6” Series 546 .070 1.778
8” Series 546 .070 1.778
1½” Series 566 .055 1.397
2” Series 566 .055 1.397
3” Series 566 .055 1.397
4” Series 566 .070 1.778
6” Series 566 .070 1.778
8” x 88” Series 566 .070 1.778
8” x 10” Series 566 .070 1.778
10” Series 566 .070 1.778
2.2 Main valve nozzle rework
Should the main valve nozzle seating face
become nicked or scratched such that the main
valve seat does not seal, the imperfections
can be removed by polishing the nozzle face
with 400 grit sandpaper on a flat surface plate.
Certain critical nozzle dimensions and finishes
must be maintained and those are shown in the
Figure and Table below.
Pilot valve
Outlet
Remote sense
Supply tube
Field test
connection
Inlet
Main valve
Minimum
projection
Thread nozzle retainer into body as seal is
compressed to keep nozzle retainer from
binding against piston.
4. Use a punch or bar with a light hammer and
tap on the nozzle retainer teeth to snug the
nozzle retainer threads.
5. Loosen cap bolts to remove load from
spacer and remove spacer from valve.
Replace seat, piston and liner seal. Apply a
light coat of Dow Corning #33 silicone lubricant
on all threads after cleaning. Do not use any
lubricant on the soft goods.
When installing the cap, make sure it is seated
squarely into body. Torque cap bolts uniformly
so as not to “cock” cap. See Table 2 for torque
values. Such a condition may result in leakage
at the liner seal or cause the piston and liner
to bind.

4
13
18
5
67
15
10
1
14 12 8
16
13
18
3
10
17
11
4 6 15 79
2
5
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
TABLE 1
Valve size and type Spacer P/N Cap bolt thread
# Cap bolts
to use
Cap bolt torque
ft·lb Nm
1½” x ⅔” Series 546 (G and H Orifice) 06.5612.003 .500-20 UNF 241 30.24
1½” x ⅔” Series 546 (G and H Orifice) 06.5612.003 .625-18 UNF 251 37.62
2” Series 546 06.5612.005 .500-20 UNF 427 19.91
3” Series 546 06.5612.007 .500-20 UNF 435 25.81
4” Series 546 06.5612.008 .750-16 UNF 4130 95.88
6” Series 546 06.5612.009 .750-16 UNF 282 60.48
6” Series 546 06.5612.009 .875-14 UNF 295 70.07
8” Series 546 06.5612.010 .875-14 UNF 4123 90.72
8” Series 546 06.5612.010 1.000-14 UNS 4140 103.26
1½” Series 566 06.5612.005 .500-20 UNF 219 14.01
2” Series 566 06.5612.007 .500-20 UNF 231 22.86
3” Series 566 06.5612.008 .750-16 UNF 2113 83.34
4” Series 566 06.5612.011 .625-18 UNF 263 46.47
6” Series 566 06.5612.012 .750-16 UNF 288 64.91
8” x 88” Series 566 06.5612.013 .875-14 UNF 4119 87.77
8” x 10” Series 566 06.5612.014 1.125-12 UNF 10 89 65.64
10” Series 566 06.5612.015 1.125-12 UNF 10 90 66.38
6 and 8 in. size 1½ thru 4 in. size
FIGURE 1
PARTS LIST
Item Part name
1Body
2Piston
3Liner
4Nozzle [1]
5Seat [2]
6Seat retainer
7Seat retainer bolt
8Cap
9Dipper tube
10 Piston seal [2]
11 Nozzle seal [1]
12 Liner seal [2]
13 Retaining ring
14 Cap bolt
15 Lock washer
16 Dome spring
17 Nozzle retainer
18 Wedge ring [3]
NOTES
1. Do not replace unless required.
2. Recommended spare parts for repair.
3. Used on 4 in. sizes and larger Series 546 and 3 in.
and larger Series 566.
See Section 7 for soft goods repair kit part number.

5
¼ 7 5.16
5
/
16 12 8.85
⅜21 15.49
7
/
16 33 24.34
½45 33.19
9
/
16 59 43.52
⅝97 71.54
¾130 95.88
⅞202 148.99
1271 199.88
1⅛ 408 300.93
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FIGURE 2
Body
Nozzle seal
Nozzle
Nozzle retainer
Piston
Liner
Spacer
Cap
Cap bolt
TABLE 2
Bolt size
Torque
ft·lb Nm

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ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
3 PILOT MAINTENANCE
3.1 Disassembly
To facilitate assembly, place all parts
removed in an orderly arrangement so that
the correct parts can be assembled in the
proper sequence. Refer to Figure 3 for parts
description and location.
NOTE
If pilot is equipped with a lift lever, the lift leverhandle
assembly must be unscrewed from cap before continuing
with disassembly. Hold lift lever in position shown
in Figure 8, unscrew bushing (Item 14) from cap and
remove handle assembly (Items 13, 14, 15, 32 and 45).
Unscrew and remove cap. Loosen jam nuts
and release spring compression by backing out
adjusting screw. Remove bonnet, spring and
spring washer. Remove lift lever adapter, rod
and support spring where used.
Loosen spindle nut before loosening jam nuts.
The spindle jam nuts serve as wrench flats on
the spindle. Remove remainder of accessible
parts except spindle. Remove nozzle
witha⅜ in.
square drive socket extension. Remove the
spindle assembly by pushing it up through
the body.
3.2 Assembly
Assemble pilot in reverse order of disassembly.
Take care not to scratch the sealing face of
the seat or nozzle. If scratched or nicked, it
must be replaced or lapped to prevent leaking.
Lubricate all screw threads and bearing end
of spring washers with NG-165 Never-Seez
lubricant. Use Dow Corning No. 33 Silicone
grease on all surfaces of the spring washer
bearing if installed. Lubricate the sealing flange
of the nozzle to prevent galling. Do not lubricate
spindle, lower end of spindle seat, nozzle face,
or PTFE seals.
3.4 Bolt make-up (item 38)
Tighten the six ⅜ in. case bolts alternately
opposite each other to approximately 32 to
36ft·lb (23.6 to 26.55 Nm).
3.3 Pilot diaphragm assembly
3.3.1 Boost diaphragm (lower diaphragm)
Install upper diaphragm shield on top
of lower diaphragm shield. Install boost
diaphragm (Item 55) over spindle on
top of the lower and upper diaphragm
shield, with spindle gaskets (Item 56) and
diaphragm gaskets (Item54 or 57) on
both sides of the diaphragm. For pressure
below 120 psi (8.27 bar), use a PTFE
diaphragm with FEP diaphragm gaskets.
For pressure between 121 to 180psi
(8.34 to 12.41 bar), use a Hastelloy
®
diaphragm with FEP diaphragm gaskets.
For pressure above 180 psi (12.41 bar),
use a Hastelloy
®
diaphragm with Peek
diaphragm gaskets. Install boost plate
(item 8) on top of the boost diaphragm.
3.3.2 Sensing diaphragm (upper diaphragm)
Install sense diaphragm (Item 55) on
top of spacer ring, with a diaphragm
gasket and a spindle gasket below the
diaphragm. For set pressure up to 30psi
(2.07 bar), use a PTFE diaphragm with
a FEP diaphragm gasket. For pressure
between 30 to 180 psi (2.07
to 12.41 bar) ,
use a Hastelloy®diaphragm with a FEP
diaphragm gasket. For pressure above
180 psi
(12.41 bar) , use a Hastelloy®
diaphragm with a PEEK diaphragm
gasket.
Hastelloy®is a registered trademark of
HaynesInternational.

7
12
17
18
25
21
40
24
11
10
22
3
7
56
8
56
36
46
2
1
47
4
27
35
9
57, 54, 55
6
39
5
38
26 33
30
34, 41
16
51
52
31
15
45
13
32
14
41
57, 54, 55
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ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
PARTS LIST
Item Description
1Body
2Nozzle
3Spindle
4Seat socket
5Diaphragm support
6Spacer ring
7Sense plate
8Boost plate
9Diaphragm shield, lower
10 Bonnet
11 Spring washer
12 Lift lever cap [1]
13 Lift lever cam [1]
14 Lift lever bushing [1]
15 Lift lever handle [1]
16 Lift rod bushing [1]
17 Lift lever rod [1]
18 Lift lever nut [1]
21 Pressure adjustment screw
22 Lift lever coupling
24 Bonnet screw
25 Retaining O-ring [1]
30 Boost plate seal
31 Spring
32 Cam spring [1]
33 Bonnet vent
34 Lockwasher
35 Shim washer
36 Seal retainer
38 Bolt
39 Diaphragm shield, upper
40 Jam nut
41 Jam nut
45 Spring pin [1]
46 Seat
47 Ball
51 Nameplate
52 Drive screw
54 Diaphragm gasket-FEP
55 Diaphragm
56 Spindle gasket
57 Diaphragm gasket-PEEK
[1] Use with lift lever option only.
Dome
FIGURE 3
15 to 275 psig
(1.03 to 18.96 bar)
NOTE
Refer to next page for Section A - A and 276 to
720psig (19.03 to 49.64 bar).

8
3
55
26
39
55
9
43
27
46
34
7
5
30
8
35
4
47
2
49
50
37
20
29
19
42
28
53
23
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Auxiliary dome
Exhaust Supply
276 to 720psig (19.03 to 49.64 bar)
Section A - A
PARTS LIST
Item Description
2Nozzle
3Spindle
4Seat socket
5Diaphragm support
7Sense plate
8Boost plate
9Diaphragm shield, lower
19 Blowdown needle
20 Blowdown bushing
23 Inlet screen
26 Bonnet seal
27 Spindle seal
28 Bushing seal
29 Needle seal
30 Boost plate seal
34 Lockwasher
35 Shim washer
37 Needle retainer
39 Diaphragm shield, upper
42 Jam nut
43 Screw
46 Seat
47 Ball
49 Tubing
50 Elbow connector
53 Pipe plug
55 Diaphragm

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ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
4 PILOT SET PRESSURE ADJUSTMENT
4.1 General
Two adjustments are provided; one for varying
the pressure at which the pilot opens and
one for varying the pressure at which the
pilot closes. The first adjustment controls the
“set” pressure; the second the “reseat” or
“blowdown” pressure.
4.2 Set pressure
Set pressure is that supply pressure where the
dome pressure is reduced to 70% ± 2% of the
supply. This corresponds to the initial audible
discharge of gas or first steady stream of liquid
from the main valve.
To adjust the set pressure, a test set up similar
to that shown in Figure 4 should be used. The set
pressure adjustment screw should be turned IN
most of the way. Increase the supply pressure
to the nameplate setting and slowly back the
adjustment screw out until the dome pressure
is 70% ± 2% of the supply pressure and supply
pressure meets the required set pressure
tolerance of paragraph 4.5. Lock the adjusting
screw with the jam nut and cycle the pilot several
times to make sure the setting is correct.
4.4 Adjustment tolerances
All pilots can be adjusted ± 5% beyond
the nameplate setting for set pressures
above 275psig (18.96 bar) and ± 10% for set
pressures 275 psig (18.96 bar) and below.
4.5 Range of adjustment
Cracking pressure: 95% of specified set
pressure
Set pressure:
± 3% of specified set
pressure above 70 psig
(4.83 bar) set
± 2 psig for
70 psig
(4.83 bar) and below
Reseat pressure: Specified as a percent
of set pressure
modulatingaction (0-3%)
4.3 Reseat pressure
Reseat pressure is that supply pressure where
the dome pressure increases to 75 ± 2% of
supply.
4.3.1 Reseat pressure - modulating action
The reseat pressure should be adjusted
with the pilot flowing. Increase the
supply pressure until the pilot opens
and steady flow is obtained. With the
blowdown adjustment screw turned in,
slowly decrease the supply pressure to
97% to 100% of set. Turn the blowdown
adjustment screw OUT until the pilot
reseats. Lock the adjusting screw with
the jam nut and cycle the pilot several
times to make sure the setting is correct.
A small interaction between set pressure
and blowdown may occur. If so, re-adjust
set pressure.
NOTE
If the blowdown adjustment screw is backed out more
than necessary to obtain 0% blowdown, pilot action
will become more sluggish and pilot crack to main
valve opening pressure spread will increase.
4.6 For steam service pilots
Set on steam, check the case bolts (Item 38)
again for tightness at zero pressure. Retighten
to 35 to 39 ft·lbs (25.81 to 28.76 Nm) of torque,
as required. Check set pressure again if bolts
are retightened.

10
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Dome
pressure
gauge
Bonnet vent
Set pressure adjustment (turn in to increase set pressure)
(turn out to decrease set pressure)
Accumulator
(approx. ¼ cu ft)
Pilot inlet (backside)
Flexible supply hose
Valve “A”
Street
elbow
Pipe nipple
Mounting stud
Vent valve “C”
Flexible supply hose
Valve “B”
Union
Elbow
Inlet supply pressure gauge
Blowdown adjustment (turn in to increase)
(turn out to shorten)
Cross
Bleed
valve
Pilot exhaust (backside)
FIGURE 4
5 TESTING COMPLETE VALVE ASSEMBLY
5.1 General
The complete valve assembly should be tested
for internal and external leakage and to verify
main valve function using a test set-up similar
to that shown in Figure 5.
5.2 Low pressure leakage check
Slowly increase the inlet pressure to 30% of
the set pressure. Check for main valve nozzle,
seat, and piston seal leakage at the main valve
outlet. No visible leakage shall occur in one
minute. To help in seating the valve seat and
piston seal, the valve may be actuated several
times.
5.3 High pressure leakage check
Apply pressure to the inlet equal to 90% of the
set pressure. Check for leakage at the main
valve outlet. Using a suiTable gas or air leak
detector solution, check for leakage at the
cap seal and other pressure connections. No
leakage shall occur at the valve outlet and no
visible leakage shall be detected at the cap seal
or other pressure connections in one minute.
5.4 Main valve function check
CAUTION
This test must be performed at a slow rate of
pressure increase to ensure that the main valve
does not go into full lift. The pressure applied to
the inlet is not to exceed 105% of nameplate set
pressure.
After completing the high pressure leakage
check of paragraph 5.3, verify main valve
opening as follows. Remove the leakage test
device from the outlet flange. Slowly increase
the inlet pressure above 90% of set pressure.
Continue increasing inlet pressure until an
audible discharge at the valve outlet verifies
main valve opening.

11
.10
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
6 PILOT SET PRESSURE FIELD TEST
PROCEDURE
NOTE
EXTREME CAUTION and appropriate safety
procedures should always be utilized when testing or
servicing a safety relief valve. Any compressible fluid
under pressure is dangerous.
6.1 General
The pilot set pressure on a valve set for
modulating action is best determined when the
main valve dome pressure is measured.
From
the discussion in Section 4 Pilot adjustment,
set
pressure is defined as that process pressure
where the dome pressure is 70% of the supply
pressure. Typically, this measurement can
not be made since access for measuring this
pressure is not available without depressurizing
the dome and installing special fittings.
Ported blind flange
Inlet pressure
Supply
¼” O.D. X .028 wall tube
External sensitivity adjustment
FIGURE 5
Alternatively, the pilot set pressure can be
checked in the field if the valve is equipped
with a field test accessory with an actuation
indicator. An external test pressure is applied
through the field test valve as shown in
Figure 6. Set pressure is the pressure when the
actuator indicator button retracts, or moves in.
NOTE
Use extreme caution when testing to prevent injury
should the main valve open and discharge product
on personnel. If the main valve must remain closed,
temporarily replace the pilot exhaust vent with an
orifice plug having an orifice diameter of .040”/.060”.
This orifice must be removed on completion of field
testing as it prevents the main valve from opening.

12
AA
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
6.2 Procedure
A.
Connect test gas bottle as shown in Figure 6.
B. Close vent valve “C”.
C. Open field test valve “B”. Test gauge will
read process pressure.
D. Open block valve “A” SLOWLY to increase
pressure until pilot opens or until the
actuator indicator button moves in. The
pressure will be the pressure indicated on
the test gauge at the time of pop.
E. To remove test set up, close valves “A” and
“B”, open valve “C”.
Indicator position
“out” - valve closed
“in” - valve open
FIGURE 6
Indicator assembly
View A - A
Vent “C”
Block valve “A”
Field test valve
“B”

13
ANDERSON GREENWOOD SERIES 500 PILOT OPERATED SAFETY RELIEF VALVES
INSTALLATION AND MAINTENANCE INSTRUCTIONS
7 SOFT GOODS REPAIR KITS
The kits listed below are available from stock. To order, specify the base number and select the
last three digits from the following tables. To ensure the purchase of the correct soft goods kits,
the order should specify the valve model number and serial number.
Kit base number: 06.3366.XXX
TYPE 546 MAIN VALVE KIT
Set pressure (psig) 1½ x 3 2 x 3 3 x 4 4 x 6 6 x 8 8 x 10
PTFE All 001 002 003 004 005 006
PEEK 276-720 010 011 012 013 014 015
TYPE 566 MAIN VALVE KIT
Set pressure (psig) 1½ x 2 2 x 3 3 x 4 4 x 6 6 x 8 8 x 8 8 x 10 10 x 14
PTFE All 002 003 004 007 008 046 009 049
PEEK 276-720 011 012 013 016 017 047 018 048
9 PILOT CONVERSION KITS
Lift lever conversion kit
Pilot set pressure Kit part no.
All pressures 06.3416.007
Kit base number: 04.4959.XXX
PILOT KIT
Description With or without lift lever
Standard soft goods 212
NACE soft goods 213
Nozzle 106
8 PILOT ACCESSORIES
Description All pressures
Field test w/indicator soft goods 192
Backflow preventer soft goods 390
Supply filter soft goods and filter screen 417
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