Emerson CROSBY Guide

CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
© 2017 Emerson. All Rights Reserved.
Before installation, these instructions must be carefully read and understood
Emerson.com
1 INTRODUCTION
Crosby Style HSL is a full nozzle reaction
type safety valve designed for saturated and
superheated steam service. The design is
suitable for set pressures to 725 psig (50 barg)
and temperatures to 1000°F (538°C), with high
capacities, two choices of inlet flange ratings
and simplicity of design to facilitate ease of
maintenance.
The HSL design meets the requirements
of ASME Code Section I, (power boilers)
and relieving capacities are certified by the
National Board of Boiler and Pressure Vessel
Inspectors. Style HSL may also be used in
steam service applications covered by ASME
code section VIII requirements.
2 SPARE PARTS
Emerson recommends spare parts as shown
on Figures 1 and 2. When ordering spare parts,
the valve size, style and serial number should
be given together with set pressure, part name,
and reference number from Figure 1 or 2.
Spare parts may be ordered from any Emerson
regional sales office or authorized Emerson
sales representative.
VCIOM-03104-EN 22/03
Engineering doc. nr.: IS V3187
Centering of the disc through the low friction
guide ensures the HSL opens precisely at set
pressure, even after repeated cycling. The
single bonnet design utilized in both inlet flange
ratings allows set pressure changes without
the need to change-out any components other
than the spring.
Style HSL safety valves are available with
optional test gags, weather hoods for outdoor
applications and Class 150# drip pan elbows.
Ring type joint inlet connection is also available.
The entire HSL range of F thru Q orifices uses
a full nozzle design (Figure 1) to facilitate
removal and ease of maintenance compared
to semi-nozzle designs.
Details of the HSL valve design, materials of
construction, pressure-temperature ratings
and dimensions are provided in Crosby
technical datasheet VCTDS-00595.
Style HSL safety valves incorporate the
Crosby FLEXI-DISC®design which is recessed
for pressure and temperature equalization
ensuring a tight seal capable of containing
system pressure at 94% of the valve set
pressure. Seat tightness testing at the factory
for Style HSL safety valves is conducted at 93%
of set pressure.

2
14
7
6
4
3
8
17 21
22
23,
24
16
18
15
13
12
14
8
30
29
20
19
28
11
10
7
6
9
5
4
3
2
1
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
FIGURE 1
F thru J
Orifice construction
BILL OF MATERIALS (F thru J Orifice)
Item Part name Material
1Body ASME SA216 Grade WCB/WCC Carbon steel (HSL-( )6)
ASME SA217 Grade WC6 Chrome Moly steel (HSL-( )8)
2Nozzle ASME SA479 Type 316 Stainless steel
3Drain plug Carbon steel
ASME SA351 Grade CF8M
4Nozzle ring Stainless steel
5Nozzle ring set screw Type 416 Stainless steel
6Disc* Type 422 Stainless steel
7Guide Monel®
ASME SA351 Grade CF8M
8Guide ring Stainless steel
9Guide ring set screw Type 416 Stainless steel
10 Bonnet stud nut ASME SA194 - Class 2H
11 Bonnet stud ASME SA193 Grade B7
12 Spring washers Carbon steel
13 Bonnet ASME SA216 Grade WCB/WCC Carbon steel (HSL-( )6)
ASME SA217 Grade WC6 Chrome Moly steel (HSL-( )8)
14 Spindle Type 416 Stainless steel
15 Adjusting bolt Type 416 Stainless steel
16 Adjusting bolt nut Steel
17 Cap Malleable iron
18 Cap set screw Stainless steel
19 Lever Malleable iron
20 Forked lever Malleable iron
21 Spindle nut Steel
22 Spindle nut cotter pin Steel
23 Cotter pin Steel
24 Forked lever pin Steel
28 Spring Alloy steel (corrosion resistant coating)**
29 Lever pin Steel
30 Cotter pin Steel
Nameplate Stainless steel (not shown)
* Recommended spare part
** May be upgraded to Inconel®X750

3
17
7A
9
10
4
3
6
20
24
26,
27
19
21
18
16
15
17
10
4
9
11
33
32
23
22
28
14
13
7A
7B
12
6
5
3
2
1
25
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
BILL OF MATERIALS (K thru Q Orifice)
Item Part name Material
1Body ASME SA216 Grade WCB/WCC Carbon steel (HSL-( )6)
ASME SA217 Grade WC6 Chrome Moly steel (HSL-( )8)
2Nozzle ASME SA479 Type 316 Stainless steel
3Drain plug Carbon steel
4Nozzle ring ASME SA351 Grade CF8M Stainless steel
5Nozzle ring set screw Type 416 Stainless steel
6Disc insert* Type 422 Stainless steel
7A and B
Disc holder and bushing Monel®/440C Stainless steel
9Disc insert cotter pin* Stainless steel
10 Guide Monel®
11 Guide ring ASME SA351 Grade CF8M Stainless steel
12 Guide ring set screw Type 416 Stainless steel
13 Bonnet stud nut ASME SA194 - Class 2H
14 Bonnet stud ASME SA193 Grade B7
15 Spring washers Carbon steel
16 Bonnet ASME SA216 Grade WCB/WCC Carbon steel (HSL-( )6)
ASME SA217 Grade WC6 Chrome Moly steel (HSL-( )8)
17 Spindle Type 416 Stainless steel
18 Adjusting bolt Type 416 Stainless steel
19 Adjusting bolt nut Steel
20 Cap Malleable iron
21 Cap set screw Stainless steel
22 Lever Malleable iron
23 Forked lever Malleable iron
24 Spindle nut Steel
25 Spindle nut cotter pin Steel
26 Cotter pin Steel
27 Forked lever pin Steel
28 Spring Alloy steel (corrosion resistant coating)
32 Lever pin Steel
33 Cotter pin Steel
Nameplate Stainless steel (not shown)
K thru Q
Orifice construction
FIGURE 2
* Recommended spare part

4
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
CAUTION
Pressure relief valves should never be lifted or
carried using the lifting lever.
WARNING
The protection and safety of equipment, property,
and personnel depends on the proper operation
of the pressure relief valves described in this
manual. All Emerson pressure relief valves
should be kept in proper working condition in
accordance with the manufacturer’s written
instructions. Periodic testing and maintenance by
the user of this equipment is essential for reliable
and safe valve operation.
All installation, maintenance, adjustment, repair
and testing performed on safety valves should be
done by qualified technicians having the necessary
skills and training adequate to perform such work.
All applicable codes and standards, governing
regulations and authorities should be adhered
to when performing pressure relief valve
repair. No repair, assembly, adjustment or
testing performed by other than Emerson or its
authorized assemblers and representatives shall
be covered by the warranty extended by Emerson
to its customers
This manual is provided as a general guide for
the repair and maintenance of the safety valves
described herein. It is not possible to describe all
configurations or variations of such equipment.
The user is advised to contact Emerson or its
authorized assemblers and representatives for
assistance in situations that are not covered
adequately or described in this manual
Before removing a safety valve for maintenance,
ensure that the system pressure has been
depressurized fully. If an isolation block valve is
used, ensure that any trapped fluid between the
block valve and the safety valve is vented safely.
Before disassembling the safety valve, ensure
that the valve has been decontaminated from any
harmful fluids and that it is at a safe temperature
range for handling.
Before installation, the Installation and
Operational Safety Instructions should be read
fully and understood. These Instructions may be
requested from the factory or are available at
Emerson.com.
3 STORAGE
Often, pressure relief valves are received at
the job site months before they actually are
installed. Unless they are stored and protected
properly, their performance may be affected
seriously. Rough handling may damage flanges
or cause misalignment of the valve parts. It is
best to store the valves vertically in a dry place
with a protective covering until they are used.
Special care should be taken to cover the inlet
and discharge flanges.
4 RIGGING AND HANDLING
Pressure relief valves must be handled carefully
and never subjected to sharp impact loads.
While in the shipment case or when uncrated
they should not be bumped or dropped.
5 INSPECTION PRIOR TO INSTALLATION
Safety valves should be inspected visually
before they are installed to ensure that no
damage has occurred during shipment or while
in storage. All protective material, sealing
plugs, and any extraneous material inside
the valve body should be removed. The valve
nameplate and other identifying tags should be
checked to ensure that the particular valve is
being installed at the location for which it was
intended. The seals protecting the spring setting
and ring adjustments should be intact. If seals
are not intact, the valve should be inspected,
tested and new seals installed prior to use.
WARNING
To ensure trouble-free performance, be sure
to clean the inlets and outlets of the valves
thoroughly before installing. All dirt, sediment and
scale in the protected vessel and piping must be
removed completely before installation (foreign
material entering the valve may cause seat
leakage, plugging and valve malfunction).
6 INLET PIPING
Safety valves should be mounted in a vertical
position, directly on the pressure vessel; the
nozzle should have a well-rounded approach
that provides smooth, unobstructed flow
between the vessel and the valve.
A safety valve should never be installed on a
fitting having an inside diameter smaller than
the inlet connection of the valve as restricted
flow can cause faulty valve operation.
Inlet piping (nozzles) must be designed to
withstand the total resultant forces due to the
valve discharging at the maximum accumulated
pressure and the expected piping loads. The
precise nature of the loading and the resulting
stresses will depend on the configuration of the
valve and the discharge piping. This must be
taken into consideration by those responsible
for the installation of the safety valve and
associated vessel or piping.
Determination of the outlet reaction forces is
the responsibility of the designer of the vessel
and/or piping.
Roughhandling may alter the pressure setting,
deform valve parts and affect seat tightness
adversely.
When it is necessary to use a hoist, a sling
should be placed around the valve body and
bonnet in a manner that ensures the valve is in
the vertical position to facilitate installation.
Flange protection should remain in place until
the valve is ready to be installed on the system.
It is essential that the valve inlet, the vessel,
and the line on which the valve is mounted
be cleaned thoroughly of all foreign material.
The inlet connection bolts or studs should
be tightened uniformly to avoid straining or
distorting the valve body.

5
Cap Stud Nut
Test Rod
Cap or
Cap Top
Spindle
Cap Plug
Cap
Plug
Gasket
Additional cap furnished for gagging
purposes only when requested
and ordered by customer.
Cap
Seal
and
Wire
Cotter Pin
Cap Top
Gasket
Dog
Dog
Shaft
Spindle
Adjusting
Bolt
Adjusting
Bolt Nut
Seal and
Wire
Cap Stud
Cap
Spindle Nut
Cap Top
Cap Gasket
Lever
Dog Shaft
Cap
O-ring
Dog
Valve
Spindle
Lever Nut
Lockwasher
Dog Shaft Bearing
Gasket
Cap
Spindle Nut
Cotter Pin
Pin
Forked Lever
Cotter Pin
Pin Cap Set
Screw
Lever
Cap
Test Rod
Threaded Cap
Type A Type B - Threaded Cap
Type E - Packed Lifting Lever
Cap and Test Rod
Type C Type C
Regular Lifting Lever Gagged Construction
Packed Lifting Lever
Type D
Packed Lifting Lever
Type D
(Top View)
Boiler Drum
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
7 DISCHARGE PIPING
Discharge piping should be simple and direct.
Where possible, a short vertical pipe connected
through a long radius elbow discharging directly
into the atmosphere is recommended.
Discharge piping should be designed so as not
to impose any loading on the valve. Excessive
discharge piping may cause seat leakage or
faulty valve operation.
The inside diameter of the discharge pipe must
never be less than the valve outlet.
Valve effluent must discharge to a safe disposal
area.
Valve bodies are provided with pipe thread
openings for drains. These should be connected
to prevent any accumulation of fluid in the
valve body. In addition, it is recommended that
discharge piping also be drained to prevent any
accumulation of fluid.
Care must be observed to ensure that the drains
are directed or piped to a safe disposal area.
8 HYDROSTATIC TESTING OF BOILER
When a hydrostatic test is made on the system,
it is recommended that the testing be performed
before installation of the pressure relief valves
and that blank flanges are used during the test.
In the event the valve has been installed, it is
recommended it be removed and blank flanges
installed for hydrostatic test purposes.
Blank flanges must be removed and the
pressure relief valve installed before the vessel
is placed in service.
In the event the pressure relief valves are left
installed during a hydrostatic test, they must be
gagged to prevent them from opening during
the test, possibly causing damage to the valve
components. When the valves are to be gagged
for a hydrostatic test, gags as shown in Figure 4
should be used but at pressures no greater than
10% above the nameplate set pressure. Use of
a gag will require the removal of the cap and
lifting lever while the gag is in use.
WARNING
While the gag is in place the valve will not open or
provide any over-pressure protection until the gag
is removed.
Test gags should be positioned evenly on the
bonnet and care must be exercised to prevent over
tightening that could damage the spindle and valve
seats. Generally, a test rod that is finger tight will
provide sufficient force to hold the valve closed.
After the hydrostatic test, the test gag must be
removed and replaced with the cap and lifting
lever.
Type C gagged construction
Additional cap furnished for gagging purposes
only when requested and ordered by customer
Cap
Test rod
Discharge
pipe
Drain
Drain
'L'
as short as
possible
Seal wire
Drip pan
Boiler drum
Rounded smooth length
Shortest possible
length, refer to ASME
Boiler Code Section
I, PG-71.2
Fixed support anchored to building structure
NOTE
Allow sufficient space to prevent
bottoming or side binding of the drip
pan on the discharge pipe under
maximum conditions of expansion.
Recommended minimum diameter
½” larger than valve inlet
FIGURE 4FIGURE 3
Safety valve installation

6
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
9 SET PRESSURE TESTING
Although each HSL has been set and tested at
the factory or the certified assembler location,
sometimes it is necessary or desirable to test
the valve prior to installation in order to meet
local jurisdictional requirements. The valve
may be tested either in a steam test facility
with the capacity to over pressure the valve,
or on site by using an in-line test device or by
over-pressuring the boiler on which the valve
will be installed. If the valve will be tested on the
boiler by over-pressuring the system it may be
necessary to gag any other pressure relief valves
mounted on the same boiler.
NOTE
Use of an in-line test device may require dimensional
information specific to the type and size valve being
tested. Contact your local Emerson sales or service
office for this information.
The HSL is designed to open with a sharp
pop at the nameplate set pressure (within the
tolerances shown in Table 1) and remain open,
relieving full capacity at 3% overpressure.
Aspressure decays below the popping pressure,
the valve will remain open until the blowdown
pressure is reached. The valve will then reseat.
When testing a valve on a steam test stand or
on the end user’s boiler without using a in-line
test device, the pressure should be increased
slowly until the valve opens, but no higher than
3% above the nameplate set point of the valve.
Toensure the valve is adjusted accurately at least
two test cycles shall be observed with the valve
opening within the tolerances shown in Table 1.
If the valve opens outside the tolerance shown in
Table 1, or fails to open by 3% over nameplate set
point, the valve may require adjustment.
WARNING
Steam under pressure can be extremely
hazardous to personnel and can cause serious
injuries including burns and scalds from the
high temperatures of the steam. Care should be
taken to protect testing personnel to prevent any
exposure to released steam from the discharge
or spring chamber of the valve. Appropriate safety
equipment, including hearing protection, should be
worn at all times when servicing a steam pressure
relief valve.
TABLE 1 - TORQUE VALUES FOR VALVE ASSEMBLY
Set pressure, psi (MPa) Tolerance - plus or minus from set pressure
≤ 70 (0.5) 2 psi (15 kPa)
> 70 (0.5) and ≤ 300 (2.1) 3% of set pressure
> 300 (2.1) and ≤ 1.000 (7.0) 10 psi (70 kPa)
> 1.000 (7.0) 1% of set pressure
Seat tightness testing
After the set pressure has been determined by
testing and any final adjustments are made,
the valve should be tested to assure it meets
acceptable seat tightness levels. In order
to perform this test it is suggested the test
pressure be raised and held at 93% of set point
and the valve observed for signs of any 'visible
leakage'. This is accomplished most easily by
viewing the discharge flange of the valve from
the side against a dark background in order to
see any steam leakage. In most cases, if the
valve leaks by the seat, this can be remedied by
re-lapping of the seating surfaces of the nozzle
and disc.
10 VALVE ADJUSTMENTS
Set pressure adjustment
Set pressure adjustment should not be
necessary on a new valve but if the valve is
tested and does not test within the required
set point tolerances, it may be necessary to
adjust the spring compression by tightening
the adjusting bolt (see instructions below).
For parts identification see Figure 1 and 2.
Before making any adjustments, reduce the
system pressure under the valve 10% - 20%
below the set pressure stamped on the valve.
This will prevent damage to internal parts and
minimize the chance of an inadvertent valve
opening.
A. Remove the cap and lifting lever device
following the instruction on page 7.
B. Loosen the adjusting bolt nut (16/19).
C. Turn the adjusting bolt (15/18) clockwise to
increase set pressure or counterclockwise
to reduce set pressure.
D. Retighten the adjusting bolt nut (16/19)
following each adjustment.
E. Repeat the testing process to determine
if the valve will open within the tolerance
shown in Table 1 for at least two test cycles.
F. Continue to adjust the valve until it is
observed to open within tolerance for at
least two test cycles.
G. Once the set pressure has been established,
replace the cap and lifting lever device
following the instruction on page 11 and
install a new seal and wire.

7
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
Adjusting the nozzle and guide rings
The HSL pressure relief valve is supplied
with two adjusting rings to allow adjustments
affecting the opening and re-closing properties
of the valve. The nozzle ring (4) and guide
ring
((8) for F thru J orifices and (11) for K thru Q
orifices) adjustments are made at the factory
but resetting in service sometimes is necessary.
Should it be necessary to adjust the rings in
order to change blowdown or reduce valve
simmer, the following steps should be taken:
CAUTION
Should any ring adjustments be made while the
valve is installed on a pressurized vessel, the
valve should be gagged. Care must be exercised
to prevent excessive tightening of the gag that
could damage the valve spindle and valve seats.
However, sufficient force must be applied to the
gag to prevent the valve from lifting.
Whenever either the nozzle ring or the guide ring
is adjusted, a record should be kept of the number
of notches and the direction the ring was moved.
This will make it possible to return to the original
setting in case of an error.
IMPORTANT
Crosby Style HSL valves have the factory ring
settings stamped on the machined surface on
the bonnet, directly under the cap.
Guide ring adjustment
T
he guide ring is the principal blowdown control
ring in the valve. To change the guide ring
position, remove the guide ring set screw (9/12)
and insert a screwdriver to engage one of the
notches. Turning the guide ring to the right
raises it and decreases the blowdown. Turning
the guide ring to the left lowers the ring, thereby
increasing the blowdown. Theguide ring should
never be moved more than ten notches either
way without resetting the valve. After each
adjustment always replace, tighten and seal wire
the guide ring pin, being careful that its point fits
in the notch in the ring, without making contact
with the ring or bearing on top of a tooth.
Nozzle ring adjustment
The nozzle ring adjustment is determined
carefully by factory testing and resetting in
service seldom is necessary. Should it be
necessary, the nozzle ring is adjusted by
removing the nozzle ring set screw (5) and
inserting a screwdriver to engage the ring
notches. Turning the ring to the right raises
and results in a strong 'pop' action that will
increase blowdown. Moving the ring to the
left lowers the ring, decreasing the blowdown
and may result in excessive warn or simmer if
lowered too far.
The range of adjustment of this ring is limited
and it should not be moved more than one
notch at a time from its set position. The valve
performance should be checked after each
adjustment. After each adjustment always
replace, tighten and seal wire the guide ring
pin, being careful that its point fits in the notch
in the ring, without making contact with the ring
or bearing on top of a tooth.
NOTE
It is very important not to allow the valve to pop prior
to reinstalling the nozzle ring set screw.
Marking the new ring settings
If different ring settings are obtained after
testing, re-stamp the valve bonnet with the
new (tested) ring settings.
11 VALVE MAINTENANCE
The functioning and service life of a safety valve
depends primarily upon methods used in its
maintenance. For this reason, the following
maintenance procedures are recommended.
When possible, remove the valve from the
system before dismantling. There should be no
system pressure when a valve is dismantled in
place or removed for shop repair.
Disassembly of cap and lifting lever gear
For parts identification, see Figures 1 and 2.
The cap and lifting lever gear consists of the cap
(17/20), spindle nut (21/25) and spindle nut cotter
pin (22/27), fork assembly [forked lever (20/23),
forked lever pin (24/27) and cotter pin (23/26)]
and the lever assembly [lever (19/22), lever pin
(29/32) and cotter pin (23/26)]. The cap cannot
be removed from the safety valve without first
removing the fork assembly which is seal wired
to prevent tampering with the adjusting bolt.
To disassemble the cap and lifting lever gear,
proceed as follows:
A. Remove the fork pin cotter pin (23/26), forked
lever pin (24/27) and forked lever (20/23).
B. Loosen the two cap screws (18/30) and
remove the cap (17/25) and lever assembly.
C. Remove the spindle nut cotter pin (22/27)
and unscrew the spindle nut (21/25) off the
spindle (14/17).
To complete disassembly of the valve proceed
as follows:
A. Remove the nozzle ring set screw. Check
the nozzle ring setting by turning the nozzle
ring to the right and counting the number of
notches turned until it makes contact with
the disc. Record the number of notches.
This location is given as minus (-) notches
from this contact position.
Remove the guide ring set screw. Check
the guide ring setting by returning the guide
ring to its level position. The guide ring is in
level position when the bottom face of the
guide ring is level with bottom face of the
disc. The guide ring position is recorded as
minus (-)(down) or plus (+) (up) notches from
this level position.
B. Before releasing the spring load, measure
and make note of the height of the adjusting
bolt over the top of the bonnet. This
information will help when reassembling
the valve to its approximate original setting.
C. Loosen the adjusting bolt nut. Count the
number of turns required to remove the
spring load by rotating the adjusting bolt in
a counterclockwise direction.
D. Loosen and remove bonnet stud nuts.
E. Lift the bonnet straight up carefully to clear
the spindle and valve spring. Exercise care
when lifting the bonnet as the spring and
spindle will then be free to fall aside.
F. Lift the spring and spring washers off the
spindle. The spring and spring washers are
fitted together and must be kept together
as a subassembly. Spring washers are not
interchangeable between ends of the spring.
G. The disc holder assembly or disc and
spindle can now be removed from the valve
body by lifting the spindle.

8
T
B.001
-B-
.001
A.001 TIR
T
B.001
/ / -B- .001
.001
1.5°
3°
45°
F -3( ), -4( ) 3.826 97.181
G -3( ), -4( ) 3.807 96.703
H -3( ), -4( ) 4.160 105.664
J -3( ), -4( ) 4.230 107.442
K -3( ), -4( ) 4.762 120.955
L -3( ), -4( ) 5.153 130.892
M -3( ), -4( ) 5.934 150.724
N -3( ) 5.807 147.496
N -4( ) 6.240 158.496
P -3( ) 6.039 153.391
P -4( ) 6.275 159.385
Q -3( ) 8.082 205.283
Q -4( ) 8.515 216.281
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
Minimum face-to-seat
dimension,
see Table 2
.014 0.356
.010 0.254 Mach.
.004 [.102] Min.
after lapping
.014 0.356
.010 0.254 Mach.
.008 [.203] Min.
after lapping
FIGURE 5
TABLE 2 - MINIMUM NOZZLE FACE TO SEAT
DIMENSIONS
Orifice and series
Dimensions
NPS DN
H. Remove the guide and guide ring from the
body as an assembly and unscrew the guide
ring from the guide.
I. If the valve has a 2-piece disc holder,
remove the disc insert cotter pin and the
disc insert from the disc holder assembly.
J. Remove the spindle from the disc holder
assembly or disc by pulling up on the
spindle rod to engage the spindle point
threads in the disc holder. Turn the spindle
counterclockwise while holding the disc/
holder still and remove the spindle rod.
K. Unscrew the nozzle ring from the nozzle.
L. Unscrew the nozzle from the body (the
Crosby Style HSL utilizes a removable full
nozzle design).
Inspection and refurbishment
All the parts should be cleaned thoroughly.
Guiding surfaces may be polished using a fine
emery cloth. All parts should be examined to
determine their condition. Inspection of valve
components is important to ensure proper valve
performance.
Measure the nozzle height using Table 2 and
Figure 5. If the nozzle measures below the
minimum dimension it should be replaced. Discs
and disc inserts should be measured using
Table 3 and Figure 8. Parts not meeting these
dimensions should be replaced.
Spindles should be inspected to ensure they are
straight using the TIR values found in Table 4.
Use either V-blocks or chuck the spindle into a
lathe and dial indicate to check for straightness.
If necessary, the spindle may be straightened
by applying force to the spindle until within
tolerances. If it is not possible to straighten a
bent spindle, it should be replaced.
Lapping valve nozzles and disc inserts
Good seating surfaces on the nozzle and disc
insert are necessary for the valve to seal tightly
when the valve is in the closed position. TheHSL
is a metal seated valve and the sealing surfaces
of the nozzle and insert may be lapped to ensure
a flat surface free from scratches and other
imperfections. The sealing surface of the nozzle
may be machined to remove deeper scratches
or damage to the nozzle as long as the nozzle
height exceeds the minimum dimensions (after
machining) as shown in Table 2.
In the following sections you find information
on lapping techniques, tools and materials.
Lapping blocks are made of a special grade of
annealed cast iron (see Figure 6). There is a
block for each orifice size. Each block has two
perfectly flat working sides and it is essential
that they retain this high degree of flatness to
produce a truly flat seating surface on the disc,
or disc insert and/or the nozzle.
Before a lapping block is used, it should be
checked for flatness and reconditioned after
use on a lapping block resurfacing plate. The
block should be lapped in a figure eight motion,
applying uniform pressure while rotating the
lapping block against the plate as shown in
Figure 7.
Lapping blocks and lapping block resurfacing
plates are available from Emerson sales,
service and distribution centers.
Experience has proven that medium coarse,
medium, fine and polish lapping compounds
will condition any damaged safety valve seat
properly except where the damage requires
machining.
The following lapping compounds, or their
commercial equivalents are suggested:
LAPPING COMPOUNDS TABLE
Grit compound no. Description
320 Medium coarse
400 Medium
600 Fine
900 Polish

9
F.002 .051
G.002 .051
H.002 .051
J.003 .076
K.003 .076
L.002 .151
M.003 .076
N.003 .076
P.003 .076
Q.005 .127
F.002 .051
G.003 .076
H.003 .076
J.004 .102
K.005 .127
L.006 .152
M.007 .178
N.008 .203
P.009 .229
Q.012 .305
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
FIGURE 7 Top lapping surface
Motion shownby
dotted line
Lapping block to
be squared up
Bottom rough
surface do not use
FIGURE 6
Lapping block resurfacing plate
Lapping block
TABLE 3 - 'B' DIMENSION
Dimensions
Orifice NPS DN
TABLE 4 - SPINDLE CONCENTRICITY (TIR) – DIMENSION
Dimensions
Orifice NPS DN
Lapping procedure
Unless the seats have been damaged badly
by dirt or scale, lapping the seating surfaces
should restore them to their original condition.
Never lap the disc insert or disc against the
nozzle.
Lap each part separately against a cast iron
lapping block of the proper size. These blocks
hold the lapping compound in surface pores
and must be reconditioned frequently. Lap the
block against the seat. Never rotate the block
continuously, but use an oscillating movement.
Extreme care should be taken throughout to
make certain the seats are kept perfectly flat.
A. If considerable lapping is required, spread
a thin coat of medium coarse lapping
compound on the block.
B. After lapping with this compound, lap again
with a medium grade compound. The first
step can be omitted unless much lapping is
needed.
C. Lap again using a fine grade compound.
D.
When all nicks and marks have disappeared,
remove all compound from the block and seat.
E. Apply polish compound to another block and
lap the seat.
F. As the lapping nears completion, only the
compound left in the pores of the block
should be present. This should provide a
very smooth finish. If scratches appear, the
cause is probably dirty lapping compound.
These scratches should be removed by
using compound free of foreign material.
Discs and disc inserts should be lapped in the
same way as nozzles. The disc insert must be
removed from the holder before to lapping.
Machining nozzle seats
If machining of the nozzle seat or other major
repairs is necessary, it is recommended that
the valve be returned to a Emerson authorized
facility for repair. All parts must be machined
accurately per Emerson specifications. No
pressure relief valve will be tight, nor will it
operate properly unless all parts are machined
correctly.
The most satisfactory way to machine a nozzle
is to remove it from the body. However, it may
also be machined while assembled within the
valve body. In any event it is vitally important
that the seating surfaces run absolutely true
and the original nozzle profile is re-established
as shown in Figure 5. Machining dimensions for
Crosby Style HSL valves are shown in Table 2
and Figure 5. Remove only enough metal to
restore the surface to its original condition.
Turning to the smoothest possible finish will
facilitate lapping. After machining, measure
the nozzle height to ensure it still exceeds the
minimum dimension from Table 2 and then lap
the nozzle seat before re-installation into the
valve body. The nozzle must be replaced when
the minimum face to seat dimension is reached.
Before the disc insert is placed back in the
holder all foreign material should be removed
from both parts. The insert must be free when
in the holder. If the disc insert is damaged too
badly to be reconditioned by lapping, it should
be replaced. Remachining the insert will
change critical dimensions, affecting the action
of the valve and is not recommended.

10
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
Refurbishing discs and disc inserts
When the damage to the disc or disc insert
seat is too severe to be removed by lapping,
the disc or disc insert should be replaced.
Re-machining of the disc or disc insert seat
is not recommended. The disc or disc insert
seating surface may be lapped provided that the
minimum overall disc height shown in Figure 8
is maintained.
Valve assembly
All components should be clean. Before
assembling the following parts, lubricate with
pure nickel 'Never-Seez' or equivalent.
• Nozzle and body threads
• Nozzle and body sealing surfaces
• All stud and nut threads
• Spindle bearing surfaces and threads
• Set screw threads
• Spring washer bevels
• Adjusting bolt and bonnet threads
For parts identification, refer to Figures 1 and 2.
A. Before installing the nozzle, lubricate the
flange surface in contact with the valve body
and on the nozzle threads. Then screw the
nozzle into the valve body and tighten until
the nozzle flange is seated fully against the
valve body.
B. Screw the nozzle ring onto the nozzle.
Note: the top of the nozzle ring should be
approximately one ring revolution above the
nozzle seating surface.
C. Thread the spindle assembly into the disc
holder or disc. Turn the spindle until it drops
off the internal threads and contact is made
between the spindle ball and the disc or disc
holder bushing.
Note: If spindle does not thread into disc, check
the design version number in the model number
for compatibility. Do not force the spindle to thread
into the disc. Reference Valve Design Version and
Interchangeability Section for more detail on the
design version numbers, and contact Emerson to
get the correct disc and spindle.
H. Place the spring and washers assembly
onto the spindle. Lower the bonnet over the
spindle and spring, onto the bonnet studs
in the body. In closed bonnet valves, the
bonnet vent should be aligned with the valve
outlet. Position the bonnet counter bore on
the OD of the guide and lower the bonnet
onto the guide.
I. Screw the bonnet stud nuts onto the
bonnet studs and tighten down evenly to
prevent unnecessary strain and possible
misalignment.
J.
Lift the disc insert slightly by lifting the
spindle rod. Lower the nozzle ring below the
seats. Release the spindle slowly to permit
the disc insert to contact the nozzle seat
gently. Check that the nozzle ring moves
freely.
K. Screw the adjusting bolt and nut into the
top of the bonnet the same number of
turns originally required to remove the
spring load. The original set pressure can
be approximated by screwing the adjusting
bolt down to the height above the bonnet
measured during disassembly.
L. Move the nozzle ring up until it touches
the d
isc holder. From this position lower it
to the original recorded position. Move the
guide ring until the bottom of the guide ring
is at the same level as the bottom face of
the disc or disc holder assembly. If the guide
ring position originally recorded is a positive
number, raise the guide ring by the number
of notches indicated. If a negative number,
lower the ring that number of notches. Rings
are moved up by turning them to the right
and lowered by turning them to the left.
M. Screw the set screws into the body,
engaging both the nozzle ring and the guide
ring. Both rings should move back and forth
slightly after the set screw is tightened.
N. The valve is now ready for testing per
test procedure T-16758. After testing, the
following steps should be taken:
1. Be sure that adjusting bolt nut is locked.
2. Install the cap assembly (see overleaf).
3. Seal wire the cap and set screws to
prevent tampering.
For test/adjustment procedures refer to page 6.
'B' min. after lapping
F thru J orifice disc K thru Q orifice disc insert
'B' min.
afterlapping
FIGURE 8
See Table 3
See Table 3
D. If the valve has a 2 piece disc design, place
the disc insert into the disc holder. Turn the
insert until the alignment is achieved between
the hole in the button end of the insert and
the hole in the bottom end of the holder.
Insert disc insert cotter pin to hold in place.
E. Thread the guide ring onto the guide.
F. Install the guide and guide ring assembly
i
nto the top of the body. The guide of valve
should be seated directly on the top surface
of the valve body. Maintain proper alignment
between the guide and the body to ensure
that the guide is seated correctly in the body.
G. Lower the spindle and disc or disc holder
assembly into the guide and onto the nozzle.

11
CROSBY STYLE HSL SAFETY VALVES
INSTALLATION, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS
Assembly of the lifting lever cap
The assembly of the cap is referred to several
times in this instruction. The cap and lifting
lever gear consists of the cap, spindle nut and
spindle nut cotter pin, fork assembly: forked
lever, forked lever pin and cotter pin, and the
lever assembly: lever, lever pin and cotter pin.
The cap cannot be removed from the safety
valve without first removing the fork assembly,
which is seal wired to prevent tampering with
the compression screw. To assemble the cap
and lifting lever gear, proceed as follows:
A. Screw the spindle nut onto the spindle.
B. Place the cap on the bonnet.
C. Install the forked lever and forked lever pin.
D. Attach the lever to the cap using the lever
pin and secure the lever pin with the lever
pin cotter
.
E. Adjust the spindle nut until the forked lever
rests on the lever and there is a
1
/
16 inch
(1.6mm) minimum of play between the
forked lever and the spindle nut. The spindle
nut is adjusted by removing the fork pin,
forked lever and cap. When the spindle nut
is in proper adjustment, install the spindle
nut cotter pin.
F. Replace the cap and forked lever and install
the forked lever pin and fork pin cotter
.
G. Position the lever opposite the valve outlet;
install the two cap set screws and tighten
them against the groove in the top of the
bonnet.
Sealing and name plating a repaired valve
After the valve has passed the set pressure and
seat tightness test successfully, the externally
adjustable elements of the valve should be
sealed, typically with sealing wire and a lead
seal. For HSL valves, the guide and nozzle ring
adjustment screws should be seal wired as
well as the cap. This will prevent unauthorized
personnel from making adjustments to the
valve after it has been serviced. This also will
provide identification of the repair organization
who last serviced the valve.
It is customary and prudent to attach a repair
nameplate to the valve after servicing to
serve as a record of when service has been
performed to the valve. Most repair certification
programs, such as the NBBI 'VR' program,
provide specific minimum requirements for
their program and guidelines for use of their
certification mark.
At minimum, it is best practice for the repair
nameplate to provide:
1. The name of the repair company
2. The date of the repair
3. The set point at which the valve was tested
4. A unique number to enable traceability of
the repair
NOTE
The original nameplate affixed to the valve when
first built should never be removed from the valve.
The repair nameplate (or any other informational
nameplates) should be attached in addition to the
original nameplate not in place of the original.
11 VALVE DESIGN VERSION AND
INTERCHANGEABILITY
The design version number is used to
distinguish specific versions of the HSL valve
design where the updated parts are not
interchangeable with the previous version. The
design version number is needed for reference
when ordering spare parts and servicing the
valve. If the design version does not match the
current design version, new spare parts may
not be compatible in the valve and the valve
may need to be upgraded to the new version.
The design version number will be at the end of
the model number, and any model number with
no design version number will be considered
"-01".
Reference Table 5 for current version of HSL
design.
TABLE 5 - DESIGN VERSION TABLE
Pressure Class
Orifice
F G H J K L M N P QQ
300# 02 02 02 02 01 01 01 01 01 01
600# 02 02 02 02 01 01 01 01 01 01
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