Farris Engineering 1800 Series User manual

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1
TABLE OF CONTENTS 1. Introduction
Topic This manualcovers the Series 1800 line of
PressureReliefValveswhich encompasses differ-
entmodel types ofsimilardesign. Itcontains suffi-
cientinformationto allowtrained maintenance per-
sonnelto properly repairvalvetypes 1850, 1850H,
1852, 1852H, 1855, 1856M, 1890, 1892, 1895
and 1896M.
1. Introduction
,Page
1
2. Disassembly
Series1850, 1852, 1855and 1856M
.page
2
All of the assembly and disassembly instructions
refer to types with plain screwed caps. When
repairing types with either open or packed lifting
levers refer to Section 3 which describes the
removal of the appropriate lever assembly.
Series 1890,1892,1895 and 1896M
.Page
3
3. Lifting Lever Assemblies
Open Ufting Lever
.Page
4
Packed LiftingLever Page4 Ifa valverepairrequires replacementparts, only
factory supplied components shallbe used. Use of
parts from other than the originalmanufacturer is
not recommended because itwill leadto potentially
dangerousoperating conditions. Iffaced with
repairsexceedingthe scope ofthismanual, we
suggestyou contact the FarrisFactory.
.Page
5
4. Lapping Procedure.
5. Assembly
Series 1850,1852,1855 and 1856M
.Page
6
Series1890,1892,1895 and 1896M
,Page
6
6. Testingand Setting
.Page
7
...,~ TELEDYNE FLUID SYSTEMS
Fams Engineering
Appendix A: Critical SeatDimensions Page 8
400 COMMERCIALAVENUE
PALISADESPARK, NEWJERSEY07650
PHONE[phone]
FAX[phone]
PRESSURERELIEFVALVES
ANDTESTINGEQUIPMENT
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2
Fig.2.2
1855 _6
c--14
-3
-4_1
_6
_15
-10
-3---4
Series 1850. 1852.1855 and 1856M (Fig. 2.1-2.3)
Mount valveverticallyin a vise utilizingthe flats in
the body.
2. Remove wire seal. Unscrew cap by turning
counterclockwise. Remove cap gasket. (For
open lever and packed lever cap construction,
referto the section on LiftingLeverAssemblies. Fig.2.3
1856M
3. Measure the distance from the top of the spring
adjusting screw to the top of the bonnet. Use
this measurementwhen reassemblingthe valve
to approximately duplicate the original set pres-
sure.
Bill of Materials
4. Using a smooth jaw wrench hold the spring
adjusting screw on wrench flats and loosen the
jam nut.
SA-4791Ype
31681 81.
Or
SA-3S1.Gr
Cf8M 51. 51.
ASTM816
HH 8rass~
Body OrASTM B62Bronze
SA-216 G( I SA-351 G( ~MA126
2 Bonnet Y«:BCarb.51 CFBM51.51 I CISCastIron
3 Disc 3165151
51.51
ASTMB16
HH.Brass
Or
ASTMB62
Bronze
ASJM862,
Bronze
5. Relieve the spring compression by turning the
spring adjusting screw counterclockwise. 3165t51 Brass
Brass
Iron
St St
Brass
Brass
Brass
:. I 316St St
-~~~! 316StSt Blass
Bronze
Brass
Brass
Brass
~ BIow riI7N!, Ring
5 Cap
6s.m ! 3165151
6. Thread a pipe into the outletand turn the bonnet
counterclockwise. Uft the bonnet out to expose
internalsub-assembly.
I 7 ISpringAdjScrewi ~ St.St 131651 51
~
I 31651.51. ICarbon51.
f:g316 51. 51. AuSI Proofed 51. 51.Carbon 51.
Ausr PrOOled 51. 51
Flexible
GraDhile
7. Remove the upper spring button, spring and
lower spring button from thestem. Flexible
Graphite Flexible Graphite
31651.51
31651.51
3165151
;;;
8a. (1850, 1852, 1856M open lever, 1856M
packed lever only) Lift the stem with stem
retainer, lockwasher and disc attached.
Unscrew the stem retainer from the disc.
Removelockwasher.
51 51
117 INameplate
(notshfNIn)
18 ISDrin-;;-
-~ I
I -I
Stainless51..1WOe/leadSeal
StainlessSleel
LapJointStub I$A-403,G;T":SA:403 Gr.
Endilnlet) WP316SI-StI WP316St SI
8b. (1855 only)Liftthe stem with the disc attached.
Removethe groove pin. Liftthe stem from the
disc.
SA-234 I SA 403 Gr.
Carbon SI. WP316 SI. SI.
N
0 !LapJointStub
T~nd(Outlet)
E LapJointflange ISA-181or TSA-182Gr
(Inlet) SA-105CarbStf316St St
1IUPJointflange ~
~ (Outletl F316S~
NOTE:1 ApplicabletotheF1850Series(lianged)
SA.181or
ISA.105CarbSt
Sc. (1856M plain cap only) Liftthe stem from the
disc. Removethe disc.
9. Unscrewthe blowdown ringfrom the body.
10. Clean all parts and threaded surfaces thor-
oughly. Replace all gaskets. Lap the body
seat and disc surfaces. (See the section on
Lappingfor details.)
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Farris Engineering
When a valve is first received in the shop it should
be given a visual inspection to note its condition
when removed from service. The valveshould then
be carefullydismantled. Proper facilities and tools
should be available. At each stage Inthe dismao-:
tling process, visually inspect all parts of the valve
for evidence of wear and corrosion. If parts are
worn, replacethem.
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Series 1890. 1892. 1895 and 1896M (Fig. 2.4)
1. Mount valveverticallyin a vise utilizingthe flats in
the body.
2. Remove wire seal. Unscrew cap by turning
counterclockwise. Remove cap gasket. (For
open lever and packed lever cap construction,
referto the section on LiftingLeverAssemblies.)
3. Measurethe distance from the top of the spring
adjusting screw to the top of the bonnet. Use
this measurementwhen reassemblingthe valve
to approximately duplicate the original set pres-
sure.
Bill of Materials
4. Using a smooth jaw wrench hold the spring
adjusting screw on wrench flats and loosen the
jam nut.
SA.479Type I SA-419 Type
316 St. 51 316 51. 51.
5. Relieve the spring compression by turning the
spring adjusting screw counterclockwise. 316St SI I 316SI. St
316SI. St.StSt.
CaIIIonSt.
St.St.
St 51
1 I!Orjy ",," ,
2 Bonnet ~~~-, ~~
3 ~ c
4 Glide StSt.
5 ~, Plain~ CaIIIonSt.
6 Sf8m St.St.
7 Sprilg Adj.Screw St.St.
8 SpIi1OBIIt1On ..-c
9 JamNut St St
10 SmmShOtJkIer St St
11BodyGasket =~
12 CapGasI<et =I:e
13 LiftSlopRing St St
14 RelainmgRing- St St
StemSOOWder .
15 WireSeal
16 Namepmm
(notshown)
17 Spring
lapJointStubEnd
N (In~)
0 LapJamtStubEnd ~234
T (OUllet) CarbonSt
E LapJoHrtRange ~181 or~105
(Inlet) CarbonSteel
1lap JointFlange ~181 QrSA-105
(O.l1et) CarbQrJSt
6. Thread a pipe into the outletand turn the bonnet
counterclockwise. Liftthe bonnet out to expose
intemalsub-assembly.
7. Uft the stem with spring and buttons attached.
Remove upper spring button, spring and lower
springbutton.
8. Removethe liftstop ring.
9. By invertingthe assembly, remove the disc from
theguide.
~. Gr SA-4O3Gr
WP31651 51 WP3165t St.
SA-403Gr
WP316St.St.
SA-182Gr.
F316St 5t.
SA-152Gr.
F3165t. 5t.
NOTAVAILABLE
10. Unscrew the guide from the valve body.
Removebody gasket. GeneralNoles:
1 ItemsnotshownareapplicabletotheF 1890Series(Flanged).
11. Cleanallparts and threaded surfaces thorough-
ly. Replaceallgaskets. Lap the body seatand
disc surfaces. (Seethe section on Lapping for
details.)
ValveNo.
1890
1892
1890/84
1892/84
1895
1896M
Spring Material
Stainless
SteelHigh
Temp. Alloy, Rust Proofed
316 Stainless SteelHigh
Temp. Alloy, Nickel Pltd.Stainless
SteelStainless
Steel
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B. PACKED LIFTING LEVER
There are several designs of packed cap constructions.
Referto the appropriate section belowfor your particularcap
construction.
(a)Fig. 3.2
1.Remove groove pinfrom leverand slide leveroffthe cam
2. Remove gland from gland nut. Unscrew gland nut from
bonnet and remove packing ring and cam. Ifany signs of
leakageexist, replacepackingring.
3. Break wire seal and unscrew cap from bonnet. Holding
the stem with pliers, remove stem jam nut and stem test
washer.
4. Reassemble in reverse order making sure the cam lobe is
pointing down. The stem test washer should be adjusted
to ensure the cam will make contact with the stem test
washer and liftthe stem when the lever isactuated.
(b) Fig. 3.3
1.Remove groove pin from leverand slide lever offthe cam shaft.
2. Complete disassembly is only required if the packing ring is
to be replaced or intemal inspection is required. To remove
assembly, rotate the leve, down and unscrew the cap.
3. To complete disassembly, remove the gland packing ring
and retaining ring.
4. Pull the cam shaft from the cap. The cam can then be
removed through the bottom of the cap.
5. Remove the stem jam nut and stem test washer.
6. Reassemble in reverse order making sure the cam rests
beneath the stem test washer.
(c) Fig. 3.4
1. Remove lever jam nut and washer. Slide lever off the cam
shaft.
2. Follow steps 2 to 6 in section (b).
STEil JAIl NUT
STEil TEST WASNER
CAIISHArT
STEIl
GlAND
CRDDV-PlN
PACKINGRING
CLAND NUT
TEST LEYER
BONNET
SPRING ADJUSTING SCREW
SEAL
CAP
CAP GASKET Figure 3.2 Packed Lifting Lever (a)
STEMTEST-.sHEW
CAMmu
ST[W JAW WUT
!T[W ftST WASHER
CAP
CAW~
STEW
CAPCASK£T111 i
~NN£T ./
CAPGAS«[T---:'"~ i !-
_MET/" .
rm l£VtR \Q)
Figure 3.4 Packed Lifting Lever (c)
TESTl£VER~
Figure 3.3 Packed Lifting Lever (b)
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Farris Engineering
A. OPEN LIFTING LEVER (Fig. 3.1)
1. Remove wire seal and cotter pin. Slide out button head
rivet to release lever from cap.
2. Remove set screw from base of cap and liftcap off bonnet.
3. Remove stem jam nut and stem test washer from the stem.
4. Clean all parts and reassemble in reverse order. Adjust
stem test washer so there is 1/8" clearance between test
lever fulcrum and stem test washer.
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4. Lapping Procedure
(For metal seats only; does not apply to a-ring seat seal valve)
1. The finish on the body seat and disc are critical to seat
tightness. After the parts have been cleaned both parts
should be lapped to remove all blemishes and score
marks. This can be done on an automatic lapping
machine or by hand using a cast iron lapping block or
Pyrex lapping glass which is known to have a perfectly
flatsurface.
that has been lapped off from the body seat in order to
maintainthe critical parts respectiverelationship.
5b. (1890/95/96M only) Remove the same thickness of
material from the bottom face of the guide as that has
been lapped offfrom the body seat.
PYREX LAPPING PLATES:
PARTNO. MAT.CODE SIZE THICKNESS 6. Carefullyclean compound from allparts. Failureto do so
may foul the seat and disc surfaces. When reinstalling
the parts in the valveand/or in assembling the disc in the
guide, becareful notto scratch or score either surface.
7688
7689 164
164 1-1;2'
2-1f4- 1;4"
%"
7. Check Appendix A for critical seat dimensions. Replace
any parts that havedimensions smallerthan the minimum
required.
2. Use Farris 1200 lapping compound. When lapping the
disc, operate with a light figure eight motion over entire
block surface. Inthis way complete contact will be made.
With this motion the complete surface of the part will be
evenly lapped and you will avoid wearing a groove in the
block.
3. Lap the disc until all blemishes and score marks have
been removed. As the figure eight motion is executed,
frequently liftthe disc away from the block to get a fresh
bite on thecompound. Mostimportantly, do not contam-
inatecompounds with dirt. Store lapping blocks and lap-
ping glass in aclean, dust-free area.
4. Measure and record the body seat height. Follow the
same procedure for lappingthe body seat. When lapping
bodies the body can be placed on a table and a lapping
block placed on the body. Be sure thatthe lapping block
does not tip over the side ofthe body (whichwould cause
rounding of the edges). Use a light, rapid figure eight
stroke, liftingthe block from the body occasionally.
5a. (1850/55/56M only) Remove the same thickness of
material from the bottom face of the blowdown ring as
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6
Series 1890. 1892. 1895 AND 1896
1. Refer to Figure 2.4 for construction details.
2. Visually inspect all parts to be assembled. Replace
gaskets, a-rings, and any parts that are worn.
Lubricate allthreaded and mating surfaces with Bostik
Never Seez(orequivalent).
2. Visually inspect all parts to be assembled. Replace
all gaskets. Lubricate all threaded and mating sur-
faces with Bostik Never Seez ( or equivalent.).
3. Examineseat of body and disc for any marks that may
cause leakage. Refer to the section on lapping if
relappingis necessary.
3. Examine seat of body and disCfor any marks or sur-
face imperfections that may neduce seat tightness.
Ifrelapping is necessary, refer to the section on lap-
.I
ping. !
4. (O-ring Seat Only) Refer to Fig. 5.1. Position the
disc on a flat surface with the O-ring groove facing
up. Insert O-ring into the disc groove. Insert the
O-ring retainer on the disc, ensuring the O-ring is
centered. Lock the O-ring and retainer to the disk
with the hex nut.
4a.(Metal Seat Only) Loosely assemble body and
guide. Insert disc in guide and verify that guide
turndown from disc contact is 1/16 to 1/4 turn.
For set pressure under 100: PSIG, 1/8 turndown
maximum isrequired. Remo~e disc.
4b.(O-Ring Seat Only) It is ~ecommended that
O-ring/disc sub-assembly be replaoed rather than
attempt removal of retainin~ ring. Do not use a
metal seat guide in O-ring se~t sealvalves.
5. Tightenthe blowdown ringto the body.
6a. (1850, 1852, 1856M open leverand 1856M packed
lever only) Place stem retainer over stem. Screw
stem retainerto disc.
5. Tighten guide to body with 11/4"dia. bar inserted
through guide exit holes with qpproximate torque of
20 ft. Ibs.
6. Insert disc and install liftstop.
disc liftis greater than .085". Verify that available
6b. (1855 only) Place stem into the disc. Drive groove pin
through the disc into the stem.
6c. (1856M Plain cap only) Insert retaining ring into the
stem groove. Place stem into disc.
7. Place disc- stem assembly over the body, making sure
that the disc and body seats are aligned. 7. Place stem shoulder over retaining ring. Install
spring and spring buttons on $tem and insert entire
assembly into bonnet/spring ~djusting screw sub-
assembly. The lower sub-a~sembly with bonnet
gasket can then be assembled and tightened to
approximately 40 ft. Ibs. torque.
8. Install lower spring button, spring and upper spring
button onstem.
9. Place bonnet over the assembled parts and screw
down onto the body.
8. Hand tighten adjusting screw until slight spring
compression occurs.
10. Thread the jam nut onto the spring adjusting screw.
11.Thread spring adjusting screw into bonnet to the posi-
tion recorded during disassembly.
12.The valve is now ready to be removed for testing.
Fig.5.1 1850Series O-Ring SeatConstruction Fig. 5.2 1890 Series O-Ring Seat Construction
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Series 1850. 1852. 1855AND 1856M
1. Referto Figures2..1-2.3 for construction details.
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WATER -Before starting the seat tightness test, the outlet
body bowl shall be filled with water, and the valve shall be
allowed to stabilize with no visible flow from the valve outlet.
The valve shall be observed for "1minute at the test pressure.
There shall be NO VISIBLE LEAKAGE at the valve outlet.
Soft Seated Valves
Soft seated valves shall be tested at 95% of set pressure
when set above 100 psig; they shall be tested at 5 psig
below set pressure when the set pressure is less than or
equal to 100 psig.
8l8: There shall be NO LEAKAGE (ZERO BUBBLES) using
the test method outlined above.
STEAMgng WATER: There shall be NO VISIBLE LEAKAGE
at the valve outlet.
2. If any valve fails to meet leakage requirements it shall be
reworked.
3. Assemble appropriate CAP CONSTRUCTION after leak
tightness has been verified. Ifvalve type is OPEN LEVER,
no back pressure test is required. PLAIN CAP and
PACKED LEVER valves must be back pressure tested as
outlined in the next section.
BACK PRESSURE TEST
1. This test applies to all valves designed for discharge to a
closed system (PLAIN or PACKED LEVER CAP CON-
STRUCTION) with inlet sizes larger than 1"NPS.
2. The secondary pressure zone of the valve shall be tested
with air or other suitable gas at a pressure of at least 30
psi. The valve should be pressurized at the outlet with
shop air or other means. A soap solution or other suitable
solution shall be applied to all connections which are
potential leakage paths (i.e., body/bonnet connection,
cap/bonnet connection, packed lever assembly/cap con-
nection). No leakage is acceptable.
3. If leakage is detected at any location the valve shall be
reworked.
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TESTING AND SETTING PROCEDURE:
1. Mount the valve on the test stand. Use air as the test
medium for air, gas and vapor or flashing service appli-
cations. Set valves for saturated steam service on satu-
rated steam. Valves for steam service set with air
should include temperature compensation. The name-
plate provides "Cold Differential Set Pressure." Set
valves for liquid service onwater.
2. Hold the STEM tightly and tighten (turn clockwise) the
SPRING ADJUSTING SCREW to increase the spring
force. Make sure the stem does not rotate while load-
ing the SPRING.
3. Slowly raise the test drum pressure and observe the
opening point. The set pressure on air or steam is the
"pop point" while on water it isthe firstcontinuous flow.
4. If necessary reduce the test drum pressure and adjust
the SPRING ADJUSTING SCREW. Repeat this until the
valve opens at the required pressure, designated as
"Cold Differential Set Pressure." At the desired setting,
torque the JAM NUT to 25 FT.LBS. and assemble CAP
and GASKET for tightness testing. Check set point once
more after locking JAM NUT.
NEVER ADJUST THE SPRING SETTING WHEN THE
PRESSURE UNDER "THEVALVE IS NEAR ITS POPPING
POINT; AS THE BODY SEAT AND DISC SEAT MIGHT
SCORE AND/OR GALL. ALWAYS LOWER THE PRES-
SURE IN THE VALVEAT LEAST 25 PERCENT BELOW
POPPING PRESSURE BEFORE MAKING ADJUST-
MENTS. THIS WILLPUT A LOADING ON THE SEATfNG
SURFACES, THUS PREVENTINGROTATION AND DAM-
AGE. SEATTIGHTNESSTESTING
SEATTIGHTNESS TESTING
NOTE: The valve must be checked for seatleakageafterthe
set pressure has been checked. Excessive leakage could
lead to fouled or inoperablevalves, serious product loss and
could be hazardousto personneland equipment.
1. The valvecan betested for tightness on the test stand by
increasing vessel pressure to the required test pressure
and observing the valve outlet for evidence of leakage.
The following is an overviewofthe test procedures used.
Metal Seated Valves:
Metal seated valves shall be tested at 90% of set pressure
when the set pressure is greater than 50 psig; they shall be
tested at 5 psig below set pressurewhen the set pressureis
lessthan or equalto 50psig.
A!B -A 5/16' 0.0. x 0.035' wall thickness copper tube or
equivalentimmersed no more than 1/2" deep in water shall
be connected to the valve outlet. See Figure6.1. Seal all
other potential leakage paths with suitable fixtures (i.e.,cap,
plugs) so that seat leakage can be detected at the outlet.
Before starting the bubble count, test pressure shall be
applied for a minimum of 1 minute. The valve shallthen be
observed for leakagefor at least1minute. The leakagerate
shall notexceed 40 bubbles perminute.
STEAM -Test pressure shallbe applied for 3 minutes before
the seattightnesstest. The valveshallbe observed for leak-
age for at least1 minute. There shall be NO VISIBLE LEAK-
AGE atthe valveoutlet.
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8
CHAMFER .005 X 45"
~
L:=
MIRRORFINISH
,
MIN.
Body #1 Body #2
I ,040 MIN,
.MIRROR FINISH
CHAMFER ,010 X 45'
DiSC 1*1
~~ TELEDYNE IFLUIDSYSTEMS
Farris Engineering
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TELEDYNE FLUID SYSTEMS
Farris Engineering
400 COMMERCIAL AVENUE
PALISADES PARK, NEW JERSEY 07650
PHONE [phone]
FAX [phone]
PRESSURERELIEFVALVES
AND TESTING EQUIPMENT
Printed In USA
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