GE Baker Hughes 2900-40 Series User manual

Consolidated*
2900-40 Series Pilot Operated
Safety Relief Valve
Maintenance Manual (Rev. C)
BHGE Data Classication : Public

2 | BHGE © 2019 Baker Hughes, a GE company. All Rights Reserved.
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC
REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND
MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BHGE
(BAKER HUGHES, A GE COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO
DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED
BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY
HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND
APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND
THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR
TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION,
OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR
PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES
THE MATTER SHOULD BE REFERRED TO BHGE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE AND THE CUSTOMER/OPERATOR ARE STRICTLY
LIMITEDTOTHOSEEXPRESSLYPROVIDEDINTHECONTRACTRELATINGTOTHESUPPLYOFTHEEQUIPMENT.
NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY BHGE REGARDING THE EQUIPMENT OR ITS USE
ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE
INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS
DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF
BHGE.

Consolidated 2900-40 Series POSRV Maintenance Manual | 3
© 2019 Baker Hughes, a GE company. All Rights Reserved.
NOTICE!
For valve congurations not listed in this
manual, please contact your local Green Tag*
Center for assistance.
Conversion Table
Note 1: Multiply USCS value with conversion factor to get metric value.
All the United States Customary System (USCS) units are
converted to metric units using the following conversion factors:
USCS Unit Conversion Factor Metric Unit
in. 25.4 mm
lb. 0.4535924 kg
in26.4516 cm2
ft3/min 0.02831685 m3/min
gal/min 3.785412 L/min
lb/hr 0.4535924 kg/hr
psig 0.06894757 barg
ft lb 1.3558181 Nm
°F 5/9 (°F-32) °C

4 | BHGE © 2019 Baker Hughes, a GE company. All Rights Reserved.
Table of Contents
I. Product Safety Sign and Label System ..........................................................................................................................................................................7
II. Safety Alerts..............................................................................................................................................................................................................................8
III. Safety Notice.......................................................................................................................................................................................................................... 10
IV. Warranty Information ........................................................................................................................................................................................................ 11
V. Terminology for Pilot Operated Safety Relief Valves ............................................................................................................................................ 12
VI. Handling and Storage......................................................................................................................................................................................................... 13
VII. Pre-Installation and Installation Instructions.......................................................................................................................................................... 14
VIII. Introduction ......................................................................................................................................................................................................................... 15
A. General Introduction................................................................................................................................................................................................. 15
B. Main Valve Introduction........................................................................................................................................................................................... 15
C. Pilot Valve Introduction............................................................................................................................................................................................ 15
IX. Consolidated 2900-40 Series Safety Relief Valves........................................................................................................................................ 16
A. 2900-40 Main Valve (Metal Seat).........................................................................................................................................................................16
B. 2900-40 Main Valve (Soft Seat)............................................................................................................................................................................ 17
C. 39PV Pilot Valve........................................................................................................................................................................................................... 18
X. Operating Principles ....................................................................................................................................................................................................... 19
A. PV Valve Closed (Normal Position) ..................................................................................................................................................................... 19
B. PV Valve Open (Relieving Position)..................................................................................................................................................................... 20
XI. General Planning for Maintenance............................................................................................................................................................................... 21
XII. Recommended Installation Practices................................................................................................................................................................... 21
A. Mounting Position ...................................................................................................................................................................................................... 21
B. Inlet Piping ..................................................................................................................................................................................................................... 22
C. Outlet Piping ................................................................................................................................................................................................................. 22
D. Remote Sensing........................................................................................................................................................................................................... 23
E. Freeze Protection........................................................................................................................................................................................................ 23
XIII. Disassembly of the 2900-40 POSRV ....................................................................................................................................................................... 25
A. Removal of the Pilot Valve from the Main Valve ........................................................................................................................................... 25
B. Disassembly of the Main Valve ............................................................................................................................................................................. 25
C. Cleaning .......................................................................................................................................................................................................................... 29
XIV. Maintenance Instructions............................................................................................................................................................................................ 30
A. General Maintenance Information...................................................................................................................................................................... 30
B. O-Ring Seat.................................................................................................................................................................................................................... 30
C. Lapping Nozzle Seats (Metal Seat - Non-O-Ring Styles)........................................................................................................................... 30
D. Lapped Nozzle Seat Widths ................................................................................................................................................................................... 32
E. Lapping Disc Seats ..................................................................................................................................................................................................... 32
F. Precautions and Hints for Lapping Seats......................................................................................................................................................... 34
G. Reconditioning of Laps............................................................................................................................................................................................. 34
H. Re-Machining Nozzle Seats.................................................................................................................................................................................... 34
I. Re-Machining the Disc Seat ................................................................................................................................................................................... 35

Consolidated 2900-40 Series POSRV Maintenance Manual | 5
© 2019 Baker Hughes, a GE company. All Rights Reserved.
XV. Inspection and Part Replacement................................................................................................................................................................................... 37
1. Guide ................................................................................................................................................................................................................................ 37
2. Base .................................................................................................................................................................................................................................. 37
3. Cover Plate..................................................................................................................................................................................................................... 37
4. O-Ring Retainer ........................................................................................................................................................................................................... 37
5. Nozzle .............................................................................................................................................................................................................................. 37
6. Spring ............................................................................................................................................................................................................................... 37
7. Standard Metal Seated Disc................................................................................................................................................................................... 37
8. Thermodisc* Metal Seated Disc ............................................................................................................................................................................ 37
9. O-Ring Seated Disc .................................................................................................................................................................................................... 38
10. Disc Holder..................................................................................................................................................................................................................... 38
11. Solid Metal Gaskets ................................................................................................................................................................................................... 38
12. Main Valve Piston........................................................................................................................................................................................................ 38
XVI. Reassembly of 2900-40 Main Valve......................................................................................................................................................................... 39
A. Lubricants and Sealants .......................................................................................................................................................................................... 39
B. Assembly Procedure with Metal Seats.............................................................................................................................................................. 39
C. Assembly Procedure with O-Ring Seats........................................................................................................................................................... 39
XVII. Disassembly of Pilot Valve .......................................................................................................................................................................................... 43
A. 39PV07/37 Disassembly......................................................................................................................................................................................... 43
B. Cleaning ......................................................................................................................................................................................................................... 43
XVIII. Part Inspection of Pilot Valve.................................................................................................................................................................................... 46
A. 39PV07/37 ..................................................................................................................................................................................................................... 46
XIX. Reassembly of Pilot Valve............................................................................................................................................................................................ 47
A. Lubricants and Sealants .......................................................................................................................................................................................... 47
B. Assembly of 39PV07/37........................................................................................................................................................................................... 47
XX. Setting and Testing .......................................................................................................................................................................................................... 50
A. General Information .................................................................................................................................................................................................. 50
B. With Standard Options ............................................................................................................................................................................................ 50
C. With Sensing Ring Option ....................................................................................................................................................................................... 51
D. Functional Testing ...................................................................................................................................................................................................... 51
E. Field Testing of POSRV Assembly ........................................................................................................................................................................ 53
E.1 Field Test Connection ...................................................................................................................................................................................... 53
E.2 Pilot Valve Tester ............................................................................................................................................................................................... 53
F. Hydrostatic Testing and Gagging ........................................................................................................................................................................ 53
XXI. Troubleshooting.................................................................................................................................................................................................................... 54
XXII. 2900-40 Series POSRV Options ................................................................................................................................................................................. 55
A. Backow Preventer.................................................................................................................................................................................................... 55
A.1 Disassembly Instructions............................................................................................................................................................................... 55
A.2 Cleaning................................................................................................................................................................................................................. 55
A.3 Parts Inspection ................................................................................................................................................................................................. 55
A.4 Reassembly Instructions................................................................................................................................................................................ 55

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B. Dual Pilots ...................................................................................................................................................................................................................... 56
C. Field Test Connection .............................................................................................................................................................................................. 56
D. Single, Dual and High Capacity Filters (optional) .................................................................................................................................. 56-57
E. Sensing Line Filter (standard) ............................................................................................................................................................................... 57
F. Gag .................................................................................................................................................................................................................................... 58
G. Heat Exchanger..................................................................................................................................................................................................... 57-59
H. Lifting Lever................................................................................................................................................................................................................... 59
I. Manual, Electrical, or Pneumatic Blowdown Valve ...................................................................................................................................... 59
J. Pilot Valve Tester......................................................................................................................................................................................................... 60
K. Pressure Dierential Switch................................................................................................................................................................................... 60
L. Pressure Spike Snubber........................................................................................................................................................................................... 61
M. Remote Pilot Mounting............................................................................................................................................................................................. 61
N. Remote Sensing........................................................................................................................................................................................................... 61
O. Sensing Ring.................................................................................................................................................................................................................. 61
XXIII. Maintenance Tools and Supplies....................................................................................................................................................................... 62-66
A. Adjuster Top Seal Insertion Tool........................................................................................................................................................................... 62
B. Insert Installation Tool ............................................................................................................................................................................................. 63
C. Lapping Tools ........................................................................................................................................................................................................ 64-65
D. Disc Holder and Guide Removal and Assembly Tool............................................................................................................................ 65-66
XXIV. Replacement Parts Planning...................................................................................................................................................................................... 67
A. Basic Guidelines .......................................................................................................................................................................................................... 67
B. Identication and Ordering Essentials.............................................................................................................................................................. 67
C. Positive Identication of Main Valve and Pilot Valve Combinations .................................................................................................... 68
XXV. Genuine Consolidated Parts ........................................................................................................................................................................................... 68
XXVI. Recommended Spare Parts...................................................................................................................................................................................... 69-74
XXVII. Manufacture's Field Service, Repair, and Training Programs ................................................................................................................. 75
A. Field Service.................................................................................................................................................................................................................. 75
B. Factory Repair Facilities........................................................................................................................................................................................... 75
C. Safety Relief Valve Maintenance Training........................................................................................................................................................ 75
End Users Notes............................................................................................................................................................................................................................. 76-79

Consolidated 2900-40 Series POSRV Maintenance Manual | 7
© 2019 Baker Hughes, a GE company. All Rights Reserved.
I. Product Safety Sign and Label System
DANGER — Immediate hazards
which WILL result in severe
personal injury or death.
WARNING — Hazards or unsafe
practices which COULD result in
severe personal injury or death.
CAUTION — Hazards or unsafe
practices which COULD result in
minor personal injury.
ATTENTION — Hazards or unsafe
practices which COULD result in
product or property damage.
If and when required, appropriate safety labels have been included in the rectangular
margin blocks throughout this manual. Safety labels are vertically oriented rectangles as
shown in the representative examples (below), consisting of three panels encircled by
a narrow border. The panels can contain four messages which communicate:
• The level of hazard seriousness
• The nature of the hazard
• The consequence of human, or product, interaction with the hazard.
• The instructions, if necessary, on how to avoid the hazard.
The top panel of the format contains a signal word (DANGER, WARNING, CAUTION or
ATTENTION) which communicates the level of hazard seriousness.
The center panel contains a pictorial which communicates the nature of the hazard, and
the possible consequence of human or product interaction with the hazard. In some
instances of human hazards the pictorial may, instead, depict what preventive measures
to take, such as wearing protective equipment.
The bottom panel may contain an instruction message on how to avoid the hazard. In
the case of human hazard, this message may also contain a more precise denition of
the hazard, and the consequences of human interaction with the hazard, than can be
communicated solely by the pictorial.
1
2
3
4
Do not remove bolts if
pressure in line, as this will
result in severe personal
injury or death.
Know all valve exhaust/
leakage points to avoid
possible severe personal
injury or death.
Wear necessary
protective equipment to
prevent possible injury
Do not drop or
strike.
123 4

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XXX
All potential hazards
may not be covered in
this manual.
Improper tools or improper
use of right tools could
result in personal injury or
product damage.
Provide and use guarding
to prevent contact with
heated and/or pressurized
parts.
Improper use or repair of
pressurized media or steam
device may result in severe
personal injury or death.
Heed all container label
warnings.
Do not work with
valves while under the
inuence of intoxicants
or narcotics.
II. Safety Alerts
1. WARNING: Allow the system to cool to room temperature
before cleaning servicing or repairing the system. Hot
components or uids can cause severe personal injury or
death.
2. WARNING: Always read and comply with safety labels on all
containers. Do not remove or deface the container. Do not
remove or deface the container labels. Improper handling
or misuse could result in severe personal injury or death.
3. WARNING: Never use pressurized uids/gas/air to clean
clothing or body parts. Never use body parts to check for
leakage or discharge rates of areas. Pressurized uids/gas/
air injected into or near the body can cause severe personal
injury or death.
4. WARNING: It is the responsibility of the owner to specify
and provide guarding to protect persons from pressurized
or heated parts. Contact with pressurized or heated parts.
Contact with pressurized or heated parts can result in
severe personal injury or death.
5. WARNING: Do not allow anyone under the inuence or
intoxicants or narcotics to work on or around pressurized
systems. Workers under the inuence intoxicants or
narcotics are a hazard both to themselves and other
employees and can cause severe personal injury or dearth
to themselves or others.
6. WARNING: Incorrect service and repair could result in
product or property damage or severe personal injury or
death.
7. WARNING: This valve product line is not intended for
radioactive nuclear applications. Some valve products
Manufactured by BHGE may be used in radioactive
environments. Consequently, prior to starting any
operation in a radioactive environment, the proper “health
physics” procedures should be followed, if applicable.
8. WARNING: Use of improper tools or improper use of right
tools could result in personal injury or product or property
damage.
Read – Understand – Practice

Consolidated 2900-40 Series POSRV Maintenance Manual | 9
© 2019 Baker Hughes, a GE company. All Rights Reserved.
II. Safety Alerts (Cont.)
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.
Wear necessary
protective equipment to
prevent possible injury
Heed all service
manual warnings. Read
installation instructions
before installing valve(s).
Know nuclear "health physics"
procedures, if applicable, to
avoid possible severe personal
injury or death.
Note: Any Service questions not covered in this manual
should be referred to your local Green Tag Center
Cautions Concerning Product Warning Labels
Appropriate service and repair important to safe, reliable
operation of all valve products. Restoration to original quality
and manufacturing specications will accomplish the desired
results. Procedures developed by BHGE as described in
the applicable installation and Maintenance Manual, when
correctly applied, will be eective.
Always use appropriate
restoration procedures.
Restoring Safety
9. WARNING: These WARNINGS are as complete as possible
but not all-inclusive. BHGE cannot know all conceivable
service methods nor evaluate all potential hazards.

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Proper installation and start-up is essential to the safe and reliable operation of all valve
products. The relevant procedures recommended by BHGE and described in these instructions
are eective methods of performing the required tasks.
It is important to note that these instructions contain various “safety messages” which
should be carefully read in order to minimize the risk of personal injury, or the possibility that
improper procedures will be followed which may damage the involved BHGE Consolidated
product, or render it unsafe. It is also important to understand that these “safety messages”
are not exhaustive. BHGE can not possibly know, evaluate, and advise any customer of all
of the conceivable ways in which tasks might be performed, or of the possible hazardous
consequences of each way. Consequently, BHGE has not undertaken any such broad
evaluation and, thus, anyone who uses a procedure and/or tool, which is not recommended by
BHGE, or deviates from BHGE's recommendations, must be thoroughly satised that neither
personal safety, nor valve safety, will be jeopardized by the method and/or tools selected.
Please contact your local Green Tag Center ifthere are any questions relative to tools/
methods.
The installation and start-up of valves and/or valve products may involve proximity to uids at
extremely high pressure and/or temperature. Consequently, every precaution should be taken
to prevent injury to personnel during the performance of any procedure. These precautions
should consist of, but are not limited to, ear drum protection, eye protection, and the use of
protective clothing, (i.e., gloves, etc.) when personnel are in, or around, a valve work area. Due
to the various circumstances and conditions in which these operations may be performed
on BHGE Consolidated products, and the possible hazardous consequences of each way,
BHGE can not possibly evaluate all conditions that might injure personnel or equipment.
Nevertheless, BHGE does oer certain Safety Precautions, listed in Section IV, for customer
information only.
It is the responsibility of the purchaser or user of BHGE's Consolidated valves/equipment to
adequately train all personnel who will be working with the involved valves/equipment. For
more information on training schedules, call 318/640-6054. Further, prior to working with
the involved valves/equipment, personnel who are to perform such work should become
thoroughly familiar with the contents of these instructions.
Wear necessary
protective equipment to
prevent possible injury
III. Safety Notice