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Consolidated
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
Consolidated Safety Relief Valve
Type 1900
Industrial Valve Operation
Dresser Valve and Controls Division
Alexandria, Louisiana 71309-1430 (USA)
®
®
Design Options
O-Ring Seat
Thermodisc
Include:
Bellows
(-30),
(DA),
Liquid Trim
(LA)
and
®
(TD)
CON-2
Revised 7/97
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Summary of Contents for Dresser Consolidated 1900
- Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL ® Consolidated Safety Relief Valve Type 1900 Design Options Include: Bellows (-30), O-Ring Seat (DA), Liquid Trim (LA) ® Thermodisc (TD) CON-2 Industrial Valve Operation Revised 7/97 Dresser Valve and Controls Division Alexandria, Louisiana 71309-1430 (USA)
- Page 2 Product Safety Sign and Label System If and when required, appropriate safety labels have The top panel of the format contains a signal word been included in the rectangular margin blocks (DANGER, WARNING, or CAUTION) which throughout this manual. Safety labels are vertically communicates the level of hazard seriousness.
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Page 3: Table Of Contents
Replacement Parts Planning ......................Basic Guidelines ........................Replacement Parts List ....................... Identification and Ordering Essentials ................. XIX. Genuine Dresser Parts ........................Recommended Spare Parts for the 1900 Safety Relief Valves ............ XXI. Manufacturer's Warranty, Field Service & Repair Program ............Warranty Information ...................... -
Page 4: Safety Alerts
WARNING: These WARNINGS are as WARNING WARNING complete as possible but not all-inclusive. Dresser cannot know all conceivable service methods nor evaluate all potential hazards. WARNING: Use of improper tools or improper use of right tools could result in personal injury or product or property damage. - Page 5 CAUTION: Wear protective breathing apparatus to protect against toxic media. NOTE: Any service questions not covered in this manual Wear necessary Heed all service manual should be referred to Dresser’s Service Department, protective equipment warnings. Read Phone (318) 640-6055. to prevent possible installation instructions injury.
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Page 6: Terminology For Safety Relief Valves
Page 4 Terminology for Safety • Lift Relief Valves Lift is the actual travel of the disc away from the closed position when a valve is relieving. • Accumulation • Maximum Allowable Working Pressure Accumulation is the pressure increase over the Maximum allowable working pressure is the maximum allowable working pressure of the maximum gauge pressure permissible in a vessel... -
Page 7: Introduction
Page 5 IV. Design Features and (Continued) Nomenclature • Safety Valve • Cap and Lever Interchangeability A safety valve is an automatic pressure-relieving Many times it is necessary to change the type of device actuated by the static pressure upstream cap or lever in the field after a valve has been of the valve, and characterized by rapid opening installed. - Page 8 Page 6 CONSOLIDATED SAFETY RELIEF VALVE TYPE 1900 - CONVENTIONAL Part No. Nomenclature Base Nozzle Adjusting Ring Adjusting Ring Pin Adj. Ring Pin Gasket Disc Disc Retainer Disc Holder Guide Guide Gasket Bonnet Bonnet Gasket Base Stud Stud Nut Spindle Spindle Retainer Spring Washer Spring...
- Page 9 Page 7 DESIGN OPTIONS THERMODISC THERMODISC (TD) DESIGN FIGURE 3 DISC RETAINER GUIDE DISC DISC HOLDER PART INTEGRITY ESPECIALLY DESIGNED FOR SHORT BLOWDOWN AND SMOOTH CHATTER- FREE OPERATION AT MAXIMUM CAPACITY. ADJUSTING RING NOZZLE FIGURE 2 FIGURE 5 LA Liquid Trim Design (See Fig.
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Page 10: Handling, Storage And Pre-Installation
Page 8 V. Handling, Storage and • Storage Safety relief valves should be stored in a dry Pre-Installation environment to protect them from the weather. • They should not be removed from the skids or Handling crates until immediately prior to installation. A flanged valve, either crated or uncrated, should always be kept with the inlet flange down (i.e., in Flange protectors and seating plugs should not be... -
Page 11: Recommended Installation Practices
Page 9 VI. Recommended Installation All flange bolts should be drawn evenly to prevent distortion of the valve body and the inlet nozzle. Practices Safety relief valves should be located for easy Mounting Position access and/or removal so that servicing can be properly performed. - Page 12 Page 10 VI.B. (Continued) Vibrations in the inlet piping systems may cause valve seat leakage and/or fatigue Safety relief valve failure of the piping. These vibrations may WARNING inlets should not be cause the disc seat to slide back and forth located at the end across the nozzle seat and result in damage of a long, horizontal...
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Page 13: Outlet Piping
Page 11 VI. (Continued) Where possible, drains should be piped away to prevent the collection of water or corrosive liquid Outlet Piping in the valve body. Attention should be given to the support of the drainage piping. Alignment of the internal parts of a safety relief valve is important to ensure proper operation When two or more valves are piped to discharge (see Figure 8, below). -
Page 14: Disassembly Instructions
Page 12 VII. Disassembly Instructions Specific Steps NOTE: Remove the Many pressure vessels CAUTION cap (includ- DANGER that are protected by lifting Consolidated® Safety gear); then, Relief Valves contain remove the dangerous materials. cap gasket, if Decontaminate and applicable. clean the valve inlet and Remove the outlet and all external a d j u s t i n g... - Page 15 Page 13 VII.B. (Continued) To remove the spindle from the disc holder pressure testing. Remove for D thru M orifice valves, clamp the skirt Compression Screw from the Bonnet. Use portion of the disc holder snugly between pliers to prevent the Spindle from turning two wooden V-blocks in a suitable vise when removing the Compression Screw.
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Page 16: Cleaning
Page 14 NOTE: VII.B. (Continued) Exercise care when inserting a rod or pipe in the outlet, in order to ensure that the valve nozzle is not damaged during this operation. Use a large pipe wrench on nozzle flange to remove the nozzle from the base (see Figure 14). - Page 17 Page 15 VIII. (Continued) FIGURE 15 TABLE 1 ENGLISH UNITS, INCH Nozzle Metal-To-Metal O-Ring Seat Seal Radius .000 .002 .005 .002 .005 ±1/2° Orifice Min. E± F± H± N± B± J± Max. .005 .002 .000 .000 .000 .000 +.000 13/32 .015 —...
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Page 18: Nozzle Seat Width
Page 16 IX.A. (Continued) 1900, 1900-30 Standard Disc Top of flange and intersecting surface are damaged from galling and/or tearing. Seat Width - see Table 7 on page 23 for Inspection Areas proper seat width. The standard 1900 disc as pictured in Figure 16 B. -
Page 19: 1900 Series Thermodisc
Page 17 IX. (Continued) TABLE 3 INCHES MILLIMETERS DISC ORIFICE “T” Minimum TYPE SIZE “N” Minimum “T” Minimum “N” Minimum in millimeters in millimeters .155 .005 3.94 .127 .158 .005 4.01 .127 .174 TYPE 1 F, D-2, E-2, .010 4.42 .254 .174 .010... -
Page 20: Disc Holder
Page 18 IX. (Continued) F. Disc Holder Inspection Criteria There are several designs of disc holders. De- pending on the service and the type of valve. The particular type may be found in the details of Figure 16. for identification purposes the “G” dimension is provided. - Page 21 Page 19 IX. (Continued) TABLE 5 G Diameter in inches for Disc Holder Identification. See Figure 18, for design details. (Detail 1, is standard unless noted). Standard Disc Holder O-Ring Disc Holder Orifice Size High Liquid Trim Liquid Trim High Pressure Pressure Pressure...
- Page 22 (Continued) TABLE 5A G Diameter in millimeters for Disc Holder Identification. See Figure 18, for design details. (Detail 1, is standard unless noted). Standard Disc Holder O-Ring Disc Holder Orifice Size Liquid Trim Liquid Trim High High Pressure Pressure Pressure Pressure LS Design DL Design...
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Page 23: Guide
Page 21 IX. (Continued) Guide Inspection Criteria 4. Spring Washers are custom made for each end of a particular spring. The maximum clearance between the A and A dimension, and B and B Guide should be discarded if: dimension (see figure 21), should be 1/32 inch Visible galling is indicated in the inside (.79mm) for springs with an inside diameter of guiding surface. -
Page 24: Maintenance Instructions
Page 22 X. Maintenance Instructions B. Lapping Nozzle Seats (Non O-Ring Styles) A. General Information NOTE: After the valve has been disassembled, a close Nozzle laps as illustrated below are available inspection should be made of the seating surfaces. from DVCD (instructions and part numbers In a majority of cases, a simple lapping of seats is are located in the tooling section of this all that is necessary to put the valve in first class... - Page 25 Page 23 X.C. (Continued) TABLE 7 Set Pressure psig (bar) Suggested Seat Width Suggested Lapped Seat Set Pressure psig (bar) Orifice for Metal Seated Valves Orifice in Inches (mm) for Width in Inches (mm) for TD Option only except TD TD Option only D thru J 15-50...
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Page 26: Lapping Disc Seats
Page 24 X.C. (Continued) 8. To check the seating surfaces, remove all compound from both the seat and the lap. Then, shine the seat with the same lap using If additional lighting is required for measuring the the lapping motion described above. Low seat, DVCD suggests a goose-neck flashlight sections on the seating surface will show up similar to the Type A Lamp Assembly Flashlight... -
Page 27: Reconditioning Of Laps
Page 25 X. (Continued) Remachining Nozzle Seats and Bores The nozzle should be removed from the valve to Reconditioning of Laps be machined (see Figure 29). See Nozzle Removal Instructions in paragraph VII.B.14. If it 1. Ring laps are reconditioned by lapping them can not be removed from the base, it should be on a flat lapping plate. -
Page 28: Remachining The Disc Seat
Page 26 X.H. (Continued) Remachining the Disc Seat* 2. Machining Procedure: Metal to Metal Seat The standard disc seating surface (see Figure 30) can easily be machined as follows: See Figure 15, page 15. 1. Grip the disc in a four-jaw independent chuck a. -
Page 29: Checking Spindle Concentricity
Page 27 (Continued) Checking Spindle Concentricity c. Apply a machinist's indicator at approximately 45° to the outer edge of the It is important that the spindle of a safety relief spring washer seat at C. Rotate the valve be straight, in order to transmit the spring spindle. -
Page 30: Set Pressure Change-Disc Holder
Page 28 X. (Continued) Set Pressure Change-Disc Holder* dimension of the D-1 or E-1, and the actual seat dimensions and bore diameter are identical to The disc holder must be replaced if the set the F orifice nozzle. pressure must be changed and the change Other 1900 series valves may be restricted in the involves crossing the dividing line between high same manner when necessary. -
Page 31: Reassembly
Page 29 X. (Continued) chamfered end must be located down, Specific Steps next to the backface of disc holder, when Use the following procedure to determine the assembled. correct limit washer length. • For bellows Type "D" and "E" valves, the 1. -
Page 32: Lubrication
Page 30 XI.A. (Continued) • If the involved valve has an O-Ring seat 3. a. For restricted lift valves, if the nozzle did seal, refer to the tag plate mounted on the not require any machining, the same limit valve (see Figure 34) to determine O-Ring washer (tagged during disassembly) may material and "as built"... - Page 33 Page 31 XI.C. (Continued) and align the spindle retainer so that the gap 7. Place the guide over the disc holder. (DO is midway between the two slots. Using a NOT DROP.) If bellows is present, the screwdriver, compress the spindle retainer weight of the guide will slightly compress the and guide it into the retaining groove.
- Page 34 Page 32 XI.C. (Continued) 11. Place a new guide gasket in the base. 13. Apply a small quantity of lubricant to the spring washer bearing surface of the spindle. 12. Install spindle/disc guide assembly. On M Place the spring assembly on the spindle. thru T sizes, use the same lifting tool (see Figure 10 on page 13) as was used during 14.
- Page 35 Page 33 XI.C. (Continued) 15. With the adjusting screw lock nut assembled near the top of the adjusting screw, apply a small quantity of lubricant to the spherical end of the adjusting screw, and also lubricate the threads. Thread the adjusting screw into the bonnet, until it contacts the spring washer.
- Page 36 Page 34 XI.C. (Continued) TABLE 12 TABLE 13 RING SETTINGS FOR VALVES WITH RING SETTINGS FOR VALVES WITH SERIAL NUMBERS BEFORE TK-68738* SERIAL NUMBERS AFTER TK-68738* ORIFICE NO. OF NOTCHES SET PRESSURE SET PRESSURE ORIFICE NO. OF NOTCHES SET PRESSURE SET PRESSURE ON ADJ.
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Page 37: Setting And Testing
Page 35 XII. Setting and Testing A. General exposed to in service. Increasing the temperature Information from ambient causes the set pressure to decrease. DANGER This decrease in set pressure is due to thermal expan- Before putting the re- sion of the seating area and spring relaxation. conditioned valve in service, it must be set Therefore, it is important to compensate for the differ-... - Page 38 Page 36 XII.E. (Continued) 4. Setting Procedure Cold Differential Set Pressure For Back NOTE: Pressure Compensation Valves for steam service should be set using NOTE: saturated steam. Valves for gaseous service should For valves with variable superimposed back be set using air or nitrogen. Valves for liquid pressure, install a bellows to allow the set service should be set using water.
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Page 39: Seat Tightness Testing
Page 37 XII. (Continued) For metal to metal valves, designated for gaseous service, the leakage rate (in F. Seat Tightness Testing bubbles per minute) shall not exceed that shown in Table 17. 1. General Information A typical test arrangement for determining seat TABLE 17 tightness for safety relief valves on air or gas service (in accordance with ANSI B147.1/API... -
Page 40: Hydrostatic Testing And Gagging
Page 38 XII.F. (Continued) b. To decrease the blowdown (raise reseating pressure), the adjusting ring On bellows valves, also install a clean must be lowered by moving the pipe plug in the bonnet vent connection, notches, from right to left, past the until it is finger tight. -
Page 41: Manual Popping Of The Valve
Page 39 XIV. Manual Popping of the Valve Consolidated Safety Relief Valves are furnished, when so ordered, with packed or plain lifting levers for hand popping, or with an air operated lifting device for remote control. (See Figures 38-42, following.) When the valve is to be opened by hand, the pressure at the valve inlet should be at least 75% of the valve's set pressure. -
Page 42: Conversion Of Type 1900 Flanged Safety Relief Valves From Conventional To Bellows Type, And Vice Versa
Page 40 XV. Conversion of Type 1900 Flanged Safety Relief Valves From Conventional to Bellows Type, and Vice Versa NOTE: General Information With regard to all bellows valves, the bonnet vent ® Consolidated Type 1900 Flanged Safety Relief plug must be removed and the bonnet vented to a Valves can be readily converted from safe area. -
Page 43: Conversion From Conventional To Bellows Type
Page 41 XV. (Continued) C. Conversion from Bellows to Conventional Type Conversion From Conventional to Bellows Type In converting from a bellows to a conventional valve, the eductor tube may be secured in the The eductor tube is not needed in bellows base by expanding, or swaging, into the hole valves, and it should be entirely removed to provided. -
Page 44: Trouble Shooting Type 1900 Valves
Page 42 XVI. Trouble Shooting Type 1900 Valves TABLE 22 CAUSE SOLUTION MALFUNCTION Damaged seats Rework seats or replace part. Improper installation Inspect installation, i.e. piping. Operating pressure too close to set pressure Increase differential. Seat Leakage Excessive system vibration Recheck application. - Page 45 Page 43 XVII. (Continued) Lifting Tools - For removal of upper internal parts of larger valves (as specified below). LAPPING TOOLS The following tools are required for proper Orifice Part No. maintenance of Consolidated ® Safety Relief Valve seats, and may be purchased from DVCD M, N 4464602 upon request.
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Page 46: Replacement Parts Planning
Page 44 XVIII. Replacement Parts Planning 2. Specify parts required by: a. Part Name (See Figures 1-6 on pages Basic Guidelines 6 and 7) b. Part Number (if known) The following guidelines should be of assistance in c. Quantity developing a meaningful replacement parts plan. Contact Parts Marketing: 1-318-640-6044 1. -
Page 47: Genuine Dresser Parts
Page 45 XIX. Geniune Dresser Parts XVIII. Replacement Parts Planning (Continued) The next time replacement parts are needed, ® In order to determine if the valve contains Glide-Alloy keep these points in mind: components (i.e., the disc holder and/or the guide), which •... -
Page 48: Recommended Spare Parts For The 1900 Safety Relief Valves
DVCD has not authorized any company or any individual to manufacture replacement parts for its valve products. When ordering replacement valve parts, please specify in your purchase order: “ALL PARTS MUST BE DOCUMENTED AS NEW AND SOURCED FROM DRESSER INDUSTRIAL VALVE & CONTROLS DIVISION” CON-2... - Page 49 DVCD has not authorized any company or any individual to manufacture replacement parts for its valve products. When ordering replacement valve parts, please specify in your purchase order: “ALL PARTS MUST BE DOCUMENTED AS NEW AND SOURCED FROM DRESSER INDUSTRIAL VALVE & CONTROLS DIVISION.” CON-2...
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Page 50: Manufacturer's Warranty, Field Service & Repair Program
Seminars, conducted either at your site, or at *Refer to Dresser’s Standard Terms of Sale for our Alexandria, Louisiana manufacturing plant, complete details on warranty and limitation of provide participants with an introduction to the remedy and liability. - Page 51 • a Coaches’ Guide to facilitate learning. Program Kits, as well as additional Training and Maintenance manuals are available through: Training Department Manager Global Aftermarket Group Dresser Valve and Controls Division PO Box 1430 Alexandria, LA 71309-1430 Telephone: (318) 640-6054 Telefax:...
- Page 52 Appendix Re: With regard to personnel safety, all personnel should be familiar with the appropriate processes as well as the Optional Glide-Aloy™ Parts and the Repair material safety data sheets supplied by the vendor of Processing of Such Components any cleaning compounds. Protective gloves, goggles, etc.
- Page 53 For more detailed instructions, consult the appropriate Dresser manual. Location of Service Engineers THE DRESSER FIELD SERVICE ORGANIZATION IS UNEQUALED For prompt field service, please call ALABAMA, Huntsville ......1 Dresser Industrial Valve Operations Service Department, Alexandria, Louisiana. FLORIDA, Jacksonville ......2 Normal Working Hours –...
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