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Consolidated* Safety Relief Valve Maintenance Manual

1. 26 XIV Inspection and Part 27 Lu 27 gt 27 C O Ring Seat Seal 55 27 Di 27 E OROG USC TER 27 r H A 28 cM nnn e 28 Table of Contents Section Subject Page No GL 28 52 28 5 ape 29 MW dsherS 29 J a 29 BONNEL TO Drier 29 Bonnet 6 30 morerei eiectus Rte cR UEBER 30 N Spindle SRR 30 Backup PICS eicere Periti tet Pee HEREIN td 30 Seat O Ring Reassembly of 19000 Series SRV 30 A Metal Seat Valves MS cccccsssssssssss
2. Note 1 Soft seat DA valves for liquid service from 5 100 psig 0 34 6 89 barg require a special base for 19000L Series Refer to Dimension M instead of Dimension F in this case 24 XIII Maintenance Contd A4 Machining the Disc Seat d The disc is now ready for lapping See Table 6 for 1 When the disc seat cannot be repaired by lapping it can proper seat Midi e When the minimum thickness dimension S is reached be machined as shown in Figure 12 using the dimensions the disc should be replaced provided in Table 7 2 GE recommends that the following procedure be adhered to when machining the disc seat B O Ring Seat Seal Valves DA Grip the disc in a collet 1 Replacing the O Ring Retainer 3 b True up the disc so that surfaces marked X and Y run truewithin 00t 1003 immi onan indicat If slight damage is present the O Ring Retainer can rue within m on an indicator be refurbished by either lapping or machining O Ring c Take light cuts across the seating surface until the damage is removed Dimensions 15 D g Na Qi dimension S minimum is exceeded see Figure 12 and angle when applicable must be maintained Table 7 able 7 Table 6 Disc Seat Lapping Width 2 Metal Seat Design Disc Width The O Ring always should be replaced to ensure seat Set P
3. 0 30 T EE F View Y Figure 11d Soft Seat Base Machining the Metal Soft Seat Maintenance Contd Valve Type Amin nee mu Z E In mm In mm In mm In mm In mm In mm 19096L 550 8 89 395 10 03 010 0 25 457 11 61 503 12 78 030 0 76 19126L 401 10 19 453 11 51 010 0 25 523 13 28 579 14 71 030 0 76 192261 537 13 64 606 15 39 010 0 25 701 17 81 781 19 84 030 0 76 193571 675 17 15 762 19 35 010 0 25 881 22 38 987 25 07 038 0 97 19567L 850 21 59 960 24 38 010 0 25 1 109 28 17 1 247 31 67 048 1 22 19096 350 8 89 395 10 03 010 0 25 457 11 61 503 12 78 030 0 76 19126 401 10 19 453 11 51 010 0 25 523 13 28 519 14 71 030 0 76 19226M 537 13 64 606 15 39 010 0 25 701 17 81 781 19 84 038 0 97 19357 675 17 15 762 19 35 010 0 25 881 22 38 987 25 07 038 0 97 19567 850 2159 960 24 38 010 0 25 1109 28 17 1 247 31 67 048 1 22 19096H 350 8 89 595 10 03 Flat Flat 457 11 61 503 12 78 030 0 76 19126H 401 10 19 453 151 Flat Flat 5235 13 28 519 14 71 030 0 76 19226H 537 13 64 606 5 39 Flat Flat 01 17 81 181 19 84 030 0 76 G 005 H 002 003 J 005 T Valve Type 0 13 mm e 0 05 0 08 mm mus 0 13 mm Tus In mm In mm In mm In mm 19096L 188 4 78 784 19 91 15 020 0 51 30 188 4 78 191261 216 5 49 784 19 91 15 023 0 58 30 188 4 78 19226L 289 7 34 1 034 26 26 15 030 0 76 30 187
4. 2350 psig 165 13 barg Test Pressure Multiplier see Table 11 X1 019 DECES C SUPET NEE Tampere iure Multiplier Cold Differential Set Pressure 2395 psig 165 13 barg m eC 100 38 1 006 Set pressure 2500 psig 172 37 temperature 200 93 1 013 100 F 37 8 constant backpressure 150 psig 10 34 300 149 1 019 barg 204 1025 Set PrESSUE 2500 psig 172 37 barg 500 260 1 031 600 316 1 038 Minus Constant Back Pressure 150 psig 10 34 barg 700 371 1 044 Cold Differential Set Pressure 2350 psig 162 03 barg 800 427 1 050 Cold Differential Test Pressure For Back Pressure Compensation When a conventional Series 19000 valve is to operate with a constant back pressure the cold differential test pressure is the set pressure minus the constant back pressure Sample Calculations For Series 19000 safety relief valves refer to Tables 11 and 12 Set pressure 2500 psig 172 37 barg temperature 500 F 260 0 C backpressure atmospheric Set PreSsU 8 mte 2500 psig 172 37 barg Multiplier see Table 1 019 Cold Differential Set Pressure 2548 psig 175 68 barg Set pressure 2500 psig 172 37 barg temperature 500 F 260 C constant backpressure 150 psig 10 34 barg Set Pressufe sette tts 2500 psig 172 37 barg Minus Constant Back Pressure 150 psig 10 34
5. the leak is at the loose bonnet top vent plug the valve should be disassembled and the backup plate O Ring and spindle O Ring must be inspected The seating surfaces for these O Rings must also be inspected for nicks damage or dirt The seating surfaces should be better than a 32 RMS finish The valve must be re tested if disassembly is required After the valve set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap gasket 17 and cap 18 or lifting gear on the valve after applying a small amount of non copper based thread lubricant to the gasket seal surfaces and the cap and bonnet top threads Be careful when removing O Rings to avoid damage to the O Ring groove 125 NPT Vent Do Not Plug Threads Threads Threads A ViewA Figure 16c Backup Plate Surface V Figure 16 Spindle O Ring Groove Figure 16 19096M DA BP Valve Two Piece Bonnet Spindle and Back up Plate 36 XVI Setting and Testing Contd J Hydrostatic Testing and Gagging When hydrostatic tests are required after installation of an SRV Sealing Plug Spindle remove the SRV and replace it with a blind flange or pipe plug cap If the hydrostatic test pressure will not be greater than NI AS MX L NS ZR the operating pressure of the equipment a test gag may be used Very little force i e finger tight pressure on the tes
6. 34 Set pressure 400 psig 27 58 barg on superheated steam temperature 650 F 343 3 C backpressure atmospheric Operating 650 F 343 3 C Minus Temperature of Saturated Steam at 400 27 58 barg 448 F 266 7 Degrees of Superheat s 202 F 94 4 C Set Pressure aecenas 400 psig 27 58 barg Multiplier see Table 12 tette X1 013 Cold Differential Set 405 psig 27 92 barg F Blowdown The blowdown for all series 19000 valves is fixed Do not attempt to adjust the blowdown on these valves Typical blowdown is less than 10 percent The blowdown under the back pressure conditions will cause a shorter blowdown than when observed with no back pressure XVI Setting and Testing Contd G Simmer If simmer causes erratic valve opening refer to the Trouble Shooting Guide in this manual H Seat Leakage 1 Air The air leakage test shall be performed with all connections and openings in the body and bonnet pressure tight The cap with the gasket which covers the adjusting screw must be installed Test the valve for leakage using an API test fixture The API leakage test procedure is described below a Per API Standard 527 ANSI B147 1 72 a standard test fixture consists of a piece of tubing of 313 7 94 mm x 035 0 89 mm wall one end of which is joined t
7. GPCL IHU TON MN ERR m 10 B Design 5 10 C ecce eec HE ERE A HERRERA OLSEN A 19000 MS amp DA Safety Relief Valves B 19096M DA BP Safety Relief Valves X Consolidated 19000 Series 12 Metal Seat 12 B 51 Cop TYPOS 13 uM Sont Seat VI er 14 D The 19096M DA BP 15 Xl Recommended Installation 16 Mounting POSION tt 16 16 C Outlet PIpIH Que obe RETE ERR ERR 17 Disassembly of 19000 Series 18 ERE 18 RR RU T e 19 Ce 19 daten dinum NE e Ter M ME 20 iMetal Seat Valves 5 eis tette ble Reel ee COOL re 20 O Ring Seat Valves DA am pene te t ir Ete 25 C Checking Spindle Concentricity
8. b Grind and polish Damaged seat or O Ring o Bearing point damage Valve leaking v c Disassemble valve inspect contact area of disc and base lower Part misalignment spring washer or spindle compression screw spindle straightness d Discharge stack binding on outlet etc as outlined in this manual 9 d Correct as required a Line vibrations a Investigate and correct cause Simmer A b Lapped seat too wide b Rework seat as specified in this manual a Improper Check for piping instructions check required capacity Chatter sizing b Built up back pressure b Check outlet piping for flow restrictions No action valve does not go into full lift valve does not close from full lift a Foreign material trapped a Disassemble valve and correct any abnormality as outlined in this between disc holder and guide manudl Inspect system for cleanliness 37 XVIII Maintenance Tools Supplies The laps identified in Table 16 are required for proper maintenance of Consolidated Series 19000 seats Note One set of three laps is recommended for each size to assure ample flat laps are available at all times The Lap Resurfacing Plate is part number 0439003 Lapping compounds are identified in Table 17 Laps and the lapping plate may be purchased from GE Table 16 Laps Valve Part Number 19096L 19110L 19126L 19096M 19110M 19126M 1672
9. N A 523 1328 579 1471 024 061 19226M 537 1364 625 1588 701 1781 781 1984 025 0464 19357M 675 1715 796 2022 N A 881 2238 987 2507 024 061 19567M 850 2159 1000 2540 N A 1109 2817 1247 3167 024 061 19096H 350 889 395 1003 N A 457 1161 503 1278 022 056 19110H 375 953 395 1003 N A 457 1161 503 1278 022 056 19126H 401 1019 444 1128 N A 523 1328 579 1471 022 056 19226H 537 1364 616 1565 N A 701 1781 781 1984 022 056 G 005 H 002 003 005 T Valve Type 0 13 mm B 0 05 0 08 mm 0 13 mm wor In mm In mm In mm In mm 19096L 190 4 85 786 19 96 Flat 022 0 56 30 187 4 75 19110L 190 4 83 786 19 96 Flat 022 0 56 30 187 4 75 19126L 218 5 54 784 19 91 025 0 64 30 187 4 75 19226L 289 7 54 1 034 26 26 Flat 030 0 76 30 187 4 75 193571 363 9 22 1 502 38 15 Flat 038 0 97 30 250 6 35 195671 457 11 61 1 502 38 15 Flat 048 1 22 30 250 6 55 19096M 122 3 10 790 20 07 Flat 022 0 56 30 187 4 75 19110 122 3 10 790 20 07 Flat 022 0 56 30 187 4 75 19126M 127 3 23 790 20 07 Flat 025 0 64 30 187 4 75 19226M 212 5 38 1 037 26 34 Flat 032 0 81 30 187 4 75 19357 246 6 25 1 550 39 57 Flat 040 1 02 30 250 6 35 19567 302 7 67 1 574 39 98 Flat 050 1 27 30 250 6 35 19096H 120
10. 1 257 31 93 19096H 654 16 61 195671 1 585 40 21 19110H 654 16 61 19096 654 16 61 19126H 747 18 97 19110 654 16 61 19226H 1 000 25 40 F Guide 5 Replace the guide if 1 Theinside surface is worn egged or galled 2 Base and bonnet seating surfaces are scratched nicked corroded or leaks Figure 15a 19000L amp M Valves 3 Hole dimension is out of tolerance see Figure 15 and Table 9 4 Guide Height Dimension 1 is out of tolerance see Figure 15 and Table 9 5 dimension is not within tolerance see Figure 15 and Table 9 G Spindle 9 G 1 MS DA Replace the spindle if 1 The bearing surfaces are galled pitted or scratched 2 Threads are torn stripped or galled 3 The stem is bent see Figure 13 G 2 DA BP The spindle should be replaced if 1 The bearing surfaces are galled pitted or scratched 2 The threads are torn stripped or galled 3 The spindle is bent 4 TheO Ring groove is nicked scratched or pitted Figure 15b 19000H Valves lt J Figure 15 Guide 28 XIV Inspection and Part Replacement Contd Table 9 Guide Dimensions 224 00 0 03 K L min Type Metal Seat MS Soft Seat DA Metal Seat MS Soft Seat DA in mm in mm in mm in mm in mm 19096L 661 16 79 810 007 20 57 0 18 4810 007 20 57 0 18 1 701 43
11. 3 05 1038 26 37 Flat 030 0 76 30 187 4 75 19110H 120 3 05 1 038 26 37 030 0 76 30 187 4 75 19126H 125 3 18 1 502 38 15 Flat 030 0 76 30 250 6 55 19226H 210 5 55 1 504 38 20 Flat 030 0 76 30 250 6 35 23 XIII Maintenance Contd Table 5 19000 Series Soft Seat DA Base Re work Dimensions 002 D 002 003 F1 005 Valve Type 0 05 mm C min 0 05 mm 0 08 mm 0 15 mm In mm In mm In mm In mm In mm 19096L 550 8 89 395 10 03 Flat 457 11 61 5503 12 78 050 1 27 191101 375 9 53 395 10 03 Flat 457 11 61 503 12 78 050 127 191261 401 10 19 453 11 51 Flat 523 13 28 579 14 71 050 1 27 19226L 537 13 64 606 15 39 Flat 701 17 81 781 19 84 054 1 57 193571 675 17 15 762 19 35 293 7 44 987 25 07 062 1 57 19567L 850 21 59 960 24 38 Flat 1 109 28 17 1 247 31 67 062 1 57 19096M 350 8 89 395 10 03 Flat 457 11 61 503 12 78 050 1 27 19110 275 9 53 395 10 03 Flat 457 11 61 503 12 78 050 1 27 19126M 401 10 19 4453 11 51 Flat 523 13 28 579 14 71 082 2 08 19226 537 13 64 606 15 39 Flat 701 17 81 781 19 84 084 2 13 19357M 675 17 15 762 19 35 Flat 895 22 68 987 25 07 092 2 54 19567M 850 21 59 960 24 38 Flat 1 109 28 17 1 247 31 67 128 3 25 19096H 350 8 89 395 10 03 Flat 457 11 61 503 12 78 048 1 22 19110H 315 9 53 395 10 03 Flat 457 11 61 503 12 78 048 1 22 19126H 401 10 19 453 11 51 Flat 523 13 28 579 14 71 048 1 22 19226H 53
12. 4 75 193571 263 9 22 1 502 38 15 5 038 0 97 30 250 6 35 195671 457 11 61 1 502 38 15 5 048 1 22 30 250 6 35 19096 188 4 78 784 19 91 15 030 0 76 30 187 4 75 19126M 216 5 49 784 19 91 15 030 0 76 30 187 4 15 19226 289 7 34 1 034 26 26 15 038 0 97 30 187 4 15 19357 363 9 22 1 502 38 15 5 038 0 97 30 250 6 35 19567 457 11 61 502 38 15 a 048 1 22 30 250 6 35 19096 188 4 78 034 26 26 Flat 030 0 76 30 187 4 75 19126H 156 3 96 524 38 71 Flat 030 0 76 30 250 6 35 19226H 210 5 33 1 504 38 20 Flat 030 0 76 30 250 6 35 22 XIII Maintenance Contd Table 4 19000 2 Series Metal Seat MS Base Re work Dimensions Valve Type Amin gun 5 NUM M Wer In mm In mm In In mm In mm In mm 19096L 350 889 408 1036 N A 457 1161 503 1278 025 19110L 375 953 408 1036 N A 457 1161 503 1278 025 19126L 401 1019 463 1176 523 1328 579 1471 024 061 19226L 537 1364 625 1588 701 1781 781 1984 022 056 19357L 675 1715 796 2022 N A 881 2238 987 2507 022 0 56 19567L 850 2159 1000 2540 N A 1109 2817 1247 3167 022 056 19096M 350 889 408 1036 N A 457 1161 503 1278 025 064 19110M 375 953 408 1036 N A 457 1161 503 1278 025 064 19126M 401 1019 463 1176
13. Ring groove is nicked scratched or pitted 4 Seat step F is at or above minimum listed in Table 5 F can 4 The O Ring retainer screw threads are torn stripped or be reestablished by machining as long as L stays within galled tolerance see Section XIII A3 2 b B Metal Seat Disc 2 The metal seat disc should be replaced if Figure 14a 1 Design Figure 14b 2 Design 1 Seatsurface Y see Figure 12 is damaged beyond lapping or machining limits 2 Seat relief height is less than R minimum and dimension S cannot be maintained see Table 7 3 Length S is less than S minimum see Table 7 C O Ring Seat Seal Assembly The O Ring seat seal assembly parts should be replaced as follows 1 O Ring Seat Seal 37 always replace 2 O Ring retainer 3 Lapped seat relief height R is less than minimum and dimension S cannot be maintained see Figure 12 and Table 7 b Length S is less than S minimum see Table 7 c Retainer Lockscrew Always replace XIV Inspection and Part Replacement Table 8 Disc Holder Dimensions Val H DIA Val H DIA 5 Ve 001 0 03 mm 4 ve 001 0 03 mm ype in mm ype in mm 9096L 654 16 61 19126 747 18 97 91101 654 16 61 19226 1 000 25 40 9126L 18 97 193577 1 257 31 93 192261 1 000 25 40 19567 1 585 40 21 19357L
14. Series SRV Contd 2 32 Bearing surfaces should be ground together using a 320 grit lapping compound see Table 17 clean all parts before assembly These surfaces are the following The disc holder spindle pocket and the spindle spherical holder spindle radius for O ring valves or 1 metal seat design b Thelower spring washer and spindle spring washer radius C The upper spring washer and adjusting screw spherical radius Carefully insert a new seat O Ring seal 37 into the disc holder 4 Make sure the seat O Ring is the right size material and hardness for the application Refer to the valve nameplate for information required when ordering an O Ring Install the O Ring retainer 3 and the retainer lockscrew 36 Apply thread locker fluid to lock the screw in position Place the disc holder assembly onto the base 1 and place the guide 5 onto the base The guide seating surfaces should be free of any nicks or scratches The guide to bonnet bottom seating and the backup plate ring to bonnet bottom seating surfaces should be free of any nicks or scratches The guide to bottom bonnet 8 seating surface should have a finish with a maximum of 63 RMS Apply non copper based thread lubricant or equivalent anti seize to the bonnet bottom threads on the base and guide seating surfaces Install the bonnet on the base 1 Tighten the bonnet bottom to the base using sufficient torque from Base Torque Specif
15. adjusting screw locknut 13 on the adjusting screw 12 Apply a light coat of non copper based thread lubricant to the adjusting screw threads and spherical radius Thread the adjusting screw locknut 13 onto the adjusting screw 12 Apply a small amount of non copper based thread lubricant to the tip of the adjusting screw Install the adjusting screw in the bonnet rotating the number of times required to compress the spring slightly XV Reassembly of 19000 Series SRV Contd VALVE ae Maximum Torque DES ft lb Nm ft lb Nm 19096L 125 169 250 339 19110L 125 169 250 339 19126L 125 169 250 339 19226L 200 271 400 542 19357L 625 847 1000 1356 19567L 625 847 1000 1356 19096M 175 237 300 407 19096M BP 175 237 300 407 19110 175 237 300 407 19126 175 237 300 407 19226 500 678 750 1017 19357M 650 881 1200 1627 19567M 650 881 1200 1627 19096H 500 678 750 1017 19110H 500 678 750 1017 19126H 1000 1356 1500 2034 19226H 1000 1356 1500 2034 Use pliers to hold the spindle 9 in position and prevent galling Adjust the adjusting screw to the measurement recorded during disassembly See Metal Seat Valves disassembly instructions point b on page 16 The valve is now ready for setting After the set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap 18 and cap gasket 17 or lifting gear on the valve after applying a small amount of non copper based thread
16. lubricant to the gasket seal surfaces as well as to the cap and bonnet threads O Ring Seat Seal Valves DA See Figure 2 All bases shall be lapped flat enough to remove nicks and burrs Bearing surfaces should be ground together using a 320 grit lapping compound see Table 17 clean all parts before assembly These surfaces are a The disc holder spindle pocket and spindle spherical nose radius b The lower spring washer and spindle spring washer radius c The upper spring washer and adjusting screw spherical radius Carefully insert a new O Ring seat seal 37 into the disc 10 holder 4 Make sure the O Ring is the right size material and hardness for the application Refer to the valve nameplate for information required when ordering an O Ring seat seal Install the O Ring retainer 3 and a new retainer lockscrew 36 Place the disc holder assembly onto the base 1 and place the guide 5 onto base The guide seating surfaces should be free of any nicks or scratches Lubricate the spindle nose with a small amount of non copper based thread lubricant and insert the spindle 9 into the disc holder spindle pocket Apply a small amount of non copper based thread lubricant on the bearing surface of the lower spring washer 10 and slip it over the spindle 9 Install the spring 11 and upper spring washer 10 The guide bonnet seating surfaces should be free of any nicks or scratches with a 63 R
17. of seats or the replacement of internal parts Appropriate set pressure can be established after reassembly See Figures 1 through 6 for parts nomenclature Notes e Before starting to disassemble the valve be sure 5 Before disassembling the there is no media pressure in the vessel 5 valve ensure there is media Many pressure vessels that are protected by pressure in the vessel Consolidated safety relief valves contain dangerous materials Decontaminate and clean the valve inlet and A CAUTION outlet and clean the valve inlet and outlet and all external surfaces in accordance with the cleaning and decontaminating recommendations in the appropriate Material Safety Data sheet Many pressure vessels e Parts from one valve should not be interchanged with protected by Consolidated parts from another valve safety relief valves contain dangerous materials Decontaminate and clean the valve inlet outlet and all external surfaces in accordance with the cleaning and decontaminating Valve caps and bonnets can recommendations in the trap fluids Use caution when Do not interchange parts from one valve with appropriate Material Safety removing to prevent injury or parts from another valve Data Sheet environmental damage 18 GE Oil amp Gas Disassembly of 19000 Series SRV Contd B Disassembly B 1 Metal Seat Valves See Figure 1 a Remove the cap 18 including lifting gear if
18. or death 6 e Do not work or allow anyone under the influence of intoxicants or narcotics to work on or around pressurized systems Workers under the influence of intoxicants or narcotics are a hazard to themselves and other employees Actions taken by an intoxicated employee can result in severe personal injury or death to themselves or others e Always perform correct service and repair Incorrect service and repair can result in product or property damage or severe personal injury or death e Always use the correct tool for a job The misuse of a tool or the use of an improper tool can result in personal injury damage to product or property e Ensure the proper health physics procedures are followed if applicable before starting operation in a radioactive environment Caution Alerts A CAUTION alert describes actions that may result in a personal injury In addition they may describe preventive measures that must be taken to avoid personal injury Cautions include e Heed all service manual warnings Read installation instructions before installing valvels e Wear hearing protection when testing or operating valves Wear appropriate eye and clothing protection Wear protective breathing apparatus to protect against toxic media Ill Safety Notice A CAUTION Wear necessary protective equipment to prevent possible injury Proper installation and start up is essential to the safe and reliable operation
19. seating area and spring relaxation Therefore it is important to compensate for the difference between production test temperature and service temperature The service temperature is the normal operating temperature of the SRV If the operating temperature is unavailable do not correct the SRV set pressure Table 11 lists the set pressure multipliers to be used when computing the cold differential test CDTP pressure for valves being set on an air or water test stand at ambient temperatures Valves to be used in saturated steam service are tested on saturated steam Therefore no CDTP is required However valves in superheated steam service are tested on saturated steam and require a CDTP Table 12 lists the multiplier to be used based on temperature above the saturated temperature degrees of superheat Consolidated 19000 Series Safety Valve January 2014 33 XVI Setting and Testing Contd Operating Temp Multiplier Operating Temp Multiplier EG oF 2 250 121 1003 900 482 1 044 300 149 1 006 950 510 1 047 350 177 1 009 1000 558 1 050 400 204 1 013 1050 566 1 055 450 232 1 016 1100 593 1 056 500 260 1 019 1150 621 1 059 550 288 1 022 1200 649 1 065 600 316 1 025 1250 677 1 066 650 345 1 028 1300 704 1 069 700 371 1 031 1350 732 1 072 750 399 1 034 1400 760 1 075 800 427 1 038 1450 788 1 078 850 454 1 041 1500 816 1 081 Differential
20. to 6 89 9496 101 or greater 6 96 or greater 9796 2 Water When a metal to metal seat valve is tested using water as the test medium there shall be no leakage as determined by sight when the pressure is held at 90 percent of set pressure For O Ring seat seal valves use Table 13 to determine the percentage of set pressure C Steam When a metal to metal seat valve is checked for tightness using steam as the test medium at 90 percent of the set pressure there shall be no visual or audible leakage after the interior of the valve is allowed to dry after popping If there is no visual or audible leakage the valve is acceptable For O Ring seat seal valves use Table 14 to determine the percentage of set pressure Back Pressure Testing 11 MS amp DA After the valve has been set for the correct opening pressure it must be back pressure tested Testing can be conducted by installing the cap with gasket and applying air or nitrogen to the valve outlet Test pressure should be 30 psig 2 07 barg or the actual valve back pressure whichever is greater Examine the base 1 to bonnet 6 joint for leakage during back pressure testing Note Leakage is best detected by application of a liquid leak detector The use of soap or household detergent as a leak detector is not recommended as it may cover up leaks Repair of leaking valve joints may be attempted by tightening the leaking joint while the valve is still on th
21. under high frequency conditions Temperature changes in the discharge piping may be caused by fluid flow in from the discharge of the valve or by prolonged exposure to the sun or heat radiated from nearby equipment A change in the discharge piping temperature will cause a change in he length of the piping which may cause stresses to be transmitted to the SRV and its inlet piping Proper support anchoring or provision for flexibility of the discharge piping can prevent stresses caused by thermal changes Do not use fixed supports C Outlet Piping Alignment of the internal parts of the SRV is important to ensure proper operation see Figure 8 Although the valve body will withstand a considerable mechanical load unsupported discharge piping consisting of more than a companion flange long radius elbow and a short vertical pipe is not recommended Use spring supports to connect outlet piping to prevent thermal expansion from creating strains on the valve The discharge piping should be designed to allow for vessel expansion as well as expansion of the discharge pipe itself This is particularly important on long distance lines A continual oscillation of the discharge piping wind loads may induce stress distortion in the valve body The resultant movement of the valve s internal parts may cause leakage Where possible use properly supported drainage piping to prevent the collection of water or corrosive liquid in the
22. upon request Incorrect Selection or Misapplication of Products GE cannot be responsible for customers incor rect selection or misapplication of our products Unauthorized Repair work GE has not authorized any non GE affiliated repair companies contractors or individuals to perform warranty repair service on new products or field repaired products of its manufacture Therefore customers contracting such repair services from unau thorized sources do so at their own risk Defective and nonconforming items must Unauthorized Removal of Seals All new valves and valves repaired in the field by GE Field be inspected by GE Service are sealed to assure the customer of our guarantee against defective workmanship Unauthorized removal and or breakage of this seal will negate our warranty Note 1 Refer to GE s Standard Terms of Sale for complete details on warranty and limitation of A CAUTION remedy and liability V Terminology for Safety Relief Valves SRV e Accumulation the pressure increase over the maximum allowable working pressure of the vessel during discharge through the SRV expressed as a percentage of that pressure or in actual pressure units Removal and or breakage of seal will negate our Built up Backpressure the pressure that develops at the valve outlet after the SRV warranty has been opened as a result of flow Backpressure the pressure on the discharge side of the SRV Superimpose
23. valve should be short and directly from the vessel or equipment being protected The radius of the connection to the vessel should permit smooth flow to the valve Avoid sharp corners If this is not practical then the inlet should be at least one additional pipe diameter larger The pressure drop from the vessel to the valve shall not exceed 3 percent of valve set pres sure when the valve is allowing full capacity flow The inlet piping should never be smaller in diameter than the inlet connection of the valve Excessive pressure drop in gas vapor or flashing liquid service at the inlet of the SRV will cause the extremely rapid opening and clos ing of the valve which is known as chattering Chattering will result in lowered capacity and damage to the seating surfaces The most desirable installation is that in which the nominal size of the inlet piping is the same as or greater than the nominal size of the valve inlet flange and in which the length does not exceed the face to face dimensions of a standard tee of the required pressure class Do not locate SRV inlets where excessive turbulence is present such as near elbows tees bends orifice plates or throttling valves Section VIII of the ASME Boiler and Pressure Vessel Code requires the inlet connection design to consider stress conditions during valve operation caused by external loading vibration and loads due to thermal expansion of the discharge piping The determination of r
24. 2 2 Male E ES ANG NS ARN oS Figure 1c 1 Design Figure 1 19000 Metal Seat Valve Construction 12 X Consolidated 19000 Series SRV Contd B Optional Cap Types Figure 2018 2 Figure 2 284 52 N 42 Figure 3 Plain Cap 4 22222222 N B Bal K SS yf 2 223 7 SY N Figure 4 Typical Screwed Cap with Gag Fart Nomenclature No 14 Gag Bolt 15 Sealing Plug 16 Sealing Plug Gasket 17 Cap Gasket 19 Packed Cap 20 Cam Shaft 21 Bushing 22 Bushing Gasket 23 Packed Lifting Lever 24 Pin 25 O Ring 26 Release Nut 27 Release Locknut 28 Plain Lever Cap 29 Plain Lifting Lever 30 Cap Screw 31 Lever Pin 32 Lifting Fork 33 Lever Shaft 34 Packing 35 Packing Nut Note 1 Available for 19096L M amp H 19110L M amp H 19126L amp M 19226L amp M Excludes 19096M DA BP Note 2 Available for 19126H 19226H 19357L amp M 19357L amp M Excludes 19096M DA BP Note 3 Available for all 19000 valves Note 4 Can be provided with a gag if required X Consolidated 19000 Series SRV Contd C Soft Seat Valve Figure 5a 1 Male NPT Figure 5b 1 Female NPT Nomenclature 1 Base 5 O Ring Retainer 4 Disc Hold
25. 21 1 701 43 21 191101 661 16 79 810 007 20 57 0 18 810 007 20 57 0 18 1 701 43 21 1 701 43 21 19126L 754 19 15 804 007 20 42 0 18 4804 007 20 42 0 18 1 717 43 61 1 717 43 61 19226L 1 007 25 58 1 109 2 009 28 17 0 23 1 109 009 28 17 0 23 2 267 57 58 2 267 57 58 19357L 1 264 32 11 1 623 012 41 22 0 30 1 623 012 41 22 0 30 3 105 78 87 3 105 78 87 19567L 1 590 40 39 1 671 012 42 44 0 30 1 671 012 42 44 0 30 3 159 80 24 3 159 80 24 19096M 661 16 79 1810 007 20 57 0 18 4810 007 20 57 0 18 1 727 43 87 1 727 43 87 19110 661 16 79 810 007 20 57 0 18 810 007 20 57 0 18 1 727 43 87 1 727 43 87 19126 754 19 15 804 007 20 42 0 18 804 007 20 42 0 18 1 743 44 27 1 743 44 27 19226M 1 007 25 58 1 109 009 28 17 0 23 1 109 009 28 17 0 23 2 267 57 58 2 292 58 22 19357M 1 264 32 11 1 623 012 41 22 0 30 1 623 012 41 22 0 30 3 105 78 87 3 196 81 18 19567 1590 40 39 1671 012 42 44 0 30 1 627 x 012 41 33 030 3 159 80 24 3 251 82 58 19096H 661 16 79 1 060 007 26 92 0 18 1 060 007 26 92 0 18 2 227 56 57 2 227 56 57 19110 661 16 79 1 060 007 26 92 0 18 1 060 007 26 92 0 18 2 227 56 57 2 227 56 57 19126H 754 19 15 1 523 007 38 68 0 18 1 523 007 38 68 0 18 2 707 68 76 2 707 68 76 19226H 1 007 25 58 1 515 009 38 48 0 23 1 515 009 38 48 0 23 3 027 76 89 3 027 76 89 H Sp
26. 455 12 2134 1201 Fax 81 43 299 1115 Fax 55 12 2134 1238 Melbourne Phone 61 3 8807 6002 KOREA SPAIN Fax 61 3 8807 6577 Phone 82 2 2274 0748 Phone 34 93 652 6430 Fax 82 2 2274 0794 Fax 34 93 652 6444 BELGIUM Phone 32 2 344 0970 MALAYSIA UNITED ARAB EMIRATES Fax 32 2 344 1123 Phone 60 3 2161 0322 Phone 971 4 8991 777 Fax 60 3 2163 6312 Fax 971 4 8991 778 BRAZIL Phone 55 11 2146 3600 MEXICO UNITED KINGDOM Fax 55 11 2146 3610 Phone 52 55 3640 5060 Wooburn Green Phone 44 1628 536300 CHINA Fax 44 1628 536319 Phone 86 10 5689 3600 THE NETHERLANDS Fax 86 10 5689 3800 0031 15 3808666 UNITED STATES Fax 0031 18 1641438 Massachusetts FRANCE Phone 1 508 586 4600 Courbevoie RUSSIA Fax 1 508 427 8971 Phone 33 1 4904 9000 Veliky Novgorod Corpus Chti Texas Fax 433 1 4904 9010 Phone 7 8162 55 7898 vis MGR one 1 361 881 8182 Fax 7 8162 55 7921 Fax 41 361 881 8246 GERMANY Ratingen no 7 495 585 1276 Deer Park Texas Phone 49 2102 108 0 a xu e Phone _ 1 281 884 1000 Fax 49 2102 108 111 Fax 1 281 884 1010 INDIA SAUDI ARABIA Houston Texas Mumbai Phone 966 3 341 0278 Phone 1 281 671 1640 Phone 491 22 8354790 Fax kaxi Fax 91 22 8354791 SINGAPORE New Delhi Phone 65 6861 6100 Phone 91 11 2 6164175 Fax 65 6861 7172 Fax 91 11 5 1659635 Visit us online at www geoilandgas com valves Consolidated Valvkeep and Green Tag Center are regist
27. 6 17 491 1247 426 1082 N A 151 3 84 91101 461 1171 025 0 64 N A N A 234 5 94 426 1082 151 3 84 19110H 461 1171 025 0 64 N A N A 491 1247 426 1082 N A N A 151 3 84 91261 527 3 39 025 0 64 243 6 17 241 6 12 489 12 42 N A N A 151 3 84 19126H 527 13 39 025 0 64 243 6 17 491 1247 489 1242 N A N A 151 3 84 1922611 705 1791 025 0 64 305 7 15 272 6 91 676 1717 025 0 64 199 5 05 19226H 705 1791 025 0 64 305 7 75 546 13 87 676 1717 025 0 64 199 5 05 1935711 885 22 48 025 0 64 493 12 52 454 1153 852 2164 025 0 64 244 6 20 1956711 1113 2827 025 0 64 493 1252 473 1201 1058 2687 025 0 64 244 6 20 Note 1 These valves have 15 angle as shown in Figure 12 2 Metal Seat Design C Checki ng Spi nd le Co nce ntricity b Support the spindle with a V block A placed near the upper end of the spindle but below the threads 1 General Information TERME Apply a machinist s indicator at approximately 45 It is important that the spindle 9 of a safety relief valve to the outer edge of the spring washer seat at C be straight in order to transmit the spring load to the Rotate the spindle The total indicator reading should not exceed 005 0 13 mm Straighten the spindle if necessary disc without lateral binding Over gagging is one of the common causes of bent spindles To check the e
28. 7 13 64 606 15 39 Flat 701 17 81 781 19 84 052 1 32 Table 5 19000 Series Soft Seat DA Base Re work Dimensions Contd 005 002 003 J 005 K Lmin E Eus Valve 0 13 mm 0 05 0 08 mm angle 0 13 mm S 0 05 0 08 mm in mm in mm in mm in mm in mm 19096L 190 4 83 786 19 96 Flat 022 0 56 30 187 4 75 032 0 81 19110L 190 4 83 786 19 96 Flat 022 0 56 30 187 4 75 050 127 191261 218 5 54 786 19 96 Flat 025 0 64 30 187 4 75 032 0 81 192261 291 7 39 1 036 26 31 032 0 81 30 187 4 75 032 0 81 193571 363 922 1503 38 18 038 0 97 30 250 6 35 040 1 02 195671 457 11 61 1503 38 18 Flat 048 1 22 30 250 6 35 050 1 27 19096 1190 4 83 812 20 62 Flat 032 0 81 30 187 4 75 N A N A 19110M 190 4 83 812 20 62 Flat 030 0 76 30 187 4 75 N A N A 19126M 180 4 57 810 20 57 Flat 030 0 76 30 187 4 75 N A N A 19226M 212 5 38 1 100 27 94 Flat 032 0 81 30 187 4 75 N A N A 19357M 363 922 1594 40 49 Flat 038 0 97 30 250 6 55 A A 19567M 300 7 62 1596 40 54 Flat 048 1 22 30 250 6 55 A A 19096H 188 4 78 1 060 26 92 Flat 030 0 76 30 187 4 75 A A 19110H 188 4 78 1060 26 92 Flat 030 0 76 30 187 4 75 A A 19126H 156 3 96 1 524 38 71 Flat 030 0 76 30 250 6 35 A A 19226H 210 5 33 1504 38 20 Flat 030 0 76 30 250 6 35 N A
29. 802 19096H 19110H 19126H 19226L 19226M 19226H 1672803 19357L 19567L 19357M 19567M 1672805 Table 17 Lapping Compounds 38 Brand Grade Grit Lapping Function Size Container Part No Clover 1A 320 General 4oz 199 3 Clover 3A 500 Finishing 4 02 199 4 Kwik Ak Shun 1000 Polishing 116 199 11 202 199 12 XIX Replacement Parts Planning A General Information The importance of maintenance planning is the key to good plant operations Part of that planning involves making sure that replacement parts needed to repair valves are available at the jobsite when required Developing and implementing a standard valve maintenance plan will quickly pay for itself by eliminating costly downtime unscheduled outages etc B Inventory Planning The basic objectives in formulating a replacement parts plan are 1 Prompt availability 2 Minimum downtime 3 Sensible cost and 4 Source control Having parts immediately available from plant storeroom inventory is obviously the best way to accomplish those objectives Since it is impractical to have every part that might be needed to accomplish a given repair in stock at all times guidelines for establishing meaningful inventory levels are summarized in Table 18 In addition you can contact your local Green Tag Center or GE authorized sales representative contact information can be found at the end of this manual for assistance in determ
30. GE Oil amp Gas 19000 series Consolidated Safety Relief Valve Maintenance Manual imagination at work Conversion Table All the United States Customary System USCS values are converted to metric values using the following conversion factors Metric values using the following Conversion Factor Metric Unit conversion factors in 25 4 mm Ib 0 4535924 kg in 6 4516 cm ft min 0 02831685 m3 min gal min 3 785412 L min lb hr 0 4535924 kg hr psig 0 06894757 barg ft Ib 1 35581 1 Nm Sir 5 9 F 32 AC Note 1 Multiply USCS value with conversion factor to get metric value For valve configurations not listed in this manual please contact your local Consolidated Green Tag Center for assistance Table of Contents Section Subject Page No CORVeILSIOR tenete esie UE Le IM 2 Product Safety Sign and Label System iei rends 5 Safety Alerts 6 50760 oer tne eee etes tse 7 IV Warranty 8 V Terminology for Safety Relief Valves 8 VI Handling Storage and 9 VI Pre Installation and Installation Instructions 10 Design Features and Nomenclature u ccccccssssssssssssesssscssssssssnssssssssssssssmusssssssssssssnuuseessecesssssnussssssssesssssnusseeseees 10
31. MS finish maximum Apply non copper based thread lubricant to the bonnet and base threads and guide seating surfaces Install the bonnet 6 on the base 1 using torque from Base Torque Specifications see Table 10 Before tightening the bonnet completely adjust the position of the guide 5 so that one of the holes in the guide is in line with the discharge of the valve Tighten the bonnet using sufficient torque from Base Torque Specification see Table 10 Thread the adjusting screw locknut 13 onto the adjusting screw 12 Apply a small amount of non copper based hread lubricant to the tip of the adjusting screw Install he adjusting screw in the bonnet rotating the number of imes required to compress the spring slightly Use pliers to hold the spindle 9 in position and prevent galling Adjust he adjusting screw to the measurement recorded during disassembly See O Ring Seat Seal Valves DA disassembly instructions point b on page 20 The valve is now ready for setting After the valve set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap gasket 17 and cap 18 or lifting gear on the valve after applying a small amount of non copper based thread lubricant to the gasket seal surfaces as well as to the cap and bonnet threads 19096M DA BP O Ring Seat Seal Valves see Figure 6 All base seats shall be lapped flat enough to remove nicks and burrs 31 XV Reassembly of 19000
32. ace is scratched nicked corroded or leaks 3 The backup plate seating surface is scratched nicked or corroded 4 Condition is porous corroded or distorted M Backup Plate 39 The backup plate should be replaced if 1 Inside circumference X is scratched nicked pitted or galled 2 O Ring groove W is scratched nicked pitted or galled 3 Backup plate is distorted N Spindle O Ring 310 011 38 The spindle O Ring should always be replaced The material and durometer of the spindle O Ring should be the same material and durometer as that specified for the Seat O Ring 37 O Backup Plate O Ring 310 030 40 The backup plate O Ring should always be replaced The material and durometer of the backup plate O Ring should be the same material and durometer as that specified for the seat O Ring 37 Seat O Ring 310 013 37 The seat O Ring should always be replaced The material and durometer of the seat O Ring should be the same material and durometer as that specified on the O Ring nameplate XV Reassembly of 19000 Series SRV A Metal Seat Valves MS See Figures 1 and 2 1 Bearing surfaces should be ground together using a 320 grit lapping compound see Table 17 These surfaces are The disc holder spindle pocket and spindle spherical nose radius b Thelower spring washer and spindle spring washer radius and The upper spring washer and adjusting screw spherical
33. any then remove the cap 17 gasket Measure the position of the valve adjusting screw 12 and record before removal Measure from the top of the screw to the adjusting screw locknut 13 C Loosen the adjusting screw locknut 13 and remove the adjusting screw 12 from the bonnet 6 d Unscrew the bonnet 6 from the base 1 e Remove the spindle 9 spring 11 and spring washers 10 f Remove the guide 5 disc holder 4 and disc 2 from the base 1 B 2 O Ring Seat Seal Valves DA See Figure 5 Follow steps a through e for Metal Seat Valves above Remove the guide 5 and O Ring disc holder assembly from the base g Remove the o ring retainer lockscrew 36 and the O Ring retainer 3 h Carefully remove the O Ring Seat Seal 37 Be sure not to damage the O Ring groove in the disc holder 4 19096M DA BP Valves See Figure 6 a Remove the cap 18 including lifting gear if any then remove the cap gasket 17 b Measure the position of the valve adjusting screw 12 and record before removal Measure from the top of the screw to the adjusting screw locknut 13 C Loosen the adjusting screw locknut 13 and remove the adjusting screw 12 from the bonnet top 7 d Unscrew the bonnet top 7 from the bonnet bottom 8 e Remove the spindle 9 backup plate 39 spring 11 and spring washers 10 f Unscrew the bonnet bottom 7 from the base 1 g Remo
34. ations e g butt welding code welding and pilot replacement Contact Valve Repair Department at 1 318 640 6057 C SRV Maintenance Training The rising costs of maintenance and repair in the utility and process industries indicate the need for trained maintenance personnel GE conducts service seminars that help your maintenance and engineering personnel reduce these costs Seminars conducted either at your site or ours provide participants with an introduction to the basics of preventative maintenance necessary to minimize downtime reduce unplanned repairs and increase valve safety While these seminars do not create instant experts they do provide the participants with hands on experience with Consolidated valves The seminar also includes valve terminology and nomenclature component inspection troubleshooting setting and testing with emphasis on the ASME Boiler and Pressure Vessel Code For further information contact the Consolidated Product Training Manager by fax at 318 640 6325 or telephone at 518 640 6054 41 Notes 42 Notes Consolidated 19000 Series Safety Valve January 2014 43 DIRECT SALES OFFICE LOCATIONS AUSTRALIA ITALY SOUTH AFRICA Brisbane Phone 39 081 7892 111 Phone 27 11 452 1550 Phone 61 7 3001 4319 Fax 39 081 7892 208 Fax 27 11 452 6542 Fax 61 7 3001 4399 Perte nba AMENCA E CARIBBEAN iba Enone er Phone 481 43 297 9222 Phone
35. d Backpressure the pressure in the discharge header before the SRV is opened Constant Backpressure the superimposed backpressure that is constant with time Variable Backpressure the superimposed backpressure that varies with time e Blowdown the difference between set pressure and re seating pressure of the SRV expressed as a percentage of the set pressure or in actual pressure units Cold Differential Set Pressure the pressure at which the valve is adjusted to open on the test stand This pressure includes the corrections for backpressure and or temperature service conditions e Differential Between Operating and Set Pressures Valves in installed process services will generally give best results if the operating pressure does not exceed 90 percent of the set pressure However on pump and compressor discharge lines the differential required between the operating and set pressures may be greater because of pressure pulsations coming from a reciprocating piston The valve should be set as far above the operating pressure as possible 8 GE Oil amp Gas V Terminology for Safety Relief Valves Contd Lift the actual travel of the disc away from the closed position when a valve is relieving e Maximum Allowable Working Pressure the maximum gauge pressure permissible in a vessel at a designated temperature A vessel may not be operated above this pressure or its equivalent at any metal temperature other than
36. e maintenance personnel to do a professional job of lapping seats 1 Keep work materials clean 2 Always use a fresh lap If signs of wearing lout of flatness are evident recondition the lap Reconditioning of laps is accomplished by lapping them on a flat lapping plate The lapping should be done with a figure eight motion as indicated in Figure 9 To assure the best results when lapping seats the laps should be reconditioned after each usage 3 Apply thin layer of compound to the lap This will prevent rounding off the edges of the seat 4 Keep the lap squarely on the flat surface and avoid any tendency to rock the lap which causes rounding of the seat 5 When lapping keep a firm grip on the part to prevent the possibility of dropping it and damaging the seat 6 Lap using an eccentric or figure eight motion in all directions while at the same time applying uniform pressure and rotating the lap slowly see Figure 9 7 Replace the compound frequently after wiping off the old compound and apply more pressure to speed the cutting action of the compound 8 Tocheckthe seating surfaces remove all compounds from both the seat and the lap Then shine the seat with the LAPPING PLATE RING LAP Figure 9 Lapping Pattern 20 same lap using the lapping motion described above Low sections on the seating surface will show up as a shadow in contrast to the shiny portion If shad
37. e parts are designed so that there is no blowdown adjustment required when setting or testing the valve B Design Options B 1 19000 MS amp DA Safety Relief Valves O Ring Seat Seal Valves 19000 Series Valves are available with an O Ring seat seal as a design option This optional design is bubble tight at 97 percent of set pressures over 100 psig 6 89 barg in order to meet application requirements beyond the normal capabilities of metal to metal seat valves Consolidated Series 19000 valves with the O Ring seat seal option are identified by the suffix DA See Table 14 Lifting Levers Caps and Gags 19000 Series Valves are designed so that field conversion from the standard screwed cap to a plain lifting lever cap or to a packed lifting lever cap lor vice versa does not require valve disassembly or resetting The lifting lever option is designed 10 to open the valve at 75 percent of the valve set pressure in compliance with ASME Code Section VIII Further all available 19000 Series Valve caps may be equipped with a gag upon customer request Inlet Outlet Connections 19000 Series Valves can be provided by GE with flanged or socket weld inlet and outlet connections upon customer request B 2 19096M DA BP Safety Relief Valves See Figure 6 In this design the bonnet and the spindle are different there are two added parts and two additional O Rings The bonnet is a two piece design rather than a
38. e stand If this does not stop the leak disassemble and inspect the leaking joint The seating surfaces should be better than a 32 RMS finish 35 XVI Setting and Testing Contd The valve must be re tested if disassembly is required After the valve set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap gasket 17 and cap 18 or lifting gear on the valve after applying a small amount of non copper based thread lubricant to the gasket seal surfaces and the cap and bonnet threads pressure 2 19096M DA BP After the valve has been set for the correct opening pressure it must be back pressure tested Testing can be conducted by installing the cap with gasket and applying air or nitrogen to the valve outlet Test pressure should be 30 psig 2 barg or the actual valve back pressure whichever is greater Examine the following components for leakage during back pressure testing a base 1 to bonnet bottom 8 joint b bonnet bottom 8 to bonnet top 7 joint and C the bonnet top vent port Note Leakage is best detected by application of a liquid leak detector The use of soap or household detergent as a leak detector is not recommended as it may cover up leaks Repair of leaking valve joints may be attempted by tightening the leaking joint while the valve is still on the stand If this does not stop the leak disassemble and inspect the leaking joint If Threads Threads
39. eaction forces during valve discharge is the responsibility of the vessel and or piping designer GE publishes certain technical information about reaction forces under various fluid flow conditions but assumes no liability for the calculations and design of the inlet piping External loading by poorly designed discharge piping and support systems and forced alignment of discharge piping can cause excessive stresses and distortions in the valve as well as the inlet piping The stresses in the valve may cause a malfunction or leak Therefore Recommended Installation Practices Contd The pressure drop P D between the source of pressure in the protected equipment and the pressure relief valve inlet is not to exceed 3 percent of the valve set pressure Figure 7 Pressure Drop on the Inlet Piping discharge piping must be independently supported and carefully aligned Vibrations in the inlet piping systems may cause valve seat leakage and or fatigue failure These vibrations may cause the disc seat to slide back and forth across the base seat and may result in damage to the seating surfaces Also vibration may cause separation of the seating surfaces and premature wear to valve parts High frequency vibrations are more detrimental to SRV tightness than low frequency vibrations This effect can be minimized by providing a larger difference between the operating pressure of the system and the set pressure of the valve particularly
40. er 5 Guide 6 Bonnet 9 Spindle 10 Spring Washer 11 Spring 12 Adjusting Screw 13 Adj Screw Locknut 17 Gasket 18 Screwed 36 O Ring Retainer Lockscrew 37 O Ring Seat Seal Inlet Nipple Extension A Not Shown Optional Figure 5c Soft Seat Assembly 42 Outlet Nipple Extension Figure 5 19000 O Ring Soft Seat Valve Construction Not Shown Optional 14 X Consolidated 19000 Series SRV Contd D The 19096M DA BP Valve O X ES A VLC lt lt LLX 5 ALLL 2 AN DS SF 7 SN gt Y SS N SN VAS E AN WN 5 Figure 6 19000 DA BP Valve Construction Nomenclature Base O Ring Retainer Disc Holder Guide Bonnet Top Bonnet Bottom Spindle Spring Washer Spring Adjusting Screw Adj Screw Locknut Cap Gasket Screwed Cap O Ring Retainer Lockscrew O Ring Seat Seal Spindle O Ring Backup Plate Backup Plate O Ring Xl Recommended Installation Practices DANGER Mount safety relief valves ina vertical upright position only DANGER Do not mount valve at the end of pipe through which there is normally no flow or near elbows tees bends etc A CAUTION Heed all service manual warnings Read installation instructions before
41. ered trademarks of the General Electric Company Other company names and product names used in this document are the registered trademarks or trademarks of their respective owners 2014 General Electric Company All rights reserved GEA19381 01 2014 Formerly Consolidated 19000
42. ication see Table 10 Place backup plate O Ring 310XX030 40 in the O Ring groove in the backup plate 39 using a small amount of O Ring lubricant Verify that the backup plate seating surface on the bonnet bottom and the backup plate ring inside diameter have no more than a 32 RMS finish Ensure that they are clean and free from nicks and scratches Place the backup plate 39 O Ring side down into the counterbore in the bonnet bottom 8 10 Place spindle O Ring 312XX011 38 into the O Ring groove on the spindle 9 Lubricate the spindle nose with a small amount of non copper based thread lubricant and insert the spindle through the backup plate into the disc holder spindle pocket Apply a small amount of non copper based thread lubricant to the bearing surface of the lower spring washer 10 and slip it over the spindle 9 Install the spring 11 and upper spring washer 10 Apply non copper based thread lubricant to the bonnet top threads for the bonnet bottom and cap joints Install the bonnet top 7 into the bonnet bottom 8 carefully allowing the spindle 9 to line up with the hole in top Torque bonnet top to bonnet bottom with 133 ft Ib 180 32 Nm recommended torque maximum torque not to exceed 500 677 91 Nm The top bonnet is vented and the top bonnet vent must not be plugged 11 12 Thread the adjusting screw locknut 13 on the adjusting screw 12 Apply a small amount of non coppe
43. ide of these ranges may cause malfunction of the intended valve operation 11 X Consolidated 19000 Series SRV A Metal Seat Valve Figure 1b 2 Female NPT Figure 1a Nomenclature Base 1 Disc 2 Disc Holder 4 5 T og 2 X NZS 5 e S oo 2 5 cs ads 5 2 d 287 c 3 x c 9 2 D VU wo Vs an 5 c aN D D oc GS gt c 6 4 lt gt x x 9 gt gt o 1 LL gt gt gt ase 5 O C Uie T o 5 9g o u ET 20 2 2 c c u is je gt 2 T ga ug m 2 D gt 3c 2 3c gt xr do o o Vn u u On On s2 On 85 wt SHH o o st 1 d Sau Succes 55 SRAD lt c Note 3 19110 Valve Not Available ZZ 2 Z A c SEES NS 22222 2 KA 060006 7 7 V I Wg 4
44. ing Selection Chart before ordering springs to determine actual quantities required in view of pressure setting potential in each spring range YOUR SAFETY IS OUR BUSINESS GE 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 GE OR YOUR LOCAL GREEN TAG CENTER GE AUTHORIZED SALES REPRESENTATIVE 40 XXII Field Service Training and Repair Program A Field Service GE provides safe reliable valve services through our Green Tag certified valve assemblers and repair centers The first valve repair network of its kind and today s industry leader our authorized Green Tag Centers have successfully served the valve market for more than 25 years Our services include Valve Survey e Comprehensive accurate record of all PRVs Interchangeability identified e Identify forgotten or overlooked valves Product upgrades to reduce cost and improve performance Inspection of the Valve amp Installation e Visual evaluation of the installation for compliance to codes and regulations e Written evaluation covering compliance issues and discrepancies e Recommendations and corrective actions Testing e On site and in place testing using the GE s EVT testing device e Total computer based valve management system e Free interchange of info
45. ining inventory evels pricing and ordering parts C Replacement Parts List Consult the Recommended Spare Parts list see Tables 19 and 20 to determine the parts to include in the inventory plan Select the desired parts and determine those required for proper maintenance of the valve population in the plant D Identification and Ordering Essentials When ordering service parts please furnish the following information to ensure receiving the correct replacement parts 1 Identify valve by the following nameplate data a Size 750 19 05 mm b Type 19096LC 1 c Temperature class Spring Selection S N d Serial Number TC75834 2 Specify parts required by a Part name b Part number if known c Quantity Table 18 Establishing Inventory Levels Part Classification Replacement Frequency Need Coverage Probability Class Most frequent 70 percent Class II Less frequent but critical 85 percent Class III Seldom replaced 95 percent Class IV Hardware 99 percent Note 1 Need Coverage Probability means that percentage of time the user plant will have the right parts to make the proper repair on the product i e if Class parts are stocked at the owner s facility the parts needed to repair valve in question will be immediately available in 70 percent of all instances XX Genuine Consolidated Parts Each time replacement parts are needed keep these points in mind GE designed
46. installing valve s 16 GE Oil amp Gas A Mounting Position Mount SRVs in a vertical upright position in accordance with RP 530 Installing a safety relief valve in any position other than vertical 1 degree will adversely affect its operation as a result of the induced misalignment of moving parts A stop valve may be placed between the pressure vessel and its relief valve only as permitted by code regulations If a stop valve is located between the pressure vessel and SRV the stop valve port area should equal or exceed the nominal internal area associated with the pipe size of the SRV inlet The pressure drop from the vessel to the SRV shall not exceed 3 percent of the valve s set pressure when flowing at full capacity The threaded inlet and outlet ports and sealing faces of the valve and all connecting piping must be free from dirt sediment and scale In the case of screwed portable valves use caution to avoid unscrewing bonnet from the base if a pipe wrench is used to install or remove the base ensure that the wrench is placed on the flats of the base and not on the bonnet If the bonnet base joint is broken the valve should be retested to ensure proper set pressure and function of the valve Position SRVs for easy access and or removal so that servicing can be properly performed Ensure sufficient working space is provided around and above the valve B Inlet Piping The inlet piping see Figure 7 to the
47. liquid or gas applications and may be furnished with a plain or screwed cap The 19096M DA BP variation is furnished as a 19096M designation with a pressure range of 50 2000 psig 3 45 137 90 barg The standard medium pressure valve is limited to a minimum of 290 psig 19 99 barg in the standard 19000 design The designation will be used since most of the parts are from the 19096M bill of material Table 1 Performance Criteria for the 19096M DA BP Valve Typical blowdown as a percent of set pressure At the low end of the spring range with the maximum allowed back pressure applied the blowdown is shortest Liquid 6 percent 20 percent Gas 3 percent 16 percent Allowable total back pressure This is the sum of the variable and constant back pressure superimposed and built up Note Thermal relief applications may be supplied with back pressures Note Total back pressure for liquid or gas shall not exceed 400 psig Liquid 70 percent of set pressure up to 90 percent of set pressure Gas 50 percent of set pressure 27 58 bargl Temperature limits Determined by O Ring material selection Minimum 20 F 28 C Maximum 600 F 315 C Seat tightness Set pressure of 50 psig 3 45 barg 92 percent 51 psig 3 52 barg 100 psig 6 8 barg 94 percent 101 psig 6 9 barg Maximum Rating 95 percent Note Refer to this Table for the performance criteria of this valve Applications outs
48. n and the use of protective clothing 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 GE products and the possible hazardous consequences of each way GE cannot possibly evaluate all conditions that might injure personnel or equipment Nevertheless GE does offer certain Safety Alerts listed in Section Il for customer information only It is the responsibility of the purchaser or user of GE 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 Additional copies of these instructions can be purchased at a minimal cost by contacting GE in writing at Box 1430 Alexandria LA 71309 1430 or by calling at 318 640 2250 Fax 318 640 6325 IV Warranty Information Warranty Statement GE warrants that its products and work will meet all applicable specifica tions and other specific product and work requirements including those of performance if any CAUTION and will be free from defects in material and workmanship CAUTION Defective and nonconforming items must be held for GE s inspection and returned to the manufacturer
49. o an adapter on the valve outlet and the other end of which is immersed 05 12 7 mm below the surface of a reservoir of water b Theleakage rate for a valve with metal to metal seats shall be determined with the valve mounted vertically and using a standard test fixture as described above The leakage rate in bubbles per minutes shall be determined with the pressure at the safety relief valve inlet held at 90 percent of the set pressure immediately after popping for valves set 51 psig 3 52 barg and above On valves set at 50 psig 3 45 barg and below test for leakage at 5 psig 0 34 barg below the set pressure immediately after popping The test pressure shall be applied for a maximum of one minute Tightness Standard is the leakage rate in bubbles per minute and shall not exceed that shown in Table 13 for metal seat valves or Table 14 for O Ring seat seal valves A valve with a seat of resilient material i e an O Ring valve shall show no leakage at pressures less than those indicated in Table 13 when the test medium is either air or water Table 13 Metal Seat Valve Leakage Rate Max Leakage Rate Approximate Leakage Rate Bubbles per minute ft per 24 hr Liters per 24 hr 40 0 06 16 99 Table 14 O Ring Seat Valve Leakage Rate Set Pressure Min Leak Point 96 of Set Pressure psig barg 15 to 30 1 03 to 2 07 9096 31to 50 2 14 to 3 45 9296 51 to 100 3 52
50. oading or unloading from a truck While hoisting the valve take care to prevent bumping the valve against steel structures and other objects or m3 min for gases in gallons per minute GPM for liquids Relief Valve an automatic pressure relieving device actuated by static pressure upstream from the valve A relief valve is used primarily for liquid service Safety Relief Valve SRV an automatic pressure relieving device used as either a safety or relief valve depending upon application The SRV is used to protect personnel and equipment by preventing excessive overpressure Safety Valve an automatic pressure relieving device actuated by the static pressure upstream of the valve and characterized by a rapid opening or pop action It is used for steam gas or vapor service Set Pressure the gauge pressure at the valve inlet for which the relief valve has been adjusted to open under service conditions In liquid service the inlet pressure at which the valve starts to discharge determines set pressure In gas or vapor service the inlet pressure at which the valve pops determines the set pressure Simmer the audible passage of a gas or vapor across the seating surfaces just before pop The difference between this start to open pressure and the set pressure is called simmer Simmer is generally expressed as a percentage of set pressure Prevent dust and debris from entering inlet or outle
51. of all valve products The relevant procedures recommended by GE and described in these instructions are effective 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 GE product or render it unsafe It is also important to understand that these safety messages are not exhaustive GE cannot 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 GE has not undertaken any such broad evaluation and thus anyone who uses a procedure and or tool which is not recommended by GE or deviates from GE recommendations must be thoroughly satisfied that neither personal safety nor valve safety will be jeopardized by the method and or tools selected Contact GE at 318 640 6055 if there are any questions relative to tools methods The installation and start up of valves and or valve products may involve proximity to fluids 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 protectio
52. one piece The top of the bonnet 7 is the male piece and it screws into the female bottom bonnet 8 The bottom bonnet has a machined shelf in the top on which a metal backup plate 39 seats via an O Ring 40 part number 310XX030 The the part number designates the material and durometer of the O Ring The spindle 9 is modified to have larger diameter in the lower section to accommodate a 310XX011 O Ring 40 which slides through the inside diameter of the backup plate 39 providing an area nearly equal to the area of the base which balances the effects of the back pressure C Nomenclature Applicable valve nomenclature for Types 19000 Male and Female inlet configurations are illustrated in Figures 1 through 6 Relevant parts nomenclature for optional lifting levers caps and the gag as applicable are provided in Figures 1 through 6 IX Introduction A 19000 MS amp DA Safety Relief Valves Consolidated Series 19000 Portable Pressure Relief Valves are designed to meet ASME Section VIII requirements for fixed blowdown pressure relief valves and liquid relief valves They may be used for various media such as air liquids process steam and hydrocarbons and may serve as either a safety valve or a relief valve depending upon the application B 19096M DA BP Safety Relief Valves 19000 back pressure version is only available in the 096 2 44 mm orifice with an O Ring seat It is available for steam
53. ows are present further lapping is necessary and only laps known to be flat should now be used Only a few minutes will be required to remove the shadows 9 When the lapping is completed any lines appearing as cross scratches can be removed by rotating the lap which has been wiped clean of compounds on the seat about its own axis 10 The seat should now be thoroughly cleaned using a lint free cloth and a cleansing fluid A2 Lapping the Base Seat For 1 design The base seat may be reconditioned using the lapping procedure however the dimensions provided in Table 2 should be used to determine the seat width Table 2 Lapping Width 1 Metal Seat Design Only SET PRESSURE SEAT WIDTH psig barg min max min max in mm 5 100 0 34 6 89 010 0 25 101 300 6 96 20 68 015 0 38 301 800 20 75 55 16 020 0 51 801 UP 55 23 Note 1 Note 1 Add 005 0 125 mm 100 psig 6 9 barg not to exceed 070 1 78 mm The seat width can be measured by the use of a Measuring Magnifier see Figure 10a GE Energy recommends the use of Model 51 34 35 37 Bausch and Lomb Optical Co or an equivalent This is a seven power glass with a 750 19 05 mm scale showing graduations of 005 0 13 mm The use of this scale in measuring the seat width is shown in Figure 10b Measuring Magnifier Figure 10a Measuring Magnifier XIII Maintenance Contd Flat Seat 5 Tape
54. peration C Test Media For best results valves shall be tested by type as follows 1 Steam valves are tested on saturated steam 2 Air or gas valves are tested on air or gas at ambient temperature and 3 Liquid valves are tested on water at ambient temperature D Setting the Valve Set the valve to open at the set pressure as shown on the nameplate If a cold differential test pressure is indicated on the nameplate set the valve to open at that pressure on the test stand The cold differential test pressure is the set pressure corrected to compensate for backpressure and or operating temperature A new cold differential test pressure may need to be determined if changes are to be made to the set pressure or backpressure or if the service temperature changes Note This design will allow the set pressure to remain constant under superimposed variable back pressure conditions If changes are to be made to the set pressure or back pressure or the service temperature changes a new cold differential test pressure may need to be determined E Set Pressure Compensation Cold Differential Test Pressure for Temperature Compensation During production testing the SRV is often tested at temperatures that are different from the temperatures the SRV will be exposed to in service Increasing the temperature from ambient temperature causes the set pressure to decrease The decrease in set pressure is due to thermal expansion of the
55. r Figure 106 Measuring Magnifier Detail For 2 Design The 2 metal seat design is a flat seat design The base seat may be lapped or machined if necessary to verify that the seat N of Figure 11 is free from indentions scratches high spots etc If additional lighting is required for verifying the seat GE suggests a goose neck flashlight similar to the Type A Lamp Assembly Flashlight Standard Molding Corporation Dayton Ohio or an equivalent Figure 11a Base General Dimensions Figure 11 A3 Figure 11b Metal Seat 1 Design Machining the Base Seat When the base seat cannot be repaired by lapping it can be machined as shown in Figure 11 using the dimensions provided in Tables 3 to 5 GE recommends that the following procedure be adhered to when machining the base seat a Using a four jaw chuck align the base so that surfaces marked and U run true within 001 0 03 mm on indicator b Take light cuts on the seat surface until all damage is removed Reestablish dimensions B F G H and Angle When L minimum is obtained the base should be replaced c After all machining has been accomplished lap the seat using same procedure for base seat ATTENTION 19000H and 19000 DA bases have flat seats 90 angle across the entire seating surface from B diameter to D diameter Figure 11c Metal Seat 2 Design N View 01 2 003
56. r based thread lubricant to the tip of the adjusting screw Install the adjusting screw in the bonnet top rotating the number of times required to compress the spring slightly Use pliers to hold the spindle in position and prevent galling Adjust the adjusting screw to the measurement recorded during disassembly see step Disassembly The valve is now ready for setting XVI Setting Testing A DANGER Decontaminate or clean if necessary before pre testing or disassembly Safety and environmental precautions must be taken for the decontamination or cleaning method used ALN A DANGER Do not stand or place hand in front of valve discharge flange if valve is under pressure A General Information Before putting the reconditioned valve in service it must be set to open at the required set pressure as shown on the nameplate Although the valve can be set on the service installation it is more convenient to set the valve and check seat tightness on a test stand Any spring replacement shall be in accordance with current guidelines B Test Equipment The test stand used for testing SRVs normally consists of a pressure source supply line with a throttle valve and receiver that have the following features Outlet for attaching the valve to be tested Pressure gauge with a shut off valve Drain line with a shut off valve and Adequate receiver volume for the valve to be tested and to achieve proper o
57. radius Clean all parts before assembly 2 Apply small amount of non copper based thread lubricant to the guide bonnet seating surface and the bonnet and base threads 3 Useaclean base 1 lapped for the valve set pressure see seat width requirement Table 5 Place a lapped disc 2 on the base with lapped surfaces facing each other Place the disc holder 4 onto the disc and base Place guide 5 over disc holder onto base Lubricate the disc holder spindle bearing surface with non copper based thread lubricant 4 Lubricate the spindle nose with a small amount of non copper based thread lubricant and insert the spindle 9 into the disc holder spindle pocket 30 5 Apply a small amount of non copper based thread lubricant on the bearing surface of the lower spring washer 10 and slip it over the spindle 9 Install the spring 11 and upper spring washer 6 Apply a small amount of non copper based thread lubricant to the bonnet base threads and guide seating surface When a stainless steel bonnet 6 and base 1 are used and or a standard bonnet for service above 500 temperature apply non copper based thread lubricant to the bonnet base threads and guide 5 seating surface Before tightening the bonnet completely adjust the position of the guide so that one of the holes is lined up with the discharge of the valve Tighten the bonnet using sufficient torque from Base Torque Specification see Table 10 7 Thread the
58. ressure 19096 19110 19226 19357 tightness 19126 19567 psig bar in mm in mm 2 Polishing the Base Seat 5 to 800 0 34t0 55 16 Flat Flat 002 0 51 Normally the base seating area on this type of valve is 801 Above 55 23 Above Flat Flat Note1 Note 1 not damaged since the O Ring absorbs the impact when foreign material is trapped between the O Ring and the Note 1 Add 005 0 125 mm per 100 psig 6 896 bar until disc seat base seating area The O Ring will therefore hold a bubble width has reached the maximum available width tight seal with slight indications on the base seating surface Nevertheless slight indications on the base seat surface may be removed by lapping the base Figure 12a Metal Seat Disc 1 Design Figure 12b Metal Seat Disc 2 Design lt lt 7 Y gt gt LAPPED SURFACE Figure 12c Soft Seat O Ring Retainer 19096 19126 Figure 12d Soft Seat O Ring Retainer 19226 19567 lt gt Q 7 Figure 12 Disc and O Ring Retainer Metal Seat amp Soft Seat Maintenance Contd Disc Metal Seat O Ring Retainer Soft Seat Valve Type Q R min m m m VERE Q R min S min in mm in mm in mm in mm in mm in mm in mm 19096L M 461 1171 025 0 64 243 6 17 234 5 94 426 1082 N A N A 151 3 84 19096H 461 1171 025 0 64 243
59. ring 11 Replace the spring if 1 The ends not ground flat and parallel 2 Thecoils are bent pitted or unevenly spaced 3 spring cannot be properly identified spring chart ATTENTION 19000 Series valve springs do not have sufficient wire diameter to allow permanent spring marking The Set Pressure of the 19000 valve should be within the spring range of the valve spring However if there is Constant Superimposed Backpressure the Cold Differential Test Pressure should be within the Spring range of the Valve Spring If the Cold Differential Test pressure is only established because of elevated temperature then the Set Pressure should be within the spring range of the valve spring and the valves should be set at the Cold Differential Test Pressure Spring Washers 10 Replace the Spring Washers if 1 The bearing surface is galled pitted or scratched 2 Corrosion affects the centering of the spring J Adjusting Screw 12 Replace adjusting screw if 1 Threads are torn stripped or galled 2 The bearing surfaces are galled pitted or scratched 3 The adjustment flats are damaged or rounded K Bonnet 7 The bonnet top should be replaced if 1 Thethreads are stripped torn or galled 29 XIV Inspection and Part Replacement Contd L Bonnet Bottom 8 The bottom bonnet should be replaced if 1 Threads are stripped torn or galled 2 The guide seating surf
60. rmation e Historical data and permanent record of traceability e Maintenance scheduling and planning e Repair intervals validated by each valves maintenance history Code compliance e Accessible via secure password protected internet connection e Downloadable and printable reports Base line history established Repair GE Audited Facility Using GE s Inspection Criteria and Critical Dimensions e By fully trained and certified pressure relief valve technicians e Using original manufactured parts Inventory Control Global access to spare parts inventories via www greentag net with your local Green Tag Center GE s authorized sales representative e Parts interchangeability Obsolete and excess inventory identified e Recommend cost effective inventories ValvKeep Total computer based valve management system e Free interchange of information e Historical data and permanent record of traceability e Maintenance scheduling and planning e Repair intervals validated by each valves maintenance history e Code compliance e Accessible via secure password protected internet connection e Downloadable and printable reports B Factory Repair Facilities The factory at Alexandria Louisiana maintains a complete Consolidated products repair center The Repair Department in conjunction with the manufacturing facilities is equipped to perform specialized repairs and product modific
61. rstand Practice Danger Alerts A DANGER alert describes actions that may cause severe personal injury or death In addition it may provide preventive measures to avoid severe personal injury or death DANGER alerts are not all inclusive GE cannot know all conceivable service methods nor evaluate all potential hazards Dangers include e temperature pressure can cause injury Ensure all system pressure is absent before repairing or removing valves e Donotstandiin front of a valve outlet when discharging STAND CLEAR OF VALVE to avoid exposure to trapped corrosive media e Exercise extreme caution when inspecting a pressure relief valve for leakage e Allow the system to cool to room temperature before cleaning servicing or repairing Hot components or fluids can cause severe personal injury or death e Always read and comply with safety labels on all containers Do not remove or deface container labels Improper handling or misuse could result in severe personal injury or death e Never use pressurized fluids gas air to clean clothing or body parts Never use body parts to check for leaks flow rates or areas Pressurized fluids gas air injected into or near the body can cause severe personal injury or death It is the owner s responsibility to specify and provide protective wear to protect persons from pressurized or heated parts Contact with pressurized or heated parts can result in severe personal injury
62. s which COULD result in severe personal injury or death The instructions if necessary on how to avoid the hazard The top panel of the format contains a signal word DANGER WARNING 3 CAUTION or ATTENTION which communicates the level of hazard seriousness CAUTION Hazards or unsafe practices which COULD result in The center panel contains a pictorial which communicates the nature of minor personal injury 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 4 equipment ATTENTION Hazards or unsafe practices which COULD result in The bottom panel may contain an instruction message on how to avoid the product or property damage hazard In the case of human hazard this message may also contain a more precise definition of the hazard and the consequences of human interaction with the hazard than can be communicated solely by the pictorial A CAUTION WV Handle valve carefully Do not drop or strike Do not remove bolts if Know all valve exhaust Wear necessary protective pressure in line as this will leakage points to avoid equipment to prevent result in severe personal possible severe personal possible injury injury or death injury or death Consolidated 19000 Series Safety Valve January 2014 5 Safety Alerts Read Unde
63. ssential working surfaces of the spindle the method stated in the next section is recommended 2 V Block Support Set Up The ball pointed spindles should be placed in a piece of material B that has been recessed to permit free rotation of the spindle see Figure 13 ee Section X X Bearing Surface T Spring Washer Seat 2 Spindle Figure 13 V Block Support Setup 26 XIV Inspection and Part Replacement A Base 1 D Bonnet 6 The base should be replaced if The bonnet should be replaced if 1 Seat Surface 1 Threads are stripped torn or galled a Metal Seated Seat surface N see Figure 11 is 2 The guide seating surface is scratched nicked corroded or scratched nicked corroded leaks or is too wide and leaks cannot be machined see Table 2 and Section XIII 3 Condition is porous corroded or distorted A3 2 b b O Ring Seat surface see insert Figure 11 is E O Ring Disc Holder 4 scratched nicked corroded or leaks The O Ring disc holder should be replaced if 2 Threads all are torn stripped or galled 1 The outside surface is worn egged or galled and or 3 Guide seating surface is scratched nicked corroded cannot meet H dimension see Figure 14 and Table 8 dimension L is less than L minimum see Figure 11 Tables 2 spindle pocket bearing surface is galled or pitted 3 to 5 and Section XIII A3 2 b 3 The O
64. sssentsnnsssnssnssssssssssssseeseeseesessssseeesmmttunsssssssssssssssseeeeeeceeseseseseseesimttnaussssnsssssesssseseees 30 B O Ring Seat Seal Valves DA 31 C 19096M DA BP O Ring Seat Seal ValVES 31 Setting and 5 33 A iGenerallntortediob stein cene 33 33 mmA mm 33 02 Setting the gt ac Mie 33 E S tPressure COmipernsatiOn icio t RU R RU HR HE ree d ATR 33 Nep eee 34 2 4 A 35 E s s o e E O E EN E E 35 B ck Pressure Testing 6 DA isse eerie tpe reete i e RE rectis 35 J Hydrostatic TESTING and GAGGING a 37 K Manual Popping of the Valve AVI Trouble Soong GIG ittm need con edem eedem ctn en Ted XVIII Maintenance Tools and Supplies Replacement Parts Planning u ccccccccssssssssssesssssccssssssssssssssessssssssussssssesssssssnusscsseessssssnuussessesssssssnuuscesseessssssnuusseeseeesssssnneesees 39 re 39 B Inventory PIONINING ssssssssscsccssssssssssssscccssssssssssessssesssssnusssessssssssssuussessesss
65. ssssnusseeseessssssnuusseesessessssnuusceesesssssssuuseeseecesssssnueceeesees 39 Repldcemerib EISE s 39 D Identification and Ordering 39 XX Genuine Consolidated 39 XXI 5 40 Field Service Training Repair 41 A Field Service tentes B Factory Repair Facilities SRV UNS 41 42 4 Product Safety Sign and Label System If and when required appropriate safety labels have been included in the 1 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 DANGER Immediate hazards which WILL result in severe personal injury or death The level of hazard seriousness 2 nature of the hazard WARNING Hazards or unsafe The consequence of human or product interaction with the hazard practice
66. t of the valve Storage Store SRVs in a dry environment and protect them from the weather Do not remove the valve from the skids or crates until immediately before installation Do not remove flange protectors and seating plugs until the valve is ready to be bolted into place during the installation Screwed portable valves should be kept in their factory foam filled carton until installation to avoid damage to external inlet threads VII Pre Installation and Installation Instructions When SRVs are uncrated and the flange protectors or sealing plugs are removed exercise meticulous care to prevent dirt and other foreign materials from entering the inlet and outlet ports while bolting the valve in place VIII Design Features and Nomenclature A General Information The Series 19000 Portable Safety Relief Valve has 316 stainless steel trim as standard material Reliable performance and easy maintenance procedures are characteristics of this valve when properly installed in suitable applications for its design The 19000 Series SRV has three pressure classes 19000L 5 290 psig 0 34 19 99 barg 19000M 291 2000 psig 20 06 137 90 barg and 19000H 2001 psig 137 96 barg and up Standard 19000 parts are used for both liquid applications and gas applications It is designed for short blowdown on all types of media typically less than 10 percent 19000 Series safety relief valves have fixed blowdown This means that th
67. t gag is Adjusting Screw sufficient to hold hydrostatic pressures Too much force applied Adjusting Screw to the gag may bend the spindle and damage the seat After a Locknut hydrostatic test the gag must be removed and replaced by the sealing plug furnished for this purpose see Figure 17 Test gags D N for Consolidated SRVs can be furnished for all types of caps and Figure 17 Typical Cap with Gag lifting gears will not become trapped on the seating surfaces When allowing K Manual Popping of the Valve the valve to close under flowing conditions completely release the lever from maximum lift to snap the valve back on its seat Consolidated safety relief valves are furnished when so ordered with packed or plain lifting levers for hand popping Since in some cases the dead weight of the lever may have a tendency to lift the valve disc the lever should be hung When the valve is to be opened by hand using the lifting lever the pressure at the valve inlet should be at least 75 percent of the valve s set pressure Under flowing conditions the valve supported or counter weighted so the lifting fork does not contact the release nut must be fully lifted from its seat so that dirt sediment and scale XVII Trouble Shooting Table 15 Trouble Shooting Guide Problem Probable Cause Corrective Action a Disassemble valve lap seating surfaces replace disc or O Ring if required as outlined in this manual
68. that used in its design Consequently for that metal temperature it is the highest pressure at which the primary pressure SRV is set to open Operating Pressure the gauge pressure to which the vessel is normally subjected in service A suitable margin is provided between operating pressure and maximum allowable working pressure For assured safe operation the operating pressure should be at least 10 percent under the maximum allowable working pressure or 5 psi 34 bar whichever is greater Overpressure a pressure increase over the set pressure of the primary relieving device Overpressure is similar to accumulation when the relieving device is set at the maximum allowable working pressure of the vessel Normally overpressure is expressed as a percentage of set pressure Rated Capacity the percentage of measured flow at an authorized percent overpressure permitted by the applicable code Rated capacity is generally expressed in pounds per hour lb hr for vapors standard cubic feet per minute SCFM VI Handling Storage Handling Valves should not be shipped with the inlet flange down These valves should be kept in their factory foam filled carton until installation ATTENTION Never lift the valve by the lifting lever ATTENTION Handle carefully Do not drop or strike the valve Do not subject SRVs either crated or uncrated to sharp impact Ensure that the valve is not bumped or dropped during l
69. the parts GE guarantees the parts GE s Consolidated valve products have been in service since 1879 GE has worldwide service GE has fast response availability for parts with the global Green Tag Center authorized sales representatives network 39 Recommended Spare Parts Class Part name Table 19 Metal to Metal Seat Valves Quantity Parts Size Type amp Material Valves in Service Need Coverage Probability Disc 1 1 70 percent Gaskets Cap 1 1 Disc Holder 1 5 Spindle 1 5 85 percent Guide 1 5 only Spring Assembly 85 Compression Screw 1 5 Compression Screw Locknut 1 5 Cap specify screwed packed or plain 1 5 IV Release Nut used on packed or plain lever only 1 5 99 Release Locknut used on packed or plain lever 1 5 Table 20 O Ring Seat Valves antity Parts Size Type amp Class Part name ou Need Coverage Probability Material Valves in Service O Ring Retainer 1 1 O Ring 1 1 70 percent Lock Screw 1 1 Gaskets Cap 1 1 Disc Holder 1 5 I Spindle 1 5 85 percent Guide 1 5 Spring Assembl 1 5 I 95 Compression Screw 1 5 Compression Screw Locknut Cap specify screwed packed or plain 1 5 Release Nut used on packed or plain lever 1 5 IV 99 percent only 1 5 Release Locknut used on packed or plain 1 5 lever only Note 1 Consult Spr
70. valve body Cap may be required for weather protection Long Radius Elbow For a closed system always keep piping strains isolated from the Pressure Relief Valve regardless of process operation and temperature Figure 8 Outlet Piping Considerations Recommended Installation Practices Contd When two or more valves are piped to discharge into a common header the built up backpressure resulting from the opening of one or more valve s may cause a superimposed A CAUTION backpressure in the remaining valves Under these conditions the use of the 19096 DA BP model is recommended In every case the nominal discharge pipe size should be at least as large as the nominal size of the SRV outlet flange In the case of long discharge piping the nominal discharge pipe size must sometimes be much larger As a final point the discharge piping size is never less than the size of the valve outlet nor heavier than schedule 40 pipe size In addition the discharge piping must be designed to limit the total backpressure to a maximum of 10 percent of the valve set pressure or 400 psig 27 58 barg whichever is smaller Wear necessary protective equipment to prevent possible injury A DANGER ATTENTION Undersized discharge piping could create built up backpressure XII Disassembly of 19000 Series SRV A General Information Consolidated SRVs can be easily disassembled for inspection the reconditioning
71. ve the guide 5 and O Ring retainer 3 h Remove the retainer lockscrew 36 and the O Ring retainer 3 Carefully remove the seat O Ring 37 Be sure not to damage the O Ring groove in the disc holder 4 C Cleaning 19000 Series Safety Relief Valve internal parts may be cleaned with industrial solvents cleaning solutions and wire brushes If you are using cleaning solvents take precautions to protect yourself from potential danger from breathing fumes chemical burns or explosion See the solvent s Material Safety Data Sheet for safe handling recommendations and equipment It is not recommended to sandblast internal parts as it can reduce the dimensions of the parts The base 1 bonnet 6 and cap 18 castings may be sandblasted with care not to erode internal surfaces or damage machined surfaces If grit blasting is required the use of glass bead media is recommended DANGER Follow recommendations for safe handling in the solvent s Material Safety Data Sheet and observe safe practices for any cleaning method XIII Maintenance A Metal Seat Valves MS A1 Precautions and Hints for Lapping Seats Reconditioning of the seat surface may be accomplished by lapping with a flat cast iron ring lap coated with a 1000 grit lapping compound or its equivalent see Table 17 A cast iron lap coated with a lapping compound is used for reconditioning the seating surfaces of the base 1 and disc 2 will enabl

Consolidated* Safety Relief Valve Maintenance Manual

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