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19000 Series Consolidated Safety Relief Valve

1. X1 019 Cold Differential Set Pressure 2548 psig Set pressure 2500 psig temperature 500 F constant backpressure 150 psig Set PEOSSUTG iicet torem tee nh edens 2500 psig Minus Constant Back Pressure 150 psig Differential Pressure 2350 psig Multiplier see Table VII X1 019 Cold Differential Set Pressure 2395 psig Set pressure 2500 psig temperature 100 F constant backpressure 150 psig Set Pressure eeeeessee 2500 psig Minus Constant Back Pressure 150 psig Cold Differential Set Pressure 2350 psig Set pressure 400 psig on superheated steam 1 ii Page 31 must be installed Test the valve for leakage using an API test fixture The API leakage test procedure is described below Per API Standard 527 a standard test fixture consists of a piece of tubing of 5 16 7 94 mm x 035 0 89 mm wall one end of which is joined to an adapter on the valve outlet and the other end of which is immersed 1 2 12 70 mm below the surface of a reservoir of water The leakage 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 im
2. 6 8 barg 94 101 psig 6 9 barg Maximum Rating 95 Applications outside of these ranges may cause malfunction of the intended valve operation 19000 Series Consolidated Safety Relief Valve Page 34 Changes in this Variation See Figure 18 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 one piece The top of the bonnet 7A is the male piece and it screws into the female bottom bonnet 7B The bottom bonnet has a machined shelf in the top on which a metal backup plate 12 seats via an O Ring 13 part number 310XX030 The XX in the part number designates the material and durometer of the O Ring The spindle 8 is modified to have a larger diameter in the lower section to accommodate a 310XX011 O Ring 9 which slides through the inside diameter of the backup plate 12 providing an area nearly equal to the area of the base which balances the effects of the back pressure Disassembly a Remove the cap 20 including lifting gear if any then remove the cap gasket 19 b Measure the position of the valve adjusting screw 14 and record before removal Measure from the top of the screw to the adjusting screw locknut 15 c Loosen the adjusting screw locknut 15 and remove the adjusting screw 14 from the bonnet top 7A d Unscrew the bonnet top 7A from the bonnet bottom
3. as a shadow in contrast to the shiny portion Lapping Plate Ring Lap Figure 10 Lapping Pattern 19000 Series Consolidated Safety Relief Valve Page 19 If shadows are present further lapping is dimensions provided in Table should be necessary and only laps known to be flat used to determine the seat width should now be used Only a few minutes will be required to remove the shadows TIE Saab wiGiiican DE mee Meise of a Measuring Magnifier See Figure 11 A ix When the lapping is completed any lines Dresser Consolidated recommends the use appearing as cross scratches can be of Model S1 34 35 37 Bausch and Lomb removed by rotating the lap which has Optical Co or an equivalent This is a seven been wiped clean of compounds on the power glass with a inch scale showing seat about its own axis graduations of 0 005 inch The use of this by the seatshould new betnoroudhiy E in measuring the seat width is shown in gure 11 B cleaned using a lint free cloth and a cleansing fluid If additional lighting is required for measuring the seat Dresser Consolidated suggests a b Lapping the Base Seat goose neck flashlight similar to the Type A The base seat may be reconditioned Lamp Assembly Flashlight Standard Molding using the lapping procedure however the Corporation Dayton Ohio or an equivalent Y T gt Magnifier 0 0 1 0 6 0 7 hu Flat Seat Base 5 Taper Figure 11 A Measuring Magni
4. reduce these costs Seminars conducted either at your site or at our manufacturing plant in Alexandria Louisiana 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 Product Training Manager by fax at 1 318 640 6325 or telephone at 1 318 640 6054 19000 Series Consolidated Safety Relief Valve Field Service Dresser Consolidated 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 e Interchangeability identified Identify forgotten or overlooked valves Product upgrades to reduce cost improve performance Inspection of the Valve amp Installation Visual evaluation of the installation for compliance to codes and regulations e Written e
5. taken for the Do not attempt to adjust the blowdown on these l decontamination or valves Typical blowdown is less than 10 The Test Equipment SS blowdown under the back pressure conditions will used cause a shorter blowdown than when observed with The test stand used for no back pressure testing SRVs normally consists of a pressure source A DANGER Seat Leakage supply line with a throttle valve and receiver that have e a Air DIS TOTEM eaten E The air leakage test shall be performed with Outlet for attaching the all connections and openings in the body valve to be tested and bonnet pressure tight The cap with the gasket which covers the adjusting screw Pressure gauge with a es ondaa must be installed Test the valve for leakage shut off valve of valve discharge using an API test fixture The API leakage test Drain line with a shut off flange if valve is procedure is described below valve and aul ean i Per API Standard 527 ANSI B147 1 72 a Adequate receiver volume standard test fixture consists of a piece of for the valve to be tested and to achieve proper tubing of 5 16 7 94 mm x 035 0 89 mm operation wall one end of which is joined to an adapter i on the valve outlet and the other end of Test Media which is immersed 1 2 12 70 mm below the For best results valves shall be tested by type as surface of a reservoir of water follows ii The leakage rate for a valve with metal
6. 18 44 270 44 270 25 58 28 17 0 23 28 17 0 23 57 580 58 220 32 11 41 22 0 3 41 22 0 3 78 870 81 180 40 39 42 44 0 3 41 33 x 0 3 80 240 82 580 19096H amp 0 661 1 06 0 007 1 06 0 007 2 221 2 221 25 58 38 48 0 23 38 48 0 23 68 760 68 760 25 58 38 48 0 23 38 48 0 23 76 880 76 880 Low Pressure Guide High Pressure Guide Figure 16 Guide 19000 Series Consolidated Safety Relief Valve Page 28 g Thread the adjusting screw locknut 10 on the Reassem bly and adjusting screw 9 Apply a light coat of non Lu brication copper based thread lubricant to the adjusting screw threads and spherical radius Metal Seat Valves MS Thread the adjusting screw locknut 10 onto the adjusting screw 9 Apply a small See Figures 1 and 2 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 Use pliers to hold the spindle 6 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 a Bearing surfaces should be ground together using a 320 grit lapping compound see Table XIII These surfaces are a the disc holder spindle pocket and spindle spherical nose radius b the lower spring washer and spindle spring washer radius and c the upper spring washer and
7. 2009 Replacement Parts Planning General Information Page 40 the end of this manual for assistance in determining inventory levels pricing and ordering parts 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 Inventory Planning The basic objectives in formulating a replacement parts plan are Replacement Parts List Consult the Recommended Spare Parts list see Tables XV A and XV B 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 Identification and Ordering Essentials When ordering service parts please furnish the following information to insure receiving the correct replacement parts e Prompt availability Minimum downtime e Sensible cost and e Source control Wu 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 summariz
8. O Ring Retainer 16 If slight damage is present the O Ring a Retainer can be refurbished by either lapping or machining O Ring Retainer should be replaced if severely damaged or if dimension S minimum is exceeded see Figure 13 and Table Ill b Polishing the Base Seat Normally the base seating area on this type of valve is not damaged since the O Ring absorbs the impact when foreign material is trapped between the O Ring and the base seating area The O Ring will therefore hold a bubble 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 b ATTENTION The O Ring always should be replaced to insure seat tightness BEARING SURFACE 2 Figure 13 an LAPPED SURFACE Page 25 Checking Spindle Concentricity General Information It is important that the spindle 6 of a safety relief valve be straight in order to transmit the spring load to the disc without lateral binding Over gagging is one of the common causes of bent spindles To check the essential working surfaces of the spindle the method stated in the next section is recommended V Block Support Set Up i 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 14 ii Support the spindle with a V block A placed near the upper end
9. and bonnet seating surfaces are scratched nicked corroded or leaks c Hole dimension K is out of tolerance see Figure 16 and Table V d Guide Height Dimension L is out of tolerance see Figure 16 and Table V e J dimension is not within tolerance see Figure 16 and Table V 19000 Series Consolidated Safety Relief Valve Page 18 Spindle 6 replace the spindle if a The bearing surfaces are galled pitted or scratched b Threads are torn stripped or galled c The stem is bent see Figure 14 Spring 8 replace the spring if 1 The ends are not ground flat and parallel 2 The coils are bent pitted or unevenly spaced 3 The spring cannot be properly identified spring chart ATTENTION 19000 Series valve springs do not have sufficient wire diameter to allow permanent spring marking Spring Washers 7 replace the Spring Washers if a The bearing surface is galled pitted or scratched b Corrosion affects the centering of the spring Adjusting Screw 9 replace adjusting screw if a Threads are torn stripped or galled b The bearing surfaces are galled pitted or scratched c The adjustment flats are damaged or rounded Maintenance Instructions Metal Seat Valves MS a Precautions and Hints for Lapping Seats Reconditioning of the seat surface may be accomplished by lapping with a flat cast iron ring lap coated
10. of the lower spring washer 10 and slip it over the spindle 8 Install the spring 11 and upper spring washer 10 j Apply non copper based thread lubricant to the bonnet top threads for the bonnet bottom and cap joints Install the bonnet top 7A into the bonnet bottom 7B carefully allowing the spindle 8 to line up with the hole in top Torque bonnet top to bonnet bottom with 133 ft lo recommended torque maximum torque not to exceed 500 ft lb ATTENTION The top bonnet is vented and the top bonnet vent must not be plugged k Thread the adjusting screw locknut 15 on the adjusting screw 14 Apply a small amount of non copper 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 b Disassembly Il The valve is now ready for setting 19000 Series Consolidated Safety Relief Valve Page 36 Plain Cap 23 ag Release Locknut 22 i Sealing Plug 17 Release Nut 21 Sealing Plug Gasket 18 Lever Pin 25 Lifting Lever 24 Plain Cap Cap with Gag Screwed Cap 20 Spindle 8 Cap Gasket 19 Adj Screw Locknut 15 Adjusting Screw 14 Spring 11 19096c BP 19096t BP Bonnet TOR Spring Washe
11. 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 reliability of the valve the operating pressure should be at least 10 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 or m min for gases and 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 actua
12. providing a larger difference between the operating pressure of the system and the set pressure of the valve particularly under high frequency conditions Temperature changes in the discharge piping may be caused by fluid flowing 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 the 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 Outlet Piping Alignment of the internal parts of the SRV is important to ensure proper operation see Figure 9 Although the valve body will withstand a considerable mechanical load unsupported discharge piping consisting of more than a companion flange for flange outlet valves long radius elbow and a short vertical pipe is not recommended Use spring supports to connect outlet piping to aid in preventing 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 These design issues are 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
13. still on the stand If this does not stop the leak disassemble and inspect the leaking joint If 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 15 Install the cap gasket 19 and cap 20 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 Threads Threads m 1 8 NPT Vent 4 Donot plug Threads Threads Threads m Threads Surface V Figure 19 19096M DA BP Valve Two Piece Bonnet Spindle and Back up Plate ATTENTION Be careful when removing O Rings to avoid damage to the O Ring groove 19000 Series Consolidated Safety Relief Valve Trouble Shooting Guide Damaged seat or O Ring Bearing point damage Valve leaking Part misalignment Discharge stack binding on outlet Simer Line vibrations Lapped seat too wide Improper installation or Chatter valve sizing Built up back pressure No action valve does not go into full lift valve does not close from full lift Foreign material trappe
14. valves use Table X to determine the percentage of set pressure Seat Leakage a Air c Steam When a metal to metal seat valve is checked carol al for tightness using steam as the test medium all connections and openings in the body and bonnet pressure tight The cap with the gasket which covers the adjusting screw Table X Table IX 15 1 034 bar to 30 psig 2 069 bar 31 2 138 bar to 50 psig 3 448 bar 51 3 517 bar to 100 psig 6 897 bar 101 6 966 bar psig or greater Bubbles per minute Standard cubic ft per 24 hr 19000 Series Consolidated Safety Relief Valve at 90 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 X to determine the percentage of set pressure Back Pressure Testing 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 base 1 to bonnet 5 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 n
15. 0 8200 0100340209000 0562210202 1121020 0 0520 2 9 00 9 20 00 000 eee 33 e eee Rec Po c E A eR a ea 33 Gs aye ala ete aie dal Kee re loa come extern e eae eee arco DO Me at re de O 34 pS T 34 FANS NS OS CLIC I tu mero i o neo da aoo Cat qui do p LL uM audeo en oe sade 34 Bonnel Topan eT 34 Bonne t Bonom EE AEE c A T s E a see E e 34 A aneen a A E E E ten EIE 34 Spindle EEA Ae AEA e T A A A O la 34 Spindle O Ring a o a o a a a dr 34 Backup Plate O Ring tara io A ct io ln E A o a 34 Seat O Ring O a Soros Aa le pacte 95 Re assembly and Lubrication NENNEN 35 Setting and Testing A 37 General Information M MM m Test EquIpMenNt occoccoccconoconaniconcccnonaconononononanicinc o A 37 Test Media oocoocccocncocconccoconoccncccncnononanonanconancnnn conc nn conc nc a E Setting the ValvVe oooonoccconncccononecoconccocnnncnancnononcnonancco ra rccc rn ccccrccc hee 2m sli weQ X e I Sf Seat Leakage e esee 37 Back Pressure Testing oooccooncoonnccconicccncononccancnnanccnanonnanenonnonannnnanconnnconarononconanennaninoncononanonancono o 38 SA PP tase On UA 39 Maintenance Tools and SuppliesS cooncconcccccciocnncnccconcnccnnoccnnconnnccnnnrnnnnrnnnrnnnnrrnnnrrnnnrrnnnrnnnrrnnrrnannrrnnnrnnarenancnnn 39 Replacement Parts PlanniN Osiris rico dictadas 40 Ge
16. 000 Series Consolidated Safety Relief Valve Page 46 Notes 19000 Series Consolidated Safety Relief Valve Page 47 Notes 19000 Series Consolidated Safety Relief Valve Dresser Consolidated Headquarters 10343 Sam Houston Park Drive Houston TX 77064 Telephone 281 671 1640 Fax 281 671 1735 O 2009 Dresser Inc All Rights Reserved Registered trademark of Dresser Inc TM Trademark of Dresser Inc Consolidated www dresser com 19000 April 2009 19000 Series Consolidated Safety Relief Valve
17. 25 15 87 0 796 19 35 25 39 0 408 10 36 0 408 10 36 0 463 MES 0 625 15 87 0 796 119 35 25 39 0 395 10 013 0 395 10 013 0 444 11 255 0 616 15 615 N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 0 457 0 022 11 61 0 558 0 19 0 784 FLAT 0 02 0 187 4 82 0 508 4 75 0 19 0 784 FLAT 0 02 0 187 4 82 0 508 4 75 0 216 0 784 FLAT 0 023 0 187 5 48 0 584 A 4 75 0 289 1 034 FLAT 0 03 0 187 0 363 1 503 FLAT 0 038 i 0 25 9 22 0 965 i 6 35 0 457 1 503 FLAT 0 048 0 25 11 61 1 219 a 6 35 0 12 0 789 FLAT 0 03 0 187 0 12 0 789 FLAT 0 03 0 187 0 125 0 789 FLAT 0 03 0 187 0 21 1 034 FLAT 0 03 0 187 5 334 0 762 i 4 75 0 244 1 548 FLAT 0 038 l 0 25 6 19 0 965 i 6 35 1 572 FLAT 0 048 0 25 0 12 1 038 FLAT 0 03 l 0 187 0 12 1 038 FLAT 0 03 0 187 0 125 1 502 FLAT 0 03 0 187 0 21 1 504 FLAT 0 03 0 187 5 334 90 0 762 d 4 75 0 457 0 022 3 11 61 0 558 B 0 523 0 022 13 28 0 558 0 701 0 022 17 81 0 558 0 881 0 022 22 38 0 558 1 109 0 022 28 17 0 558 0 457 0 022 11 61 0 558 0 457 0 022 11 61 0 558 0 523 0 022 13 28 0 558 0 701 0 022 17 81 0 558 0 881 0 022 22 36 0 558 1 109 0 022 28 17 0 558 0 457 0 022 11 61 0 558 0 457 0 022 11 61 0 558 0 523 0 022 13 28 0 558 0 701 0 022 17 81 0 558 19000 Series Consolidated Safety Relief Valve Metal Seat VALVE R MIN IN MM 0 461 0 025 1909
18. 38 29 07 0 965 9722 38 18 1 219 0 85 0 96 0 1 109 1 247 0 048 0 457 1 503 0 03 19567M MS 1 21 59 24 38 0 025 28 17 31 67 1 219 11 61 38 18 0 762 0 35 0 395 0 0 457 0 503 0 03 0 188 1 034 0 03 19096H MS 1 FLAT 8 89 10 03 0 025 11 61 12 78 0 762 4 78 26 26 0 762 0 401 0 453 0 523 0 579 0 03 0 156 1 524 0 03 19126H MS 1 FLAT FLAT 10 19 11 51 13 28 14 71 0 762 3 96 38 71 0 762 0 537 0 606 0 781 0 03 0 21 1 504 0 03 19226H MS 1 FLAT FLAT 13 64 15 39 17 81 19 84 0 762 5 33 38 2 0 762 Co O ow e 30 30 30 ow e wo e 30 30 30 ow e Co S C2 e o o o o o o o o o o o o o 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 0 187 4 75 19000 Series Consolidated Safety Relief Valve 19096L MS 2 19110L MS 2 19126L MS 2 19226L MS 2 19357 MS 2 19567L MS 2 19096M MS 2 19110M MS 2 19126M MS 2 19226M MS 2 19357M MS 2 19567M MS 2 19096H MS 2 19110H MS 2 19126H MS 2 19226H MS 2 o ow Table Il C 19000 2 Series Metal Seat MS Base Dimensions 0 35 8 89 0 375 9 525 0 401 10 19 0 537 13 64 0 675 17 15 0 85 21 59 0 35 8 89 0 375 9 525 0 401 10 19 0 537 13 64 0 675 veo 0 85 21 59 0 35 8 89 0 375 9 525 0 401 10 19 0 537 13 64 0 408 10 36 0 408 10 36 0 463 11 75 0 6
19. 6L M 11 71 0 64 0 461 0 025 19096H 11 71 0 64 0 426 10 82 0 426 10 82 0 461 0 025 0 491 0 426 19110H N A 11 71 0 64 12 47 10 82 0 527 0 025 0 243 19126L M 13 39 0 64 6 17 0 234 0 489 5 94 12 42 0 527 0 025 0 243 0 491 0 489 19126H 13 39 0 64 6 17 12 47 12 42 0 705 0 025 0 301 19226L M 17 91 0 64 7165 These valves have a 15 angle as shown in Figure 13 2 Design Table lll A Disc Seat Lapping Width 2 Design Only Disc Seat Width 19096 19110 19126 VALVE TYPE Set Pressure 19226 19357 19567 VALVE TYPE BAR Add 0 005 In 0 125mm per 100 psi 6 896 bar until disc seat width has reached the maximum available width Table lll Reworking Dimensions of the Disc Seat O Ring Retainer Soft Seat NS 0 461 0 025 0 234 0 426 19110L M N A 11 71 0 64 5 94 10 82 0 272 0 676 0 025 6 91 11 43 0 705 0 025 0 301 0 540 0 676 19226H 0 025 17 91 0 64 7165 13 72 11 43 885 0 025 0 493 454 852 19357L M 0 025 22 48 0 64 12 52 11 53 21 64 1 113 0 025 0 493 0 473 1 056 19567L M 0 025 28 27 0 64 12 52 12 01 26 82 0 156 3 06 0 156 3 06 0 156 3 06 0 156 3 06 0 156 3 06 0 156 3 06 0 204 5 18 0 204 5 18 0 249 6 32 0 249 6 32 19000 Series Consolidated Safety Relief Valve O Ring Seat Seal Valves DA a Replacing the
20. 7B e Remove the spindle 8 backup plate 12 spring 11 and spring washers 10 f Unscrew the bonnet bottom 7B from the base 1 g Remove the guide 6 and O Ring retainer 2 h Remove the retainer lockscrew 4 and the O Ring retainer 2 i Carefully remove the seat O Ring 3 Be sure not to damage the O Ring groove in the disc holder 5 Parts Inspection See Figure 18 Bonnet Top 7A the bonnet top should be replaced if The threads are stripped torn or galled Bonnet Bottom 7B the bottom bonnet should be replaced if a Threads are stripped torn or galled b The guide seating surface is scratched nicked corroded or leaks c The backup plate seating surface is scratched nicked or corroded d Condition is porous corroded or distorted Backup Plate 12 the backup plate should be replaced if a Inside circumference X is scratched nicked pitted or galled b O Ring groove W is scratched nicked pitted or galled c Backup plate is distorted Spindle 8 the spindle should be replaced if a The bearing surfaces V are galled pitted or scratched b The threads are torn stripped or galled c The spindle is bent d The O Ring groove is nicked scratched or pitted Spindle O Ring 310XX011 9 The spindle O Ring should always be replaced The material and durometer of the spindle O Ring should be the same material and durometer a
21. D 38 18 0 965 6 35 1 016 0 85 0 96 1 109 1 247 060 0 457 1 503 0 048 0 25 050 19567L DA FLAT FLAT 30 21 59 24 38 28 17 31 67 1 524 11 61 38 18 1 219 6 35 1 27 0 35 0 395 0 457 0 503 0 045 0 188 0 789 0 03 0 187 19096M DA FLAT FLAT 30 8 89 10 03 11 61 12 78 1 143 4 78 20 04 0 762 4 75 0 375 0 395 0 457 0 503 0 045 0 188 0 789 0 03 0 187 19110M DA FLAT FLAT 30 9 525 10 03 11 61 12 78 1 143 4 78 20 04 0 762 4 75 0 401 0 453 0 523 0 579 0 08 0 216 0 789 0 03 0 187 19126M DA FLAT FLAT 30 10 19 11 51 13 28 14 71 2 032 5 49 20 04 0 762 4 75 0 537 0 606 0 701 0 781 0 08 0 21 1 034 0 03 0 187 19226M DA FLAT FLAT 30 13 64 15 39 17 81 19 84 2 032 5 33 26 26 0 762 4 75 0 675 0 762 0 881 0 987 0 09 0 363 1 548 0 038 250 19357M DA FLAT FLAT 30 edis 19 35 22 38 25 07 2 286 9722 39 32 0 965 6 35 0 85 0 96 1 109 1 247 0 125 0 3 1 526 0 048 0 25 19567M DA FLAT FLAT 30 21 59 24 38 28 17 31 67 3 175 7 62 38 76 1 219 6 35 0 35 0 395 0 457 0 503 0 045 0 188 1 038 0 03 0 187 19096H DA FLAT FLAT 30 8 89 10 03 11 61 12 78 1 143 4 78 26 37 0 762 4 75 30 0 0 0 375 0 395 0 457 0 503 0 045 0 188 1 038 0 03 0 187 19110H DA FLAT FLAT 9 525 10 03 11 61 12 78 1 143 4 78 26 37 0 762 4 75 0 401 0 453 0 523 0 579 0 045 0 156 1 502 0 03 0 187 19126H DA FLAT FLAT 3 10 19 11 51 13 28 14 71 1 143 3 96 38 15 0 762 4 75 0 537 0 606 0 701 0 781 0 05 0 21 1 504 0 03 0 187 19226H DA FLAT FLAT 3 13 64 15 39 17 81 19 84 1 27 5 33 38 2 0 762 4 75 Soft s
22. DA disassembly instructions point b on page 16 The valve is now ready for setting After the valve set pressure has been adjusted tighten the adjusting screw locknut 10 Install the cap gasket 14 and cap 15 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 Setting and Testing 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 decontamination or replacement shall be in cleaning method accordance with current used Dresser guidelines Au DANGER Decontaminate or clean if necessary before pre testing or disassembly Safety and environmental precautions must be taken for the Test Equipment 4h DANGER The test stand used for testing SRVs normally q consists of a pressure source E supply line with a throttle valve and receiver that have the following features IDOL SIT OE place hand in front of valve discharge flange if valve is under pressure Outlet for attaching the valve to be tested Pressure gauge with a shut off valve 19000 Series Consolidated Safety Relief Valve Page 30 e Drain line with a shut off va
23. DRESSERS ANS Te Safety Relief Valves INSTALLATION OPERATION AND MAINTENANCE MANUAL 19000 Series Consolidated Safety Relief Valve Series types include the following design options O Ring Seat Seal DA 19096M DA BP WWW dresser com Table of Contents Page Seley SGD E aa AA ao AA 5 Safety Alerts Read Understand IP ele ccoo rc ee 6 Taule oe rel Seley REMIT ecc A 7 eee leyes OEE AAO AE OOOO 2002200 A 8 Design Features ca cccmncncnnanrnncn rana narran 9 Handling Storage and Pre nstallatiom n seme ETE cnn nn nn annua nnne 12 ItecommencdedilnstallalionPraciices eI MEE Occ nana 13 Mounin gie OSH Oli ec cH M LM TR 13 e il A E T3 Outlet Pining aa a os oe ee A cc 14 Disassembly instructions yorar ac eene eco uL OP COPIE n 15 GeneralntormaHoti cesi 5 cole SS ecco Ld reine ed ode oe addi cote eom 15 Metal iseab valves MS o dte unos O e el ee mia are MUR 16 O Ring Sedt SCal Waves DA a a a MM icem 16 eer ir pr eer 16 Parts INSDECUIO eee co tesco ctecrae oo ae ene ncaa ee reas ee senso eee catia eure Seca ae ate naan tater E 17 BaS ee ON rR oe MEC ae CL RM A HUM eo CE 17 Metals Samil SIDES EAN a am m A M 17 O Ring Seat Seal DAVASSemDIY a eo ed tosta ruote t 17 MIR cats cn ne Se Nea le el nee nar eaten 17 Metal Seat MS Disco de A E O E ee ee 17 O Ring DA DISC Ho dental mmt 17 E EE e 17 A A E E E E A3 e Qeon caris Ceost bi quof EN De oer ion 18 SPAA EAE cu E A oye ane A E aM E E cae n 18 Sonning Wa
24. adjusting screw spherical radius Clean all parts before assembly h The valve is now ready for setting After the set pressure has been adjusted tighten the adjusting screw locknut 10 Install the cap 15 and cap gasket 14 or lifting gear on the valve after applying a small amount of b Apply small amount of non copper based thread lubricant to the guide bonnet seating surface and the bonnet and base threads c Use a clean base 1 lapped for the valve set non copper based thread lubricant to the pressure see seat width requirement Table gasket seal surfaces as well as to the cap Il Place a lapped disc 2 on the base with and bonnet threads lapped surfaces facing each other Place the disc holder 3 onto the disc and base PTS Place guide 4 over disc holder onto base Table VI Base Torque Specifications Lubricate the disc holder spindle bearing ecom surface with non copper based thread lubricant t Ih d Lubricate the spindle nose with a small 19096L amount of non copper based thread lubricant and insert the spindle 6 into the disc holder 19110L spindle pocket e Apply a small amount of non copper based thread lubricant on the bearing surface of the 19226L lower spring washer 7 and slip it over the 19357L 1000 spindle 6 Install the spring 8 and upper f Apply a small amount of non copper based 19096M thread lubricant to the bonnet base threads 19110M and guide seating surface When a
25. alve Consolidated Safety Relief Valves are furnished when so ordered with packed or plain lifting levers for hand popping When the valve is to be opened by hand using the lifting lever the pressure at the valve inlet should be at least 75 of the valve s set pressure Under flowing conditions the valve must be fully lifted from its seat so that dirt sediment and scale will not become trapped on the seating surfaces When allowing the valve to close under flowing conditions completely release the lever from maximum lift to snap the valve back on its seat Since in some cases the dead weight of the lever may have a tendency to lift the valve disc the lever should be hung supported or counter weighted so the lifting fork does not contact the release nut 19000 Series Consolidated Safety Relief Valve Addendum the 19096M DA BP Valve This is an addendum to the Consolidated 19000 Series portable safety relief valve installation operation and maintenance manual to incorporate 19096M DA BP valve requirements This section contains information specific to the 19096M DA BP Safety Relief Valve The safety precautions warranty information terminology handling storage pre installation instructions recommended installation disassembly cleaning parts inspection maintenance reassembly lubrication setting testing troubleshooting and inventory instructions will be those of the general manual unless they are indic
26. aminating recommendations in the appropriate EE IRSE Data Sheet A DANGER Before disassembling the valve ensure there is no media pressure in the vessel For a closed system always keep piping strains isolated from the pressure relief valve regardless of process operation and temperature Figure 9 Outlet Piping Considerations Disassembly Instructions General Information Consolidated Safety Relief Valves can be easily disassembled for inspection reconditioning seats or replacing internal parts Appropriate set pressure can be established after reassembly Refer to Figures 1 through Figure 7 for Parts Nomenclature Wear necessary protective equipment to prevent possible injury Valve caps and bonnets can trap fluids Use caution when removing to prevent injury or environmental damage NOTES Before starting to disassemble the valve be sure there is no media pressure in the vessel Many pressure vessels that are protected by Consolidated Safety Relief Valves contain dangerous materials Decontaminate 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 Parts from one valve should not be interchanged with parts from another valve ATTENTION Do not interchange parts from one valve with parts from another valve 19000 Series Consolidated Safe
27. ated differently within this section Page 33 Introduction The 19000 back pressure version is only available in the 0 096 inch orifice with an O Ring seat It is available for steam 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 The standard medium pressure valve is limited to a minimum of 290 psig in the standard 19000 design The designation will be used since most of the parts are from the 19096M bill of material Table XI 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 Allowable total back pressure This is the sum of the variable and constant back pressure superimposed and built up Temperature limits Determined by O Ring material selection Seat tightness Note Refer to this Table for the performance criteria of this valve Liquid 6 20 Gas 3 16 Liquid 70 of set pressure Note Thermal relief applications may be supplied with back pressures up to 90 of set pressure Gas 50 of set pressure Note Total back pressure for liquid or gas shall not exceed 400 psig 27 58 barg Minimum 20 F 28 C Maximum 600 F 315 C Set pressure of 50 psig 3 45 barg 92 51 psig 3 52 barg 100 psig
28. ation 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 VII 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 VIII lists the multiplier to be used based on temperature above the saturated temperature degrees of superheat 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 Table VIII Set Pressure Multipliers for Cold Differential Test Pressure e a am 19000 Series Consolidated Safety Relief Valve Sample Calculations For Series 19000 Consolidated Safety Relief Valves refer to Tables VII and VIII Set pressure 2500 psig temperature 500 F backpressure atmospheric Set Pressure eeeseesee 2500 psig Multiplier see Table VII
29. base The guide seating surfaces should be free of any nicks or scratches f Lubricate the spindle nose with a small amount of non copper based thread lubricant and insert the spindle 6 into the disc holder spindle pocket g Apply a small amount of non copper based thread lubricant on the bearing surface of the lower spring washer 7 and slip it over the spindle 6 Install the spring 8 and upper spring washer 7 h The guide bonnet seating surfaces should be free of any nicks or scratches with a 63 rms finish maximum Apply non copper based thread lubricant to the bonnet and base threads and guide seating surfaces Install the bonnet 5 on the base 1 using torque from Base Torque Specifications see Table VI Before tightening the bonnet completely adjust the position of the guide 4 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 VI Page 29 i Thread the adjusting screw locknut 10 onto the adjusting screw 9 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 Use pliers to hold the spindle 6 in position and prevent galling Adjust the adjusting screw to the measurement recorded during disassembly See O Ring Seat Seal Valves
30. d The pictorial may depict preventive measures to take such as wearing protective equipment Do not remove bolts The bottom panel Wear necessary if ized contains an instruction tecti IT pressurized message on how to avoid protective This will result in si raat ene ay equipment to serious personal definition of the hazard prevent possible a and the consequences of pen injury or death mr NE injury ATTENTION labels are horizontal bands describing special situations and issues that could potentially damage the SRV ATTENTION Exercise care when inserting a rod or pipe in the outlet Ensure the valve nozzle is not damaged during the operation NOTE Any service questions not covered in this manual should be referred to Dresser Consolidated Field Service Department Phone 1 318 640 6055 In addition you can contact your local Green Tag Center or Dresser Consolidated authorized sales representative contact information can be found on pages 44 amp 45 19000 Series Consolidated Safety Relief Valve Safety Alerts Read Understand 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 Dresser Consolidated cannot know all conceivable service methods nor evaluate all potential hazards Some dangers are listed below
31. d between disc holder and guide Maintenance Tools and Supplies The laps identified in Table XII are required for proper maintenance of Dresser 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 e Lapping compounds are identified in Table XIII e Laps and the lapping plate may be purchased from Dresser Consolidated a b c Disassemble valve lap seating surfaces replace disc or O Ring if required as outlined in this manual Grind and polish Disassemble valve inspect contact area of disc and nozzle lower spring washer or spindle compression screw spindle straightness etc as outlined in this manual Correct as required Investigate and correct cause Rework seat as specified in this manual Check for piping instructions check required capacity Check outlet piping for flow restrictions Disassemble valve and correct any abnormality as outlined in this manual Inspect system for cleanliness Table XII Laps 19096L 19110L 19126L Kwik Ak T 199 11 Shun ES 1000 Polishing 1 Ib 2 oz 199 12 19096M 19110M 19126M 1672802 19096H 19110H 19126H 19226L 19226M 19226H 1672803 19357L 19567L 19357M 19567M 1672805 Table XIII Lapping Compounds 199 4 OZ OZ 19000 Series Consolidated Safety Relief Valve 19000 April
32. ded by Dresser Consolidated with flanged or socket weld inlet and outlet connections upon customer request Nomenclature Applicable valve nomenclature for Types 19000 Male and Female inlet configurations are illustrated in Figures 1 through 3 Relevant parts nomenclature for optional lifting levers caps and the gag as applicable is provided in Figures 4 through 7 19000 Series Consolidated Safety Relief Valve Design Features and Nomenclature Screwed Cap 15 Spindle 6 Adjusting Screw 9 Adjusting Screw Locknut 10 Cap Gasket 14 Spring Washers 7 Spring 8 Bonnet 5 Disc Holder 3 Disc 2 Guide 4 Base 1 Spindle 6 Disc 2 19000 2 Design Disc Holder 3 e 19000 2 Design Guide 4 19000 1 Design Figure 1 Metal Seat MS Valves Figure 2 Metal Seat MS Valves Male NPT Inlet Female NPT Inlet 19096L 19110L 19126L 19226L 19096M 19096L 19110L 19126L 19226L 19357L 19567L 19110M 19126M and 19226M 19096M 19110M 19126M 19226M 19357M 19567M 19096H 19110H 19126H and 19226H 19000 Series Consolidated Safety Relief Valve Page 10 Design Features and Nomenclature continued Screwed Cap 15 Spindle 6 Adjusting Screw 9 Adjusting Screw Locknut 10 Cap Gasket 14 Spring Washers 7 Spring 8 Bonnet 5 Disc Holder 3 Disc 2 Guide 4 Base 1 Retainer Lock 18 Disc ockscrew 18 Holder 3 O Ring i Seat Seal 17 Re
33. dheri East Mumbai India 400 059 Telephone 91 22 2 835 4790 838 1134 Fax 91 22 2 835 4791 ITALY Dresser Italia S r l Via Cassano 77 80020 Casavatore Naples Italy Telephone 39 081 7892 111 Fax 39 081 7892 419 JAPAN Dresser Japan Ltd DJL 20th Floor Marive East Tower WBG 2 6 Nakase Mihama ku Chiba shi Chiba 261 7120 Japan Telephone 81 43 297 9222 Fax 81 43 299 1115 KOREA Dresser Korea Inc 17 Fl Hyundai Swiss Tower 143 40 Samsun dong Kangnam ku Soeoul Korea 135 090 Telephone 82 2 2274 0748 Fax 82 2 2274 0720 MALAYSIA Dresser Inc Asia Pacific Headquarters Business Suite 18 1 81 2 amp 18 3 Wisma UOA II No 21 Jalan Pinang 50450 Kuala Lumpur Malaysia Telephone 60 3 2267 2600 Fax 60 3 2267 2711 19000 Series Consolidated Safety Relief Valve MEXICO Dresser De Mexico S A de C V Henry Ford 114 Esq Fulton Fraccionamiento Industrial San Nicolas C P 54030 Tlalnepantla Estado de Mexico Telephone 52 55 3640 5060 Fax 52 55 5310 5584 RUSSIA Dresser Europe Derbenevskaya Ulitsa 1 Bldg 3 Office 17 Moscow Russian Federation 115 114 Telephone 7 4955 851276 Fax 7 4955 851279 SAUDI ARABIA Dresser Al Rushaid Valve amp Inst Co Ltd DARVICO P O Box 10145 Jubail Industrial City 31961 Kingdom of Saudi Arabia Telephone 966 3 341 0278 Fax 966 3 341 7624 SINGAPORE Dresser Si
34. e High temperature pressure can cause injury Ensure all system pressure is absent before repairing or removing valves Always perform correct service and repair Incorrect service and repair can result in product or property damage or severe personal injury or death 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 Ensure the proper health physics procedures are followed if applicable before starting operation in a radioactive environment Caution Alerts o Do not stand in front of a valve outlet when discharging STAND CLEAR OF VALVE to avoid exposure to trapped corrosive media CAUTION alerts describe actions that may result in a personal injury In addition they may describe preventive measures that must be taken to avoid personal injury Some caution alerts are listed below e Exercise extreme caution when inspecting a pressure relief valve for leakage 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 Never use pressurized fluids gas air to clean clothing or body parts Never use body parts to check for leaks flo
35. eat DA valves for liquid service from 5 100 psig require a special base Refer to Dimension O instead of Dimension F in this case Angles in degrees 19000 Series Consolidated Safety Relief Valve 19000 April 2009 Table II B 19000 1 Series Metal Seat MS Base Dimensions 0 675 0 038 19357L MS 1 0 965 0 35 0 395 0 0 457 0 503 0 03 0 188 0 784 0 02 19096L MS 1 1 8 89 10 03 0 11 61 12 78 0 762 4 78 19 91 0 508 0 401 0 453 0 0 523 0 579 0 03 0 216 0 784 0 023 19126L MS 1 10 19 11 51 0 025 13 28 14 71 0 762 5 49 19 91 0 584 0 537 0 606 0 0 701 0 781 0 03 0 289 1 034 0 03 19226L MS 1 5 13 64 15 39 0 025 17 81 19 84 0 762 7 34 26 26 0 762 lw al h alialalo ofs o afolo 01 25 01 01 0 762 01 0 881 0 987 0 038 0 363 1 503 17 15 19 35 0 025 22 38 25 07 0 965 9 22 38 18 0 85 0 01 12109 1 247 0 048 0 457 ESOS 19567L MS 1 20499 24 38 0 025 28 17 31 67 1219 11 61 38 18 0 01 01 01 01 01 01 0 96 0 048 ANS 0 35 0 395 0 457 0 503 0 03 0 188 0 784 0 03 19096M MS 1 8 89 10 03 0 025 11 61 12 78 0 762 4 78 19 91 0 762 0 401 0 453 0 0 523 057 0 03 0 216 0 784 0 03 19126M MS 1 10 19 11 51 0 025 13 28 14 71 0 762 5 49 19 91 0 762 0 537 0 0 038 19226M M S 1 13 64 0 965 0 606 0 701 0 781 0 03 0 289 1 034 15 39 0 025 17 81 19 84 0 762 7 34 26 26 e N e al 0 675 0 762 0 0 881 0 987 0 038 0 363 1 503 0 048 19357M MS 1 17 15 19 95 0 025 22
36. ed has an extensive worldwide sales and service network Listed here are Dresser Consolidated offices that can help you locate a representative for your locale UNITED STATES Dresser Consolidated Headquarters 10343 Sam Houston Park Drive Houston TX 77064 Telephone 1 281 671 1640 Fax 1 281 671 1735 Dresser Consolidated Dresser Inc LA Hwy 3225 US Hwy 167N P O Box 1430 Alexandria LA 71309 1403 Telephone 1 318 640 2250 Fax 1 318 640 6222 Dresser Direct 1250 Hall Court Deer Park TX 77536 6557 Telephone 1 281 884 1000 Fax 1 281 884 1010 Dresser Direct 905A Industrial Road Clute TX 77531 5720 Telephone 1 979 265 1309 Fax 1 979 265 2514 Dresser Direct 4841 Leopard Street Corpus Christi TX 78408 2621 Telephone 1 361 881 8182 Fax 1 361 881 8246 BRAZIL Dresser Industria E Comercio Ltda Rua Funchal 129 Conj 5A 04551 060 Sao Paulo Brazil Telephone 55 11 2146 3600 Fax 55 11 2146 3610 CHINA Dresser Inc Suite 1703 Capital Mansion Beijing Rep Office 6 Xinyuan S Road Chaoyang District Beijing 100004 P R China Telephone 86 10 8486 4515 4516 4517 Fax 86 10 8486 5305 GERMANY Dresser Valves Europe GmbH Heiligenstrasse 75 41751 Viersen Germany Tel 49 2162 81700 Fax 49 2162 8170 280 INDIA Dresser Valve India Pvt Ltd 305 306 Midas Sahar Plaza Mathuradas Vasanji Road J B Nagar An
37. ed in Table XIV 2 In addition you can contact your local Green Tag Center or Dresser Consolidated authorized sales representative contact information can be found at Identify valve by the following nameplate data a Size 3 4 b Type 19096LC 1 c Temperature class Spring Selection S N d Serial Number TC75834 Specify parts required by a Part name b Part number if known c Quantity Table XIV Establishing Inventory Levels Most frequent Anc Class I Less frequent but critica Class il Seldom replaced Class IV 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 of all instances Genuine Dresser Parts i Each time replacement parts are needed keep these points in mind e Dresser Inc designed the parts e Dresser Inc guarantees the parts Consolidated valve products have been in service since 1879 Dresser Inc has worldwide service Dresser Consolidated has fast response availability for parts with the global Green Tag Center authorized sales representatives network 19000 Series Consolidated Safety Relief Valve Recommended Spare Parts for Series 19000 Safety Relief Valves Table XV A Metal to Metal Seat Valves Disc Gaskets Ca
38. eration as a result of the induced misalignment of moving parts Mount safety relief valves in a vertical upright position only 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 of the valve s set pressure when flowing at full capacity PIN DANGER The threaded inlet and outlet ports and sealing faces of the valve and all connecting piping must be free from dirt sediment and scale Ensure all flange bolts are drawn evenly to prevent distortion of the valve body and the inlet nozzle In the case of screwed portable valves use caution to avoid unscrewing bonnet Do not mount valve from the base if a pipe wrench is used to install or remove the base ensure that at the end of pipe the wrench is placed on the flats of the base and not on the bonnet If the bonnet through which there is base joint is broken the valve should be retested to insure proper set pressure and normally no flow or function of the valve near elbows tees bends etc 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 Inlet Piping The inl
39. et piping see Figure 8 to the 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 H The pressure drop from the vessel to the valve shall not exceed 3 of valve set eed all service ud manual warnings pressure when the valve is allowing full capacity flow The inlet piping must never be Read installation smaller in diameter than the inlet connection of the valve Excessive pressure drop in instructions before gas vapor or flashing liquid service at the inlet of the SRV will cause the extremely installing valve s rapid opening and closing 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 and in which the length does not exceed the face to face dimensions of a standard tee of the required pressure class Figure 8 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 of the valve set pressure 19000 Series Consolidated Safety Relief Valve Page 14 Do not locate SRV inlets where exce
40. fier Figure 11 B Measuring Magnifier Detail Table Dimensions for Determining Seat Width 21 100 1 449 6 806 101 300 301 800 801 800 301 1000 1001 1100 19000 Series Consolidated Safety Relief Valve Page 20 c Machining the Base Seat i When the base seat cannot be repaired by lapping it can be machined as shown in Figure 12 using the dimensions provided in Table Il 11 Dresser Consolidated recommends that the following procedure be adhered to when machining the base seat ii i Using a four jaw chuck align the base so that surfaces marked X and Y run true within 001 on an indicator 11 11 Take light cuts on the seat surface until all damage is removed Re establish dimensions B C F G H and Angle When L minimum is obtained the base should be replaced 11 111 After all machining has been accomplished lap the seat using same procedure for base seat H An G Y Guide Seating L es Metal Seat Base ATTENTION 19000H and 19000 DA bases have flat seats 90 angle across the entire seating surface from B diameter to D diameter d Machining the Disc Seat i When the disc seat cannot be repaired by lapping it can be machined as shown in Figure 13 using the dimensions provided in Table Ill 11 Dresser Consolidated recommends that the following procedure be adhered to when machining the disc seat ii i Grip the disc in a co
41. l c Length S is less than S minimum see Table III O Ring Seat Seal Assembly the O Ring seat seal assembly parts should be replaced as follows a O Ring Seat Seal 17 always replace b O Ring retainer 16 i Lapped seat relief height R is less than R minimum and dimension S cannot be maintained see Figure 13 and Table Ill 11 Length S is less than S minimum see Table III iii Retainer Lockscrew Always replace Page 17 Bonnet 5 the bonnet should be replaced if a Threads are stripped torn or galled b The guide seating surface is scratched nicked corroded or leaks c Condition is porous corroded or distorted Metal Seat Disc Holder 3 the disc holder should be replaced if a The outside surface is worn egged or galled and or cannot meet H dimension b The spindle pocket bearing surface is galled or pitted c The disc seating surface Y is galled or pitted see Figure 15 O Ring Disc Holder 3 the O Ring disc holder should be replaced if a The outside surface is worn egged or galled and or cannot meet H dimension see Figure 15 b The spindle pocket bearing surface is galled or pitted c The O Ring groove is nicked scratched or pitted d The O Ring retainer screw threads are torn stripped or galled Guide 4 replace the guide if a The inside surface is worn egged or galled b Base
42. l 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 of set pressure For O Ring seat seal valves use Table X 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 9096 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 X to determine the percentage of set pressure Back Pressure Testing 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 7B joint b bonnet bottom 7B to bonnet top 7A 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
43. llet 11 11 True up the disc so that surfaces marked X and Y run true within 001 on an indicator ii iii Take light cuts across the seating surface until the damage is removed Dimensions R and D and 15 angle when applicable must be maintained 1 iv The disc is now ready for lapping See Table III A for proper seat width ii vy When the minimum thickness dimension S is reached the disc should be replaced Angle U O Ring Base Surface N Flat Seat 0 010 radius on seat OD t F Refer to O dim in place of F dim for liquid service 5 1000psig Figure 12 Machining the Base Seat 19000 Series Consolidated Safety Relief Valve Table ll A 19000 Series Soft Seat DA Base Dimensions 0 35 0 395 0 457 0 503 045 0 188 0 784 0 02 0 187 032 19096L DA FLAT FLAT 201 8 89 10 03 11 61 12 78 1 143 4 18 19 91 0 508 4 75 0 813 0 375 0 395 0 457 0 503 045 0 188 0 784 0 02 0 187 032 19110L DA FLAT FLAT 30 9 525 10 03 11 61 12 78 1 143 4 78 19 91 0 508 4 75 0 813 0 401 0 453 0 523 0 579 045 0 216 0 784 0 023 0 187 032 19126L DA FLAT FLAT 920 10 19 11 51 13 28 14 71 1 143 5 49 19 91 0 584 4 75 0 813 0 537 0 606 0 701 0 781 050 0 289 1 034 0 03 0 187 032 19226L DA FLAT FLAT 30 13 64 15 39 17 81 19 84 1 27 7 34 26 26 0 762 4 75 0 813 0 675 0 762 0 881 0 987 060 0 363 1 503 0 038 0 25 040 19357L DA FLAT FLAT 30 S 19 35 22 38 25 07 1 524
44. lve and Adequate receiver volume for the valve to be tested and to achieve proper operation Test Media For best results valves shall be tested by type as follows e Steam valves are tested on saturated steam e Air or gas valves are tested on air or gas at ambient temperature and Liquid valves are tested on water at ambient temperature 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 Table VII Set Pressure Multipliers for Cold Differential Test Pressure at Ambient Temperature pom ome som om e 10m Le xe oues 0 es 1099 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 seating area and spring relax
45. mance if any and will be free from defects in material and workmanship Defective and nonconforming items must be held for Dresser Consolidated s inspection and returned to the manufacturer upon request INCORRECT SELECTION OR MISAPPLICATION OF PRODUCTS Dresser Inc cannot be responsible for customers incorrect selection or misapplication of our products UNAUTHORIZED REPAIR WORK Dresser Inc has not authorized any non Dresser 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 unauthorized sources do so at their own risk Refer to Dresser s Standard Terms of Sale for complete details on warranty and limitation of remedy and liability Factory Repair Facilities The factory at Alexandria Louisiana maintains a complete Consolidated repair center The Repair Department in conjunction with the manufacturing facilities is equipped to perform specialized repairs and product modifications e g butt welding code welding and pilot replacement Contact Valve Repair Department at 1 318 640 6057 SRV Maintenance Training The rising costs of maintenance and repair in the utility and process industries indicate the need for trained maintenance personnel Dresser Consolidated conducts service seminars that help your maintenance and engineering personnel
46. mediately after popping for valves set 51 psig 3 517 bar and above On valves set at 50 psig 3 448 bar and below test for leakage at 5 psig 0 345 bar below the set pressure immediately after popping The test pressure shall be applied for a temperature 650 F backpressure atmospheric l maximum of one minute Operating Temperature o c c 650 F Minus Temperature of iii The Tightness Standard is the leakage rate in saturated Steam at 400 psig 448 F bubbles per minute and shall not exceed that Degrees of Superheat E 202 F shown in Table IX for metal seat valves or Set Pressure aci n cada 400 psig Table X for O Ring seat seal valves Multiplier see Table VII X1 013 Cold Differential Set Pressure 405 psig A valve with a seat of resilient material i e an O Ring valve shall show no leakage at Blowdown pressures less than those indicated in Table X l when the test medium is either air or water The blowdown for all series 19000 valves is fixed Do not attempt to adjust the blowdown on these b Water H 0 valves Typical blowdown is less than 10 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 of set pressure Simmer If simmer causes erratic valve opening refer to the Trouble Shooting Guide in this manual For O Ring seat seal
47. neral ONN AON NND 40 Inventory Planning af ohn cxcattenasonsacesdnneietlsanetesentiateadantsinacasdaiiniasseneul ex timaeeeseaeabenoqdictnadtacnnctseiatonnsbansxatuntaendaenee 40 PCDI AG CRMC Gr c LEUR NE m 40 Identification and ee p AA ee REM 40 Genuine Dresser Paris aint isaac 40 Recommended Spare Parts for 19000 Series SRVS 0ooooccocccconnccoccconcnconanoconconcncnnnnnnnnnnnnnrnnancnnnnrnnnnrnnarenanennnn 41 Manufacturer s Warranty Field Service Training and Repair Program eese 42 Waraniy INOMma UO Ue eateries tetas vse sagt tse tn eect ts octet EE 42 Factory Repair Faciles nintendo epica obio ici iia 42 Safety Relief Valve Maintenance Training oocccococnccccnnnoccnnnononnonononononononnnnnnnnnnonnnnnonnnnnnnnrnnonnnnnonnnnnenanens 42 o TREE 43 Sales OMICS LOG AU ON Sarria nido RENE ERE MUERE MR A 44 19000 April 2009 19000 Series Consolidated Safety Relief Valve Safety Sign and Label System Appropriate safety labels have been included in the practices and procedures throughout this manual The labels communicate Level of hazard seriousness Nature of the hazard e Consequence of human or product interaction with the hazard e Instructions on how to avoid the hazard The top panel describes the level of hazard seriousness DANGER or CAUTION Ah DANGER The center panel contains a E pictorial that communicates the nature and possible consequence of the hazar
48. ngapore Pte Ltd 16 Tuas Avenue 8 Singapore 639231 Telephone 65 6861 6100 Fax 65 6427 8100 SOUTH AFRICA Dresser International Ltd South Africa Branch P O Box 2234 16 Edendale Road Eastleigh Edenvale 1610 Republic of South Africa Telephone 27 11 452 1550 Fax 27 11 452 2903 Page 45 SPAIN Dresser Masoneilan C Murcia 39C 08830 Sant Boi de Llobregat Barcelona Spain Telephone 34 93 652 64 30 Fax 34 93 652 64 44 SWITZERLAND Dresser Consolidated Windenboden 23 CH 6345 Neuheim Switzerland Telephone 41 41 755 27 03 Fax 41 41 755 28 13 UNITED ARAB EMIRATES Dresser International Inc Middle East Operations P O Box 61302 R A 8 Blue Sheds JA1 amp JA2 Jebel Ali Free Zone Dubai United Arab Emirates Telephone 971 4 8139200 Fax 971 4 8838038 UNITED KINGDOM DI U K Limited Unit 4 Suite 2 1 Nobel House Grand Union Office Park Packet Boat Lane Uxbridge Middlesex England UB8 2GH United Kingdom Telephone 44 1895 454900 Fax 44 1895 454919 Dresser Consolidated DI U K Limited Dresser House Gillibrands Road East Gillibrands Estate Skelmersdale Lancashire England WN8 9TU United Kingdom Telephone 44 1695 52600 Fax 44 1695 52601 FOR YOUR GREEN TAG CENTER IN USA CANADA CALL 1 800 245 VALV or contact the locations listed above for international service For the most current listings see www dresser com 19
49. ns for its design The 19000 Series SRV has three pressure classes 19000L 5 290 psig 19000M 291 2000 psig and 19000H 2001 psig 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 All 19000 Series safety relief valves have fixed blowdown This means that the parts are designed so that there is no blowdown adjustment required when setting or testing the valve Design Options O Ring Seat Seal Valves All 19000 Series Valves are available with an O Ring seat seal as a design option This optional design is bubble tight at 97 of set pressures over 100 psig 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 X on page 31 Lifting Levers Caps and Gags All 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 or vice versa does not require valve disassembly or resetting The lifting lever option is designed to open the valve at 75 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 All 19000 Series Valves can be provi
50. ns of the parts The base 1 bonnet 5 and cap 15 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 Au DANGER Follow recommendations for safe handling in the solvent s Material Safety Data Sheet and observe safe practices for any cleaning method 19000 Series Consolidated Safety Relief Valve Parts Inspection Base 1 the base should be replaced if a Seat Surface i Metal Seated Seat surface N see Figure 12 is scratched nicked corroded leaks or is too wide and cannot be machined see Table and c ii ii on page 20 ii O Ring Seat surface N see insert Figure 12 is scratched nicked corroded or leaks b Threads all are torn stripped or galled c Guide seating surface U is scratched nicked corroded or dimension L is less than L minimum see Figure 12 Table Il and c ii ii on page 20 d Seat step F is at or above minimum listed in Table Il F can be reestablished by machining as long as L stays within tolerance see c ii ii on page 20 Metal Seat Disc 2 the metal seat disc should be replaced if a Seat surface Y see Figure 13 is damaged beyond lapping or machining limits b Seat relief height R is less than R minimum and dimension S cannot be maintained see Table Il
51. of the spindle but below the threads Apply a machinist s indicator at approximately 45 to the outer edge of the spring washer seat at C Rotate the spindle The total indicator reading should not exceed 005 Straighten the spindle if necessary iii Bearing Surface 15 19000 Series Consolidated Safety Relief Valve Table IV Disc Holder Dimensions 0 65 19096L 19096 amp 19110L 16 61 1 47 19126L 18 97 1 000 19226L 25 40 1 26 19357L te 31 93 1 58 19567L 40 21 A top view Spring Washer Seat 0 65 19096M amp 19110M 16 61 Bearing Surface T 0 75 2 Spindle 19126M ema 18 97 1 000 Figure 14 V Block Support Set Up 19226M 25 40 1 26 perde SL lt H dia 1 58 19567M amp 19110H 40 21 0 65 19096H 16 61 0 75 19126H 18 97 1 000 2 Metal Seat Disc Holder 19226H 25 40 lt H dia gt i Metal Seat Disc Holder O Ring Disc Holder Figure 15 Disc Holder 19000 Series Consolidated Safety Relief Valve Page 27 Table V Guide Dimensions 19096L amp 0 661 0 810 0 007 0 81 0 007 1 701 1 701 19 15 20 42 0 18 20 42 0 18 43 610 43 610 25 58 28 17 t023 28 17 0 23 57 580 57 580 32 11 41 22 0 3 41 22 X 0 3 78 870 78 870 40 39 42 44 0 3 42 44 0 3 80 240 80 240 19096M amp 0 661 0 81 0 007 0 81 0 007 1 727 1 727 19 15 20 42 0 18 20 42 0
52. 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 valve body 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 backpressure in the remaining valves Under these conditions the use of the 19096 DA BP model is recommended see page 33 In every case the nominal discharge pipe size must 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 of the valve set pressure or 400 psi whichever is smaller ATTENTION Undersized discharge piping could create built up backpressure 19000 Series Consolidated Safety Relief Valve Cap may be required for weather protection Long Radius Elbow Au DANGER Many pressure vessels protected by Consolidated Safety Relief Valves contain dangerous materials Decontaminate and clean the valve inlet outlet and all external surfaces in accordance with the cleaning and decont
53. ot 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 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 10 Install the cap gasket 14 and cap 15 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 Hydrostatic Testing and Gagging When hydrostatic tests are required after installation of an SRV remove the SRV and replace it with a blind flange or pipe plug cap If the hydrostatic test pressure will not be greater than the operating pressure of the equipment a test gag may be used Very little force i e finger tight pressure on the test gag is sufficient to hold hydrostatic pressures Too much force applied to the gag may bend the spindle and damage the seat After a hydrostatic test the gag must be removed and replaced by the sealing plug furnished for this purpose see Figure 17 Test gags for Consolidated SRVs can be furnished for all types of caps and lifting gears Page 32 Gag Bolt Sealing Plug Sealing Plug Gasket Figure 17 Typical Cap with Gag Manual Popping of the V
54. p Disc Holder Spindle Guide Spring Assembly p Compression Screw Compression Screw Locknut Cap specify screwed packed or plain Release Nut used on packed or plain lever only Release Locknut used on packed or plain lever only Table XV B O Ring Seat Valves Disc Holder spiele Spring Assembly pa Compression Screw Compression Screw Locknut Cap specify screwed packed or plain Release Nut used on packed or plain lever only Release Locknut used on packed or plain lever only Consult Spring Selection Chart before ordering springs to determine actual quantities required in view of pressure setting potential in each spring range O Ring Retainer Lock Screw Gaskets Cap 19000 Series Consolidated Safety Relief Valve Page 42 YOUR SAFETY IS OUR BUSINESS Dresser Inc 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 INC OR YOUR LOCAL GREEN TAG CENTER DRESSER CONSOLIDATED AUTHORIZED SALES REPRESENTATIVE Manufacturer s Warranty Field Service Factory Repair Facilities and Training Warranty Information WARRANTY STATEMENT Dresser Inc warrants that its products and work will meet all applicable specifications and other specific product and work requirements including those of perfor
55. re 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 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 Test 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 Differential Between Operating and Set Pressures Valves installed in process services will generally give best results if the operating pressure does not exceed 90 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 Lift the actual travel of the disc away from the closed position when a valve is relieving 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 that used in its design Consequently for that metal temperature it is the highest
56. rs 10 Back up Plate O Ring 13 Back up Plate 12 Bonnet Bottom 7B Spindle O Ring 9 Disc Holder 5 O Ring Retainer Lockscrew 4 Retainer 2 Seat O Ring 3 Guide 6 Base 1 These parts differ from the standard 19096M DA Figure 18 19096M DA BP Valve Nomenclature 19000 Series Consolidated Safety Relief Valve Page 37 Setting and Testing backpressure and or operating temperature A new cold differential test pressure may need to be determined if changes are to be made to General Information the set pressure or backpressure or if the service temperature changes r in ona ave in A DANGER See Set Pressure Compensation 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 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 Decontaminate or cold differential test pressure may need to be l clean if necessary determined and check seat tightness before pre testing or on a test stand Any spring disassembly Safety Blowdown replacement shall be in and environmental accordance with current precautions must be The blowdown for all series 19000 valves is fixed Dresser guidelines
57. s that specified for the seat O Ring 3 Backup Plate O Ring 310XX030 13 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 3 19000 Series Consolidated Safety Relief Valve Page 35 Seat O Ring 310XX013 3 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 Re assembly and Lu a b Note c d e 1 brication All base seats shall be lapped flat enough to remove nicks and burrs Bearing surfaces should be ground together using a 320 grit lapping compound see Table XIII These surfaces are the following i the disc holder spindle pocket and the spindle spherical holder spindle radius for O ring valves or 1 design ii the lower spring washer and spindle spring washer radius and iii the upper spring washer and adjusting screw spherical radius Clean all parts prior to re assembly Carefully insert a new seat O Ring seal into the disc holder 5 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 2 and the retainer lockscrew 4 Apply thread locker fluid to lock
58. shers T es ty 18 AUS o cree cop a eet a 18 Maintenance Instructions a An no a e a S a a sardina 18 Metal Seat Wales MS Jina ratte tese M a Pie arte du c det om el uet 18 O Ring Seat S alvalves DA asen ieh a tdt ole rote a ee a a ET 25 Checking Spindle Concentricity eae roe e re ee oe E a dd n Dres 25 Reassembly and Lubrication 5 2 a a E eirecangeceeavmonreessueemercesd 28 Metal Seat Valves MS secco co reete me dom oc cesi aeta cmi st ose cto ome d for 28 O Ring Seat Valves ID ct oce o e ae 29 Setting and Testing Mia aa Aen CURSO TENEROS 29 General Information scs Eoi ucc etin cu E Um ete pe 29 Test Equipment 2999Su9e neo Su P feat commun nami EE NA o II ono nce diim 29 Test Med a 9928 4 x f cei xa ea c UMOR cce NOE c Mae Oe INA iren 30 Setting the Valve 598 4s 8 X NS e Ue eM ANA e LA eM Ee a AI TE 30 Set Pressure CompenS atom ree e IO o oat ruina state ce S E Su Blowdown mira i tie risa Pee cl tate Ce italia Ep ELM EAE 31 oimmer 8 SM E Roc MEO ele er eae onec Wo E Dc c nte 31 Seat Leakage Aam N m Mat tah ink T E hae E can ad Pers dee seco ue tol Ant cell 31 Back Pressure Testers nee T cel st E T aon E E a 32 19000 Series Consolidated Safety Relief Valve Hydrostatic Testing and Gagging 6250005 ANA 32 Manual Popping of the Valve reote mM we Si aed ta ee ee e aoe se eves reese Peer eat 32 Addendum the 1S9096M DA BP Valve ota 0205290625170 00
59. ssive 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 reaction forces during valve discharge is the responsibility of the vessel and or piping designer Dresser Consolidated 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 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 nozzle 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 Low frequency vibrations are more detrimental to SRV tightness than high frequency vibrations This effect can be minimized by
60. stainless steel bonnet 5 and base 1 are used 19126M and or a standard bonnet for service above 19226M 500 temperature apply non copper based thread lubricant to the bonnet base threads 19357M 1200 and guide 4 seating surface Before tightening the bonnet completely adjust 19567M 1200 the position of the guide so that one of the 19096H holes is lined up with the discharge of the valve Tighten the bonnet using sufficient 19110H torque from Base Torque Specification 19126H 1000 1500 see Table VI 19226H 1000 1500 19000 Series Consolidated Safety Relief Valve O Ring Seat Seal Valves DA See Figure 3 a All bases shall be lapped flat enough to remove nicks and burrs b Bearing surfaces should be ground together using a 320 grit lapping compound see Table XIII These surfaces are a the disc holder spindle pocket and spindle spherical nose radius b the lower spring washer and spindle spring washer radius and c the upper spring washer and adjusting screw spherical radius Clean all parts before assembly c Carefully insert a new O Ring seat seal 17 into the disc holder 3 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 d Install the O Ring retainer 16 and a new retainer lockscrew 18 e Place the disc holder assembly onto the base 1 and place the guide 4 onto
61. tainer 16 Base 1 Figure 3 O Ring Soft Seat DA Valves Types 19000 DA 19000 Series Consolidated Safety Relief Valve Page 11 Design Features and Nomenclature continued Figure 4 Figure 5 Typical Cap with Gag Packed Cap with Lifting Lever Both the standard screwed cap and the optional For types 19096L 19096M 19096H caps can be provided with a gag if required 19110H 19110L 19110M 19126L 19126M 19226L and 19226M Gag Bolt Packed Cap Bushing Release Lock Nut Standard Drive Pin Release Nut Screwed Cap Cam Shaft Sealing Plug Bushing Gasket Sealing Plug Gasket O Ring Cap Gasket Lifting Lever Figure 6 Figure 7 Packed Cap with Lifting Lever Plain Cap with Lifting Lever For types 19126H 19226H 19357L For all series 19000 valves 19357M 19567L and 19567M Plain Cap Lifting Fork Packed Cap Release Lifting Lever Lock Nut Living Lifting Shaft Lever rw Packing Lever Pin Release Locknut Release Nut Packing Nut Release Nut Cap Gasket Cap Screw Can be provided with a gag 19000 Series Consolidated Safety Relief Valve Page 12 Handling Storage and Pre Installation 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 val
62. ted 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 19000 Series Consolidated Safety Relief Valve Introduction The 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 Design Features and Nomenclature 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 applicatio
63. the screw in position Place the disc holder assembly onto the base 1 and place the guide 6 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 7B 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 Specification see Table VI g Place backup plate O Ring 310XX030 13 in the O Ring groove in the backup plate 12 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 Insure that they are clean and free from nicks and scratches Place the backup plate 12 O Ring side down into the counterbore in the bonnet bottom h Place spindle O Ring 312XX011 9 into the O Ring groove on the spindle 8 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 i Apply a small amount of non copper based thread lubricant to the bearing surface
64. to metal seats shall be determined with e Steam valves are tested on saturated steam the valve mounted vertically and using a Air or gas valves are tested on air or gas at standard test fixture as described above The ambient temperature and leakage rate in bubbles per minutes shall Liquid valves are tested on water at ambient be determined with the pressure at the safety temperature relief valve inlet held at 90 percent of the set pressure immediately after popping for Setting the Valve valves set 51 psig 3 517 bar and above On valves set at 50 psig 3 448 bar and below test for leakage at 5 psig 0 345 bar below the set pressure immediately after popping The test pressure shall be applied for a maximum of one minute Set the valve to open at the set pressure as shown on the nameplate If a cold differential set pressure is indicated on the nameplate set the valve to open at that pressure The cold differential test pressure is the test pressure corrected to compensate for 19000 Series Consolidated Safety Relief Valve Page 38 iii The Tightness Standard is the leakage rate in bubbles per minute and shall not exceed that shown in Table IX for metal seat valves or Table X 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 X when the test medium is either air or water b Water When a meta
65. ty Relief Valve Page 16 SRV Disassembly Metal Seat Valves See Figures 1 2 a Remove the cap 15 including lifting gear if any then remove the cap 14 gasket b Measure the position of the valve adjusting screw 9 and record before removal Measure from the top of the screw to the adjusting screw locknut 10 c Loosen the adjusting screw locknut 10 and remove the adjusting screw 9 from the bonnet 5 d Unscrew the bonnet 5 from the base 1 e Remove the spindle 6 spring 8 and spring washers 7 f Remove the guide 4 disc holder 3 and disc 2 from the base 1 O Ring Seat Seal Valves DA See Figure 3 Follow steps a through e for Metal Seat Valves above f Remove the guide 4 and O Ring disc holder assembly from the base g Remove the retainer lockscrew 18 and the O Ring retainer 16 h Carefully remove the O Ring Seat Seal 17 Be sure not to damage the O Ring groove in the disc holder 3 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 dimensio
66. valuation highlighting compliance and discrepancies Recommendations and corrective actions Testing On site and in place testing using Dresser Consolidated s EVT testing device e Shop testing on high capacity testing facilities with steam air or water by fully trained and certified pressure relief valve technicians e Baseline history established Repair Dresser Audited Facility Using Dresser Consolidated s Inspection Criteria and Critical Dimensions Byfully trained and certified pressure relief valve technicians Using original manufactured parts Inventory Control Global access to spare parts inventories via www greentag net with your local Green Tag Center Dresser Consolidated authorized sales representative Parts interchangeability Obsolete and excess inventory identified Recommend cost effective inventories Page 43 ValvKeep Total computer based valve management system Free interchange of information Historical data and permanent record of traceability Maintenance scheduling and planning Repair intervals validated by each valves maintenance history Code compliance Accessible via secure password protected internet connection Downloadable and printable reports Call 1 800 245 VALV to find your local Dresser Consolidated Certified Green Tag Service Center 19000 Series Consolidated Safety Relief Valve Page 44 Sales Office Locations Dresser Consolidat
67. ve Do not subject SRVs either crated or uncrated to sharp impact Ensure that the valve is not bumped or dropped during loading or unloading While hoisting the valve take care to prevent bumping the valve against steel structures and other objects Particular care needs to be taken when handling screwed portable valves to avoid damage to external inlet threads ATTENTION Prevent dust and debris from entering inlet or outlet 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 Pre Installation 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 19000 Series Consolidated Safety Relief Valve Page 13 A DANGER Recommended Installation Practices Mounting Position H Mount SRVs in a vertical upright position in accordance with API RP 530 Part Il Installing a safety relief valve in any position other than vertical 1 degree will adversely affect its op
68. w rates or areas Pressurized fluids gas air injected into or near the body can cause severe personal injury or death e 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 or death 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 Heed all service manual warnings Read installation instructions before installing valve s Wear hearing protection when testing or operating valves Wear appropriate eye and clothing protection Wear protective breathing apparatus to protect against toxic media 19000 Series Consolidated Safety Relief Valve Terminology for Safety Relief Valves SRV 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 Backpressure the pressure on the discharge side of the SRV Built up Backpressure the pressure that develops at the valve outlet after the SRV has been opened as a result of flow Superimposed Backpressu
69. with a 1000 grit lapping compound or its equivalent see Table XIII The following precautions and hints will enable maintenance personnel to do a professional job of lapping seats i Keep work materials clean 11 Always use a fresh lap If signs of wearing out 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 10 To assure the best results when lapping seats the laps should be reconditioned after each usage iii Apply a very thin layer of compound to the lap This will prevent rounding off the edges of the seat iv Keep the lap squarely on the flat surface and avoid any tendency to rock the lap which causes rounding of the seat v When lapping keep a firm grip on the part to prevent the possibility of dropping it and damaging the seat vi 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 10 vii Replace the compound frequently after wiping off the old compound and apply more pressure to speed the cutting action of the compound viii To check the seating surfaces remove all compounds from both the seat and the lap Then shine the seat with the same lap using the lapping motion described above Low sections on the seating surface will show up

19000 Series Consolidated Safety Relief Valve

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