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Consolidated* Safety Relief Valve Maintenance Manual

1. D Setting the Valve Set the valve to open at the set pressure as shown on the nameplate If a cold differential test pressure is indicated on the nameplate set the valve to open at that pressure on the test stand The cold differential test pressure is the set pressure corrected to compensate for backpressure and or operating temperature A new cold differential test pressure may need to be determined if changes are to be made to the set pressure or backpressure or if the service temperature changes NOTE This design will allow the set pressure to remain constant under superimposed variable back pressure conditions If changes are to be made to the set pressure or back pressure or the service temperature changes a new cold differential test pressure May need to be determined E Set Pressure Compensation Cold Differential Test Pressure for Temperature Compensation During production testing the SRV is often tested at temperatures that are different from the temperatures the SRV will be exposed to in service Increasing the temperature from ambient temperature causes the set pressure to decrease The decrease in set pressure is due to thermal expansion of the seating area and spring relaxation Therefore it is important to compensate for the difference between production test temperature and service temperature The service temperature 2015 General Electric Company All rights reserved is the normal operating temperatu
2. Bushing Bushing Gasket Figure 2b 54 Packed Lifting Lever Drive Pin O Ring D Release Nut Release Locknut Plain Lever Cap _ amp ZZZZLZLL XL ZL ZZ A A Plain Lifting Lever or A LLL Cap Screw 3 N Lever Pin KAN N N Y SS Lill ZZ IS Lei KN N Lifting Fork Lever Shaft Packing Packing Nut Available for 19096L M amp H 19110L M amp H 19126L amp M 19226L amp M Excludes 19096M DA BP Available for 19126H 19226H 19357L amp M 19357L amp M Excludes 19096M DA BP gt _N Note 3 Available for all 19000 valves CES SR E E EE SO VO Va P 5 AL Note 4 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 13 X Consolidated 19000 Series SRV Contd C Soft Seat Valve Nomenclature O Ring Retainer Disc Holder Spring Washer Adjusting Screw Adj Screw Locknut Cap Gasket Screwed Cap O Ring Retainer Lockscrew O Ring Seat Seal Inlet Nipple Extension Not Shown Optional Outlet Nipple Extension Not Shown Optional 15 17 18 36 Sf az E SN EN NY SS 000000000 A TVD D he NIK Z QA GES ZAL A R ERS 4 MN EKS V Re E way WW 4 ANENE i ae N AUS cati y NES gt Dar ANS a Z DV O D A I 5 LO O LL 5 AS DG Figure 5c Soft Seat Assembly Figure 5 19000 O Ring Soft Seat Valve Construction
3. Place the backup plate 39 o ring side down into the counterbore in the bonnet bottom 32 GE Oil amp Gas 8 10 Place spindle o ring 312XX011 38 into the o ring groove on the spindle 9 Lubricate the spindle nose with a small amount of non copper based thread lubricant and insert the spindle through the backup plate into the disc holder spindle pocket Apply a small amount of non copper based thread lubricant to the bearing surface of the lower spring washer 10 and slip it over the spindle 9 Install the spring 11 and upper spring washer 10 Apply non copper based thread lubricant to the bonnet top threads for the bonnet bottom and cap joints Install the bonnet top 7 into the bonnet bottom 8 carefully allowing the spindle 9 to line up with the hole in top Torque bonnet top to bonnet bottom with 133 ft lb 180 32 Nm recommended torque maximum torque not to exceed 500 ft lb 677 91 Nm ATTENTION The top bonnet is vented and the top bonnet vent must not be plugged LL Le Thread the adjusting screw locknut 13 on the adjusting screw 12 Apply a small amount of non copper based thread lubricant to the tip of the adjusting screw Install the adjusting screw in the bonnet 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 s
4. The outside surface is worn egged or galled and or 3 Guide seating surface U is scratched nicked corroded or cannot meet H dimension see Figure 14 and Table 8 dimension L is less than L minimum see Figure 11 Tables 2 The spindle pocket bearing surface is galled or pitted 3 to 5 and Section XIII A3 2 b 3 The o ring groove is nicked scratched or pitted A Seat step F is at or above minimum listed in Table 5 F can 4 The o ring retainer screw threads are torn stripped or be reestablished by machining as long as L stays within galled tolerance see Section XIII A3 2 b B Metal Seat Disc 2 The metal seat disc should be replaced if Figure 14a 1 Design Figure 14b 2 Design 1 Seat surface Y see Figure 12 is damaged beyond lapping or machining limits d Seat relief height R is less than R minimum and dimension S cannot be maintained see Table 7 3 Length S is less than S minimum see Table 7 C O Ring Seat Seal Assembly The O Ring seat seal assembly parts should be replaced as follows 1 O ring seat seal 37 always replace 2 O ring retainer 3 a Lapped seat relief height R is less than R minimum and dimension S cannot be maintained see Figure 12 and Table 7 b Length S is less than S minimum see Table 7 c Retainer lockscrew always replace Figure 14 Dis
5. from the base 1 e Remove the spindle 9 spring 11 and spring washers 10 f Remove the guide 5 disc holder 4 and disc 2 from the base 1 2 O Ring Seat Seal Valves DA See Figure 5 Follow steps a through e for Metal Seat Valves above f Remove the guide 5 and O Ring disc holder assembly from the base g Remove the o ring retainer lockscrew 36 and the O Ring retainer 3 h Carefully remove the O Ring Seat Seal 37 Be sure not to damage the O Ring groove in the disc holder 4 3 19096M DA BP Valves See Figure 6 a Remove the cap 18 including lifting gear if any then remove the cap gasket 17 b Measure the position of the valve adjusting screw 12 and record before removal Measure from the top of the screw to the adjusting screw locknut 13 c Loosen the adjusting screw locknut 13 and remove the adjusting screw 12 from the bonnet top 7 d Unscrew the bonnet top 7 from the bonnet bottom 8 2015 General Electric Company All rights reserved e Remove the spindle 9 backup plate 39 spring 11 and spring washers 10 f Unscrew the bonnet bottom 7 from the base 1 g Remove the guide 5 and O Ring retainer 3 h Remove the retainer lockscrew 36 and the O Ring retainer 3 i Carefully remove the seat O Ring 37 Be sure not to damage the O Ring groove in the disc holder 4 C Cleaning 19000 Series Safety Relief Valve interna
6. 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 e Identify forgotten or overlooked valves e Product upgrades to reduce cost and improve performance Inspection of the Valve and Installation e Visual evaluation of the installation for compliance to codes and regulations e Written evaluation covering compliance issues and discrepancies e Recommendations and corrective actions Testing e On site and in place testing using the GE s EVT testing device e Total computer based valve management system e Free interchange of information e Historical data and permanent record of traceability e Maintenance scheduling and planning e Repair intervals validated by each valves maintenance history e Code compliance e Accessible via secure password protected internet connection e Downloadable and printable reports e Base line history established Repair e GE Audited Facility e Using GE s Inspection Criteria and Critical Dimensions e By fully trained and certified pressure relief valve technicians e Using original manufactured parts Inventory Control e Global access to spare parts inv
7. unplanned repairs and increase valve safety While these seminars do not create instant experts they do provide the participants with hands on experience with Consolidated valves The seminar also includes valve terminology and nomenclature component inspection troubleshooting setting and testing with emphasis on the ASME Boiler and Pressure Vessel Code For further information contact the Consolidated Product Training Manager by fax at 318 640 6325 or telephone at 318 640 6054 Consolidated 19000 Series Safety Valve Maintenance Manual 41 DIRECT SALES OFFICE LOCATIONS AUSTRALIA ITALY SOUTH AFRICA Brisbane Phone 39 081 7892 111 Phone 27 11 452 1550 Phone 61 7 3001 4319 Fax 39 081 7892 208 Fax 27 11 452 6542 Fax 61 7 3001 4399 porta i oc i CARIBBEAN IDO li RER Phone 81 43 297 9222 Phone 55 12 2134 1201 Fax 91 43 299 1115 Fax 365 142 21301238 Melbourne Phone 61 3 8807 6002 KOREA SPAIN Fax 61 3 8807 6577 Phone 82 2 2274 0748 Phone 34 93 652 6430 Fax 82 2 2274 0794 Fax 34 93 652 6444 BELGIUM Phone 32 2 344 0970 MALAYSIA UNITED ARAB EMIRATES Fax 32 2 344 1123 Phone 60 3 2161 0322 Phone 971 4 8991 777 Fax 60 3 2163 6312 Fax 971 4 8991 778 BRAZIL Phone 55 11 2146 3600 MEXICO UNITED KINGDOM Fax 55 11 2146 3610 Phone 52 5 310 9863 Bracknell Phone 44 1344 460 500 CHINA THE NETHERLANDS Fax 44 1344 460 537 Phone 86 10 5689 3600 Phone 31 15 3808666 Fa
8. Class Part name Q i S i di Need Coverage Probability Material Valves in Service 70 percent Disc Gaskets Cap Disc Holder Spindle 85 percent Guide Spring Assembly 175 95 percent Compression Screw z Cap specify screwed packed or plain 1 5 Release Nut used on packed or plain lever only ei 99 percent nal Locknut used on packed or plain lever 1 5 only NOTE Consult Spring Selection Chart before ordering springs to determine actual quantities required in view of pressure setting potential in each spring range Table 20 O Ring Seat Valves uantity Parts Size Type amp Part name Q gt di Need Coverage Probability Material Valves in Service Es 85 percent Spring Assembly K 95 percent Compression Screw 1 5 1 5 99 percent 1 5 1 5 NOTE Consult Spring Selection Chart before ordering springs to determine actual quantities required in view of pressure setting potential in each spring range YOUR SAFETY IS OUR BUSINESS GE has not authorized any company or any individual to manufacture replacement parts for its valve products When ordering replacement valve parts please specify in your purchase order ALL PARTS MUST BE DOCUMENTED AS NEW AND SOURCED FROM GE OR YOUR LOCAL GREEN TAG CENTER GE AUTHORIZED SALES REPRESENTATIVE 40 GE Oil amp Gas 2015 General Electric Company All rights reserved XXII Field Service Training and Repair Program A Field Service GE provides safe
9. Figure 5a 1 Male NPT 2015 General Electric Company All rights reserved 14 GE Oil amp Gas X Consolidated 19000 Series SRV Contd D The 19096M DA BP Valve OI L_ I Ces OI E S ng Retainer t Bottom ing Washer SMAA EXT TE i ocknut iner Lockscrew O Ring NI IN BR K ZAITZAN Ne ZARA mA NEL ER N N Figure 6 19000 DA BP Valve Construction 15 Manua Safety Valve Maintenance Consolidated 19000 Series d Electric Company All rights reserve 2015 Genera XI Recommended Installation Practices A DANGER Mount safety relief valves in a vertical upright position only A DANGER Do not mount valve at the end of pipe through which there is normally no flow or near elbows tees bends etc A CAUTION Heed all service manual warnings Read installation instructions before installing valve s 16 GE Oil amp Gas A Mounting Position Mount SRVs in a vertical upright position in accordance with API RP 530 Installing a safety relief valve in any position other than vertical 1 degree will adversely affect its operation as a result of the induced misalignment of moving parts A stop valve may be placed between the pressure vessel and its relief valve only as permitted by code regulations If a stop valve is located between the pressure vessel and SRV the stop valve port area should equal or exceed the
10. Information C Replacement Parts List The importance of maintenance planning is the key to good Consult the Recommended Spare Parts list see Tables 19 and plant operations Part of that planning involves making sure that 20 to determine the parts to include in the inventory plan replacement parts needed to repair valves are available at the Select the desired parts and determine those required for proper jobsite when required Developing and implementing a standard maintenance of the valve population in the plant valve maintenance plan will quickly pay for itself by eliminating costly downtime unscheduled outages etc D Identification and Ordering Essentials When ordering service parts please furnish the following B Inventory Planning The basic objectives in formulating a replacement parts plan information to ensure receiving the correct replacement parts are 1 Identify valve by the following nameplate data 1 Prompt availability a Size 750 19 05 mm 2 Minimum downtime b Type 19096LC 1 3 Sensible cost c Temperature class Spring Selection S N A Source control l d Serial Number TC75834 Having parts immediately available from plant storeroom 2 Specify parts required by inventory is obviously the best way to accomplish those objectives Since it is impractical to have every part that might be needed a Part name to accomplish a given repair in stock at all times guidelines for b Part number i
11. N gt N gt N lt gt N 24 GE Oil amp Gas 2015 General Electric Company All rights reserved XIII Maintenance Contd A4 Machining the Disc Seat d The disc is now ready for lapping See Table 6 for 1 When the disc seat cannot be repaired by lapping it can proper seat width be machined as shown in Figure 12 using the dimensions e When the minimum thickness dimension S is reached provided in Table 7 the disc should be replaced d GErecommends that the following procedure be adhered B O Ring Seat Seal Valves DA to when machining the disc seat a Grip the disc in a collet 1 Replacing the o ring retainer 3 b True up the disc so that surfaces marked X and Y run cu un If slight damage is present the o ring retainer can be true within 001 0 03 mm on an indicator S refurbished by either lapping or machining O Ring retainer c Take light cuts across the seating surface until the oo i a should be replaced if severely damaged or if dimension S damage is removed Dimensions R and Q and 15 co minimum is exceeded see Figure 12 and Table 7 angle when applicable must be maintained ATTENTION Table 6 Disc Seat Lapping Width 2 Metal Seat Design The O Ring always should be replaced to ensure seat Disc Width tightness Set Pressure SE SE 19019 VALVE 2 Polishing the base seat SALE ISS TI oe 126 567 Normally the
12. Screwed Cap 2 Inlet Extension Not Shown Inlet Flange Not Shown Sie AZL LLA 74 Outlet Extension Not AGE XP ana DAN Outlet Flange Not TRES g DI 4 SJ LLLLLLL e a A A N GE RE A A A A AL ANN WVA TNN KS a TS AZZZZZV RZ LZ A IX gt H Lp KE Greg SS Inlet Nipple Extension Not Shown Optional Z AST WS Outlet Nipple Ext Not Shown Optional Note 1 d Ly ed CARTE Available as 19096L 19110L 19126L 19226L 19096M 19110M 19126M 19226M AAA ALL NE WO NI N Day Laz Wer Se a gt Oo ao ed 7 oO a EZ sc n gt i LO DI WO O ed O a D AD Hd N ee KO Un tn O On Ou e Q O N LF om gt Or TH N E ee ut SANI ST LL Kom Kom Or Kom L tO O en Kom gt LO LC en Kom gt e ND Or e gt LO N N en Kom L LO N N ex e sE WO N Kom Or Kom gt a Figure 1c 1 Design Note 3 19110 Valve Not Available Figure 1 19000 Metal Seat Valve Construction 2015 General Electric Company All rights reserved 12 GE Oil amp Gas X Consolidated 19000 Series SRV Contd B Optional Cap Types Figure 20184 Nomenclature Gag Bolt Sealing Plug Sealing Plug Gasket Cap Gasket Packed Cap Li NN NOS SD Se No dd Sd Cam Shaft SN n n Ze ES 1 TS
13. Series Valves are designed so that 10 GE Oil amp Gas 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 percent of the valve set pressure in compliance with ASME Code Section VIII Further all available Consolidated 19000 Series Valve caps may be equipped with a gag upon customer request Inlet Outlet Connections All Consolidated 19000 Series can be provided by GE Consolidated with flanged or socket weld inlet and outlet connections upon customer request B 2 19096M DA BP Safety Relief Valves See Figure 6 In this design the bonnet and the spindle are different there are two added parts and two additional o rings The bonnet is a two piece design rather than a one piece The top of the bonnet 7 is the male piece and it screws into the female bottom bonnet 8 The bottom bonnet has a machined shelf in the top on which a metal backup plate 39 seats via an o ring 40 part number 310XX030 The XX in the part number designates the material and durometer of the o ring The spindle 9 is modified to have a larger diameter in the lower section to accommodate a 310XX011 O Ring 40 which slides through the inside diameter of the backup plate 39 providing an area nearly equal to the area of the base which balances the effects of
14. ai 30 XV Reassembly of Consolidated 19000 Series SRV i 30 A Mei 30 B O Ring Seat Seal Valves DA Lic on si C 19096M DA BP O Ring Seat Seal VAIVES wi i 31 XVI Setting and Testing esse 55 eE e S aE E E A A E EE a 33 bo EMIR aa asi 35 ce TO MONO ae IA on 33 R ale E 33 MS CS COS enanssa snaa EENE Eae S ne Ee 25 FE 34 ca 35 SCOR Perm eRe MOT tO ne 35 Ke Pr o cure Jee lee ee 35 Ji HIT 37 K Manual Popping f the ONE aoc Esere E aE N EEEN EEEE ETENE 37 ATOS OC E Ke XVIIE Maintenonce 1008 GAS Obs run 38 XIX Replacement Parts PI Lul asa 39 A CERO iaia 39 L OEIL 39 C eeler ug Farts ell 39 D Identification and Ordering Cssentole esse 39 XX Genuine Consolidated Parts iii 39 XXI Recommended Spare Parts eee ne ne en 40 XXI Field Service Training and Repair Program 41 Pe F U A A E AE AE A EAA A 41 B Factory Repair ECS mies 41 Co SRY Gelle ROC NK CAI a a EEE E EAE 41 le 42 4 GE Oil amp Gas 2015 General Electric Company All rights reserved I Product Safety Sign and Label System If and when required appropriate safety labels have been included in the 1 rectangular margin blocks throughout this manual Safety labels are vertically oriented rectangles as shown in the representative examples below consisting of three panels encircled by a narrow border The panels can contain four messages which communicate DANGER Immediate hazards which WILL result in severe personal inju
15. between the movement of the valve s internal parts may cause leakage operating pressure of the system and the set pressure of the _ Where possible use properly supported drainage piping to valve particularly under high frequency conditions ae prevent the collection of water or corrosive liquid in the valve Temperature changes in the discharge piping may be caused body by fluid flow in from the discharge of the valve or by prolonged exposure to the sun or heat radiated from nearby equipment A change in the discharge piping temperature will cause a change in the length of the piping which may Capmaybe cause stresses to be transmitted to required for weather the SRV and its inlet piping Proper e protection support anchoring or provision for flexibility of the discharge piping can pr Long Radius prevent stresses caused by thermal Elbow changes Do not use fixed supports C Outlet Piping Alignment of the internal parts of the SRV is Important to ensure proper operation see Figure 8 Although For a closed system always keep piping strains isolated from the the valve body will withstand a Pressure Relief Valve regardless of process operation and temperature considerable mechanical load Figure 8 Outlet Piping Considerations 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 17 XI Recommended Installation Practices Contd When two or m
16. blowdown on these valves Typical blowdown is less than 10 percent The blowdown under the Set Dreseure ii 2500 psig 172 37 barg back pressure conditions will cause a shorter blowdown than Minus Constant Back Pressure 150 psigl 10 34 barg when observed with no back pressure 34 GE Oil amp Gas 2015 General Electric Company All rights reserved XVI Setting and Testing Contd G Simmer If simmer causes erratic valve opening refer to the Trouble Shooting Guide in this manual H Seat Leakage 1 Air The air leakage test shall be performed with all connections and openings in the body and bonnet pressure tight The cap with the gasket which covers the adjusting screw must be installed Test the valve for leakage using an API test fixture The API leakage test procedure is described below a Per API Standard 527 ANSI B147 1 72 a standard test fixture consists of a piece of tubing of 313 7 94 mm x 035 0 89 mm wall one end of which is joined to an adapter on the valve outlet and the other end of which is immersed 05 12 7 mm below the surface of a reservoir of water b 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 t
17. lapping is completed any lines appearing as cross scratches can be removed by rotating the lap which has been wiped clean of compounds on the seat about its own axis 10 The seat should now be thoroughly cleaned using a lint free cloth and a cleansing fluid 2 Lapping the Base Seat For 1 Material Seat Design The base seat may be reconditioned using the lapping procedure however the dimensions provided in Table 2 should be used to determine the seat width Table 2 Base Lapping Width 1 Metal Seat Design Only SET PRESSURE barg SEAT WIDTH min max in mm Note 1 Add 005 0 127 mm per 100 psig 6 896 barg not to exceed 070 1 78 mm The seat width can be measured by the use of a Measuring Magnifier see Figure 10a GE recommends the use of Model S1 34 35 37 Bausch and Lomb Optical Co or an equivalent This is a seven power glass with a 750 19 05 mm scale showing graduations of 005 0 13 mm The use of this scale in measuring the seat width is shown in Figure 10b v mmm Measuring A Magnifier Figure 10a Measuring Magnifier 2015 General Electric Company All rights reserved XIII Maintenance Contd A3 Machining the Base Seat 1 When the base seat cannot be repaired by lapping it can be machined as shown in Figure 11 using the dimensions provided in Tables 3 to 5 0 7 Lull d GErecommends that the following procedure be adhered to when machining
18. nominal internal area associated with the pipe size of the SRV inlet The pressure drop from the vessel to the SRV shall not exceed three 3 percent of the valve s set pressure when flowing at full capacity The threaded inlet and outlet ports and sealing faces of the valve and all connecting piping must be free from dirt sediment and scale In the case of screwed portable valves use caution to avoid unscrewing bonnet from the base if a pipe wrench is used to install or remove the base ensure that the wrench is placed on the flats of the base and not on the bonnet If the bonnet base joint is broken the valve should be retested to ensure proper set pressure and function of the valve Position SRVs for easy access and or removal so that servicing can be properly performed Ensure sufficient working space is provided around and above the valve B Inlet Piping The inlet piping see Figure 7 to the valve should be short and directly from the vessel or equipment being protected The radius of the connection to the vessel should permit smooth flow to the valve Avoid sharp corners If this is not practical then the inlet should be at least one additional pipe diameter larger The pressure drop from the vessel to the valve shall not exceed three 3 percent of valve set pressure when the valve is allowing full capacity flow The inlet piping should never be smaller in diameter than the inlet connection of the valve Excessive pressure dro
19. of the spring washer seat at C be straight in order to transmit the spring load to the Rotate the spindle The total indicator reading should dISCWITOULiateraLomemg Qvergaggino is One rtne not exceed 005 0 13 mm Straighten the spindle if common causes of bent spindles To check the essential necessary working surfaces of the spindle the method stated in the next section is recommended d V Block Support Set Up a The ball pointed spindles should be placed in a piece of material B that has been recessed to permit free rotation of the spindle see Figure 13 Section X X Bearing Surface T Spring Washer 2 Spindle Figure 13 V Block Support Setup 26 GE Oil amp Gas 2015 General Electric Company All rights reserved XIV Inspection and Part Replacement A Base 1 D Bonnet 6 The base should be replaced if The bonnet should be replaced if 1 Seat surface 1 Threads are stripped torn or galled a Metal seated seat surface N see Figure 11 is 2 The guide seating surface is scratched nicked corroded or scratched nicked corroded leaks or is too wide and leaks cannot be machined see Table 2 and Section XIII 3 Condition is porous corroded or distorted A3 2 b b O ring seat surface N see insert Figure 11 is E O Ring Disc Holder 4 scratched nicked corroded or leaks The o ring disc holder should be replaced if d Threads all are torn stripped or galled 1
20. rotating the number of times required to compress the spring slightly 2015 General Electric Company All rights reserved XV Reassembly of Consolidated 19000 Series SRV Contd Table 10 Base Torque Specifications pie Ib mn me nie 190961 125 169 a ST et SES SN omg 125 169 250 339 192260 200 271 400 sa asser 625 847 100 1356 19096M 175 237 300 407 19096M 8P_ 175 237 300 407 mum 175 237 300 407 Use pliers to hold the spindle 9 in position and prevent galling Adjust the adjusting screw to the measurement recorded during disassembly See Metal Seat Valves disassembly instructions point b on page 16 8 The valve is now ready for setting After the set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap 18 and cap gasket 17 or lifting gear on the valve after applying a small amount of non copper based thread lubricant to the gasket seal surfaces as well as to the cap and bonnet threads B O Ring Seat Seal Valves DA See Figure 2 1 All bases shall be lapped flat enough to remove nicks and burrs 2 Bearing surfaces should be ground together using a 320 grit lapping compound see Table 17 clean all parts before assembly These surfaces are a The disc holder spindle pocket and spindle spherical nose radius b The lower spring washer and spindle spring washer radius c The upper s
21. 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 12 Relief Valve An automatic pressure relieving device actuated by static pressure upstream from the valve A relief valve is used primarily for liquid service VI Handling Storage Handling Valves should not be shipped with the inlet flange down These valves should be kept in their factory foam filled carton until installation ATTENTION Never lift the valve by the lifting lever ATTENTION Handle carefully Do not drop or strike the valve Do not subject SRVs either crated or uncrated to sharp impact Ensure that the valve is not bumped or dropped during loading or unloading from a truck While hoisting the valve take care to prevent bumping the valve against steel structures and other objects 2015 General Electric Company All rights reserved 13 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 14 Safety Valve An automatic pressure relieving device actuated by the static pressure upstream of the valve and characterized by a rapid opening or pop action It is used for steam gas or vapor service 15 Set Pressur
22. 02 0 05 19357M 0 675 17 15 0 796 20 22 0 881 22 38 0 987 25 07 0 024 0 000 0 00 0 002 0 05 19567M 0 850 21 59 1 000 25 40 1 109 28 17 1 247 31 67 0 024 _ 0 000 a te 19096H 0 350 EC 0 395 10 03 0 457 11 61 0 503 12 78 0 022 0 002 CACI 19110H 0 375 RES 0 395 10 03 0 457 11 61 0 503 12 78 0 022 0 002 0 523 13 28 0 579 14 71 0 024 0 002 19126H 0 401 10 19 0 444 11 28 19226H 0 537 13 64 0 616 15 65 ER 0 701 17 81 0 781 19 84 0 022 0 002 Table 4 19000 2 Series Metal Seat MS Base Re work Dimensions Contd ES Type BEER RI RI angle angle SCR ele ele le lee 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 23 Table 5 19000 Series Soft Seat DA Base Re work Dimensions E 003 0 08 mm D 002 0 05 mm B 002 Valve Amin 0 05 mm Type i in 0 550 8 89 0 375 9 53 0 401 10 19 0 350 8 89 0 375 9 53 0 401 10 19 0 850 21 59 0 960 0 350 8 89 0 395 0 375 9 55 0 395 0 401 10 19 0 453 G 005 Valve 0 13 mm Type mm n C min 3 0457 0 503 0000 0457 050 0 000 0523 0 579 0000 0701 0781 0000 m 3 5 3 0 050 0 000 0 050 0 000 0 050 0 000 0 050 0 000 0 076 0 050 0 076 0 050 0 050 0 000 0 050 0 000 0 050 0 000 0 050 0 000 0 076 0 050 0 050 0 076 0 050 0 076 0 050 0076 0 050 0 076 0 076 0 050 0 395 10 03 Fla
23. GE Oil amp Gas 19000 series Consolidated Safety Relief Valve Maintenance Manual GE Data Classification Public THESE INSTRUCTIONS PROVIDE THE CUSTOMER OPERATORWITH IMPORTANT PROJECT SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER OPERATOR S NORMAL OPERATION AND MAINTENANCE PROCEDURES SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY GE GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS THEREFORE THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION OPERATION OR MAINTENANCE SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER OPERATOR S PURPOSES THE MATTER SHOULD BE REFERRED TO GE THE RIGHTS OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSL
24. N Spindle O Ring 310XX011 38 The spindle O Ring should always be replaced The material and durometer of the spindle O Ring should be the same material and durometer as that specified for the Seat O Ring 37 O Backup Plate O Ring 310XX030 40 The backup plate O Ring should always be replaced The material and durometer of the backup plate O Ring should be the same material and durometer as that specified for the seat O Ring 37 P Seat O Ring 310XX013 37 The seat o ring should always be replaced The material and durometer of the seat o ring should be the same material and durometer as that specified on the o ring nameplate XV Reassembly of Consolidated 19000 Series SRV A Metal Seat Valves MS See Figures 1 and 2 1 Bearing surfaces should be ground together using a 320 grit lapping compound see Table 17 These surfaces are 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 2 Apply small amount of non copper based thread lubricant to the guide bonnet seating surface and the bonnet and base threads 3 Use a clean base 1 lapped for the valve set pressure see seat width requirement Table 5 Place a lapped disc 2 on the base with lapped surfaces facing each other Place the disc holder 4 onto the disc and bas
25. Y PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER OPERATOR SOLELY TO ASSIST IN THE INSTALLATION TESTING OPERATION AND OR MAINTENANCE OF THE EQUIPMENT DESCRIBED THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE Conversion Table All the United States Customary System USCS values are converted to metric values using the following conversion factors Metric values using the following Conversion Factor Metric Unit conversion factors In 252 mm Ib 0 4535924 kg in 6 4516 S ft min 0 02831685 m min gal min GEA L min lb hr 0 4535924 kg hr psig 0 06894757 barg ft Ib 1 3558181 Nm 5 9 F 32 Note Multiply USCS value with conversion factor to get metric value NOTICE For valve configurations not listed in this manual please contact your local Consolidated Green Tag Center for assistance 2 GEOIl amp Gas 2015 General Electric Company All rights reserved Table of Contents Section Subject Page No COPIO 2 Product Satew Sion and Lapel Syste E 5 Il SLA E AA I en ee 6 i i 7 VANI O e 8 V Terminology for Safety Relief VIVES i 8 vi Hadid 9 Vil Pre Installotion and Installation IMStTUCtIONS 2 nee entiers 10 VIII Design Fe
26. alve after applying a small amount of non copper based thread lubricant to the gasket seal surfaces and the cap and bonnet threads pressure I 2 19096M DA BP After the valve has been set for the correct opening pressure it must be back pressure tested Testing can be conducted by installing the cap with gasket and applying air or nitrogen to the valve outlet Test pressure should be 30 psig 2 barg or the actual valve back pressure whichever is greater Examine the following components for leakage during back pressure testing a base 1 to bonnet bottom 8 joint b bonnet bottom 8 to bonnet top 7 joint c the bonnet top vent port Note Leakage is best detected by application of a liquid leak detector The use of soap or household detergent as a leak detector is not recommended as it may cover up leaks Repair of leaking valve joints may be attempted by tightening the leaking joint while the valve is still on the stand If this does Threads 125 NPT Vent Do Not Plug Threads Figure 16a Bonnet Top Threads Figure 16 Spindle Figure 16b Bonnet Bottom 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 fi
27. and spindle spring washer radius c The upper spring washer and adjusting screw spherical radius Carefully insert a new seat o ring seal 37 into the disc holder 4 Make sure the seat o ring is the right size material and hardness for the application Refer to the valve nameplate for information required when ordering an O Ring Install the o ring retainer 3 and the retainer lockscrew 36 Apply thread locker fluid to lock the screw in position Place the disc holder assembly onto the base 1 and place the guide 5 onto the base The guide seating surfaces should be free of any nicks or scratches The guide to bonnet bottom seating and the backup plate ring to bonnet bottom seating surfaces should be free of any nicks or scratches The guide to bottom bonnet 8 seating surface should have a finish with a maximum of 63 RMS Apply non copper based thread lubricant or equivalent anti seize to the bonnet bottom threads on the base and guide seating surfaces Install the bonnet on the base 1 Tighten the bonnet bottom to the base using sufficient torque from Base Torque Specification see Table 10 Place backup plate O Ring 310XX030 40 in the o ring groove in the backup plate 39 using a small amount of o ring lubricant Verify that the backup plate seating surface on the bonnet bottom and the backup plate ring inside diameter have no more than a 32 RMS finish Ensure that they are clean and free from nicks and scratches
28. atures and Nomenclature 10 A General Information 10 e RO DOS a E A E 10 NO RERO one Ea ere oe vena ee ee ee ea 10 P Edo 11 A 19000 MS amp DA Safety Relief Valves nee 11 B 19096M DA BP Safety Relief Valves ie 11 X Consolidated 19000 Series RV 12 Metal SOG NY en a ne ee ha I2 bi SON Da 13 COSI 14 D The 19096M DA BP Vohve _ J 1 1 T 9p0q0606cc6eeeeeeeeeiic 0000008 15 XI Recommended Installation Practices 16 Gute treie PO Te 16 SEP INT TT nn rd ee TT Orn 16 OC I EEE RAEAN E E AAE A EA 17 XII Disassembly of Consolidated 19000 Series SRV ou cccccssssessssesssssssesssessssesssecssssessesseessseessusesseesseeesseeen 18 A General Information einen 18 Bo DE PPE eae OE ROE ROSE E E ee ere ene eee 19 GIO 19 AI MORE alia 20 PC OR ER 20 Bi CRAS rv 25 C CIECHI PRICE RC asa 26 XIV Inspection and Part Replacement sn el A DOTE se ace eee a ea tee EE reece el PD MAO ii E E E a 27 SE Tute le 24 RO ner nee A eee eee eee ee EA ef CRD orn Ory Oper Em Ate or ero ner ee mT eee et fe lan 28 ee e mean a ena E E To IE AE E EPO AA NOTE Rea eee eerie ere 28 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 3 Table of Contents Section Subject Page No LI 28 a eae 28 AS Feo CREO a EE 29 KEE ee 29 RC E E EAS 29 ki PRC 29 L POR 30 D Ee TIO aap E sa eeaasnee sce av A E E E 30 i EER ire 30 O Back p Fiate OI ie 30 Rara
29. ause severe personal injury or death e Itis the owner s responsibility to specify and provide personal protective wear to protect persons from pressurized or heated parts Contact with pressurized or heated parts can result in severe personal injury or death 6 GE Oil amp Gas e Do not work or allow anyone under the influence of intoxicants or narcotics to work on or around pressurized systems Workers under the influence of intoxicants or narcotics are a hazard to themselves and other employees Actions taken by an intoxicated employee can result in severe personal injury or death to themselves or others e Always perform correct service and repair Incorrect service and repair can result in product or property damage or severe personal injury or death e Always use the correct tool for a job The misuse of a tool or the use of an improper tool can result in personal injury damage to product or property e Ensure the proper health physics procedures are followed if applicable before starting operation in a radioactive environment Caution Alerts A CAUTION alert describes actions that may result in a personal injury In addition they may describe preventive measures that must be taken to avoid personal injury Cautions include e Heed all service manual warnings Read installation instructions before installing valve s e Wear hearing protection when testing or operating valves e Wear appropriate eye and clothi
30. base seating area on this type of valve is 5 to 800 0 34 to 55 16 0 010 0 254 foreign material is trapped between the o ring and the Note Note base seating area The o ring will therefore hold a bubble 801 Above 55 23 Above Flat Flat 0 010 0 254 1 1 tight seal with slight indications on the base seating surface Nevertheless slight indications on the base seat Note 1 Add 005 0 125 mm per 100 psig 6 896 bar until disc seat width has reached the maximum available width surface may be removed by lapping the base Figure 12a Metal Seat Disc 1 Design Figure 12b Metal Seat Disc 2 Design SURFACE Figure 12c Soft Seat O Ring Retainer 19096 19126 Figure 12d Soft Seat O Ring Retainer 19226 19567 S LINK 7 JL LY Figure 12 Disc and O Ring Retainer Metal Seat amp Soft Seat 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 25 XIII Maintenance Contd Table 7 Rework Dimensions of the Disc Seat 10 82 10 82 19226L1M 0 705 0 705 Note 1 These valves have a 15 angle as shown in Figure 12 2 Metal Seat Design C Checking Spindle Concentricity b Support the spine a V block A placed near the upper end of the spindle but below the threads 1 General Information l c Apply a machinist s indicator at approximately 45 It is important that the spindle 9 of a safety relief valve to the outer edge
31. c Holder 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 27 XIV Inspection and Part Replacement i 3 Hole dimension K is out of tolerance see Figure 15 and Table 8 Disc Holder Dimensions Ste H DIA H DIA e Valve 001 0 03 mm Valve 001 0 03 mm 4 Guide Height Dimension L is out of tolerance see Figure Type 3 Type di di 15 and Table 9 19096L 0 654 16 61 19126M 0 747 18 97 5 J dimension is not within tolerance see Figure 15 and Table 9 19110L 0 654 16 61 19226M 1 000 25 40 19126L 0 747 18 97 19357M 1 257 31 93 G Spi ndle 9 19226L 1 000 25 40 19567M 1583 40 21 G 1 MS DA 19357L 1257 3193 19096H 0 654 16 61 Replace the spindle if 1 The bearing surfaces are galled pitted or scratched 19567L 1 583 40 21 19110H 0 654 16 61 2 Threads are torn stripped or galled 19096M 0 654 16 61 19126H 0 747 18 97 3 The stem is bent see Figure 13 19110M 0 654 16 61 19226H 1 000 25 40 G 2 DA BP F Gu ide 5 The spindle should be replaced if 1 The bearing surfaces V are galled pitted or scratched Replace the guide if 1 The inside surface is worn egged or galled d The threads are torn stripped or galled 2 Base and bonnet seating surfaces are scratched nicked 3 The spindle is bent corroded or leaks A The O Ring groove is nicked scratched or pitted Figure 15a 19000L amp M Valves Fig
32. d Table 3 19000 1 Series Metal Seat MS Base Re work Dimensions eri D 002 E 003 F 005 i 0 05 mm 0 08 mm 0 13 mm in mm mm in B 002 A min 0 05 mm Valve Type in in mm SS 0395 1003 040 045 053 050 en 076 085 096 Se SS 040 045 053 050 en 076 085 096 SS 030 ou 045 053 050 11 51 0 010 20 17 3167 15 39 0 006 1935 0 006 24 38 0 006 10 03 0 011 11 51 0 011 15 39 0 011 19 35 0 011 Se 10 03 11 51 15 39 Table 3 19000 1 Series Metal Seat MS Base Re work Dimensions Contd G 005 J 005 Seng Valve Type 0 13 mm x ola pant d angle angle i i mm 0 002 0 005 19096L 0 188 784 oons 1991 6008 mm 6 63 PE EE S 22 GE Oil amp Gas 2015 General Electric Company All rights reserved XIII Maintenance Contd Table 4 19000 2 Series Metal Seat MS Base Re work Dimensions Ge e I En Vente lan 19535 L 0675 17 15 0 796 20 22 0 881 22 38 0 987 25 07 0 022 0 002 EC 0 05 19567L 0 850 21 59 1 000 25 40 1 109 28 17 1 247 31 67 0 022 0 002 CI 10 05 A 210 05 0 03 0 05 0 00 0 05 19096M 0 350 REC 0 408 10 36 EN 0 457 1161 0503 1278 0 024 Ge 19110M 0 375 RES 0 408 10 36 E3 0 457 1161 0 503 1278 0 024 0 00 0 05 0 00 0 03 0 05 19126M 0 401 10 19 0 463 11 76 0 523 13 28 0 579 14 71 0 024 19226M 0 537 13 64 0 625 15 88 0 701 17 81 0 781 19 84 0 025 0 001 0 0
33. e 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 16 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 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 Consolidated 19000 Series Safety Valve Maintenance Manual 9 VII Pre Installation and Installation Instructions When SRVs are uncrated and the flange protectors or sealing plugs are removed exercise meticulous care to prevent dirt and other foreign materials from entering the inlet and outlet ports while bolting the valve in place VIII Design Features a
34. e Place guide 5 over disc holder onto base Lubricate the disc holder spindle bearing surface with non copper based thread lubricant 4 Lubricate the spindle nose with a small amount of non copper based thread lubricant and insert the spindle 9 into the disc holder spindle pocket 30 GE Oil amp Gas 5 Apply a small amount of non copper based thread lubricant on the bearing surface of the lower spring washer 10 and slip it over the spindle 9 Install the spring 11 and upper spring washer 6 Apply a small amount of non copper based thread lubricant to the bonnet base threads and guide seating surface When a stainless steel bonnet 6 and base 1 are used and or a standard bonnet for service above 500 temperature apply non copper based thread lubricant to the bonnet base threads and guide 5 seating surface Before tightening the bonnet completely adjust the position of the guide so that one of the holes is lined up with the discharge of the valve Tighten the bonnet using sufficient torque from Base Torque Specification see Table 10 7 Thread the adjusting screw locknut 13 on the adjusting screw 12 Apply a light coat of non copper based thread lubricant to the adjusting screw threads and spherical radius Thread the adjusting screw locknut 13 onto the adjusting screw 12 Apply a small amount of non copper based thread lubricant to the tip of the adjusting screw Install the adjusting screw in the bonnet
35. e ER SCO diameter to allow permanent spring marking 2 The bearing surfaces are galled pitted or scratched 3 The adjustment flats are damaged or rounded The Set Pressure of the Consolidated 19000 series valve should be within the spring range of the valve spring However if there is Constant Superimposed Backpressure K Bon net Top 7 the Cold Differential Test Pressure should be within the The bonnet top should be replaced if Spring range of the Valve Spring If the Cold Differential Test pressure is only established because of elevated 1 The threads are stripped torn or galled temperature then the Set Pressure should be within the spring range of the valve spring and the valves should be set at the Cold Differential Test Pressure 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 29 XIV Inspection and Part Replacement Contd L Bonnet Bottom 8 The bottom bonnet should be replaced if 1 Threads are stripped torn or galled 2 The guide seating surface is scratched nicked corroded or leaks 3 The backup plate seating surface is scratched nicked or corroded 4 Condition is porous corroded or distorted M Backup Plate 39 The backup plate should be replaced if 1 Inside circumference X is scratched nicked pitted or galled d O Ring groove W is scratched nicked pitted or galled 3 Backup plate is distorted
36. ee step b Disassembly The valve is now ready for setting 2015 General Electric Company All rights reserved XVI Setting and Testing A DANGER Decontaminate or clean if necessary before pre testing or disassembly Safety and environmental precautions must be taken for the decontamination or cleaning method used P_S ei Ze Do not stand or place hand in front of valve discharge flange if valve is under pressure A General Information Before putting the reconditioned valve in service it must be set to open at the required set pressure as shown on the nameplate Although the valve can be set on the service installation it is more convenient to set the valve and check seat tightness on a test stand Any spring replacement shall be in accordance with current guidelines B Test Equipment The test stand used for testing SRVs normally consists of a pressure source supply line with a throttle valve and receiver that have the following features Outlet for attaching the valve to be tested Pressure gauge with a shut off valve Drain line with a shut off valve and Adequate receiver volume for the valve to be tested and to achieve proper operation C Test Media For best results valves shall be tested by type as follows 1 Steam valves are tested on saturated steam 2 Air or gas valves are tested on air or gas at ambient temperature and 3 Liquid valves are tested on water at ambient temperature
37. entories with your local Green Tag Center GE s authorized sales representative e Parts interchangeability e Obsolete and excess inventory identified 2015 General Electric Company All rights reserved e Recommend cost effective inventories ValvKeep e Total computer based valve management system e Free interchange of information e Historical data and permanent record of traceability e Maintenance scheduling and planning e Repair intervals validated by each valves maintenance history e Code compliance e Accessible via secure password protected internet connection e Downloadable and printable reports B Factory Repair Facilities The factory at Alexandria Louisiana maintains a complete Consolidated products repair center The Repair Department in conjunction with the manufacturing facilities is equipped to perform specialized repairs and product modifications e g butt welding code welding and pilor replacement Contact Valve Repair Department at 1 318 640 6057 C SRV Maintenance Training The rising costs of maintenance and repair in the utility and process industries indicate the need for trained maintenance personnel GE conducts service seminars that help your maintenance and engineering personnel reduce these costs Seminars conducted either at your site or ours provide participants with an introduction to the basics of preventative maintenance necessary to minimize downtime reduce
38. erefore 2015 General Electric Company All rights reserved XI Recommended Installation Practices Contd from protected equipment Vessel The pressure drop P D between the source of pressure in the protected equipment and the pressure relief valve inlet is not to exceed 3 percent of the valve set pressure Figure 7 Pressure Drop on the Inlet Piping discharge piping must be independently supported and unsupported discharge piping consisting of more than a carefully aligned companion flange long radius elbow and a short vertical pipe is ani ne not recommended rin r nn let pipin Vibrations in the inlet piping systems may cause valve seat SE Gees K SN i na EE a to prevent thermal expansion from creating strains on the valve leakage and or fatigue failure These vibrations may cause the ii ae disc seat to slide back and forth across the base seat and may 7 di SE A ee K o dl expansion as well as expansion of the discharge pipe itself This result in damage to the seating surfaces Also vibration May is particularly important on long distance lines cause separation of the seating surfaces and premature wear to valve parts High frequency vibrations are more detrimental A continual oscillation of the discharge piping wind loads to SRV tightness than low frequency vibrations This effect can may induce stress distortion in the valve body The resultant be minimized by providing a larger difference
39. es and or valve products may involve proximity to fluids prevent possible injury at extremely high pressure and or temperature Consequently every precaution should be taken to prevent injury to personnel during the performance of any procedure These precautions should consist of but are not limited to ear drum protection eye protection and the use of protective clothing i e gloves etc when personnel are in or around a valve work area Due to the various circumstances and conditions in which these operations may be performed on GE products and the possible hazardous consequences of each way GE cannot possibly evaluate all conditions that might injure personnel or equipment Nevertheless GE does offer certain Safety Alerts listed in Section II for customer information only It is the responsibility of the purchaser or user of Consolidated valves equipment to adequately train all personnel who will be working with the involved valves equipment For more information on training schedules call 318 640 6054 Further prior to working with the involved valves equipment personnel who are to perform such work should become thoroughly familiar with the contents of these instructions Additional copies of these instructions can be purchased at a minimal cost by contacting GE in writing at PO Box 1430 Alexandria LA 71309 1430 or by calling at 318 640 2250 Fax 318 640 6325 2015 General Electric Company All rights rese
40. ess are evident recondition the lap Reconditioning of laps is accomplished by lapping them on a flat lapping plate The lapping should be done with a figure eight motion as indicated in Figure 9 To assure the best results when lapping seats the laps should be reconditioned after each usage 3 Apply a very thin layer of compound to the lap This will prevent rounding off the edges of the seat 4 Keep the lap squarely on the flat surface and avoid any tendency to rock the lap which causes rounding of the seat 5 When lapping keep a firm grip on the part to prevent the possibility of dropping it and damaging the seat 6 Lap using an eccentric or figure eight motion in all directions while at the same time applying uniform pressure and rotating the lap slowly see Figure 9 7 Replace the compound frequently after wiping off the old compound and apply more pressure to speed the cutting action of the compound 8 To check the seating surfaces remove all compounds from both the seat and the lap Then shine the seat with the LAPPING PLATE RING LAP Figure 9 Lapping Pattern 20 GE Oil amp Gas same lap using the lapping motion described above Low sections on the seating surface will show up as a shadow in contrast to the shiny portion If shadows are present further lapping is necessary and only laps known to be flat should now be used Only a few minutes will be required to remove the shadows 9 When the
41. f known establishing meaningful inventory levels are summarized in Table c Quantity 18 In addition you can contact your local Green Tag Center or GE authorized sales representative contact information can be found at the end of this manual for assistance in determining inventory levels pricing and ordering parts Table 18 Establishing Inventory Levels Part Classification Replacement Frequency Need Coverage Probability Most frequent 70 percent Class Il Less frequent but critical 85 percent Class III Seldom replaced 95 percent Note 1 Need Coverage Probability means that percentage of time the user plant will have the right parts to make the proper repair on the product i e if Class parts are stocked at the owner s facility the parts needed to repair valve in question will be immediately available in 70 percent of all instances XX Genuine Consolidated Parts Each time replacement parts are needed keep these points in mind e GE designed the parts e GE has worldwide service e GE guarantees the parts e GE has fast response availability for parts with the global Green Tag Center authorized sales representatives e GE s Consolidated valve products have been in network service since 1879 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 39 XXI Recommended Spare Parts Table 19 Metal to Metal Seat Valves uantity Parts Size Type amp
42. he set pressure immediately after popping for valves set 51 psig 3 52 barg and above On valves set at 50 psig 3 45 barg and below test for leakage at 5 psig 0 34 barg below the set pressure immediately after popping The test pressure shall be applied for a maximum of one minute c The Tightness Standard is the leakage rate in bubbles per minute and shall not exceed that shown in Table 13 for metal seat valves or Table 14 for O Ring seat seal valves A valve with a seat of resilient material i e an O Ring valve shall show no leakage at pressures less than those indicated in Table 13 when the test medium is either air or water Table 13 Metal Seat Valve Leakage Rate Max Leakage Rate Approximate Leakage Rate Bubbles per minute ft per 24 hr Liters per 24 hr 40 0 6 16 99 2015 General Electric Company All rights reserved Table 14 O Ring Seat Valve Leakage Rate Set Pressure Min Leak Point 15 to 30 31 to 50 51 to 100 101 or greater 10510207 2 14 to 3 45 3 52 to 6 89 6 96 or greater 2 Water When a metal to metal seat valve is tested using water as the test medium there shall be no leakage as determined by sight when the pressure is held at 90 percent of set pressure For O Ring seat seal valves use Table 13 to determine the percentage of set pressure C Steam When a metal to metal seat valve is checked for tightness using steam as the test medium at 90 percent of the
43. l 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 personal protective equipment It is not recommended to sandblast internal parts as it can reduce the dimensions of the parts The base 1 bonnet 6 and cap 18 castings may be sandblasted with care not to erode internal surfaces or damage machined surfaces If grit blasting is required the use of glass bead material is A DANGER recommended Follow recommendations for safe handling in the solvent s Material Safety Data Sheet and observe safe practices for any cleaning method Consolidated 19000 Series Safety Valve Maintenance Manual 19 XIII Maintenance A Metal Seat Valves MS A1 Precautions and Hints for Lapping Seats Reconditioning of the seat surface may be accomplished by lapping with a flat cast iron ring lap coated with a 1000 grit lapping compound or its equivalent see Table 17 A cast iron lap coated with a lapping compound is used for reconditioning the seating surfaces of the base 1 and disc 2 The following will enable maintenance personnel to do a professional job of lapping seats 1 Keep work materials clean 2 Always use a fresh lap If signs of wearing out of flatn
44. l types of caps Figure 17 Typical Cap with Gag and lifting gears will not become trapped on the seating surfaces When allowing K Manual Popping of the Valve the valve to close under flowing conditions completely release the lever from maximum lift to snap the valve back on its seat Consolidated safety relief valves are furnished when so ordered with packed or plain lifting levers for hand popping Since in some cases the dead weight of the lever may have a tendency to lift the valve disc the lever should be hung When the valve is to be opened by hand using the lifting lever supported or counter weighted so the lifting fork does not the pressure at the valve inlet should be at least 75 percent of 8 contact the release nut the valve s set pressure Under flowing conditions the valve must be fully lifted from its seat so that dirt sediment and scale XVII Trouble Shooting Table 15 Trouble Shooting Guide Problem Probable Cause Corrective Action a Disassemble valve lap seating surfaces replace disc or o ring if required as outlined in this manual b Grind and polish a Damaged seat or o ring b Bearing point damage Valve leaking D c Disassemble valve inspect contact area of disc and base lower c Part misalignment i i spring washer or spindle compression screw spindle straightness d Discharge stack binding on outlet etc as outlined in this manual d Correct as required a Line vibrati
45. n severe personal possible severe personal possible injury injury or death injury or death 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 5 ll 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 GE cannot know alll conceivable service methods nor evaluate all potential hazards Dangers include e High temperature pressure can cause injury Ensure all system pressure is absent before repairing or removing valves e Donotstand in front of a valve outlet when discharging STAND CLEAR OF VALVE to avoid exposure to trapped corrosive media e Exercise extreme caution when inspecting a pressure relief valve for leakage e Allow the system to cool to room temperature before cleaning servicing or repairing Hot components or fluids can cause severe personal injury or death e Always read and comply with safety labels on all containers Do not remove or deface container labels Improper handling or misuse could result in severe personal injury or death e Never use pressurized fluids gas air to clean clothing or body parts Never use body parts to check for leaks flow rates or areas Pressurized fluids gas air injected into or near the body can c
46. nd Nomenclature A General Information The Consolidated 19000 Series Portable Safety Relief Valve has 316 stainless steel trim as standard material Reliable performance and easy maintenance procedures are characteristics of this valve when properly installed in suitable applications for its design The Consolidated 19000 Series SRV has three pressure classes 19000L 5 290 psig 0 34 19 99 barg 19000M 291 2000 psig 20 06 137 90 barg and 19000H 2001 psig 137 96 barg and up Standard Consolidated 19000 Series parts are used for both liquid applications and gas applications It is designed for short blowdown on all types of media typically less than 10 percent All Consolidated 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 B Design Options B 1 Consolidated 19000 Series MS amp DA Safety Relief Valves O Ring Seat Seal Valves All Consolidated 19000 Series Valves are available with an o ring seat seal as a design option This optional design is bubble tight at 97 percent of set pressures over 100 psig 6 89 barg in order to meet application requirements beyond the normal capabilities of metal to metal seat valves Consolidated Series 19000 valves with the O Ring seat seal option are identified by the suffix DA See Table 14 Lifting Levers Caps and Gags All Consolidated 19000
47. ng protection e Wear protective breathing apparatus to protect against toxic materials 2015 General Electric Company All rights reserved III Safety Notice A CAUTION Proper installation and start up is essential to the safe and reliable operation of all valve products The relevant procedures recommended by GE and described in these instructions are effective methods of performing the required tasks It is important to note that these instructions contain various safety messages which should be carefully read in order to minimize the risk of personal injury or the possibility that improper procedures will be followed which may damage the involved GE product or render it unsafe It is also important to understand that these safety messages are not exhaustive GE cannot possibly know evaluate and advise any customer of all of the conceivable ways in which tasks might be performed or of the possible hazardous consequences of each way Consequently GE has not undertaken any such broad evaluation and thus anyone who uses a procedure and or tool which is not recommended by GE or deviates from GE recommendations must be thoroughly satisfied that neither personal safety nor valve safety will be jeopardized by the method and or tools selected Contact GE at 318 640 6055 if there Wear necessary personal are any questions relative to tools methods protective equipment to OE The installation and start up of valv
48. nish The valve must be re tested if disassembly is required After the valve set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap gasket 17 and cap 18 or lifting gear on the valve after applying a small amount of non copper based thread lubricant to the gasket seal surfaces and the cap and bonnet top threads ATTENTION Be careful when removing o rings to avoid damage to the o ring groove Figure 16c Backup Plate Surface V O Ring Groove Figure 16 19096M DA BP Valve Two Piece Bonnet Spindle and Back up Plate 36 GE Oil amp Gas 2015 General Electric Company All rights reserved XVI Setting and Testing Contd J Hydrostatic Testing and Sealing Plug Gagging Spindle When hydrostatic tests are required after installation of an SRV i Jr g g S 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 Adjusting Screw WON sufficient to hold hydrostatic pressures Too much force applied Adjusting Screw to the gag may bend the spindle and damage the seat After a Locknut DEE L WEN Ye 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 al
49. nus Constant Back Pressure 150 psig 10 34 barg 1 044 Cold Differential Set Pressure 2350 psig 162 03 barg 1 050 2500 psig 172 37 barg LI O 70 EE C 38 93 149 204 260 316 3 1 427 Set pressure 400 psig 27 58 barg on superheated steam Cold Differential Test Pressure For Back Pressure temperature 650 F Compensation 343 3 C backpressure atmospheric When a conventional Series 19000 valve is to operate with a Operating TEMPETAUTE nn 650 F 343 3 C constant back pressure the cold differential test pressure is the Minus Temperature of set pressure minus the constant back pressure Saturated Steam at Sample Calculations For Series 19000 safety relief valves 400 psig 27 58 e 448 F 266 7 C refer to Tables 11 and 12 Degrees of Superhegt oi 202 F 94 4 C Set pressure 2500 psig 172 37 barg temperature UPS licia 400 psig 27 58 barg 500 F 260 0 C backpressure atmospheric Multiplier see Table 12 X1 013 Set PPESSUFE ii 2500 psig 172 37 barg Cold Differential Set Pressure ssssssssss 405 psig 27 92 barg Multiplier see Table LL X1 019 Cold Differential Set Pressure 2548 psig 175 68 barg S Blowd own Set pressure 2500 psig 172 37 barg temperature 500 The blowdown for all Series 19000 valves is fixed Do not F 260 C constant backpressure 150 psig 10 34 barg attempt to adjust the
50. ny pressure vessels that are protected by pressure in the vessel Consolidated safety relief valves contain dangerous materials e Decontaminate and clean the valve inlet and outlet A CAUTION and all external surfaces in accordance with the cleaning and decontaminating recommendations in the appropriate Material Safety Data Sheet e Parts from one valve should not be interchanged with Many pressure vessels parts from another valve 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 decontaminating Valve caps and bonnets can ancre oi trap fluids Use caution when appropriate Material Safety removing to prevent injury or Data Sheet environmental damage ATTENTION Do not interchange parts from one valve with parts from another valve 18 GE Oil amp Gas 2015 General Electric Company All rights reserved XII Disassembly of 19000 Series SRV Contd B Disassembly 1 Metal Seat Valves See Figure 1 a Remove the cap 18 including lifting gear if any then remove the cap 17 gasket b Measure the position of the valve adjusting screw 12 and record before removal Measure from the top of the screw to the adjusting screw locknut 13 c Loosen the adjusting screw locknut 13 and remove the adjusting screw 12 from the bonnet 6 d Unscrew the bonnet 6
51. ons a Investigate and correct cause Simmer a b Lapped seat too wide b Rework seat as specified in this manual a Improper installation or valve Chatter sizing b Built up back pressure a Check for piping instructions check required capacity b Check outlet piping for flow restrictions No action valve does not go into full lift valve does not close from full lift a Foreign material trapped a Disassemble valve and correct any abnormality as outlined in this between disc holder and guide manual Inspect system for cleanliness 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 37 XVIII Maintenance Tools and Supplies The laps identified in Table 16 are required for proper maintenance of Consolidated Series 19000 seats NOTE One set of three laps is recommended for each size to assure ample flat laps are available at all times e The Lap Resurfacing Plate is part number 0439003 e Lapping compounds are identified in Table 17 e Laps and the lapping plate may be purchased from GE Table 16 Laps 19096L 19110L 19126L 19096M 19110M 19126M 1672802 190965 19110 19126 19226L 19226M 19226H 1672803 19357L 19567L 19557M 19567M 1672805 Table 17 Lapping Compounds Kwik Ak Shun 1000 Polishing 1 Ib 199 11 2 OZ 199 12 38 GE Oil amp Gas 2015 General Electric Company All rights reserved XIX Replacement Parts Planning A General
52. ore valves are piped to discharge into a common header the built up backpressure resulting from the opening of one or more valvels may cause a superimposed A CAUTION backpressure in the remaining valves Under these conditions the use of the 19096 DA BP model is recommended In every case the nominal discharge pipe size should be at least as large as the nominal size of the SRV outlet flange In the case of long discharge piping the nominal discharge pipe size must sometimes be much larger As a final point the discharge piping size is never less than the size of the valve outlet nor heavier than schedule 40 pipe size In addition the discharge piping must be designed to limit the total backpressure to a maximum of 10 percent of the valve set pressure or 400 psig 27 58 barg whichever is smaller Wear necessary protective equipment to prevent possible injury ATTENTION Undersized discharge piping could create built up backpressure DANGER XII Disassembly of 19000 Series SRV A General Information Consolidated SRVs can be easily disassembled for inspection the reconditioning of seats or the replacement of internal parts Appropriate set pressure can be established after reassembly See Figures 1 through 6 for parts nomenclature 6 EN NOTES e Before starting to disassemble the valve be sure Before disassembling the there is no material pressure in the vessel valve ensure there is no media e Ma
53. ow end of the spring range with the maximum allowed back pressure applied the blowdown is shortest Gas 5 percent 16 percent Liquid 6 percent 20 percent Liquid 70 percent of set pressure Note Thermal relief applications may be supplied with back pressures up to 90 percent of set pressure Allowable total back pressure This is the sum ofthe variable and constant back pressure superimposed and built up Gas 50 percent of set pressure Note Total back pressure for liquid or gas shall not exceed 400 psig 27 58 barg Temperature limits Minimum 20 F 28 C Determined by o ring material selection Maximum 600 F 315 C Set pressure of 50 psig 3 45 barg 92 percent Seat tightness 51 psig 3 52 barg 100 psig 6 8 barg 94 percent 101 psig 6 9 barg Maximum Rating 95 percent Note Refer to this Table for the performance criteria of this valve Applications outside of these ranges may cause malfunction of the intended valve operation 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 11 X Consolidated 19000 Series SRV A Metal Seat Valve Figure 1b 2 Female NPT Figure la 2 Male NPT d ES ap Oy Disc Holder 4 E Z K A A d ag 4 yY UY 2 7 SS Y NS WS NAS Spring Washer 10 XX 34 e ASSA hop ROSAS Adjusting Screw Adj Screw Locknut Cap Gasket
54. p in gas vapor or flashing liquid service at the inlet of the SRV will cause the extremely 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 flange and in which the length does not exceed the face to face dimensions of a standard tee of the required pressure class Do not locate SRV inlets where excessive turbulence is present such as near elbows tees bends orifice plates or throttling valves Section VIII of the ASME Boiler and Pressure Vessel Code requires the inlet connection design to consider stress conditions during valve operation caused by external loading vibration and loads due to thermal expansion of the discharge piping The determination of reaction forces during valve discharge is the responsibility of the vessel and or piping designer GE publishes certain technical information about reaction forces under various fluid flow conditions but assumes no liability for the calculations and design of the inlet piping External loading by poorly designed discharge piping and support systems and forced alignment of discharge piping can cause excessive stresses and distortions in the valve as well as the inlet piping The stresses in the valve may cause a malfunction or leak Th
55. pring washer and adjusting screw spherical radius 3 Carefully insert a new o ring seat seal 37 into the disc 2015 General Electric Company All rights reserved holder 4 Make sure the o ring is the right size material and hardness for the application Refer to the valve nameplate for information required when ordering an O Ring seat seal 4 Install the o ring retainer 3 and a new retainer lockscrew 36 5 Place the disc holder assembly onto the base 1 and place the guide 5 onto base The guide seating surfaces should be free of any nicks or scratches 6 Lubricate the spindle nose with a small amount of non copper based thread lubricant and insert the spindle 9 into the disc holder spindle pocket 7 Apply a small amount of non copper based thread lubricant on the bearing surface of the lower spring washer 10 and slip it over the spindle 9 Install the spring 11 and upper spring washer 10 8 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 6 on the base 1 using torque from Base Torque Specifications see Table 10 Before tightening the bonnet completely adjust the position of the guide 5 so that one of the holes in the guide is in line with the discharge of the valve Tighten the bonnet using sufficient torque from Ba
56. re of the SRV If the operating temperature is unavailable do not correct the SRV set pressure Table 11 lists the set pressure multipliers to be used when computing the cold differential test pressure CDTP pressure for valves being set on an air or water test stand at ambient temperatures Valves to be used in saturated steam service are tested on saturated steam Therefore no CDTP is required However valves in superheated steam service are tested on saturated steam and require a CDTP Table 12 lists the multiplier to be used based on temperature above the saturated temperature degrees of superheat Consolidated 19000 Series Safety Valve Maintenance Manual 33 XVI Setting and Testing Contd Table 11 Set Pressure Multipliers for Cold Differential Test Pressure at Ambient Temperature T 2 gt Multiplier 2 Multiplier SS 121 2 10 8 6 4 8 5 350 177 1000 53 56 593 500 260 621 649 600 28 1028 1250 677 650 343 704 73 760 800 427 788 850 454 816 Table 12 Set Pressure Multipliers for Cold Differential Differential Pressure 2350 psig 165 13 barg Test Pressure Multiplier see Table 1711 X1 019 re en ASI Multiplier Cold Differential Set Pressure 2395 psig 165 13 barg 100 1 006 Set pressure 2500 psig 172 37 temperature 200 1 013 100 F 37 8 C constant backpressure 150 psig 10 34 2 1072 O Em 200 1 019 barg 400 1 025 D LPO a mn 0 1 031 1 038 Mi
57. re pulsations coming from a reciprocating piston The valve should be set as far above the operating pressure as possible 7 Lift The actual travel of the disc away from the closed position when a valve is relieving 8 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 2015 General Electric Company All rights reserved V Terminology for Safety Relief Valves Contd temperature it is the highest pressure at which the primary pressure SRV is set to open 9 Operating Pressure The gauge pressure to which the vessel is normally subjected in service A suitable margin is provided between operating pressure and maximum allowable working pressure For assured safe operation the operating pressure should be at least 10 percent under the maximum allowable working pressure or 5 psi 34 bar whichever is greater 10 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 11 Rated Capacity The percentage of measured flow at an authorized percent overpressure permitted by
58. rved Consolidated 19000 Series Safety Valve Maintenance Manual 7 IV Warranty Information Warranty Statement GE warrants that its products and work will meet all applicable specifications and other specific product and work requirements including those of performance if any and will be free from defects in material and workmanship CAUTION Defective and nonconforming items must be held for GE s inspection and returned to the manufacturer upon request Incorrect Selection or Misapplication of Products GE cannot be responsible for customers incorrect selection or misapplication of our products Unauthorized Repair work GE has not authorized any non GE affiliated repair companies contractors or individuals to perform warranty repair service on new products or field repaired products of its manufacture Therefore customers contracting such repair services from unauthorized sources do so at their own risk Unauthorized Removal of Seals All new valves and valves repaired in the field by GE Consolidated Field Service are sealed to assure the customer of our guarantee against defective workmanship Unauthorized removal and or breakage of this seal will negate our warranty NOTE Refer to GE s Standard Terms of Sale for complete details on warranty and limitation of remedy and liability V Terminology for Safety Relief Valves SRV 1 Accumulation The pressure increase over the maximum allowable working pres
59. ry or death e The level of hazard seriousness O e The nature of the hazard WARNING Hazards or unsafe e The consequence of human or product interaction with the hazard practices which COULD result in severe personal injury or death e The instructions if necessary on how to avoid the hazard The top panel of the format contains a signal word DANGER WARNING 3 CAUTION or ATTENTION which communicates the level of hazard seriousness CAUTION Hazards or unsafe practices which COULD result in The center panel contains a pictorial which communicates the nature of the minor personal injury hazard and the possible consequence of human or product interaction with the hazard In some instances of human hazards the pictorial may instead depict what preventive measures to take such as wearing personal protective 4 equipment ATTENTION Hazards or unsafe practices which COULD result in The bottom panel may contain an instruction message on how to avoid the product or property damage hazard In the case of human hazard this message may also contain a more precise definition of the hazard and the consequences of human interaction with the hazard than can be communicated solely by the pictorial CAUTION ATTENTION Do not remove bolts if Know all valve exhaust Wear necessary protective Handle valve carefully Do pressure in line as this will leakage points to avoid equipment to prevent not drop or strike result i
60. se Torque Specification see Table 10 9 Thread the adjusting screw locknut 13 onto the adjusting screw 12 Apply a small amount of non copper based thread lubricant to the tip of the adjusting screw Install the adjusting screw in the bonnet rotating the number of times required to compress the spring slightly Use pliers to hold the spindle 9 in position and prevent galling Adjust the adjusting screw to the measurement recorded during disassembly See o ring seat seal valves DA disassembly instructions point b on page 20 10 The valve is now ready for setting After the valve set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap gasket 17 and cap 18 or lifting gear on the valve after applying a small amount of non copper based thread lubricant to the gasket seal surfaces as well as to the cap and bonnet threads C 19096M DA BP O Ring Seat Seal Valves see Figure 6 1 All base seats shall be lapped flat enough to remove nicks and burrs Consolidated 19000 Series Safety Valve Maintenance Manual 31 XV Reassembly of Consolidated 19000 Series SRV Contd Zi Bearing surfaces should be ground together using a 320 grit lapping compound see Table 17 clean all parts before assembly These surfaces are the following a The disc holder spindle pocket and the spindle spherical holder spindle radius for o ring valves or 1 metal seat design b The lower spring washer
61. set pressure there shall be no visual or audible leakage after the interior of the valve is allowed to dry after popping If there is no visual or audible leakage the valve is acceptable For O Ring seat seal valves use Table 14 to determine the percentage of set pressure I Back Pressure Testing 1 MS amp DA After the valve has been set for the correct opening pressure it must be back pressure tested Testing can be conducted by installing the cap with gasket and applying air or nitrogen to the valve outlet Test pressure should be 30 psig 2 07 barg or the actual valve back pressure whichever is greater Examine the base 1 to bonnet 6 joint for leakage during back pressure testing NOTE Leakage is best detected by application of a liquid leak detector The use of soap or household detergent as a leak detector is not recommended as it may cover up leaks Repair of leaking valve joints may be attempted by tightening the leaking joint while the valve is still on the stand If this does not stop the leak disassemble and inspect the leaking joint Consolidated 19000 Series Safety Valve Maintenance Manual 35 XVI Setting and Testing Contd The seating surfaces should be better than a 32 RMS finish The valve must be re tested if disassembly is required After the valve set pressure has been adjusted tighten the adjusting screw locknut 13 Install the cap gasket 17 and cap 18 or lifting gear on the v
62. sure of the vessel during discharge through the SRV expressed as a percentage of that pressure or in actual pressure units 2 Backpressure The pressure on the discharge side of the SRV a Built up Backpressure the pressure that develops at the valve outlet after the SRV has been opened as a result of flow b Superimposed Backpressure the pressure in the discharge header before the SRV is opened 3 Constant Backpressure The superimposed backpressure that is constant with time 4 Variable Backpressure The superimposed backpressure that varies with time 5 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 8 GE Oil amp Gas A CAUTION Defective and nonconforming items must be inspected by GE A CAUTION 6 Cold Differential Set Pressure Removal and or breakage of seal will negate our warranty 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 in installed process services will generally give best results if the operating pressure does not exceed 90 percent of the set pressure However on pump and compressor discharge lines the differential required between the operating and set pressures may be greater because of pressu
63. t 1 270 0 595 10 03 Flat 1 270 0 453 11451 Flat 1 270 13 64 0 606 15 39 Flat 1 5372 0893 Ge 0002 1209 e 0002 0 457 0 503 0 000 0457 0508 0000 0523 ex 0000 0701 e 0000 0893 0987 0002 1109 SS 000 0457 Z 0003 0457 Z 0003 0523 en 0003 0701 e 0002 Table 5 19000 Series Soft Seat DA Base Re work Dimensions Contd M Liquid Valve il J ACOs only 002 l 0 13 mm K L min 003 angle angle 0 05 0 08 mm in mm in in in 0 002 0 050 0 786 6000 1996 0 000 GE GE GE 0 002 0 050 0 786 9000 12 0000 Ge GE GE 0 002 0 050 CAF EE fo cos AI 17 15 0 762 19 35 Flat toro 21 59 0 960 24 38 Flat 1 570 O O O N 0 395 10 03 Flat 1 270 0395 10 03 Flat 1 270 0 453 11 51 Flat 2 134 13 64 0 606 15 39 Flat 2 134 17 15 0 762 19 35 Flat 2 950 24 38 Flat 10 03 Flat 1 219 10 03 Flat 1219 1151 Flat 1219 13 64 0 606 15 32 Flat 1 321 N ex ieee cote 0 048 0 323 0 050 1 CB exe PHOT ro cos La cos TU ET IR SE 27 0 261 N A N A N E gt gt CHER EC IR IEEE am ax wa Note 1 Soft seat DA valves for liquid service from 5 100 psig 0 34 6 89 barg require a special base for 19000L Series Refer to Dimension M instead of Dimension F in this case 0 261 N A 0 261 N A Og25 N A 0 325 N A 0 261 N A 0 261 N A N lt gt N N lt gt N Si gt
64. the back pressure C Nomenclature Applicable valve nomenclature for Types Consolidated 19000 Series Male and Female inlet configurations are illustrated in Figures 1 through 6 Relevant parts nomenclature for optional lifting levers caps and the gag as applicable are provided in Figures 1 through 6 2015 General Electric Company All rights reserved IX Introduction A 19000 MS amp DA B 19096M DA BP Safety Relief Valves Safety Relief Valves Consolidated Series 19000 Portable Pressure Relief Valves The 19000 back pressure version is only available in the 096 2 44 are designed to meet ASME Section VIII requirements for fixed mm orifice with an O Ring seat It is available for steam liquid or blowdown pressure relief valves and liquid relief valves They gas applications and may be furnished with a plain or screwed cap may be used for various media such as air liquids process The 19096M DA BP variation is furnished as a 19096M designation steam and hydrocarbons and may serve as either a safety valve with a pressure range of 50 2000 psig 3 45 137 90 barg The or a relief valve depending upon the application standard medium pressure valve is limited to a minimum of 290 psig 19 99 barg in the standard 19000 design The designation will be used since most of the parts are from the 19096M bill of material Table 1 Performance Criteria for the 19096M DA BP Valve Typical blowdown as a percent of set pressure At the l
65. the base seat Flat Seat a Using a four jaw chuck align the base so that surfaces 5 Taper marked X and U run true within 001 0 03 mm on an indicator b Take light cuts on the seat surface until all damage is Figure 10b Measuring Magnifier Detail removed Reestablish dimensions Di Los E G H and Angle I When L minimum is obtained the base should be replaced For 2 Metal Seat Design c After all machining has been accomplished lap the The 2 metal seat design is a flat seat design The base seat may seat using same procedure for base seot be lapped or machined if necessary to verify that the seat N of Figure 11 is free from indentions scratches high spots etc If additional lighting is required for verifying the seat GE ATTENTION suggests a goose neck flashlight similar to the Type A Lamp 19000H and 19000 DA bases have flat seats Assembly Flashlight Standard Molding Corporation Dayton 90 angle across the entire seating surface from B Ohio or an equivalent diameter to D diameter Figure 11a Base General Dimensions Figure 11b Metal Seat Figure 11c Metal Seat 1 Design 2 Design N ia bi ea View Y 003 Met 030 99 mm View Y Figure 11d Soft Seat Base Figure 11 Machining the Metal and Soft Seat Base 2015 General Electric Company All rights reserved Consolidated 19000 Series Safety Valve Maintenance Manual 21 XIII Maintenance Cont
66. ure 15b 19000H Valves Figure 15 Guide 28 GE Oil amp Gas 2015 General Electric Company All rights reserved XIV Inspection and Part Replacement Contd Table 9 Guide Dimensions J DIA 001 0 03 Valve mm Type Metal Seat MS Soft Seat DA Metal Seat MS Soft Seat DA in mm in in in 3 mm 19096L 0 661 43 87 in m 19110L 0 661 43 87 19126L 0 754 43 61 19226L 1 007 57 58 19357L 1 264 78 87 32 11 1 623 0 012 41 22 0 30 1 623 0 012 41 22 0 30 3 105 18 87 2 105 40 39 1 671 0 012 42 44 0 30 167140012 42 44 0 30 3 159 80 24 3 159 19567L 1 590 80 24 19096M 0 661 43 87 16 79 0 810 0 007 20 57 0 18 0 810 0 007 20 57 0 18 Liver 43 87 1727 16 79 0 810 0 007 20 57 0 18 0 810 0 007 20 57 018 1727 43 87 Leg 19 15 0 804 0 007 20 42 0 18 0 804 0 007 20 42 0 18 1 743 44 27 1 743 19110M 0 661 43 87 19126M 0 754 44 27 19226M 1 007 50e H Spring 11 I Spring Washers 10 Replace the spring if Replace the spring washers if 1 The ends are not ground flat and parallel 1 The bearing surface is galled pitted or scratched 2 The coils are bent pitted or unevenly spaced 2 Corrosion affects the centering of the spring 3 The spring cannot be properly identified J Adjusting Screw 12 spring chart ATTENTION Replace adjusting screw if 1 Thread torn stri d led 19000 Series valve springs do not have sufficient wir
67. x 86 10 5689 3800 Fax 31 18 1641438 Skelmersdale Phone 44 1695 526 00 FRANCE RUSSIA Fax 44 1695 526 01 Courbevoie Veliky Novgorod Phone 33 1 4904 9000 Phone 7 8162 55 7898 UNITED STATES Fax 33 1 4904 9010 Fax 8162 55 921 Massachusetts FARINA Phone 1 508 586 4600 GERMANY i ii Fax 1 508 427 8971 oe ERRE Fax 7 495 585 1279 Corpus Christi Texas Fax 49 2102 108 111 ne te SAUDI ARABIA Fax 1 361 881 8246 INDIA SC EE Deer Park Texas Mumbai Phone 1 281 884 1000 Phone 91 22 8354790 SN Fax 1 281 884 1010 ie E Phone 65 6861 6100 TEE E New Delhi Fax 65 6861 7172 Phone 1 281 671 1640 Phone 91 11 2 6164175 Fax 12816 71 1735 Fax 91 11 5 1659635 Visit us online at www geoilandgas com valves Denotes a trademark of the General Electric Company Other company names and product names used in this document are the registered trademarks or trademarks of their respective owners 2015 General Electric Company All rights reserved GEA19381B 04 2015

Consolidated* Safety Relief Valve Maintenance Manual

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