Consolidated®

Consolidated® Safety ValveType 2700 Series

Type2700

Series

CON-14Revised 04/02

INSTALLATION, OPERATIONAND MAINTENANCE MANUAL

P.O. Box 1430Alexandria, Louisiana 71309-1430 (USA)

Do not drop or strike.

HH ATTENTION!

Do not remove bolts ifpressure in line, as this

will result in severepersonal injury or death.

HH DANGER!

Know all valveexhaust/leakage points

to avoid possible severepersonal injury or death.

HH WARNING!

Wear necessaryprotective equipment toprevent possible injury.

HH CAUTION!

2 Con-14

Product Safety Sign and Label System

If and when required, appropriate safety labels have been included in the rectan-gular margin blocks throughout this manual. Safety labels are vertically orientedrectangles as shown in the representative examples (left and below), consistingof three panels encircled by a narrow boarder. The panels can contain four mes-sages which communicate:

• The level of hazard seriousness.• The nature of the hazard.• The consequence of human, or product, interaction with the hazard.• The instructions, if necessary, on how to avoid the hazard.

CAUTIONHazards or unsafe

practices which COULDresult in minorpersonal injury.

ATTENTIONHazards or unsafe prac-

tices which COULDresult in product orproperty damage.

The top panel of the format con-tains a signal word (DANGER,WARNING, CAUTION or ATTEN-TION) which communicates thelevel of hazard seriousness.

The center panel contains a pictor-ial which communicates the natureof the hazard, and the possibleconsequence of human or productinteraction with the hazard. Insome instances of human hazardsthe pictorial may, instead, depictwhat preventive measures to take,such as wearing protective equip-ment.

The bottom panel may contain aninstruction message on how toavoid the hazard. In the case ofhuman hazard, this message mayalso contain a more precise defini-tion of the hazard, and the conse-quences of human interaction withthe hazard, than can be communi-cated solely by the pictorial.DANGER

Immediate hazardswhich WILL result in

severe personalinjury or death.

WARNINGHazards or unsafe prac-

tices which COULDresult in severe personal

injury or death.

Con-14 3

Contents

Section Subject Page

Product Safety Sign and Label System .......................................................................... 1I. Safety Alerts................................................................................................ 4II. Terminology for Safety Relief Valves .......................................................... 5

Consolidated® 2700 Series Valve Blow-Up................................................. 7Warranty Information................................................................................... 8Explanation of Nameplate........................................................................... 8Valve Operation .......................................................................................... 9

III. Storage and Handling Prior to Installation .................................................. 10IV. Recommended Installation Practices.......................................................... 10

A. General Requirements ......................................................................... 10B. Outdoor Safety Valve Installation ......................................................... 14C. Indoor Safety Valve Installation ............................................................ 14

V. Hydrostatic Test Plug Removal – Domestic and Export ............................. 15A. General Information.............................................................................. 15B. Domestic Plugs..................................................................................... 16C. Export Plugs ......................................................................................... 17

VI. Testing......................................................................................................... 18A. General Information.............................................................................. 18B. Application of Test Gags....................................................................... 19C. Presetting Adjusting Rings ................................................................... 19D. Steam Testing Instruction ..................................................................... 20E. Hydroset/Electronic Valve Testing (EVT).............................................. 23

VII. Disassembly Instructions ............................................................................ 23A. General Information.............................................................................. 23B. Specific Steps....................................................................................... 23

VIII. Inspection and Restoration of Parts............................................................ 25A. General ................................................................................................ 25B. Specific Components............................................................................ 25

IX. Re-Assembly............................................................................................... 31A. General Information.............................................................................. 31B. Specific Steps....................................................................................... 31

X. Trouble Shooting the Type 2700 Valve....................................................... 35XI. Maintenance Tools & Supplies.................................................................... 36XII. Service Parts Inventory Philosophy ............................................................ 37XIII. Manufacturer’s Field Service & Repair Program ........................................ 38

Glossary ...................................................................................................... 39Service Department Locations.................................................................... 40Sales Office Locations ................................................................................ 44

Heed all containerlabel warnings.

HH WARNING!

Improper use or repair ofpressurized media or

steam device may resultin severe personal

injury or death.

HH WARNING!

XXX

Do not work with valveswhile under the

influence of intoxicantsor narcotics.

HH WARNING!

Provide and useguarding to preventcontact with heated

and/or pressurized parts.

HH WARNING!

Improper tools orimproper use of righttools could result inpersonal injury orproduct damage.

HH WARNING!

All potential hazardsmay not be covered in

this manual.

HH WARNING!

4 Con-14

I. SAFETY ALERTS!READ – UNDERSTAND –PRACTICE

1. WARNING: Allow the system to cool to roomtemperature before cleaning, servicing orrepairing the system. Hot components or fluidscan cause severe personal injury or death.

2. WARNING: Always read and comply with safetylabels on all containers. Do not remove ordeface the container labels. Improper handlingor misuse could result in severe personal injuryor death.

3. WARNING: Never use pressurized fluids/gas/airto clean clothing or body parts. Never use bodyparts to check for leaks or flow rates or areas.Pressurized fluids/gas/air injected into or nearthe body can cause severe personal injury ordeath.

4. WARNING: It is the responsibility of the ownerto specify and provide guarding to protect per-sons from pressurized or heated parts. Contactwith pressurized or heated parts can result insevere personal injury or death.

5. WARNING: Do not allow anyone under the influ-ence of intoxicants or narcotics to work on oraround pressurized systems. Workers under theinfluence of intoxicants or narcotics are a haz-ard both to themselves and other employeesand can cause severe personal injury or deathto themselves or others.

6. WARNING: Incorrect service and repair couldresult in product or property damage or severepersonal injury or death. See page 16.

7. WARNING: These WARNINGS are as completeas possible but not all-inclusive. Dresser cannotknow all conceivable service methods nor eval-uate all potential hazards.

8. WARNING: Use of improper tools or improperuse of right tools could result in personal injuryor product or property damage.

9. WARNING: This valve product line is not intend-ed for radioactive nuclear applications. Somevalve products manufactured by DFC may beused in radioactive environments. Consequently,prior to starting any operation in a radioactiveenvironment, the proper “health physics” proce-dures should be followed, if applicable.

Con-14 5

Heed all service manualwarnings. Read

installation instructionsbefore installing valve(s).

HH CAUTION!

Know nuclear “healthphysics” procedures, if

applicable, to avoidpossible severe personal

injury or death.

HH WARNING!

Wear necessaryprotective equipment toprevent possible injury.

HH CAUTION!

1. CAUTION: Heed all service manual warnings. Read installation instructionsbefore installing valve(s).

2. CAUTION: Wear hearing protection when testing or operating valves.3. CAUTION: Wear appropriate eye and clothing protection.4. CAUTION: Wear protective breathing apparatus to protect against toxic

media.

NOTE:Any service questions not covered in this manual should be referred to Dresser’sService Department, Phone (318) 640-6055.

II. Terminology for Safety Relief Valves

• AccumulationAccumulation is the pressure increase over the maximum allowable workingpressure of the vessel during discharge through the pressure relief valve,expressed as a percentage of that pressure, or actual pressure units.

• Back PressureBack pressure is the pressure on the discharge side of a safety relief valve:

1. Superimposed Back PressureSuperimposed back pressure is the pressure in the discharge headerbefore the safety relief valve opens.

a) Constant-Specify single constant back pressure (e.g., 20 psig/1.38 bar).

b) Variable-Specify variable back pressure range using min. and max.limits (e.g., 0 to 20 psig/1.38 bar).

2. Built-up Back PressureBuilt-up back pressure is pressure which develops at the valve outlet asa result of flow, after the safety relief valve has been opened.

• BlowdownBlowdown is the difference between set pressure and reseating pressure ofa pressure relief valve, expressed as a percentage of the set pressure, oractual pressure units.

• Cold Differential Set PressureCold differential set pressure is the pressure at which the valve is adjusted toopen on the test stand. This pressure includes the corrections for back pres-sure and/or temperature service conditions.

• Differential Between Operating and Set PressuresValves in process service will generally give best results if the operating pres-sure does not exceed 90% of the set pressure. However, on pump and com-pressor discharge lines, the differential required between the operating andset pressures may be greater because of pressure pulsations coming from areciprocating piston. It is recommended that the valve be set as high abovethe operating pressure as possible.

• LiftLift is the actual travel of the disc away from the closed position when a valveis relieving.

6 Con-14

• Maximum Allowable Working PressureMaximum allowable working pressure is the maximum gauge pressure permissible in a vessel at a designat-ed temperature. A vessel may not be operated above this pressure, or its equivalent, at any metal tempera-ture other than that used in its design. Consequently, for that metal temperature, it is the highest pressure atwhich the primary pressure safety relief valve is set to open.

• Operating PressureThe operating pressure is the gauge pressure to which the vessel is normally subjected in service. A suitablemargin is provided between operating pressure and maximum allowable working pressure. For assured safeoperation, the operating pressure should be at least 10% under the maximum allowable working pressure or5 psi (.34 bar), whichever is greater.

• OverpressureOverpressure is a pressure increase over the set pressure of the primary relieving device. Overpressure issimilar to accumulation when the relieving device is set at the maximum allowable working pressure of the ves-sel. Normally, overpressure is expressed as a percentage of set pressure.

• Rated CapacityRated capacity is the percentage of measured flow at an authorized percent overpressure permitted by theapplicable code. Rated capacity is generally expressed in pounds per hour (lb/hr) for vapors; standard cubicfeet per minute (SCFM) or m3/min for gases; and in gallons per minute (GPM) for liquids.

• Relief ValveA relief valve is an automatic pressure-relieving device, actuated by static pressure upstream from the valve,a relief valve is used primarily for liquid service.

• Safety Relief ValveA safety relief valve is an automatic pressure-relieving device which may be used as either a safety or reliefvalve, depending upon application. A safety relief valve is used to protect personnel and equipment by pre-venting excessive overpressure.

• Safety ValveA safety valve is an automatic pressure-relieving device actuated by the static pressure upstream of the valve,and characterized by rapid opening or pop action. It is used for steam, gas or vapor service.

• Set PressureSet pressure is the gauge pressure at the valve inlet, for which the relief valve has been adjusted to openunder service conditions. In liquid service, set pressure is determined by the inlet pressure at which the valvestarts to discharge. In gas or vapor service, the set pressure is determined by the inlet pressure at which thevalve pops.

• SimmerSimmer is characterized by the audible passage of a gas or vapor across the seating surfaces just prior to“pop”. The difference between this “start to open pressure” and the set pressure is simmer, and is generallyexpressed as a percentage of set pressure.

• Valve TrimValve trim includes the nozzle and disc.

Con-14 7

Text Goes Here. TextGoes Here. Text GoesHere. Text Goes Here.Text Goes Here. Text

Goes Here.

HH SWAP ME!

20

20

10

9

17

19

18

10

5 THRU Q ORIFICE

VENT (90˚ OUT OF POSITION)DO NOT PLUG

4

11

15

1

2

14

5

6

8

7

13

12

3

VALVE INLET

VALVEEXHAUST

21 & 22

15

18

173 THRU Q ORIFICE

PartNo. Nomenclature

1. Disc Holder2. Guide3. Base4. Yoke5. Upper Adj. Ring6. Upper Adj. Ring Pin7. Lower Adj. Ring8. Lower Adj. Ring Pin9. Spring

10. Top Spring Washer11. Bottom Spring

Washer12. Bushing13. Disc14 Disc Collar15. Lift Stop16. Spindle17. Compression Screw18. Thrust Bearing19. Com. Screw Adaptor

(2756-2776Q Only)20. Lifting Gear21. Studs22. Nuts

CONSOLIDATED® 2700 SERIES VALVE

Warranty Information

*WARRANTY STATEMENT - Dresser warrants thatits products and work will meet all applicable specifi-cation and other specific product and work require-ments (including those of performance), if any, andwill be free from defects in material and workmanship.

Defective and nonconforming items must be held forDresser’s inspection and returned to the originalF.O.B. point upon request.

INCORRECT SELECTION OR MISAPPLICATIONOF PRODUCTS - DFC cannot be responsible for cus-tomer’s incorrect selection or misapplication of ourproducts.

UNAUTHORIZED REPAIR WORK - DFC has notauthorized any non-Dresser affiliated repair compa-nies, contractors or individuals to perform warrantyrepair service on new products or field repaired prod-ucts of its manufacture. Therefore, customers con-tracting such repair services from unauthorizedsources must do so at their own risk.

UNAUTHORIZED REMOVAL OF SEALS - All newvalves and valves repaired in the field by DresserField Service are sealed to assure the customer ofour guarantee against defective workmanship.Unauthorized removal and/or breakage of this sealwill negate our warranty.

*Refer to Dresser’s Standard Terms of Sale for com-plete details on warranty and limitation of remedy andliability.

Explanation of Nameplate

The valve nameplate contains several necessarypieces of information necessary to the proper opera-tion of the valve. Included are:

• Valve Type• ASME, and National Board of Boiler and

Pressure Vessel Inspectors Approval Stamp• Serial Number• Set Pressure or Opening Pressure• Disc Lift• Operating Temperature• Capacity

2700 Valve Series nameplate is located on the baseof the valve, to the left of the Adjusting Ring Pins. Ifthe nameplate is missing, a duplicate nameplate canbe supplied by Dresser Flow Control. To order thereplacement nameplate, call the DFC Field ServiceSupervisor at a/c (318) 640-6055, with the valve seri-al number as stamped on the top of the dischargeflange of the valve.

8 Con-14

VALVE IDENTIFICATION

VALVE TYPE CODING27 3 7 B 2 7 3 7 W B

Series Temp.Class

Orifice ButtPressure Weld

Designation Class Inlet

ORIFICESIZE

PRESSURERANGE

OPERATINGTEMPERATURE

TABLE I

DESIG-

NATION

1

2

3

4

5

6

7Q

BORE

DIAMETER

1.125

1.350

1.800

2.250

2.062

3.000

3.750

No.

5

6

7

CLASS

600

900

1500

LTR.

B

D

DEG. F (MAX)

750˚

1020˚

Con-14 9

F

A

B

D

E

G

H

C

FIGURE 1

Valve Operation

The Type 2700 Safety Valve operates on the principle that when steam pressure at the valve inlet, acting over thearea of the disc seat (C) and bushing seat (A), generates a force that approaches that produced by the spring, thevalve opens. Minimal leakage into the volume generated by the lower adjusting ring (B) causes additional forceover a larger area acting on the disc holder (E), causing the valve to “pop” open. Proper adjustment of the upperadjusting ring allows the disc to go into full lift at overpressure. When full lift is attained, lift stop (H) rests againstthe yoke to prevent hunting, thus adding stability.

When the inlet pressure drops to the desired closing pressure, the disc (C) moves downward, causing the valveto close. The arrangement of the disc and its complement of parts, that is disc holder (E), spindle (G), disc collar(F), and lift stop (H), allow the disc to seek its natural position for tight closure. The THERMOFLEX™ Disc design,by allowing for the rapid equalization of temperature around the valve seat, provides a degree of tightness farabove that offered by competitive valves.

10 Con-14

Lift only in verticalupright position.

HH ATTENTION!➨

ANCHOR DISCHARGE PIPINGSOLIDLY TO BLDG. STRUCTURE

RADIAL CLEARANCE REQUIREDWHEN VALVE IS OPERATING

VERTICAL CLEARANCEREQUIRED WHEN VALVEIS OPERATINGVENT (SEE FIGURE 3.)

BODY DRAIN

DRAIN

*

DRAINFLANGED INLETSHOWN WELDEDINLET SIMILAR

BORE EQUAL TO MINIMUMOF VALVE INLET DIAMETER

BORE EQUAL TOMINIMUM VALVEOUTLETDIAMETER

*MAX. DIMS.3" 150# - 7-1/4 (185MM)6" 150#-12-1/2 (318MM)8" 150#-16 (407MM)3" 3OO# - 7-5/8 (194MM)6" 3OO#-12-7/8 (327MM)8" 3OO#-16-3/8 (416MM)

FIGURE 2

Handle valve carefully.Do not drop or strike.

HH ATTENTION!

Prevent dirt fromentering outlet or

inlet port.

HH CAUTION!

III. Storage and Handling Prior to InstallationSafety valves should be stored in a dry environment to protect them from theweather. They should not be removed from the skids or crates until immediatelyprior to installation. Flange protectors and sealing plugs should remain installeduntil just prior to installation.

Safety valves, either crated or uncrated, should never be subjected to sharpimpact. This would be most likely to occur by bumping or dropping during loadingor unloading from a truck or while moving with a power conveyor, such as a forklift truck. The valve, either crated or uncrated, should always be kept with the inletdown (i.e., never laid on its side), to prevent misalignment and damage to inter-nals. Even crated valves should always be lifted with the inlet down.

Uncrated valves should be moved or hoisted by wrapping a chain or sling, aroundthe discharge neck, then around the upper yoke structure, in such manner as willensure that the valve is in vertical position during lift, (i.e., not lifted in horizontalposition). Never lift the full weight of the valve by the lifting lever. Never hook tothe spring to lift. When safety valves are uncrated and the flange protectorsremoved, immediately prior to installation, meticulous care should be exercised toprevent dirt from entering the outlet port while bolting in place.

While hoisting to the installation, care should be exercised to prevent bumping thevalve against steel structures and other objects.

IV. Recommended Installation Practices

A. General Requirements

The valve should be installed to meet allthe requirements of Figure 2 (below).

Con-14 11

The safety valve shall be connected to the headerindependent of any other connection, and attachedas close as possible to the header, without anyunnecessary intervening pipe or fitting. “Necessary”intervening pipe or fittings shall not be longer thanthe face-to-face dimension of the corresponding teefitting of the same diameter and pressure, perANSI/ASME Standards.

No valve of any description should be placedbetween the safety valve and the header, nor on thedischarge pipe between the safety valve and theatmosphere.

In no case may the inlet piping to thevalve have a flow area less than the areaof the valve inlet.

Excessive pressure loss at the inlet of thesafety valve will cause extremely rapidopening and closing of the valve, which isknown as “chattering”. Chattering mayresult in lowered capacity as well as dam-age to the seating surface of the valve.Severe chattering can cause damage toother parts of the valve.

The following recommendations willassist in eliminating the factors that pro-duce chatter:

1. The downstream corner of the head-er nozzle must be rounded to a radiusof not less than 1/4 of the openingdiameter. (See Fig. 3)

2. Pressure drop due to friction flow tothe inlet of the valve should not begreater than 50% of the expectedblowdown of the safety valve.

To decrease the effects of a phenomenonknown as “sonic vibrations,” or “flowinduced vibrations”, the following recom-mendations are made:1. Safety valves should be installed at least eight to ten pipe diameters downstream from any bend in a steam

line. This distance should be increased when the valve is installed on the horizontal section of a header whichis preceded by an upward section.

2. Safety valves should not be installed closer than eight to ten pipe diameters either upstream or downstreamfrom a diverging, or a converging, “Y”.

3. In cases where a piping configuration renders the above two recommendations impractical, or impossible, thedownstream corner of the header nozzle inlet should be rounded to a greater extent than the upstream cor-ner. The header nozzle entrance should be rounded so the radius at the downstream corner will be equal to aminimum of 1/4 of the nozzle diameter. The radius should be reduced gradually, leaving only a small portionof the upstream corner with a smaller radius. (See Fig. 3)

4. Safety valves should never be installed, in a steam line, in a position directly opposite to a branch line.

OrificeDesignation

1235*4*6

7Q

TABLE II2700 YOKE VENT SIZES

Yoke VentSize (NPT)

1/21/21/23/43/411

*#5 is a smaller orifice than #4.

ANCHOR DISCHARGE PIPING SOLIDLYTO BUILDING STRUCTURE

FABRICATEDDRIP PANSHOWN

AS CLOSEPOSSIBLE

YOKE VENTSCHEDULE 40 PIPE

UNIONDRAIN

A A

SECTION A-A FIGURE 3

12 Con-14

Excessive line vibrations are known to produce shifts in safety valve set pressures. Vibrations may possibly intro-duce chatter, causing damage to the valve and reduce its capacity. This vibration also contributes to increased inci-dents of seat leakage. Considerations should be given to eliminating this problem prior to installing the valve onthe unit.

Steam flowing vertically out a discharge elbow produces a downward reaction on the elbow. Effects of reactionforce, vibration, and seismic loads, on all valve components and discharge piping, should be considered whendesigning the valve system.Refer to ANSI B.31.1, Non-Mandatory Appendix II, Dresser Product Information SheetSV/PI-15, and Dresser Bulletin SV-5 for further information.

For optimum performance, safety valves must be serviced regularly and otherwise maintained. So that servicingcan be properly performed, valves should be located in a manner that allows for easy access. Sufficient workingspace should be provided around and above the valve to permit access to adjusting rings. If two or more valvesare located close together, the outlets should be parallel so as to offer as much protection as possible to person-nel repairing, or working close to, the safety valve.

Because foreign material passing into, and through, a safety valve is damaging, the system on which the valve isinstalled must also be inspected and cleaned. New systems are prone to contain welding beads, pipe scale, andother foreign materials which are inadvertently trapped during construction, and destroy the valve seating surfacesthe first few times the valve opens.

With regard to weld-end inlet valves, completely assembled valves may be installed without disassembly beingnecessary at the time of welding. During welding, the valve neck should be insulated to reduce thermal stresses.When stress relieving, insulation should also be utilized to reduce thermal stresses. In service, the valve neckshould be insulated at least to the point of the inlet neck/valve body-bowl juncture.

Safety valves should be installed in a vertical position. Nominal tolerance on vertical installation is plus or minus 1degree.

The discharge area of the outlet piping from a safety valve should not be less than the area of the outlet connec-tion. Where more than one safety valve is connected to a common outlet pipe, the area of the pipe should not beless than the combined area of the outlet connections to the safety valves.

All safety valve discharges should be piped so that the effluent is discharged clear from walkways or platforms.Ample provision for gravity drain should be made in the discharge pipe at, or near, each safety valve where water,or condensation, may collect. Each valve has an open gravity drain through the body, below the level of the valveseat, and this drain should be piped to a safe discharge area.

If a silencer is used on a safety valve, it should have sufficient outlet area to prevent back pressure from interfer-ing with the proper operation and discharge capacity of the valve. The silencer or other piping components shouldbe constructed so as to avoid the possibility of creating corrosion deposit restrictions in the steam passages.

Exhausts, drains, and vents must be installed so that they will not impose undue stresses on the safety valve. Anysuch stresses can produce body distortion and leakage. Therefore, the following recommendations are provided:

1. Discharge piping should not be supported by the valve. The maximum weight on the outlet of the valve shouldnot exceed the weight of a flange and short radius elbow, plus a twelve (12) inch (304.8 mm) straight lengthof standard weight thickness pipe (with drip pan).

2. Clearance between the valve exhaust piping and the discharge stack should be sufficient to prevent contactwhen considering thermal expansion of the header, valve, and discharge stack. Movements due to vibration,temperature changes, and valve reaction forces should also be considered, to ensure adequate clearancebetween the exhaust piping and the discharge stack.

3. Flexible metal hoses are not generally recommended, but if used to connect valve outlets to discharge stacks,they must be of sufficient length, and be configured/installed in such a manner, that they will not become “solid”in any one position. Better results are obtained if the hoses are installed so that they will permit movement bybending, rather than by stretching and compressing along their length.

Con-14 13

The yoke can be vented to the atmosphere as in Figure 2. Precautions should be taken to vent the yoke insuch a manner that it will exhaust into a safe area to prevent injury to personnel near the valve. The yokevent piping must not be connected to the body drain piping.

Do not plug the yoke vent hole or reduce vent hole pipe size, (Reference Table II), as this could lead tovalve malfunction and damage.

Precautions should be taken to prevent accumulations of foreign material or water in the vent pipe. This vent is acritical part of the valve system for controlling valve blowdown and lift.

All face surfaces which require gaskets, to seal pressure, shall be inspected for cleanliness, or any defects that cancause leakage. Burrs, mashed serrations, uneven surfaces, etc., are all possible leakage producing defects. Propergasket sizes and pressure ratings should be checked prior to starting valve installation.

It is of utmost importance that the gaskets used be dimensionally correct for the specific flange, and that they fullyclear the valve inlet and outlet openings. Gaskets, flange facings, and bolting should meet the service require-ments for the pressure and temperature involved. Other valve installation considerations include:

1. Install the inlet gasket, if required, on the header mounting flange. Check for cleanliness, surface alignmentcondition, gasket condition, etc. When possible, inlet studs on the mounting flange should be used to guidethe valve on the header mounting flange. Inlet studs should be lubricated with the appropriate lubricant.

2. When installing flanged valves, the flange bolts must be pulled down evenly to prevent body distortion, mis-alignment, and leakage.

3. With valve in position, screw on the stud nuts until all nuts are finger tight. An initial torque shall be placed, inturn, on each stud nut. Increase the torque progressively until the final torque is applied. Upon completion,recheck each stud nut’s torque. Required torque will vary with bolting material and gaskets used. See yourcompany engineering or specification department for details on torquing sequence and torque values. As anextra precaution, the gap between the two mating flanges should be checked during the torquing process toensure that the flanges are being pulled together evenly. A final inspection and review should be made toensure that all of the requirements for bolting the valve inlet have been implemented.

4. The outlet piping may now be installed. A complete inspection of components and their cleanliness is to bemade prior to further work. Studs are to be lubricated with an appropriate lubricant.

5. Install the outlet gasket, studs and nuts. Stud nuts are to be pulled down finger tight. An initial value of torqueis to be applied. The additional procedures outlined, in Step 3 are also to be followed.

After being assured that the valve is properly installed, the drainage piping from the valve body-bowl is to be con-nected. This line also must be flexible, so it will not create stress on the valve under operating conditions.

Prior to completing the installation, a visual check should be made to ensure that the valve lifting lever has roomand is free to operate.

At the time of installation, an inspection of the valve should be made to confirm that all adjustment components(i.e., ring pins, cap, etc.) are properly locked and sealed, as required by the ASME Code.

For operational hydrostatic tests at the valve inlet, which do not exceed valve set pressure, the valve should begagged. Refer to the final “Field Testing” portion of this manual (i.e., Section VI) for proper techniques. Ensure thatthe gag is removed upon completion of the inlet hydrostatic test.

Prior to startup of the unit on steam, the sections of this manual which specify requirements for set pressure test-ing should be reviewed. For conditions where the valve is subjected to high steam pressures (i.e., those exceed-ing normal operating conditions), preparations should be made to gag the valves. These preparations should thenbe cleared with the boiler manufacturer and DFC Engineering. Refer to Section VI. B.3 of this manual for the prop-er gagging techniques.

The safety valve should be tested with full steam pressure to ensure that the safety valve installation has beenproperly accomplished. In some cases this is not practical, thus the use of the CONSOLIDATED® Hydroset, or theElectronic Valve Tester (EVT), should be considered. For valves being tested for set pressure by using a Hydrosetor EVT, only the set pressure is being verified. Other factors such as blowdown, lift, reaction force, proper dis-charge stack sizes and effects of thermal expansion cannot be determined, using these setting devices. Full flowsteam testing is recommended at initial start-up to adjust blowdown and verify proper installation. Proper adjust-ing ring position can then be recorded and maintained when valves are serviced.

Vent and drain piping should have a union connection to facilitate valve removal or servicing in place. (See Fig. 2)

B. Outdoor Safety Valve Installation

Safety valves operating under the best possible conditions (i.e., of favorable operating gap, relatively stable ambi-ent temperatures, the absence of dirt and in relatively still air) will provide the maximum degree of safety, tightnessand dependability.

When a safety valve is installed in an outdoor location, it may be exposed to wind, rain, snow, ice, dirt and vary-ing temperatures. Therefore, the following recommendations are made for proper protection, and to ensure thatoperational dependability can be restored to a level near that of the valve installed under ideal conditions:

The inlet neck of the safety valve and safety valve body, up to the top of the base, should be insulated. The exte-rior surface of any such insulation should be made weather-proof by any suitable means. In addition to maintain-ing a more even temperature within the valve body, especially during widely fluctuating ambient temperatures, thisinsulation will effectively reduce thermal stresses, due to high temperature gradients, through the walls of the safe-ty valve nozzle.

Spring covers should be used to stabilize (as nearly as possible) the temperature of the spring, to prevent the accu-mulation of snow and ice between the coils of the spring, and to prevent dirt and fly ash from accumulating betweenthe coils of the spring.

Lifting gear covers should be installed to prevent ice, dirt and fly ash from accumulating in areas inside the safetyvalve cap.

C. Indoor Safety Valve Installation

Indoor valve installations should have inlet necks insulated only up to the under-side of the valve body. Considerations should be given to ambient temperaturechanges greater than 100˚F (37.8˚C), because of possible set point changeswhich may occur.

14 Con-14

Know all valveexhaust/leakage points

to avoid possible severepersonal injury or death.

HH WARNING!

Con-14 15

V. Hydrostatic Test PlugRemoval-Domestic &Export

A. General Information

Flanged inlet safety valves shippedwithout Hydrostatic Test Plugsshould be removed from the boilerduring hydrostatic tests and boilernozzles blanked off to prevent possi-ble valve damage.

All valves shipped outside the continen-tal United States are shipped with anexport hydroplug (See Fig. 6). All weld-ed inlet valves shipped within the conti-nental United States are shipped with adomestic hydroplug (See Fig. 5), unlessthe customer specifically requests oth-erwise. All flanged inlet valves shippedwithin the continental United States areshipped without a hydroplug, unlessone is specifically requested by the cus-tomer.

Valves shipped with either type ofhydroplug are identified by a Red onWhite CAUTION TAG which is attachedto the valve by wires extending throughthe drain hole in the valve body. (SeeFig. 4)

Hydrostatic test plugs must beremoved prior to firing boiler.

The hydrostatic plugs are placed in the bore of the valve, inside the seat-ing surface. Their purpose is twofold. First, they effect closure at a pointdiffering from the seating surface of the valve so that, if the valve is liftedon hydrostatic test, the seating surface is not as likely to be damaged.Second, by raising the disc of the valve off its seat and increasing springcompression, the set pressure of the valve is increased to a point wherethe valve will not leak at one and one-half times design boiler pressure. Itis not necessary to gag the safety valves when hydrostatic plugs areused.

These plugs must, of course, be removed from the valves prior to placingthe boiler in service. However, they should be retained, and reinstalled,whenever a hydrostatic test is conducted which exceeds the low set valvepressure.

Before starting to disassemble the valve, be sure that there is nosteam pressure in the drum or header.

HYDROPLUG

FIGURE 4

Do not disassemble valvewith pressure in drum orheader, as this will resultin severe personal injury

or death.

HH DANGER!

16 Con-14

B. Domestic Plugs

To remove the domestic plug, the fol-lowing steps must be followed:1. Remove the cap assembly, adjust

release nut to 2nd hole from thetop of the spindle and install cotterpin.

2. Back off the yoke stud nuts uni-formly until compression screwengages release nut. Now removeyoke stud nuts.

3. Remove yoke and spring assem-bly, (See Fig. 7), from base, beingcareful not to damage the disc.

4. Remove the hydrostatic test plugfrom the seat bushing. This maybe accomplished by inserting athreaded rod into the tapped holein the plug and lifting up until freefrom bushing. Care should betaken as not to damage the seatbushing.

5. Remove the disc from the discholder by turning clockwise until itis disengaged from spindlethreads.

NOTE: Hold the disc holder againstthe disc adjusting collar during thisstep, otherwise the disc holder willfall from the spindle and becomedamaged.

6. Lap the disc and seat bushing and thoroughlyclean the seats with a clean cloth.

7. Lubricate the spindle tip with “Anti-Seize”, andassemble the disc and disc holder to spindle byturning the disc until the dropout threads disen-gage.

8. Reassemble yoke and spring assembly (See Fig.7) into base, being careful not to damage the disc.Locate the yoke vent to the side of the valve. Thelug on the top spring washer should be on theright side of the valve when facing the outlet.

9. Replace the yoke and the stud nuts. Tighten thestud nuts according to Table III.

10. Remove cotter pin from release nut and positionrelease nut so that 1/8 inch (3.175mm) of clear-ance is visible between lifting fork and release nut,then install cotter pin.

11. Install cap and lever assembly.12. Valve is now ready for the initial field test on steam in order to check valve set point and blowdown.

CAP

3 THRU Q ORIFICE

COMPRESSION SCREW

COMPRESSION SCREWADAPTOR (5 THRUQ ORIFICE)

THRUST BEARING

TOP SPRINGWASHER

RELEASE NUT

COMPRESSION SCREWCOMPRESSION SCREWLOCKNUT

THRUST BEARING

TOP SPRING WASHER

SPRING

STUDS & NUTS

VENT

DRAIN SERVICEPLUG

CAP

LEVER PIN

LEVER

TOP WASHERARM

SPINDLE

YOKE

LIFT STOP

DISC HOLDER

GUIDEDISC COLLARUPPER ADJ.RINGDISCLOWER ADJ.RING

SEAT BUSHING

BASE

UPPER & LOWERADJ. RING PINS

FIGURE 5

DROPLEVER

Orifice Designation1235*4*6

7Q

TABLE III

Nut Torque60 Ft. Lbs.60 Ft. Lbs.

110 Ft. Lbs.170 Ft. Lbs.375 Ft. Lbs.375 Ft. Lbs.375 Ft. Lbs.

*#5 is a smaller orifice than #4.

TORQUE OF YOKE NUTS

Con-14 17

C. Export Plugs

When hydrostatic plugs are installed in 2700Valves scheduled for shipment to foreign coun-tries, the disc is removed and dipped in preserv-ative, then packed in a box. The package is theninserted into the valve outlet.To remove the special export plug, the followingsteps must be followed:

1. Remove the cap assembly, adjust releasenut to 2nd hole from the top of the spindleand install cotter pin.

2. Back off the yoke stud nuts uniformly untilcompression screw engages release nut.Now remove yoke stud nuts.

3. Remove yoke and spring assembly, (SeeFig. 7), from base.

4. Remove hydrostatic plug by turning until it isdisengaged from spindle threads.

NOTE:Hold the disc holder against the disc adjust-ing collar during this step, otherwise the discholder will fall from the spindle and becomedamaged.

5. Remove the seal peel preservative from thedisc.

6. Lap the disc and seat bushing, thoroughlyclean the seats with a clean cloth.

7. Lubricate the spindle tip with “Anti-Seize”,and assemble the disc and disc holder tospindle by turning the disc until the dropoutthreads disengage.

8. Reassemble yoke and spring assembly (SeeFig. 7) into base being careful not to damagethe disc. Locate the yoke vent to the side ofthe valve. The lug on the top spring washershould be on the right side of the valve whenfacing the outlet.

9. Replace the yoke and the stud nuts. Tightenthe stud nuts according to Table III.

10. Remove cotter pin from release nut andposition release nut so that 1/8 inch(3.175mm) of clearance is visible betweenlifting fork and release nut, then install cotterpin.

11. Install cap and lever assembly.12. Valve is now ready for the initial field test on

steam in order to check valve set point andblowdown.

SPINDLE

DISC HOLDER

EXPORT HYDROPLUG

SEAT BUSHING

FIGURE 6

FIGURE 7

18 Con-14

VI. Testing

A. General Information

Upon completion of hydrostatic testing of the boiler, but prior to placing the boiler in service, ENSURETHAT THE HYDROSTATIC TEST PLUGS ARE REMOVED FROM ALL VALVES.

All Type 2700 Safety Valves are steam tested at the factory to verify set pressure adjustability and seat tightness.Every valve is set to have a clean popping action and to reseat tightly. However, because the boiler used in set-ting the valves has a small capacity, compared to the capacities of the Type 2700 Valves, the valves are factoryset with a long blowdown to prevent chattering under initial start-up conditions. Final adjustments should be madeon the operating system with conditions approximately those that will be realized under actual operating conditions.

Note: DFC recommends full flow steam testing upon initial start up.

Adjusting ring settings are initial adjustments only and are not intended to be final adjustments.

The use of a DFC Hydroset or EVT, unit can serve to establish set pressure but cannot be used for verifying blow-down, lift, etc. (For additional information, see page 12, of this manual). It is recommended that the safety valvesbe tested and adjusted with the boiler isolated.Factors which can affect valve operation, and which should be considered when initially setting a valve, are as fol-lows:

1. Ambient temperature near the valve and valve temperature stabilization.2. Line vibration.3. Valve capacity versus rated flow through the line on which the valve is mounted.4. Discharge stack or drain piping binding.5. Flow induced vibrations or pressure pulsations set up by upstream bends. Valve inlet nozzle configuration, or

other internal piping configuration problems.6. High water level in the drum.

When the valves are subjected to working hydrostatic tests not exceeding the set pressure of the low set valve,valves may be gagged rather than using hydrostatic test plugs. For higher pressures, hydrostatic plugs should beused.

A common source of safety valve trouble is over-gagging. During hydrostatic testing, and during safety valve set-ting, gags should be applied only hand tight. During setting, overgagging will also cause damage to the seatingsurface and result in seat leakage.

The gag load applied should be only enough to ensure that the valves do not lift at the expected overpressure.

During start-up, gags should never be applied when the boiler is cold. The spindle of the safety valve expands con-siderably with the temperature increase. If it is not free to expand with this temperature change it may become seri-ously overstressed and bent.

Except for hydrostatic tests, boiler pressure should be brought up to within 80% of the pressure of the low set valvebefore applying gags.

Tighten the gags of drum and superheater valves finger tight.

When adjusting the ring positions of a valve, the valve must be gagged to prevent accidental lifting and personaldanger.

If testing the set pressure of a valve, the other valves in the system should also be gagged.

B. Application of Test Gags (All Pressures)

1. Refer to Figure 5 on page 16. Remove top lever pin and top lever, then loosen the cap screw. Remove capand drop lever as an assembly. The release nut is fixed to the spindle by means of a cotter pin. Note that therelease nut does not quite engage top of compression screw.

2. Center the test gag in the exposed end of the SPINDLE and hook the legs of gag under the sides of the YOKE.

Do not apply the gag load until the system steam pressure is equal to 80% of the pressure to which thelow set valve is adjusted.

3. Apply the gag load by turning the gag screw clockwise. If the gag on any valve has not been tightened suffi-ciently, the valve will leak. On steam service the leakage is accompanied by a “Sizzling” sound.

If this occurs, the hydrostatic test pressure or steam pressure should be reduced until the valve becomestight and, then, the gag should be tightened still further.

This procedure must be followed exactly, since it is very difficult to stop the leak by additional gagging once it hasstarted. Any attempt to stop the leakage through the valve, without first lowering the system pressure, could resultin damage to the valve seats.

4. After the hydrostatic test or steam test is completed, the gags should be removed when the hydrostatic pres-sure has been reduced to 80% to 90% of the pressure of the low set valve.

Note: Under no circumstances should the gags be left on the valves during normal boiler operation.

C. Presetting Adjusting Rings

1. Remove the caps on all valves to be set on the steam drum and main steam line.2. Install a currently calibrated pressure gauge on the drum near the valve being set. When main steam valve

are to be set, install the calibrated gauge upstream from the valves on the main steam line to read line pres-sure.

3. After the pressure in the boiler has increased to 80% of operating pressure, install gags on all boiler valvesnot being tested. Gags should be installed hand tight, (no wrenches or mechanical force).

Con-14 19

GAG

Gag safety valve duringring adjustments to

avoid possible severepersonal injury or death.

HH WARNING!

LOWER RINGSEAT LEVEL

ADJUSTMENTIN NOTCHES(Column A)ORIFICE

UPPER RINGSEAT LEVEL

ADJUSTMENTIN NOTCHES(Column B)

123546

7Q

78

1212123030

10121616164545

TABLE IV

20 Con-14

4. On the valve to be tested, use the following procedure and Table IV, to bring the adjusting ring to seat level.a) Gag the valve to prevent the disc from accidentally lifting from the seat during adjustment.b) Remove both service port plugs.c) Remove the upper ring pin.d) Move the upper ring until it is level with the disc holder.e) From this point, move the upper adjusting ring down, (from right to left as viewed through the service

plug hole), counting the number of notches until the number in Column “B” in Table IV, appropriate to theorifice size is reached. This will establish the upper adjusting ring at seat level.

f) Adjust the upper adjusting ring as indicated in the upper ring Column of Table V use either the SaturatedColumn or Superheated Column as conditions warrant

g) Replace the ring pin in the valve to hold the upper adjusting ring in position without binding.h) Remove the lower ring pin.i) Move the lower adjusting ring up until it contacts the disc holder.j) After referring to Table IV, lower the adjusting ring the number of notches indicated in Column “A”.

This setting will place the lower adjusting ring at seat level.k) Once the lower adjusting ring is at seat level it can be preset to the beginning test position by moving

the adjusting ring down one notch for each 600 PSI or part thereof. (Example: 1,000 PSI Set Pressure =2 notches.)

l) Replace the adjusting ring pin in the valve to hold the lower adjusting ring in position without binding.5. Wire the adjusting ring pins together to prevent them from loosening and vibrating out under pressure.6. Replace the service port plugs.7. Remove the gag from the valve to be tested, and reinstall the cap and lever assembly on the valve.8. Now the valve is ready for steam testing.

D. Steam Testing Instructions

1. Attach a rope to the lifting lever on the valve to be tested.2. Increase the boiler pressure at a rate not to exceed 2 PSI per second. Note and record the pressure indicat-

ed on the pressure gauge when the valve “pops” open. After the valve pops open, reduce the fire in the boil-er and lower the pressure until the valve closes, note and record the pressure when the valve closes.If in raising the boiler pressure, the valve doesn’t open within 3% overpressure (for ASME Section I valves),or 10% overpressure (for ASME Section VIII valves), reduce the fire in the boiler and pull the rope toopen the valve.

3. Determine if the valve popping point and reseating points comply with the ASME requirements for valveoperation as recorded in Table V. (See ASME Boiler and Pressure Code Section I, or Section VIII ValveOperation Standards for more details).To determine which standard to use, look at the nameplate on the valve. The symbol that is present on thenameplate will indicate the proper standard of operation. (See Table VI)

4. If the valve operation is in compliance with the standard, proceed to step 7.5. If the valve is not in compliance, reduce boiler pressure to approximately 85% of valve set pressure. GAG

the safety valve being adjusted.a) If set pressure is out of compliance turn the compression screw one sixth of a turn (clockwise to raise

set pressure, and, counterclockwise to lower set pressure). Retest, and note the change in set pressurefor one sixth turn-then calculate the number of turns needed to bring the set pressure to the desiredpressure. Adjust as necessary.

b) If the blowdown is excessive, raise the upper adjusting ring (5 to 10 notches). If the blowdown is insuffi-cient, lower the upper adjusting ring (5 to 10 notches). Re-test as in step 2, if the blowdown is not withinspecification repeat step 5.

6. Remove the gag, and repeat Step 2, raising the pressure until the valve pops then proceed with the follow-ing steps until the subject valve is in compliance with the appropriate standard.

7. After one pop has been determined to be in compliance, test the valve two more times for consistency of setpressure and blowdown. Allow a minimum of 10 minutes between pops. If the operation remains in compli-ance with the standard, reduce the boiler pressure to approximately 85% of the set pressure and seal thevalve cap and adjusting ring pins.

8. Proceed to the next valve to be tested.9. When all valve have been tested and sealed, return the boiler to normal operating pressure. (See Table VII.)

Con-14 21

PRESETTING INFORMATION FOR USE ON 2700 SERIES SAFETY VALVES

Set Pressure Lower Upper RingOrifice (See Note 2 Below) Ring Position

from toPosition

Saturated Superheated

#1

#2

#3

#4

#5

#6

Q.

(See Note 1 Below)

300500900

150025002800

300500900

150025002800

300500900

150025002800

300500900

150025002800

300500900

150025002800

300500900

500900

1500250028003000

500900

1500250028003000

500900

1500250028003000

500900

1500250028003000

500900

1500250028003000

500900

1100

20N↑20N↑15N↑10N↑10N↑5N↑

20N↑20N↑15N↑10N↑10N↑5N↑

25N↑25N↑20N↑15N↑15N↑25N↑

50N↑40N↑40N↑40N↑45N↑65N↑

55N↑50N↑45N↑45N↑45N↑60N↑

70N↑65N↑60N↑

Set upperadjustingring flushwith seatlevel.

Seat LevelSeat Level

5N↓10N↓10N↓15N↓

Seat LevelSeat Level

5N↓10N↓10N↓15N↓

Seat LevelSeat Level10N↓20N↓20N↓20N↓

Seat Level10N↓10N↓15N↓25N↓25N↓

Seat Level10N↓15N↓20N↓25N↓25N↓

Seat Level10N↓20N↓

Set upperadjustingring 1/2turn belowseat level.

1N downper each600 psignot toexceed5N down

1N downper each600 psignot toexceed5N down

1N downper each600 psignot toexceed5N down

1N downper each600 psignot toexceed5N down

1N downper each600 psignot toexceed5N down

1N downper each600 psignot toexceed5N down

1N downper each600 psignot toexceed3N down

All setpressures

900

TABLE V

NOTE: 1. If the valve is to be set on superheated steam, establish1. the position of the lower adjusting ring at seat level.2. If set pressure is under 300 psig or valve is not listed on1. above chart, contact the Consolidated® Field Service1. Department for setting information.

22 Con-14

Boiler Design Pressure,psig (KPa)

Over 15 to 300(100 to 2100)

Over 300 to 1000(2100 to 6900)

Over 1000 to 2000(6900 to 13, 788)

Minimum Differential as a Percentof Boiler Design Pressure

10% but not less than7 psi (48 KPa)

7% but not less than30 psi (210 KPa)

5% but not less than70 psi (483 KPa)

TABLE VIIRECOMMENDED OPERATING GAP

ASME Boiler and PressureVessel Code Section and

Symbol

CODE SYMBOL STAMP

ASME Section I

CODE SYMBOL STAMPASME Section VIII

Set Pressure Tolerance (The valve must “POP” openwithin the range indicated below.)

If valve set pressure is less than or equal to 70 psig+/-2 psig

If valve set pressure is 71 psig up to and including300 psig

+/-3% of set pressure

If valve set pressure is 301 psig up to and including1000 psig

+/-10 psig

If valve set pressure is 1001 or greater+/-1% of set pressure

If valve set pressure is less than or equal to 70 psig+/-2 psig

If valve set pressure is 71 psig or greater+/-3% of set pressure

Blowdown Requirements

After opening, the valve must reclose with-in a range of 98% to 96%, however, if thevalve set pressure is 100 psig or less thevalve must reclose within a range of 2 to 4psig below set pressure.

After opening the valve must reclosebefore the system pressure returns to nor-mal operating pressure.

TABLE VI

V

UV

E. Hydroset/Electronic Valve Testing (EVT)

Periodic tests may be required for verification of valve set pressure. Both the DFCHydroset Test Device and EVT provide for this capability; however, set pressureis the only factor which can be verified. Valves should be initially set using full sys-tem pressure (as outlined in sections VI.A. through VI.C. of this manual). TheHydroset, or EVT used for subsequent checks of set pressure.

Setting safety valves by the recommended method of lifting valves under steampressure presents a number of problems. In high pressure conventional boilers,superheater tubes may be damaged if the turbine is not operating. Also, theexpense of feed water, fuel and personnel involved is considerable.

Although these problems cannot be eliminated entirely, they can be reduced byusing a hydraulic or electronic device that allows the set pressure to be checked,while the system pressure remains below the set pressure.

Accuracy of results obtained by the use of either of these devices depends onseveral factors. First, friction must be reduced as a source of error so that, for agiven pressure, the Hydroset or the EVT repeatedly produces exactly the samelifting force. Second, gauge calibration and vibration, in the effective seating areabetween valves of the same size and type, will also affect accuracy. With well cal-ibrated gauges and valve seats in good condition, accuracy on the order of ±1%of set pressure may be expected. Upon request, DFC will provide pertinent writ-ten material concerning the DFC Hydroset Device, or the EVT. This material spec-ifies all required information necessary to ensure proper usage of these devices.

VII. Disassembly Instructions

A. General Information

The Type 2700 Safety Valve can be easily disassembled for inspection, recondi-tioning seats or replacing internal parts. The initial spring load can be establishedafter reassembly. (Again, refer to Figure 5, on page 17, for parts nomenclature).

NOTES:• Before starting to disassemble the valve, be sure that there is no steam

pressure in the drum or header.

• Parts from one valve should not be interchanged with parts from anoth-er valve.

B. Specific Steps

1. Remove the top lever pin and top lever.2. Loosen cap set screw and lift off cap and drop lever assembly.3. Remove the cotter pin which retains the release nut, and then remove the

release nut.4. Refer to Figure 8 (See Page 23), and measure and record Dimension A, as

this information will be required to correctly re-assemble the valve.5. Loosen the compression screw locknut and the compression screw, to

remove tension from the spring.6. Loosen and remove the yoke stud nuts.

Con-14 23

Do not disassemble valvewith pressure in drum orheader, as this will resultin severe personal injury

or death.

HH DANGER!

Improper lift adjustmentmay result in severe

personal injury or death.

HH DANGER!

7. Carefully lift the yoke and springassembly over the spindle, andaway from the valve.

8. Remove the thrust bearing assem-bly and the spring washer assembly.Mark the spring to indicate the top ofthe spring, as this formation will beused in reassembly.

9. Remove the spindle, disc and discholder assembly from the valve bylifting the spindle. Take care toensure that the disc seating surfaceis not damaged from improper han-dling.

10. To remove the disc and disc holderfrom the spindle, first insert the spin-dle into a vise (see Figure 9, right)being careful not to damage thethreaded end of the spindle. Then,lift up on the disc holder and turn thedisc/disc holder counterclockwise toengage the “drop-thru” threads.Once the threads are engaged,release the disc holder and continueto unthread and remove the disc.After the disc is removed, lift discholder from the spindle.

NOTE:Removal of the lift stop and/or thedisc collar from the spindle is usuallyunnecessary, unless the spindle is tobe replaced.

11. Measure from the top of the guide tothe bushing seat (Dimension B,Figure 10, right) with a depthmicrometer or other suitable measur-ing device. Record Dimension B.

12. Place a scale or other thin flat metalsurface against the lower face of theupper adjusting ring and measurefrom the top of the guide to the faceof the upper adjusting ring (dimen-sion C, Figure 10). Record Dimen-sion C.

13. Remove the upper adjusting ring pinfrom the valve base.

24 Con-14

UPPER ADJ.RING PIN

LOWER ADJ.RING PIN

SCALE

SEAT

FIGURE 10

B

DEPTH MICROMETER

YOKE

ASPINDLE

COMPRESSION SCREW

COMPRESSION SCREW LOCKNUT

FIGURE 8

DISC

DISC COLLAR

DISC HOLDER

LIFT STOP

SOFT METAL

VISE

FIGURE 9

14. Loosen the lower adjusting pin untilthe pin is slightly clear of the notch-es in the lower adjusting ring. Beingcareful not to move the lower adjust-ing ring, place a ring lap on top ofthe bushing seat. (See Figure 11,left). Then, using the ring pin as a“pointer”, or reference point, rotatethe lower adjusting ring counter-clockwise and count the number ofnotches that pass in front of the“pointer” until contact is made withthe ring lap. Record this information,as it will be required to correctly re-assemble the valve.

15. Remove both the lower adjustingring pin and the lower adjusting ringfrom the valve base.

16. The valve is now ready to becleaned and the parts inspected forproper size and condition.

Con-14 25

RING LAP

LOWER ADJUSTINGRING

SEAT BUSHING

FIGURE 11

VIII. Inspection and Restoration of Parts

A. GeneralOnce the valve is disassembled, appropriate parts can be inspected for damage and their suitability for reuse.

B. Specific Components1. Lift Lever and Cap Assembly

Visually inspect the lift lever and cap assembly for damage from improper handling or severe corrosion.Components should be replaced if damage interferes with proper function or manual lifting of the valve.

2. Compression Screw and LocknutThe compression screw must be replaced if the threads are damaged to the point that spring adjustment isaffected. The wrench flats should not be worn or rounded or distorted due to the improper use of an adjustingwrench on either the compression screw or locknut. The spring washer bearing surface or compression screwadapter surface, (5 through Q orifice only), should not be pitted or torn and should have a 32 RMS finish.

3. Thrust BearingThe aligning washer must match evenly to the lower thrust bearing spherical surface, such that full face con-tact is achieved between the parts. Therefore, grind together, or replace the entire thrust bearing, as neces-sary.

4. Top and Bottom Spring WashersThe lower spring washer bearing surface must be ground to the spindle. To grind the lower spring washer, a320 grit (Clover 1A) lapping compound is used for roughing-in, and then finish lap with 1000 grit Kwik-Ak-Shunlapping compound until a satisfactory bearing band is obtained. The bearing width should be 1.8 in. (3.2 mm)min. to 3.16 in. (4.8 mm) max. Clean lower spring washer and spindle when complete.

5. SpringVisually inspect for pitting and corrosion of coils that will reduce the coil diameter. When this condition is found,replace the spring. Inspect for end parallelism in the free height and any obvious unevenness in coils, collapseof coils or general distortion.

6. SpindleIt is important that the spindle be kept very straight in order to transmitthe spring force to the disc without lateral binding. Overgagging is oneof the common causes of bent spindles. A method to check the essen-tial working surfaces of the spindle is illustrated in Figure 12 (right). Thismay be performed either with or without the disc collar and lift stop onthe spindle.a. Using Figure 12 (right) as a reference, clamp a V block (A) made of

wood, fiber or other suitable material onto the platform railing.Imbed the ball end of the spindle in a piece of soft wood (B) andplace the top of the Spindle, below the threads, in the V block (A).Clamp a dial indicator onto the railing and locate at point (C). Thetotal indicator reading should not exceed .007 in. (.177 mm) whenthe spindle is rotated. If it does, the spindle must be straightenedprior to reuse.

b. To straighten the spindle, place the unthreaded portion of the smalland large end in padded V blocks, with the point of maximum indi-cator readout upward, and then apply a downward force with apadded press or jack as required, until the spindle is within the spec-ifications.

c. Other parts of the spindle not used as working surfaces may run outconsiderably more than .007 in. (.177 mm), but this should not beregarded as unacceptable. Although the upper thread end is not aworking surface, excessive bending in this area could effect theaccuracy of the DFC Hydroset device and/or the DFC ElectronicValve Tester, if either of these devices is used to verify valve setpressure.

d. Apply a small amount of lapping compound (1A) on the tip of thespindle. Install the disc - without the disc holder - onto the spindletip, turning it clockwise until the disc threads drop out. Place a ringlap on a table, or similar flat surface, and wipe the exposed surfaceof the lap clean. Insert the disc nose into a ring lap, so that the seatcontacts the lap surface. Oscillate the spindle using 360 degreeoscillations for approximately 15 seconds, then check the spindle tipand disc “pocket” to determine progress. (See Figure 13, below ).

26 Con-14

SECTION X-X

XX

AA

C

B

FIGURE 12

45˚

SPINDLE

DISC

RING LAPFLAT SURFACE

FIGURE 13

e. The spindle nose should be ground into the disc pocket until the bearing is clearly marked. The band positionis shown in Figure 14 (below).

f. Place the disc holder on the spindle, allowing it to rest on the face of the disc collar as previously shown inFigure 9 on page 23. Then assemble the disc holder and new disc. The disc should be free enough to rock onthe spindle tip. If there is no freedom, lower the disc collar until the disc is free to rock slightly initially, approx-imately .001 to .002 inches (0.25 to .05 mm) rock. The disc collar must then be lowered two additional notch-es from this initial position and secured with a stainless steel cotter pin. (See Figure 15, below).

NOTE:Failure to provide the recommended disc rock at assembly will result in a leaking valve.

Con-14 27

SPINDLENOSE

BEARING BAND WIDTH

FLATDIAMETER

FIGURE 14

SEATSTEP

R

DISC

FIGURE 15

28 Con-14

g. The desired band width for Type 2700 valves is shown in Table VIII below. In addition, the finished machinedsize of the spindle nose radius, and the flat diameter for each orifice size, are also shown in this Table.

If the required bearing band cannot be obtained by hand grinding, then this radius should be checked andremachined if necessary.

h. If the band extends too high on the radius it will be difficult to rock the disc, and the disc may lock up underpressure. If the band is too narrow, the spindle may indent the disc and again the rock will be lost.

i. When the bearing area is re-established, clean both surfaces. Then apply lubricant to the spherical surface ofthe spindle tip, and work it into the surfaces by rotating the disc on the spindle.

NOSERADIUS “R”

BEARINGBAND WIDTH

ORIFICE

FLAT DIA.

IN.

MM

IN.

MM

IN.

MM

TYPE 2700 VALVES

TABLE VIII

1

2

3

4

5

6

Q

0.277

7.038

0.371

9.423

0.495

12.573

0.485

12.573

0.495

12.573

0.485

12.573

0.582

17.323

+.000-.004+.000-.102+.000-.004+.000-.102+.000-.005+.000-.127+.000-.005+.000-.127+.000-.005+.000-.127+.000-.005+.000-.127+.000-.005+.000-.127

1/8

3.175

3/16

4.783

1/4

9.358

1/4

8.350

1/4

6.350

1/4

6.350

1/4

6.350

1/8

3.175

1/8

3.175

7/32

5.556

7/32

5.558

7/32

5.556

7/32

5.556

9/32

7.143

Con-14 29

7. GuideInspect the guide inside diameter foregging, and ensure the inside surfaceis smooth. The threads on the outsidemust be in good condition to ensurethe upper ring will adjust, even whenthe valve is hot. If serious galling ispresent, the guide should be replaced.

1. Clearance — The maximum clear-ance between the disc holder andguide should be in accordancewith Table IX.

8. Disc HolderThe surface on the end of the discholder closest to the disc must be freefrom steam erosion. The two smallholes must be open to ensure the pas-sage of steam to the chamber abovethe disc. Make sure the outside diam-eter is not egg shaped and the surfaceis smooth. If any small indication ofgalling is present, polish the high spots with an emery cloth. If serious or large scale galling is present, the discholder should be replaced.

9. DiscInspect the disc seat for steam cuts, nicks, or other damage. If the seat step measures less than dimensionsspecified in Table III, this indicates that the thermal lip has been lapped to the minimum thickness.

Do not machine any ThermoDisc™;however, a disc which is not below min-imum relief can be lapped to removeminor damage.

1. To Lap Disc Seat

a. The above lapping method is alsoused on the disc seat. Whenlapping the disc seat, the discshould be held stationery, butnot rigidly, and the lap movedas above. Use care not tostrike the cone of the disc, asthis would cause the seat to behigh on the inside.

b. The Thermo Disc™ can notbe machined. If, after lapping,Dimension M, in Figure 17(right), does not meet the mini-mum specified in Table IV(right), the disc should bereplaced.

TEMPERATUREORIFICE SIZE MAX. CLEARANCE

#1

#2

#3

#4

#5

#6

#Q

UP TO 750˚FABOVE 750˚F

UP TO 750˚FABOVE 750˚F

UP TO 750˚FABOVE 750˚F

UP TO 750˚FABOVE 750˚F

UP TO 750˚FABOVE 750˚F

UP TO 750˚FABOVE 750˚F

UP TO 750˚FABOVE 750˚F

.005

.008

.008

.012

.010

.015

.012

.018

.011

.017

.014

.014

.020

.020

TABLE IX

BEARINGSURFACE X

SURFACE L M (MIN.)

FIGURE 16

M (MIN.)ORIFICE

MINIMUM SEAT RELIEF

TABLE X

123546Q

.004

.005

.006

.007

.008

.010

.012

c. It may not be necessary to use all the laps at any one time, but having a sufficient supply on hand willsave reconditioning time. The laps should be reconditioned on a flat lapping plate. A lap should not beused on more than one valve without being reconditioned. Laps must be checked for flatness prior touse, and at frequent intervals during use. A lap that is flat within one-half light band is considered sat-isfactory. Information on the Monochromatic Light and optical flat is available, upon request, from theDFC Field Service Department.

d. To recondition a ring lap, wipe all compound from the lapping plate and ring lap, then move the ringlap in a figure-eight motion on a lapping plate. If the lap is not flat, a shadow will be apparent. Toremove the shadow, coat the lapping plate with 1000 Grit Compound and lap the ring, with figure-eightmotions covering the lapping plate.

10. Seat Bushing

1. A DFC reseating machine should be used to recondition badly worn, out of tolerance, bushing seats. Thismachine can be provided by the DFC Service Department, and eliminates the need to remove a valvefrom the unit. The machine is mounted in place of the yoke and cuts the top face, inside diameter, and out-side of the bushing, to establish the correct height, angles, and diameters.

2. The use of a reseating machine is suggested for reconditioningbadly worn seats, or for re-establishing Dimension E per Figure18 (right). Dimension E should be re-established when it is lessthan .010” for orifices 1, 2, 3, 5 and 4; and less than .030” for ori-fices 6 and Q.

3. To lap the bushing seat.

NOTE:If the bushing seat surface requires extensive lapping or reconditioning, a reseating machine should beused prior to lapping.

a. Cover the seat lap face with a light coating of 1-A Clover Compound and gently place the lap on thevalve bushing seat.

NOTE:A heavy coat of lapping compound tends to round off the edges of the seat.

b. Lap, using an oscillating motion in various directions, while holding the lap loosely in the fingers andallowing the weight of the lap to rest on the seat surface. Control the motion of the lap to prevent eitherthe inside or outside edge of the lap from crossing the bushing seat surface. If either edge touches theseat surface, the seat can become scratched and/or rounded.

NOTE:Care should be used not to run off the seating surface with the lap, as this will cause the seat to becomeuneven.

c. Do not lap excessively with a ring lap without resurfacing on a lapping plate. Use a new ring lap, if fur-ther lapping is required, to remove any defect in the seat. To finish lapping the bushing seat, apply alight coating of #1000 Grit Compound to the face of the new lap, and repeat the lapping motiondescribed previously.

d. Remove the ring lap and wipe the lap surface with a clean, lint free cloth, leaving compound on thebushing seat. Replace the ring lap on the seat and lap as above, but without adding compound.Repeat this operation until the seat has a mirror finish. Any evidence of defects, such as gray areasor scratches, will require a repeat of the whole lapping procedure until a mirror finish is attained.

e. While the finer points of lapping and “grinding-in” may be considered as a mechanical art, it is notbeyond the ability of the average mechanic to produce good seats with some practice. No effort hasbeen made in this manual to establish an exact procedure to cover each and every case, because dif-ferent persons can get the same results using their own techniques.

30 Con-14

E

FIGURE 17

f. The following precautions and hints will be of assistance when lapping nozzle and/or disc seats:(1) Two (2) ring laps per valve(2) 1A Clover Grinding Compound per tool list*(3) 1000 Grit Kwik-Ak-Shun Grinding Compound per tool list*(4) Clean, lint free cotton rags

•This tool list is located on page 35 of this manual

3. Before lapping the nozzle and disc seat, the leading edges (inside diameter of seats) of both must beslightly chamfered as follows:

Use a fine grade sandpaper to lightly break the inner edge and outer edge of the nozzle seat and disc seat.The purpose of this is to remove any small metal particles or fins attached to the sharp corner surfaces.Do not exceed .002 inches (.05 mm) chamfer for this purpose.

IX. Re-Assembly

A. General Information

The Type 2700 Safety Valve can be easily re-assembled after required inspection/maintenance of internal partshas been performed. All parts should be clean prior to assembly. See Section XI for recommended compounds,lubricants, and tools.

B. Specific Steps

1. Prior to reinstalling the lower adjusting ring, lubricate the threads of the lower adjusting ring pin and par-tially insert the pin into the valve body. Now the pin can again serve as a “pointer”, or reference point, aspreviously described in Section VII.B.15 of “Disassembly”.

2. Lubricate the threads of the lower adjusting ring, and install the ring in the valve body. Then, turn the loweradjusting ring clockwise until the top of the ring clears the seat.

3. The lower adjusting ring is to be installed in the position it originally held prior to disassembly. To effect thisrelocation, place a clean ring lap on the nozzle seat and turn the lower adjusting ring in a counterclock-wise direction until it makes contact with the ring lap. If the original location of the adjusting ring wasrecorded, simply lower the ring, by turning it clockwise, the same number of notches as was recorded inStep VII.B.15 of “Disassembly”. If information on the original lower ring position is not available, the ringshould be lowered, by turning it clockwise one notch for every 600 psig (20.7 bar) of set pressure. Thisposition represents a staring position. See Note below.

NOTE:For a valve set pressure of 1200 psig (81.6 bar), the ring will have to be lowered two (2) notchesbelow the bushing seat. This will be the starting position, with the final position being determinedduring field testing.

4. Once the lower adjusting ring is in its correct location, lock it in place by installing in the lower adjustingring pin. Verify that the lower ring is capable of a slight movement. If the lower ring does not move, the pinis too long. Should this be the case, grind the end of the pin slightly to shorten it, while retaining the orig-inal tip contour, then reinstall the pin.

5. If the upper adjusting ring has been removed from the guide, lubricate the ring threads and re-install thering on the guide.

Con-14 31

6. Install the adjusting ring and guide assembly into the valve base such that the scribe marks will be visiblefrom the valve outlet or the inspection port.

7. Measure the overall length of the upper ring and guide assembly. Adjust the upper ring to the DimensionC recorded in Step 12 of Section VII.B., Disassembly. Observe the marks made on the ring and guide andadjust the ring to align the marks. Recheck the overall length of the adjusting ring and guide assembly toassure that the upper ring is in its original position.

8. Measure from the top of the guide to the bush-ing seat with a depth micrometer. SubtractDimension B as measured in Step 11, SectionVII.B., of Disassembly, from the dimension pre-viously measured. The difference is the distancethe upper adjusting ring must be lowered. Referto Table XI (right) to determine the number ofnotches that the ring is to be lowered.

9. Once the upper adjusting ring/guide assembly isproperly set, lubricate the guide seating surfacein the valve base, and re-install the assemblyinto the base, then, lubricate the threads of theupper adjusting ring pin, and lock the ring/guideassembly in place by installing in the pin.

10. Verify that the upper ring is capable of a slight movement. If the upper ring does not move, the pin is toolong. Should this be the case, grind the end of the pin to shorten it, while retaining the original tip contour,then reinstall the pin.

11. Clamp the spindle in a padded vise, with the “ball end” of the spindle upward.

12. Verify that the spindle bearing has been ground to the disc pocket, as specified in Section VIII.B.6.e., ofthis manual.

NOTE:This step must be accomplished before proceeding with re-assembly.

13. If the lift stop was removed from the spindle, lubricate the threads and install the lift stop. Do not install thecotter pin at this time.

14. If the disc collar was removed, lubricate the threads and install on the spindle. Do not install the cotter pinat this time. Then, carefully lower the disc holder onto the spindle, allowing it to sit on the face of the disccollar.

15. Thread the disc onto the spindle, ensuring that the disc is free to “rock” on the spindle tip as specified inSection VIII.B.6.f., of this manual. If disc “rock” is not satisfactory, correct the cause before proceeding.

16. When disc “rock” is satisfactory, remove the disc and disc holder, and secure the disc collar with a stain-less steel cotter pin. Using side cutters, carefully cut-off excess cotter pin legs, and bend the cotter pin fora neat installation.

17. Lubricate the spindle tip, and assemble the disc holder and disc to spindle. Recheck the rock.

18. Remove complete assembly from the vise, being sure to protect the disc seat surface at all times.

19. Prior to installing the spindle assembly into the valve base, wipe the disc seat with a soft, lint-free cloth.Then, carefully install the spindle assembly into the guide.

32 Con-14

ORIFICEVERTICAL RING TRAVEL

FOR EACH NOTCHOF ADJUSTMENT

TABLE XI

123546Q

.0025

.0020

.0015

.0015

.0015

.0009

.0010

20. Lubricate the compression screw threads with “Fel-Pro Nickel Ease”, and thread into the yoke. Install thelower washer on the spring and, then, install the upper washer on the spring. Lubricate the bearing assem-bly with “Fel-Pro Nickel Ease” and install on the upper spring washer.

21. For orifice sizes 5-Q, next place the compression screw adaptor on top of the bearing.

22. Place the spring and bearing assembly into the yoke.

23. Lubricate the yoke studs with “Fel-Pro Nickel Ease”. Carefully lower the yoke/spring assembly over thespindle while aligning the yoke as shown in Figure 5 on page 16 of this manual. Ensuring that the yokevent hole is on the side of the valve opposite the inspection port, make certain that the yoke does not bindon the lift stop. Care should then be taken to tighten down the yoke evenly, so as to prevent distortion andmisalignment.

24. Raise the lift stop until it contacts the yoke. Then, lower the lift stop to achieve the proper dimension shownin Table XII (below), or the restricted lift identified on the valve nameplate.

NOTE: DO NOT DEVIATE FROM STAMPED NAMEPLATE LIFT.

The lift stop must be adjusted to the rated lift marked on the nameplate, plus an additional amount as indicated.The additional lift is to compensate for heated condition of the lower spindle when the valve is in operation.

NOTE:For all Type 2700 valves, one revolution of the lift stop equals .0625 in. of lift. There are six (6) notches onthe lift stop, so each notch of adjustment represents approximately .010 lift.

Con-14 33

ORIFICEBORE

DIAMETERRATED

LIFT

REQUIREDADDITION

LIFT

TABLE XII

123546Q

1.125 (28.6mm)1.350 (34.3mm)1.800 (28.6mm)2.062 (52.4mm)2.250 (57.2mm)

3.000 (76.2 mm)3.948 (100.3mm)

.282 (7.16mm)

.338 (8.59mm)

.450 (7.16mm).517 (13.13 mm).563 (14.30mm).750 (19.05mm).985 (25.02mm)

.020 (.508mm)

.020 (.508mm)

.030 (.762mm).040 (1.016mm).050 (1.270mm).060 (1.524mm).070 (1.778mm)

25. Secure the lift stop with acotter pin.

26. Refer to Figure 19 (right)and establish DimensionA to that previouslyrecorded in SectionVII.B.4 of “Disassembly”.

27. Ensure that the topwasher arms do notremain in contact with theyoke, after each com-pression screw adjust-ment.

28. The valve is now readyfor testing, after whichthe following steps canbe taken:

a. Following testing, the compression screw should be locked firmly in place with the lock nut.

b. Install the release nut onto the spindle; then, thread clockwise until the release nut is fully engaged onthe spindle thread and the cotter pin hole is aligned. For numbers 1, 2, 3, and 4 orifices, run the releasenut down enough to allow the lock nut to fully engage, and then, loosely install the lock nut.

c. Install the cap over the release nut, and seat the cap firmly into place on the yoke. Install the top leverin the cap and, then, insert the top lever pin through the top lever and cap holes.

d. Adjust the release nut, until it clears top lever by 1/8 inches (3.2 mm). Remove the lever pin, top leverand cap. Next, insert a cotter pin through the release nut slots and the spindle, and spread the cotterpin ends. Re-assemble the cap with the drop lever, top lever, and top lever pin. Install a cotter pin tolock the top lever pin in place. A final check should be made to ensure the proper clearance existsbetween the release nut and the top lever. Finally, tighten the cap set screw to secure the cap.

29. After testing the valve for proper set point and blowdown, the ring pins, top lever pin and lift stop shall besealed. Run a continuous wire through the sealing wire holes leaving both ends in such a manner that alead seal may be threaded to them. Before crimping the seal, assure that the parts being sealed can notbe tampered with, without removing the seal.

34 Con-14

DEPTH MICROMETER

YOKE

ASPINDLE

COMPRESSION SCREW

COMPRESSION SCREW LOCKNUT

FIGURE 18

Con-14 35

Problem

No Action,Valve does not gointo full lift.

Simmer

Valve Leakingand/or exhibitserratic poppingactions.

Hangup, or valvedoes not closecompletely.

Excessiveblowdown

Chatter or shortblowdown

Possible Cause

A. Upper ring too high.

B. Foreign material trappedbetween disc holder & guide.

A. Lower ring too low.

B. Steam line vibrations.

A. Damaged seat

B. Part misalignment.

C. Disc has insufficient rock.

D. Discharge stack binding onoutlet.

A. Lower ring too high.

B. Foreign material.

A. Upper ring too low.

B. Exhaust pressure too high.

A. Upper ring too high.B. Inlet piping pressure drop

too high.

C. Yoke vent is plugged.

Corrective Action

A. Increase blowdown as outline inSection X.C.4. of this manual.

B. Disassemble valve and correct anyabnormality as outline in Section XI.of this manual. Inspect system forcleanliness

A. Adjust per Section X.C.2. of thismanual.

B. Investigate and correct cause.

A. Disassemble valve, lap seating sur-faces, replace disc if required, asoutlined in Section XII.B. of this man-ual.

B. Disassemble valve, inspect contactarea of disc and nozzle, lower springwasher or spindle, compressionscrew, spindle straightness, etc.

C. Disassemble valve and check discrock per Section XIII.E. of this manual.

D. Correct as required.

A. Move lower ring counterclockwise,one notch per adjustment, until prob-lem is eliminated.

B. Disassemble valve and correct anyabnormal condition. Inspect systemfor cleanliness.

A. Decrease blowdown as outlined inSection X.C.3. of this manual.

B. Decrease exhaust pressure byincreasing discharge stack area.

A. Lower upper ring.B. Reduce inlet pressure drop to less

than one-half of required valve blow-down by redesigning inlet piping.

C. Clear yoke vent.

X. Trouble Shooting The Type 2700 Valve

XI. Maintenance Tools and SuppliesLAPPING TOOLSThe following tools are required for proper maintenance of Consolidated® Type 2700 Safety Valve seats:

Ring LapThe ring lap is used for lapping the nozzle and disc seats.

36 Con-14

Lapping PlateThe lapping plate is used for reconditioning the ring laps. Only one 11'' diameter plate is required for all sizes ofring laps.

Resurfacing Plate – 11'' Diameter. (Part No. 0439004)

Lapping CompoundLapping compound is used asa cutting medium for lappingand polishing the seats andbearing surfaces in Type 2700Safety Valves.

VALVE ORIFICE**LAP

PART NO.

123546Q

1672806167280716728081672810167280916728111672812

VALVE ORIFICEGAG

PART NO.

123546Q

VJ5920VJ592043630014363001436300143630014363001

Brand Grand GritLappingFunction

SizeContainer Part No.

CloverCloverKwik-Ak-Shun

1AC-

3202201000

GeneralCoarse

Polishing

4 oz.4 oz.1 lb.2 oz.

199-3199-2199-11199-12

Location Lubricant

Bearing Points1. Spindle/Disc2. Compression Screw/Top

Spring Washer3. Spindle/Bottom Spring

WasherAll ThreadsAll Nut Contact Faces

Fel-Pro Nickel Ease

LubricantGags

Rings Laps*

* Note: One set of (2) Ring Laps is recommended for each ori-fice valve in service, to assure ample flat laps are available at alltimes.

** Note 2: Valve orifice number is third digit of valve type number,e.g. a2737A valve has a #3 orifice.

Con-14 37

2700ORIFICE

YOKE STUDSIZE

WRENCHSIZE

#1

#2

#3

#5

#4

#6

#Q

5/8-11

5/8-11

3/4-10

7/8-9

7/8-9

1-1/8-7

1-1/8-7

1-1/16

1-1/16

1-1/4

1-7/16

1-7/16

1-13/16

1-13/16

Wrench Sizes

XII. Service Parts Inventory PhilosophyThe basic objectives in formulating a replacement parts plan are:

• PROMPT AVAILABILITY

• MINIMUM DOWNTIME

• SENSIBLE COST

• SOURCE CONTROL

Guidelines for establishing meaningful inventory levels:

PARTCLASSIFICATION

REPLACEMENTFREQUENCY

CLASS I MOST FREQUENT

CLASS II

CLASS III

CLASS IV

CLASS V

LESS FREQUENTBUT CRITICAL

SELDOM REPLACED

HARDWARE

PRACTICALLY NEVERREPLACED

PARTS CLASSIFICATION

Consult the Recommended Spare Parts list (see Section XX of this manual) to define the parts to be included inthe inventory plan.

Select parts and specify quantities.

XIII. Manufacturer’s Field Service & Repair Program

A. Factory Setting vs. Field SettingEvery CONSOLIDATED® Safety Valve is set and adjusted on steam before shipment from the factory. Initial ringadjustments are made at the factory. However, actual field operating conditions may vary considerably from fac-tory test conditions.

Conditions beyond the manufacturer’s control that affect Safety Valve operation include:

• Improper header nozzle design.• Quality of media being discharged.• Discharge piping stresses and back pressure.• Ambient temperature.• Shipping or storage damage.• Improper gagging• Damage due to foreign material in the steam.

Final Safety Valve adjustments made on the actual installation are the best means of ensuring that the valves per-form in compliance with the ASME Boiler Code and/or other applicable code requirements.

B. Field ServiceUtilities and Process Industries expect and demand service on a moment’s notice. CONSOLIDATED Field Servicecan be depended upon for prompt response, even in extreme off-hour emergency situations.

DFC maintains the largest and most competent field service staff in the industry. Service Engineers are located atstrategic points throughout the United State to respond to customer’s requirements for service. Each ServiceEngineer is factory trained and long experienced in servicing Safety Valves. DFC Service Engineers restore discand nozzle critical dimensions, which effect valve performance, and are capable of modernizing valves in the field.

It is highly recommended that the professional talents of a DFC Field Service Engineer be employed to make finalfield adjustments during the initial setting of all CONSOLIDATED Safety Valves.

All Field Service Engineers’ activities are coordinated from the Alexandria, Louisiana, Field Service Office. Uponreceipt of a purchase order number authorizing the trip, the engineer is dispatched.

Contact: Field Service Department, Field Service Supervisor, at (318) 640-6055.

C. Factory Repair Facilities

The factory at Alexandria, Louisiana maintains a Consolidated Repair Center. The repair department, in conjunc-tion with the manufacturing facilities is equipped to perform specialized repairs and product modifications, e.g.bushing replacements, hydroset calibrations, electromatic relief valve repairs, etc.

D. Safety Valve Maintenance TrainingRising costs of maintenance and repair in the Utility and Process Industries indicate the need for trained mainte-nance personnel. Dresser Industrial Valve Operation conducts service seminars that can help your maintenanceand engineering personnel to reduce these costs.

Seminars, conducted either at your site, or at our Alexandria, Louisiana manufacturing plant, provide participantswith an introduction to the basics of preventative maintenance necessary to minimize downtime, reduce unplannedrepairs and increase valve safety. While these seminars do not make “instant” experts, they do provide the partic-ipants with “hands on” experience with Consolidated Valves. The seminar also includes valve terminology andnomenclature, component inspection, trouble shooting, setting and testing, with emphasis on the ASME Boiler andPressure Vessel Code.

For further information, Please contact the Product Training Manager by fax at (318) 640-6041, or telephoneat (318) 640-6054.

38 Con-14

Glossary

(Paraphrased from ASME PTC 25.3)

Back PressureBack pressure is the static pressure existing at the outlet of a safety valve device due to pressure in the dischargesystem.

BlowdownBlowdown is the difference between actual popping pressure of a safety valve and actual reseating or closing pres-sure expressed as a percentage of set pressure, or in pressure units.

ChatterChatter is abnormal, rapid reciprocating motion of the moveable parts of a safety valve, in which the disc contactsthe seat.

DiscA disc is the pressure containing moveable member of a safety valve which effects closure.

Leak Test PressureLeak test pressure is the specified inlet static pressure at which a quantitative seat leakage test is performed inaccordance with a standard procedure.

LiftList is the actual travel of the disc away from closed position when a valve is relieving. Rated lift is the design liftat which a valve attains its rated relieving capacity.

Lifting LeverA lifting lever is a device for manually opening a safety valve, by the application of external force to lessen thespring loading which holds the valve closed.

Nozzle/Seat BushingA nozzle is the pressure containing element which constitutes the inlet flow passage and includes the fixed portionof the seat closure.

Safety ValveA safety valve is a pressure relief valve actuated by inlet static pressure and characterized by rapid opening or popaction, normally used for steam service.

Set PressureSet pressure is the value of increasing inlet static pressure at which the disc moves in the opening direction at afaster rate as compared with corresponding movement at higher or lower pressures. It applies only to safety orsafety relief valves on compressible fluid service.

SeatA seat is the pressure containing contact between the fixed and moving portions of the pressure containing ele-ments of a valve.

SimmerSimmer is the audible or visible escape of fluid between the seat and disc at an inlet static pressure below the setpressure and at no measurable capacity. It applies to safety valves on compressible fluid service.

Con-14 39

40 Con-14

THE DRESSER FIELD SERVICE ORGANIZATION IS UNEQUALED.For prompt field service, please call Dresser Valve and Controls

Division Service Department, Alexandria, Louisiana.Normal Working Hours – (318) 640-6055

After Hours, Weekends, Holidays – (318) 640-2250

Location of Service Engineers

INDIANA, Crawfordsville .............................1KENTUCKY, Maysville.................................2LOUISIANA, Alexandria...............................3PENNSYLVANIA, Philadelphia ....................4SOUTH CAROLINA, Charleston .................5VIRGINIA, Richmond...................................6GEORGIA, Atlanta.......................................7

Service Department

1

2

3

4

5

6

7

Con-14 41

Notes:

42 Con-14

Notes:

Con-14 43

Notes:

Consolidated® is a registered Trademark of Dresser, Inc., all other referencedBrands or trade Names are Trademarks of their respective companies.

Copyright 2002. Dresser, Inc.

04/02

44 Con-14

UNITED STATESDresser Flow ControlDresser, Inc.LA. Hwy. 3225 @ U.S. Hwy. 167 NP.O. Box 1430Alexandria, Louisiana 71309-1430Telephone 1-318-640-2250Fax 1-318-640-6222

Northern RegionDresser Flow ControlDresser, Inc.85 Bodwell StreetAvon, Massachusetts 02322Telephone 1-508-586-4600Fax 1-508-941-5497

Southern RegionDresser Flow ControlDresser, Inc.11100 West Airport Blvd.Stafford, TX 77477-3014Telephone 1-281-568-2211Fax 1-281-568-6731

BRAZILDresser Industria E Comercio Ltda.Rua Senador Verqueiro, 43309521-320 Sao Caetano Do SulSao Paulo, BrazilTelephone (55) 11-453-5511Fax (55) 11-453-5565

CANADADI Canada, Inc.5010 North Service RoadBurlington, Ontario L7L 5R5CanadaTelephone 1-905-335-3529Fax 1-905-336-7628

DI Canada, Inc.#333-5th Ave. SW Suite 1100Calgary, AlbertaT2P 3B6 CanadaTelephone 1-403-290-0001Fax 1-403-299-1526

CHINADresser Valve DivisionSuite 2403, Capital Mansion6 Xinyuannan Road, Cho YangDistrictBeijing, China 100040Telephone 86-10-6466-1164Fax 86-10-6466-0195

FRANCEDresser Produits Industrials4 Place de Saverne92971 CoabevoieTelephone 33-1-49-04-9000Fax 33-1-49-04-9020

GERMANYDresser Valve EuropeKlein-Kollenburg Strasse 78-80P.O. Box 120847877 Willich, GermanyTelephone (49) 2156-91890Fax (49) 2156-41058

ITALYDresser Italia S.p.A.Masoneilan OperationVia Cassano 77P.O. Box 12380020 Casavatore (Naples)ItalyTelephone (39) 81-789-2111Fax (39) 81-789-2259

JAPANNigata Masoneilan Co., Ltd.Dresser Valve Division20th Floor Marive East TowerWBG 2-6 Nakase, Mihama-Ku,Chiba-shi, Chiba 261-7120 JapanTelephone (81) 43-297-9222Fax (81) 43-299-1115

KOREADresser Korea, Inc.#2107 Kuk Dong Building60-1, 3-Ka, Choongmu-ro, Chung-KuSeoul, KoreaTelephone (82) 2-274-0792Fax (82) 2-274-0794

MALAYSIADresser Valve DivisionFar East Regional OfficeBusiness Suite 19A-9-1, Level 9UOA Centre, No. 19 Jalan Pinang50450 Kuala Lumpur, West MalaysiaTelephone (60-3) 2163-2322Fax (60-3) 2163-6312

MEXICODresser Valve de Mexico, S.A. deC.V.Av. Henry Ford No. 114 Esq. FultonFraccionamiento Ind. San Nicholas54030 Tlalnepantla, Estado de MexicoTelephone (52) 5-310-9863Fax (52) 5-310-5584

SAUDI ARABIADresser Al Rushaid Valve& Instrument Co., Ltd.P.O. Box 10145Jubail Industrial City 31961Kingdom of Saudi ArabiaTelephone (966) 3-341-0278Fax (966) 3-341-7624

SINGAPOREDresser Singapore, Pte. Ltd.Dresser Valve Division16, Tuas Ave 8Singapore 639231Telephone (65) 861-6100Fax (65) 861-7172

SOUTH AFRICADresser Limited, South Africa BranchValve DivisionP.O. Box 2234, 16 Edendale RoadEastleigh, Edenvale 1610Republic of South AfricaTelephone (27) 11-452-1550Fax (27) 11-452-2903

Dresser Valve DivisionPlot 90, Ajose Adeogun StreetVictoria Island, LagoeLagos, NigeriaTelephone (23) 41-2620765Fax (23) 41-2620768

Sales Offices

FOR YOUR GREEN TAG

CENTER IN USA/CANADA

CALL 1-800-245-VALVor contact the locations listed above

for international service.

SPAINDresser Valve DivisionMasoneilan, S.A.C/Murcia 39 C08830 Sant Boi deBarcelona, SpainTelephone: (34) 93-652-6430Fax: (34) 93-652-6444

UNITED ARAB EMIRATESDresser Valve DivisionMiddle East OperationsP. O. Box 61302Jebel Ali Free ZoneUnited Arab EmiratesCourier:Units Nos. JA01 + JA02Roundabout 8Jebel Ali Free ZoneUnited Arab EmiratesTelephone (971) 4-838752Fax (971) 4-838038

UNITED KINGDOMDI UK Ltd.Unit 4, Suite 1.1Nobel HouseGrand Union Office ParkPacket Boat Ln.Uxbridge, MiddlesexEngland UB8 2GHTelephone (44) 1895-454900Fax (44) 1895-454919Telex (851) 627039