Consolidated® MPV™

Modular Pilot
INSTALLATION, OPERATION Valve Types
AND MAINTENANCE MANUAL 39MV07-2
39MV37-2

39PV07-2
Consolidated Pilot Operated ® 39PV37-2

Safety Relief Valve

Type 2900 Series

Series
2900

OPTIONS:
• Backflow Preventer
• Filter
• Manual Blowdown
• Pressure Differential
Switch
• High Temperature
• Low Temperature
• Dirty Service

CON-29
CON-29
March,
March, 2003
2003
P.O. Box 1430
Alexandria, Louisiana 71309-1430 (USA)
Contents
Section Subject Page
I Cover .................................................... 1
II Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
III Product Safety Sign and Label System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IV Safety Alerts! Read - Understand - Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
V Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VI Handling and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VII Pre-installation and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VIII Hydrostatic Testing and Service Considerations . . . . . . . . . . . . . . . . . . . . . . . 10
IX General Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. Pilot Valve Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. Main Valve Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
X. 2900 Series MPV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A. 2900 Series with Type 39-PV (Pop) Pilot . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. 2900 Series with Type 39-MV (Modulating) Pilot . . . . . . . . . . . . . . . . . . . 15
XI Cross Sectional Drawings and Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . 17
A. 39-PV Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
B. 39-MV Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C. 39-PV Dirty Service Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D. 2900 Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
XII. Restoring Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
XIII. General Planning for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
XIV Disassembly of the 2900 Pilot Operated Safety Relief Valve . . . . . . . . . . . . . . 22
A. Removal of the Pilot Valve from the Main Valve . . . . . . . . . . . . . . . . . . . . 22
B. Disassembly of the Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
D Parts Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1. Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2. Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3. Thermodisc® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4. Disc Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5. Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6. Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. Coverplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 Con-29
Contents
Section Subject Page
XV. Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
A. General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
B. Nozzle Seat Width - Lapped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
C. Precautions and hints for Lapping Seats . . . . . . . . . . . . . . . . . . . . . . . . . 31
D. Grinding O-ring Metal seating surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . 32
E. Reconditioning of Laps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F. Machining Nozzle Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
G. Lapping the Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
H. Machining the Disc Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
I. Coverplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
J. Bearing Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
XVI Assembly of 2900 Main Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B. Specific steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
XVII Disassembly of the 39MPV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A. Removal and Disassembly of the Liquid or Gas Modulator . . . . . . . . . . . . 38
B. Disassembly of the 39 MPV Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 38
C. Disassembly of the Field Test Connection . . . . . . . . . . . . . . . . . . . . . . . . 39
D. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
XVIII Inspection and Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A. Pilot Valve Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
B. Field Test Connection Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 40
C. Modulator Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
XIX Pilot Valve Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
XX Assembly of the 39-MPV Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
A. Assembly of the Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
B. Assembly of the Field Test Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
C. Assembly of the Liquid or Gas Modulator. . . . . . . . . . . . . . . . . . . . . . . . . 44
XXI Assembly of the Pilot to the Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
XXII Testing General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
A. Calibration of the Pilot Valve Prior to mounting
on the main valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1. Pilot Calibration and Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 48
2. Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3. Pilot Calibration and Test Procedure
PV and MV Included . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Contents
Section Subject Page
4. Final Set Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5. Final Seat Tightness and Leakage Test . . . . . . . . . . . . . . . . . . . . . . . 51
B. Testing on the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
XXIII 2900 Pilot Valve Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
A. Available options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
B. Backflow Preventer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
C. Auxiliary Canister Supply Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
D. Manual Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
E. Dirty Service with Auxiliary Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
F. Heat Exchanger used on Cryogenic Service . . . . . . . . . . . . . . . . . . . . . . 56
G. Heat Exchanger used on Steam and Hot Service. . . . . . . . . . . . . . . . . . . 57
H. Optional Line Filter (Standard with Steam Service) . . . . . . . . . . . . . . . . . 57
I. Assembly of Options and Alternative Piping . . . . . . . . . . . . . . . . . . . . . . . 58
XXIV Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
XXV Replacement Parts Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
A. Basic Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
B. Identification and Ordering Essentials . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
C. Positive Identification of Main Valve and Pilot Valve
Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
D. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
XXVI Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A. Insert Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
B. Adjuster Top Seal Insertion Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
C. Disc Holder and Guide Removal and Assembly Tool. . . . . . . . . . . . . . . . . 64
XXVII Replacement Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
XXVIII Manufacturer’s Field Service, Repair, and Training Programs . . . . . . . . . . . . . 69
XXIX Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
XXX Office Locations and Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4 Con-29
H
! ATTENTION SECTION III.
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 oriented
rectangles as shown in the representative examples (left and below), consisting
of three panels encircled by a narrow border. The panels can contain four mes-
sages which communicate:

• The level of hazard seriousness.

Do not drop or strike.
• The nature of the hazard.
• The consequence of human, or product, interaction with the hazard.
ATTENTION • The instructions, if necessary, on how to avoid the hazard.
Hazards or unsafe prac-
tices which COULD
result in product or
property damage.

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

The center panel contains a pictor-

Know all valve ial which communicates the nature
exhaust/leakage points
to avoid possible severe
of the hazard, and the possible
personal injury or death. consequence of human or product
interaction with the hazard. In
WARNING some instances of human hazards
Hazards or unsafe prac-
tices which COULD the pictorial may, instead, depict
result in severe personal what preventive measures to take,
injury or death.
such as wearing protective equip-
ment.

H! CAUTION The bottom panel may contain an

instruction message on how to
Do not remove bolts if
avoid the hazard. In the case of
pressure in line, as this human hazard, this message may
will result in severe also contain a more precise defini-
personal injury or death. tion of the hazard, and the conse-
quences of human interaction with
the hazard, than can be communi-
DANGER cated solely by the pictorial.
Wear necessary
protective equipment to Immediate hazards
prevent possible injury.
which WILL result in
CAUTION severe personal
Hazards or unsafe
practices which COULD
injury or death.
result in minor
personal injury.

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 SECTION IV.
H! WARNING H! WARNING Safety Alerts!
Read – Understand – Practice
1. WARNING: Allow the system to cool to room
temperature before cleaning, servicing or
repairing the system. Hot components or fluids
can cause severe personal injury or death.
2. WARNING: Always read and comply with safety
labels on all containers. Do not remove or
Improper use or repair of
pressurized media or deface the container labels. Improper handling
Heed all container or misuse could result in severe personal injury
steam device may result
label warnings.
in severe personal or death.
injury or death.
3. WARNING: Never use pressurized fluids/gas/air
to clean clothing or body parts. Never use body

H! WARNING H! WARNING parts to check for leaks or flow rates or areas.

Pressurized fluids/gas/air injected into or near
the body can cause severe personal injury or
death.
4. WARNING: It is the responsibility of the owner
to specify and provide guarding to protect per-
XXX sons from pressurized or heated parts. Contact
with pressurized or heated parts can result in
severe personal injury or death.
5. WARNING: Do not allow anyone under the influ-
Provide and use Do not work with valves ence of intoxicants or narcotics to work on or
guarding to prevent while under the around pressurized systems. Workers under the
contact with heated influence of intoxicants influence of intoxicants or narcotics are a haz-
and/or pressurized parts. or narcotics. ard both to themselves and other employees
and can cause severe personal injury or death
to themselves or others.
H! WARNING H! WARNING 6. WARNING: Incorrect service and repair could
result in product or property damage or severe
personal injury or death.
7. WARNING: This valve product line is not intend-
ed for radioactive nuclear applications. Some
valve products manufactured by Dresser, Inc.
may be used in radioactive environments.
Consequently, prior to starting any operation in a
radioactive environment, the proper “health
physics” procedures should be followed, if
Improper tools or applicable.
All potential hazards improper use of right
may not be covered in tools could result in 8. WARNING: Use of improper tools or improper
this manual. personal injury or use of right tools could result in personal injury
product damage.
or product or property damage.

6 Con-29
9. WARNING: These WARNINGS are as complete as possible but not all-inclu-
sive. Dresser cannot know all conceivable service methods nor evaluate all
potential hazards.
H! WARNING
Cautions Concerning Product Warning Labels

1. CAUTION: Heed all service manual warnings. Read installation instructions

before 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. Know nuclear “health
physics” procedures, if
applicable, to avoid
NOTE: possible severe personal
Any service questions not covered in this manual should be referred to injury or death.
Dresser’s Service Department, Phone (318) 640-6055.

H! CAUTION

Heed all service manual

warnings. Read
installation instructions
before installing valve(s).

H! CAUTION

Wear necessary
protective equipment
to avoid possible
personal injury.

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 SECTION V.
H! CAUTION Warranty Information
*Warranty Statement – Dresser, Inc. warrants that its products and work will
meet all applicable specifications and other specific product and work require-
ments (including those of performance), if any, and will be free from defects in
material and workmanship.

CAUTION: Defective and nonconforming items must be held for Dresser's inspec-
tion and returned to the original F.O.B. point upon request.

Incorrect Selection or Misapplication of Products - Dresser, Inc. cannot be

Defective and responsible for customer's incorrect selection or misapplication of our products.
nonconforming items
must be inspected by Unauthorized Repair Work – Dresser, Inc. has not authorized any non-Dresser
Dresser. affiliated repair companies, contractors or individuals to perform warranty repair
service on new products or field repaired products of its manufacture. Therefore,
customers contracting such repair service from unauthorized sources must do so
at their own risk.
H! CAUTION Unauthorized Removal of Seals – All new valves and valves repaired in the field
by Dresser Field Service are sealed to assure the customer of our guarantee
SEA
against defective workmanship. Unauthorized removal and/or breakage of this
LED seal will negate our warranty.

*Refer to Dresser's Standard Terms of Sales for complete details on warranty and
limitation of remedy and liability.

Removal and/or breakage

of seal will negate our
warranty.

8 Con-29
SECTION VI.
HANDLING H! CAUTION
1. CAUTION: Flanged valves, either crated or uncrated, should always be kept
with the inlet flange down, in the normal installation position, to prevent mis-
alignment and damage to internal parts.

2. CAUTION: Pressure relief valves, either crated or uncrated, should never be

subjected to sharp impact. Particular care should be exercised when the
valve is being loaded onto or unloaded from a truck, and when it is being
hoisted into position for installation.

3. CAUTION: Never attempt to lift the full weight of the valve by the pilot assem-
bly, external devices or tubing. Lift the valve by the eyebolts shown on figure Always keep valve in an
safety sign. upright position when
handling or storing.
STORAGE

Pressure relief valves should be stored in a dry environment and protected from
the weather. They should not be removed from the skids or crates until immedi-
ately prior to installation on the system. This includes both inlet and outlet protec- H! CAUTION
tors.

FLANGE PROTECTORS

Flange protectors and sealing plugs should not be removed until the valve is to
be installed on the system. This includes both inlet and outlet protectors.

Do not subject valves

to sharp impact.

H! CAUTION

Never attempt to lift the

valve by anything other
than the eyebolts.

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 SECTION VII.
H! CAUTION PRE-INSTALLATION AND INSTALLATION
CAUTION: After the valve is uncrated and protective devices removed, exercise
care to prevent dirt and other foreign matter from entering either the inlet or the
outlet port.
Mounting Instructions –
CAUTION: Pressure relief valves should be mounted in a vertical, upright posi-
tion. Installing a valve in any other position will adversely affect its operation in
varying degrees as a result of induced misalignment of parts.
No stop valve should be placed between the pressure vessel and its relief valve
except as permitted by Code regulations. If a stop valve is located between the
pressure vessel and pressure relief valve, its port area should equal or exceed the
nominal internal area of the piping to the relief valve inlet. Pressure drop in the
Prevent dirt from entering piping from the vessel to the relief valve must not exceed 3% of the valve set pres-
outlet or inlet port. sure when it is flowing at full capacity.
Flanges and gasket surfaces must be free from dirt and debris when valves are
installed. Flange bolts should be tightened evenly to prevent distortion of the valve
body and inlet nozzle. The length, size and maximum change in height of the
H! CAUTION remote sensing line should be verified through analysis, taking into account the
requirement to re-charge the dome through the pilot valve. On request, Dresser
will assist in the analysis to determine the appropriate length, size and maximum
change in height for the sensing line and to determine the correct capacity of the
pressure relief valve. Before start-up, be sure all threaded joints are tight and
secure.

SECTION VIII.
Hydrostatic Testing –
Prior to hydrostatic test of the pressure vessel system, the pilot-operated safety
relief valve should be removed and the mounting flange for the valve blocked.
Service Considerations –
Always install valve in a For best performance, pressure relief valves should be serviced annually unless
vertical, upright position maintenance history dictates otherwise. They should be located for easy access
and removal for service.
Remote Sensing –
If the pressure drop between the source of pressure in the equipment to be pro-
tected and the pressure at the relief valve inlet exceeds 3%, the sensing line to
the pilot valve should be connected directly to the equipment being protected. The
optional sensing ring should not be installed. For remote sensing, 3/8-inch diam-
eter tubing is adequate for distances up to 10 feet, (3.048 m).
For block valve and other special installation features consult API 520 or the fac-
tory.

SECTION IX.
General Introduction
*"A pilot operated pressure relief valve is a pressure relief valve in which the major
relieving device is combined with and is controlled by a self-actuated auxiliary
pressure relief valve."
*Source: ASME Code, Section VIII – Div. 1, Paragraph UG-126.
The CONSOLIDATED® Modular Pilot Valve (MPV) is designed to provide reliable
performance characteristics and stable operation within a pressure range of 15 to
3750 psig.
10 Con-29
SECTION IX.A
Pilot Valve Introduction
Standard pilot construction consists of 316SS parts with nitrile o-rings with Teflon® based seals throughout.
Standard Steam and High Temperature Pilot Construction consists of 316SS parts with Teflon® o-rings and seals.
Alternate materials can be provided by contacting the factory.

Pilot Valve Features

• One pilot fits all main valves • Reduces icing and clogging
• Standard o-ring seals • Field test connection
• Superior seat tightness • Remote sensing
• Accurate adjustment of blowdown and set point • External blowdown adjustments
• Positive closure after blowdown

Service and Applications

Model Service Pressure Range Temperature Range

39PV07 Gas, Air, Steam 15 psig to 750 psig –40˚F to +505˚F
GS, SS, or Liquid 1.05 kg/cm2 to 52.7 –40˚C to +262˚C
or LS kg/cm2
39MV07 Gas, Air or 15 psig to 750 psig –40˚F to +505˚F
GS or SS Steam 1.05 kg/cm2 to 52.7 –40˚C to +262˚C
kg/cm2
39MV07 Liquid 15 psig to 750 psig –40˚F to +505˚F
LS 1.05 kg/cm2 to 52.7 –40˚C to +262˚C
kg/cm2
39PV37 Gas, Air, Steam 751 psig to 3750 psig –40˚F to +505˚F
GS, SS or Liquid 52.8 kg/cm2 to 263.6 –40˚C to +262˚C
or LS kg/cm2
39MV37 Gas, Air or 751 psig to 3750 psig –40˚F to +505˚F
GS or SS Steam 52.8 kg/cm2 to 263.6 –40˚C to +262˚C
kg/cm2
39MV37 Liquid 751 psig to 3750 psig –40˚F to +505˚F
LS 52.8 kg/cm2 to 263.6 –40˚C to +262˚C
kg/cm2
TABLE I

Note: With the installation of the heat exchanger, temperature range may be expanded to -450°F to 1200°F.

Main Valve pressure and temperature limitations are combined in pressure class categories according to ANSI
Standards. Conversely, the pressure and temperature limits of the Pilot Valve are presented separately.

NOTE:
WHEN REPLACING OR REPAIRING THE MAIN VALVE AND PILOT VALVE ASSEMBLY, PAY PARTICULAR
ATTENTION TO THE PRESSURE AND TEMPERATURE LIMITATIONS FOR BOTH THE MAIN VALVE AND
PILOT VALVE TO ENSURE COMPATIBILITY.

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 SECTION IX.B
Main Valve Introduction
The CONSOLIDATED® 2900 Pilot Operated Safety Relief Valve (POSRV) cast bodies are designed to meet the
API 526 spring loaded specified inlet and outlet connection combinations. API orifice sizes range from 1" – 10"
pressure ratings from 150 – 1500 class. The standard metal seat is the same design that has been successfully
utilized in the CONSOLIDATED® SRV for over 50 years.

Capacities are certified by National Board of Boiler and Pressure Vessel Inspectors and published in their NB18
entitled "Pressure Relief Device Certifications."

Main Valve Features

• Orifice controlled capacity
• Superior tightness
• Removable nozzles for replacement or remachining
• Standard O- Ring sizes: readily available, easily replaced
• Meets ASME Section VIII, Div. 1
• National Board certified capacities
• Uses many parts standard on 1900 Series SRV

REF.
NO. NOMENCLATURE
12
1 BASE
13 1905-1916
10 1920-1926
1A BASE PLUG
14 1905-1916
11 1920-1926
2 NOZZLE
8 3 DISC
4 DISC RETAINER
5 DISC HOLDER
9 6 GUIDE
7 GUIDE GASKET
7 8 COVER PLATE
9 COVER PLATE GASKET
10 BASE STUD
6 11 STUD NUT
12 MAIN VALVE PISTON
5 13 MAIN VALVE PISTON O-RING
14 GUIDE RING
4 15 PLUG/ADAPTER
16 PLUG/ADAPTER GASKET
3

15

16

FIGURE 1

12 Con-29
SECTION X.
2900 Series MPV Operational Descriptions

SECTION X.A
2900 Series with Type 39PV (Pop) Pilot Operational Descriptions
PV VALVE CLOSED (Normal Position)
System pressure from the main valve inlet is fed to the dome by the pilot through interconnecting tubing. This
equalizes the pressure on the top of the piston with inlet pressure on the seating surface (bottom) of the disc. Since
the area of the top of the piston is larger than the area of the seating surface, the differential area results in a net
downward force keeping the main valve tightly closed.

FIGURE 2

Con-29 13
 SECTION X.A Continued
PV VALVE OPEN (Relieving Position)
As inlet pressure increases, the pilot piston strokes and seals off the main valve inlet pressure from the dome pres-
sure. The pilot simultaneously opens the vent seal to relieve the dome pressure to atmospheric pressure. The main
valve disc is allowed to lift off the seat as the fluid force overcomes the now removed pressure load above the main
valve piston. The valve discharges to relieve system pressure.

When the discharging main valve reduces the inlet pressure to the pre-set blowdown pressure of the pilot, the pilot
piston closes the vent seal. Simultaneously, the inlet seal is reopened in the pilot. The main valve inlet pressure is
again allowed to enter the dome above the main valve piston. As the dome pressure equalizes with the inlet pres-
sure, the downward force created by the differential areas of the piston and disc closes the main valve.

FIGURE 3

14 Con-29
SECTION X.B
2900 Series 39 MV (Modulating) Pilot – Operational Description
MV VALVE CLOSED (Normal Position)
System pressure from the main valve inlet is fed to the dome by the pilot through interconnecting tubing. This
equalizes the pressure on the top of the piston with inlet pressure on the seating surface (bottom) of the disc. Since
the area of the top of the piston is larger than the area of the seating surface, the differential area results in a net
downward force keeping the main valve tightly closed.

TO
DOME

TO
DOME

SHOWN 90°
OUT OF
POSITION

FIGURE 4

Con-29 15
 SECTION X.B Continued
MV VALVE MODULATING (Partial Relieving Position)
As inlet pressure increases, the pilot piston strokes and seals off the main valve inlet pressure from the dome pres-
sure. The pilot simultaneously opens the vent seal to relieve the dome pressure to the bottom of the modulator pis-
ton. The modulator piston has a differential area with the smaller area being on top of the modulator piston. The
top of this piston always sees the main valve inlet pressure. When the dome pressure is applied to the bottom of
the modulator piston, there is a net upward force. This is due to both pressures being equal (at this point), and the
lower area is larger than the upper
area. The modulator relieves the
pressure from the dome to the
atmosphere until force from the inlet
pressure on top of the modulator pis-
ton is sufficient to move it to the
closed position. A certain amount of
pressure remains in the dome. This
pressure is controlled by the differen-
tial area in the modulator. Since the
dome pressure has not been
dropped to atmospheric pressure,
the main valve only partially opens at
the set point. The modulator piston
will remain closed until the main
valve disc is forced into higher lift by
increasing inlet pressure. As this
occurs, the modulator piston may
relieve further pressure from the
TO
dome as necessary to achieve the
DOME
required main disc lift within 10%
overpressure.

MV FULLY OPEN (Full Relieving

Position)
As the inlet pressure increases fur-
ther, the net upward force on the
main valve disc increases, allowing
the main valve to relieve more pres- TO
sure. The disc obtains full lift (full DOME
capacity) within 10% of set pressure.

When the discharging valve reduces

SHOWN 90°
the inlet pressure to the pre-set blow- OUT OF
POSITION
down pressure of the pilot, the pilot
piston closes the vent seal.
Simultaneously, the inlet seal is
reopened in the pilot. The main valve
inlet pressure is again allowed to
enter the dome above the main valve
piston. As the dome pressure equal-
izes with the inlet pressure, the
downward force created by the differ-
ential areas of the piston and disc
closes the main valve.

FIGURE 5

16 Con-29
Section XI.
Cross Sectional Drawings and Nomenclature

SECTION XI.A
39PV Pilot Valve Cross Sectional Drawings and Nomenclature

REF.
NO. NOMENCLATURE
1 MAIN BASE
2 ADJUSTER CAP
3 ADJUSTER TOP
4 ADJUSTER BOTTOM
5 ADJUSTER LOCK NUT
6 COMPRESSION SCREW
7 COMPRESSION SCREW LOCK NUT
8 SPRING WASHER
9 SPRING 13
10 INSERT TOP
11 INSERT BOTTOM 6
12 MAIN PISTON 7
13 CAP (COMPRESSION SCREW)
14 CAP SCREW (YOKE)
15 O-RING (ADJUSTER BOTTOM)
16 O-RING (ADJUSTER TOP)
17 O-RING (INSERT) 19
18 O-RING (MAIN BASE) 20
8
19 YOKE
12 9
20 SPRING SEAL (MAIN PISTON)
21 SPRING SEAL (ADJUSTER TOP)
22 SPRING SEAL (INSERT)
23 FIELD TEST CONNECTOR
12 8
24 BUG SCREEN
25 VENT ASSY. 39PV37-2 20 14
26 PIPE PLUG (PILOT VALVE) HIGH PRESSURE
23 18

24

26
10
11 17
25
22 3
4
16 21
SHOWN 90°
1 OUT OF
POSITION
15 5
2

39PV07-2
FIGURE 6

Con-29 17
 Section XI.B REF.
NO. NOMENCLATURE
39MV Cross Sectional Drawing and 1
2
MAIN BASE
ADJUSTER CAP
Nomenclature 3
4
ADJUSTER TOP
ADJUSTER BOTTOM
5 ADJUSTER LOCK NUT
6 COMPRESSION SCREW
7 COMPRESSION SCREW LOCK NUT
8 SPRING WASHER
13
9 SPRING
10 INSERT TOP
6
11 INSERT BOTTOM
7 12 MAIN PISTON
13 CAP (COMPRESSION SCREW)
14 CAP SCREW (YOKE)
15 O-RING (ADJUSTER BOTTOM)
16 O-RING (ADJUSTER TOP)
17 O-RING (INSERT)
19 18 O-RING (MAIN BASE)
8 19 YOKE
20 SPRING SEAL (MAIN PISTON)
9
21 SPRING SEAL (ADJUSTER TOP)
22 SPRING SEAL (INSERT)
23 FIELD TEST CONNECTOR
24 BUG SCREEN
12 8 25 PLUG FILTER
20 31 MODULATOR BASE
14 32 MODULATOR STOP
23
18 33 MODULATOR PISTON TOP
34 MODULATOR PISTON BOTTOM
31 33 35 O-RING RETAINER
40
45 36 LOCK SCREW
24 37 CAP SCREW (MODULATOR)
43
40 O-RING (MODULATOR BASE)
44 41 O-RING (MODULATOR STOP)
10 42 O-RING (MODULATOR SEAT)
34
11 43 O-RING (MODULATOR PISTON BOTTOM)
17 44 SPRING SEAL (PISTON BOTTOM)
45 SPRING SEAL (PISTON TOP)
22 3
42 OPTIONS
4 41 52 SPRING SHIELD (NOT SHOWN)
16 21 53 NEEDLE VALVE (MANUAL BLOWDOWN)
35 (NOT SHOWN)
1
40 37 41 32 36 54 PILOT SUPPLY FILTER (NOT SHOWN)
15 5
SHOWN 90° 55 CANISTER FILTER (NOT SHOWN)
2 OUT OF 56 CANISTER FILTER (NOT SHOWN)
POSITION
W/FLUSH VALVE (NOT SHOWN)
57 BACKFLOW PREVENTER (NOT SHOWN)
39MV07-2 58 BACKFLOW PREVENTER LINE (NOT SHOWN)
69 VENT ASSY.
70 TOP PLATE
71 SET SCREW
72 BONNET
20
72
69
12
71

70

39MV37-2
HIGH PRESSURE BONNET OPTION

FIGURE 7

18 Con-29
Section XI.C
39PV-Dirty Service Option

COMPRESSION SCREW

COMPRESSION SCREW
LOCKNUT

YOKE

SPRING WASHER

SPRING

SHOWN 90° SPRING WASHER

OUT OF
POSITION CAP SCREW

DIRTY INSERT

BASE

ADJUSTER TOP

MAIN PISTON

INSERT ASSEMBLY
(INSERT TOP
INSERT BOTTOM) SHOWN 90°
ADJUSTER LOCKNUT OUT OF
POSITION
ADJUSTER BOTTOM
ADJUSTER CAP

FIGURE 7A
DIRTY SERVICE OPTION

Note: Dirty Service Option can be applied to the following pilot valves: 39PV07, 39PV37, 39MV07 and
39MV37.

Con-29 19
 Section XI.D REF.
NO. NOMENCLATURE
2900 Main Valve Cross Section and 1 BASE
1905-1916
Nomenclature 1920-1926
1A BASE PLUG (NOT SHOWN)
1905-1916
1920-1926
2 NOZZLE
3 DISC
4 DISC RETAINER
5 DISC HOLDER
6 GUIDE
7 GUIDE GASKET
8 COVER PLATE
9 COVER PLATE GASKET
12 10 BASE STUD
11 STUD NUT
13 12 MAIN VALVE PISTON
10 13 MAIN VALVE PISTON O-RING*
14 GUIDE RING
14 15 PLUG/ADAPTER
16 PLUG/ADAPTER GASKET
11 * For higher temperatures and specific
medias, a spring energized Teflon®
8 seal is used.

15

16

2900 MAIN VALVE

FIGURE 8

20 Con-29
SECTION XII.
Restoring Safety H! CAUTION
Appropriate service and repair are important to safe, reliable operation of all valve
products. Restoration to original quality and manufacturing specifications will
accomplish the desired results. Procedures developed by Consolidated® as
described in the applicable Installation and Maintenance Manual, when correctly
applied, will be effective.

SECTION XIII.
General Planning for Maintenance
A 12 month maintenance interval is recommended for general service conditions. Always use appropriate
For severe service applications, a 3 to 6 month inspection and test interim may restoration procedures.
be more appropriate. The specific plant's operating and service history will better
determine this frequency. Dresser encourages preventive maintenance.

The 2900 series Pilot Operated Safety Relief Valve (POSRV) is easily maintained.
Normal maintenance usually involves: H! CAUTION
• Removal of pilot valve from main valve
• Disassembly of both the pilot and main valve ▲
• Cleaning
• Component Inspection
• Parts Replacement as Needed
• Reassembly
• Setting, Testing and Resealing the Valve ▲

Occasionally, remachining the nozzle may be necessary to extend the service life
of the valve. Keep all parts for each valve separated to ensure replacement in the
same valve. Do not interchange
parts from one valve
Note: Insure there is no pressure in the inlet of the valve before attempting to another.
to remove it from the piping system.

H! DANGER

Decontaminate or clean if
necessary before pretesting or
disassembly. Safety and
environmental precautions must
be taken for the decontamination
or cleaning method used.

Con-29 21
 SECTION XIV.
H! DANGER Disassembly of the 2900 Pilot Operated Safety
Relief Valve

SECTION XIV.A
Removal of Pilot Valve from Main Valve
1. Make sure there is no media pressure in the vessel, in the valve inlet, in the
main, or in the pilot valve.
Lower pressure and
stand clear of discharge 2. Disconnect the Sensing Tube, Dome Tube and Discharge Line from the Pilot
when working on valve to Valve.
avoid severe personal
injury or death. 3. All other external attachments should be removed to free the Pilot Valve for
Disassembly.

H! CAUTION 4. Loosen and remove the two cap bolts holding the pilot valve to the mounting
bracket.

5. Place parts in the order they are disassembled to facilitate reassembly.

Wear necessary
protective equipment to
prevent possible injury.

H! DANGER H! WARNING

Do not remove bolts if

Know all valve
valve is under pressure,
exhaust/leakage points
as this will result in
to avoid possible severe
severe personal injury
personal injury or death.
or death.

22 Con-29
SECTION XIV.B
Disassembly of the Main Valve
To disassemble the main valve, see Figure 8 for a cross sectional drawing and designated parts nomenclature.
Follow these specific steps.

1. Loosen and remove the stud nuts or cap screws on the Cover Plate.

2. Lift off the Cover Plate.

3. Remove the piston from the Cover Plate using a dowel pressed through the center hole in the top of the Cover
Plate.

4. Remove the Cover Plate Gasket.

5. Install the Disc Holder Removal tool in the top of the Disc Holder. Use the tool indicated in Table 2 and Figure
9. On "V" and "W" Orifice Valves Thread two 5/8-11 NC Standard Eye Bolts into the top of the Disc Holder as
shown in Figure 10.

Disc Holder Removal Tool*

Tool Number For use on Orifice size See Section XXVI for
4464601 "D through G" construction plans
4464602 "H, K and L"
4464603 M and N
4464604 "P, Q, R and T"
Use Standard Eye Bolts "V and W"
Supplied 5/8-11NC
TABLE 2

LIFTING TOOL EYE BOLTS

DISC HOLDER DISC HOLDER
GUIDE GUIDE
TOP OF BASE
TOP OF BASE

“D” THROUGH “T” ORIFICE VALVES

See Section XXVI
“V” AND “W” ORIFICE VALVES
FIGURE 9 FIGURE 10

6. Lift out and remove the Guide and Disc holder together.

7. Remove the Lifting tool or Eye Bolts from the top of the Disc holder.

8. Lift the Guide off the Disc Holder. If the valve has a bellows avoid damage to the gasket seating surfaces, and
if present the convolutions or the flange section of the Bellows.

9. Using the Drift Pins as illustrated in Figure 11, remove the Disc from the Disc Holder. Use care to avoid scar-
ring the bearing surface on the back of the Disc.

Con-29 23
 DRIFT PIN DRIFT PIN
DISC

DISC HOLDER

FIGURE 11

8'–10' LONG ROD

OR HEAVY PIPE
BASE
NOZZLE PIPE WRENCH

3 JAW CHUCK
CHUCK STAND
NOZZLE

BASE

FIGURE 12 FIGURE 13

10. Remove the Nozzle from the Valve Base as suggested in Figure 12, or by using a Hex wrench or a pipe wrench
on the flange as indicated in Figure 13.

Note: Exercise care not to damage the Nozzle when inserting a rod or pipe in the outlet to remove the
Nozzle.

11. The Main valve is ready for cleaning, inspection and refurbishing.

24 Con-29
SECTION XIV.C
Cleaning H! DANGER
Parts are to be free of any oil or grease except for lubrication as specified in this
instruction.

Cleaning agents used should be such that effective cleaning is assured without
injuring the surface finishes or material properties of the part.

Acceptable cleaning agents include demineralized water, non-phosphate deter-

gent, acetone or isopropyl alcohol. Parts must be blown dry or wiped dry after
cleaning.
Follow recommendations
for safe handling in the
If you are using cleaning solvents, take precautions to protect yourself from poten- solvent’s Material Safety
tial danger from breathing fumes, chemical burns, or explosion. See the solvent's Data Sheet and observe
Material Safety Data Sheet for safe handling recommendations and equipment. safe practices for any
cleaning method.

It is not recommended to "sand blast" internal parts as it can reduce the dimen-
sions of the parts. The base may be sand blasted with care not to erode internal
surfaces, or damage machined surfaces.

SECTION XIV.D
Parts Inspection
See Figure 8 for a cross sectional drawing and designated parts nomencla-
ture.

1. 2900, 2900-30 Nozzle Inspection Criteria

A Nozzle should be replaced if:

1. The seat width requires adjustment, and the Dimension from the seat to
the first thread is less than "D" minimum on Table 5.

2. Thread sections are damaged from pitting and/or corrosion.

3. Top of the nozzle flange and intersecting surface are damaged from
galling and/or tearing.

4. The nozzle flange thickness can change center to face Dimensions. The
minimum dimension for orifices "D" through "P" is 43/64" (.672" or 16.5
mm) and "Q" through "W" orifices are 51/64 (.797" or 20.2 mm).

Note: See Table 5A or 5B for information concerning reestablishing the

Seat width and other critical dimensions of the nozzle seat area.

Con-29 25
 METAL SEATED O-RING SEAL
NOZZLE NOZZLE
K
F

5°
surface L H
N
M L B
A
G

E D min. D min.
45°
J
P
nozzle
bore
FIGURE 14A FIGURE 14B

TABLE 5A
ENGLISH UNITS, INCH
Nozzle Metal-To-Metal O-Ring Seat Seal
D Radius L
Orifice Min. E+– .005 + .000
.000 F – .002 H+– .002 + .005
.000 N – .000 P+ + .002 +
– 1/2˚ B – .000 J – .005 K+ .000
– .007 Max.
+.000
D-1 13/32 .015 — .518 — 30˚ .015 .062 .573 –.002 .538
E-1 15/32 .020 .788 .686 .025 30˚ .015 .060 .733 +.000
–.002 .688
D-2, E-2, F 5/16 .030 .955 .832 .035 30˚ .015 .079 .868 +.000
–.003 .814
G 5/16 .035 1.094 .954 .035 30˚ .021 .090 1.060 +.000
–.003 .999
H 1/4 .035 1.225 1.124 .035 45˚ .021 .060 1.216 +.000
–.003 1.167
J 3/8 .035 1.546 1.436 .035 45˚ .021 .074 1.534 +.000
–.003 1.481
K 7/16 .063 1.836 1.711 .063 45˚ .021 .126 1.838 +.000
–.004 1.781
L 7/16 .063 2.257 2.132 .063 45˚ .016 .126 2.208 +.000
–.004 2.158
M 7/16 .063 2.525 2.400 .063 45˚ .021 .126 2.536 +.000
–.004 2.480
N 1/2 .063 2.777 2.627 .063 45˚ .021 .101 2.708 +.000
–.004 2.652
P 5/8 .093 3.332 3.182 .093 45˚ .021 .150 3.334 +.000
–.004 3.279
Q 7/8 .093 4.335 4.185 .093 45˚ .021 .188 4.338 +.000
–.006 4.234
R 1 .093 5.110 4.960 .093 45˚ .021 .215 5.095 +.000
–.006 5.036
T-3 3/4 — 6.234 6.040 .093 45˚ .021 .142 6.237 +.000
–.007 6.174
+.000
T-4 3/4 .093 6.510 6.315 .093 30˚ .021 .142 6.517 –.007 6.424
+.000
V 1-1/8 .250 8.816 8.336 .275 30˚ .020 .275 9.130 –.007 8.341
+.000
W 1-5/8 .350 11.058 10.458 .348 30˚ .020 .353 11.130 –.007 10.463

TABLE 5B
METRIC UNITS, MM
Nozzle Metal-To-Metal O-Ring Seat Seal
D Radius L
Orifice Min. E+– .13
.0 F+– .0
.05 H+– .05
.0 N+– .13
.0 P+ + .05 J+– .13
– 1/2˚ B – .0 K+– .007
.000
Max.
D-1 10.3 .38 — 13.16 — 30˚ .38 1.57 14.55 +.00
–.05 13.64
E-1 11.9 .51 20.01 17.43 .64 30˚ .38 1.52 18.62 +.00
–.05 17.47
D-2, E-2, F 7.9 .76 24.26 21.13 .89 30˚ .38 2.01 22.05 +.00
–.08 20.68
G 7.9 .89 27.79 24.24 .89 30˚ .53 2.29 26.92 +.00
–.08 25.37
H 6.3 .89 31.12 28.55 .89 45˚ .53 1.52 30.89 +.00
–.08 29.64
J 9.5 .89 39.27 36.47 .89 45˚ .53 1.88 38.96 +.00
–.08 37.62
K 11.1 1.60 46.63 43.46 1.60 45˚ .53 3.20 46.69 +.00
–.10 45.24
L 11.1 1.60 57.33 54.15 1.60 45˚ .41 3.20 56.08 +.00
–.10 54.81
M 11.1 1.60 64.14 60.96 1.60 45˚ .53 3.20 64.41 +.00
–.10 62.99
N 12.7 1.60 70.54 66.73 1.60 45˚ .53 2.57 68.78 +.00
–.10 65.07
P 15.9 2.36 84.63 80.82 2.36 45˚ .53 3.81 84.68 +.00
–.10 83.28
Q 22.2 2.36 110.11 106.30 2.36 45˚ .53 4.78 110.19 +.00
–.15 107.54
R 25.4 2.36 129.79 125.98 2.36 45˚ .53 5.46 129.41 +.00
–.15 127.92
T-3 19.0 — 158.34 153.41 2.36 45˚ .53 3.60 158.42 +.00
–.17 156.82
+.00
T-4 19.0 2.36 165.35 160.40 2.36 30˚ .53 3.60 165.53 –.17 163.17
+.00
V 28.6 6.35 223.92 211.73 6.98 30˚ .508 6.99 231.90 –.17 211.86
+.00
W 41.2 8.89 280.87 265.63 .353 30˚ .508 8.96 282.70 –.17 265.76

26 Con-29
2. 2900, 2900-30 Standard Metal Seated Disc Inspection Areas

A Disc should be replaced if:

1. The disc has been machined or lapped to remove damage from seat surface “L” and the “N” dimension as
indicated in Figure 14 measures less than “N” minimum as indicated in Table 3.

2. The “T” dimension (See Figure 15) is reduced by machining or lapping seat surface “L” and measures less
than “T” minimum indicated in Table 3.

Note: See Section X for information concerning re-establishing the disc seating surface.

T T T

N (MIN.) N (MIN.)
B B B N (MIN.)

90°
C C

L seat surface L TYPE 3

(FOR 2900V AND 2900W O

TYPE 1 TYPE 2 C TYPE 3

(D-H) (J-T) (FOR 2900V AND 2900W ONLY)

FIGURE 15

TABLE 3
DISC ORIFICE INCHES MILLIMETERS
TYPE SIZE "T" Minimum "N" Minimum "T" Minimum "N" Minimum
in millimeters in millimeters
D-1 .155 .005 3.94 .127
E-1 .158 .005 4.01 .127
TYPE 1 F, D-2, E-2, .174 .005 4.42 .127
G .174 .005 4.42 .127
H .335 .010 8.51 .254
J .359 .015 9.12 .381
K .417 .043 10.72 1.09
L .452 .043 11.61 1.09
M .452 .043 11.61 1.09
TYPE 2 N .480 .043 12.57 1.09
P .605 .073 15.49 1.85
Q .605 .073 15.49 1.85
R .605 .073 15.49 1.85
T .817 .073 20.88 1.85
V 1.230 .120 28.32 3.05
TYPE 3
W 1.855 .168 42.98 4.27
Minimum Allowable Dimensions after
Machining of the Disc Seat

Con-29 27
 3. 2900 Series Thermodisc® Replacement Criteria

If seat defects and damage can not be lapped out without reducing the "A" dimension below that shown on
Table 4, the Thermodisc® may not be machined and must be replaced.

Note: "A" dimension on D through H orifices is difficult to measure. If you cannot measure the .006 min-
imum thickness of the thermal lip, replace the Thermodisc®.

4. 2900, 2900-30 Disc Holder should be replaced if the sliding surface of the Holder is galled, pitted or scratched.

5. 2900, 2900-30 Guide should be replaced if the sliding surface is galled, pitted or scratched or the machined
gasket surfaces are damaged.

6. Solid Metal Gaskets may be re-used unless they are corroded, pitted or crimped.

7. The Coverplate should be reused if:

a. The sliding surface in the dome area is not galled, scratched, corroded or pitted.
b. The Gasket surface is not scratched, corroded or pitted.

8. The Piston should be re-used if there is no indication of galling, scratched, corroded or pitted on any surface
of the piston.

TABLE 4
ORIFICE "A" MIN. "A" MIN.
SIZE DIMENSION (IN) DIMENSION (MM)
D, E, F, G, & H .006 .153
J .013 .331
K, L, M & N .014 .356
P .017 .432
Q&R .015 .381
T .025 .635
V&W .035 .89

Thermodisc® Thermodisc®

A A
®
Thermodisc Design J-W Orifices
D-H Orifices

FIGURE 16

28 Con-29
SECTION XV
Maintenance Instructions
A. General Maintenance Information
DISC
After the valve has been disassembled, a close inspection should be made of the
seating surfaces. In a majority of cases, a simple lapping of seats is all that is nec- 5°
essary to put the valve in first class working order. If an inspection of the parts
SEAT WIDTH
shows the valve seating surfaces to be badly damaged, machining will be
required before lapping. O-Ring seat seal valve nozzles can only be reconditioned NOZZLE
by machining, not lapping. (For specific information concerning the machining of
nozzle and disc seating surfaces, see Paragraphs F and G which follow.) FIGURE 17

The seating surfaces of the metal seated Consolidated® Safety Relief Valve are flat. The nozzle seat is relieved by
a 5° angle on the outside of the flat seat. The disc seat is wider than the nozzle seat; thus, the control of seat width
is the nozzle seat (see Figure 17).

Reconditioning of the seating surfaces of the nozzle and disc is accomplished by lapping with a cast iron lap, and
lapping compound.

Anytime the V or W orifice valve is disassembled, be sure to inspect the guide rings for wear. If worn, replace
before reassembly.

NOTE:
In order to establish leak free valve seats, the nozzle seating surface and the disc seating surface must be
lapped flat.

B. Nozzle Seat Widths-Lapped

A wide nozzle seat will induce leak, especially in the smaller orifice lower pressure valves. For this reason, the seat
on non-O-Ring valves should be as narrow as practical. Since the seat must be wide enough to carry the bearing
load imposed upon it by the piston and system pressure, the higher pressure valves must have wider seats than
the lower pressure valves. The nozzle seat width should conform with those listed in Table 6 or 7.

The seat width can be measured by the use of a "Measuring Magnifier". Figure 18 shows its use to determine seat
width. Measuring Magnifiers are available through Industrial/Machinists Supplies.

MEASURING
MAGNIFIER

NOZZLE

FIGURE 18

Con-29 29
 STANDARD METAL SEAT DESIGNS
APPROXIMATE NOZZLE SEAT WIDTH

VALVE SET PRESSURE (PSIG)1 LAPPED SEAT WIDTH (IN.)

2900 D - G 15 - 50 .012
51 - 100 .018
101 - 250 .025
251 - 400 .032
401 - 800 .038
801 - UP .038

2900 H - J 15 - 50 .019
51 - 100 .025
101 - 250 .029
251 - 400 .032
401 - 800 .038
801 - UP ADD .005 PER 100 LBS.2

2900 K - N 15 - 50 .025
51 - 100 .030
101 - 250 .035
251 - 400 .040
401 - 800 .045
801 - UP ADD .005 PER 100 LBS.2

2900 P -R 15 - 50 .030
51 - 100 .037
101 - 250 .045
251 - 400 .052
401 - 800 .059
801 - UP .064

2900 T 15 - 50 .040
51 - 100 .045
101 - 250 .053
251 - 250 .060

2900 V 15 - 50 .075
51 - 100 .095
101 - 250 .115
251 - 250 .130

2900 W 15 - 50 .100
51 - 100 .120
101 - 250 .140
251 - 250 .160

2
NOT TO EXCEED .070 ± .005 IN.

TABLE 6

30 Con-29
 THERMODISC® DESIGN
APPROXIMATE NOZZLE SEAT WIDTH

VALVE SET PRESSURE (PSIG)1 LAPPED SEAT WIDTH (IN.)

2900 D - F 15 - 100 .020 - .030

101 - 300 .035 - .045
301 - 800 .045 - .055
801 - UP FULL WIDTH

2900 G - J 15 - 100 .020 - .030

101 - 300 .035 - .045
301 - 800 .045 - .055
801 - UP FULL WIDTH

2900 K - N 15 - 100 .035 - .045

101 - 300 .045 - .055
301 - 800 .055 - .065
801 - UP FULL WIDTH

2900 P -R 15 - 100 .040 - .050

101 - 300 .050 - .065
301 - 800 .060 - .070
801 - UP FULL WIDTH

2900 T 15 - 100 .050 - .065

101 - 300 .060 - .075

2900 V 15 - 100 .075 - .100

101 - 300 .095 - .130

2900 W 15 - 100 .100 - .125

101 - 300 .120 - .160

TABLE 7

C. Precautions and Hints for Lapping Seats

The following precautions and hints will enable maintenance personnel to do a "professional" job of lapping sets:

1. Keep work materials clean.

2. Always use a fresh lap. If signs of wearing (out of flatness) are evident, recondition the lap.

3. Apply a very thin layer of compound to the lap. This will prevent rounding off the edges of the seat.

4. Keep the lap squarely on the flat surface, and avoid any tendency to rock the lap which causes rounding of
the seat.

Con-29 31
 5. When lapping, keep a firm grip on the part to prevent the possibility of dropping it and damaging the seat.

6. Lap, using eccentric or figure-eight motion in all directions, at the same time applying uniform pressure and
rotating the lap slowly. (See Paragraph G for further information.)

7. Replace the compound frequently after wiping off the old compound, and apply more pressure to speed the
cutting action of the compound.

8. To check the seating surfaces, remove all compound from both the seat and the lap. Then, shine the seat with
the same lap using the lapping motion described above. Low sections on the seating surface will show up as
a shadow in contrast to the shiny portion. If shadows are present, further lapping is necessary and only laps
known to be flat should now be used. Only a few minutes will be required to remove the shadows.

9. When the lapping is completed, any lines appearing as cross scratches can be removed by rotating the lap
(which has been wiped clean of compound) on the seat about its own axis.

10. The seat should now be thoroughly cleaned using a lint-free cloth and a cleansing fluid.

D. Grinding O-Ring Metal Seating Surfaces

The contact surfaces of the nozzle and O-ring Retainer are to be lightly ground together during the assembly
process to minimize leakage in the event of a O-ring failure. After assembling the reconditioned Nozzle in to the
base according to instruction in Section XVI, place a small amount of 1000 grit lapping compound on the 45°
angled surface. Then for the “D”-”J” orifice fasten the o-ring retainer without installing the o-ring into Disc Holder
and placing into the guide. Install the guide and Disc Holder together in the valve base and gently allow the Disc
Holder and retainer to come in contact with the nozzle. Turn the Disc Holder within the Guide 15 to 20 rotations
and remove, disassemble and clean lapping compound from the Nozzle, Disc Holder and O-ring Retainer. For ori-
fices K and larger the process does not require assembling the nozzle in to the base and it does not require the
use of the Disc Holder. Assemble the O-ring retainer into the O-ring Disc and placing a small amount of 1000 grit
Lapping Compound on the 45° angled surface of the nozzle, place the disc and retainer on the nozzle lightly grind
the o-ring retainer into the nozzle. About 15 to 20 rotations are recommended to establish full contact between the
O-ring retainer and the nozzle.

Remove the retainer screw(s) and retainer, and thoroughly clean the retainer, retainer screws and disc holder or
disc.

LAPPING PLATE RING LAP

E. Reconditioning of Laps

Ring laps are reconditioned by lapping them on a flat lapping

plate. The lapping should be done with a figure-eight motion as
indicated in Figure 19. To assure the best results when lapping
seats, the ring laps should be reconditioned after each usage
and checked with an optical flat.

FIGURE 19

32 Con-29
F. Machining Nozzle Seats
C
The nozzle should be removed from the valve to be machined (see B NOZZLE
Figure 20). See Nozzle Removal Instructions in Section XIV.B, and D
Figures 12 and 13. If it can not be removed from the base, it should be
machined inside the base.

1. Lathe Set Up – Nozzle Removed A

CHUCK JAW
a. Grip the nozzle in a four-jaw independent chuck, using a
piece of soft material such as copper or fiber between the
jaws and the nozzle as shown at A in Figure 20. FIGURE 20

b. True up the nozzle so that the surfaces marked B, C and

D run true within .001" on indicator.

2. Machining Procedure: Metal to Metal Seat

See Figure 14A

a. Take light cuts across the surface L at 5˚, until the damaged areas are removed. (See Figure 15) Turn
to the smoothest possible finish.

b. Cut back the outside surface at G, until dimension N is obtained. The surface at G is common to all
nozzles except the D-1. Omit this step on the D-1 orifice nozzles.

c. Machine bore diameter H, until dimension E is obtained. Re-establish angle P.

d. The nozzle is now ready for lapping.

e. When the minimum dimension D is reached, the nozzle should be replaced.

3. Machining Procedure: O-Ring Seat Seal

See Figure 14B.

a. Take light cuts across surface A (45˚), until the damaged areas are removed. Turn to the smoothest
possible finish.

b. Cut back the outside surface M, until dimension J is obtained.

c. Machine radius B.

d. The nozzle is now ready for grinding.

e. When the minimum dimension D is reached, the nozzle should be replaced.

Con-29 33
 G. Lapping Disc Seats

The disc seat may be lapped with a ring lap or a lapping plate. Lapping should be done in an eccentric or Figure-
eight motion in all directions, applying uniform pressure and rotating the disc or lap slowly.

H. Machining the Disc Seat*

The standard disc seating surface L (see Figure 21) can easily be machined as follows:

1. Grip the disc in a four-jaw independent chuck (or collet, if appropriate), using a piece of soft material such
as copper or fiber between the jaws and the disc as shown at A.

2. True up the disc so that the surface marked B and C run true within .001" (0.025 mm), TIR.

3. Take light cuts across the seating surface L until damaged areas are removed. Turn to smoothest possi-
ble finish.

4. The disc is now ready for lapping.

5. When the minimum dimension N or T (see Table 3) is reached the disc should be discarded. Do not re-
establish surface C.

CHUCK
JAW
A

N (MIN.)
DISC

90°
C
L

FIGURE 21
Note: *Thermodisc® and O-Ring discs are not to be machined.

If the involved valve has an O-Ring seat seal, refer to the tag plate mounted on the valve (see Figure 36)
to determine O-Ring material and "as built" part number.

I. Coverplate

Beyond cleaning and inspection, no maintenance is required for the coverplate.

Note: Do not machine the inside of the coverplate dome.

J. Bearing Point

The bearing point on the piston should be ground into the piston pocket of the disc holder.

34 Con-29
SECTION XVI.
Assembly of the 2900 Main Valve
A. Lubrication Nozzle Torque Values +10% - 0%

Orifice Required Torque ft.lbs. Required Torque nm

Use a nickel based anti-seize lubricant on all threads, and
D-1 95 129
bearing surfaces.
D-2
E-1 165 224
Note: All O-rings (except silicone) and energized E-2
seals should be lightly lubricated with silicone grease
F-1
(supplied with o-ring kits).
G 145 197
H 165 224
B. Specific Steps 455
J 335
1. If the valve nozzle was removed, apply thread lubricant K 430 584
to the nozzle threads before reinstalling in the valve L 550 746
base. Insert it into the inlet flange of the base, and 746
M 550
torque to the correct value listed in Table 8.
N 640 868
2. Assemble the disc/disc holder as follows: P 1020 1383
Q 1400 1898
a. Prior to assembly of the Disc into the Disc
R 1070 1451
Holder, remove the spring clip from the back of
the disc. Use 1000 grit grinding compound on T 1920 2604
the bearing surface to grind the disc into the V 2000 2712
disc holder to properly establish the bearing W 2000 2712
surface.
b. For all orifices, metal-to-metal discs, place the TABLE 8
disc retainer into the groove in the disc. The
disc with the retainer should “snap” into the disc
holder pocket with moderate finger or hand force. DO NOT USE EXCESSIVE FORCE TO ASSEM-
BLE THESE PARTS. Be sure that the Disc is free to “wobble” after it is in place.
For V and W orifice discs, place Disc into Disc Holder and secure disc retaining bolts.
c. For O-Ring disc sizes K thru T, reassemble the disc using a new O-Ring, O-Ring retainer, and new
screws. Assemble the disc into the disc holder as described in b. above.
d. For O-Ring disc sizes D thru J, reassemble the disc holder using a new O-Ring, O-Ring retainer, and
new screw(s). These disc holders are ready for the next step.

3. For bellows valves “D” through “T”, place a new bellows gasket on the disc holder. Thread the bellows, fin-
ger-tight, down to the gasket on the disc holder. Use a pin spanner wrench, or special cable type wrench
to turn the bellows ring down until a pressure tight joint is obtained.
For bellows valves V and W, place a new bellows gasket on the disc holder. Bolt down using proper torque
as found in the assembly instructions.
4. Set the disc holder (disc side down), on the work surface. Place a small amount of 1000 grit grinding com-
pound onto the ball end of the piston and place it in the disc holder pocket. Turn the piston clockwise, and
then counter clockwise, to seat the piston. Clean all grinding compound from parts.
5. Place the guide over the disc holder. (DO NOT DROP.) If bellows is present, the weight of the guide will
slightly compress the bellows.
6. Place the guide gasket in the base.

Con-29 35
 COVER PLATE NUT TORQUE (FT-LBS)
2905 2906 2910 2912 2941 2916 2918 2920 2921 2922 2923 2924 2926 2928
D 55 55 55 60 60 60 120 55 — 55 — 60 60 115
E 55 55 55 60 60 60 120 55 — 55 — 60 60 115
F 55 55 55 60 70 70 115 55 — 55 — 70 70 115
G 55 55 55 60 70 70 75 55 — 60 — 70 70 75
H 90 90 60 75 65 65 — 60 — 60 — 75 85 —
J 60 60 75 100 100 100 — 75 — 75 — 100 100 —
K 65 65 60 60 135 145 — 60 — 60 — 60 140 —
L 75 75 90 90 140 140 — 90 — 90 — 140 140 —
M 95 95 110 95 95 — — 90 — 95 — 95 — —
N 105 105 130 85 85 — — 130 — 85 — 85 — —
P 120 120 145 125 125 — — 145 — — 125 125 — —
Q 105 105 125 150 — — — 105 — 150 — — — —
R 115 115 115 135 — — — 115 — 135 — — — —
T 95 95 125 — — — — 125 — — — — — —
V 130 130 130 — — — — 130 — — — — — —
W 130 130 130 — — — — 130 — — — — — —
TABLE 9A

7. Install disc guide assembly. Use the same lifting tool (see Figure 9) as was used during disassembly, then
carefully lower it into the valve base.
On V and W sizes, use the same lifting lugs as were used during disassembly.

8. Using a small amount of Silicone Grease supplied with soft goods replacement kit, rub a small amount on
the seals and O-rings prior to assembly.

9. Take the piston and measure and cut diagonally the proper length of Guide Ring material to fit in the
groove of the piston. Allow 1/16 of an inch gap between the ends for proper fit.

10. Install energized seal onto (see note below) piston with the exposed spring facing upwards. For o-ring
seals, install the o-ring onto the piston. Locating it in the groove below the energized seal groove.

Note: Spring energized seal on piston is only for Teflon® o-ring material option. All other o-ring material
options will include an o-ring for the piston. For valve sizes D, E, F, G, H, J, K, L, M, N, & P and set
pressure below 50 psig, remove and discard the spring in the energize seal before installing.

11. Install the guide ring(s) onto the piston. If there is more than one guide ring, stagger the cut locations 180°
apart.

12. To prevent seal damage during assembly, check the chamfer on the bottom of the coverplate for burrs. If
any sharp edges exist, polish the chamfer.

13. Insert piston (energize seal/o-ring side first) into bottom of coverplate. Continue pushing piston into cov-
erplate, being careful not to pinch the guide rings. Push piston in until bottom of piston is even with the
bottom of the coverplate.

14. Install coverplate gasket. Place the coverplate on the main valve base and replace the stud nuts.

36 Con-29
 15. Torque to the values found in Table 9 using the torque patterns in Figure 22 and Table 10.

16. Once the Main Valve is assembled before any tubing is connected reach through the hole in the center of
the Coverplate and force the Piston down until it contacts the Disc Holder. Failure to complete this proce-
dure will prevent the main valve from loading and closing, when pressure is applied to the valve.

17. The Main Valve is ready to receive the pilot and finished assembly.

COVERPLATE NUT TORQUE (N-M) + 10% - 0%

2905 2910 2912 2914 2916 2918 2920 2921 2922 2923 2924 2926 2928
D-1 75 75 75 82 82 163 75 ** 75 ** 102 82 156
E-1 75 75 75 82 82 163 75 ** 75 ** 82 82 156
F 75 75 82 95 95 156 75 ** 75 ** 95 95 156
G 75 75 82 95 95 102 75 ** 82 ** 95 95 102
H 123 82 102 89 89 ** 82 ** 82 ** 102 116 **
J 82 102 136 136 136 ** 102 ** 102 ** 136 136 **
K 89 82 82 184 197 ** 82 ** 82 ** 82 189 **
L 102 123 123 189 189 ** 123 ** 123 ** 189 189 **
M 129 150 129 129 ** ** 123 ** 129 ** 129 ** **
N 143 177 116 116 ** ** 177 ** 116 ** 116 ** **
P 163 197 170 170 ** ** 197 ** ** 125 170 ** **
Q 143 170 204 ** ** ** 143 ** ** ** ** ** **
R 156 156 184 ** ** ** 156 ** 204 ** ** ** **
T 129 ** ** ** ** ** 170 ** 184 ** ** ** **
-2T ** 170 ** ** ** ** ** 170 ** ** ** ** **
V 177 177 ** ** ** ** 177 ** ** ** ** ** **
W 177 177 ** ** ** ** 177 ** ** ** ** ** **

TABLE 9B

1
3 1
3
6
4 6
HOLES HOLES TABLE 10
5
2 4 4
2
Torque required for each round of pattern
Round Percentage of required torque
5 1 5 1 7 1 Wrench tight
9 11
3
8 2 25
8 12 4
3
7 HOLES HOLES 3 60
4 12 10
2 6 8 6 4 100
2
5 100
5 1 7
13 15
17 20
9 20 12
3 HOLES 4
11 10
19 18
16 14
8 2 6

FIGURE 22

Con-29 37
 SECTION XVII.
Disassembly of the 39MPV Pilot Valve

A. Removal and Disassembly of the Liquid or Gas Modulator

1. Remove the seal and seal wire.

2. Remove socket head cap screws holding the modulator to the main pilot.

3. Remove and discard the 2 O-Rings between the modulator and the main pilot.

4. Remove both cap screws from the bottom of modulator.

5. Remove modulator stop from modulator base. This can be done by rotating the modulator stop enough to be
able to push against the ears on the modulator base to remove the modulator stop.

6. Remove both O-Rings from modulator stop and discard.

7. Remove modulator piston from the modulator base by hitting the base on a firm surface. Make sure surface is
clean so that when the piston comes out, the seat does not hit any object that might damage it.

8. Disassemble the modulator piston by removing the lock screw.

9. Remove and discard both O-Rings. Be careful not to bend the lip enclosing medium modulator O-Ring (seat)
during removal of the O-Ring.

10. Discard both Teflon® seals.

B. Disassembly of the 39MPV Pilot Valve

1. Remove the compression screw cap.

2. Measure and record compression screw height for later use when resetting.

3. Loosen compression screw locknut.

4. Turn compression screw counterclockwise to remove it from the yoke. The spring, spring washers, and spring
cover (if present) can now be removed.

5. Remove the 4 cap screws holding the yoke to the base, and remove the yoke. Remove and discard the O-
Ring (if present) and the Teflon® seal (if present) from the yoke.

5A. If the Pilot Valve has a Bonnet instead of a Yoke, loosen the bonnet set screw, then remove the Bonnet
counterclockwise using a wrench on the wrenching flats near the top of the Bonnet. Then remove the
spring, spring washers and the four cap screws that hold the bonnet adapter to the pilot base. Remove
and discard the O-ring and Teflon® seal from the Bonnet adapter.

5B. For dirty service option, remove the yoke or bonnet, remove the dirty service insert and throw away the o-
ring. Remove the insert assembly from the dirty insert using procedure in step 7.

6. Remove main piston from the base.

38 Con-29
7. Remove Insert Assembly from the top of the main base with tool 4995401. See Section XXVI for construction
drawing. Remove and discard the O-Ring on the bottom of the insert. Disassemble Insert Assembly by remov-
ing Insert Bottom from the Insert Top. Discard Teflon® seal.

8. Loosen the Adjuster Plug Lock Nut.

9. Turn the Adjuster Plug to the right and count the number of “Flats” until the Adjuster Plug stops against the
Pilot Valve Base. Record the number of “flats” of adjustment for use when reassembling the pilot.

10. Remove Adjuster Plug Cap from the bottom of the base.

11. Loosen Adjuster Plug Lock Nut.

12. Remove Adjuster Assembly from the base. Remove both O-Rings from Adjuster Assembly and discard.
Disassemble Adjuster Top from the Adjuster Bottom. Discard Teflon® seal.

C. Disassembly of the Field Test Connection

1. Remove Shuttle Plug from the Field Test Connector.
H! DANGER
2. Remove and discard O-Rings, ball and filter.

D. Cleaning
Parts are to be free of any oil or grease except for lubrication as specified in this
instruction.

Cleaning agents used shall be such that effective cleaning is assured without
injuring the surface finishes or material properties of the part. Follow recommendations
for safe handling in the
Acceptable cleaning agents include demineralized water, non phosphate deter- solvent’s Material Safety
gent, acetone and isopropyl alcohol. Parts must be blown dry or wiped dry after Data Sheet and observe
safe practices for any
cleaning. cleaning method.

If you are using cleaning solvents, take precautions to protect yourself from
potential danger from breathing fumes, chemical burns, or explosion. See the solvent’s Material Safety Data Sheet
for safe handling recommendations and equipment.

SECTION XVIII.
Inspection and Part Replacement
A. Pilot Valve Parts Inspection
After the pilot valve has been disassembled, all parts should be given a visual inspection. Some key areas to check
with the boundaries for reworking parts are listed below.

1. Main Pilot Valve Piston – Galling or excessive wear on the small diameter end where it engages the seals or
on the spherical bearing surface. Any corrosion or pitting. The part can be polished as long as the outside
diameter of the stem remains at 0.243 +/– .001 inches. The stem itself must have a TIR of 0.001 inches along
its length.
Con-29 39
 2. Insert Top – Galling or excessive wear on the inside diameter that guides the Main Piston. Check for any cor-
rosion or pitting. Also, check for galling of threads.

3. Insert Bottom – Galling or excessive wear on the inside diameter that guides the Main Piston. Check for any
corrosion or pitting.

4. Adjuster Top – Galling or excessive wear on the inside diameter that guides the Main Piston. Check for any
corrosion or pitting. Also, check for galling of threads.

5. Adjuster Bottom – Galling or excessive wear on the inside diameter that guides the Main Piston. Check for any
corrosion or pitting. Also check for galling of threads.

6. Yoke – Galling or excessive wear on the inside diameter that guides the Main Piston Assembly. Any corrosion
or pitting. Check for any galling on the threads for the compression screw.

7. Compression Screw – Galling at the spherical bearing surface or in the thread. Check for any corrosion or pitting.

8. Spring Washers – Galling at the spherical bearing surface. Check for any corrosion or pitting.

B. Field Test Connection Parts Inspection

1. Field Test Connection Base – Galling or excessive wear in the threads.

2. Field Test Connection Plug – Galling or excessive wear in the threads.

C. Modulator Parts Inspection

1. Modulator Stop – Top seating surface for cuts or deformities. The surface can be lapped if the distance from
the seat to the outside shoulder does not reduce to less than 0.086 inches.

2. O-Ring Retainer – Seating surface for cuts or deformities. The surface can be lapped if the overall height of
the part does not reduce to less than 0.160 inches. Also, check the outside diameter for any scratches that
might prevent the O-Ring from sealing.

3. Modulator Piston Bottom – Galling or excessive wear on the outside diameter that rubs against the modulator
base. Make sure that the lip holding the O-Ring for the seat is not deformed. Also, check the outside diame-
ter of the O-Ring groove for scratches that might cause the O-Ring not to seal. Check for any corrosion or pit-
ting.

4. Modulator Piston Top – Galling or excessive wear on the outside diameter that rubs against the modulator
base. Check for any corrosion or pitting.

5. Modulator Base – Galling or excessive wear on any inside diameter. Any corrosion or pitting.

6. If any damage listed above is present, the part should be replaced or repaired per instruction. Other valve parts
may be acceptable with light corrosion, pitting, or minor damage of other types if it can be determined that it
will not affect product performance. All O-Rings, and seals should be replaced each time the valve is disas-
sembled.

Refer to Tables 14 through 28 for a list of Parts and O-Ring repair kits. Recommended spare parts are listed in
Table 12.

40 Con-29
SECTION XIX.
Pilot Valve Lubrication
1. Lightly lubricate all O-Rings except Silicone O-Rings, with Silicone Grease as provided in the kit.

2. Lubricate and Seal pipe threads with a Teflon® thread compound such as Dresser SP-364-AB pipe sealant or
Teflon® tape.

3. Lubricate standard threads and bearing points with fluorolube (GR362) or equivalent.

SECTION XX. Assembly of 39MPV Pilot Valve and Components

Note: 39MV07 and 39MV37 are assembled identically to the 39PV except for the final addition of the mod-
ulator after the Pilot Valve is calibrated and tested.

A. Assembly of the 39PV Pilot Valve Adjuster Plug

1. Assemble the following parts
1 Adjuster Bottom
1 Adjuster Top
1 Teflon® Seat Seal
2 Small main O-rings

2. Install first small main O-Ring into groove in the Adjuster Top.

3. Install second O-Ring in to the groove on adjuster bottom. Install on the opposite end of the square wrench-
ing flats.

4. Use the special seal insertion tool pictured in Figure 39 to correctly insert the vent seal into the Adjuster Top
prior to assembly on the Adjuster Bottom.

a. Place the seal (with the energizer spring facing you), onto the smaller end of the Plunger Cylinder.

b. Place the male part of the Plunger through the seal and into the Plunger Cylinder.

c. Insert the small end of the Plunger/Seal/Plunger Cylinder assembly in to the larger opening of the Funnel
Tube and press the seal through the funnel tube until it is about 1/4 of an inch 5 or 6 mm) from exiting the
smaller end of the tube.

d. Remove the Plunger from the assembly leaving the seal and female part of the insertion assembly in the
Funnel Tube.

e. Seat the seal, plunger and funnel into the end of the Adjuster Top.

f. Press the plunger to seat the seal in the recessed area in the Adjuster Top.

g. Remove the insertion tool leaving the seal in the Adjuster Top with the energizer spring oriented toward
the four small holes in the Adjuster Top.

Note: Do not install adjuster assembly into main base with O-Rings installed without wrench tightening
adjuster top and adjuster bottom together. Adjuster top can get stuck in base.

Con-29 41
 5. Cycle main piston through Teflon® seat seal in the Adjuster Plug top 10 times.

6. Lightly lubricate both O-Rings. Install assembly into base with the adjuster top going in first. Rotate the assem-
bly at the same time as it is being inserted until the threads are engaged. This helps the O-Rings get by the
chamfers and holes.

7. Continue to thread adjuster assembly into base until it stops. Do not tighten.

8. Thread adjuster lock nut on to adjuster plug.

9. Hand tighten Lock nut.

10. Thread adjuster cap onto adjuster assembly. Hand tighten.

NOTE: Make sure cap threads freely on adjuster bottom.

11. Making the insert assembly.

This assembly consists of:
1 – Insert top
1 – Insert bottom
1 – Teflon® seat seal
2 – Small main o-ring

12. Press Teflon® seat seal into groove on the insert bottom. Make sure spring is facing upwards.

13. Install insert top over insert bottom with the seal side going in first.

14. Lightly lubricate O-Ring groove now formed by the two insert parts. This lubrication is used to hold the O-Ring
in place when it is being inserted into base.

15. Place small main O-Ring into groove.

16. Thread the insert assembly into base with T-handle groove wrench (part #4995401.) Tighten wrench tight.
Make sure milled slot is facing up.

17. Cycle main piston through Teflon® seat seal 10 times.

17A. For the Dirty Service option, (see Figure 7A), use steps 11 through 17 to build up the insert assembly
for the dirty insert.

18. Place large O-Ring in groove on top of base.

18A. For the Dirty Service option, install the o-ring in the groove on the dirty insert.

19. Install the Teflon® seal into yoke. The energizer spring should be facing you (down, toward the pressure) when
installed.

20. Install main piston yoke with the spring washer bearing point going in first.

21. Install main piston and yoke assembly into base by inserting small diameter end of piston through insert
assembly. Line up the yoke arms with the dome port and the inlet port.

21A. For the dirty service option, install the dirty insert on to the main valve base with the dirty insert inlet
port facing opposite the vent on the main pilot base.

42 Con-29
 21B. For the dirty service option, insert the small end of the piston into the insert assembly in the dirty insert
and through to the pilot valve base.

22. Lubricate and insert the four cap screws through the yoke and thread into the main base. Tighten to 300 in–lbs
+/– 30 in–lbs.

23. Lubricate and thread locknut onto compression screw.

24. Thread compression screw into top of yoke until the bearing point begins to protrude through yoke.

25. Place spring washers on the ends of the spring.

26. Place spring and spring washer assembly into the yoke and on top of main piston. Hold this assembly in place
while turning compression screw down to the top spring washer.

27. Tighten compression screw and locknut hand tight.

28. The pilot valve is ready to be calibrated prior to assembly on the main valve.

B. Assembly of Field Test Connector Field Test Connection

1. Install shuttle seat O-Ring into shuttle base.

2. Install tube filter into shuttle base.

3. Drop ball into tube filter.

4. Install shuttle new seat O-Ring into shuttle plug.

3
5. Install shuttle new plug O-Ring over threads on shuttle plug. 2

1
6. Place new tube filter and ball in shuttle base. REF.
2 NO. PART
1 Shuttle Ball
7. Lubricate and thread Shuttle Plug into Shuttle Base and tighten to
2 O-Ring
350 in–lbs +/– 35 in–lbs. 5 3 Shuttle Base
4 Shuttle Plug
4
5 Tube Filter
8. The field test connector is ready for test on 39MPV.
FIGURE 23

Con-29 43
 C. Gas or Liquid Modulator Assembly
1. Making the modulator piston assembly. REF.
This assembly consists of: 38 NO. NOMENCLATURE
30 O-Ring (Modulator Stop)
1 – Modulator piston top 40
31 O-Ring (Modulator Seat)
1 – Modulator piston bottom 37 32 O-Ring (Modulator Piston)
1 – O-Ring retainer 36 Spring Seal (Piston Bottom)
1 – Lock screw 37 Spring Seal (Piston Top)
32
1 – Small modulator O-Ring 38 Modulator Base
36 39 Modulator Stop
1 – Teflon® inlet seal
40 Modulator Piston Top
1 – Teflon® balance seal 41
41 Modulator Piston Bottom
1 – Medium modulator O-Ring 42 O-Ring Retainer
43 Lock Screw
2. Install Teflon® inlet seal into groove on modulator pis- 45 Cap Screw (Modulator)
31
ton top. Be sure to have the spring in the seal facing
up. 30
42
NOTE: Make sure that the proper service (gas or liq- 45 30 39 43
uid) is stamped on the top of the modulator piston
top. Steam service requires a liquid modulator. FIGURE 24

3. Install the piston seat O-Ring into groove on modu-

lator piston bottom.

4. Turn modulator piston bottom over and place small modulator piston O-Ring into inner groove.

5. Install spring energized Teflon® seal onto modulator piston bottom in outer groove. Make sure spring opening
is facing down.

6. Insert modulator piston top into modulator piston bottom through the side with the small modulator O-Ring and
the Teflon® balance seal.

7. Turn assembly over and install O-Ring retainer. The chamfered outside diameter goes in first.

8. Lubricate and thread lock screw through O-Ring retainer into modulator piston top. Tighten 40 in.–lbs +/– 5
in.–lbs.

9. Lubricate Teflon® seals before inserting into modulator base.

NOTE: Make sure that the proper service is stamped on the top of the modulator base and it matches what
is stamped on modulator piston top.

10. Insert modulator piston assembly into modulator base with the modulator piston top going in first. Push piston
in with thumbs until it stops. There will be some resistance due to the Teflon® seals compressing to fit into the
bore of the modulator base. If necessary for installation, insert the proper wrench into the lock screw. Lightly
tapping the wrench with a hammer will force the piston into the modulator base.

11. Lubricate and install both large modulator O-Rings into grooves on modulator piston stop.

Insert modulator stop into modulator base with the seat going in first. Make sure the side hole in the modula-
tor stop is facing towards the flat side of the modulator base.

12. Lubricate and thread the cap screws through the modulator stop into the pilot modulator. Tighten to 365 in.–lbs
+/– 30 in.–lbs.

44 Con-29
SECTION XXI.
Assembly of Pilot to the Main Valve
WITH STANDARD OPTIONS:

NOTE: Seal all pipe threads with a non-organic sealant or Teflon® tape.

1. Assemble the 1/2” NPT x 3/8” ferrule to the main valve cover plate. Tighten “wrench tight.”
2. Assemble the pilot mounting bracket to the main valve using cover plate stud nuts. Torque nuts to the value
listed in Table 9a or 9b.
3. Assemble the pilot to the mounting bracket using the two cap bolts (30) provided. Do not tighten.
4. Connect the dome sensing line (28) to the dome port of the pilot and the ferrule fitting in the main valve cover.
Tighten “wrench tight.”
5. Connect the inlet sensing line (27) to the pilot inlet port (23) and the inlet sensing fitting. Tighten “wrench tight.”
6. Tighten the two pilot-to-bracket Allen (30)cap bolts “wrench tight.”
7. Assemble remaining options. See Section XXIII.
8. Tighten all tubing connections wrench tight.
9. Connect the inlet sensing line (27), to the system pressure or to the sensing tube (38), if the sensing ring option
(39), is used.

WITH SENSING RING OPTION:

Remote sensing is the standard pressure connection to the pilot valve used on the 2900 Pilot Operated Safety
Relief Valve. However with the Sensing Ring Option, the pilot valve pressure can be picked up just before the inlet
of the main valve.
The center to face dimensions for a 1900 valve being replaced or converted should be reviewed.
The 2900 “Center to Outlet” dimension remains the same as a 1900 valve. However the “Center to Inlet” dimen-
sion increases by 1-1/2 inches due to the Sensing ring and two inlet gaskets (to be supplied by the customer). The
gaskets are to be inserted between the Valve Nozzle and the Sensing Ring and between the Sensing Ring and
the system flange.

28

23

30

27
Pipe in 29
System
Pressure

Sensing Ring
(optional)

38 39

FIGURE 25

Note: #38 Sensing Tube must be used with #39 Sensing Ring if used on 2900 MPV valve.

Con-29 45
 SECTION XXII.
General Information

General Information on Testing Set Pressure and Blowdown on

Pilot Operated Valves.

If testing is to be accomplished while the valve is installed on a pressurized system (in the field) it is possible to
adjust the blowdown as well as the set pressure as indicated in the field testing Section XXII.B.

If the valve has been removed from the installation for servicing, an extra precaution should be taken to prevent
an artificial indication of a long blowdown.

There is a maximum time delay of about .4 of a second as the plow of pressure from the dome flows through the
tubing that connects the pilot and it to the Main Valve. The greater the dome volume the more time it takes for the
evacuation of the dome.

Like wise the reverse is true when the valve is closing. It take time for the system pressure to flow through the
sensing line to fill up the dome and close the valve. During this period of time the main valve is open and dis-
charging pressure from the test vessel. The test vessel is still decreasing in pressure while Dome pressure builds
up to close the valve. The pressure gauge measuring the pressure in the test vessel after the valve has closed
shows an artificially long blowdown.

DO NOT ATTEMPT TO SET THE BLOWDOWN ON A 2900 SERIES POSRV IF THE PILOT VALVE DOME CON-
NECTION IS CONNECTED TO THE MAIN VALVE DOME AND THE VALVE IS TO BE TESTED ON A SHOP
TEST STAND. ATTEMPTING TO REDUCE BLOWDOWN IN THIS TEST SITUATION WILL RESULT IN RAPID
CYCLING OF THE MAIN VALVE UNDER NORMAL OPERATING CONDITIONS.

The 2900 Series Pilot Operated Pressure Relief Valve may be tested for set pressure as follows.

1. The first is to calibrate the Pilot Valve on a calibration stand prior to testing it on the main valve on a shop test
facility. Blowdown may also be established using this method.

2. The complete valve (main and pilot) can be tested in the field through the use of the Field Test Connection and
a pressure source that can attain set pressure. This method will also measure blowdown and will cause the
Main Valve to Open and discharge media.

46 Con-29
A. Pilot Valve Calibration/Strand
The pilot test stand should consist of the following equipment: (refer to Figure 26 for recommended set up.) All
equipment must be rated for at least 4200 psi (264 kg/cm2) psig pressure.
1. Suitable pressure source with regulator.
2. 1/2 cubic foot (14 liter) inlet side accumulator.
3. 1/30 cubic foot (1 liter) dome simulator.
4. Inlet and dome pressure gauges.
5. Inlet supply throttle valve.
6. Inlet supply vent/throttle valve.
7. Inlet supply and dome simulator pressure gauges.
The inlet accumulator and dome simulator should be fitted with a drain valve at the lowest point in the vessel to
allow draining moisture before testing.

SOURCE INLET 39MPV PILOT VALVE

SUPPLY
THROTTLE
VALVE VENT
THROTTLE
INLET VALVE
GAUGE

DOME
GAUGE

ACCUMULATOR

DOME

SIM
UL
AT
OR
DRAIN VALVE

FIGURE 26

NOTE:
Do not attempt to adjust blowdown when testing the pilot/main assembly. The 39PV and 39MV can only be
tested for set pressure and tightness when the pilot/main valve assembly is tested together.
NOTE:
The in-line accumulator must be at least 1/2 cubic foot (14 liters), in volume.
NOTE:
A suitable dome simulator may be made out of a short length of stainless steel tubing, tubing fittings and
a suitable pressure gauge. The dome simulator will increase in pressure as the pilot valve inlet increases
in pressure. Set pressure is indicated when the dome simulator pressure gauge drops off in pressure. As
inlet pressure is decreased in the pilot valve to 95% of the set pressure or 3 psig (.21 kg/cm2 ) whichever
is greater, the dome simulator should show an increase in pressure to match the inlet pressure.

Con-29 47
 A1. Pilot Calibration and Test Procedure
NOTE: The pilot should be adjusted for both set point and blowdown on a suitable test stand prior to
mounting on a main valve.

1. Mount the pilot on the stand.

2. Connect dome chamber to pilot.

3. Connect sensing line to pilot inlet.

A2. Definitions
1. Set Point: Point where vent pressure is felt from port.

2. Closing Point: Point where dome pressure begins to reload.

3. Blowdown: Set point minus closing point.

4. Notch: Any peak or valley on bottom of main pilot which is used for adjustment.

A3. Specific Steps

1. Pre-setting the Blowdown: Remove Adjuster Cap and install NPT pipe plug into top hole on flat surface of
pilot.

2. Turn Adjuster into base until it stops. Turn out 1 turn.

3. Adjust compression screw until dome pressure stops increasing between 75 and 125 psig. If set point is below
75 psig, use any dome pressure between 15 and 75 psig.

NOTE: If vent pressure is felt and dome pressure has not stopped, drop inlet pressure until it is not felt
and raise adjuster clockwise 1 flat.

4. Raise inlet pressure 0.5 to 5 psig above pressure found in step 8.3.2. Keep in mind the blowdown that is
required for the given set point.

NOTE: If pilot vents, continue with #5.

5. With finger over vent port, turn adjuster out slowly until the vent pressure is felt.

NOTE: If pressures become equal while adjusting, increase inlet pressure again until a differential pres-
sure occurs. Continue.

6. Lower inlet pressure until it equals dome pressure.

7. Increase inlet pressure. Dome pressure should have started dropping with 1% or 1 psig over pressure,
whichever is greater, of the point the vent pressure was felt.

NOTE: If dome pressure does not drop, adjuster has been turned out too far. Turn in (raise)1 flat and
repeat steps 3 through 7.

8. Check pilot for leakage at 10% or 5 psig, below set point, whichever is greater.

9. Final Setting of Seals

9a. Adjust compression screw to approximately +/–10% of set point of pilot. Final setting will be done later.

48 Con-29
10. Make adjustments in 2 notches or less. Match any corner of the square on the bottom of the adjuster to a notch
on the base. Only turn adjuster when there is less than 125 psig in dome.

11. Long Blowdown

Turn adjuster out.

12. Pilot flowing and dome not dropping at 1% or 1 psig over pressure, whichever is greater.

Turn adjuster in.

13. Adjusting Blowdown. Lower inlet pressure so that inlet and dome pressures are equal, approximately 90% of
Set Pressure.

14. Slowly increase pressure to note the set point.

15. Increase inlet pressure to 1% or 1 psig above set point, whichever is greater, and hold for a couple of seconds
to make sure dome pressure is dropping. If dome pressure is dropping, continue to increase to 10% over pres-
sure or 3 psig, whichever is greater. Dome pressure should drop to 0 psig. If dome pressure is not dropping,
adjust as noted in 16.

16. Slowly drop inlet pressure to note the closing point.

17. Use the following guidelines when setting blowdown.

18. For Gas Service:

S.P. is 15 to 75 psig: 0 to 1.5 psig blowdown

S.P. is 76 to 750 psig: 0% to 2% blowdown

S.P. is 751 to 3750 psig: 0% to 3% blowdown

For Liquid Service:

S.P. is 15 to 30 psig: 1 to 3 psig blowdown

S.P. is 31 to 75 psig: 2 to 4 psig blowdown

S.P. is 76 to 3750 psig: 3% to 6% blowdown.

19. If blowdown adjustments are necessary, increase inlet pressure to release dome pressure to less than 125
psig. Make adjustments as noted in #14 or #15 and retest beginning with #16.

20. If adjustments are not necessary, continue with 20.

21. Adjust compression screw for set pressure without modulator attached.

For 39PV
Set at 1% to 2% BELOW S.P. or 1 psig, whichever is greater.

For 39MV
Set at 0% to 1% BELOW S.P. or 1 psig, whichever is greater.

FOR EXAMPLE: S.P. = 150 psig

The following valves would be set at:
39PV01 & 39PV07 = 147.0 psig
Closing point = 144.1 psig
Pilot 0 BPM = 144 psig
Pilot <40 BPM = 165 psig

Con-29 49
 30 MV01 & 39MV07 = 148.5 psig
Closing point = 145.5 psig
Pilot 0 BPM = 144 psig
Pilot 0 BPM = 165 psig

S.P. = 1000 psig

The following valves would be set at:
39PV37 = 1000.0 psig
closing point = 970 psig
Pilot 0 BPM = 960 psig
Pilot 0 BPM = 1100 psig

22. After adjustments have been made, tighten locknut on compression screw and tighten adjuster cap to secure
settings.

23. Re-Verify Settings:

24. Lower inlet pressure so that inlet and dome pressures are equal. Approximately 90% of set pressure.

25. Slowly increase pressure to verify that pilot is tight (0 Bubbles per minute) at 4% below set point, or 2 psig
whichever is greater.

26. Increase inlet pressure to 1% or 1 psig above set point, whichever is greater, and hold for a couple of seconds
to make sure dome pressure is dropping. If dome pressure is dropping, continue to increase to 10% over pres-
sure or 3 psig, whichever is greater. Dome pressure should drop to 0 psig. If dome pressure is not dropping,
adjust as noted in #15 or #16. Retest beginning with #24.

27. Check rate of leakage from pilot at 10% or 3 psig, whichever is greater, above set point. It should be less than
40 BPM.

28. Slowly drop inlet pressure to note the closing point.

29. Final Test of Modulator. Remove pipe plug on flat modulator surface of main base. Check to verify that no
Teflon® tape has been left in vent port or the port above it.

30. Place two small modulator O-Rings into grooves on flat surface of main pilot.

31. Attach modulator to main base with two hollow head cap screws with 95 in–lbs. +/–10 in–lbs. of torque.

32. Re-pop pilot five times then check for the following:

33. Do not re-adjust compression screw or adjuster.

34. Pilot should be tight (0 Bubbles Per Minute) up to 4% below set pressure, or 2 psig, whichever is greater.

35. Pilot should be tight (0 Bubbles Per Minute) at 10% above set pressure, or 3 psig, whichever is greater.

36. When set pressure is above or equal to 75 psig, at 10% over pressure, or 3 psig, whichever is greater, the
dome pressure should drop to the following level:

GAS: 45% to 60% of S.P.

LIQUID: 15% TO 35% OF S.P.

37. When set pressure is below 75 psig, at 10% over pressure the dome pressure should drop to the following
level:

GAS: 0% to 60% of S.P.

LIQUID: 0% to 35% of S.P.

50 Con-29
A.4 Final Set Pressure Adjustment
Once the pilot valve set pressure and blowdown are calibrated on the pilot valve calibration stand, and the pilot
valve is installed on the main valve, increase the pressure on the main valve and check to see that set pressure
is within the popping pressure tolerance allowed for the set pressure of the valve. The Compression Screw may
be adjusted to fine tune the Set Pressure if necessary.

NOTE: The blowdown cannot be successfully adjusted in the shop when the pilot valve is installed on the
main valve. The pilot valve must be set on the pilot valve calibration stand.

A.5 Seat Tightness and Leakage Test

After the set point and blowdown have been set, the valve must be checked for seat tightness. Pressurize the valve
to 96% or within two psig of set pressure, whichever is greater. (Use a bubble cup filled with water to check for
leakage.) Check all fittings and ports for leakage.

B. Testing on Installation H! DANGER

Field testing may be used to verify the valve opening point on repaired valves, or
to periodically check the function of valves in service. A test set up similar to that
shown in Figure 27 should be used.

The set pressure of the 2900 series POSRV is defined as the pressure at which
the main valve opens. The following table indicates the allowable set pressure
tolerances according to the ASME Boiler and Pressure Vessel Code.

Required Set Point Tolerance

15-70 psig +/–2 psig
Do not stand or place
(1.05-4.92 kg/cm2) (+/–.14 kg/cm2) hand in front of valve
71 psig and greater (4.99 kg/cm2) +/–3% of the set pressure discharge flange if valve
is under pressure.

1. Loosen and remove the tubing connecting the pilot valve and the discharge flange.

2. Close the vent valve and isolation valve in Figure 27.

3. Connect the isolation valve to the pilot valve through the test port labeled “Test”. DO NOT REMOVE ANY
OTHER PLUGS.

4. Open the valve at the inlet neck of the nitrogen tank.

5. Turn the regulator control knob clockwise gradually until a pressure of 10 psi is indicated on the test gauge
attached to the regulator.

6. Open the vent valve to purge the test system.

7. Close the vent valve.

8. Increase the test pressure by turning the control knob on the regulator clockwise until the pilot valve begins to
vent.

Con-29 51
 9. Note the test gauge reading when the pilot valve vents. The pilot opening pressure should be within tolerances
referenced in Section XXII.B.

NOTE: The main valve will open using field test connection.

10. After the set pressure is noted, turn the control knob counterclockwise to reduce the pressure in the pilot valve
and close the main valve.

11. Confirm the pilot valve opening pressure by repeating the above test twice more for a total of three tests. All
test results should be within the proper set pressure tolerance.

Testing on Installation

PRESSURE ISOLATION VALVE

GAUGE

CONNECTION TO
NITROGEN VALVE TEST PLUG
REGULATOR

NITROGEN BOTTLE
VALVE VENT VALVE

NITROGEN
BOTTLE

TYPICAL FIELD
TEST ARRANGEMENT

Field Test Connection

FIGURE 27

52 Con-29
SECTION XXIII.
2900 Pilot Valve Options

A. Available Options

Backflow preventer
Auxiliary Canister Filter
Manual Blowdown
Dirty Service with Auxiliary Canister Filter
Heat Exchanger used on Cryogenic Service
Heat Exchanger used on Steam and Hot Service
Optional Line Filter 3
2

B. Backflow Preventer 1

FIELD DOME
REF. PART TEST LINE

BACKFLOW
NO. PREVENTOR 5
1 Shuttle Ball DISCHARGE
LINE

SENSING
2 O-Ring LINE 4
3 Shuttle Base
SENSING
4 Shuttle Plug RING
SENSING
TUBE
5 Tube Filter
PIPE TO
SYSTEM (OPTIONAL)
PRESSURE
CONNECT TO FIELD TEST
CONNECTOR TO ESTABLISH
SYSTEM PRESSURE IN PILOT

BACKFLOW PREVENTOR

BACKFLOW PREVENTER

Note: The backflow preventer is the same part as

the field test connection. FIGURE 28

When a pilot operated relief valve is not vented directly to atmosphere, it is possible to build up a back pressure
in the discharge line. This is typical in applications where several valves manifold into a common discharge head-
er. Should the discharge line back pressure exceed the valve inlet pressure, it could cause the main valve piston
to lift and allow reverse flow through the main valve. This trouble can be avoided by use of the Backflow Preventer
optional feature.

Con-29 53
 Backflow Preventer Maintenance

Backflow Preventer
DISASSEMBLY
Ref. Figure 28

Remove plug (located near the valve discharge flange) from body by unscrewing counterclockwise. Remove ball
and filter.

MAINTENANCE AND REASSEMBLY

Remove and discard O-Rings.

Clean all parts and inspect for damage and wear.

Lubricate O-Rings with silicone grease or equivalent.

Reassemble with new O-Rings. Ref. Table VIII, O-Ring kit information.

WITH BACKFLOW PREVENTER:

Refer to Figure 28 for location of Backflow Preventer, Pilot Valve, Mounting Plate, Tubing, etc.

1. Insert bushing into cover plate and tighten.

2. Insert threaded end of backflow preventer into bushing and tighten. Make sure that the 1/4-FNPT threads
are facing 90 degrees from pilot.

3. When viewed from the outlet of the valve, the right side is piped to the dome port of the pilot. The left side is
piped to the outlet of the main valve.

4. Install the pilot valve and sensing lines as described above.

5. Install the sensing line between the main valve outlet and the backflow sensing port.

54 Con-29
C. Auxiliary Canister Supply
Filter:
The supply filter is an option available and is used
to prevent foreign material from entering the
pilot valve.
CANISTER
1. The filter is connected to the main valve. See FILTER
Figure 29.

2. Connect and tighten the inlet sensing line to the

inlet of the filter and the sensing fitting at the
inlet of the main valve.
SENSING
3. Connect and tighten the pilot sensing line to the RING
outlet of the filter and the pilot valve inlet sens- SENSING
TUBE
ing port.
PIPE TO
SYSTEM
PRESSURE (OPTIONAL)

CONNECT TO FIELD TEST

CONNECTOR TO ESTABLISH
SYSTEM PRESSURE IN PILOT

FIGURE 29

D. Manual Blowdown

Manual DOME

Blowdown H! WARNING FIELD

TEST
LINE

MANUAL
BLOWDOWN

An optional manual
blowdown valve is
available for opening
the main valve. See
Figure 30. When SENSING
LINE
open, the manual
blowdown valve
SENSING
reduces the pressure RING
above the main valve Know all valve SENSING
disc head, allowing exhaust/leakage points TUBE
the main valve to to avoid possible severe
open. personal injury or death. PIPE TO
SYSTEM (OPTIONAL)
PRESSURE
CONNECT TO FIELD TEST
CONNECTOR TO ESTABLISH
SYSTEM PRESSURE IN PILOT

MANUAL BLOWDOWN

FIGURE 30

Con-29 55
 E. Auxiliary Canister and Dirty Service Option

DOME
LINE

FIELD
TEST
REGULATOR

CANISTER
FILTER

TO CLEAN
MEDIA SOURCE

SENSING
LINE

TO
DIRTY
MEDIA
SOURCE
SENSING
RING

SENSING
TUBE

(OPTIONAL)

CONNECT TO FIELD TEST

CONNECTOR TO ESTABLISH
SYSTEM PRESSURE IN PILOT

FIGURE 31

F. Heat Exchanger used on Cryogenic Service

SENSING
Pilot valves are traditionally limited to the service LINE
ranges on its elastomers and Teflon® products.

The 2900 series valve , metal seat design is able to

HEAT EXCHANGER
operate at a design temperature that is above 505°F
and below 40°F with the use of an air cooled or air
warmed Heat Exchanger. For temperatures 41°F BRACKET
and below as well as those 506°F and above consult
the factory. The Heat exchanger located upstream of
the pilot valve in order to condition the temperature
of the process fluid within the acceptable range of SENSING
LINE
the pilot valve and soft goods (see figure 7A). The
Heat exchanger must be sized and selected to meet
the service conditions for each application and valve SENSING
size. RING

SENSING
WARNING: Medium may freeze if ambient tem- TUBE

perature drops below the freezing point of the PIPE TO

media when a heat exchanger is installed. SYSTEM
SENSING RING
PRESSURE
(OPTIONAL)
CRYOGENIC CONNECT TO FIELD TEST
CONNECTOR TO ESTABLISH
SERVICE SYSTEM PRESSURE IN PILOT

FIGURE 32

56 Con-29
G. Heat Exchanger for Steam and Hot Service
SENSING
LINE

HEAT EXCHANGER

BRACKET

SENSING
LINE

SENSING
RING

SENSING
TUBE

PIPE TO
SYSTEM
PRESSURE SENSING RING
(OPTIONAL)
CONNECT TO FIELD TEST
CONNECTOR TO ESTABLISH
SYSTEM PRESSURE IN PILOT

FIGURE 33

H. Optional Line Filter (Standard with Steam Option)

FIELD
Filter TEST
DOME
LINE

Additional protection for the standard,

filtered pilot valve is provided by an
optional sensing line pilot filter. See Fig.
LINE
34. Greater filter capacity will boost FILTER
removal of unusual amounts of scale,
deposits or foreign particles, which oth- SENSING SENSING
RING
erwise may obstruct the sensing line, LINE

causing malfunction of the pilot. SENSING

TUBE

PIPE TO
SYSTEM (OPTIONAL)
PRESSURE
CONNECT TO FIELD TEST
CONNECTOR TO ESTABLISH
SYSTEM PRESSURE IN PILOT

FIGURE 34

Con-29 57
 I. Assembly of Options and Alternative Piping
Additional information concerning the installation and appropriate piping designs is available in the Consolidated
2900 Series Pilot Operated Safety Relief Valve Catalog. Suggested References begin on page 2900.42 and con-
tinue through 2900.62

SECTION XXIV.
Troubleshooting
Problem Possible Cause Corrective Action

Pilot valve is not open at set A. Wrong set Pressure. A. Readjust the set pressure
pressure and main valve will valve of the valve.
not open.

Main valve does not close A. Start-up procedures pres- A. Slowly increase the inlet
upon start up, P2 chamber surize the valve too rapid- pressure.
does not load with system. ly.
B. Sensing tube is installed B. Re-install the sensing tube
upside down. correctly.
C. Closed filter. C. Clear or replace.

A. Operating pressure too A. Adjust operating pressure.

Leakage through the Pilot high. B. Disassemble and replace
Valve B. O-ring or seal degradation. O-Ring or seals.

A. Back pressure is greater A. Install backflow preventer.

than the set pressure and
Main Valve opens and allows forces the main disc up,
the discharge media to flow and the media flows back-
back into the pressure ves- ward into the vessel.
sel. B. Discharging into a closed B. Install backflow preventer.
container or not enough
capacity in the discharge
system.

Blowdown incorrect A. Incorrect Adjuster Plug A. Re-set Adjuster Plug (See

Setting Pilot Valve Settings)

Leakage around fittings A. Fittings are not tightened A. Re-install fittings correctly.
or are cross threaded.

Leakage under the cover A. Guide or coverplate gasket A. Disassemble valve and
plate when valve is open. is damaged. replace gasket.
B. Cap screws or stud nuts B. Tighten as required.
on coverplate are loose.

Main valve leaks through the A. Damaged seat O-Ring A. Disassemble valve and
seat. replace O-Ring.

B. Damaged metal seat B. Disassemble valve and

replace seating surfacer.

TABLE 11

58 Con-29
SECTION XXV. Identify valve by the following nameplate data:
Replacement Parts Planning A. Size
B. Type
C. Pressure/Temperature Class Rating
A. Basic Guidelines D. Serial Numbers from both main valve and pilot
valve
The following guidelines should be of assistance in
developing a meaningful replacement parts plan. Example:

A. The total number of valves in service should be POSRV IDENTIFICATION

classified by size, type and temperature class.
NAMEPLATES (2) FOR MAIN VALVE
B. The parts inventory should be classified by the
tendency to require replacement.
CONSOLIDATED
Class I – Most frequently replaced CERTIFIED ALEXANDRIA,
Class II – Less frequently replaced but critical BY Flow Control
LOUISIANA, USA

in an emergency TYPE

ALEXANDRIA
C. Parts for the valve types covered by this manu- SIZE
LOUISIANA, USA
SERIAL
NO.
al are classified on Table 12. “Qty. parts” is the num- SET PSI CDTP PSI
PRESS.
ber of parts or sets which is recommended to BACK PSI TEMP. °F
PRESS.
achieve a desired need-probability, as it relates to LBS/HR. STD. CU. FT. /
CAP.
the total number of valves in service by size and SAT. STEAM MIN. AIR
GPM STD. CU. FT. /
type. For example, a “Qty. parts” of 1 for “Valves in CAP. WATER MIN. N.G.

service” of 5 means that 1 part should be stocked for B/M DATE

each 5 valves of the same type and size in service.

D. When ordering replacement parts, please spec-

FIGURE 35
ify in accordance with applicable nomenclature (see
Figures 6, 7 or 8). Be sure to state the size, type and
serial number of the valve for which parts are
required. When ordering pilot parts please state THIS VALVE CONTAINS
specific pilot type (39PV07, 37, etc.) TEFLON® SEALS AND AN
For ease of maintenance O-Ring kits are avail- O-RING
SEAT SEAL
able for each main valve and pilot type. A stock of
O-RING
these kits should be kept on hand for maximum PART NO.
operating efficiency. See Section XXVII.
FIGURE 36

NAMEPLATE FOR PILOT VALVE

CONSOLIDATED
ALEXANDRIA
Flow Control LOUISIANA, USA

B. Identification and Ordering PILOT VALVE

MODEL
Essentials NO.

SERIAL
NO.
Identification and Ordering Essentials O-RING
SET
PRESS.
When ordering service parts, please furnish the fol- B/M DATE
lowing information to ensure receiving the correct
replacement parts.
FIGURE 37

Con-29 59
 How to verify materials of
O-Rings and Seals

Kit coding indicates O-Ring and seals material.

Examples:
PSGK-38B018 B018 = Buna N 70
B008 = Buna N 90
PSGK-35V022 V022 = Viton® 75
V005 = Viton® 90
T006 = Teflon®
PSGK-32E019 E002 = Ethylene 90
Propylene
E019 = Propylene 70

Note: For Kalrez material, contact factory

C. Positive Identification of Main Valve and Pilot Valve

Combinations
POSRV’s shipped direct from the factory to the end-user probably have main valves and pilot valves with identical
serial numbers (S/N’s). Those shipped unconnected to the Dresser Green Tag network may have main valves and
pilot valves with different S/N’s. During service and repair, the following inspection steps will ensure the proper
match of main valves to pilot valves.
1. Record main valve and pilot valve S/N’s of original POSRV’s in plant records.
2. Inspect S/N’s for agreement with Step 1, after any disassembly involving removal of pilot valve from main
valve.
3. Make sure the set pressures of the main valve and pilot valve are identical.
4. Check O-Ring and Seals Kit material code to ensure they are the same for main valve and pilot valve.
Any discrepancies should be promptly report to the appropriate plant authority.
Specify parts required by:
1. Part Name (See Nomenclature. See Figures 1, 2 & 3)
2. Part Number (if known)
3. Quantity
Contact Parts Marketing: 1-318-640-2250
In addition, the main valve serial number is stamped on the top edge of the outlet flange. Be sure to include the
one or two letters preceding the figures in the serial number. Typical valve nameplates are shown in Figures 35,
36 and 37.

60 Con-29
D. Recommended Spare Parts
PILOT OPERATED SAFETY RELIEF VALVES (POSRV)
FOR 2900-1 MAIN VALVE
CLASS PART NAME

Guide Ring on Piston

Class 1 parts should be stocked at the rate of one Disc
(1) per valve. Maintaining this level of spare parts I Retainer Ring on Disc
will provide replacement parts for 70% of possible *O-Ring
maintenance requirements. *Spring Energized Teflon® Seal
Gasket (1)
Gasket (2)

Class II parts should be stocked at the rate of one Stud (2)

(1) part per each five (5) valves in the population. Nozzle
Class II parts will provide replacement parts of an Disc Holder
additional 15% of possible maintenance require- II
ments.

A combination of Class I and II parts will satisfy maintenance requirements 85% of the time.

**Note: Depending on service, either an O-ring or Spring Energized Teflon® Seal is required.
TABLE 12

Con-29 61
 XXVI. Special Tools

A. Insert Installation Tool

2
1
1
WELD WELD

90°
2
2

3 1/2 (REF)

90° 3 WELD

3
125

3/8 .148
125
ASSEMBLY
.297

4 32
.250 HEX (NOTE 1) .238 ± .002 DIA
1 1/2
.080 DIA

32 10°

.125 (TYP)
ITEM 1
SCALE: 2-1

2 15/16 .750

125 5/16 SQ

.250 DIA
ITEM 2 ITEM 3
SCALE: 2-1
SCALE: 2-1

FIGURE 38

62 Con-29
B. Adjuster Top Seal Insertion Tool
ASSEMBLY VIEW OF INSERTION TOOL

Seal

Plunger

Plunger Cylinder
Funnel Tube

DETAIL OF PLUNGER CYLINDER

.375 ± .002 A

ø5/32
A
ø9/16
1/32 ø15/64
1/4
1 15/32

DETAIL OF FUNNEL TUBE

5/32
A
.520 ± .002 .380 ± .002
.465 ± .003

1 1/16

DETAIL OF PLUNGER
1.00

.145 ± .002

.375 ± .002

1 9/16

FIGURE 39

Con-29 63
64
C. Disc Holder and Guide Removal and Assembly Tool

DET. 4

I
K 95°
J DET. 5
C
DET. 1
E
D K A
C
M
95° 95° D
DET. 2
H
G M THREADS
DET. 3 DET. 4
F DET. 5
DET. 4 DRILL L DIA. HOLE

95° DET. 3
DET. 5

FIGURE 40

Disassembly See Notes Dia. Dia. Dia. Dia. Dia. Dia. Dia. Dia. Radius Radius Dia. Dia. Drill NC Tap
Tool for Eye Jam “A” “B” “C” “D” “E” “F” “G” “H” “I” “J” “K” “L” Size Size
Orifices Sizes Bolt Nut M M
D,E,F,G,H,J #1 #5 .703 .250 .437 .730 .094 .750 .406 .156 .047 .034 .798 .375 #7 1/4-20
K&L #2 #6 .828 .250 .437 .847 .125 .750 .438 .188 .062 .040 .927 .375 5/16 3/8-16
M&N #3 #7 .828 .250 .437 .828 .125 .750 .438 .188 .062 .047 1.126 .500 5/16 3/8-16
P,Q,R,T #4 #8 1.375 .376 .750 1.375 .125 1.000 .750 .375 .094 .055 1.834 .750 17/32 5/8-11
Notes:
1) Use a Standard Eye-Bolt – 1/4"-20 thd. x 3-1/2" Long
2) Use a Standard Eye-Bolt – 3/8"-16 thd. x 4-1/2" Long
3) Use a Standard Eye-Bolt – 3/8"-16 thd. x 4-1/2" Long
4) Use a Standard Eye-Bolt – 5/8"-11 thd. x 4-1/2" Long
5) Use a Standard Nut – 1/4"-20 thd.
6) Use a Standard Nut – 3/8"-16 thd.
7) Use a Standard Nut – 3/8"-16 thd.
8) Use a Standard Nut – 5/8"-11 thd.

Note: Use an appropriate sized O-ring in groove “I,” to hold the parts together.

Con-29
TABLE 13
SECTION XXVII
Replacement Parts Kits
39PV-2 PILOT VALVE SEAL KITS
Material Class “CC” per configuration
PILOT VALVE SEAL KITS
PILOT MATERIAL PART NO.
39PV07-2 GS & LS Buna N (Nitrile 70) PSGK-38B018
39PV07-2 GS & LS Viton® (Fluoro-Carbon 75) PSGK-38V022
39PV07-2 GS & LS E.P.R. (Ethylene Propylene 70) PSGK-38E019
39PV07-2 GS, LS & SS Teflon® PSGK-38T006
39PV07-2 SS E.P.R. (Ethylene Propylene 90) PSGK-38E002
39PV37-2 GS & LS Buna N (Nitrile 70) PSGK-35B018
39PV37-2 GS & LS Viton® (Fluoro-Carbon 75) PSGK-35V022
39PV37-2 GS & LS E.P.R. (Ethylene Propylene 70) PSGK-35E019
39PV37-2 GS & LS Teflon® PSGK-35T006
Pilot valve seal kits consist of o-rings in materials shown above, spring energized Teflon® seals, one 9/32” ball,
one tube filter, grease and instruction sheet.
TABLE 14

39MPV-2 PILOT VALVE MODULATOR

SERVICE PART NO.
With Spring Energized Teflon® Seals and Buna N (Nitrile 70) O-rings
Gas 4985001
Liquid 5040301
With Spring Energized Teflon® Seals and Viton® (Fluoro-Carbon 75) O-rings
Gas 4985002
Liquid 5040302
With Spring Energized Teflon® Seals and E.P.R. (Ethylene Propylene 70) O-rings
Gas 4985003
Liquid 5040303
With Spring Energized Teflon® Seals and Teflon® O-rings
Gas 4985005
Liquid & Steam 5040306
With Spring Energized Teflon® Seals and E.P.R. (Ethylene Propylene 90) O-rings
Steam 5040307
Note: For repair or replacement of 39MV, or conversion of Pop Pilot (39PV) to Modulating
Pilot (39MV). The pilot valve modulator listed is a complete assembly including
necessary mounting screws.
TABLE 15

Con-29 65
 39MPV-2 PILOT VALVE MODULATOR
SEAL KITS FOR MODULATOR CONVERSION OR REPAIR KIT
CONTAINS SPRING ENERGIZED TEFLON® SEALS AND O-RINGS AS INDICATED.

SERVICE MATERIAL PART NO.

Gas Buna N (Nitrile 70) PSGK-32B018
Liquid PSGK-34B018
Gas Viton® (Fluoro-Carbon 75) PSGK-32V022
Liquid PSGK-34V022
Gas E.P.R. (Ethylene Propylene 70) PSGK-32E019
Liquid PSGK-34E019
Gas Teflon® PSGK-32T006
Liquid PSGK-34T006
Steam PSGK-34T006
Steam E.P.R. (Ethylene Propylene 90) PSGK-34E002
Note: A modulating valve requires both a pilot valve seal kit and a seal kit for modulator
conversion or repair.
TABLE 16

II. d) 39MPV-2 PILOT VALVE MODULATOR

BACKFLOW PREVENTER/FIELD TEST CONNECTION

39PV-2 BACKFLOW PREVENTER KIT

MATERIAL PART NO.
Buna N (Nitrile 70) PAP79B018
E.P.R. (Ethylene Propylene 70) PAP79E019
Viton® (Fluoro-Carbon 75) PAP79V022
Teflon® PAP79T006
E.P.R. (Ethylene Propylene 90) PAP79E002
EACH KIT CONSISTS OF:
DESCRIPTION QTY. PART NO.
Fitting 1 **6000609
Fitting 1 **6000608
Reducing Bushing 1 4941504
TABLE 17

AND ONE OF THE FOLLOWING SHUTTLE VALVE ASSEMBLIES:

SEAL MATERIAL PART NO.
Buna N (Nitrile 70) 5040101
Viton® (Fluoro-Carbon 75) 5040102
E.P.R. (Ethylene Propylene 70) 5040103
Teflon® 5040105
E.P.R. (Ethylene Propylene 90) 5040106
TABLE 18

66 Con-29
 39MV-2 BACKFLOW PREVENTER KIT
Material Class “CC” per configuration
MATERIAL PART NO.
Buna N (Nitrile 70) PAP79B018
Viton® (Fluoro-Carbon 75) PAP79V022
E.P.R. (Ethylene Propylene 70) PAP79E019
Teflon® PAP79T006
E.P.R. (Ethylene Propylene 90) PAP79E002
EACH KIT CONSISTS OF:
DESCRIPTION QTY. PART NO.
*Fitting 1 **6000622
*Fitting 1 **6000608
Reducing Bushing 1 4941504
TABLE 19

AND ONE OF THE FOLLOWING SHUTTLE VALVE ASSEMBLIES:

SEAL MATERIAL PART NO.
Buna N (Nitrile 70) 5040101
Viton® (Fluoro-Carbon 75) 5040102
E.P.R. (Ethylene Propylene 70) 5040103
Teflon® 5040105
E.P.R. (Ethylene Propylene 90) 5040106
Note: Field Test Connector Consist of one of the Select Shuttle Valve
Assemblies Shown Above.
* Fittings are Swagelok – other brands available.
** SP561-Q replaced by 6000609
SP561-R replaced by 6000608
SP468-G replaced by 6000622

TABLE 20

39MV-2 PILOT VALVE MODULATOR

SEAL KITS FOR REPAIR OR CONVERSION OF BACKFLOW PREVENTER OR FIELD TEST CONNECTION

BACKFLOW PREVENTER SEAL KITS

MATERIAL PART NO.
Buna N (Nitrile 70) PSGK-37B018
Viton® (Fluoro-Carbon 75) PSGK-37V022
E.P.R. (Ethylene Propylene 70) PSGK-37E019
Teflon® PSGK-37T006
E.P.R. (Ethylene Propylene 90) PSGK-37E002
TABLE 21

MANUAL BLOWDOWN
MANUAL BLOWDOWN VALVE ASSEMBLY
Material Class “CC” per configuration
PART NO.
PAP72
TABLE 22
Con-29 67
 Note: PAP72 is listed above, PAP75 shown in the 39MV bill of materials is identi-
cal to PAP72. PAP75 and PAP72 are interchangeable.

MANUAL BLOWDOWN VALVE ASSEMBLY CONSIST OF:

DESCRIPTION QTY. PART NO.
Needle Valve 1 SP348-E
*Fitting 1 **62000622
*Fitting is Swagelok – other brands available.
** SP468-AE replaced by 6000622
TABLE 23

III. PILOT VALVE OPTIONS

Material Class “CC” per configuration
LINE FILTER
LINE FILTER ASSEMBLY
SEAL MATERIAL PART NO.
TEFLON® SP540-J
LINE FILTER KIT (FOR REPAIR OF LINE FILTER ASSEMBLY)
SEAL MATERIAL PART NO.
TEFLON® SP540-J Kit
Line filter kit consists of filter element and two Teflon® o-rings only

TABLE 24

HIGH CAPACITY FILTER SPRING COVER

HIGH CAPACITY FILTER/CC
SPRING COVER
SEAL MATERIAL PART NO.
TEFLON® 9465-1851 MATERIAL PART NO.
HIGH CAPACITY FILTER/S4
SEAL MATERIAL PART NO. PEEK 4982901
TEFLON® 9465-18191 BONNET METAL COVER KIT 9999742
BONNET 5039701
HIGH CAPACITY FILTER REPLACEMENT PARTS CLOTH SOCK TO GO OVER YOKE 9999740

NO. REQUIRED TABLE 26

DESCRIPTION PART NO.
PER VALVE
FILTER ELEMENT 6027301 1
O-RINGS 31006131 2
TABLE 25

PILOT VALVE HARDWARE

TUBING
MOUNTING BRACKET SCREWS TUBING
NO. REQUIRED DESCRIPTION PART NO.
DESCRIPTION PART NO. PER VALVE Low Pressure Tubing S31607310004
High Pressure Tubing S31607310124
SS SCREW 2310166 2
Tubing is sold in 4 foot sections.
2916 requires high pressure tubing.
TABLE 27
TABLE 28
68 Con-29
SECTION XXVIII.
Manufacturer’s Field Service, Repair and Training Program

A. Field Service
Utilities and Process Industries expect and demand service on a moment’s notice. CONSOLIDATED® Field Service
can be depended upon for prompt response, even in extreme off-hour emergency situations.

Dresser, Inc. maintains the largest and most competent field service staff in the Industry. Service Engineers are
located at strategic points throughout the United State to respond to customer’s requirements for service. Each
Service Engineer is factory trained and long experienced in servicing Safety Valves. Dresser Service Engineers
restore disc and nozzle critical dimensions which affect valve performance and are capable of modernizing valves
in the field.

It is highly recommended that the professional talents of a Dresser, Inc. Field Service Engineer be employed to
make final field adjustments during the initial setting of all CONSOLIDATED® POSRV’s.

All Field Service Engineer’s activities are coordinated from the Alexandria, Louisiana, Field Service Office. Upon
receipt of a purchase order number authorizing the trip, the service engineer is dispatched.

Contact: Field Service Dept.,

Field Service Supervisor, (318) 640-6055

B. Factory Repair Facilities

The factory at Alexandria, Louisiana maintains a CONSOLIDATED® Repair Center. The Repair Department, in con-
junction with the manufacturing facilities, is equipped to perform specialized repairs and product modifications, e.g.
butt-weld, bushing replacements, code welding, pilot replacement, etc.

Contact: Repair Dept., Mgr. Valve Repair,

(318) 640-6057

Safety Relief Valve Maintenance Training

Rising costs of maintenance and repair in the Utility and Process Industries indicate the need for trained mainte-
nance personnel. Dresser Flow Control conducts service seminars that can help your maintenance and engineer-
ing personnel to reduce these costs.

Seminars, conducted either at your site, or at our Alexandria, Louisiana manufacturing plant, provide participants
with an introduction to the basics of preventive maintenance necessary to minimize downtime, reduce unplanned
repairs 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,
trouble shooting, setting and testing, with emphasis on the ASME Boiler and Pressure Vessel Code.

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

Con-29 69
 SECTION XXIX.
Glossary
General
PRESSURE RELIEF DEVICE –
a device designed to prevent internal fluid pressure from rising above a predetermined maximum pressure in a
pressure vessel exposed to emergency or abnormal conditions.

PILOT OPERATED PRESSURE RELIEF VALVE–

a pressure relief valve in which the major relieving device is combined with, and is controlled by, a self-actuated
auxiliary pressure relief valve.

DISC–
the pressure containing movable element of a pressure relief valve which effects closure.

NOZZLE–
a pressure containing element which constitutes the inlet flow passage and includes the fixed portion of the seat
closure.

SEAT–
the pressure containing contact between the fixed and moving portions of the pressure containing elements of a
valve.

BORE AREA–
the minimum cross-sectional flow area of a nozzle.

LIFT–
the actual travel of the disc away from the closed position when a valve is relieving.

70 Con-29
Operational Characteristics
SET PRESSURE–
the gauge pressure at the valve inlet for which the PRV has been adjusted to open under service conditions. In
liquid service, set pressure is determined by the inlet pressure at which the valve starts to discharge a continuous
stream of liquid. In gas or vapor service, the set pressure is determined by the inlet pressure at which the valve
pops.

OPERATING PRESSURE–
the gauge pressure to which the vessel is normally subjected in service. A suitable margin is provided between
operating pressure and maximum allowable working pressure. For assured safe operation, the operating pressure
should be at least 10% under the maximum allowable working pressure or 5 psi (.34 bar), whichever is greater.

OPERATING AND SET PRESSURE DIFFERENTIAL–

valves in process service will generally give best results if the operating pressure does not exceed 90% of the set
pressure.

On pump and compressor discharge lines, however, the differential required between the operating and set pres-
sures may be greater because of pressure pulsations coming from a reciprocating piston. It is recommended that
the valve be set as high above the operating pressure as possible.

MAXIMUM ALLOWABLE WORKING PRESSURE–

Maximum allowable working pressure is the maximum gauge pressure permissible in a vessel at a designated
temperature. A vessel may not be operated above this pressure, or its equivalent, at any metal temperature other
than that used in its design. Consequently, for that metal temperature, it is the highest pressure at which the pri-
mary pressure safety relief valve is set to open.

ACCUMULATION–
pressure increase over the maximum allowable working pressure of the vessel during discharge through the pres-
sure relief valve, expressed as a percentage of that pressure, or pounds per square inch.

OVERPRESSURE–
Overpressure is a pressure increase over the set pressure of the primary relieving device. Overpressure is similar
to accumulation when the relieving device is set at the maximum allowable working pressure of the vessel.
Normally, overpressure is expressed as a percentage of set pressure.

RATED CAPACITY–
Rated capacity is the percentage of measured flow at an authorized percent overpressure permitted by the applic-
able code. Rated capacity is generally expressed in pounds per hour (lb/hr) for vapors; standard cubic feet per
minute (SCFM) or m3/min for gases; and in gallons per minute (GPM) for liquids.

BLOWDOWN–
Blowdown is the difference between set pressure and reseating pressure of a pressure relief valve, expressed as
a percentage of the set pressure, or actual pressure units.

BACK PRESSURE–
pressure on the discharge side of a pressure relief valve, distinguished as follows:
1. Superimposed Back Pressure which occurs prior to valve opening:
a. Constant–consistent back pressure on the outlet (e.g. 20 psig).
b. Variable–fluctuating back pressure (e.g. 0 to 35 psig).
2. Built-up back pressure which occurs as (or after) the valve opens (e.g. builds to 25 psig).

Con-29 71
Sales Offices
UNITED STATES CHINA MALAYSIA SPAIN
Dresser Flow Control Dresser Valve Division Dresser Valve Division Dresser Valve Division
Dresser, Inc. Suite 2403, Capital Mansion Far East Regional Office Masoneilan, S.A.
LA. Hwy. 3225 @ U.S. Hwy. 167 N 6 Xinyuannan Road, Cho Yang Business Suite 19A-9-1, Level 9 C/Murcia 39 C
P.O. Box 1430 District UOA Centre, No. 19 Jalan Pinang 08830 Sant Boi de
Alexandria, Louisiana 71309-1430 Beijing, China 100040 50450 Kuala Lumpur, West Malaysia Barcelona, Spain
Telephone 1-318-640-2250 Telephone 86-10-6466-1164 Telephone (60-3) 2163-2322 Telephone: (34) 93-652-6430
Fax 1-318-640-6222 Fax 86-10-6466-0195 Fax (60-3) 2163-6312 Fax: (34) 93-652-6444

Northern Region FRANCE MEXICO UNITED ARAB EMIRATES

Dresser Flow Control Dresser Produits Industrials Dresser Valve de Mexico, S.A. de C.V. Dresser Valve Division
Dresser, Inc. 4 Place de Saverne Av. Henry Ford No. 114 Esq. Fulton Middle East Operations
85 Bodwell Street 92971 Coabevoie Fraccionamiento Ind. San Nicholas P. O. Box 61302
Avon, Massachusetts 02322 Telephone 33-1-49-04-9000 54030 Tlalnepantla, Estado de Mexico Jebel Ali Free Zone
Telephone 1-508-586-4600 Fax 33-1-49-04-9020 Telephone (52) 5-310-9863 United Arab Emirates
Fax 1-508-941-5497 Fax (52) 5-310-5584 Courier:
GERMANY Units Nos. JA01 + JA02
Southern Region Dresser Valve Europe SAUDI ARABIA Roundabout 8
Dresser Flow Control Klein-Kollenburg Strasse 78-80 Dresser Al Rushaid Valve Jebel Ali Free Zone
Dresser, Inc. P.O. Box 1208 & Instrument Co., Ltd. United Arab Emirates
11100 West Airport Blvd. 47877 Willich, Germany P.O. Box 10145 Telephone (971) 4-838752
Stafford, TX 77477-3014 Telephone (49) 2156-91890 Jubail Industrial City 31961 Fax (971) 4-838038
Telephone 1-281-568-2211 Fax (49) 2156-41058 Kingdom of Saudi Arabia
Fax 1-281-568-6731 Telephone (966) 3-341-0278 UNITED KINGDOM
ITALY Fax (966) 3-341-7624 DI UK Ltd.
BRAZIL Dresser Italia S.p.A. Unit 4, Suite 1.1
Dresser Industria E Comercio Ltda. Masoneilan Operation SINGAPORE Nobel House
Rua Senador Verqueiro, 433 Via Cassano 77 Dresser Singapore, Pte. Ltd. Grand Union Office Park
09521-320 Sao Caetano Do Sul P.O. Box 123 Dresser Valve Division Packet Boat Ln.
Sao Paulo, Brazil 80020 Casavatore (Naples) 16, Tuas Ave 8 Uxbridge, Middlesex
Telephone (55) 11-453-5511 Italy Singapore 639231 England UB8 2GH
Fax (55) 11-453-5565 Telephone (39) 81-789-2111 Telephone (65) 861-6100 Telephone (44) 1895-454900
Fax (39) 81-789-2259 Fax (65) 861-7172 Fax (44) 1895-454919
CANADA Telex (851) 627039
DI Canada, Inc. JAPAN SOUTH AFRICA
5010 North Service Road Nigata Masoneilan Co., Ltd. Dresser Limited, South Africa Branch
Burlington, Ontario L7L 5R5 Dresser Valve Division Valve Division
Canada 20th Floor Marive East Tower P.O. Box 2234, 16 Edendale Road
Telephone 1-905-335-3529 WBG 2-6 Nakase, Mihama-Ku, Eastleigh, Edenvale 1610
Fax 1-905-336-7628 Chiba-shi, Chiba 261-7120 Japan Republic of South Africa
Telephone (81) 43-297-9222 Telephone (27) 11-452-1550
DI Canada, Inc. Fax (81) 43-299-1115 Fax (27) 11-452-2903
#333-5th Ave. SW Suite 1100
Calgary, Alberta KOREA Dresser Valve Division
T2P 3B6 Canada Dresser Korea, Inc. Plot 90, Ajose Adeogun Street
Telephone 1-403-290-0001 #2107 Kuk Dong Building Victoria Island, Lagoe
Fax 1-403-299-1526 60-1, 3-Ka, Choongmu-ro, Chung-Ku Lagos, Nigeria
Seoul, Korea Telephone (23) 41-2620765
Telephone (82) 2-274-0792 Fax (23) 41-2620768
Fax (82) 2-274-0794
FOR YOUR GREEN TAG
CENTER IN USA/CANADA
CALL 1-800-245-VALV
or contact the locations listed above
for international service.

Consolidated is a registered Trademark of Dresser, Inc., all other referenced

Brands or trade Names are Trademarks of their respective companies.
Copyright 2000. Dresser, Inc.
72 Con-29