Operation & Maintenance Manual For Safety Valve

Doosan Heavy Industries
& Construction
Seoul Office
1303-22, Seocho-Dong, Seocho-Gu,
Seoul, 137-920, Korea
T +82 2 513 6114
F +82 2 513 6200
FOR COMMENTS
A 22-05-2013 K.H.LEE T.G.LEE J.Y.KIM FOR COMMENTS

Rev Date Prepared Checked Approved Details of Revision
Owner
AES-VCM MONG DUONG
POWER COMPANY LIMITED

Consultant
POWER ENGINEERING CONSULTING
JOINT STOCK COMPANY 2

Contractor
Doosan Heavy Industries & Construction Co., Ltd.
Project PC T10206
Mong Duong II 2 x 560MW(NET) UAS CT00
COAL FIRED POWER PROJECT UNIT P0
Title KKS UHA

Operation & Maintenance Manual for Safety Valve
Reg. No. 310086
Rev. A
Document No. Page-No.
T10206-CT00-P0UHA-310086 1 of 176
®
Consolidated
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
®
Consolidated Safety Valve
Type 1700-2-S and 1700-3-S
Type
1700
Series
CON-16
Industrial Valve Operation 2/99
Dresser Valve and Controls Division
Alexandria, Louisiana 71309-1430 (USA)
1. Product Safety Sign and Label System
DANGER — Immediate
hazards which WILL result If and when required, appropriate safety labels have been included in the
in severe personal injury or
rectangular margin blocks throughout this manual. Safety labels are vertically
death.
oriented rectangles as shown in the representative examples (below), consisting
2. of three panels encircled by a narrow border. The panels can contain four
messages which communicate:
WARNING — Hazards or
unsafe practices which • The level of hazard seriousness.
COULD result in severe • The nature of the hazard.
personal injury or death. • The consequence of human or product interaction with the hazard.
• The instructions, if necessary, on how to avoid the hazard.
3.
The top panel of the format contains a signal word (DANGER, WARNING,
CAUTION — Hazards or CAUTION or ATTENTION) which communicates the level of hazard seriousness.
unsafe practices which
COULD result in minor The center panel contains a pictorial which communicates the nature of the
personal injury. hazard, and the possible consequence of human or product interaction with the
hazard. In some instances of human hazards the pictorial may, instead, depict
what preventive measures to take, such as wearing protective equipment.
4.
The bottom panel may contain an instruction message on how to avoid the
ATTENTION — Hazards or
hazard. In the case of human hazard, this message may also contain a more
unsafe practices which
COULD result in product or
precise definition of the hazard, and the consequences of human interaction with
property damage. the hazard, then can be communicated by the pictorial.
1 2 3 4
▲
! CAUTION ▲
! ATTENTION
Know all valve Wear necessary Do not drop or strike

exhaust/leakage points protective equipment valve.
to avoid possible to prevent possible
severe personal injury injury.
or death.
CON-14
CON-6
CONSOLIDATED
MAXIFLOW SAFETY VALVE
WELDED INLET
2500 PSIG (175.8 Kg/cm2) CLASS
Part
No. Nomenclature
1 Base
1a Inlet Neck
2 Disc Holder
3 Guide
4 Upper Adj. Ring
5 Spring Assembly
5a Top Washer
5b Bottom Washer
5c Spring
6 Seat Bushing
7 Disc
8 Lower Adj. Ring
9 Disc Collar
10 Lift Stop
11 Overlap Collar
*12 Cover Plate Assy.
12a Cover Plate
12b Floating Washer
12c Washer Retainer
13 Top Plate Assy.
13a Top Plate
13b Washer Retainer
13c Floating Washer
14 Spindle
15 Compression Screw
16 Yoke
**17 Yoke Rod
**18 Lifting Gear
19 Upper Adj. Ring Pin
20 Lower Adj. Ring Pin
21 Release Nut
Lock Nut
* Includes Pin Screws

** See Figure 7 on page 19
CON-1
MAXIFLOW SAFETY VALVE
FLANGED INLET
900 PSIG (63.3 Kg/cm2) CLASS
Part
No. Nomenclature
1 Base
2 Disc Holder
3 Guide
4 Upper Adj. Ring
5 Spring Assembly
5a Top Washer
5b Bottom Washer
5c Spring
6 Seat Bushing
7 Disc
8 Lower Adj. Ring
9 Disc Collar
10 Lift Stop
11 Overlap Collar
*12 Cover Plate Assy.
12a Cover Plate
12b Floating Washer
12c Washer Retainer
13 Top Plate Assy.
13a Top Plate
13b Washer Retainer
13c Floating Washer
14 Spindle
16 Yoke
**17 Yoke Rod
**18 Lifting Gear
19 Upper Adj. Ring Pin
20 Lower Adj. Ring Pin
21 Release Nut
Lock Nut
* Includes Pin Screws

** See Figure 7 on page 19
CON-14
Page 1
Contents
Section Subject Page
I. Safety Notice....................................................................................... 2
II. A. Safety Precautions ....................................................................... 3
B. Warranty Information .................................................................... 3
III. Introduction ......................................................................................... 4
IV. Safety Valve Terminology ................................................................... 5
V. Design Features.................................................................................. 7
VI. Operating Principles............................................................................ 8
VII. Storage and Handling Prior to Installation........................................... 11
VIII. Recommended Installation Practices.................................................. 12
A. General Requirements.................................................................. 12
B. Outdoor Safety Valve Installation ................................................. 16
C. Indoor Safety Valve Installation .................................................... 17
D. Cover Plate Vent Piping ............................................................... 17
IX. Hydrostatic Test Plug Removal - Domestic and Export ...................... 18
A. General Information ...................................................................... 18
B. Domestic Plugs............................................................................. 19
C. Export Plugs ................................................................................. 20
X. Field Testing........................................................................................ 21
B. Popping Point Adjustment ............................................................ 22
C. Ring Adjustments, Blowdown and Overlap Collar Adjustments ... 22
D. Restricted Lift Valves .................................................................... 27
E. Hydroset/EVT Testing................................................................... 27
F. Sealing Valves After Test ............................................................. 28
XI. Disassembly Instructions .................................................................... 28
B. Specific Steps ............................................................................... 28
XII. Inspection............................................................................................ 34
B. Specific Steps ............................................................................... 34
XIII. Maintenance Instructions .................................................................... 36
B. Lapping Procedure ....................................................................... 36
C. Reseating Machine Information .................................................... 39
D. Spindle Runout ............................................................................. 41
E. Disc Replacement and Disc/Spindle Bearing Requirements........ 41
F. Grinding the Compression Screw................................................. 45
G. Thrust Bearing Surfaces ............................................................... 45
H. Grinding the Lower Spring Washer .............................................. 45
XIV. Re-Assembly....................................................................................... 46
B. Specific Steps ............................................................................... 46
XV. Hydrostatic Testing & Gagging ........................................................... 54
XVI. Trouble Shooting the Type 1700 Valve............................................... 56
XVII. Maintenance Tools & Supplies............................................................ 57
XVIII. Service Parts Inventory Philosophy .................................................... 59
XIX. Genuine Dresser Parts........................................................................ 61
XX. Recommended Spare Parts................................................................ 62
XXI. Manufacturer’s Field Service & Repair Program................................. 63
CON-1
Page 2
I. Safety Notice
▲ Proper installation, operation and maintenance is essential to the safe and

reliable operation of all valve products. The relevent procedures
recommended by Dresser Valve and Controls Division (DVCD), and
described in this manual, are effective methods of performing the required
tasks. Some of these procedures require the use of tools specifically
designed for an intended purpose. These special tools should be used
when, and as, recommended.
It is important to note that this manual contains various “safety messages”
which should be carefully read in order to minimize the risk of personal
injury, or the possibility that improper procedures will be followed which
may damage the involved DVCD product, or render it unsafe. It is also
important to understand that these “safety messages” are not exhaustive.
DVCD can not possibly know, evaluate, and advise any customer of all of
the conceivable ways in which tasks might be performed, or of the possible
hazardous consequences of each way. Consequently, DVCD has not
undertaken any such broad evaluation and, thus, anyone who uses a
procedure and/or tool, which is not recommended by DVCD, or deviates
from DVCD recommendations, must be thoroughly satisfied that neither
personal safety, nor valve safety, will be jeopardized by the method and/
or tools selected. If not so satisfied, contact DVCD (at 318/640-2250) if there
Know nuclear “health
are any questions relative to tools/methods. Some of the products
physics” procedures,
if applicable, to avoid manufactured by DVCD may be used in radioactive environments.
possible severe injury Consequently, prior to starting any operation in a radioactive environment,
or death. the proper “health physics” procedures should be consulted and followed,
if applicable.
The installation, operation and maintenance of valves and/or valve products
▲
! CAUTION may involve proximity to fluids at extremely high pressure and/or
temperature. Consequently, every precaution should be taken to prevent
injury to personnel during the performance of any procedure. These
precautions should consist of, but are not limited to, ear drum protection,
eye protection, and the use of protective clothing. (i.e., gloves, etc.) when
personnel are in or around a valve work area. Due to the various
circumstances and conditions in which these operations may be performed
on DVCD products, and the possible hazardous consequences of each
way, DVCD can not possibly evaluate all conditions that might injure
personnel or equipment. Nevertheless, DVCD does offer the safety
precautions listed on page 3 for customer information only.
Wear necessary It is the responsibility of the purchaser or user of DVCD valves/equipment

protective equipment to adequately train all personnel who will be working with the involved
to prevent possible valves/equipment. Further, prior to working with the involved valves/
injury. equipment, personnel who are to perform such work should become
thoroughly familiar with the contents of this manual. Accordingly, should
additional copies of this manual be required, they can be purchased, at a
minimal cost, by contacting DVCD (in writing) at P.O. Box 1430, Alexandria,
LA 71309-1430, or (telephonically) at 318/640-2250.
CON-14
CON-6
CON-1
Page 4
III. Introduction
The “safety valve” is the final safeguard between a controlled boiler and a
catastrophic explosion. In an over-pressure situation, the pressure in the valve
inlet increases until the force on the disc exerted by the system pressure equals
the force exerted by the spring. This causes the safety valve to pop, or lift,
relieving the excess steam until the system pressure is reduced to the desired
level.
The Type 1700 Maxiflow Safety Valve represents the state of the art in pressure
relief products. As well as its back pressure assisted closing feature, the
Maxiflow Safety Valve incorporates a pressure assisted/temperature stabilizing
THERMOFLEX™ disc for improved seat tightness. This design has been
proven in hundreds of installations world wide.
The Type 1700 Maxiflow Safety Valve is sold with a flanged outlet and either a
flanged or buttwelded inlet. Other variations include a thrust bearing assisted
compression screw for high pressure valves, a spring cover and a lifting gear
cover for outdoor installations. All export and weld inlet valves are shipped with
a hydro plug for protecting the internal parts of the valve and to provide a means
for the end user to hydrostatically test his system without damaging the disc or
nozzle seats.
The information contained in this manual provides the customer with basic
concepts required in maintenance of the Maxiflow Safety Valve, but in no way
is it intended to take the place of experience and technical knowledge required
to perform adequate valve repair work and maintenance.
CON-14
Page 5
IV. Terminology for Safety Valves

(Paraphrased from PTC 25.3)
• Back Pressure
Back pressure is the static pressure existing at the outlet of a safety valve
device due to pressure in the discharge system.
• Blowdown
Blowdown is the difference between actual popping pressure of a safety
valve and actual reseating pressure expressed as a percentage of set
pressure, or in pressure units.
• Bore Area
Bore area is the minimum cross-sectional area of the nozzle.
• Bore Diameter
Bore diameter is the minimum diameter of the nozzle.
• Chatter
Chatter is abnormal, rapid reciprocating motion of the moveable parts of
a safety valve, in which the disc contacts the seat.
• Closing Pressure
Closing pressure is the value of decreasing inlet static pressure at which
the valve disc re-establishes contact with the seat, or at which lift becomes
zero.
• Disc
A disc is the pressure containing moveable member of a safety valve
which effects closure.
• Inlet Size
Inlet size is the nominal pipe size of the inlet of a safety valve, unless
otherwise designated.
• Leak Test Pressure
Leak test pressure is the specified inlet static pressure at which a
quantitative seat leakage test is performed in accordance with a standard
procedure.
• Lift
Lift is the actual travel of the disc away from closed position when a valve
is relieving.
• Lifting Device
A lifting device is a device for manually opening a safety valve, by the
application of external force to lessen the spring loading which holds the
valve closed.
• Nozzle/Seat Bushing
A nozzle is the pressure containing element which constitutes the inlet flow
passage and includes the fixed portion of the seat closure.
• Outlet Size
Outlet size is the nominal pipe size of the outlet passage of a safety valve,
unless otherwise designated.
• Overpressure
Overpressure is a pressure increase over the set pressure of a safety
valve, usually expressed as a percentage of set pressure.
CON-1
Page 6
IV. (Continued)
• Popping Pressure
Popping pressure is the value of increasing inlet static pressure at which
the disc moves in the opening direction at a faster rate as compared with
corresponding movement at higher or lower pressures. It applies only to
safety or safety relief valves on compressible fluid service.
• Pressure Containing Member
A pressure containing member of a safety valve is a part which is in actual
contact with the pressure media in the protected vessel.
• Pressure Retaining Member
A pressure retaining member of a safety valve is a part which is stressed
due to its function in holding one or more pressure containing members in
position.
• Rated Lift
Rated lift is the design lift at which a valve attains its rated relieving
capacity.
• Safety Valve
A safety valve is a pressure relief valve actuated by inlet static pressure
and characterized by rapid opening or pop action.
• Set Pressure
Set pressure is the value of increasing inlet static pressure at which a
safety valve displays the operational characteristics as defined under
“Popping Pressure.” It is one value of pressure stamped on the safety
valve.
• Seat
A seat is the pressure containing contact between the fixed and moving
portions of the pressure containing elements of a valve.
• Seat Diameter
Seat diameter is the smallest diameter of contact between the fixed and
moving members of the pressure containing elements of a valve.
• Seat Tightness Pressure
Seat tightness pressure is the specific inlet static pressure at which a
quantitative seat leakage test is performed in accordance with a standard
procedure.
• Simmer
Simmer is the audible or visible escape of fluid between the seat and disc
at an inlet static pressure below the popping pressure and at no measurable
capacity. It applies to safety valves on compressible fluid service.
• Warn
See “Simmer” (definition above).
CON-14
Page 7
V. Design Features
• Blowdown
The Consolidated ® Maxiflow Safety Valve is the valve with 3% attainable
blowdown certified by the National Board of Boiler and Pressure Vessel
Inspectors. Adjusting rings are preset at the factory to give slightly longer
blowdown. If a verified value of 3% blowdown is required, this can be
obtained by actuating the valve on the installation where sufficient capacity
is available, and where system operating parameters will permit such
blowdown.
• Body and Neck Materials
All pressure retaining parts, with the exception of reheat valves rated to 900
psi (62.1 Bar) and lower, are made of forged materials. Forged welded inlet
neck valves have the three-piece weld construction. Flanged inlet valves
and cast neck welded inlet valves have a top-inserted seal-welded bushing.
• Design Life
For most service conditions, pressure retaining parts subject to mechanical
stresses, such as valve necks, yoke rods, etc., are designed for a design life
equivalent to the boiler, and are well in excess of the requirements of the
Power Boiler Code.
• Operating Gap
The operating gap is defined as the difference between the operating
pressure and the valve set pressure. Consolidated Safety Valves are tested
and proven tight for operating gaps of 6%. Although tightness is a function
of design, it should be realized that with smaller operating gaps it is also
necessary to increase maintenance. Increase in incidents of valve lift,
simmer, etc. can be expected with a small operating gap, because there is
less allowance for system pressure transients and other unidentified
variables.
• Supercritical Valves
Maxiflow Supercritical Valves are used for steam at pressures above
approximately 3200 psig. Its internal design is similar to that used in
subcritical boiler safety valves.
The springs for supercritical valves are made from alloy steel, the discs from
Inconel "X" and the seating surface of the bushing from Stellite. These
materials have been found to work very well under the high temperatures
and pressures to which the valves are subjected. A ball thrust bearing is
used on the compression screw in all of the valves for better adjustment.
• Thermal Compensation
The yoke rod design, together with proper selection of yoke rod and spindle
materials, renders the valve relatively free from changes in pressure
settings due to inlet temperature variations. High ambient temperatures
adjacent to the valve spring and yoke rods may cause set pressure
variations, and need to be considered when adjusting the valve. Temperature
stabilization is always necessary prior to adjusting a valve for set pressure.
• THERMOFLEX™ disc
The THERMOFLEX™ disc design, by allowing for the rapid equalization of
temperature around the valve seat, provides a degree of tightness far above
that offered by competitive valves. Selection of materials provides desired
“Thermal Flexibility” and “Mechanical Flexibility”. THERMOFLEX™ discs
are now giving excellent results at 5500 psi (379.3 Bar) and 1150° F (621°C).
CON-1
Page 8
VI. Operating Principles

The 1700-S series Maxiflow valve operates during closing on a back pressure
principle, that is, the force of trapped steam on the upper side of the disc holder
is utilized to assist the spring in forcing the disc back down onto its seat.
In Figure 1 (below), 100 percent lift is attained by proper location of the upper and
lower adjusting rings (G) and (O), respectively. When full lift is attained, as in
Figure 2 (see next page), lift stop (M) rests against coverplate (P) to eliminate
hunting, thus adding stability to the valve. When the valve discharges in an open
position, steam is bled into chamber (H) through two bleed holes (J) in the roof
of the disc holder. Similarly, the spindle overlap collar (K) rises to a fixed position
above the floating washer (L). The area between the floating washer and the
spindle is thereby increased by the difference in the two diameters on the overlap
collar.
CON-14
Page 9
VI. (Continued)
Under this condition, steam in chamber (H) enters into chamber (Q) through the
secondary area formed by the floating washer (L) and the overlap collar (K) on
the spindle, then through orifice (N), and escapes to atmosphere through the
pipe discharge connection (R).
CON-1
Page 10
VI. (Continued)
When closing, as in Figure 3 (below), the spindle overlap collar (K) is adjusted
so that it moves down into the floating washer (L), thereby effectively reducing
the escape of steam from chamber (H).
The resulting momentary pressure building-up in chamber (H), at a rate controlled
by orifice (N), produces a downward thrust in the direction of spring loading. The
combined thrust of the pressure and spring loading results in positive and precise
closing. Cushioning of the closing is controlled by the lower adjusting ring (O).
CON-14
Page 11
VII. Storage and Handling Prior to Installation

Safety valves should be stored in a dry environment to protect them from the
weather. They should not be removed from the skids or crates until immediately
prior to installation. Flange protectors and sealing plugs should remain installed
until just prior to installation.
Safety valves, either crated or uncrated, should never be subjected to sharp
impact. This would be most likely to occur by bumping or dropping during loading
or unloading from a truck or while moving with a power conveyor, such as a fork
lift truck. The valve, either crated or uncrated, should always be kept with the inlet
down (i.e., never laid on its side), to prevent misalignment and damage to
internals. Even crated valves should always be lifted with the inlet down.
Uncrated valves should be moved or hoisted by wrapping a chain or sling, around
the discharge neck, then around the upper yoke structure, in such manner as will
insure that the valve is in vertical position during lift, (i.e., not lifted in horizontal
position). Never lift the full weight of the valve by the lifting lever. Never hook to
the spring to lift. When safety valves are uncrated and the flange protectors
removed, immediately prior to installation, meticulous care should be exercised
to prevent dirt from entering the outlet port while bolting in place.
While hoisting to the installation, care should be exercised to prevent bumping
the valve against steel structures and other objects.
CON-1
Page 12
VIII. Recommended Installation Practices

A. General Requirements
1. The valve should be installed to meet all the requirements of Figure
4 (below).
2. The safety valve shall be connected to the header independent of any

other connection, and attached as close as possible to the header,
without any unnecessary intervening pipe or fitting. “Necessary”
intervening pipe or fitting shall not be longer than the face-to-face
dimension of the corresponding tee fitting of the same diameter and
pressure, per ANSI Standards.
3. No valve of any description should be placed between the safety valve
and the header, nor on the discharge pipe between the safety valve
and the atmosphere.
4. In no case may the inlet piping to the valve have a flow area less than
the area of the valve inlet.
5. Excessive pressure loss at the inlet of the safety valve will cause
extremely rapid opening and closing of the valve, which is known as
“chattering”. Chattering may result in lowered capacity as well as
damage to the seating surface of the valve. Severe chattering can
cause damage to other parts of the valve.
CON-14
Page 13
VIII.A. (Continued)
The following recommendations will assist in eliminating the factors that produce
chatter:
a. Header nozzle corners must be rounded to a radius of not less than
1/4 of the opening diameter.
b. Pressure drop due to friction flow to the inlet of the valve should not be
greater than 50% of the expected blowdown of the safety valve.
6. To decrease the effects of a phenomenon known as “sonic vibrations,” the
following recommendations are made.
a. Safety valves should be installed at least eight to ten pipe diameters
downstream from any bend in a steam line. This distance should be
increased when the valve is installed on the horizontal section of a
header which is preceded by an upward section.
b. Safety valves should not be installed closer than eight to ten pipe
diameters either upstream or downstream from a diverging, or a
converging, “Y”.
c. In cases where a piping configuration renders the above two
recommendations impractical, or impossible, the downstream corner of
the header nozzle inlet should be rounded to a greater extent than the
upstream corner. The header nozzle entrance should be rounded so the
radius at the downstream corner will be equal to a minimum of 1/4 of the
nozzle diameter. The radius should be reduced gradually, leaving only
a small portion of the upstream corner with a smaller radius.
d. Safety valves should never be installed, in a steam line, in a position
directly opposite to a branch line.
7. Excessive line vibrations are known to produce shifts in safety valve set
pressures. Vibrations may possibly introduce chatter, causing damage to
the valve, and reduce its capacity. This vibration also contributes to increased
incidents of seat leakage. Considerations should be given to eliminating this
problem prior to installing the valve on the unit.
8. Steam flowing vertically out a discharge elbow produces a downward
reaction on the elbow. Bending stress in the valve is determined by the
product of this reactive force and the moment arm between the point of
steam exhaust and the section being analyzed for bending stress. The
effects of reaction force, vibration, and seismic loads, on all valve components
and discharge piping, should be considered when designing the valve
system.
9. For optimum performance, safety valves must be serviced regularly and
otherwise maintained. So that servicing can be properly performed, valves
should be located in a manner that allows for easy access. Sufficient working
space should be provided around and above the valve to permit access to
adjusting rings. If two or more valves are located close together, the outlets
should be parallel so as to offer as much protection as possible to personnel
repairing, or working close to, the safety valve.
10. Because foreign material passing into, and through, a safety valve is
damaging, the system on which the valve is tested and finally installed must
also be inspected and cleaned. New systems are prone to contain welding
beads, pipe scale, and other foreign materials which are inadvertently
trapped during construction, and destroy the valve seating surfaces the first
few times the valve opens. Therefore, the system should be thoroughly
purged before the safety valve is installed.
CON-1
Page 14
VIII.A. (Continued)
11. With regard to weld-end inlet valves, completely assembled valves may be
installed without disassembly being necessary at the time of welding. During
welding, the valve neck should be insulated to reduce thermal stresses.
When stress relieving, insulation should also be utilized to reduce thermal
stresses. In service, the valve neck should be insulated at least to the point
of the inlet neck/valve body-bowl juncture.
12. Safety valves should be installed in a vertical position. Nominal tolerance on
vertical installation is plus or minus 1 degree.
13. The discharge area of the outlet piping from a safety valve should not be less
than the area of the outlet connection. Where more than one safety valve is
connected to a common outlet pipe, the area of the pipe should not be less
than the combined area of the outlet connections to the safety valves.
14. All safety valve discharges should be piped so that the effluent is discharged
clear from running boards or platforms. Ample provision for gravity drain
should be made in the discharge pipe at, or near, each safety valve where
water, or condensation, may collect. Each valve has an open gravity drain
through the body, below the level of the valve seat, and this drain should be
piped to a safe discharge area.
15. If a silencer is used on a safety valve, it should have sufficient outlet area to
prevent back pressure from interfering with the proper operation and
discharge capacity of the valve. The silencer or other piping components
should be constructed so as to avoid the possibility of creating corrosion
deposit restrictions in the steam passages.
16. Exhausts, drains, and vents must be installed so that they will not impose
undue stresses on the safety valve. Any such stresses can produce body
distortion and leakage. Therefore, the following recommendations are
provided:
a. Discharge piping should not be supported by the valve. The maximum
weight on the outlet of the valve should not exceed the weight of a short
radius elbow and flange, plus a twelve (12) inch (304.8 mm) straight
length of standard weight thickness pipe (with drip pan).
b. Clearance between the valve exhaust piping and the discharge stack
should be sufficient to prevent contact when considering thermal
expansion of the header, valve, and discharge stack. Movements due
to vibration, temperature changes, and valve reaction forces should also
be considered, to insure adequate clearance between the exhaust
piping and the discharge stack.
c. Flexible metal hoses are not generally recommended, but if used to
connect valve outlets to discharge stacks, they must be of sufficient
length, and be configured/installed in such a manner, that they will not
become “solid” in any one position. Better results are obtained if the
hoses are installed so that they will permit movement by bending, rather
than by stretching and compressing along their length.
17. When liftinga valve, the valve should always remain in a vertical position.
The valve may be lifted by using a sling around the valve yoke and the valve
outlet neck. In no case should the valve be lifted by the lifting lever.
The valve should not be bumped or dropped during installation. If the valve
is dropped, an inspection for damage should be made, and the set pressure
of the valve rechecked.
CON-14
Page 15
VIII.A. (Continued)
18. At the time of installation, all protective covers on the valve should be
removed. The internals of the valve are to be checked for cleanliness. No
foreign matter is permitted in the valve inlet or outlet, since it may possibly
damage the valve components, or be dropped into the header.
All face surfaces which require gaskets, to seal pressure, shall be inspected
for cleanliness, or any defects that can cause leakage. Burrs, mashed
serrations, uneven surfaces, etc., are all possible leakage producing defects.
Proper gasket sizes and pressure ratings should be checked prior to starting
valve installation.
19. It is of utmost importance that the gaskets used be dimensionally correct for
the specific flange, and that they fully clear the valve inlet and outlet
openings. Gaskets, flange facings, and bolting should meet the service
requirements for the pressure and temperature involved. Other valve
installation considerations include:
a. Install the inlet gasket, if required, on the header mounting flange. Check
for cleanliness, surface alignment condition, gasket condition, etc.
When possible, inlet studs on the mounting flange should be used to
guide the valve on the header mounting flange. Inlet studs should be
lubricated with the appropriate lubricant.
b. When installing flanged valves, the flange bolts must be pulled down
eveningly to prevent body distortion, misalignment, and leakage.
c. With valve in position,screw on the stud nuts until all nuts are finger tight.
An initial torque shall be placed, in turn, on each stud nut. Increase the
torque progressively until the final torque is applied. Upon completion,
recheck each stud nut’s torque. Required torque will vary with bolting
material and gaskets used. See your company engineering or
specification department for details.
As an extra precaution, the gap between the two mating flanges should
be checked during the torquing process to insure that the flanges are
being pulled together evenly. Calipers may be used for this verification.
A final inspection and review should be made to insure that all of the
requirements for bolting the valve inlet have been implemented.
d. In like manner, the outlet piping may now be installed. A complete
inspection of components and their cleanliness is to be made prior to
further work. Studs are to be lubricated with an appropriate lubricant.
e. Install the outlet gasket, studs and nuts. Stud nuts are to be pulled down
finger tight. An initial value of torque is to be applied. The additional
procedures outlined, in Step 19.c., (above), are also to be followed.
20. After being assured that the valve is properly installed, the drainage piping
from the valve body-bowl is to be connected. This line also must be flexible,
so it will not create loads on the valve under operating conditions.
21. Prior to completing the installation, a visual check should be made to insure
that the valve lifting lever is free to operate.
22. At the time of installation, an inspection of the valve should be made to
confirm that all adjustment components (i.e., ring pins, cap, etc.) are properly
locked and sealed, as required by the ASME Code.
23. Flanged valves may be installed without insulation.
24. For operational hydrostatic tests at the valve inlet, which do not exceed valve
CON-1
Page 16
VIII.A. (Continued)
set pressure (1.0 x design pressure), the valve may be gagged. Refer to the
“Field Testing” portion of this manual (i.e., Section X) for proper techniques.
Insure that the gag is removed upon completion of the inlet hydrostatic test.
25. Prior to startup of the unit on steam, the sections of this manual which specify
requirements for set pressure testing should be reviewed. For conditions
where the valve is subjected to high steam pressures (i.e., those exceeding
normal operating conditions), preparations should be made to gag the
valves. These preparations should then be cleared with the boiler
manufacturer and DVCD Engineering. Refer to Section XV of this manual for
the proper gagging techniques.
26. The safety valve should be tested with full steam pressure to insure that the
safety valve installation has been properly accomplished. In some cases this
is not practical, thus the use of the CONSOLIDATED® Hydroset, or the
Electronic Valve Tester (EVT), should be considered. For valves being
tested for set pressure by using a Hydroset or EVT, only the set pressure
is being verified. Other factors such as blowdown, lift, reaction force, proper
discharge stack sizes and effects of thermal expansion cannot be determined.
27. Vent and drain piping should have a union connection to facilitate valve
removal.
B. Outdoor Safety Valve Installation

Safety valves operating under the best possible conditions (i.e., of favorable
operating gap, relatively stable ambient temperatures, the absence of dirt and
in relatively still air) will provide the maximum degree of safety, tightness and
dependability.
When a safety valve is installed in an outdoor location, it may be exposed to wind,
rain, snow, ice, dirt and varying temperatures. Therefore, the following
recommendations are made for proper protection, and to insure that operational
dependability can be restored to a level near that of the valve installed under ideal
conditions:
1. The inlet neck of the safety valve and safety valve body, up to the bottom
of the cover plate in the Maxiflow Safety Valve, should be insulated. The
exterior surface of any such insulation should be made weather-proof by
any suitable means. In addition to maintaining a more even temperature
within the valve body, especially during widely fluctuating ambient
temperatures, this insulation will effectively reduce thermal stresses, due
to high temperature gradients, through the walls of the safety valve nozzle.
2. Spring covers should be used to stabilize (as nearly as possible) the
temperature of the spring, to prevent the accumulation of snow and ice
between the coils of the spring, and to prevent dirt and fly ash from
accumulating between the coils of the spring.
3. Lifting gear covers should be installed to prevent ice, dirt and fly ash from
accumulating in areas inside the safety valve cap.
CON-14
VIII. (Continued)
C. Indoor Safety Valve Installation
Indoor valve installations should have inlet necks insulated only up to the
underside of the valve body. Considerations should be given to ambient
temperatures of greater than 100° F (37.8° C), because of possible set point
changes which may occur due to these higher ambient temperatures.
D. Cover Plate Vent Piping

The cover plate can be vented to atmosphere as shown in Figure 5 (below).
Precautions should be taken to vent the cover plate in such a manner that
it will exhaust into a safe area to prevent injury to personnel near the valve.
The cover plate vent drain must not be connected to the body drain piping.
Do not plug the cover plate vent hole or reduce vent hole pipe size, as this
will lead to valve malfunction and damage.
Precautions should be taken to prevent accumulations of foreign material or
water in the vent pipe. This vent is a critical part of the valve system for controlling
valve blowdown and lift.
CON-1
Page 18
IX. Hydrostatic Test Plug Removal-

Domestic and Export
A. General Information
Flanged inlet safety valves should be removed from the boiler during
hydrostatic tests and boiler nozzles blanked off to prevent possible valve
damage.
All valves shipped outside the continental United States are shipped with an
export hydroplug. All welded inlet valves shipped within the continental United
States are shipped with a domestic hydroplug, unless the customer specifically
requests otherwise. All flanged inlet valves shipped within the continental United
States are shipped without a hydroplug, unless one is specifically re-quested by
the customer.
Valves shipped with either type of hydroplug are identified by a Red on White
CAUTION TAG which is attached to the valve by wires extending through the
drain hole in the valve body. See Figure 6 (below).
The hydrostatic plugs are placed in the bore of the valve, inside the seating
surface. Their purpose is twofold. First they effect closure at a point differing from
the seating surface of the valve so that, if the valve is lifted on hydrostatic test,
the seating surface is not as likely to be damaged. Second, by raising the disc
of the valve off its seat and increasing spring compression, the set pressure of
the valve is increased to a point where the valve will not leak at one and one-half
times design boiler pressure. It is not necessary to gag safety valves tightly when
hydrostatic plugs are used.
These plugs must, of course, be removed from the valves prior to placing the
boiler in service. However, they should be retained, and reinstalled, whenever
a hydrostatic test exceeding the low set valve pressure is conducted.
CON-14
Page 19
IX. (Continued)
B. Domestic Plugs
1. Disassemble the valve as outlined in Section XI of this manual.
2. Remove the hydrostatic test plug from the seat bushing, and lap disc
and bushing seat.
3. Always be certain that all parts are clean and free of dirt and foreign
material. Dirt trapped on seating surfaces or in the inlet, when the
valve is reassembled, will damage the seats. Reassemble the valve
as outlined in Section XIII of this manual. The lug on the top spring
washer should be on the left side of the valve when facing in the same
direction as the outlet. (See Figure 7, below.)
4. Replace the cap, and locate the drop lever vertically on the center line
of the valve.
5. Remove the top lever from the cap, and reassemble in position in
accordance with Figure 7. If properly positioned, the top lever should
have 1/8" (3.175 mm) of vertical movement prior to engaging bottom
surface of release nut. The valve is now ready for the initial field test,
on steam, to check valve set point and blowdown.
CON-1
Page 20
IX. (Continued)
C. Export Plugs
When hydrostatic plugs are installed in Maxiflow Valves scheduled for shipment
to foreign countries, the disc is removed and dipped in preservative, then packed
in a box. The package is then inserted into the valve outlet and taped to the floor
of the valve body.
To remove the special export plug, Figure 8 (below), the following steps must be
followed.
1. Disassemble the valve as outlined in Section XI of this manual.

2. Remove the export plug by turning it counterclockwise, until it is
disengaged from the spindle thread.
NOTE:
Hold the disc holder against the disc adjusting collar during this
step, otherwise the disc holder will fall from the spindle and
become damaged.
3. Remove the seal peel preservative from the disc and thoroughly clean
the disc seat with a clean cloth. Then, lap the disc and bushing seat.
Lubricate the spindle tip with "Anti-Seize", and assemble the disc and
disc holder to spindle by turning the disc clockwise until the dropout
thread disengages. Reassemble the valve as outlined in Section XIII
of this manual. The lugs on the top spring washer should be on the left
side of the valve when facing in the same direction as the outlet.
(Again, see Figure 7 on the preceeding page.)
4. Remove cotter pin from release nut and position release nut so that
1/8 in. (3.175 mm) of clearance is visible between lifting fork and
release nut, then install cotter pin.
5. Install lifting gear as outlined in Section XIV of this manual.
CON-14
Page 21
X. Field Testing
All 1700 Maxiflow Safety Valves are steam tested at the factory to verify set
pressure adjustability and seat tightness. Every valve is set to have a clean
popping action and to reseat tightly. However, because the boiler used in setting
the valves has a small capacity, compared to the capacities of the Maxiflow type
of valves, adjustments on the actual installation are necessary to ensure proper
valve action and “adjusting ring” settings.
When supplied for pressures over 2500 psi (172.4 Bar), the compression screw
lock nut will be locked to the compression screw with a 1/4-20 Allen screw, in
order to locate the exact amount of compression screw engagement in the valve
yoke. The compression screw has then been backed out to decrease the spring
load on the seat by 75%. See Red Letter Warning Tag, attached to compression
screw of each Maxiflow Valve by means of double strand sealing wire, which
reads as follows:
WARNING
This valve has been steam tested and set to the proper set
pressure; however the compression on the spring has been
relaxed by backing out the compression screw.
Before the hydrostatic test on the boiler the compression screw
must be turned clockwise until the lock nut makes up on the yoke.
Remove the 1/4-20 allen screw to allow the lock nut to turn on
compression screw for future adjustments.
(Note attached tag for hydrostatic plug removal).*
Upon completion of hydrostatic testing of the boiler, but prior to placing the boiler
in service, insure that the hydrostatic plugs are removed from all valves. (Note:
See Figure 6 on page 18 of this manual). The use of a DVCD Hydroset or EVT,
unit can serve to establish set pressure but cannot be used for verifying
blowdown, lift, etc. (For additional information, see Section X.E., of this manual).
Gagging of other valves not being set will not generally be necessary; however,
for setting of high pressure valves, depending on system pressure being used,
it may be necessary to gag the lower set valves.
Boiler safety valve tests can be conducted with the unit either on or off the line.
However, with the unit on the line under full load, a sudden load drop could be
dangerous as most of the safety valves will be gagged. Therefore, it is
recommended that the safety valves be tested and adjusted with the boiler
isolated, or with light load. Boiler control can then be maintained, with little or no
outside influence due to load change.
It is important to note that all adjustments of adjusting rings are DVCD initial
adjustments only, and are not intended to be final adjustments. This final
adjustment must be made on the operating system with conditions approximately
those that will be realized under actual operating conditions. Valves are factory
set for long blowdown to prevent chattering under initial setting conditions.
* This parenthetical statement is a reference to the tag shown in Figure 6, on page 18 of this manual.
CON-1
Page 22
X.A. (Continued)
Factors which can affect valve operation, and which should be considered when
initially setting a valve, are as follows:
1. Ambient temperature near the valve and valve temperature stabilization.
2. Line vibration.
3. Line capacity at time when the valve must lift.
4. Discharge stack or drain piping binding.
5. Fluid flow vibrations set up by upstream bends and other disturbances.
B. Popping Point Adjustment
NOTE:
Prior to beginning this procedure, lower the operating pressure
on the boiler to a point which ensures that the valve will not
open during adjustment of the compression screw.
To change the popping pressure of the valve, remove the cap and lever
assembly, loosen the compression screw locknut and turn the compression
screw clockwise to increase the pop point, or counterclockwise to decrease the
pop point.
After each adjustment of the compression screw, the lock nut should be
tightened. The arm of the top spring washer should always be free from bearing
against the yoke rod. This can be accomplished by holding a screw driver
between the arm and the rod to prevent any movement of the top spring washer
while adjusting the compression screw. Install the cap and lever assembly after
set pressure adjustments have been completed, as outlined in the Re-assembly
instructions (see Section XIV of this manual).
C. Ring Adjustments, Blowdown and

Overlap Collar Adjustments
1. General
The positions of the upper adjusting ring and the lower adjusting ring
are locked by means of the upper adjusting ring pin and the lower
adjusting ring pin, respectively. These pins are threaded into the valve
body and engage notches which are cut into the rings. To adjust either
ring, the corresponding ring pin must be removed. A screw driver (or
other suitable tool), inserted through the ring pin hole, can be used to
turn the rings.
NOTE:
Always gag the Safety Valve for protection. This will ensure that the
disc is not accidentally lifted from the seat by the adjusting tool
during ring adjustment. This will also ensure that an unexpected rise
in system pressure will not be a hazard to service personnel.
CON-14
Page 23
X.C. (Continued)
2. Lower Ring Adjustment
If the lower adjusting ring position is in question, the factory position
can be attained as follows:
a. Gag the safety valve to prevent the disc from being accidentally
lifted from the seat.
b. Remove the service port plugs.
c. Remove the lower adjusting ring pin.
d. Move the lower adjusting ring up until it contacts the disc holder.
e. Refer to Figure 9 (below), and move the lower adjusting ring down
the number of notches indicated in Column A, plus 1 additional
notch for each 600 psig increment of set pressure, not to exceed
six notches (see Table I, also below).
TABLE I
Final Factory Positions
(Field Starting Positions)
LOWER RING UPPER RING
HOLDER TO SEAT HOLDER TO SEAT
IN NOTCHES IN NOTCHES
ORIFICE (Column A) (Column B)
1 7 10
2 8 12
3 12 16
5 12 16
4 12 16
6 30 45
7 30 45
Q 30 45
8 37 45
R 38 47
CON-1
Page 24
X.C. (Continued)
f. Lock the lower adjusting ring into position by installing the lower
adjusting ring pin, clockwise, until tight.
g. Remove the gag.
h. Test the valve on the system and adjust the lower ring to the lowest
position which does not produce simmer.
The ideal ring position must then be found by test for the set of
operating conditions present. If simmer is present or the valve fails
to lift, the lower ring should be moved upward slowly, one notch at
a time, to remove the simmer. The most ideal position for the lower
ring is the lowest position that does not introduce simmer or a
buzzing sound.
WARNING 3. Relationship Between Upper Ring and Overlap Collar Adjustments
and Blowdown
The correct method of obtaining proper blowdown adjustment can be
best explained by reference to Figure 10 (below).
The upper ring is used to obtain full lift at the popping pressure.
However, its position also determines the point at which the valve
begins to drop out of full lift and starts the closing portion of its cycle. For
example, if the upper ring is in such a position that the valve barely
attains full lift at the popping pressure, and starts to drop out of full lift
at a slight reduction of boiler pressure, the first portion of the valve cycle
will be represented by the line ABF. If it were not for the lift stop, the
action of the valve would be represented by the line ABCF. If the upper
ring is in a more positive position (lower setting), the action of the valve
would be represented by the line ABG and, if it were not for the lift stop,
the line ABDG. If the upper ring is in a still lower position, the action of
the valve is represented by the line ABH and, if it were not for the lift
stop, ABEH. From this it can be seen that a lower position of the upper
ring causes that valve to remain in full lift for a longer period of time and
over a greater period of pressure reduction.
CON-14
Page 25
X.C. (Continued)
It will further be noted that there is a distinct difference between the
actual overlap setting on the valve and the point at which the overlap
begins to take effect. This can be understood since the area in the
overlap vent begins to reduce considerably ahead of the point where
the upper corner of the overlap bevel actually enters the floating
washer. This has the effect of rounding off the corners of the diagram
at points J, K & L. If the upper ring is in a position to produce the line
ABH, the overlap will have to be set considerably higher to obtain a
short blowdown than if the upper ring is set at such a position as to
produce the line ABF. Excessive overlap settings may cause seat
damage when the valve closes. It is therefore desirable to set the upper
ring in such a position as to cause the valve to stay in full lift for as short
a time as possible. The most desirous complete cycle is represented
by the line ABFJM.
NOTES:
• When steam safety valves are subjected to an excessively high
water level, the valve can be expected to have a long blowdown
which the upper adjusting ring position will be unable to correct.
It is recommended that the cause of high water level be corrected,
so valves may function correctly at the ordered condition.
• If a superheater valve is set with low temperature steam, it is
advisable to increase the blowdown to compensate for the change
in density and other thermal effects taking place when the steam
is brought up to working temperature. An approximate rule is to
add 1/2 of 1% of set pressure to the blowdown for each 100°F
(37.8°C) of steam temperature below the final temperature.
4. Upper Ring Adjustment

If the upper adjusting ring position is in question, the factory position
can be attained as follows:
a. Gag the safety valve to prevent the disc from being accidently lifted
from the seat.
b. Remove both service port plugs.
c. Remove upper adjusting ring pin.
d. Move the upper adjusting ring until it is level with the disc holder.
A flashlight may be needed to provide adequate lighting for this
observation.
If so, the observation can be made from one of the service ports
while the flashlight is positioned to shine through the other service
port.
e. From this point, move the upper adjusting ring down the number of
notches indicated by Column B of Table I (see page 23). This is
also Dimension B in Figure 9 (again, see page 23).
f. Lock the upper adjusting ring into position by installing the upper
adjusting ring pin.
g. Remove the gag.
CON-1
Page 26
X.C. (Continued)
5. Blowdown Adjustments
When further adjustments are required to obtain final blowdown setting,
the upper adjusting ring should be moved 5-10 notches at a time as
follows:
a. To reduce blowdown - MOVE RING UP - TURN COUNTER-
CLOCKWISE.
b. To increase blowdown - MOVE RING DOWN - TURN CLOCKWISE.
It is possible to raise the upper ring too far and prohibit attainment of full
lift. When this occurs, lower the upper adjusting ring to the point where
full lift is attainable and finalize the blowdown setting with the overlap
collar adjustments (see Section X.C.6., below). If the valve fails to lift,
the lower adjusting ring requires further adjustment (see Lower Ring
Adjustment on page 23).
In attempting to obtain blowdown of 4%, it is important to be sure that
the upper and lower adjusting ring positions are not so far apart as to
cause loss of control of the valve. The first indication of reaching this
condition is a slow “up and down hunting” action of the valve immediately
before closing. If this action occurs at a blowdown longer than desired,
moving both rings downward a small amount will generally produce a
slightly shorter blowdown. When making this adjustment, move the
upper ring twice as many notches as the lower.
After adjustments are complete, check the ring pins to see that they
engage the ring grooves, but without touching the bottom of the groove.
The pins should not bear against the rings.
6. Overlap Collar Adjustment

The overlap collar is a secondary adjustment point for blowdown
control. It is utilized in conjunction with the upper adjusting ring. There
will be some field conditions where it may not be necessary to use the
overlap collar. However, in no case should the overlap collar be used
exclusively for blowdown setting without first giving due adjustment
attention to the upper adjusting ring.
The overlap collar is moved downward to shorten blowdown and
upward to lengthen blowdown. After final setting, be sure to lock the
overlap collar in position by installing the cotter pin.
A guide to how movement of the overlap collar assists in making final
blowdown adjustments is as shown in Table II on the next page.
CON-14
Page 27
X.C. (Continued)
TABLE II
Orifice Movement of Overlap Collar
1, 2 & 3 May not need further adjustment. If needed move 1 notch
at a time.
4&5 First adjustment 5 notches. Subsequent adjustments 2-3
notches each time.
6, 7, Q & R First and subsequent adjustment, 5-8 notches each time.
NOTE:
The overlap collar positions shown in Table XII, on page 52, are final DVCD
factory settings, but are only starting positions for field setting of blowdown.
Further adjustments may be necessary as stated in Table II, above.
D. Restricted Lift Valves

A Restricted Lift Valve is identified by a nameplate attached to the valve body.
It reads: “Restricted Lift Valve. See nameplate for lift.”
As a starting position for the adjusting rings, use the method outlined in this
manual for the conventional valves (see Section X.C.).
E. Hydroset/EVT Testing
Periodic tests may be required for verification of valve set pressure. Both the
DVCD Hydroset Testing Device and EVT provide for this capability; however, set
pressure is the only factor which can be verified. Valves should be initially set
using full system pressure (as outlined in sections X.A. through X.C. of this
manual) and the Hydroset, or EVT, used for only subsequent checks of set
pressure.
Setting safety valves by the usual method of lifting valves under steam pressure
presents a number of problems. In high pressure conventional boilers, superheater
tubes may be damaged if the turbine is not operating. Also, the expense of feed
water, fuel and personnel involved is considerable.
Although these problems cannot be eliminated entirely, they can be reduced by
using a hydraulic or electronic device that allows the valve’s set pressure to be
checked, while the system pressure remains below the valve’s set pressure.
Accuracy of results obtained by the use of either of these devices depends on
several factors. First, friction must be reduced as a source of error so that, for a
given pressure, the Hydroset or the EVT repeatedly produces exactly the same
lifting force. Second, gauge calibration and vibration, and the effective seating
area between valves of the same size and type, will also affect accuracy. With
well calibrated gauges and valve seats in good condition, accuracy on the order
of 1% of set pressure may be expected. Upon request, DVCD will provide
pertinent written material concerning the Consolidated® Hydroset Device, or the
EVT. This material specifies all required information necessary to ensure proper
usage of these devices.
CON-1
Page 28
X. (Continued)
F. Sealing Valves After Test
After testing the valve for proper set point and blowdown, the ring pins, overlap
collar and top lever pin will be sealed to conform with the applicable ASME Code.
In addition, the cover plate is sealed on restricted lift valves.
Means are provided in the design of all 1700 Maxiflow valves, for use under
Section I of the ASME Code, for sealing all external adjustments. Seals are
installed by DVCD at the time of shipment. It is also required that seals be
installed, after field adjustment or repair of the valves, by the manufacturer, its
authorized representative, or the user.
Seals should be installed in such a manner as to prevent changing the
adjustment without breaking the seal. They also serve as a means of identifying
the manufacturer, repairer, or user making the adjustment. Unauthorized
breakage of the seals will void the valve warranty.
XI. Disassembly Instructions

The Type 1700 Maxiflow Safety Valve can be easily disassembled for inspection,
reconditioning seats, or replacing internal parts. The initial spring load can be
established after reassembly. (Again, refer to Figure 7, on page 19, for parts
nomenclature.)
NOTES:
• Before starting to disassemble the valve, be sure that there is
no steam pressure in the drum or header.
• Parts from one valve should not be interchanged with parts
from another valve.
B. Specific Steps
1. Remove the top lever pin and top lever.
2. Loosen cap set screw and lift off cap and drop lever assembly.
3. Remove the cotter pin which retains the release nut, and then remove
the release nut.
CON-14
Page 29
XI.B. (Continued)
4. Refer to Figure 11 (below), and measure and record Dimension A, as
this information will be required to correctly re-assemble the valve.
5. Remove the two top yoke rod nuts evenly, so as to prevent binding of
the yoke.
6. Carefully lift the yoke over the spindle, and away from the valve.
Remove the thrust bearing assembly (if applicable) and the top
spring washer.
7. Ensure that the bottom spring washer is not stuck to the spring. If the
bottom spring washer is stuck to the spring it may accidentally jar
loose and fall. Next, mark the top of the spring, in order to correctly
install the spring during re-assembly. Finally, lift the spring over the
spindle and away from the valve, and then remove the bottom spring
washer.
8. Remove the overlap collar cotter pin from the collar and spindle
assembly. Note which overlap collar notch is opposite the cotter pin
hole in the spindle. (See Figure 12, below.) Carefully counting each
collar notch that passes in front of the cotter pin hole in the spindle,
begin rotating the collar counterclockwise until the bottom line (of the
four lines) on the collar is even with the upper floating washer. Record
the number of overlap collar notches that passed in front of the cotter
pin hole in the spindle, as this information will be required to correctly
re-assemble the valve.
CON-1
Page 30
XI.B. (Continued)
9. Mark the cover plate vent to establish its relationship to the valve
base, as this will ensure correct alignment during re-assembly, then,
remove the cover plate stud nuts, and lift the cover plate over the
studs.
10. Remove the spindle, disc and disc holder assembly from the valve
by lifting the spindle. Take care to insure that the disc seating
surface is not damaged when the assembly is placed on the ground
or some other work surface.
11. To remove the disc and disc holder from the spindle, first insert the
spindle into a vise (see Figure 13, below) being careful not to
damage the threaded end of the spindle. Then, lift up on the disc
holder and turn the disc/disc holder counterclockwise to engage the
"drop-thru" threads. Once the threads are engaged, release the disc
holder and continue to unthread and remove the disc. After the disc
is removed, lift the disc holder from the spindle.
NOTE:
Removal of the overlap collar, the lift stop and/or the disc collar
from the spindle is usually unnecessary, unless the spindle is to
be replaced.
CON-14
Page 31
XI.B. (Continued)
12. Measure from the top of the guide to the bushing seat (Dimension
B, Figure 14, below) with a depth micrometer or other suitable
measuring device. Record Dimension B. Place a scale or other
thin flat metal surface against the lower face of the upper adjusting
ring and measure from the top of the guide to the face of the upper
adjusting ring (Dimension C, Figure 14, below). Record Dimension
C.
CON-1
Page 32
XI.B. (Continued)
13. Remove the upper adjusting ring pin from the valve base. Remove
the upper adjusting ring and guide assembly from the base by lifting
straight up on the guide being careful not to disturb the upper
adjusting ring adjustment. Mark the radial position of the upper
ring notches relative to the guide by marking or scribing axially on
the guide, then making a corresponding mark axially on the upper
adjusting ring (see Figure 15, below). Recording Dimensions B and
C and marking of the upper adjusting ring and guide will aid in setting
the adjusting ring in exactly the same position it was in prior to
disassembly.
CON-14
Page 33
XI.B. (Continued)
14. Loosen the lower adjusting pin until the pin is slightly clear of the
notches in the lower adjusting ring. Being careful not to move the
lower adjusting ring, place a ring lap on top the busing seat. (See
Figure 16, below). Then, using the ring pin as a “pointer”, or
reference point, rotate the lower adjusting ring counterclockwise
and count the number of notches that pass in front of the “pointer”
until contact is made with the ring lap. Record this information, as it
will be required to correctly re-assemble the valve.
FIGURE 16
15. Next, remove both the lower adjusting ring pin and the lower
adjusting ring from the valve base.
16. Normally the yoke rods do not have to be removed from the valve
base. If however, it becomes necessary to remove them, the
procedure below should be followed:
a. Mark each rod relationship to where it contacts the valve base
"ears", and also identifying which rod is to the right and which
rod is to the left of the valve outlet.
b. Loosen the yoke rod nuts using the appropriate size socket
and handle.
c. Remove the nuts, and then pull up on each rod to remove it
from the base.
17. The valve is now ready to be cleaned and the parts inspected for
proper size and condition.
CON-1
Page 34
XII. Inspection
A. General
Once the valve is disassembled, appropriate parts can be inspected for damage
and their suitability for reuse.
B. Specific Steps
As a minimum, the following parts should be inspected as specified below:
1. Disc Holder
The surface on the end of the disc holder closest to the disc must be
free from steam erosion. The two small holes must be open to insure
the passage of steam to the chamber above the disc. Make sure the
outside diameter is not egg shaped and the surface is smooth. If any
small indication of galling is present, polish the high spots with an
emery cloth. If serious or large scale galling is present, the disc holder
should be replaced.
2. Guide
Inspect the guide inside diameter for egging, and insure the inside
surface is smooth. The threads on the outside must be in good
condition to insure the upper ring will adjust, even when the valve is
hot. If serious or large scale galling is present, the guide should be
replaced.
3. Clearance
The maximum clearance between the disc holder and guide should be
in accordance with Table III (below):
TABLE III
ORIFICE SIZE TEMPERATURE MAX. CLEARANCE
#1 UP TO 750°F .005
ABOVE 750°F .008
#2 UP TO 750°F .008
ABOVE 750°F .012
#3 UP TO 750°F .010
ABOVE 750°F .015
#4 UP TO 750°F .012
ABOVE 750°F .018
#5 UP TO 750°F .011
ABOVE 750°F .017
#6 UP TO 750°F .016
ABOVE 750°F .016
#7 UP TO 750°F .020
ABOVE 750°F .020
#Q UP TO 750°F .020
ABOVE 750°F .020
#8 UP TO 750°F .020
ABOVE 750°F .020
#R UP TO 750°F .020
ABOVE 750°F .020
CON-14
Page 35
XII.B. (Continued)
4. Disc
Inspect the disc seat for steam cuts, nicks, or other damage. If the seat
step measure less than dimensions specified in Table IV (below), this
indicates that the thermal lip has been lapped to the minimum
thickness.
Do not machine any THERMOFLEX™ disc; however, a disc which
is not below minimum relief can be lapped to remove minor damage.
(See Figure 18, on page 38 for more information.)
TABLE IV
MINIMUM SEAT RELIEF

ORIFICE M(MIN.)
1 .004
2 .005
3 .006
5 .007
4 .008
6 .010
7 .012
Q .012
8 .012
R .012
5. Overlap Collar
Inspect the outside diameter for nicks, burrs, tears, pitting and signs
of galling. Then, inspect the lugs for bending or damage, and the
threads for signs of galling, tearing, and damage.
6. Cover Plate
Ensure that the floating washers are free to move and are not bent or
deformed. Check the surface of the inside diameter on the floating
washers and the washer retainers for tears, pitting, corrosion, and
signs of galling. Ensure that the bleed hole in the cover plate is not
obstructed.
CON-1
Page 36
XIII. Maintenance Instructions

A. General
It is not necessary to remove Type 1700 Maxiflow Safety Valves from the boiler
for maintenance. The normal maintenance required is generally confined to
touching up seats and occasionally replacing the disc.
The following tools are recommended for this work:
1. Flat lapping plate (Part No. 0439004)
2. Grinding compounds
3. High temperature lubricant (Fel-Pro Nickel Ease)
4. Two (2) ring laps per valve size and type
See Maintenance Tools & Supplies (in Section XVII of this manual).
All of the above tools can be procured from DVCD, with prices being those that
are in effect at the time of delivery. It may not be necessary to use all of the ring-
laps at any one time, but having a sufficient supply on hand will save the time of
reconditioning them during a boiler outage. After the boiler is back on the line,
the ringlaps should be reconditioned on the flat lapping plate, or returned to the
factory for reconditioning, at a nominal cost, on a special lapping machine. A lap
should not be used on more than one valve without being reconditioned.
Valves that have been leaking should be disassembled in accordance with prior
instructions. Since the position of the adjusting rings has been recorded, the
rings can be removed for cleaning every time the valve is disassembled. Parts
for each valve should be kept together or marked, to ensure that they are
replaced in the same valve.
Reconditioning of the seat surface of the disc and seat bushing is accomplished
by lapping with a flat cast iron, ring lap, as outlined in the lapping procedure.(See
Section XIII.B, below).
B. Lapping Procedure
1. General Information
While the finer points of lapping and “grinding-in” may be considered
as a mechanical art, it is not beyond the ability of the average
mechanic to produce good seats with some practice. No effort has
been made in this manual to establish an exact procedure to cover
each and every case, because different persons can get the same
results using their own techniques.
The following precautions and hints will be of assistance when lapping
nozzle and/or disc seats:
a. Two (2) ring laps per valve
b. 1A Clover Grinding Compound per tool list*
c. 1000 Grit Kwik-Ak-Shun Grinding Compound per tool list*
d. Clean, lint free cotton rags
CON-14 * This tool list is located on page 57 of this manual

Page 37
XIII.B. (Continued)
Before lapping the nozzle and disc seat, the leading edges (inside
diameter of seats) of both must be slightly chamfered as follows:
Use a fine grade sandpaper to lightly break the inner edge and outer
edge of the nozzle seat and disc seat. The purpose of this is to remove
any small metal particles or fins attached to the sharp corner surfaces.
Do not exceed .002 inches (.05 mm) chamfer for this purpose.
2. To Lap The Bushing Seat
NOTE:
If the bushing seat surface requires extensive lapping or
reconditioning, a reseating machine should be used prior to
lapping. (See “Reseating Machine“, in Section XIII.C., of this
manual.)
Cover the seat lap face with a light coating of 1-A Clover Compound
and gently place the lap on the valve bushing seat.
NOTE:
A heavy coat of lapping compound tends to round off the edges
of the seat.
Lap, using an oscillating motion in various directions, while holding the

lap loosely in the fingers and allowing the weight of the lap to rest on
the seat surface. Control the motion of the lap to prevent either the
inside or outside edge of the lap from crossing the bushing seat
surface. If either edge touches the seat surface, the seat can become
scratched and/or rounded.
NOTE:
Care should be used not to run off the seating surface with the lap,
as this will cause the seat to become uneven.
CON-1
Page 38
XIII.B. (Continued)
Do not lap excessively with a ring lap without resurfacing on a lapping

plate as shown in Figure 17 (below). Use a new ring lap, if further
lapping is required, to remove any defect in the seat. To finish lapping
the bushing seat, apply a light coating of #1000 Grit Compound to the
face of the new lap, and repeat the above lapping motion.
Remove the ring lap and wipe the lap surface with a clean, lint free
cloth, leaving compound on the bushing seat. Replace the ring lap on
the seat and lap as above, but without adding compound. Repeat this
operation until the seat has a mirror finish. Any evidence of defects,
such as gray areas or scratches, will require a repeat of the whole
lapping procedure until a mirror finish is attained.
3. To Lap Disc Seat
The above lapping method is also used on the disc seat. When lapping
the disc seat, the disc should be held stationery, but not rigidly, and the
lap moved as above. Use care not to strike the cone of the disc, as this
would cause the seat to be high on the inside.
The THERMOFLEX™ disc can not be machined. If, after lapping,
Dimension M , in Figure 18 (below), does not meet the minimum
specified in Table V (on the opposite page), the disc should be
replaced.
CON-14
Page 39
XIII.B. (Continued)
TABLE V
MINIMUM SEAT RELIEF

ORIFICE M(MIN.)
1 .004
2 .005
3 .006
5 .007
4 .008
6 .010
7 .012
Q .012
8 .012
R .012
It may not be necessary to use all the laps at any one time, but having
a sufficient supply on hand will save reconditioning time. The laps
should be reconditioned on the flat lapping plate, and a lap should not
be used on more than one valve without being reconditioned. Laps
must be checked for flatness prior to use, and at frequent intervals
during use. A lap that is flat within one-half light band is considered
satisfactory. Information on the Monochromatic Light and optical flat is
available, upon request, from the DVCD Field Service Department.
To recondition a ring lap, wipe all compound from the lapping plate and
ring lap, then move the ring lap in a figure-eight motion on a lapping
plate. If the lap is not flat, a shadow will be apparent. To remove the
shadow, coat the lapping plate with 1000 Grit Compound and lap the
ring, with figure-eight motions covering the lapping plate, as shown in
Figure 17 (on page 38).
C. Reseating Machine Information

A DVCD reseating machine should be used to recondition badly worn, out of
tolerance, bushing seats. This machine can be provided by the DVCD Service
Department, and eliminates the need to remove a valve from the unit. The
machine is mounted in place of the yoke and cuts the top face, inside diameter,
and outside of the bushing, to establish the correct height, angles, and diameters.
CON-1
Page 40
XIII.C. (Continued)
Replace the seat bushing if critical dimension K (Max.) is exceeded. See Figure
19 and Table VI below. Do not remove threads.
TABLE VI
Critical Dimension
Valve Type K (Max.)
#1 3-1/16
#2 3-13/16
17.35, 36, 37 4-7/8
17.38, 39, 30 5-11/16
#4 5-11/16
#5 5-11/16
#6 4-3/4
#7 5-9/16
#Q 5-9/16
#8 5-9/16
#R 5-9/16
1706RXHPI
and
1707R only 7-9/16
The use of the reseating machine is suggested for reconditioning badly worn
seats, or for re-establishing Dimension E per Figure 20 (below). Dimension E
should be re-established when it is less than .010 inches for orifices 9, 1, 2, K,
3, and 5, and 4 or less than .030 inches for orifices 6, 7, 8, R and RR.
FIGURE 20
As a result of machining the bushing seat, the length of disc holder extending
above the disc guide will decrease. Therefore, the top of the disc guide should
be kept to a distance of at least 1/16 in. (1.587 mm), beneath the top of the disc
holder, to facilitate freeing the disc holder, in case a deposit of dirt forms in the
pocket between the two parts. This dimension is obtained by machining the top
of the disc guide (see Figure 21, on opposite page).
CON-14
Page 41
XIII.C. (Continued)
D. Spindle Runout
It is important that the spindle be kept very straight in order to transmit the spring
force to the disc without lateral binding. Overgagging is one of the common
causes of bent spindles. A method to check the essential working surfaces of the
spindle is illustrated in Figure 22 (below). This may be performed either with or
without the disc collar and lift stop on the spindle.
Using Figure 22 (above) as a reference, clamp a V block (A) made of wood, fiber
or other suitable material onto the platform railing. Imbed the ball end of the
spindle in a piece of soft wood (B) and place the top of the spindle, below the
threads, in the V block (A). Clamp a dial indicator onto the railing and locate at
point (C). The total indicator reading should not exceed .007 in. (.177 mm) when
the spindle is rotated. If it does, the spindle must be straightened prior to reuse.
To straighten the spindle, place the unthreaded portion of the small and large end
in padded V blocks, with the point of maximum indicator readout upward, and
then apply a downward force with a padded press or jack as required, until the
spindle is within the specifications.
CON-1
Page 42
XIII.D. (Continued)
Other parts of the spindle not used as working surfaces may run out considerably
more than .007 in. (.177 mm), but this should not be regarded as unacceptable.
Although the upper thread end is not a working surface, excessive bending in this
area could effect the accuracy of the DVCD Hydroset device and/or the DVCD
Electronic Valve Tester, if either of these devices is used to verify valve set
pressure.
E. Disc Replacement and Disc-Spindle Bearing Requirements

To replace the disc, disassemble the valve in accordance with the instructions
provided in Section XI of this manual.
Apply a small amount of lapping compound (1A) on the tip of the spindle. Install
the disc - without the disc holder - onto the spindle tip, turning it clockwise until
the disc threads drop out. Place a ring lap on a table, or similar flat surface, and
wipe the exposed surface of the lap clean. Insert the disc nose into a ring lap, so
that the seat contacts the lap surface. Oscillate the spindle using 360 degree
oscillations for approximately 15 seconds, then check the spindle tip and disc
“pocket” to determine progress. (See Figure 23, below).
CON-14
Page 43
XIII.E. (Continued)
The desired band width for subcritical valves is shown in Table VII (below), and
the desired band width for supercritical valves is shown in Table VIII on the next
page. In addition, the finished machine size of the spindle nose radius, and the
flat diameter for each orifice size and valve type are also shown in these two (2)
tables.
TABLE VII
SUB CRITICAL
NOSE FLAT DIA. BEARING
RADIUS “R” BAND WIDTH
ORIFICE
IN. IN. IN.
MM MM MM
0.277 +.000 1/8 1/8
-.004
1
7.038 +.000 3.175 3.175
-.102
0.371 +.000 3/16 1/8
-.004
2
9.423 +000 4.783 3.175
-.102
0.495 +.000 1/4 7/32
-.005
3
12.573 +.000 9.358 5.556
-.127
0.485 +000 1/4 7/32
-.005
4
+.000
12.573 -.127
8.350 5.558
+.000
0.495 -.005
1/4 7/32
5
+.000
12.573 -.127 6.350 5.556
+.000
0.485 -.005 1/4 7/32
6
+.000
12.573 -.127 6.350 5.556
+.000
0.582 -.005 1/4 9/32
7
+.000
17.323 -.127 6.350 7.143
+.000
0.582 -.005 1/4 9/32
Q
+.000
17.323 -.127 6.350 7.143
+.000
0.713 -.005 5/16 5/16
8
+.000
18.118 -.005 7.938 7.937
+.000
0.713 -.005 5/16 5/16
R
+.000
18.118 -.127 7.938 7.937
CON-1
Page 44
XIII.E. (Continued)
TABLE VIII
SUPER CRITICAL
NOSE BEARING
FLAT DIA.
RADIUS "R" BAND WIDTH
IN IN IN
ORIFICE
MM MM MM
.371 3/16 5/32
1
9.423 4.763 3.968
.371 3/16 5/32
2
9.423 4.763 3.968
.594 NONE 1/4
K
15.087 NONE 5.35
.495 1/4 7.32
3
12.573 6.350 5.556
.495 1/4 7/32
4
12.573 6.350 5.556
.495 1/4 7/32
5
12.573 6.350 5.556
If the required bearing band cannot be obtained by hand grinding, then this radius
should be checked and remachined if necessary.
If the band extends too high on the radius it will be difficult to rock the disc, and
the disc may lock up under pressure. If the band is too narrow, the spindle may
indent the disc and again the rock will be lost.
When the bearing area is re-established, clean both surfaces. Then apply
lubricant to the spherical surface of the spindle tip, and work it into the surfaces
by rotating the disc on the spindle.
Place the disc holder on the spindle, allowing it to rest on the face of the disc collar
as previously shown in Figure 13 on page 30. Then assemble the disc holder and
new disc. The disc should be free enough to rock on the spindle tip. If there is no
freedom, lower the disc collar until the disc is free to rock slightly initially,
approximately .001 to .002 inches (0.25 to .05mm) rock. The disc collar must
then be lowered two additional notches from this initial position and secured with
a stainless steel cotter pin. (See Figure 25, below).
NOTE:
Failure to provide the recommended disc rock at assembly will result in a
leaking valve.
CON-14
Page 45
XIII. (Continued)
F. Grinding the Compression Screw
Some valve designs feature a compression screw with a spherical radius tip as
shown in Figure 26 (below). For these designs, the compression screw spherical
bearing surface must be ground into the upper washer so that full contact along
the spherical radius is obtained. To grind these items, a 320 grit (Clover 1A)
lapping compound is used for roughing-in and then finish lap with 1000 Grit Kwik-
Ak-Shun lapping compound, until a satisfactory bearing band is obtained. Clean
the compression screw, and upper spring washer when completed.
G. Thrust Bearing Surfaces

For those designs utilizing a ball-type thrust bearing, the aligning washer must
match evenly to the lower thrust bearing spherical surface, such that full face
contact is achieved between the parts (see Figure 27, below). Therefore, grind
together, or replace the entire thrust bearing, as necessary.
H. Grinding The Lower Spring Washer

The lower spring washer bearing surface must be ground to the spindle. To grind
the lower spring washer, a 320 grit (Clover 1A) lapping compound is used for
roughing-in, and then finish lap with 1000 Grit Kwik-Ak-Shun lapping compound
until a satisfactory bearing band is obtained. The bearing width should be 1/8 in.
(3.2 mm) min. to 3/16 in. (4.8 mm) max. Clean the lower spring washer and
spindle when complete.
CON-1
Page 46
XIV. Re-Assembly
The Type 1700 Safety Valve can be easily re-assembled after required inspection/
maintenance of internal parts has been performed. (Again, refer to Figure 7, on
page 19, for parts nomenclature.) All parts should be clean prior to assembly.
See Section XVII for recommended compounds, lubricants, and tools.
B. Specific Steps
1. If they have been removed, the yoke rods are installed into the base,
and then the yoke rod nuts installed. Locate the yoke rods in the
original location in the valve base as recorded during disassembly.
Lubricate all threads. Yoke rod nuts are then to be torqued using the
yoke rod nut torque wrench and socket. Torque nuts in accordance
with Table IX (below).
NOTE:
Use of an impact device to produce required torque values is
not recommended.
TABLE IX
YOKE ROD NUT TORQUES - FOOT POUNDS
ORIFICE PRESSURE CLASS
5 6 7 8 9 0
1 150 150 150 120 120 120

2 150 120 120 150 150 150
3 250 150 150 300 300 300
5 300 300 300 350 350 350
4 300 300 300 350 350 350
6 300 300 300 500 1000
7 500 350 500
8 500 500 750
8-xhp 750
R 500 500 750
R-xhp 750
2. Prior to reinstalling the lower adjusting ring, lubricate the threads of

the lower adjusting ring pin and partially insert the pin into the valve
body. Now the pin can again serve as a “pointer”, or reference point,
as previously discribed in Section XI.B.14 of “Disassembly” . Next
lubricate the threads of the lower adjusting ring, and install the ring
in the valve body. Then, turn the lower adjusting ring clockwise until
the top of the ring clears the seat.
CON-14
Page 47
XIV.B. (Continued)
3. To position the lower adjusting ring, place a clean ring lap on the
nozzle seat and move the lower adjusting ring up until it makes
contact with the ring lap. If the original location of the adjusting ring
was recorded, simply lower the ring, by moving it down, the same
number of notches as was recorded in Step XI.B.12 of “Disassembly”.
If information on the original lower ring position is not available, the
ring should be lowered, by moving it down one notch for every 600
psig (20.7 bar) of set pressure.
NOTE:
For a valve set pressure of 1200 psig (81.6 bar), the ring will
have to be lowered two (2) notches below the bushing seat. This
will be the starting position, with the final position being
determined during field testing (see Figure 28, below).
4. Once the lower adjusting ring is in its correct location, lock it in place
by screwing in the lower adjusting ring pin. Verify that the lower ring
is capable of a slight movement. If the lower ring does not move, the
pin is too long. Should this be the case, grind the end of the pin
slightly to shorten it, while retaining the original tip contour, then
reinstall the pin.
5. If the upper adjusting ring has been removed from the guide,
lubricate the ring threads and re-install the ring on the guide.
CON-1
Page 48
XIV.B. (Continued)
6. Install the adjusting ring and guide assembly into the valve base
such that the scribe marks will be visible from the valve outlet or an
inspection port. Place a scale or other suitable thin flat metal object
on the lower face of the upper adjusting ring and measure the overall
length of the upper ring and guide assembly. Adjust the upper ring
to the Dimension C (see Figure 29, below) recorded in Step 12 of
Section XI.B., "Disassembly". Observe the marks made on the ring
and guide and adjust the ring to align the marks (see Figure 30,
below). Recheck the overall length of the adjusting ring and guide
assembly to assure that the upper ring is in its original position.
CON-14
Page 49
XIV.B. (Continued)
7. Measure from the top of the guide to the bushing seat with a depth
micrometer. Subtract Dimension B as measured in Step 12, Section
XI.B., "Disassembly", from the dimension previously measured.
The difference is the distance the upper adjusting ring must be
lowered. Refer to Table X, below, to determine the number of
notches that the ring is to be lowered.
TABLE X
VERTICAL RING TRAVEL

ORIFICE FOR EACH NOTCH
OF ADJUSTMENT
1 .0025
2 .0020
3 .0015
5 .0015
4 .0015
6 .0009
7&Q .0010
8 .0016
R .0011
8. Once certain that the upper adjusting ring/guide assembly is properly

set, lubricate the guide seating surface in the valve base, and re-
install the assembly into the base, then, lubricate the threads of the
upper adjusting ring pin, and lock the ring/guide assembly in place
by screwing in the pin. Verify that the upper ring is capable of a slight
movement. If the upper ring does not move, the pin is too long.
Should this be the case, grind the end of the pin to shorten it, while
retaining the original tip contour, then reinstall the pin.
9. Clamp the spindle in a padded vise, with the “ball end” of the spindle
upward.
10. Verify that the spindle bearing has been ground to the disc pocket,
as specified in Section XIII.E, “Disc Replacement and Disc Spindle
Bearing Requirements”, of this manual.
NOTE:
This step must be accomplished before proceeding with re-
assembly.
11. If the lift stop was removed from the spindle, lubricate the threads
and install the lift stop. Do not install the cotter pin at this time.
12. If the disc collar was removed, lubricate the threads and install on
the spindle. Do not install the cotter pin at this time. Then, carefully
lower the disc holder onto the spindle, allowing it to sit on the face
of the disc collar.
CON-1
Page 50
XIV.B. (Continued)
13. Thread the disc onto the spindle, ensuring that the disc is free to
“rock” on the spindle tip as specified in Section XIII.E., “Disc
Replacement and Disc Spindle Bearing Requirements”, of this
manual. If disc “rock” is not satisfactory, correct the cause before
proceeding. When disc “rock” is satisfactory, remove the disc and
disc holder, and secure the disc collar with a stainless steel cotter
pin. Using side cutters, carefully cut off excess cotter pin legs, and
bend the cotter pin for a neat installation.
14. Lubricate the spindle tip, and assemble the disc holder and disc to
spindle. Recheck the rock.
15. Remove complete assembly from the vise, being sure to protect the
disc seat surface at all times.
16. Prior to installing the spindle assembly into the valve base, wipe the
disc seat with a soft, lint-free cloth. Then, carefully install the spindle
assembly into the guide.
17. Install the cover plate over the spindle assembly, ensuring that the
cover plate is correctly oriented with regard to the valve base, as
previously marked for this purpose during disassembly. (See Step
XI.B.9., in this manual.) Then, install the cover plate nuts, with the
nuts being only hand tightened.
18. Next, install the yoke and compression screw assembly over the
yoke rods and spindle.
19. Next, refer to Figure 31 (below) and establish Dimension A.
20. Pull up on the spindle until the lift stop contacts the cover plate and
repeat the measurement of Dimension A, while the lift stop and
cover plate are in contact. The difference between these two
measurements is the valve lift. The valve lift should be equal to the
nameplate lift, plus the additional recommended lift as shown in
Table XI, on the opposite page.
NOTE:
Do not deviate from stamped nameplate lift.
CON-14
Page 51
XIV.B. (Continued)
TABLE XI
Required
Bore Rated Additional
Orifice Diameter Lift Lift
1 1.125(28.6mm) .282(7.16mm) .020(.508mm)

2 1.350(34.3mm) .338(8.59mm) .020(.508mm)
3 1.800(45.7mm) .450(11.43mm) .030(.762mm)
5 2.062(52.4mm) .517(13.13mm) .040(1.016mm)
4 2.250(57.2mm) .563(14.30mm) .050(1.270mm)
6 3.000(76.2mm) .750(19.05mm) .060(1.524mm)
7 3.750(95.3mm) .938(23.83mm) .070(1.778mm)
Q 3.948(100.3mm) .985(25.02mm) .070(1.778mm)
8 4.250(108.0mm) 1.063(27.00mm) .080(2.032mm)
R 4.515(114.7mm) 1.129(28.68mm) .090(2.286mm)
K 1.531(38.9mm) .384(9.75mm) .030(.762mm)
21. If the measured dimension is:

a. Correct:
(1) Remove the yoke and cover plate.
(2) If the cotter pin has been removed from the lift stop, lift
the spindle assembly from the valve and disassemble it.
(3) Install the lift stop cotter pin, re-assemble the spindle
assembly, and re-install the spindle assembly into the
valve guide.
(4) Install the cover plate and torque cover plate nuts to fifty
(50) ft/lbs. (Do not re-install yoke at this time.)
b. Incorrect:
(1) Remove yoke and cover plate.
(2) Adjust valve lift, as required, in the following manner:
(a) Increase valve lift by moving the lift stop down one
(1) notch for each .010" increase required.
(b) Decrease valve lift by moving the lift stop up one (1)
notch for each .010" decrease required.
22. Verify that the valve lift is now correct by repeating Steps XIV.D.17
through XIV.D.21 (above). If the lift is correct, proceed to Step
XIV.D.21.a (above). If the lift is incorrect, repeat Step XIV.D.21.b
(above).
CON-1
Page 52
XIV.B. (Continued)
23. If the overlap collar has been removed from the spindle, lubricate
the collar threads and place over the spindle with the notches in the
collar up (i.e., away from the cover plate). Note that the overlap
collar has four circumferential scribe lines. The lower scribe line is
the one farthest away from the notches. (See Figure 32, below.)
Thread the overlap collar onto the spindle by turning in a clockwise

direction, until the lower scribe line is even with the visible floating
washer. Align the nearest overlap collar notch with the drilled hole
in the spindle by moving the overlap collar down.
24. Refer to Table XII (below) before making the initial overlap collar
adjustment.
TABLE XII
Adjustments (Notches)
Orifice Bore Diameter Standard Restricted Lift
1 1.25 (28.6mm) 6 3
2 1.350 (34.3mm) 7 3
3 1.800 (45.7mm) 8 4
5 2.062 (52.4mm) 9 4
4 2.250 (57.2mm) 10 5
6 3.000 (76.2mm) 13 6
7 3.750 (95.3mm) 16 8
Q 3.984 (100.3mm) 16 8
8 4.250 (108.0mm) 18 9
R 4.515 (114.7mm) 20 10
Note that these adjustments differ for each orifice size. (Also note
that restricted lift valves require a different overlap collar adjustment.)
25. To adjust the overlap collar, move the collar down the number of
notches specified in Table XII (above) or, if the original setting is to
be re-established, reset the collar to the position previously recorded
during disassembly. (See Section XI.B.8 in this manual.)
26. Install cotter pin through overlap collar notches and spindle. Trim
cotter pin to proper length, and bend the ends to secure the overlap
collar and spindle together.
27. Before installing the spring washer, lubricate the bearing surfaces
on lower spring washer and the spindle. Then, install lower spring
washer onto the spindle.
CON-14
Page 53
XIV.B. (Continued)
28. Determine which end of the spring is to be fitted to the lower spring
washer as determined in the disassembly procedure. (See Section
XI.B.7 in this manual.) Lower the spring gently over the spindle until
it is seated on lower spring washer. Install the top spring washer
onto the spring, and insure that the lug engages the left yoke rod
when facing in the same direction as the outlet.
29. If compression screw has been removed, lubricate the threads of
the compression screw and yoke. Install the lock nut onto the
compression screw and thread the compression screw into yoke,
until the screw is just protruding from lower end of the yoke.
NOTE:
If the valve utilizes a bearing with a compression screw
adaptor as shown in Figure 27 (on page 45 of this manual),
install the adaptor onto the top spring washer. Install the
bottom race and pack the thrust bearing with lubricant, then
install the bearing and the top race into the adaptor.
30. Lubricate upper yoke rod threads. Carefully position the yoke
assembly over the yoke rods taking care to align the compression
screw with either the bearing or upper spring washer as applicable.
31. Using the yoke rod nut torque wrench and the socket, torque the
yoke rod nuts as specified in Table IX, on page 46 of this manual.
32. Next, return the compression screw to its original position recorded
during disassembly (see Section XI.B.4 of this manual), and tighten
compression screw lock nut.
33. Ensure that the top washer lug does not remain in contact with the
yoke rod, after final compression screw adjustment.
34. Install the release nut onto the spindle and thread clockwise, until
the release nut is fully engaged on the spindle thread.
35. Install the cap over the release nut, and seat the cap firmly into
place on the yoke. Install the top lever in the cap and, then, insert
the lever pin through the top lever and cap holes.
36. Adjust the release nut, until it clears top lever by 1/8 inches
(3.175mm). Remove the lever pin, top lever, and cap. Next, insert
a cotter pin through the release nut slots and spindle, and spread
cotter pin ends. (If spindle has been replaced, a cotter pin hole must
be drilled through the replacement spindle.) Re-assemble the cap
with the drop lever, top lever, and top lever pin. Install a cotter pin
to lock the top pin in place. A final check should be made to ensure
the proper clearance exists between the release nut and the top
lever. Finally, tighten cap set screw to secure the cap.
CON-1
Page 54
XV. Hydrostatic Testing & Gagging

During any hydrostatic test, all safety valves on the unit, which have not been
removed and do not have hydroplugs, must be gagged. This gagging procedure
prevents the possibility of damage to the safety valve internals in the event that
the test pressure exceeds the safety valve set pressure. When adjusting valve
set pressures, other valves in the system should also be gagged.
When valves are subjected to working hydrostatic tests not exceeding the set
pressure of the low set valve, valves may be gagged rather than using
hydrostatic test plugs. For higher pressures, hydrostatic plugs should be used.
Probably the most common source of Safety Valve trouble is over-gagging.
During hydrostatic testing, and during Safety Valve setting, gags should be
applied only hand tight. During setting, overgagging will also cause damage to
the seating surface and result in seat leakage. In applying gags remember that
the valve spring will hold the valve closed against its set pressure.
The additional gag load applied should be only enough to ensure that the valves
do not lift at the expected overpressure.
During start-up, gags should never be applied when the boiler is cold. The
spindle of the Safety Valve expands considerably with the temperature increase.
If it is not free to expand with this temperature change it may become seriously
overstressed and bent.
Except for hydrostatic tests, boiler pressure should be brought up to within 80%
of the pressure of the low set valve before applying gags.
Tighten the gags of drum and superheater valves with only a light force applied
to the gag screw head.
CON-14
Page 55
XV. (Continued)
APPLICATION OF TEST GAGS (All Pressures)
Refer to Figure 7 on page 19. Remove top lever pin and top lever then loosen the
cap screw. Remove cap and drop lever as an assembly. The release nut is fixed
to the spindle by means of a cotter pin. Note that the release nut does not quite
engage top of compression screw.
Center the test gag in the exposed end of the SPINDLE and hook the legs of gag
under the sides of the YOKE as shown in Figure 33 (below).
Do not apply the gag load until the system steam pressure is equal to 80%
of the pressure to which the low set valve is adjusted.
Apply the gag load by turning the gag screw clockwise. If the gag on any valve
has not been tightened sufficiently, the valve will leak. On steam service the
leakage is accompanied by a “sizzling” sound.
If this occurs, the hydrostatic test pressure or steam pressure should be
reduced until the valve becomes tight and, then, the gag should be
tightened still further.
This procedure must be followed exactly, since it is very difficult to stop the leak
by additional gagging once it has started. Any attempt to stop the leakage
through the valve, without first lowering the system pressure, could result in
damage to the valve seats.
After the hydrostatic test or steam test is completed, the gags should be removed
when the hydrostatic pressure has been reduced to 80% to 90% of the pressure
of the low set valve.
NOTE:
Under no circumstances should the gags be left on the valves.
CON-1
Page 56
XVI. Trouble Shooting The 1700 Series Valve
Problem Possible Cause Corrective Action
No Action, A. Upper ring too high. A. Increase blowdown as outlined in

Valve does not go Section X.C.5. of manual.
into full lift. B. Foreign material trapped B. Disassemble valve and correct any
between disc holder & guide. abnormaility as outlined in Section
XI. of manual. Inspect system for
cleanliness.
C. Overlap collar adjusted too C. Reset initial setting per Section
low. XIV.B.24. of manual, then move
overlap collar from right to left one or
two notches, then retest. Repeat
additional adjustment as necessary.
Simmer A. Lower ring too low. A. Adjust per Section X.C.2. of manual.
B. Steam line vibrtations. B. Investigate and correct cause.
Valve Leaking A. Damaged seat. A. Disassemble valve, lap seating

and/or exhibits surfaces, replace disc if required, as
erratic popping outlined in Section XII.B. of manual.
actions. B. Part misalignment. B. Disassemble valve, inspect contact
area of disc and nozzle, lower spring
washer or spindle, compression
screw, spindle straightness, etc.
C. Disassemble valve and check disc
C. Disc has insufficient rock. rock per Section XIII.E. of manual.
D. Discharge stack binding on D. Correct as required.

outlet.
Hangup, or valve A. Lower ring too high. A. Move lower ring to the left one notch
does not close per adjustment until problem is
completely. eliminated.
B. Foreign material. B. Disassemble valve and correct any
abnormal condition. Inspect system
for cleanliness.
Excessive A. Upper ring too low. A. Decrease blowdown as outlined in

blowdown Section X.C.4. of manual.
B. Exhaust pressure too high. B. Decrease exhaust pressure by
increasing discharge stack area.
C. Overlap collar too high. C. Check initial setting per Section
XIV.B.24. of manual, then move
overlap collar from right to left one or
two notches, then retest. Repeat
additional adjustment as necessary.
Chatter or short A. Upper ring way too high. A. Lower upper ring.
blowdown B. Raise overlap collar. Reestablish in
B. Overlap collar way too low. accordance with Section XIV.B.24. of
manual.
C. Inlet piping pressure drop too C. Reduce inlet pressure drop to less
high. than one-half of required valve
blowdown by redesigning inlet piping.
CON-14
Page 57
XVII. Maintenance Tools and Supplies

LAPPING TOOLS
The following tools are required for proper maintenance of Consolidated® Type
1700 Safety Valve seats:
Ring Lap
The ring lap is used for lapping the nozzle and disc seats.
Rings Laps*
Valve Lap
Orifice** Part No.
1 1672806
2 1672807
3 1672808
4 1672810
5 1672809
6 1672811
7 and Q 1672812
8, R and RR 1672813
Lapping Plate
The lapping plate is used for reconditioning the ring laps. Only one 11” diameter
plate is required for all sizes of ring laps.
Resurfacing Plate - 11” Diameter.
Part No. 0439004
Lapping Compound
Lapping compound is used as a cutting medium for lapping and polishing the
seats and bearing surfaces in Type 1700 Safety Valves.
Lapping Size
Brand Grade Grit Function Container Part No.
Clover 1A 320 General 4 oz. 199-3
Clover C 220 Coarse 4 oz. 199-2
Kwik- - 1000 Polishing 1 lb. 199-11
Ak-Shun 2 oz. 199-12
Gags
Valve Gag
Orifice** Part No.
1 4363001
2 4363001
3 4363001
4 4217701
5 4217701
6 4217701
7 and Q 4217701
8, R and RR 4217701
* Note 1: One set of two (2) Ring Laps is recommended for each orifice valve
in service, to assure ample flat laps are available at all times.
** Note 2: Valve orifice number is third digit of valve type number, e.g. a 1737A
valve has a #3 orifice.
CON-1
Page 58
XVII. (Continued)
Lubricant
Location Lubricant
Bearing Points
1. Spindle/Disc
2. Compression Screw/Top
Spring Washer Fel-Pro Nickel Ease
3. Spindle/Bottom Spring
Washer
All Threads
All Nut Contact Faces
Wrench Sizes
Maxiflow Maxiflow
Series 1-7/16 1-5/8 2 2-3/8 2-3/4 3-1/8 Series 1-7/16 1-5/8 2 2-3/8 2-3/4 3-1/8
Number Number
1710 1748
1712 1749
1715
1716 1750
1717 1752
1718 1755
1719 1756
1757
1720 1758
1722 1759
1725
1726 1765
1727 1766
1728 1767
1729
1775
1730 1775Q
1732 1776
1735 1776Q
1736 1777Q
1737
1738 1785
1739 1786
1787
1740
1742 1705R
1745 1706R
1746 1707R
1747
CON-14
Page 59
XVIII. Service Parts Inventory Philosophy

The basic objectives in formulating a replacement parts plan are:
• PROMPT AVAILABILITY
• MINIMUM DOWNTIME
• SENSIBLE COST
• SOURCE CONTROL
Guidelines for establishing meaningful inventory levels:
PARTS CLASSIFICATION
PART REPLACEMENT PREDICTED

CLASSIFICATION FREQUENCY AVAILABILITY
CLASS I MOST FREQUENT 70%
CLASS II LESS FREQUENT 85%

BUT CRITICAL
CLASS III SELDOM REPLACED 95%
CLASS IV HARDWARE 99%
CLASS V PRACTICALLY NEVER 100%

REPLACED
Consult the Recommended Spare Parts list (see Section XX of this manual) to
define the parts to be included in the inventory plan.
Select parts and specify quantities.
CON-1
Page 60
XVIII. (Continued)
Identification and Ordering Essentials
When ordering service parts, please furnish the following information to insure
receiving the correct relacement parts:
Identify valve by the following nameplate data:
1. Size
2. Type
3. Temperature Class
4. Serial Number
Example One: 2“ 1729WA
S/N BG-5171
Example Two: 1 1/2” 1712WD
S/N BH-9547
Specify parts required by:

1. Part Name (See Figure 7 on page 19)
2. Part Number (if known)
3. Quantity
Contact Parts Marketing: 1-318-640-6044
In addition, the 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.
A typical valve nameplate is shown in Figure 34 (below).
FIGURE 34
CON-14
Page 61
XIX. Genuine Dresser Parts

The next time replacement parts are needed, keep these points in mind:
• DVCD designed the parts.
• DVCD guarantees the parts.
• DVCD valve products have been around since 1877.
• DVCD has worldwide service.
• DVCD has fast response availability for parts.
WHERE IN THE WORLD?
USA AND CANADA

Dresser Industrial Valve Masoneilan North America
& Controls Division Operations
P.O. Box 1430 Dresser Canada, Inc.
Alexandria, LA 71309-1430 5010 North Service Road
Telephone: 318/640-6044 Burlington, Ontario
L7L 5R5, Canada
Telephone: 416/335-3529
EUROPE
Dresser Europe, S.A. Masoneilan Division
Dresser IVO Dresser U.K., LTD.
Badenerstrasse 156 Controls House
P.O. Box 369 Riverside Way
CH-8021 Zurich Uxbridge, Middlesex
Switzerland UB8 2YF England
Telephone: 41-1-241-0533 Telephone: 44-895-58161
Dewrance Div. Dresser UK LTD. Masoneilan S.A.

Trevithick Works Zona Franca
Gillibrands Estate Sector M., Calle Y
Skelmersdale, Lancashire 08004 Barcelona, Spain
WN8 9TU England Telephone: 345-3-335-4200
Telephone: 44-695-24234
JAPAN INDIA
Dresser Japan, LTD. BHEL LTD.
I.V.O. High Pressure Boiler Plant
Room 405, Maersk Building Tiruchirapalli 620014
Yokohama 231 Tamil Nadu, India
Japan Telex: 455211 (BHTP IN)
Telephone: 81-45-651-5601
VENEZUELA SOUTH AFRICA

Riese & CIA, S.A. Dresser Limited Valve
Apartado 372 & Controls Division
Caracas, Venezuela P.O. Box 2234
Telephone: (011-582) 541-1311 16 Edendale Road
Eastleigh, Edenvale 1610
Telephone: 27-11-452-1550 thru 1557
CON-1
Page 62
XX. Recommended Spare Parts

For 1700 Maxiflow Safety Valves
Quantity Parts/Same Size,

Type, Set Pressure, and
Temperature Class Valves
In Service
Class Part Name Super- Reheat

Drum heater Section
1. Disc 1/1 1/1 1/4

I 2. Adj. Ring Pin (Upper) 1/1 1/1 1/4
3. Adj. Ring Pin (Lower) 1/1 1/1 1/4
4. Adj. Ring (Upper) 1/4 1/4 1/4

5. Adj. Ring (Lower) 1/4 1/4 1/4
II 6. Holder 1/4 1/4 1/4
7. Spindle 1/2 1/2 1/6
8. Guide 1/4 1/4 1/4
9. Disc Collar 1/4 1/4 1/6

10. Lift Stop 1/4 1/4 1/6
III 11. Spring 1/6 1/6 1/6
12. Spring Washers(2) 1 Set/6 1 Set/6 1 Set/6
13. Compression Screw 1/4 1/4 1/6
14. Disc Collar Pin 1/4 1/4 1/6

IV 15. Lift Stop Pin 1/4 1/4 1/6
16. Compression Screw 1/4 1/4 1/6
17. Top Plate Screws 1 Set/4 1 Set/4 1 Set/6
YOUR SAFETY IS OUR BUSINESS!!!

DVCD has not authorized any company or any individual to manufacture
replacement parts for it’s valve products.
When ordering replacement valve parts, please specify in your purchase order:
“ALL PARTS MUST BE DOCUMENTED AS NEW AND SOURCED FROM
DRESSER INDUSTRIAL VALVE & CONTROLS DIVISION”
BE SURE! BE SURE!
CON-1
Page 63
XXI. Manufacturer’s Field Service & Repair Program

FACTORY SETTING VS. FIELD SETTING
Every CONSOLIDATED® Safety Valve is set and adjusted on steam before
shipment from the factory. Blowdown adjustments are made as carefully and
accurately as possible on the factory test boiler. However, it must be recognized
that actual field operating conditions may vary considerably from factory test
conditions.
Conditions beyond the manufacturer’s control that affect Safety Valve operation
are:
• Quantity of steam being discharged through the valve, i.e. the actual
installation capacity exceeding that of the test boiler, thus permitting the
valve to flow its full rated capacity.
• Quality of steam being discharged.
• Discharge piping stresses and back pressure.
• Ambient temperature.
• Shipping or storage damage.
• Improper gagging
• Improper bolting of flanges.
• Damage due to foreign material in the steam.
Final Safety Valve adjustments made on the actual installation are the best
means of insuring that the valves perform in compliance with the ASME Boiler
Code and/or other applicable code requirements.
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.
DVCD maintains the largest and most competent field service staff in the
industry. Service Engineers are located at strategic points throughout the United
States to respond to customer’s requirements for service. Each Service Engineer
is factory trained and long experienced in servicing Safety Valves. DVCD
Service Engineers restore disc and nozzle critical dimensions which effect valve
performance, and are capable of modernizing valves in the field.
It is highly recommended that the professional talents of a DVCD Field Service
Engineer be employed to make final field adjustments during the initial setting of
all CONSOLIDATED Safety Valves.
All Field Service Engineers’ activities are coordinated from the Alexandria,
Louisiana, Field Service Office. Upon receipt of a purchase order number
authorizing the trip, the engineer is dispatched.
Contact: Field Service Dept., Field Service Supv., (318) 640-6055
FACTORY REPAIR FACILITIES
If boiler downtime permits, it may be desirable to return the valves to the factory
for repair or modernizing. The factory at Alexandria, Louisiana, maintains a
complete CONSOLIDATED repair center. The Repair Department is staffed to
provide you rapid repair that meets your needs.
Contact: Repair Dept., Mgr. Valve Repair, (318) 640-6058.
CON-1
Service Department
THE DRESSER FIELD SERVICE ORGANIZATION IS UNEQUALED.

For prompt field service, please call
Dresser Industrial Valve Operations Department, Alexandria, Louisiana.
Normal Working Hours – (318) 640-6055
After Hours, Weekends, Holidays – (318) 640-2250
Location of Service Engineers
ALABAMA, Huntsville ................................. 1

FLORIDA, Jacksonville .............................. 2
GEORGIA, Cartersville .............................. 3
ILLINOIS, Chicago ..................................... 4
INDIANA, Crawfordsville ............................ 5
KENTUCKY, Maysville ............................... 6
LOUISIANA, Alexandria ............................. 7
LOUISIANA, New Orleans ......................... 8
NORTH CAROLINA, Winston-Salem ......... 9
OKLAHOMA, Tulsa .................................. 10
PENNSYLVANIA, Philadelphia ................ 11
SOUTH CAROLINA, Charleston .............. 12
TEXAS,Dallas .......................................... 13
TEXAS,Houston ....................................... 14
VIRGINIA, Richmond ............................... 15
Sales Offices Locations
UNITED STATES IVO Headquarters & Main Factory
LA Hwy. 3225 at U.S. Hwy. 167 North, P.O. Box 1430, Alexandria, Louisiana 71309-1430
Telephone 1-318-640-2250, Telex 586423, Rapifax 1-318-640-6222
Northern Region
3201 North Wolf Road, Franklin Park, Illinois 60131
Telephone 1-708-451-3913, Rapifax 1-708-451-3997
Pacific Region
3931 MacArthur Blvd., Suite 202, Newport Beach, California 92660-3014
Southern Region
16503 Park Row, Houston, Texas 77084-5016
CANADA Dresser Canada, Inc., Valve & Controls – Canadian Operations

5010 North Service Road, Burlington, Ontario, L7L 5R5 Canada
JAPAN Dresser Japan, Ltd., Industrial Valve Operation, Room 405, Maersk Bldg.,
18, Nihon-Odori, Naka-ku., Yokohama 231 Japan
KOREA Dresser Korea, Inc., Room #2107, Kuk Dong Building

60-1, 3-KA, Choongmu-Ro Chung-Ku, Seoul, Korea 100-705
Telephone 82-2-274-0792, Telex K22801 DRESSER, Rapifax 82-2-274-0794
MEXICO Masoneilan Internacional y Compania, S, en N.C., Av. Henry Ford No. 114
Apartado Postal 572, 54030 Tlalnepantla, Mexico
Telephone 52-5-310-9863, Telex (383) 172645, Rapifax 52-5-310-5584
SAUDI ARABIA Dresser Al Rushaid Valve & Instrument Co., Ltd., P.O. Box 10145
Jubail Industrial City 31961, Kingdom of Saudi Arabia
SOUTH AFRICA Dresser Limited Valve & Controls Division

P.O. Box 2234, 16 Edendale Road, Eastleigh, Edenvale 1610, South Africa
Telephone 27-11-452-1550/1-7, Rapifax 27-11-452-2903
SWITZERLAND Dresser Europe, S.A. Industrial Valve Operation

Badenerstrasse 156, P.O. Box 369, CH-8021 Zurich, Switzerland
UNITED KINGDOM Dresser U.K., Limited, Industrial Valve Operation, Trevithick Works
Gillibrands Estate, Skelmersdale, Lancashire, WN8 9TU England
Telephone 44-695-24234, Telex (851) 627039, Rapifax 44-695-20175
Masoneilan Division Dresser U.K., Ltd., Controls House

Riverside Way, Uxbridge, Middlesex, UB8 2YF England
Telephone 44-895-258161, Telex (851) 935174, Rapifax 44-895-234318
VENEZUELA RIESE & CIA S.A.

Apartado 372, Caracas, Venezuela
Telephone 58-2-541-1311/541-3812, Telex (395) 24796, Rapifax 58-2-545-2702
Note: Numbers in ( ) are codes to be used for calling from U.S.A.
CONSOLIDATED is a registered trademark

of Dresser Industries, Inc.
2M 10/93
© 1991 Dresser Industries, Inc.
CON-6
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
1900TM Series Consolidated® Safety Relief Valve

The Eductor Tube AdvantageTM
Design Options Include:

• Bellows (-30)
• O-Ring Seat (DA)
• Liquid Trim (LA)
• Thermodisc ® (TD)
Consolidated® Pressure Relief Valves

www.dresser.com
1900 (Q4.07)
Page
Table of Contents
Page
Safety Sign and Label System............................................................................................................................ 4

Safety Alerts! Read - Understand - Practice.................................................................................................... 5
Terminology for Safety Relief Valves.................................................................................................................. 6
Introduction ........................................................................................................................................................ 7
Design Features and Nomenclature................................................................................................................... 7
Handling, Storage, and Pre-Installation........................................................................................................... 11
Recommended Installation Practices............................................................................................................... 12
Mounting Position.......................................................................................................................................... 12
Inlet Piping..................................................................................................................................................... 12
Outlet Piping.................................................................................................................................................. 13
Disassembly Instructions.................................................................................................................................. 14
General Information....................................................................................................................................... 14
SRV Disassembly.......................................................................................................................................... 14
Cleaning.............................................................................................................................................................. 17
Parts Inspection................................................................................................................................................. 18
Nozzle Inspection Criteria.............................................................................................................................. 18
Nozzle Seat Width......................................................................................................................................... 18
Nozzle Bore Inspection.................................................................................................................................. 18
1900™ Series SRV Standard Disc Inspection Areas..................................................................................... 18
1900™ Series Thermodisc® Replacement Criteria........................................................................................ 18
Disc Holder Inspection Criteria...................................................................................................................... 22
Guide Inspection Criteria............................................................................................................................... 25
Spindle Inspection Criteria............................................................................................................................. 25
Spring Inspection Criteria............................................................................................................................... 25
Maintenance . ..................................................................................................................................................... 27
Lapping Nozzle Seats (Non-O-Ring Styles)................................................................................................... 27
Lapped Nozzle Seat Widths........................................................................................................................... 28
Lapping Disc Seats........................................................................................................................................ 30
Precautions and Hints for Lapping Seats....................................................................................................... 30
Lapping O-Ring Seating Surfaces................................................................................................................. 30
Reconditioning of Laps.................................................................................................................................. 30
Re-Machining Nozzle Seats and Bores......................................................................................................... 31
Re-Machining the Disc Seat.......................................................................................................................... 31
Checking Spindle Concentricity..................................................................................................................... 32
Set Pressure Change-Disc Holder................................................................................................................. 32
Checking Lift on Restricted Lift Valves........................................................................................................... 32
1900 (Q4.07) 1900™ Series Consolidated® Safety Relief Valve

Page

Page
Reassembly........................................................................................................................................................ 34
Preparation.................................................................................................................................................... 34
Lubrication..................................................................................................................................................... 35
Reassembly Procedure.................................................................................................................................. 35
Setting and Testing............................................................................................................................................ 40
Test Equipment.............................................................................................................................................. 40
Test Media...................................................................................................................................................... 40
Setting the Valve............................................................................................................................................ 41
Set Pressure Compensation.......................................................................................................................... 41
Seat Tightness Testing................................................................................................................................... 43
Hydrostatic Testing and Gagging..................................................................................................................... 45
Manual Popping of the Valve............................................................................................................................ 45
Conversion of 1900™ Series Flanged SRVs................................................................................................... 46
Conversion from Conventional to Bellows Type............................................................................................ 46
Conversion from Bellows to Conventional Type............................................................................................ 48
Troubleshooting 1900™ Series SRVs.............................................................................................................. 49
Maintenance Tools and Supplies...................................................................................................................... 49
Replacement Parts Planning............................................................................................................................. 51
Basic Guidelines............................................................................................................................................ 51
Replacement Parts List.................................................................................................................................. 51
Identification and Ordering Essentials ......................................................................................................... 51
Genuine Dresser Parts...................................................................................................................................... 52
Recommended Spare Parts for 1900™ Series SRVs...................................................................................... 53
Manufacturer’s Warranty, Field Service, Training, and Repair Program....................................................... 55
Warranty Information ................................................................................................................................... 55
Field Service ................................................................................................................................................ 55
Factory Repair Facilities .............................................................................................................................. 56
SRV Maintenance Training .......................................................................................................................... 56
Self-Study Edition of the 1900™ Series SRV Maintenance Training Program............................................. 56
Optional Glide-Aloy™ Parts ............................................................................................................................ 57
Sales Office Locations....................................................................................................................................... 58
1900™ Series Consolidated® Safety Relief Valve 1900 (Q4.07)

Page
Safety Sign and Label System

Appropriate safety labels have been included in the practices and procedures
throughout this manual. The labels communicate:
• Level of hazard seriousness
• Nature of the hazard
• Consequence of human or product interaction with the hazard
• Instructions on how to avoid the hazard
The top panel describes the

! DANGER level of hazard seriousness
(DANGER or CAUTION).
! CAUTION
The center panel contains a
pictorial that communicates
the nature and possible
consequence of the hazard.
The pictorial may depict
preventive measures to
take, such as wearing
protective equipment.
Do not remove bolts The bottom panel Wear necessary

contains an instruction
if pressurized. message on how to avoid protective
This will result in the hazard. This message
may give a more precise
equipment to
serious personal definition of the hazard prevent possible
and the consequences of
injury or death. the hazard.
injury.
ATTENTION labels are horizontal bands describing special situations and

issues that could potentially damage the SRV.
ATTENTION!
Exercise care when inserting a rod or pipe in the outlet. Ensure the
valve nozzle is not damaged during the operation.
NOTE:
Any service questions not covered in this manual should
be referred to Consolidated® Field Service Department,
Phone (318) 640-6055.

Page
Safety Alerts! Read - Understand - Practice

Danger Alerts
A DANGER alert describes actions that may cause • Always perform correct service and repair.
severe personal injury or death. In addition, it Incorrect service and repair can result in product
may provide preventive measures to avoid severe or property damage or severe personal injury or
personal injury or death. death.
DANGER alerts are not all-inclusive. Dresser • Always use the correct tool for a job. The misuse
cannot know all conceivable service methods nor of a tool or the use of an improper tool can
evaluate all potential hazards. Dangers include: result in personal injury, damage to product or
property.
• High temperature/pressure can cause injury.
Ensure all system pressure is absent before • Ensure the proper “health physics” procedures
repairing or removing valves. are followed, if applicable, before starting
operation in a radioactive environment.
• Do not stand in front of a valve outlet when
discharging. STAND CLEAR OF VALVE to avoid
exposure to trapped, corrosive media. Caution Alerts
• Exercise extreme caution when inspecting a A CAUTION alert describes actions that may result
pressure relief valve for leakage. in a personal injury. In addition, they may describe
preventive measures that must be taken to avoid
• Allow the system to cool to room temperature personal injury. Cautions include:
before cleaning, servicing, or repairing. Hot
components or fluids can cause severe personal • Heed all service manual warnings. Read
injury or death. installation instructions before installing valve(s).
• Always read and comply with safety labels on all • Wear hearing protection when testing or
containers. Do not remove or deface container operating valves.
labels. Improper handling or misuse could result • Wear appropriate eye and clothing protection.
in severe personal injury or death.
• Wear protective breathing apparatus to protect
• Never use pressurized fluids/gas/air to clean against toxic media.
clothing or body parts. Never use body parts to
check for leaks, flow rates, or areas. Pressurized
fluids/gas/air injected into or near the body can
cause severe personal injury or death.
• It is the owner’s responsibility to specify and
provide protective wear to protect persons
from pressurized or heated parts. Contact with
pressurized or heated parts can result in severe
personal injury or death.
• Do not work or allow anyone under the influence
of intoxicants or narcotics to work on or around
pressurized systems. Workers under the
influence of intoxicants or narcotics are a hazard
to themselves and other employees. Actions
taken by an intoxicated employee can result in
severe personal injury or death to themselves or
others.

Page
Terminology for Safety Relief Valves

• Accumulation - the pressure increase over • Operating Pressure - the gauge pressure
the maximum allowable working pressure of to which the vessel is normally subjected in
the vessel during discharge through the SRV, service. A suitable margin is provided between
expressed as a percentage of that pressure or in operating pressure and maximum allowable
actual pressure units. working pressure. For assured safe operation,
the operating pressure should be at least 10%
• Backpressure - the pressure on the discharge under the maximum allowable working pressure
side of the SRV: or 5 psi (.34 bar), whichever is greater.
○ Built-up Backpressure - the pressure that • Overpressure - a pressure increase over the
develops at the valve outlet, after the SRV set pressure of the primary relieving device.
has been opened, as a result of flow. Overpressure is similar to accumulation when
○ Superimposed Backpressure - the pressure the relieving device is set at the maximum
in the discharge header before the SRV is allowable working pressure of the vessel.
opened. Normally, overpressure is expressed as a
percentage of set pressure.
○ Constant Backpressure - the superimposed
• Rated Capacity - the percentage of measured
backpressure that is constant with time.
flow at an authorized percent overpressure
○ Variable Backpressure - the superimposed permitted by the applicable code. Rated capacity
backpressure that varies with time. is generally expressed in pounds per hour
(lb/hr) for vapors, standard cubic feet per minute
• Blowdown - the difference between set (SCFM) or m3/min for gases, and in gallons per
pressure and re-seating pressure of the SRV, minute (GPM) for liquids.
expressed as a percentage of the set pressure
• Relief Valve - an automatic pressure-relieving
or in actual pressure units.
device, actuated by static pressure upstream
• Cold Differential Set Pressure - the pressure from the valve. A relief valve is used primarily for
at which the valve is adjusted to open on the test liquid service.
stand. This pressure includes the corrections • Safety Relief Valve (SRV) - an automatic
for backpressure and/or temperature service pressure-relieving device used as either a safety
conditions. or relief valve, depending upon application. The
SRV is used to protect personnel and equipment
• Differential Between Operating and Set by preventing excessive overpressure.
Pressures - Valves in installed process services
will generally give best results if the operating • Safety Valve - an automatic pressure-relieving
pressure does not exceed 90% of the set device actuated by the static pressure upstream
pressure. However, on pump and compressor of the valve, and characterized by a rapid
discharge lines, the differential required between opening or “pop” action. It is used for steam,
the operating and set pressures may be greater gas, or vapor service.
because of pressure pulsations coming from a
• Set Pressure - the gauge pressure at the valve
reciprocating piston. The valve should be set as
inlet for which the relief valve has been adjusted
far above the operating pressure as possible.
to open under service conditions. In liquid
• Lift - the actual travel of the disc away from the service, the inlet pressure at which the valve
closed position when a valve is relieving. starts to discharge determines set pressure. In
gas or vapor service, the inlet pressure at which
the valve pops determines the set pressure.
• Maximum Allowable Working Pressure - the
maximum gauge pressure permissible in a • Simmer - the audible passage of a gas or
vessel at a designated temperature. A vessel vapor across the seating surfaces just before
may not be operated above this pressure, or its “pop.” The difference between this start-to-open
equivalent, at any metal temperature other than pressure and the set pressure is called “simmer.”
that used in its design. Consequently, for that Simmer is generally expressed as a percentage
metal temperature, it is the highest pressure at of set pressure.
which the primary pressure SRV is set to open.

Page
Introduction Design Features and

The safety relief valve (SRV) is an automatic, Nomenclature
pressure-actuated relieving device suitable for use
either as a safety valve or relief valve, depending
on application. Cap and Lever
SRVs are used on hundreds of different Interchangeability
applications, including liquids and hydrocarbons; In the field, it is often necessary to change the type
therefore, the valve is designed to meet many of cap or lever after a valve has been installed.
requirements. All flanged Consolidated® SRVs are designed to
The 1900™ Series valves included in this manual be converted to any type of lever or cap desired.
may be used to meet the requirements for ASME It is not necessary to remove the SRV from the
Section III and Section VIII. They cannot be installation, nor will the set pressure be affected
used on ASME Code Section I steam boilers or when making such a change.
superheaters, but may be used on process steam.
Design Simplicity
Consolidated® SRVs have few component parts,
resulting in savings by minimizing spare parts
inventory and simplifying valve maintenance.
Nomenclature Related to
Design Features
The nomenclature of the components of 1900™
Series valves, including those with design
options for bellows, O-ring seat, liquid trim, and
Thermodisc®, is identified in Figures 1 through 6.
Simple Blowdown Adjustment

The Consolidated® single blowdown ring design
makes it possible to set and test a valve at the
customer’s shop when it is impractical to set and
media may be very low, the ring can be positioned
so that the set point can be observed without
damaging the valve. Blowdown can be attained by
positioning the ring in accordance with the adjusting
ring position (see Tables 12 through 14).
Valve Interchangeability
A standard Consolidated® SRV may be converted
to the bellows type, the O-ring seat seal type, etc.,
and vice versa. Should conversion be required, this
interchangeability lowers costs and requires fewer
new parts than replacing entire valve types.

Page
Safety Relief Valve Components
Screwed Cap (21)
Adjusting Screw (19)
Adjusting Screw Locknut (20)
Cap Gasket (27)
Spring Washer (17)
Spring (18)
Bonnet (11)
Spindle (15) Bonnet Plug (41)
Spring Washer (17) Base Stud (13)
Spindle Retainer (16) Stud Nut (14)
Bonnet Gasket (12) Eductor Tube (40)
Guide Gasket (10)
Guide (9)
Disc Holder (8)
Disc Retainer (7)
Disc (6)
Adjusting Ring (3)
Adjusting Ring Pin (4)
Adjusting Ring Pin Gasket (5)
Nozzle (2)
Base (1)
Figure 1 - 1900TM Series Consolidated® Safety Relief Valve

Page
Types of SRVs are illustrated in Figures 2 through 6. A combination of the O-ring seat seal (see Figure 5) and
liquid trim (see Figure 6) design options are designated as DA and LA respectively.
Bonnet Bonnet Spindle

Gasket Gasket Retainer
Bellows Guide Guide
Gasket
Guide
Bellows
Guide
Gasket Disc
Holder
Disc Bellows Disc
Holder Gasket Bellows Retainer
Gasket
Disc
Disc
Disc
Retainer
1900TM-30D THROUGH G 1900TM-30H THROUGH U
Figure 2 - 1900TM-30D through 1900TM-30U Bellows Design
Bonnet Gasket
et Spindle
Guide Cap Screw

(Bellows)
Guide Gasket
Bellows Disc
Disc Holder Disc Retainer

Screw
Figure 3 - 1900TM-30V and 1900TM-30W Bellows Design

Page 10
Thermodisc®
Figure 4 - Thermodisc® (TD) Design
Disc Retainer Disc

Holder Lock Holder
O-Ring Screw Disc
Retainer Retainer
Retainer
Lock O-Ring
O-Ring Seat Seal Disc
Screw
Seat Seal
Retainer
Retainer O-Ring Seating
Seating Retainer Surface
Nozzle Surface
Nozzle
D THROUGH J ORIFICE K THROUGH U ORIFICE
Figure 5 - O-Ring Seal (DA) Designs
Guide
Retainer
Disc Holder
Disc
Adjusting Ring
Nozzle
Figure 6 - Liquid Trim (LA) Design

Page 11
Handling, Storage, and Pre-Installation

Handling Storage
Always keep the inlet flange down on a crated or Store SRVs in a dry environment and protect them
uncrated flange valve to prevent misalignment and from the weather. Do not remove the valve from the
damage to valve internals. skids or crates until immediately before installation.
Do not remove flange protectors and seating plugs
ATTENTION! until the valve is ready to be bolted into place
Never lift the full weight of the valve by the during the installation.
lifting lever.
Pre-Installation
ATTENTION! When SRVs are uncrated and the flange protectors
Do not rotate the valve horizontally or or sealing plugs are removed, exercise meticulous
lift/carry using the lifting lever. care to prevent dirt and other foreign materials from
entering the inlet and outlet ports while bolting the
valve in place.
Wrap a chain or sling around the discharge neck
and around the upper bonnet structure to move or
hoist an uncrated valve. Ensure the valve is in a
vertical position during the lift.
ATTENTION!
Handle carefully. Do not drop or strike the
valve.
Do not subject SRVs, either crated or uncrated, to

sharp impact. Ensure that the valve is not bumped
or dropped during loading or unloading from a
truck. While hoisting the valve, take care to prevent
bumping the valve against steel structures and
other objects.
ATTENTION!
Prevent dust and debris from entering inlet
or outlet of the valve.

Page 12
! DANGER Recommended Installation Practices

Mounting Position
Mount SRVs in a vertical (upright) position (in accordance with API RP 520). Installing
a safety relief valve in any position other than vertical (±1 degree) will adversely affect
its operation as a result of the induced misalignment of moving parts.
Mount safety relief A stop valve may be placed between the pressure vessel and its relief valve only as
valves in a vertical,
permitted by code regulations. If a stop valve is located between the pressure vessel
upright position
only. and SRV, the stop valve port area should equal or exceed the nominal internal area
associated with the pipe size of the SRV inlet. The pressure drop from the vessel
to the SRV shall not exceed 3% of the valve’s set pressure, when flowing at full
capacity.
! DANGER
Ensure the flanges and sealing faces of the valve and connective piping are free from
dirt, sediment, and scale.
Ensure all flange bolts are drawn evenly to prevent distortion of the valve body and
the inlet nozzle.
Do not mount valve Position SRVs for easy access and/or removal so that servicing can be properly
at the end of pipe performed. Ensure sufficient working space is provided around and above the valve.
through which there is
normally no flow or Inlet Piping
near elbows, tees,
bends, etc. The inlet piping (see Figure 7) to the valve should be short and directly from the
vessel or equipment being protected. The radius of the connection to the vessel
should permit smooth flow to the valve. Avoid sharp corners. If this is not practical,
! CAUTION then the inlet should be at least one additional pipe diameter larger.
The pressure drop from the vessel to the valve shall not exceed 3% of valve set
pressure when the valve is allowing full capacity flow. The inlet piping should never
be smaller in diameter than the inlet connection of the valve. Excessive pressure
drop in gas, vapor, or flashing-liquid service at the inlet of the SRV will cause the
extremely rapid opening and closing of the valve, which is known as “chattering.”
Heed all service Chattering will result in lowered capacity and damage to the seating surfaces. The
manual warnings. most desirable installation is that in which the nominal size of the inlet piping is the
Read installation same as, or greater than, the nominal size of the valve inlet flange; and in which the
instructions before
length does not exceed the face-to-face dimensions of a standard tee of the required
installing valve(s).
pressure class.
The pressure drop

(P.D.) between
the source of
pressure in the
protected
equipment and
the pressure relief
valve inlet is not
to exceed 3% of
the valve set
P.D. pressure.
P.D. P.D.
Stop P.D.
Valve From Protected Equipment
Vessel Vessel Vessel
Figure 7 - Pressure Drop on the Inlet Piping

Page 13
Do not locate SRV inlets where excessive Outlet Piping

turbulence is present, such as near elbows, tees,
bends, orifice plates or throttling valves. Alignment of the internal parts of the SRV is
important to ensure proper operation (see
Section VIII of the ASME Boiler and Pressure Figure 8). Although the valve body will withstand
Vessel Code requires the inlet connection design to a considerable mechanical load, unsupported
consider stress conditions during valve operation, discharge piping consisting of more than a
caused by external loading, vibration, and loads companion flange, long-radius elbow, and a short
due to thermal expansion of the discharge piping. vertical pipe is not recommended. Use spring
The determination of reaction forces during valve supports to connect outlet piping to prevent thermal
discharge is the responsibility of the vessel and/or expansion from creating strains on the valve. The
piping designer. Dresser publishes certain technical discharge piping should be designed to allow for
information about reaction forces under various vessel expansion as well as expansion of the
fluid flow conditions, but assumes no liability for the discharge pipe itself. This is particularly important
calculations and design of the inlet piping. on long distance lines.
External loading, by poorly designed discharge A continual oscillation of the discharge piping
piping and support systems, and forced alignment (wind loads) may induce stress distortion in the
of discharge piping can cause excessive stresses valve body. The resultant movement of the valve’s
and distortions in the valve as well as the inlet internal parts may cause leakage.
piping. The stresses in the valve may cause a Where possible, use properly supported drainage
malfunction or leak. Therefore, discharge piping piping to prevent the collection of water or corrosive
must be independently supported and carefully liquid in the valve body.
aligned.
When two or more valves are piped to discharge
Vibrations in the inlet piping systems may cause into a common header, the built-up backpressure
valve seat leakage and/or fatigue failure. These resulting from the opening of one (or more) valve(s)
vibrations may cause the disc seat to slide back may cause a superimposed backpressure in the
and forth across the nozzle seat and may result remaining valves. Under these conditions, the
in damage to the seating surfaces. Also, vibration use of bellows valves is recommended. The use
may cause separation of the seating surfaces and of bellows valves may also permit the use of a
premature wear to valve parts. High-frequency smaller-size manifold.
vibrations are more detrimental to SRV tightness
than low-frequency vibrations. This effect can be In every case, the nominal discharge pipe size
minimized by providing a larger difference between should be at least as large as the nominal size of
the operating pressure of the system and the the SRV outlet flange. In the case of long discharge
set pressure of the valve, particularly under high piping, the nominal discharge pipe size must
frequency conditions. sometimes be much larger.
Temperature changes in the discharge piping may
be caused by fluid flowing from the discharge of ATTENTION!
the valve or by prolonged exposure to the sun or All non-bellows valves should have a bonnet
heat radiated from nearby equipment. A change plug installed. Bellows valves must have an
in the discharge piping temperature will cause open bonnet vent.
a change in the length of the piping, which may
cause stresses to be transmitted to the SRV and its
inlet piping. Proper support, anchoring or provision
for flexibility of the discharge piping can prevent
stresses caused by thermal changes. Do not use
fixed supports.

Page 14
Cap may Attach stack rigidly to structure.

be required Do not connect to drain pan or the
for weather discharge piping.
protection.
Stack
G
ON
Drain WR
Pan
Pan For a closed system,

Drain always keep piping
strains isolated from
Long-Radius Long-Radius the pressure relief
Elbow Elbow valve, regardless of
process operation
Vessel Vessel Vessel and temperature.
Figure 8 - SRV Parts Alignment
! DANGER Disassembly Instructions

General Information
Consolidated® SRVs can be easily disassembled for inspection, the reconditioning
of seats or the replacement of internal parts. Appropriate set pressure can be
established after reassembly. (See Figures 1 through 6 for parts nomenclature.)
Many pressure
vessels protected ATTENTION!
by Consolidated®
Safety Relief Do not interchange parts from one valve with parts from another valve.
Valves contain
dangerous
materials. ! CAUTION SRV Disassembly
Decontaminate and
clean the valve 1. If equipped, remove the lifting lever gear as follows:
inlet, outlet, and all
• Plain Lever (see Figure 36)
external surfaces in
accordance with ○ Remove cotter pin, lever pin and plain lever
the cleaning and [one-piece design] or top lever [two-piece design].
decontaminating
recommendations Wear necessary
• Packed Lever (see Figures 37 through 40)
in the appropriate protective equipment
Material Safety to prevent possible ○ Disassembly not required. Rotate lever
Data Sheet. injury. counterclockwise, positioning lifting fork so that it
clears release nut during cap removal.
! DANGER ! CAUTION 2. Remove the cap.

3. Remove the cap gasket (27), if applicable.
4. Remove adjusting ring pin (4) and adjusting ring pin gasket (5).
5. If the existing blowdown is to be restored upon reassembly,
Valve caps and determine the position of the adjusting ring (3) with respect
Before bonnets can trap to the disc holder (8) as follows:
disassembling the fluids. Use caution
valve, ensure there when removing to • Turn the adjusting ring counterclockwise (move
is no media prevent injury or notches on the adjusting ring from left to right).
pressure in the environmental
vessel. damage.
• Record the number of notches that pass the ring pinhole
before the ring contacts the disc holder.

Page 15
ATTENTION! 7. Remove the stud nuts (14) and lift off the bonnet
(11).
This procedure does not substitute for actual
pressure testing. 8. Remove the bonnet gasket (12).
9. Remove the spring (18) and the spring washers
6. Follow the procedure appropriate to the orifice (17). Keep the spring and spring washers
valve type: together, as a unit, at all times.
• Using a depth micrometer or a dial caliper, 10. Follow the procedure appropriate to the valve type:
measure the distance from the top of the
spindle (15) to the top of the adjusting • D through L orifice valves:
screw (19). This allows the adjusting screw ○ Remove the upper internal parts by
to be readjusted close to the proper spring carefully pulling “straight up” on the
compression without excessive testing. spindle (15). For bellows valves, take
• Record the measurement for reference when care to avoid damaging the bellows or its
reassembling the valve. flange. If parts are fouled, use a suitable
solvent for loosening the components.
• D through U orifice valves:
○ Clamp the skirt portion of the disc holder
○ Loosen the adjusting screw locknut (20). (8) snugly between two wooden V-blocks
in a suitable vise.
○ Remove the adjusting screw from the
bonnet (11). Use pliers to prevent the ○ Compress the spindle retainer (16) with a
spindle from turning when removing the screwdriver or similar tool through the slots
adjusting screw. provided and remove the spindle.
• V and W orifice valves: ATTENTION!
○ Attach the setting device (see Figure 9). Special lifting tools are available for ease of
upper internal part removal.
○ Apply enough pressure to the plunger
using the ram to free the adjusting screw.
• M through U orifice valves:
○ Loosen the adjusting screw locknut.
○ Use a screwdriver to compress the spindle
○ Completely unscrew the adjusting screw
retainer (16).
from the bonnet.
○ Remove the spindle (15).
ATTENTION!
○ Insert the lifting tool (see Figure 10a) into
Set the valve using the setting procedures
the disc holder spindle pocket and tighten
after reassembly.
the eyebolt.
○ Remove the disc holder (8) and disc (6) by
Hydraulic Jack Cap Screw Nut Setting Plate lifting up on the lifting tool.
Adaptor Nut
• Valve V and W orifice valve:
○ Use the lifting lugs to lift the disc holder (8)
and to remove all internals (see Figure 10b).
21" Hose Gauge Hydraulic Pump
Stud 11. Remove the guide (9) from the disc holder (8).
Adjusting (For restricted lift valves, see Checking Lift on
Screw Plunger Restricted Lift Valves.) For V and W orifice,
Spring
Plunger Nut retainer used unbolt the bellows from guide before guide
to hold Adj.
Screw and removal.
Bonnet Spring Plunger
Spindle
together during 12. For D through U orifice bellows valves (see
assembly
Figure 2), the bellows is attached to the disc
holder (8) by right-hand threads. Use a special
Figure 9 – Setting Device for V and W spanner wrench on the bellows ring to remove it
Orifices by turning counterclockwise (see Figure 11).

Page 16
Disc Holder Lifting Tool

Top of Base Guide Bellows Ring Bellows
Convolutions
Bellows Gasket Spanner Wrench
Soft Material
Vise
Disc Holder
Figure 10a - Lifting Tools for Figure 11 - Removing the

M through U Orifice Valves Bellows Ring
○ Start inserting special drift pins into

Disc Holder Eye Bolts Guide
the holes in the disc holder (see
Top of Base Figure 12) with the tapered portion of
the pins working against the top of the
disc, as indicated.
○ Use a light machinist hammer to tap each
pin alternately until the disc snaps out of
the recess in the disc holder.
• For V and W orifice valves (see Figure 3),
remove the disc from the disc holder as
Figure 10b - Lifting Lug for V and W follows:
Orifices ○ Turn the disc holder on its side.
○ Remove the retaining bolts.
ATTENTION!
○ Attach the lifting lug to the disc and lift out.
The bellows convolutions (see Figure 11)
are very thin and fragile. Take care to protect ○ Inspect guide rings for wear and replace if
them from damage. necessary.
15. For O-ring seat seal valves only (see Figure
13. Remove the bellows gasket. For V and W orifice 5), remove the retainer lock screw(s), O-ring
bellows valves (see Figure 3), the bellows is retainer, and O-ring.
bolted to the disc holder (8). Remove these
bolts to disassemble the bellows from the disc 16. Remove the adjusting ring (3) by turning it
holder. counterclockwise (from left to right).
14. Follow the procedure appropriate to the orifice

valve type:
Drift Pin Disc Drift Pin
• For D through U orifice valves (see Figure 2),
remove the disc (6) from the disc holder (8)
as follows:
○ Grasp disc holder by the stem portion,
disc end down, and firmly strike down
onto a clean, wood surface. Disc should Disc Holder
dislodge from disc holder.
○ If disc did not dislodge from disc holder,
then clamp the stem portion of the disc
holder, disc end up, firmly between two Figure 12 - Removing the Disc
wooden V-blocks in a vise.
with Drift Pins

Page 17
ATTENTION!
View From Top
The nozzle (2) is normally removed for
routine maintenance and service.
17. The nozzle (2) is threaded onto the base (1) and
is removed by turning it counterclockwise (from
right to left). Before removing the nozzle, soak View From Side
the threaded joint with a suitable penetrating
liquid or solvent. If the nozzle is frozen to the Pipe Wrench
base, apply dry ice or other cooling medium to
the inside of the nozzle and heat the base from
the outside with a blowtorch in the area of the Nozzle
nozzle threads.
Base
ATTENTION!
Should heat be applied, use care to prevent
cracking of cast parts. Figure 14 - Removing the Nozzle
from the Base
18. Using a three- or four-jaw chuck welded
vertically to a stand bolted to a concrete floor,
clamp the nozzle (2) into the chuck and break
the body loose with a heavy rod or pipe Cleaning
(see Figure 13).
1900™ Series SRV internal parts may be cleaned
ATTENTION! with industrial solvents, cleaning solutions, and
wire brushes. If cleaning solvents are used, take
Exercise care when inserting a rod or pipe precautions to protect yourself from potential
in the outlet. Ensure the valve nozzle is not danger from fume inhalation, chemical burns, or
damaged during the operation. explosion. See the solvent’s Material Safety Data
Sheet (MSDS) for safe handling recommendations
and equipment.
19. Use a large pipe wrench on the nozzle flange
to remove the nozzle (2) from the base (1) Do not sandblast internal parts because it can
(see Figure 14). reduce the dimensions of the parts. The base
(1), bonnet (11), and screwed cap (21) may be
8'-10' Long Rod sandblasted, but take care not to erode internal
Base or Heavy Pipe surfaces or damage machined surfaces.
! DANGER
Nozzle
3 Jaw Chuck
Chuck Stand
Follow
Figure 13 - Loosening the recommendations
for safe handling in
Nozzle from the Base the solvent’s
Material Safety Data
Sheet and observe
safe practices for
any cleaning
method.

Page 18
Parts Inspection Nozzle Bore Inspection

All 1900™ Series SRV nozzles manufactured
after August 1978 have increased bore diameters.
Nozzle Inspection Criteria Original and new nozzles are interchangeable, but
Nozzle should be replaced if: the rated capacities are different (see Table 2).
• Dimension from seat to first thread, after re-
machining and lapping, is less than D minimum
1900TM Series SRV Standard
(see Table 1). Disc Inspection Areas
• Threads are damaged from pitting and/or The standard 1900TM Series disc (see Figure
corrosion. 16) can be machined until the N dimension is
reduced to its minimum size (see Table 3). The T
• Top of flange and intersecting surface are
dimension is provided to ensure the disc has not
damaged from galling and/or tearing.
been machined beyond its limits. If re-machining
• Seat width is outside specification (see Tables reduces the thickness of the disc (T minimum),
7a or 7b). the entire disc holder assembly drops with respect
to the seating plane of the nozzle. This creates
Nozzle Seat Width a significant change in the huddle chamber
configuration and results in significantly more
Using a measuring magnifying glass (see Lapped simmer before opening.
Nozzle Seat Widths), determine whether the
seating surface must be machined before lapping. 1900TM Series Thermodisc®
If the seat can be lapped flat without exceeding the
required seat width (see Tables 7a or 7b), it does Replacement Criteria
not require machining. To reduce the seat width,
The Thermodisc® must be replaced if:
the 5º angle surface must be machined. The nozzle
must be replaced if the D dimension is reduced • Seat defects and damage cannot be lapped out
below the minimum (see Table 1). without reducing the A dimension below those
listed in Table 4 (see Figure 17).
ATTENTION!
Flange thickness changes the center-to-face ATTENTION!
dimension. Ensure the minimum dimension The A dimension on orifices D through H is
for orifices D through P is 42/64˝, and for Q difficult to measure. If the .006˝ minimum
through W is 51/64˝. thickness of the thermal lip cannot be
measured, replace the Thermodisc®.
Metal F O-Ring K
5° L N M
Seated H Seal L B
Nozzle G Nozzle A
E D min. D min.
J
45°
P
Nozzle
Bore
Figure 15 - Metal Seated and O-Ring Nozzles

Page 1
Table 1 - Seat Surface Machined Dimensions

Nozzle Metal-to-Metal O-Ring Seat Seal
Inches Inches
D Radius L
Orifi ce Min. E ± ..005
000 F H N ± .005
.000 P ± 1/2° B ± .002
.000 J ± .005 K Max.
D-1 13/32 .015 n/a .518 ±.001 n/a 30° .015 .062 .573 ± .000
.002 .537
E-1 15/32 .020 .788 ±.001 .686 ±.001 .025 30° .015 .060 .733 ± .000
.002 .688
.000
D-2, E-2, F 5/16 .030 .955 ±.001 .832 ±.001 .035 30° .015 .079 .868 ± .003 .814
.000
G 5/16 .035 1.094 ±.001 .954 ±.001 .035 30° .021 .090 1.060 ± .003 .999
.000
H 1/4 .035 1.225 ±.001 1.124 ±.001 .035 45° .021 .060 1.216 ± .003 1.167
J 3/8 .035 1.546 ±.001 1.436 ±.001 .035 45° .021 .074 1.534 ±.000
.003 1.481
K 7/16 .063 1.836 ±.002 1.711 ±.002 .063 45° .021 .126 1.838 ± .000
.004 1.781
.000
L 7/16 .063 2.257 ±.002 2.132 ±.002 .063 45° .016 .126 2.208 ± .004 2.158
.000
M 7/16 .063 2.525 ±.002 2.400 ±.002 .063 45° .021 .126 2.536 ± .004 2.480
.000
N 1/2 .063 2.777 ±.002 2.627 ±.002 .063 45° .021 .101 2.708 ± .004 2.652
.000
P 5/8 .093 3.332 ±.003 3.182 ±.003 .093 45° .021 .150 3.334 ± .004 3.279
.000
Q 7/8 .093 4.335 ±.003 4.185 ±.003 .093 45° .021 .188 4.338 ± .006 4.234
.000
R 1 .093 5.110 ±.003 4.960 ±.003 .093 45° .021 .215 5.095 ± .006 5.036
.000
T 3/4 .093 6.234 ±.003 6.040 ±.003 .093 45° .021 .142 6.237 ± .007 6.174
T-4 3/4 .093 6.510 ±.003 6.315 ±.003 .093 45° .021 .142 6.513 ± .000
.007 6.424
U 3/4 .093 6.993 ±.003 6.798 ±.003 .093 45° .021 .142 6.996 ± .000
.007 6.907
V 1 1/4 .250 8.816 ±.005 8.336 ±.005 .275 30° .019 ±.005 .275 9.130 ± .000
.010 8.341
.000
W 1 3/4 .350 11.058 ±.005 10.458 ±.005 .348 30° .019 ±.005 .353 11.130 ± .010 10.463
Metric Units, MM Metric Units, MM
D Radius L
Orifi ce Min. E ± ..13
00 F H N ± .13
.00 P ± 1/2° B ± .05
.00 J ± .13 K Max.
D-1 10.3 .38 n/a 13.16 ± .03 n/a 30° .38 1.57 14.55 ± .00
.05 13.64
E-1 11.9 .51 20.01 ± .03 17.43 ± .03 .64 30° .38 1.52 18.62 ± .00
.05 17.47
.00
D-2, E-2, F 7.9 .76 24.26 ± .03 21.13 ± .03 .89 30° .38 2.01 22.05 ± .08 20.68
.00
G 7.9 .89 27.79 ± .03 24.24 ± .03 .89 30° .53 2.29 26.92 ± .08 25.37
.00
H 6.3 .89 31.12 ± .03 28.55 ± .03 .89 45° .53 1.52 30.89 ± .08 29.64
.00
J 9.5 .89 39.27 ± .03 36.47 ± .03 .89 45° .53 1.88 38.96 ± .08 37.62
.00
K 11.1 1.60 46.63 ± .05 43.46 ± .05 1.60 45° .53 3.20 46.69 ± .10 45.24
.00
L 11.1 1.60 57.33 ± .05 54.15 ± .05 1.60 45° .41 3.20 56.08 ± .10 54.81
M 11.1 1.60 64.14 ± .05 60.96 ± .05 1.60 45° .53 3.20 64.41 ± .00
.10 62.99
N 12.7 1.60 70.54 ± .05 66.73 ± .05 1.60 45° .53 2.57 68.78 ± .00
.10 65.07
P 15.9 2.36 84.63 ± .08 80.82 ± .08 2.36 45° .53 3.81 84.68 ± .00
.10 83.28
.00
Q 22.2 2.36 110.11 ± .08 106.30 ± .08 2.36 45° .53 4.78 110.19 ± .15 107.54
.00
R 25.4 2.36 129.79 ± .08 125.98 ± .08 2.36 45° .53 5.46 129.41 ± .15 127.92
.00
T 19.0 2.36 158.34 ± .08 153.42 ± .08 2.36 45° .53 3.61 158.42 ± .18 156.82
.00
T-4 19.0 2.36 165.35 ± .08 160.40 ± .08 2.36 45° .53 3.61 165.43 ± .18 163.17
.00
U 19.0 2.36 177.62 ± .08 172.67 ± .08 2.36 45° .53 3.61 177.70 ± .18 175.44
.00
V 31.8 6.35 223.93 ± .13 211.73 ± .13 6.99 30° .48 ± .13 6.99 231.90 ± .25 211.86
.00
W 44.5 8.89 280.90 ± .13 266.30 ± .13 8.84 30° .48 ± .13 8.97 282.70 ± .25 265.76

Page 0
Table 2 - Bore Diameters

Pre-1978 Current Pre-1978 Current
Orifice (inches) (inches) (millimeters) (millimeters)
D-1 .393-.398 .404-.409 9.98-10.11 10.26-10.39
E-1 .524-.529 .539-.544 13.31-13.44 13.69-13.82
D-2 .650-.655 .674-.679 16.51-16.64 17.12-17.25
E-2 .650-.655 .674-.679 16.51-16.64 17.12-17.25
F .650-.655 .674-.679 16.51-16.64 17.12-17.25
G .835-.840 .863-.868 21.21-21.34 21.92-22.05
H 1.045-1.050 1.078-1.083 26.54-26.67 27.38-27.51
J 1.335-1.340 1.380-1.385 33.91-34.04 35.05-35.18
K 1.595-1.600 1.650-1.655 40.51-40.64 41.91-42.04
L 1.985-1.990 2.055-2.060 50.42-50.55 52.20-52.32
M 2.234-2.239 2.309-2.314 56.74-56.87 58.65-58.78
N 2.445-2.450 2.535-2.540 62.10-62.23 64.39-64.51
P 2.965-2.970 3.073-3.078 75.31-75.44 78.05-78.18
Q 3.900-3.905 4.045-4.050 99.06-99.19 102.74-102.87
R 4.623-4.628 4.867-4.872 117.42-117.55 123.62-123.75
T 6.000-6.006 6.037-6.043 152.40-152.55 153.34-153.49
T-4 6.202-6.208 157.53-157.68
U 6.685-6.691 169.80-169.95
V 8.000-8.005 203.20-203.33
W 10.029-10.034 254.74-254.86
T T
N min.
N min. N min.
B
B B
90°°
C C
L L
C
Type 1 Type 2 Type 3
D through H Orifice Discs J through U Orifice Discs V and W Orifice Discs
Figure 16 - Disc Inspection Areas

Page 1
Table 3 - Minimum Dimensions after Machining of the Disc Seat

Inches Millimeters
Disc Orifice T N T N
Type Size Minimum Minimum Minimum Minimum
TYPE 1 D-1 .155 .005 3.94 .127
E-1 .158 .005 4.01 .127
F, D-2, E-2 .174 .010 4.42 .254
G .174 .010 4.42 .254
H .335 .010 9.02 .254
TYPE 2 J .359 .010 9.12 .254
K .422 .015 10.72 .381
L .457 .015 11.61 .381
M .457 .015 11.61 .381
N .495 .015 12.57 .381
P .610 .015 15.49 .381
Q .610 .015 15.49 .381
R .610 .015 15.49 .381
T .822 .015 20.88 .381
U .822 .015 20.88 .381
TYPE 3 V 1.125 .015 28.58 .381
W 1.692 .015 42.98 .381
Thermodisc® Thermodisc®
A A
D - H Orifices J - W Orifices
Figure 17 - Thermodisc® Design (D through W Orifices)
Table 4 - Minimum A Dimensions

Orifice Size A Min. Dimension (in.) A Min. 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, U .025 .635
V, W .033 .838

Page 22
Disc Holder Inspection Criteria

Several disc holder designs are available, depending on the service and the type of valve (see Figure 18).
For identification, the G diameter (Dia.) is provided (see Tables 5a and 5b).
45°
G Dia. (Max.) G Dia. (Max.)
Detail 1 Detail 2
Standard Disc Holder O-Ring Disc Holder
G Dia. (Max.) G Dia. (Max.)
Detail 3 Detail 4
Liquid Service Disc Holder O-Ring Liquid Service (DALA Design)
(LA Design) D-2, E-2 F and G Orifice
G Dia. (Max.)
Detail 5
O-Ring Liquid Service (DALA Design)
H and J Orifice
Figure 18 - Disc Holder Designs

Page
Table 5a - Diameter in Inches for Disc Holder Identification

(Detail 1 is standard unless otherwise noted.)
Orifi ce Air/Gas Trim Liquid Trim Air/Gas Trim Liquid Trim
Size Low High LS LA Low High DL DALA
Pressure Pressure Design Design Pressure Pressure Design Design
D-1 0.715 0.715 0.811 0.765 0.811 0.811 0.811 n/a
Detail 3
E-1 1.012 0.922 0.971 1.061 0.940 0.971 0.971 n/a
Detail 3 Detail 2
D-2 1.167 1.032 1.167 1.265 1.100 1.032 1.100 1.092
Detail 3 Detail 2 Detail 2 Detail 4
E-2 1.167 1.032 1.167 1.265 1.100 1.032 1.100 1.092
F 1.167 1.032 1.167 1.265 1.100 1.032 1.167 1.092
G 1.272 1.183 1.272 1.374 1.270 1.183 1.272 1.262
Detail 3 Detail 2 Detail 4
H 1.491 1.394 1.491 1.655 1.489 1.394 1.491 1.494
J 1.929 1.780 1.929 2.155 1.851 1.780 1.929 1.865
K 2.126 2.126 2.264 2.468 2.264 2.264 2.264 2.468
Detail 3 Detail 3
L 2.527 2.527 2.762 3.062 2.527 2.527 2.762 3.062
Detail 3 Detail 3
M 2.126 2.126 3.054 3.358 2.264 2.980 3.054 3.358
Detail 3 Detail 3
N 3.088 3.088 3.480 3.827 2.527 2.527 3.480 3.827
Detail 3 Detail 3
P 3.950 3.950 4.361 4.811 2.980 2.980 4.361 4.811
Detail 3 Detail 3
Q 5.197 5.197 5.546 6.108 5.197 5.197 5.546 6.108
Detail 3 Detail 3
R 6.115 6.115 6.563 7.218 6.155 6.155 6.563 7.218
Detail 3 Detail 3
T 7.494 7.494 7.840 8.624 7.494 7.494 7.840 8.624
Detail 3 Detail 3
T-4 7.841 7.841 n/a 8.624 7.841 7.841 n/a 8.624
Detail 3 Detail 3
U 8.324 8.324 n/a ** ** ** n/a **
V 10.099 10.099 n/a 11.843 10-37/64 10-37/64 n/a 11.843
Detail 3 Detail 3
W 12-21/32 12-21/32 n/a 14.640 13-3/64 13-3/64 n/a 14.640
Detail 3 Detail 3
** Contact the factory for this information.

Page
Table 5b - Diameter in Millimeters for Disc Holder Identification

(Detail 1 is standard unless otherwise noted.)
Orifi ce Air/Gas Trim Liquid Trim Air/Gas Trim Liquid Trim
Size Low High LS LA Low High DL DALA
Pressure Pressure Design Design Pressure Pressure Design Design
D-1 18.16 18.16 20.60 19.43 20.60 20.60 20.60 n/a
Detail 3
E-1 25.70 23.42 24.66 26.95 23.88 24.66 24.66 n/a
Detail 3 Detail 2
D-2 29.64 26.21 29.64 32.13 27.94 33.53 27.94 27.74
E-2 29.64 26.21 29.64 32.13 27.94 26.21 27.94 27.74
F 29.64 26.21 29.64 32.13 27.94 26.21 29.64 27.74
G 32.31 30.05 32.31 34.90 32.26 30.05 32.31 32.05
H 37.87 35.41 37.87 42.04 37.82 35.41 37.87 37.95
J 49.00 45.21 49.00 54.74 47.01 45.21 49.00 47.37
K 54.00 54.00 57.50 62.69 57.50 57.50 57.50 62.69
Detail 3 Detail 3
L 64.19 64.19 70.15 77.77 64.19 64.19 70.15 77.77
Detail 3 Detail 3
M 54.00 54.00 77.57 85.29 57.50 75.69 77.57 85.29
Detail 3 Detail 3
N 78.44 78.44 88.39 97.21 64.19 65.28 88.39 97.21
Detail 3 Detail 3
P 100.33 100.33 110.77 122.20 75.69 75.69 110.77 122.20
Detail 3 Detail 3
Q 132.00 132.00 140.87 155.14 132.00 132.00 140.87 155.14
Detail 3 Detail 3
R 155.32 155.32 166.70 183.34 156.34 156.34 166.70 183.34
Detail 3 Detail 3
T 190.35 190.35 199.14 219.05 190.35 190.35 199.14 219.05
Detail 3 Detail 3
T-4 199.16 199.16 n/a 219.05 199.16 199.16 n/a 219.05
Detail 3 Detail 3
U 211.43 211.43 n/a ** ** ** n/a **
V 256.51 256.51 n/a 300.81 268.68 268.68 n/a 300.81
Detail 3 Detail 3
W 321.47 321.47 n/a 371.85 331.39 331.39 n/a 371.85
Detail 3 Detail 3
** Contact the factory for this information.

Page 25
Guide Inspection Criteria

Disc Replace the guide (9) if:
Holder
• Visible galling is present on the inside guiding
surface.
• Gasket seating areas are pitted and cause the
Adjusting valve to leak between the bonnet (11) and base
Ring
(1).
The guide (9) type varies depending on the valve
type: O-ring valve, bellows valve, or standard valve.
Liquid Trim Design Inspect the guide as follows:
Figure 19 - 1900TM Series Liquid • Find the correct valve orifice size and disc holder
(8) measurements (see Table 6).
Service (LS) Internals
• Measure the barrel portion of the disc holder
and compare it to the nominal measurement on
Guide Table 6 to determine the maximum allowable
clearance between the disc holder and the
Disc Disc guide.
Retainer Holder
• Replace the guide and disc holder if the
clearance between the inner diameter (ID)
Disc and the guide and/or the outer diameter (OD)
Adjusting of the disc holder is not within the clearance
Ring
dimensions.
Nozzle Spindle Inspection Criteria

Replace the spindle (15) if:
Figure 20 - 1900TM Series Liquid
• The bearing point is pitted, galled, or distorted.
Service (LA) Internals
• Threads are torn so that release nut and/or
release locknut will not thread on or off.
Set Pressure Change: If it is necessary to change
valve set pressure, it may also be necessary to • The spindle cannot be straightened less than
change the disc holder (8). Determine if the disc the .007˝ total indicator reading (See Checking
holder must be changed to/from low pressure from/ Spindle Concentricity and Figure 29).
to high pressure when changing the set pressure
(see Table 8). Spring Inspection Criteria
Media Change: If the protected media is changed Replace the spring (18) if:
in form from a compressible fluid (air, gas, or
steam) to a non-compressible fluid (liquid), it is • Pitting and corrosion of the coils reduce coil
necessary to change from a standard to a liquid diameter.
trim disc holder.
• Spring ends are not parallel in the free height
Bellows Conversion: If a conventional 1900TM condition.
Series SRV has a D, E, F, G or H orifice disc holder
• Obvious uneven coil spacing or spring distortion
(8), the disc holder must be replaced with a new
is present.
disc holder included in the bellows conversion kit.
O-Ring Conversion: If a standard metal-seated ATTENTION!
1900TM Series SRV is to be converted to an O-ring If a spring must be replaced, order a spring
valve, the disc holder (8) must be replaced with an assembly, as it includes custom fit spring
O-ring disc holder which is included in the O-ring washers.
conversion kit. For K through U orifice valves, the
standard disc holder may be machined to receive
the larger O-ring disc.

Page
• The maximum clearance between A and A1 and

between B and B1 (see Figure 21) is more than: Allowed Tolerance
Per H.4
A1
○ 1/32˝ (.79 mm) for springs with an inner
A
diameter (ID) of less than 4˝ (100 mm).
Top of Spring
○ 3/64˝ (1.19 mm) for springs with an ID of 4˝
(100 mm) or greater.
If there is constant backpressure in a conventional

1900™ Series SRV (without balancing bellows),
check that the cold differential set pressure of the
replacement spring (18) is within the recommended Bottom of Spring
B
range. If the relieving temperature causes the
cold differential set pressure, then select a spring B1
based on the valve’s actual set pressure, not on
the cold differential set pressure (See Set Pressure
Compensation).
Figure 21 - Spring Allowed Tolerance
Table 6 - Allowable Clearance for the Guide and Disc Holder

Disc Holder Nominal Barrel Size in Inches Disc Holder Nominal Barrel Size in Millimeters
Orifice
Size Non-bellows Clearances Bellows Clearances Non-bellows Clearances Bellows Clearances
D-1 0.450 .003 - .007 0.449 .003 - .008 11.43 .076 - .178 11.40 .076 - .203
D-2 0.995 .004 - .008 0.449 .003 - .008 25.27 .102 - .203 11.40 .076 - .203
E-1 0.527 .003 - .007 0.449 .003 - .008 13.39 .076 - .178 11.40 .076 - .203
E-2 0.995 .004 - .008 0.449 .003 - .008 25.27 .102 - .203 11.40 .076 - .203
F 0.995 .004 - .008 0.449 .003 - .008 25.27 .102 - .203 11.40 .076 - .203
G 0.995 .004 - .008 0.495 .003 - .008 25.27 .102 - .203 12.57 .076 - .203
H 1.118 .005 - .010 0.681 .004 - .009 28.40 .127 - .254 17.30 .102 - .229
J 0.993 .005 - .010 0.993 .005 - .010 25.22 .127 - .254 25.22 .127 - .254
K 1.241 .007 - .012 1.241 .007 - .012 31.52 .076 - .305 31.52 .076 - .305
L 1.366 .007 - .012 1.366 .007 - .012 34.70 .076 - .305 34.70 .076 - .305
M 1.743 .005 - .010 1.743 .005 - .010 44.27 .127 - .254 44.27 .127 - .254
N 1.869 .004 - .009 1.869 .004 - .009 47.47 .102 - .229 47.47 .102 - .229
P 2.303 .008 - .013 2.303 .008 - .013 58.50 .102 - .330 58.50 .102 - .330
Q 2.303 .008 - .013 2.303 .008 - .013 58.50 .102 - .330 58.50 .102 - .330
R 2.303 .008 - .013 2.303 .008 - .013 58.50 .102 - .330 58.50 .102 - .330
T 2.303 .008 - .013 2.303 .008 - .013 58.50 .102 - .330 58.50 .102 - .330
U 2.303 .008 - .013 2.303 .008 - .013 58.50 .102 - .330 58.50 .102 - .330
V 6.425 .013 - .027 6.425 .013 - .027 163.20 .330 - .686 163.20 .330 - .686
W 8.425 .013 - .027 8.425 .013 - .027 214.00 .330 - .687 214.00 .330 - .687
Note: For valves manufactured prior to 1978, contact the factory for dimensions and clearances.

Page 27
Maintenance Lapping Nozzle Seats

(Non-O-Ring Styles)
General Information ATTENTION!
After the valve has been disassembled, closely Nozzle laps (as illustrated below) are
inspect the seating surfaces. Usually, a lapping available from Dresser, Inc. Do not use
of seats is all that is necessary to return a valve these laps if the valve nozzle can be
to working order. If an inspection shows badly removed and machined to the proper seat
damaged valve seating surfaces, machining will dimensions (see Tables 7a and 7b).
be required before lapping. O-ring seat seal valve
nozzles can only be reconditioned by machining,
not lapping. (For specific information concerning Lap the 5º angle of the nozzle first (see Figure 23,
the machining of nozzle and disc seating surfaces, View A). Then, invert the nozzle lap and use the flat
see the Re-Machining Nozzle Seats and Bores and side as a “starter” lap to ensure the seat is square
Re-Machining the Disc Seat sections.) (see Figure 23, View B). Use a ring lap in a circular
motion to finish lapping (see Figure 23, View C and
Reconditioning of Laps). Keep the lap squarely on
ATTENTION! the flat surface and avoid rocking it. Rocking will
See Optional Glide-Aloy™ Parts to cause rounding of the seat.
determine if the valve contains Glide-Aloy™
treated components (i.e. the disc holder
and/or the guide). Coding on the valve
nameplate identifies these components.
Nozzle
Lap
The seating surfaces of the metal-seated
Consolidated® SRV are flat. The nozzle seat is 90°
relieved by a 5º 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 22). 85°
Nozzle
Lap
Disc
85°
5°
View A
90°
Seat Width
Ring
Lap
Nozzle
Figure 22 - Seating Surface

View B
A cast iron lap, coated with a lapping compound, is
used for reconditioning the seating surfaces of the
nozzle (2) and disc (6).
ATTENTION!
To establish leak-free valve seats, the nozzle View C
seating surface and the disc seating surface
must be lapped flat. Figure 23 - Lapping Nozzle Seats

Page
Lapped Nozzle Seat Widths

A wide nozzle seat will induce simmer, especially load imposed upon it by the spring force, the
in the smaller-orifi ce, lower-pressure valves. For higher-pressure valves must have wider seats than
this reason, the seats of valves other than O-ring the lower-pressure valves. The nozzle seat width
valves should be as narrow as is practical. Since should conform to the measurements in Tables 7a
the seat must be wide enough to carry the bearing and 7b.
Table 7a - Nozzle Seat Width

Orifice Set Pressure psig (barg) for Metal Suggested Lapped Seat Width
Seated Valves except TD in Inches (mm)
D through J 15-50 (1.03-3.45) .012-.020 (.30-.51)
51-100 (3.52-6.90) .018-.028 (.46-.71)
101-250 (6.96-17.24) .025-.035 (.64-.89)
251-400 (17.31-27.58) .032-.042 (.81-1.07)
401-800 (27.65-55.16) .038-.048 (.96-1.22)
D through F 801-1500 (55.23-103.42) .042-.052 (1.07-1.32)
1501-3000 (103.49-206.84) .045-.055 (1.14-1.40)
3001-6000 (206.91-413.69) .050-.060 (1.27-1.52)
G through J 801-1000 (55.23-68.95) .040-.050 (1.02-1.27)
1001-2800 (69.02-193.05) .042-.055 (1.07-1.40)
2801-6000 (193.12-413.79) .045-.060 (1.14-1.52)
K through N 15-50 (1.03-3.45) .025-.040 (.64-1.02)
51-100 (3.52-6.90 ) .030-.045 (.76-1.14)
101-250 (6.96-17.24) .035-.050 (.89-1.27)
251-400 (17.31-27.58) .040-.055 (1.02-1.40)
401-800 (27.65-55.16) .045-.060 (1.14-1.52)
P through R 15-50 (1.03-3.45) .030-.045 (.76-1.14)
51-100 (3.52-6.90) .035-.050 (.89-1.27)
101-250 (6.96-17.24) .045-.060 (1.14-1.52)
251-400 (17.31-27.58) .050-.065 (1.27-1.65)
401-800 (27.65-55.17) .060-.070 (1.52-1.78)
801-1000 (55.23-68.95) .062-.070 (1.57-1.78)
T and U 15-50 (1.03-3.45) .040-.060 (1.02-1.52)
51-100 (3.52-6.90) .045-.065 (1.14-1.65)
101-200 (6.96-13.79) .050-.070 (1.27-1.78)
201-300 (13.86-20.68) .060-.080 (1.52-2.03)
V 15-50 (1.03-3.45) .070-.080 (1.78-2.03)
51-100 (3.52-6.90) .090-.100 (2.29-2.54)
101-250 (6.96-17.24) .110-.120 (2.79-3.05)
251-300 (17.31-20.68) .125-.135 (3.18-3.43)
W 15-50 (1.03-3.45) .095-.105 (2.41-2.67)
51-100 (3.52-6.90) .115-.125 (2.92-3.17)
101-250 (6.96-17.24) .135-.145 (3.43-3.68)
251-300 (17.31-20.68) .155-.165 (3.94-4.19)

Page
To measure the seat width, use a Model S1-34- If additional lighting is required for measuring, use
35-37 Bausch and Lomb Optical Co. measuring a gooseneck fl ashlight similar to the Type A Lamp
magnifi er or an equivalent seven-power glass with Assembly (Standard Molding Corp.), or equivalent.
a 3/4˝ scale showing graduations of 0.005 inch.
Figures 24a and 24b illustrate the use of this tool in
measuring the nozzle seat width.
Table 7b - Nozzle Seat Width

Orifice Set Pressure psig (barg) Suggested Seat Width in Inches (mm)
for TD Option only for TD Option only
D through F 15-50 (1.03-3.45) .020-.030 (.50-.76)
101-300 (6.96-20.68) .035-.045 (.89-1.14)
301-800 (20.75-55.17) .045-.055 (1.14-1.40)
801 plus (55.24 plus) Full Width
G through J 15-100 (1.03-6.89) .025-.035 (.64-.89)
101-300 (6.96-20.68) .035-.040 (.89-1.01)
301-800 (20.75-55.17) .045-.055 (1.14-1.40)
K through N 15-100 (1.03-6.89) .035-.040 (.89-1.01)
101-300 (6.96-20.68) .045-.055 (1.14-1.40)
301-800 (20.75-55.17) .055-.065 (1.40-1.65)
P through R 15-100 (1.03-6.89) .040-.050 (1.01-1.27)
101-300 (6.96-20.68) .055-.065 (1.40-1.65)
301-800 (20.75-55.17) .060-.070 (1.52-1.78)
801-1000 (55.24-68.95) .065-.075 (1.65-1.90)
T and U 15-100 (1.03-6.89) .050-.065 (1.27-1.65)
101-300 (6.96-20.68) .060-.075 (1.52-1.90)
V 15-100 (1.03-6.89) .075-.100 (1.90-2.54)
101-300 (6.96-20.68) .095-.130 (2.41-3.30)
W 15-100 (1.03-6.89) .100-.125 (2.54-3.18)
101-300 (6.96-20.68) .120-.160 (3.05-4.06)
Nozzle
Width
Measuring
Magnifier
0 0.3 6 0.7
Flat Seat
Nozzle
5° Taper
Figure 24a - Measuring Magnifier Figure 24b - Measuring Magnifier Detail

Page 30
Lapping Disc Seats Lapping O-Ring Seating

Use a ring lap or lapping plate to lap the disc in Surfaces
a circular motion, applying uniform pressure and
slowly rotating the disc or lap. Refer to Figure 5 and assemble the O-ring retainer
to the disc holder (8) (D through J orifice) or disc (6)
Precautions and Hints for (K through U orifice) using the retainer lock
screw(s) as follows:
Lapping Seats
1. Apply 3A lapping compound to the retainer-
To ensure a quality lapping process, observe seating surface.
precautions and guidelines as follows:
2. Place the retainer on the nozzle seat (see
• Keep work materials clean. Figure 22) and lap the retainer to the nozzle (2).
• Always use a fresh lap. If signs of wear (out of 3. Once uniform contact is established, clean the
flatness) are evident, recondition the lap. nozzle (2) and O-ring retainer.
• Apply a very thin layer of lapping compound to
4. Repeat the procedure with 1000-grit compound.
the lap to prevent rounding off the edges of the
seat. 5. Remove the retainer lock screw(s) and O‑ring
retainer, and thoroughly clean the O-ring
• Keep the lap squarely on the flat surface, and
retainer, retainer lock screws, and disc holder
avoid rocking the lap, which causes rounding of
(8) or disc (6).
the seat.
• When lapping, keep a firm grip on the lapped Reconditioning of Laps
part to prevent dropping it and damaging the
seat. Ring laps are reconditioned by lapping them on
a flat lapping plate in a figure-eight motion (see
• Lap in a circular motion while applying a Figure 25). To ensure the best results, recondition
uniform pressure. Slowly rotate the lap to evenly the ring laps after each use. Use an optical flat to
distribute the lapping compound. check the quality of the lap.
• Wipe off the old compound and replace it with
new compound frequently. Apply more pressure
Lapping Plate Ring Lap
to speed the cutting action of the compound.
• To check the seating surfaces, remove all
compound from the seat and the lap. Then,
shine the seat with the same lap using the
lapping method as described above. Low
sections on the seating surface show up
as shadow in contrast to the shiny portion.
If shadows are present, further lapping is
necessary. Only laps known to be flat can
be used. It should take only a few minutes to
remove the shadows.
• When lapping is complete, any lines appearing
as cross-scratches can be removed by rotating
the lap on its axis (which has been wiped clean
of compound) on the seat. Figure 25 - Lapping Pattern
• Thoroughly clean the lapped seat using a lint-
free cloth and a cleansing fluid. Nozzle laps (see Figure 23) must be re-machined
to recondition the lapping surfaces. Place the
ATTENTION! nozzle lap in a lathe between centers (see Figure
Before assembly, lap the contact surfaces 26). The surfaces marked A and B must be running
of the nozzle and O-ring retainer to provide concentrically.
metal-to-metal seat tightness in the event of
O-ring failure.

Page 31
until the damaged areas are removed. Turn

A C D B to the smoothest possible finish.
• 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.
90 85° • Re-machine diameter H, until dimension E is
Lathe Center Lathe Center
obtained. Reestablish angle P.
Figure 26 - Nozzle Lap in a Lathe The nozzle is now ready for lapping.
• Discard the nozzle when the minimum
One lapping surface is 90º and the other is 85º. dimension D (see Figure 15 and Table 1) is
The angle of each surface is marked on the lap. reached.
Machine surfaces C and D by taking light cuts at
4. Re-machine the O-ring seat seal (see Figure 15
the proper angle until the lapping surfaces are
and Table 1) as follows:
reconditioned.
• Make light cuts across surface A at 45º until
Re-Machining Nozzle Seats the damaged areas are removed. Turn to the
smoothest possible finish.
and Bores
• Cut back the outside surface at M until
1. Remove the nozzle (2) from the valve to be re- dimension J is obtained.
machined. If it cannot be removed from the base
(1), re-machine it inside the base. • Re-machine radius B.
2. Set-up the lathe and nozzle (2) as follows: The nozzle is now ready for lapping.
• Grip the nozzle in a four-jaw independent • Discard the nozzle when the minimum
chuck (or collet, if appropriate) using a dimension D (see Figure 15 and Table 1) is
piece of soft material such as copper or reached.
fiber between the jaws and the nozzle (see
Figure 27, A). Re-Machining the Disc Seat
• True-up the nozzle so that the surfaces Machine the standard disc seating surface (see
marked B, C, and D run true within .001” Figure 28) as follows:
(.025 mm) on the total indicator reading (see
Figure 27). 1. Grip the disc (6) 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 (see Figure 28, A).
C
Nozzle 2. True-up the disc (6) so that the surface marked
B
D
B and C run true within .001" (0.025 mm) on the
total indicator reading (see Figure 28).
3. Make light cuts across the seating surface L
until damaged areas are removed. Turn to the
smoothest possible finish.
A
The disc (6) is now ready for lapping.
Chuck Jaw
• Discard the disc if the minimum dimension N
or T (Figure 16 and Table 3) is reached. Do
not reestablish surface C as (see Figure 28).
Figure 27 - Nozzle Positioned in a Jaw
ATTENTION!
3. Re-machine the metal-to-metal seat (see
Do not machine a Thermodisc® or O-ring
Figure 15 and Table 1) as follows:
Seat disc.
• Make light cuts across the surface L at 5º

Page 32
Chuck Jaw
A X X A X X
A
A A
Section X-X Section X-X

C
Disc Spring C
45° Spring
Washer 45°
Seat Washer
B B Seat
90°
C Figure 29 - V-Block Support Setup

L
Set Pressure Change-Disc Holder

B
The disc holder (8) must be replaced if the set
pressure must be changed and the change involves
crossing the dividing line between high pressure
and low pressure. Determine whether the disc
Figure 28 - Standard Disc
holder must be changed when changing the set
Seating Surface pressure (see Table 8).
Checking Lift on Restricted

Checking Spindle
Lift Valves
Concentricity
ATTENTION!
It is important that the spindle (15) of an SRV be
straight in order to transmit the spring load to the Restricted lift valves may be identified by the
disc (6) without binding laterally. Over-gagging restricted lift nameplate.
is a common cause of bent spindles. Check the
essential working surfaces of the spindle using any
of the recommended methods as follows: General
1. Set up the V-block support (see Figure 29) as Restricted lift valves have a limit washer that
follows: prevents the disc (6) and disc holder (8) from lifting
beyond the required lift and resulting capacity. The
• Place the ball-pointed spindles in a piece of D-1 and E-1 valves do not require limit washers.
material B that has been recessed to permit The D-2 and E-2 valves have a special nozzle with
free rotation of the spindle (15). For hollow the overall height and flange dimension of the D-1
spindles, a ball-pointed support is required. or E-1, and the seat dimensions and bore diameter
are identical to the F orifice nozzle.
• Support the spindle with a V-block A placed
near the upper end of the spindle, but below Other 1900™ Series valves may be restricted in
the threads. the same manner when necessary. These valves
may be restricted to a minimum lift of 30% of the
• Apply a dial indicator at approximately 45º to
full rated capacity or .080˝ (2.03 mm) (See National
the outer edge of the spring washer seat at C.
Board Code Case 1945-2).
• Rotate the spindle. The total indicator reading
It is important to check lift on all restricted lift valves
should not exceed .007” (.17 mm). Straighten
after servicing or replacing parts. This procedure
the spindle, if necessary. To straighten the
is necessary to ensure reliability of the nameplate
spindle, place the unthreaded portion of the
capacity.
small and large end in padded V-blocks,
with the point of maximum indicator readout ATTENTION!
upward, and then apply a downward force
with a padded press or jack as required, until The required lift for a restricted lift valve is
the spindle is within the specifications. indicated on the restricted lift nameplate
(see Figure 30).

Page
Determining the Correct Limit • Install the eductor tube (40) in base (1),
Washer Length if applicable.
Determine the correct limit washer length (see • Install the adjusting ring (3) below the seat.
Figure 31) as follows:
1. Assemble the disc (6) and disc holder (8)
(installing the bellows gasket and bellows, if
applicable) as follows:
ATTENTION!
For O-ring Seat (DA) valves, do not install
the O-ring seat seal when determining the
correct limit washer length.
• Place the guide over the disc holder barrel

and connect the spindle (15) to the disc
holder (8). Figure 30 - Restricted Lift Nameplate
Table 8 - Disc Holder Selection Criteria

Pressure in psig (barg) Units.
Air/Gas Non Liquid Service Liquid Service
Metal Seat O-Ring DA LS Design LA Design
Orifice Use Low Use High Use Low Use High Metal O-Ring Metal O-Ring
Size Pressure Pressure Pressure Pressure Seat Seat Seat Seat
Disc Disc O-Ring O-Ring
Holder Holder Disc Disc
Holder Holder
D-1 Not Use for all Use for all Not Use LS Use DL or Use LA LA-DA
-30D-1 available pressures pressures applicable disc holder LS-DA disc for all disc holder
same as for all holders pressures is not
DL disc pressures for all applicable
holder pressures
E-1 5 - 100 101 and 5 - 35 36 Use LS Use DL or Use LA LA-DA
-30E-1 (0.34-6.89) greater (0.34-2.41) (2.48) and disc holder LS-DA disc disc holder disc holder
(6.96) greater for all holders for all is not
and greater same as pressures for all pressures applicable
DL disc pressures
holder
D-2 5 - 100 101 and 5 - 35 36 Use LS - Use DL or Use LA Use
E-2 greater (0.34-2.41) (2.48) and same LS-DA disc disc holder DA-LA disc
-30D-2 (0.34-6.89) greater as low holders for all holders
(6.96) same as pressure for all pressures for all
-30E-2
and greater DL disc air/gas disc pressures pressures
F-1
-30F-1 holder holder
G-1 5 - 50 51 and 5 - 120 121 Use LS - Use DL or Use LA Use

-30G-1 greater same LS-DA disc disc holder DA-LA disc
H-1 (0.34-3.45) (0.34-8.27) (8.34) and as low holders for all holders
(3.52) and greater pressure for all pressures for all
-30H-1
greater air/gas disc pressures pressures
J-2
-30J-2 holder
K-W Not Use Not All Use LS Use DL or Use LA Use

-30K-W applicable standard applicable pressures disc holder LS-DA disc disc holder DA-LA disc
disc holder for all holders for all holders
for all pressures for all pressures for all
pressures pressures pressures

Page 34
Guide
Guide
Required Lift
Bellows
Limit Washer
Limit Washer
Disc Holder Measured Lift
Bellows Ring
Bellows Gasket
Limit Washer Length Disc Holder
Conventional Bellows
Figure 31 - Determining Lift and Limit Washer Length
2. Install the guide gasket (10), and insert the disc 11. Once correct lift is obtained, disassemble the
assembly from Step 1 into the base (1). valve.
3. Install the bonnet gasket (12) and bonnet (11) ATTENTION!
(leaving out the spring assembly at this time).
Ensure the limit washer has been chamfered to
ATTENTION! fit over the radius of the disc holder (8). The limit
washer must be installed so that the chamfered
Do not use an impact wrench on bellows valves. end is mating to the back face of disc holder.
4. Tighten the stud nuts (14) to compress the

ATTENTION!
bonnet gasket (12).
Check all dimension requirements for each
5. Place a dial indicator on the bonnet (11) and valve. Do not interchange internal parts or
over the spindle (15) and then zero the indicator. use a different base after a set of parts has
Measure total lift by pushing the disc (6) been custom-fit.
upward. Subtract the required lift of the valve
from the measured lift to find the required limit
washer length. ATTENTION!
6. Machine the limit washer to the required length. For bellows Type D and E valves, check the
outside diameter and, if necessary, emery
7. Machine the inside chamfer, deburring and cloth down to .680˝ (17.3 mm) maximum
polishing as required. diameter in order to avoid interference with
the bellows threads.
8. Disassemble the valve.
9. Install the limit washer with the chamfer down
and reassemble the valve as described in Steps Reassembly
2 through 4.
10. Measure the lift of the valve and compare it General Information
with the required lift as given on the restricted The 1900™ Series SRV can be easily reassembled
lift nameplate (-0.000”, +0.005” [-0.000 mm, after the required internal parts maintenance has
+0.127 mm]). Take one of the following steps, been performed. All parts should be clean before
based on the results, if the lift is not correct: reassembly.
• If the actual lift is less than required, machine
the limit washer as necessary to obtain the Preparation
required lift. (Machine chamfer, deburr and
polish before installation into the valve.) Before beginning reassembly take these steps as
follows:
• If the actual lift is greater than required,
obtain a new limit washer, and return to 1. Inspect guiding surfaces, bearing surfaces,
Step 7. (Machine chamfer, deburr and polish flange faces, retainer recesses, and grooves for
before installation into valve.) cleanliness (See Replacement Parts Planning
for recommended compounds and tools).

Page 35
2. Check all gaskets used during reassembly.

Reuse undamaged, solid metal gaskets (not
pitted or creased) and replace all soft gaskets.
3. Before installing the (flat) gaskets, apply a light
uniform coating of lubricant to the surface to
be sealed. Then coat the top of the gasket with
Figure 32 - Valve O-Ring Tag
lubricant.
4. If lapping of bearing points was necessary, • Use 1000-grit lapping compound on the
ensure all lapping compound is removed. Then, bearing surface to lap the disc (6) into the disc
thoroughly clean both surfaces and rinse with holder (8) and to properly establish the bearing
alcohol or another suitable cleaner. surface.
5. Apply a light, uniform layer of lubricant to each • For D through U orifice valves with metal-
bearing surface. to-metal discs (see Figure 2), place the disc
retainer (7) into the groove in the disc (6). The
6. If the valve has an O-ring seat seal, the O-ring retainer should “snap” into the disc holder (8)
should be replaced. Please refer to its tag plate with moderate finger or hand force. Check that
(see Figure 32) to determine O-ring material and the disc “rocks” after set in place.
“as-built” part number.
ATTENTION!
Lubrication Do not use excessive force to insert the
Use a nickel-based, anti-seize lubricant on all disc (6) into the disc holder (8).
threads and bearing surfaces. Recommended
lubricant is Jet – Lube, Dresser Non-metallic, • For V and W orifice discs (see Figure 3), place
product code #14613. the disc into the disc holder and secure it with
disc retaining bolts.
Reassembly Procedure • For O-ring disc sizes D through J (see
1. If the nozzle (2) was removed, apply thread Figure 5), reassemble the disc holder using
lubricant to the nozzle threads before a new O-ring Seat Seal, O-ring retainer, and
reinstalling it in the valve base (1). retainer lock screw(s).
2. Insert the nozzle (2) into the inlet flange of the • For O-ring disc sizes K through U (see Figure 5),
base (1) and torque to the correct value (see reassemble the disc using a new O‑ring Seat
Table 9). Seal, O-ring retainer, and retainer lock screws.
Assemble the disc into the disc holder.
3. Install the adjusting ring (3) on the nozzle (2)
below the seat level so that the disc (6) will seat 6. Install the bellows gasket and bellows ring as
on the nozzle and not on the adjusting ring. follows:
4. For restricted lift valves: • For bellows valves D through U (see

Figure 11):
• If the nozzle (2) did not require machining,
○ Clamp the stem portion of the disc holder
the same limit washer (tagged during
disassembly) may possibly be reused. (8), barrel-end up, firmly between two
However, lift should be checked and verified wooden V-blocks in a vise.
as described in Checking Lift on Lift- ○ Place a new bellows gasket on the disc
Restricted Valves. holder.
• If the nozzle was remachined, measure the ○ Thread the bellows ring, hand-tight, down to
required lift as described in Checking Lift the gasket on the disc holder.
on Lift-Restricted Valves and replace limit
washer if necessary. ○ Use a pin spanner wrench or special cable-
type wrench to tighten the bellows ring until
5. Assemble the disc/disc holder as follows: a pressure-tight joint is formed.
• Before assembly of the disc (6) into the disc • For bellows valves V and W:
holder (8), remove the disc retainer (7) from
the back of the disc. ○ Place a new bellows gasket on the disc
holder.
Page
○ Bolt the assembly in place and tighten Table 9 - Nozzle Torque

bolts to 7-9 ft-lbs (9.5-12.2 nm).
Values +10% - 0%
7. On restricted lift valves, install the limit washer
with the chamfered side down. Required Required
Orifi ce Torque ft-lbs Torque newton-m
8. For D through U valves: D-1 95 129
Place the guide (9) over the disc holder (8). If D-2
bellows are present, the weight of the guide will E-1
165 224
slightly compress the bellows. E-2
F-1
For V and W orifi ce valves: G 145 197
Install guide rings into the grooves located H 165 224
inside the guide ID. Make sure the space where J 335 455
the upper and lower guide ring ends meet is K 430 584
positioned 180° apart. Mark both the guide
L 550 746
and disc holder at the point where the bottom
guide ring ends meet. This mark must be faced M 550 746
180° away from the outlet when the assembly N 640 868
is place into the valve. Gently lower the guide P 1020 1383
down onto the disc holder ensuring that guide Q 1400 1898
rings remain in their respective groove. R 1070 1451
9. Set the disc holder (8), disc side down, on the T 1920 2604
work surface. Place a small amount of 1000- U 1920 2604
grit lapping compound onto the ball end of the V 1960 2658
spindle (15) and place it in the spindle socket W 2000 2712
of the disc holder. Turn the spindle clockwise
and then counterclockwise to seat the spindle/
spindle retainer and guide it into the retaining
disc holder bearing point. When fi nished, clean
groove. Ensure the spindle turns freely.
lapping compound from all parts.
○ Lift complete assembly and carefully lower it
10. Spread a small amount of 320-grit lapping com- into the valve base (1).
pound on the spring washer bearing surface. ○ Ensure proper fi t for a conventional valve
11. Place the spring washer (17) over the spindle/ by aligning the hole in the guide (9) over the
spring washer bearing surface and turn it extended end of the eductor tube (40).
clockwise and then counterclockwise to seat it
• For M through U size valves:
on the bearing surface. In the same manner,
lap the adjusting screw (19) into the bearing ○ Install lifting tool (see Figure 10a) onto disc
surface of the upper spring washer to establish holder and carefully lower the disc holder
a smooth bearing surface. When fi nished, clean assembly into the valve base.
lapping compound from all parts. ○ Ensure proper fi t for a conventional valve
12. Place the spindle retainer (16) over the end by aligning the hole(s) in the guide over the
of the spindle head or disc holder (8), as extended end of the eductor tube(s).
applicable. ○ Then, install the spindle in the disc holder
and align the spindle retainer so that the gap
13. Apply lubricant sparingly to the ball tip of the
is midway between the two slots.
spindle (15).
○ Use a screwdriver to compress the spindle
14. Place a new guide gasket (10) in the base (1). retainer and guide it into the retaining groove.
Ensure the spindle turns freely.
15. Install the spindle/disc guide assembly as follows:
• For V and W size valves:
• For D through L size valves:
○ Using the same lifting lugs used during
○ Place the spindle (15) in the disc holder (8)
disassembly (see Figure 10b), carefully lower
and align the spindle retainer (16) so that
the disc holder assembly into the valve base.
the gap is midway between the two slots.
○ Install the spindle in the disc holder and align
○ Use a screwdriver to compress the

Page
the spindle retainer so that the gap is • For V and W orifi ces, use the setting device
midway between the two slots. to assemble the spring plunger and adjusting
○ Use a screwdriver to compress the spindle screw. Contact the factory for procedure on how
retainer and guide it into the retaining to use the setting device.
groove. Ensure the spindle turns freely. 21. Use pliers to hold the spindle (15) and prevent
16. Apply a small quantity of lubricant to the spring it from turning in the disc holder (8). Turn the
washer bearing surface of the spindle (15). adjusting screw (19) clockwise until the original
distance between the end of the spindle and the
17. Place the spring assembly on the spindle (15). top of the adjusting screw is obtained. This method
of compressing the spring (18) will approximately
18. Place a new bonnet gasket (12) in the base
reestablish the original set pressure. The valve
(1) before installing the bonnet (11). Uniformly
must still be reset for the required pressure.
tighten the stud nuts (14) using the appropriate
bolt tightening pattern (see Figure 33). 22. Restore the adjusting ring (3) to its original position,
Determine the required torque for the subject with reference to the disc holder (8), as recorded.
valve (see Tables 10a or 10b). Determine the
torque values for each round of the pattern (see 23. Fit the adjusting ring pin (4) with a new adjusting
Table 11). The last round ensures that all stud ring pin gasket (5).
nuts are at the required torque. 24. Install the adjusting ring pin (4) in the valve
19. With the adjusting screw locknut (20) assembled assembly in the original position. If the original
near the top of the adjusting screw (19), apply position is not known, verify the number of notches
a small quantity of lubricant to the spherical end on the adjusting ring (3) and refer to Tables 12, 13
and threads of the adjusting screw. or 14, depending on the valve serial number or trim.
Set the ring position according to the applicable set
20. Thread the adjusting screw (19) into the bonnet pressure and orifi ce size.
(11) until it contacts the spring washer (17).
The valve is now ready for setting and testing.
Table 10a - Bonnet Nut Torque in ft-lbs +10% - 0%

1905 1910 1912 1914 1916 1918 1920 1921 1922 1923 1924 1926 1928
1906
D-1 55 55 55 60 60 120 55 ** 55 ** 75 60 115
D-2 55 55 60 60 60 120 55 ** 55 ** 60 60 115
E-1 55 55 55 60 60 120 55 ** 55 ** 60 60 115
E-2 55 55 60 60 60 120 55 ** 55 ** 60 60 115
F 55 55 60 70 70 115 55 ** 55 ** 70 70 115
G 55 55 60 70 70 75 55 ** 60 ** 70 70 75
H 90 60 75 65 65 ** 60 ** 60 ** 75 85 **
J 60 75 100 100 100 ** 75 ** 75 ** 100 100 **
K 65 60 60 135 145 ** 60 ** 60 ** 60 140 **
L 75 90 90 140 140 ** 90 ** 90 ** 140 140 **
M 95 110 95 95 ** ** 90 ** 95 ** 95 ** **
N 105 130 85 85 ** ** 130 ** 85 ** 85 ** **
P 120 145 125 125 ** ** 145 ** ** 125 125 ** **
Q 105 125 150 ** ** ** 105 ** 150 ** ** ** **
R 115 115 135 ** ** ** 115 ** 135 ** ** ** **
T 95 ** ** ** ** ** ** ** ** ** ** ** **
-2T ** 125 ** ** ** ** ** 125 ** ** ** ** **
T-4 95 95 95 ** ** ** 125 ** 125 ** ** ** **
U 95 95 95 ** ** ** 125 ** 125 ** ** ** **
V 130 130 ** ** ** ** 130 ** ** ** ** ** **
W 130 130 ** ** ** ** 130 ** ** ** ** ** **
** Valves have not been built in this confi guration.

Page
Table 10b - Bonnet Nut Torque in newton-m, +10% - 0%

1905 1910 1912 1914 1916 1918 1920 1921 1922 1923 1924 1926 1928
1906
D-1 75 75 75 82 82 163 75 ** 75 ** 102 82 156
D-2 75 75 82 82 82 163 75 ** 75 ** 82 82 156
E-1 75 75 75 82 82 163 75 ** 75 ** 82 82 156
E-2 75 75 82 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 ** 82 190 **
L 102 123 123 190 190 ** 123 ** 123 ** 190 190 **
M 129 150 129 129 ** ** 123 ** 129 ** 129 ** **
N 143 177 116 116 ** ** 177 ** 116 ** 116 ** **
P 163 197 170 170 ** ** 197 ** ** 170 170 ** **
Q 143 170 204 ** ** ** 143 ** 204 ** ** ** **
R 156 156 184 ** ** ** 156 ** 184 ** ** ** **
T 129 ** ** ** ** ** ** ** ** ** ** ** **
-2T ** 170 ** ** ** ** ** 170 ** ** ** ** **
T-4 129 129 129 ** ** ** 170 ** 170 ** ** ** **
U 129 129 129 ** ** ** 170 ** 170 ** ** ** **
V 177 177 ** ** ** ** 177 ** ** ** ** ** **
W 177 177 ** ** ** ** 177 ** ** ** ** ** **
** Valves have not been built in this confi guration.
1
Table 11 - Torque Required for
3 1 Each Round of Pattern
3 6
4 6
Holes Holes Round Percentage of
5 4
2 4 Required Torque
2
1 Wrench Tight
5 1 5 1 2 25
9 7
3
8 8 3 12 11 3 60
Holes Holes 4 4 100
7 4 12
8 10 5 100
2 6 2 6
13 5 1 7
17 15
9 20
3 20 12
11 Holes 4
19 10
16 18
8 2 6 14
Figure 33 - Bolt Tightening Patterns

Page
Table 12 - Ring Settings for Valves with Table 13 - Ring Settings for Valves with
Serial Number before TK-68738* Serial Numbers after TK-68738*
(Steam, Air or Gas Trim) (Steam, Air or Gas Trim)
Set Set Set Set
No. of Pressure Pressure No. of Pressure Pressure
Notches 100 psig Above Notches 100 psig Above
on Adj. (6.90 barg) 100 psig on Adj. (6.90 barg) 100 psig
Orifice Ring & Below (6.90 barg) Orifice Ring & Below (6.90 barg)
D-1 16 1 Notch 4 Notches D-1 16 1 Notch 4 Notches
D-2 16 1 Notch 4 Notches D-2 16 1 Notch 4 Notches
24 2 Notches 6 Notches 24 2 Notches 6 Notches
E-1 16 1 Notch 4 Notches E-1 16 1 Notch 4 Notches
E-2 16 1 Notch 4 Notches E-2 16 1 Notch 4 Notches
F 16 1 Notch 4 Notches F 16 1 Notch 4 Notches
G 18 1 Notch 4 Notches G 18 1 Notch 4 Notches
H 24 1 Notch 5 Notches H 24 1 Notch 5 Notches
J 24 1 Notch 5 Notches J 24 1 Notch 5 Notches
K 24 6 Notches 14 Notches K 24 2 Notches 5 Notches
L 24 6 Notches 18 Notches L 24 2 Notches 6 Notches
M 24 7 Notches 20 Notches M 24 2 Notches 7 Notches
N 24 7 Notches 20 Notches N 24 3 Notches 8 Notches
P 24 8 Notches 24 Notches P 24 3 Notches 9 Notches
Q 28 10 Notches 28 Notches Q 28 5 Notches 15 Notches
R 32 28 Notches 36 Notches R 32 7 Notches 20 Notches
T 24 30 Notches 38 Notches T 24 6 Notches 19 Notches
U n/a n/a n/a U 24 6 Notches 19 Notches
V n/a n/a n/a V 24 10 Notches 30 Notches
W n/a n/a n/a W 24 10 Notches 30 Notches
* Valves’ serial numbers are alphabetically and * Valves’ serial numbers are alphabetically and
numerically chronological. numerically chronological.

Page 0
ATTENTION!
Table 14 - Liquid Trim Ring Settings
If the valve has an O-ring seat seal, tighten
Old - LS New - LA and lock the adjusting screw (19) before fi nal
Ring Ring setting of the adjusting ring (3).
Orifice Position Orifice Position
D 10 D 5
E 10 E 5 ATTENTION!
F 10 F 5
Ensure the adjusting ring pin (4) enters the
G 14 G 5
notch in the adjusting ring (3) but does not
H 20 H 5 bind the adjusting ring. If binding occurs,
J 20 J 5 cut the adjusting ring pin until adjusting ring
K 24 K 5 moves freely from side-to-side within the
L 24 L 5 notch.
M 24 M 5
N 24 N 5
P 36 P 5
Q 42 Q 5
R 48 R 5
T 36 T 5
U n/a U 5
V n/a V 5
W n/a W 5
! DANGER
Setting and Testing
General Information
Before putting the reconditioned valve in service, it must be set to open at the
required set pressure as shown on the nameplate. Although the valve can be set
on the service installation, it is more convenient to set the valve and check seat
Decontaminate or tightness on a test stand. Any spring replacement shall be in accordance with current
clean, if necessary, Dresser guidelines.
before pre-testing or
disassembly. Safety
and environmental Test Equipment
precautions must be
taken for the
The test stand used for testing SRVs normally consists of a pressure source supply
decontamination or line with a throttle valve and receiver that have the following features:
cleaning method
• Outlet for attaching the valve to be tested
used.
• Pressure gauge with a shut-off valve
• Drain line with a shut-off valve
! DANGER
• Adequate receiver volume for the valve to be tested and to achieve proper
operation
Test Media
For best results, valves shall be tested by type as follows:
Do not stand or
place hand in front • Steam valves are tested on saturated steam.
of valve discharge
flange if valve is • Air or gas valves are tested on air or gas at ambient temperature.
under pressure.
• Liquid valves are tested on water at ambient temperature.

Page 1
Setting the Valve temperature causes the set pressure to decrease.

The decrease in set pressure is due to thermal
Set the valve to open at the set pressure as shown expansion of the seating area and spring relaxation.
on the nameplate. If a cold differential set pressure Therefore, it is important to compensate for the
is indicated on the nameplate, set the valve to open difference between production test temperature and
at that pressure. (The cold differential set pressure service temperature. The service temperature is
is the set pressure corrected to compensate for the normal operating temperature of the SRV. If the
backpressure and/or operating temperature.) operating temperature is unavailable, do not correct
A new cold differential set pressure may need to the SRV set pressure.
be determined if changes are to be made to the
set pressure or backpressure or if the service Table 15 lists the set pressure multipliers to be used
temperature changes. when computing the cold differential set (CDS)
pressure for valves being set on an air or water test
stand at ambient temperatures.
Set Pressure Compensation
Valves to be used in saturated steam service are
Cold Differential Set Pressure for tested on saturated steam. Therefore, no CDS is
required. However, valves in superheated steam
Temperature Compensation service are tested on saturated steam and require
During production testing, the SRV is often a CDS.
tested at temperatures that are different from
Table 16 lists the multiplier to be used based on
the temperatures the SRV will be exposed to in
temperature above the saturated temperature
service. Increasing the temperature from ambient
(degrees of superheat).
Table 15 - Set Pressure Multipliers for Cold Differential

Set Pressure at Ambient Temperature
Operating Multiplier Operating Multiplier
Temp. F Temp. C Temp. F Temp. C
250 120 1.003 900 498 1.044
300 149 1.006 950 510 1.047
350 177 1.009 1000 538 1.050
400 204 1.013 1050 565 1.053
450 248 1.016 1100 593 1.056
500 260 1.019 1150 621 1.059
550 288 1.022 1200 649 1.063
600 316 1.025 1250 676 1.066
650 343 1.028 1300 704 1.069
700 371 1.031 1350 732 1.072
750 415 1.034 1400 760 1.075
800 427 1.038 1450 788 1.078
850 454 1.041 1500 815 1.081

Page
Set pressure 2500 psig, temperature 500º F,

Table 16 - Set Pressure Multipliers for constant backpressure 150 psig
Cold Differential Set Pressure Set Pressure .......................................2500 psig
Minus Constant Back Pressure .......... -150 psig
Superheat Temperature Differential Pressure ...........................2350 psig
Multiplier (see Table 15) ................. X1.019
Degrees of Superheat, Multiplier
Cold Differential Set Pressure ............2395 psig
Temp. above Sat.
Fahrenheit Celsius Set pressure 2500 psig, temperature 100º F,
100 55.6 1.006 constant backpressure 150 psig
200 111.1 1.013 Set Pressure .......................................2500 psig
Minus Constant Back Pressure .......... -150 psig
300 166.7 1.019 Cold Differential Set Pressure ............2350 psig
400 222.2 1.025
500 277.8 1.031 Set pressure 400 psig on superheated steam,
temperature 650º F, backpressure atmospheric
600 333.3 1.038
Operating Temperature....................... 650º F
700 388.9 1.044 Minus Temperature of
800 444.4 1.050 Saturated Steam at 400 psig ......... -448º F
Degrees of Superheat ....................... 202º F
Set Pressure .........................................400 psig
Cold Differential Set Pressure for Back
Multiplier (see Table 16) ................. X1.013
Pressure Compensation Cold Differential Set Pressure ..............405 psig
ATTENTION! Setting the Pressure
Install a bellows to allow the set pressure
to remain constant for valves with variable ATTENTION!
superimposed backpressure. • Ensure valves for steam service are set
using saturated steam.
When a conventional 1900™ Series SRV operates • Ensure valves for gaseous service are set
with a constant backpressure, the cold differential using air or nitrogen.
set (CDS) pressure is the set pressure minus the • Ensure valves for liquid service are set
constant backpressure. using water.
When a 1900TM-30 D-1 or 1900TM-30 E-1 non-

ATTENTION!
balanced bellows valve is used with constant
backpressure, the set pressure must be The ASME Boiler and Pressure Vessel
compensated. This valve design cannot be used for Code Section VIII set pressure tolerance is
variable backpressure. If the valve’s set pressure or +/- 2 psi (.14 bar) for set pressures less than
backpressure changes, call Dresser Field Service 70 psi (4.8 bar) and +/- 3% for pressures
at (318) 640-6055 for the CDS of the valve. equal to or greater than 70 psi (4.8 bar).
When Consolidated® Type 1900TM-30 D-2, 1900TM-
1. Before mounting the valve on the test stand,
30 E-2, and 1900TM-30 F through W balanced
remove all dirt, sediment, or scale from the
bellows valves are used with constant or variable
test tank nozzle and the inlet port of the valve.
backpressure, no compensation to the valve’s set
Ensure the test gauge has recently been
pressure is required due to backpressure.
calibrated on a deadweight gauge tester.
Sample Calculations for 1900™ Series 2. Mount the valve on the test stand.
Consolidated® Safety Relief Valve ATTENTION!
Set pressure 2500 psig, temperature 500º F, Hold the spindle (15) and ensure it is
backpressure atmospheric. centrally located within the adjusting screw
Set Pressure .......................................2500 psig (19) when turning the adjusting screw. Hard-
Multiplier (see Table 15) ................. X1.019 rubbing of the spindle against the side of the
Cold Differential Set Pressure ............2548 psig adjusting screw can cause poor valve action.

Page
3. If the adjusting screw (19) of the reconditioned ATTENTION!

valve has been turned down to its original
position, slowly bring the pressure up in the Do not use soap or household detergent as
test tank to the CDS pressure. If the valve a leak detector as it may bridge small leaks.
opens before the desired pressure is reached,
additional compression is required on the spring 1. Cut the end of a piece of 5/16˝ OD tubing with
(18), as follows: 0.035˝ wall so that it is square and smooth.
• Hold the spindle (15) to prevent rotation and 2. Insert the tubing so that it is perpendicular to
turn the adjusting screw clockwise. and 1/2˝ below the surface of the water.
• If the valve does not open at the desired 3. Use the tubing to take a leakage measurement.
pressure, maintain the required pressure
in the test tank and slowly release the
compression on the spring by turning the
adjusting screw counterclockwise until the
valve opens.
5/16" OD x 0.035"
• Continue adjustment until the valve opens at Tubing
the desired pressure. 1/2 " of Water
ATTENTION!
On compressible fl uids, set pressure is defi ned
Cover Plate
as the pressure where the valve pops open,
NOT as the pressure when it begins to simmer. Test Receiver
Figure 34 - Typical Test Arrangement

ATTENTION!
On liquid valves, set pressure is indicated
by the fi rst continuous fl ow of water from the Seat Tightness Testing: Metal-to-Metal Seats
valve outlet. 1. With the valve mounted vertically (see Figure 34),
determine the leakage rate, in bubbles per minute,
4. After the required set pressure is obtained, with pressure at the SRV inlet held at 90% of
tighten the adjusting screw locknut (20) and the set pressure immediately after popping. For
repeat the test. Obtain at least two repeat valves set at 50 psig (3.45 barg) or below, hold
openings at the same pressure to ensure the pressure at 5 psig (.34 barg) below set point.
valve is set accurately. The test pressure shall be applied for a minimum
of 1 minute for valves on inlet sizes through
2˝; 2 minutes for sizes 2-1/2˝, 3˝ and 4˝, and
Seat Tightness Testing 5 minutes for the 6˝, 8˝, 10˝ and 12˝ sizes. For
metal-to-metal valves designated for gaseous
General Information service, the leakage rate shall not exceed
maximum bubbles per minute (see Table 17).
Set up a typical test arrangement for determining
seat tightness for SRVs on air or gas service 2. Check that there is no visible leakage for valves
(in accordance with ANSI B147.1/API RP 527) designated for steam service (and tested on
(see Figure 34). steam) or for liquid service (and tested on water).
Table 17 - Allowable Leakage Rate

Type of Valve Manufacturer’s Maximum Approximate Leakage Rate
Orifice Size (Bubbles per (Standard Cubic Feet per 24 Hour)
Minute) Maximum
Conventional E and smaller 40 0.60
F and larger 20 0.30
Balanced E and smaller 50 0.60
Bellows F and larger 30 0.45

Page
Seat Tightness Testing for O-Ring Seat Seal Valve

The tightness standard for O-ring seat seal valves shall be no leakage at or below the
test pressures listed (see Table 18).
Table 18 - Seat Tightness Testing

for O-Ring Seat Seals
Set Pressure Test Pressure
(psig) (barg) (% of Set Pressure)
5 to 30 0.34 to 2.07 90
31 to 50 2.14 to 3.45 92
51 to 100 3.52 to 6.90 94
100 and above 6.90 and above 95
Recommended Backpressure Testing for Joint Leakage

If the valve is to be used in a closed discharge system, backpressure-test the valve
after it has been set for the correct opening pressure. Conduct testing by installing
the screwed cap (21) with a cap gasket (27) and applying air or nitrogen to the base
drain connection or to the valve outlet. Seal all other openings.
Test pressure should be the greater of 30 psig (2 barg) or the actual valve
backpressure. Hold air or nitrogen pressure for 3 minutes before applying leak
detector solution to all connections (joints).
On bellows valves, hand-tighten a clean pipe plug in the bonnet vent connection in
order to obtain the smallest possible leak path. Remove this plug after the test.
Apply liquid leak detector to the following SRV components and examine for leakage
during backpressure testing:
• Nozzle/base joint.
• Adjusting ring pin seal.
• Base/bonnet joint.
• Bonnet/cap joint.
• “Tight” bonnet vent plug, if conventional valve.
• “Loose” bonnet vent plug, if bellows valve.
If a leak is discovered, attempt repair of the leaking joint(s) by tightening it while the
! DANGER SRV is still on the stand. If the leak continues, tear down the leaking joint(s) and
inspect both the metal surface(s) and gasket(s). If the valve internals have been
disturbed, it is necessary to retest in accordance with the instructions within this
manual. Otherwise, repeat the backpressure tests outlined above.
Blowdown Adjustment
Gag the safety Blowdown adjustments are made by means of the adjusting ring (3) on 1900™
valve during ring Series SRVs.
adjustments to
avoid possible If longer or shorter blowdown is required, it can be obtained as follows:
severe personal
injury or death. • To increase the blowdown (lower reseating pressure), raise the adjusting ring (3)
by moving the notches from left to right past the ring pin hole.

Page 45
• To decrease the blowdown (raise reseating

pressure), lower the adjusting ring by moving the Manual Popping
notches from right to left past the adjusting ring
pin hole. of the Valve
ATTENTION! Consolidated® SRVs are furnished, when so
Unless the test stand capacity is equal to ordered, with packed or plain lifting levers for hand-
or greater than that of the valve, return popping or with an air-operated lifting device for
the adjusting ring (3) to the recommended remote control (see Figures 36 through 40).
position and do not attempt to set blowdown When the valve is to be opened by hand, ensure
(see Tables 12 through 14). the pressure at the valve inlet is at least 75% of the
valve’s set pressure. Under flowing conditions, the
ATTENTION! valve must be fully lifted from its seat so that dirt,
sediment, and scale do not become trapped on the
The valve will not achieve rated relieving seating surfaces. When allowing the valve to close
capacity if the adjusting ring (3) is positioned under flowing conditions, completely release the
too low. lever from maximum lift to snap the valve back on
its seat.
Since the deadweight of a Packed Lever, L-Type
Hydrostatic Testing Packed Lever, R-Type Packed Lever or and
Air-Operated Packed Lever has a tendency to
and Gagging lift the valve, the lever should be supported or
counterweighted so that the lifting fork does not
When hydrostatic tests are required after contact the release nut (see Figures 37 through 40)
installation of an SRV, remove the SRV and replace
it with a blind flange. If the hydrostatic test pressure The air-operated lifting device is designed to fully
will not be greater than the operating pressure of open the valve with 75% of set pressure under the
the equipment, a test gag may be used. Very little valve disc in compliance with ASME Section VIII.
force, i.e. hand-tight pressure, on the test gag is For certain applications, the air operator may be
sufficient to hold hydrostatic pressures. Too much designed to fully open the valve with no pressure
force applied to the gag may bend the spindle (15) at the valve inlet. An air-operated device can be
and damage the seat. After a hydrostatic test, the operated from a remote point and can be used as
gag must be removed and replaced by the sealing a “drop out” valve. (A typical design is shown in
plug furnished for this purpose (see Figure 35). Figure 40, and can be purchased from Dresser,
(Test gags for Consolidated® SRVs can be Inc.)
furnished for all types of caps and lifting gears.)
Release Nut Plain Cap
Gag Release Locknut
Sealing Plug Adjusting

and Gasket Screw Top Lever
Cap Locknut
Spindle
Cap Set Screw
Adjusting Adjusting Drop Lever

Adjusting Screw
Screw Screw
Locknut
Spindle
Figure 36 - Plain Lever

Figure 35 - Hydrostatic Testing

Page 46
Packed Cap Release Locknut Conversion of 1900™

Release Nut Lever
Series Flanged SRVs
Lever Shaft
Packing Adjusting
Screw Locknut
General Information
Lifting Fork Cap Bolt Consolidated® Type 1900TM Flanged SRVs can
be readily converted from conventional to bellows
Adjusting
Screw style, or vice versa, in the customer’s repair shops.
Spindle However, the Type 1901 and 1902 valves were
constructed in the conventional type only. Table 19
Figure 37 - Packed Lever shows the parts necessary for the typical conversion.
Packed Cap Release Locknut

Conversion from
Packing Conventional to Bellows Type
Lever Shaft Pipe
ATTENTION!
Lever Remove the bonnet plug (41) from the
Lifting Fork bellows valves (see Figure 2) and vent the
Cap Bolt Weight bonnet (11) to a safe area.
Adjusting Spindle
Screw Locknut
Convert from a conventional to a bellows type valve
Adjusting Screw
as follows:
Figure 38 - L-Type Packed Lever 1. Remove the eductor tube (40) from the base (1)
by selecting a drill bit approximately 1/64” smaller
in diameter than the outside diameter of the
Packed Cap
Extension eductor tube. Drill into the bore of the eductor
Release Locknut
Arm
Release Nut
tube where the tubing is attached to the base.
Lever Pipe This will reduce the tube wall thickness to the
extent that it can easily be collapsed for removal.
The bellows flange will cover the hole in the
Lever Shaft
guide surface which will remain after the tube is
Packing
removed.
Lifting Fork Weight
Cap Bolt Adjusting Screw 2. Machine the existing lower spring washer (17)
Adjusting (see Figure 41 and Table 20).
Screw Locknut Spindle
Figure 39 - R-Type Packed Lever B

E
F
Air Cylinder
Mounting Plate Cap
Mounting Stud Release

Locknut
Stud Nut D
Release Nut C
Pin Spindle 45°
Lever
Clevis
Lever Shaft
Lever Shaft Collar Cap Bolt Figure 41 - Lower Spring Washer
Collar Retaining Ring Cap Gasket
Packing Nut
Packing
Lever Nut
Lifting Fork
Figure 40 - Air-Operated Packed Lever

Page
Table 19 - Conversion Parts: Conventional and Bellows Style Valves

Valve Orifice New Parts to Convert From
Size Conventional to Bellows Valve Bellows to Conventional Valve
1. Bellows assembly - Standard Material, 1. Eductor tube for conventional valve.
316L Stainless Steel. 2. Set of gaskets for conventional valve.
2. Set of gaskets for bellows valve. 3. Guide for conventional valve.
3. Guide for bellows valve. 4. Disc holder for conventional valve.
4. Disc holder for bellows valve. 5. Spindle for conventional valve
5. Spindle for bellows valve (F, G and H only).
(F, G and H only). 6. Spindle retainer for conventional valve.
D, E, F, G, H 6. Spindle retainer for bellows valve. 7. Base studs for conventional valve
7. Base studs for bellows valve (D, E, F and G only).
(D, E, F and G only). 8. New lower spring washer for
8. Machine existing lower spring washer conventional valve
(F, G and H orifi ces only). (F, G and H orifi ces only).
Upper spring washer, no change. Upper spring washer, no change.
9. Drill 23/32˝ dia. on bonnet boss and tap 9. Bonnet vent plugged (if desired).
1/2 N.P.T. (as required)*
K, L, M, Q, R, 316L Stainless Steel. 2. Set of gaskets for conventional valve.
T, U 2. Set of gaskets for bellows valve. 3. Bonnet vent plugged (if desired).
**Also J, N, P 3. Drill 23/32˝ dia. on bonnet boss and tap 4. Studs (1905 K and L, 1906 K and L
manufactured 1/2 N.P.T. (as required)* only).
after 1981 4. Studs (1905-30 K and L, 1906-30 K
and L only).
316L Stainless Steel. 2. Set of gaskets for conventional valve.
2. Set of gaskets for bellows valve. 3. Bonnet vent plugged (if desired).
J, N, P
3. Guide for bellows valve. 4. Drill 7/16˝ dia. through guide fl ange
**Manufactured 4. Disc holder for bellows valve. 1-13/16˝ from guide bore centerline
before (J orifi ce only).
5. Drill 23/32˝ dia. on bonnet boss and tap
1982
1/2 N.P.T. (as required)* 5. Studs (1905 N and P, 1906 N and P
6. Studs (1905-30 N and P, 1906-30 N only).
and P only).
1. Bellows assembly. 1. Set of gaskets for conventional valve.
2. Set of gaskets for bellows valve. 2. Bonnet vent plug (if desired).
3. Disc holder for bellows valve.
V, W
4. Guide for bellows valve.
5. Lift restricting ring.
6. Studs.
* Valves manufactured after 1980 are furnished with bonnet vent machined.
** J, N, P orifi ce valves manufactured after 1981 are furnished with threaded disc holder and reduced guide
bore for balanced bellows conversion.

Page
Machine to Table 20 - Machining Conventional to

Fit Spring
E Bellows Type Lower Spring Washer
F
Valve Type B C
1905F 1906F
A
1910F 1912F
1920F 1922F 11/16˝ 1˝
D
1905G 1906G 17.5 mm 25.4 mm
1910G 1912G
Figure 42 - Lower Spring Washer 1920G 1922G
F, G, and H Valves 1914F 1916G
1924F 1926F
7/8˝ 1-1/4˝
1914G 1916G
Conversion from Bellows to 22.2 mm 31.8 mm
1918G 1924G
1926G 1928G
Conventional Type
1˝ 1-7/16˝
Convert from a bellows to a conventional type valve 1918F 1928F
25.4 mm 36.5 mm
as follows:
1905H 1906H
11/16˝ 1-1/8˝
1. Secure the eductor tube (40) in the base (1) by 1910H 1911H
17.5 mm 28.6 mm
expanding or swaging into the hole provided. 1920H 1922H
The upper end of the eductor tube should 7/8˝ 1-5/16˝
project above the guide surface of the base 1912H 1924H
22.2 mm 33.3 mm
approximately 1/8˝ and the lower end should 1914H 1916H 1˝ 1-1/2˝
point directly and squarely toward the valve 1926H 25.4 mm 38.1 mm
outlet. When the valve is assembled, the hole
at the outer edge of the guide fl ange must fi t When indicated at surfaces D and E
loosely around the projection of the eductor (see Figure 41), run out at surface F is not to
tube. exceed .005˝ (.127 mm) full indicator reading.
2. For F, G and H orifi ce valves only, machine the

new lower spring washer (17) (see Figure 42
and Table 21). Table 21 - Machining Bellows Type to
Conventional Lower Spring Washer
ATTENTION!
For all 1900™ Series SRVs, dimension A Valve Type A
may not be less than specifi ed in Table 21. 1905-30F 1906-30F 1910-30F
1920-30F 1922-30F 1905-30G 1/4˝
1906-30G 1910-30G 1920-30G 6.35 mm
1905-30H 1906-30H
1912-30F 1922-30G
5/16˝
1910-30H 1911-30H 1920-30H
7.94 mm
1922-30H
1914-30F 1916-30F 1924-30F
1926-30F 1914-30G 1916-30G 3/8˝
1918-30G 1924-30G 1926-30G 9.52 mm
1928-30G 1912-30H 1924-30H
7/16˝
1918-30F 1928-30F
11.11 mm
1/2˝
1914-30H 1916-30H 1926-30H
12.7 mm
When indicated at surfaces D and E
(see Figure 42), run out at surface F is not to
exceed .005˝ (.127 mm) full indicator reading.

Page
Troubleshooting 1900™ Series SRVs

Table 22 - Troubleshooting Seat Leakage, Simmer, and Chatter
Malfunction Cause Solution
Damaged seats. Rework seats or replace part.
Improper installation. Inspect installation, i.e. piping.
Operating pressure too close to set pressure. Increase differential.
Seat
Leakage Excessive system vibration. Recheck application.
Misalignment of valve Ensure valve is installed vertically.
components. Ensure valve has been properly assembled.
Debris trapped on seats. Pop valve to clean seats. Rework seats.
Damaged seats. Rework seats or replace part.
Wide nozzle seat. Rework seat.
Simmer
Improper adjusting ring setting. Check ring setting.
Misalignment/binding. Inspect valve and installation.
Improper installation or Check for piping restrictions.
valve sizing. Check required capacity.
Chatter
Built-up back pressure. Check outlet piping.
Improper ring setting. Check ring setting.
Maintenance Tools and Supplies

Table 23 - Nozzle Bore Diameters
*Original Nozzle *New Nozzle
Nozzle Bore Diameter Nozzle Nozzle Bore Diameter Nozzle **Nozzle
Lap Lap Lap ***Ring
Orifice (in.) (mm) Part No. (in.) (mm) Part No. Handle Lap
D .393 - .398 9.98 - 10.11 0543001 .404 - .409 (*4)
10.26 - 10.39(*4) 4451501 0544603 1672805
E .524 - .529 13.31 - 13.44 0543002 .539 - .544(*5) 13.69 - 13.82(*5) 4451502 0544601 1672805
F .650 - .655 16.51 - 16.64 0543003 .674 - .679 (*6)
17.12 - 17.25(*6) 4451503 0544601 1672805
G .835 - .840 21.21 - 21.34 0543004 .863 - .868 21.92 - 22.05 4451504 0544601 1672805
H 1.045 - 1.050 26.54 - 26.67 0543005 1.078 - 1.083 27.38 - 27.51 4451505 0544601 1672805
J 1.335 - 1.340 33.91 - 34.04 0543006 1.380 - 1.385 35.05 - 35.18 4451506 0544601 1672805
K 1.595 - 1.600 40.51 - 40.64 0543007 1.650 - 1.655 41.91 - 42.04 4451507 0544601 1672807
L 1.985 - 1.990 50.42 - 50.55 0543101 2.055 - 2.060 52.20 - 52.32 4451601 0544601 1672807
M 2.234 - 2.239 56.74 - 56.87 0543102 2.309 - 2.314 58.65 - 58.78 4451602 0544601 1672809
N 2.445 - 2.450 62.10 - 62.23 0543103 2.535 - 2.540 64.39 - 64.51 4451603 0544601 1672809
P 2.965 - 2.970 75.31 - 75.44 0543104 3.073 - 3.078 78.05 - 78.18 4451604 0544602 1672810
Q 3.900 - 3.905 99.06 - 99.19 0543105 4.045 - 4.050 102.74 - 102.87 4451605 0544602 1672812
R 4.623 - 4.628 117.42 - 117.55 0543106 4.867 - 4.872 123.62 - 123.75 4451606 0544602 1672812
T 6.000 - 6.006 152.40 - 152.55 0543107 6.037 - 6.043 153.34 - 153.49 4451607 0544602 1672813
T-4 n/a n/a n/a 6.202 - 6.208 157.53 - 157.68 4451608 0544602 1672814
U n/a n/a n/a 6.685 - 6.691 169.80 - 169.95 None None 1672814
V n/a n/a n/a 8.000 - 8.005 203.20 - 203.33 None None 6267201
W n/a n/a n/a 10.029 - 10.034 254.74 - 254.86 None None 4875201
* After August 1978, all 1900TM SRV Nozzles manufactured have increased bore diameter. The above chart shows how each orifi ce was affected.
Nozzles - original vs. new - are interchangeable, but nozzle laps are not. On the outer diameter (OD) of the new nozzles, the letter “C” is stamped.
If this stamp becomes obliterated, the nozzle bore diameter must be measured to select the correct nozzle lap from above chart (see Table 23).
** Nozzle lap handles are interchangeable between original and new nozzle laps.
*** Ring laps - One set of three (3) ring laps is recommended for each orifi ce to assure ample fl at laps are available at all times.
(*4) Use for all D-1 designs.
(*5) Use for all E-1 designs.
(*6) Also used for all D-2 and E-2 designs.

Page 0
Lapping Tools Lifting Tools - Lifting tools are used for the removal
of the upper internal parts of larger valves (see
The following tools are required for proper Table 26).
maintenance of Consolidated® Safety Relief seats,
and may be purchased from Dresser, Inc. Spanner Wrench - Spanner wrench is used for
the removal of the bellows from the disc holder (8)
Nozzle Lap - The nozzle lap is used for lapping the (see Table 27).
nozzle seat and has one fl at side, and one side
with a 5º angle. This lap guides in the bore of the
nozzle; therefore, a different size lap is required for Table 26 - Lifting Tool Types
each valve orifi ce.
Orifice Part No.
Ring Lap - The ring lap is used for lapping the disc
seat and fi nish lapping the nozzle seat. M, N 4464602
Lapping Plate - The lapping plate is used for

reconditioning the ring lap. It may also be used
for lapping the disc (6). One 11˝ diameter plate
is required for the entire line of valves (Part No. Table 27 - Spanner Wrench Types
0439004). Pin
Lapping Compound - Lapping compound is used Spanner
as a cutting medium when lapping the valve seats Valve Wrench
(see Table 24). Orifice Description of Wrench No.
D, E, F 3/4˝ Radius - 7/32˝ Pin 4451801
Drift Pins - Two drift pins are required for the G 3/4˝ Radius - 7/32˝ Pin 4451801
removal of the disc (6) from the disc holder (8) H 7/8˝ Radius - 15/64˝ Pin 4451802
(see Figure 43 and Table 25).
J 1-1/8˝ Radius - 17/64˝ Pin 4451803
K 1-1/4˝ Radius - 9/32˝ Pin 4451804
A L 1-3/8˝ Radius - 19/64˝ Pin 4451805
M 1-5/8˝ Radius - 21/64˝ Pin 4451806
N 1-7/8˝ Radius - 23/64˝ Pin 4451807
P 1-7/8˝ Radius - 23/64˝ Pin 4451807
45° Q 2-1/2˝ Radius - 7/16˝ Pin 4451808
B Diameter
R 3˝ Radius - 1/2˝ Pin 4451809
T 3-3/4˝ Radius - 1/2˝ Pin 4451810
Figure 43 - Drift Pins Specification U 3-3/4˝ Radius - 1/2˝ Pin 4451810
Table 24 - Lapping Compound Types

Lapping Size
Brand Grade Grit Function Container Part No.
Clover 1A 320 General 4 oz 199-3
Clover 3A 500 Finishing 4 oz 199-4
Kwik-Ak-Shun ---- 1000 Polishing 1 lb 199-11
2 oz 199-12
Table 25 - Drift Pin Types

Orifice A (in.) A (mm) B (in.) B (mm) Part No.
D,E,F,G,H,J,K 1-3/4 44.5 7/32 55.5 0430401
L,M,N,P 2-1/2 63.5 3/8 95.3 0430402
Q,R 3 76.2 5/8 158.7 0430403
T, U 3-1/2 88.9 7/8 222.2 0430404

Page 51
Replacement Parts Identification and Ordering

Planning Essentials
When ordering service parts, furnish the following
information to ensure receipt of the correct
Basic Guidelines replacement parts:
Use the following guidelines as reference for 1. Identify valve by the following nameplate data:
developing a replacement parts plan: • Size
• Type
1. Classify the total number of valves in service by • Temperature Class
size, type, and temperature class. • Serial Number
2. Classify parts inventory by the tendency to ○ Example 1: 1-1/2˝ 1910Fc
require replacement. S/N TD-94578
• Class I - Most frequently replaced 2. Specify parts required by:
• Part Name (see Figures 1 through 6)
• Class II - Less frequently replaced but critical
• Part Number (if known)
in an emergency
• Quantity
3. Parts for the valve types covered by this manual
In addition, the serial number is stamped on the top
are classified on Tables 28 and 29. “Qty. Parts”
edge of the outlet flange. Include the one or two
is the number of parts or sets recommended to
letters preceding the figures in the serial number
achieve a desired need probability as it relates
(see Figures 44 through 47).
to the total number of valves in service by size
and type. For example, a “Qty. Parts of 1” for Contact Parts Marketing: (318) 640-6044.
“Valves in Service of 5” means that one part
should be stocked for every five valves of the
same type and size in service.
4. When ordering replacement parts, state the
size, type, and serial number of the valve
for which parts are required using correct
nomenclature (see Figures 1 through 6).
5. Predicted availability indicates the percentage
chance the user plant will have the right parts
to make a proper repair (i.e., if Class I parts
are stocked at the owner’s facility, the parts
needed to repair the valve in question will be
immediately available in 70% of all instances). Figure 44 - Typical Valve Nameplate
Replacement Parts List

Consult the Recommended Spare Parts list (see
Tables 28 and 29) to define the parts to be included
in the inventory plan. Select the desired parts and
determine those required for proper maintenance of
the valve population in the plant.
Figure 45 - Typical Valve Nameplate

Page 52
Genuine Dresser Parts

Each time replacement parts are needed, keep
these points in mind:
• Dresser, Inc. designed the parts.
Figure 46 - Typical Valve Nameplate • Dresser, Inc. guarantees the parts.

• Consolidated® valve products have been in
service since 1879.
• Dresser, Inc. has worldwide service.
• Dresser, Inc. has fast response availability for
parts.
Figure 47 - Optional Tag Number

Nameplate
ATTENTION!
To determine if the valve contains Glide-
Aloy™ components (i.e., the disc holder (8)
and/or the guide (9)), which are identified by
the coding found on the valve nameplate,
see Optional Glide-Aloy™ Parts.
When the SRV is repaired, a metal repair

nameplate (see Figure 48), Board “VR” symbol
and stamp number, and the date of repair is
permanently attached to the valve near the original
nameplate. This repair nameplate may also contain
information regarding altered set pressures,
capacities, or blowdown, as applicable.
Figure 48 - Repair Nameplate

Page
Recommended Spare Parts for 1900™ Series SRVs

Table 28
1900 Conventional and 1900TM-30 Bellows
TM
1900 Conventional and 1900TM-30 Bellows with Liquid Trim (LS)

TM
1900TM Conventional and 1900TM-30 Bellows with Thermodisc® (TD)

Qty. Parts/ Need
C-conventional Same Valves in Probability
Class Part Name B-bellows Service Coverage
I. Disc (TD) C and B 1/1
Disc (Standard) C and B 1/3
Stocking Class I Nozzle C and B 1/10
parts at the Qty. *Limit Washer C and B 1/1
Parts column rate Bellows B 1/3
provides suffi cient Adj. Ring Pin C and B 1/3
replacements Disc and Spindle Retainers C and B 1 Set/1
for 70% of 70%
Gasket (Set)
maintenance (1) Cap Gasket C and B 1/1
requirements. (1) Bonnet Gasket C and B 1/1
(1) Guide Gasket C and B 1/1
(1) Adj. Ring Pin Gasket C and B 1/1
(1) Bellows Gasket B 1/1
II. Disc Holder C and B 1/6

Spindle C and B 1/6
Stocking Class II Guide C and B 1/6
parts, in addition to Studs, Base C and B 1 Set/6
Class I, at the Qty. Nuts, Base Stud C and B 1 Set/6
Parts column rate
85%
provides suffi cient
replacements
for 85% of
maintenance
requirements.
*For restricted lift valves only.

Dresser, Inc. has not authorized any company or any individual to manufacture replacement parts for its valve
products. When ordering replacement valve parts, please specify in your purchase order: “ALL PARTS MUST
BE DOCUMENTED AS NEW AND SOURCED FROM DRESSER, INC.”

Page
Table 29
TM TM
1900 Conventional and 1900 -30 Bellows with O-Ring Seat Seal Design (DA)
1900TM Conventional and 1900TM-30 Bellows with O-Ring Seat Seal Design
and Liquid Trim (DL)
Qty. Parts/ Need
C-conventional Same Valves in Probability
Class Part Name B-bellows Service Coverage
I. O-Ring C and B 1/1
Disc (K-U only) C and B 1/10
Stocking Class I O-Ring Retainer C and B 1/5
parts at the Qty. Retainer Lock Screw C and B 1 Set/1
Parts column rate *Limit Washer C and B 1/1
provides suffi cient Nozzle C and B 1/5
replacements Adj. Ring Pin C and B 1/1
for 70% of Gasket (Set) C and B 1 Set/1
maintenance (1) Cap Gasket C and B 1/1 70%
requirements. (1) Bonnet Gasket C and B 1/1
(1) Guide Gasket C and B 1/1
(1) Adj. Ring Pin Gasket C and B 1/1
(1) Bellows Gasket B 1/1
Bellows B 1/3
Disc Retainer (K-U only) C and B 1/1
Spindle Retainer C and B 1/1
II. Disc Holder C and B 1/6

Spindle C and B 1/6
Stocking Class II Guide C and B 1/6
parts, in addition to Studs, Base C and B 1 Set/6
Class I, at the Qty. Nuts, Base Stud C and B 1 Set/6
Parts column rate
85%
provides suffi cient
replacements
for 85% of
maintenance
requirements.
*For restricted lift valves only.

Dresser, Inc. has not authorized any company or any individual to manufacture replacement parts for its valve
products. When ordering replacement valve parts, please specify in your purchase order: “ALL PARTS MUST
BE DOCUMENTED AS NEW AND SOURCED FROM DRESSER, INC.”

Page 55
Inspection of the Valve & Installation

Manufacturer’s
• Visual evaluation of the installation for
Warranty, Field Service, compliance to codes and regulations
• Written evaluation covering compliance
Training, and Repair issues and discrepancies
Program • Expert recommendations and corrective
actions
Warranty Information Testing
*WARRANTY STATEMENT - Dresser, Inc. warrants • On-site and in-place testing using the Dresser
that its products and work will meet all applicable Consolidated® EVT™ testing device
specifications and other specific product and work • High-capacity shop testing with steam, air or
requirements (including those of performance), if water
any, and will be free from defects in material and
workmanship. • Fully trained and certified pressure relief
valve technicians
Defective and nonconforming items must be
held for Dresser’s inspection and returned to the • Base line history established
manufacturer upon request.
Repair
INCORRECT SELECTION OR MISAPPLICATION
• Audited facility with Dresser Consolidated®
OF PRODUCTS - Dresser, Inc. cannot be
inspection criteria and critical dimensions
responsible for customers’ incorrect selection or
misapplication of our products. • Fully trained and certified pressure relief
valve technicians
UNAUTHORIZED REPAIR WORK - Dresser, Inc.
has not authorized any non-Dresser-affiliated repair • Original manufacturer replacement parts
companies, contractors or individuals to perform
warranty repair service on new products or field-
repaired products of its manufacture. Therefore, Inventory Control
customers contracting such repair services from
unauthorized sources do so at their own risk. • Global access to spare parts inventories
* Refer to Dresser’s Standard Terms of Sale for complete • Parts interchangeability

details on warranty and limitation of remedy and liability.
• Obsolete and excess inventory identification
Field Service • Recommend cost effective inventories
Dresser Consolidated provides safe, reliable valve

services through our Green Tag® certified valve ValvKeep™
assemblers and repair centers. The first valve
repair network of its kind and today’s industry • Comprehensive computer-based valve
leader, our authorized Green Tag Centers have management service
successfully served the valve market for over 25
• Historical data storage and permanent record
years. Our services include:
tracking
Valve Survey
• Maintenance scheduling and planning
• Comprehensive, accurate record of all PRVs
• Repair intervals validated by maintenance
• Identification of overlooked valves and valve history of each valve
interchangeability
• Code Compliance
• Product upgrades to reduce cost and improve
• Interfaces easily with enterprise or legacy
performance
systems

Page 56
Factory Repair Facilities Self-Study Edition of

Our factories maintain a complete Consolidated ®
repair center. The Repair Department, in the 1900™ Series SRV

conjunction with the manufacturing facilities,
is equipped to perform specialized repairs and Maintenance Training
product modifications, e.g., butt-welding, bushing
replacements, code welding, and pilot replacement. Program is Available
Contact: Valve Repair Department at (318) 640- for Valve Shop
6057.
Personnel
SRV Maintenance Training
The Self-Study Program consists of a video tape
The rising costs of maintenance and repair in the
that is integrated with a participant workbook.
utility and process industries indicate the need
A participant begins with an introduction to the
for trained maintenance personnel. Dresser,
product and progresses through the various
Inc. conducts service seminars that help your
stages of disassembly, cleaning, maintenance
maintenance and engineering personnel reduce
repair, reassembly, setting, testing, installation,
these costs.
and conversions. The program can also be used
Seminars, conducted either at your site or ours, as an instructor-led course. The training package
provide participants with an introduction to the includes:
basics of preventative maintenance necessary to
• Five Participant Training Manuals
minimize downtime, reduce unplanned repairs,
and increase valve safety. While these seminars • Five Consolidated® 1900TM and 1900TM-30
do not create “instant experts,” they do provide SRV Installation, Operation, and Maintenance
the participants with hands-on experience with Manuals
Consolidated® valves. The seminar also includes
valve terminology and nomenclature, component • Integral 1900™ Series SRV video tape
inspection, troubleshooting, setting, and testing with • Coaches’ Guide to facilitate learning
emphasis on the ASME Boiler and Pressure Vessel
Code. Program kits, as well as additional training and
maintenance manuals, are available through:
For further information, contact the Product Training
Manager by fax at (318) 640-6325 or telephone at Dresser, Inc.
(318) 640-6054. Consolidated® Product Training Manager
P.O. Box 1430
Alexandria, LA 71309-1430
Telephone: (318) 640-6054
Fax: (318) 640-6325

Page 57
process is completed, visually inspect parts

Optional Glide-Aloy™ to ensure all debris is removed, and that the
components have the required finish.
Parts and the Repair
Dresser, Inc.’s experience indicates that if the
Processing of Such components have been properly cleaned, adequate
coating will remain to ensure proper operation.
Components The coating may appear lighter or missing in some
areas, but the desired results will be achieved as a
Glide-Aloy™ is a proprietary process of Dresser, result of the coating characteristics imparted to the
Inc. utilized to provide a combination of a low parent metal during the original coating process.
coefficient of friction between sliding components
ATTENTION!
and to protect the surfaces of the components
to which the process has been applied. A Glide- Do not machine the guiding surfaces that
Aloy™ surface-hardened valve component may have been Glide-Aloy™ treated.
be recognized by its flat, dull gray color and slick
surface. The parent metal should not be visible on a Components that are deeply gouged or galled, and
new component. that do not meet dimensional requirements, cannot
ATTENTION! be cleaned and returned to service. Machining
removes the coating and renders the parts
Do not attempt to remove the coating of a unacceptable. The surface-hardness approximates
Glide-Aloy™ treated component. that of diamonds, and is approximately 0.002˝
(0.051 mm) thick.
The Glide-Aloy™ reaction bonding process is
commonly applied to Consolidated® 1900™ Series ATTENTION!
SRV disc holders and/or guides, when specified. Follow recommendations for safe handling
Although the entire surface area of the component of solvents as specified in the MSDS and
is treated, only the guiding surface is critical. When observe safe practices for any cleaning
Consolidated® 1900™ Series SRVs contain Glide- method.
Aloy™ parts, they may be identified by the coding
found on the valve nameplate.
Example: 1905Jc-2-G1 where the “G” designation
indicates Glide-Aloy™:
G1 - Glide-Aloy™ Holder
G2 - Glide-Aloy™ Guide
G3 - Glide-Aloy™ Holder and Guide
Glide-Aloy™ treated components may be cleaned
by low-pressure compressed air, microbead
blasting, or brushing. Also, a non-chlorinated,
hydrocarbon shop solvent may be used. The latter
is for personnel safety reasons and not because of
any incompatibility between chlorides and Glide-
Aloy™.
Regarding personnel safety, all personnel should
be familiar with the appropriate processes as well
as the material safety data sheets (MSDS) supplied
by the vendor of any cleaning compounds used.
Personal protective equipment (protective gloves,
goggles, etc.) should be worn so as to avoid
contact with materials that may be splashed during
the cleaning process.
For a component in service after the cleaning

Page 58
Sales Office Locations

UNITED STATES FRANCE
Dresser Consolidated®
Dresser Produits Industriels
Dresser, Inc. Residence les Toits
LA Hwy. 3225 @ US Hwy. 167N 13 Rue de L’Erable
P.O. Box 1430 95540 Mery Sur Oise - France
Alexandria, LA 71309-1430 Tel: + (33) 1 34 21 53 71
Telephone: + (1) 318 640 2250 Fax: + (33) 1 34 21 68 77
Fax: + (1) 318 640 6222
GERMANY
Dresser Consolidated®
Headquarters Dresser Valves Europe GmbH
16240 Port Northwest Drive Heiligenstrasse 75
Houston, TX 77041 41751 Viersen, Germany
Telephone: + (1) 832 590 2634 Tel: + (49) 2162 8170 0
Fax: + (1) 713 953 0959 Fax: + (49) 2162 8170 280
Dresser Direct INDIA

1250 Hall Court Dresser Valve India Pvt. Ltd.
Deer Park, TX 77536 305/306, “Midas”, Sahar Plaza
Telephone: + (1) 281 884 1000 Mathuradas Vasanji Road
Fax: + (1) 281 884 1010 J B Nagar, Andheri East, Mumbai, India 400 059
Dresser Direct Telephone: + (91) 22 2 835 4790 / 838 1134
905A Industrial Road Fax: + (91) 22 2 835 4791
Clute, TX 77531 ITALY
Telephone: + (1) 979 265 1309
Fax: + (1) 979 265 2514 Dresser Italia S.r.l.
Via Cassano 77
Dresser Direct 80020 Casavatore (Naples), Italy
4841 Leopard Street Telephone: + (39) 081 7892 111
Corpus Christi, TX 78408 Fax: + (39) 081 7892 308
Telephone: + (1) 361 881 8182
Fax: + (1) 361 881 8246 JAPAN
BRAZIL Niigata Masoneilan Co. Ltd. (NIMCO)

20th Floor Marive East Tower
Dresser Industria E Comercio Ltda WBG 2-6 Nakase
Rua Funchal, 129 - Conj. 5A Mihama-ku Chiba-shi
04551-060 Sao Paulo, Brazil Chiba 261-7120 Japan
Telephone: + (55) 11 2146 3600 Telephone: + (81) 43 297 9222
Fax: + (55) 11 2146 3610 Fax: + (81) 43 299 1115
CHINA KOREA
Dresser Machinery (Suzhou) Co., Ltd. Dresser Korea, Inc.
81, Suhong Zhong Road #2109, 21st Fl. Kuk-Dong Building
Suzhou Industrial Park 60-1, Choongmoo-Ro 3-Ka, Joong-Gu
Suzhou, P.R. China 215021 Seoul 100-705, Korea
Telephone: + (86) 512 6258 6500 Telephone: + (82) 2 2274 0748
Fax: + (86) 512 6258 8590 Fax: + (82) 2 2274 0720
Dresser, Inc.
Suite 1703, Capital Mansion
6 Xinyuan S. Road, Chaoyang District
Beijing 100004 P.R. China
Telephone: + (86) 10 8486 4515
Fax: + (86) 10 8486 5305

Page 59
MALAYSIA SPAIN
Dresser, Inc. Dresser Masoneilan
Asia Pacific Headquarters C/Murcia 39C
Business Suite 19A-9-1, Level 9 08830 Sant Boi de Llobregat
UOA Centre, No. 19 Jalan Pinang Barcelona, Spain
50450 Kuala Lumpur, West Malaysia Telephone: + (34) 93 652 64 30
Telephone: + (60) 3 2161 0322 Fax: + (34) 93 652 64 44
Fax: + (60) 3 2163 6312
SWITZERLAND
MEXICO
Dresser Valves Europe GmbH
Dresser De Mexico S.A. de C.V. Windenboden 23
Henry Ford #114 Esq. Fulton CH-6345 Neuheim, Switzerland
Fraccionamiento Industrial San Nicolas Telephone: + (41) 41 755 27 03
C.P. 54030 Tlalnepantla, Estado de Mexico Fax: + (41) 41 755 28 13
Telephone: + (52) 55 5310 9863
Fax: + (52) 55 5310 4279 UNITED ARAB EMIRATES
THE NETHERLANDS Dresser International, Inc. - Middle East Operations

Dresser Valves Europe GmbH P. O. Box 61302
Steenhouwerstraat 11 R/A 8, Blue Sheds JA01 & JA02,
NL-3194 AG Hoogvliet, The Netherlands Jebel Ali Free Zone
Telephone: + (31) 10 438 4122 Dubai, United Arab Emirates
Fax: + (31) 10 438 4443 Telephone: + (971) 4 8838752
Fax: + (971) 4 8838038
RUSSIA
UNITED KINGDOM
Dresser Europe
Derbenevskaya Ulitsa 1, Bldg. 3, Office 17 DI U.K. Limited
Moscow, Russian Federation 115 114 Unit 4, Suite 2.1 Nobel House
Telephone: + (7) 4955 851276 Grand Union Office Park
Fax: + (7) 4955 851279 Packet Boat Lane
Uxbridge, Middlesex
SAUDI ARABIA England UB8 2GH United Kingdom
Telephone: + (44) 1895 454900
Dresser Al Rushaid Valve & Inst. Co. Ltd. Fax: + (44) 1895 454919
(DARVICO)
P. O. Box 10145 Dresser U.K. Limited
Jubail Industrial City 31961 Dresser House
Kingdom of Saudi Arabia East Gillibrands
Telephone: + (966) 3 341 0278 Skelmersdale, Lancashire
Fax: + (966) 3 341 7624 England WN8 9TU United Kingdom
Telephone: + (44) 1695 52600
SINGAPORE Fax: + (44) 1695 52601
Dresser Singapore, Pte. Ltd.
Dresser Flow Solutions
16 Tuas Avenue 8
Singapore 639231
Telephone: + (65) 6861 6100 FOR YOUR GREEN TAG CENTER
Fax: + (65) 6861 7197 IN USA/CANADA
CALL 1-800-245-VALV
SOUTH AFRICA
Dresser International, Ltd., South Africa Branch or contact the locations listed above for
Dresser Flow Solutions international service.
P. O. Box 2234, 16 Edendale Road
Eastleigh, Edenvale 1610 Dresser® and Consolidated® are registered trademarks of
Republic of South Africa Dresser, Inc.
Telephone: + (27) 11 452 1550
Copyright 2007, Dresser, Inc.
Fax: + (27) 11 452 2903

Consolidated® Pressure Relief Valves
www.dresser.com

Operation & Maintenance Manual For Safety Valve

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Operation & Maintenance Manual For Safety Valve

Transféré par

Droits d'auteur :

Formats disponibles

Doosan Heavy Industries

A 22-05-2013 K.H.LEE T.G.LEE J.Y.KIM FOR COMMENTS

POWER COMPANY LIMITED

JOINT STOCK COMPANY 2

Doosan Heavy Industries & Construction Co., Ltd.

COAL FIRED POWER PROJECT UNIT P0

Title KKS UHA

Know all valve Wear necessary Do not drop or strike

* Includes Pin Screws

* Includes Pin Screws

Section Subject Page

▲ Proper installation, operation and maintenance is essential to the safe and

Wear necessary It is the responsibility of the purchaser or user of DVCD valves/equipment

IV. Terminology for Safety Valves

VI. Operating Principles

VII. Storage and Handling Prior to Installation

VIII. Recommended Installation Practices

2. The safety valve shall be connected to the header independent of any

B. Outdoor Safety Valve Installation

D. Cover Plate Vent Piping

IX. Hydrostatic Test Plug Removal-

1. Disassemble the valve as outlined in Section XI of this manual.

B. Popping Point Adjustment

C. Ring Adjustments, Blowdown and

4. Upper Ring Adjustment

6. Overlap Collar Adjustment

D. Restricted Lift Valves

XI. Disassembly Instructions

MINIMUM SEAT RELIEF

XIII. Maintenance Instructions

CON-14 * This tool list is located on page 57 of this manual

Lap, using an oscillating motion in various directions, while holding the

Do not lap excessively with a ring lap without resurfacing on a lapping

MINIMUM SEAT RELIEF

C. Reseating Machine Information

E. Disc Replacement and Disc-Spindle Bearing Requirements

G. Thrust Bearing Surfaces

H. Grinding The Lower Spring Washer

YOKE ROD NUT TORQUES - FOOT POUNDS

ORIFICE PRESSURE CLASS

1 150 150 150 120 120 120

2. Prior to reinstalling the lower adjusting ring, lubricate the threads of

VERTICAL RING TRAVEL

8. Once certain that the upper adjusting ring/guide assembly is properly

1 1.125(28.6mm) .282(7.16mm) .020(.508mm)

21. If the measured dimension is:

Thread the overlap collar onto the spindle by turning in a clockwise

XV. Hydrostatic Testing & Gagging

XVI. Trouble Shooting The 1700 Series Valve

Problem Possible Cause Corrective Action

No Action, A. Upper ring too high. A. Increase blowdown as outlined in

Valve Leaking A. Damaged seat. A. Disassemble valve, lap seating

D. Discharge stack binding on D. Correct as required.

Excessive A. Upper ring too low. A. Decrease blowdown as outlined in

XVII. Maintenance Tools and Supplies

XVIII. Service Parts Inventory Philosophy

Guidelines for establishing meaningful inventory levels:

PART REPLACEMENT PREDICTED

CLASS I MOST FREQUENT 70%

CLASS II LESS FREQUENT 85%

CLASS III SELDOM REPLACED 95%

CLASS IV HARDWARE 99%

CLASS V PRACTICALLY NEVER 100%