Operation, and Maintenance Manual
Reset Relief Valve
Titan Class Type C M-34000 Address: NOV Valve Group 9700 West Gulf Bank Houston TX 77040 Phone #: 281 272 7700
Installation and Operation Manual Reset Relief Valve – C 34000
Foreword… This manual is published as a guide for the normal operation of your NATIONAL OILWELL VARCO equipment. Because of many factors which contribute to the function or malfunction of this machinery, and not having complete knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We must therefore confine the scope of this presentation and when situations encountered are not fully encompassed by complete, understandable instructions, these situations must be referred to the manufacturer. The dimension and tolerances specified in this publication are those desirable for the most efficient operations of the equipment. When components become worn or when new parts are introduced into a worn unit, it may not be possible or economically feasible to reestablish such strict alignment and correct all dimensional deviations. Improvements in design, engineering, materials, production methods, etc., may necessitate changes in these products and result in inconsistencies between the content of this publication and the physical equipment. We reserve the right to make these changes without incurring any liability or obligation beyond that which is stipulated in the purchase contract. The pictures, photographs, charts, diagrams, drawings, verbal contents and specifications are not to be construed as giving rise to any warranty on the part of NATIONAL OILWELL VARCO. NATIONAL OILWELL VARCO makes no warranty either expressed or implied beyond that which is stipulated in the purchase contract.
! CAUTION ! CAUTION ! CAUTION ! EXERCISE SAFETY IN ALL PERFORMANCES: DO NOT IGNORE ANY WARNINGS, USE ONLY APPROVED METHODS, MATERIALS AND TOOLS. DO NOT PERMIT ANY FUNCTION OF QUESTIONABLE SAFETY; ACCIDENTS ARE CAUSED BY UNSAFE ACTS AND UNSAFE CONDITIONS. SAFETY IS YOUR BUSINESS AND YOU ARE INVOLVED.
! WARNING ! WARNING ! WARNING ! BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED FROM ITS POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY FORM OF ENERGY FROM ENTERING THE EQUIPMENT. THIS WOULD INCLUDE ELECTRICAL OR MECHANICAL ENERGY INTO OR FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE COMPRESSOR/AIR SYSTEM, ETC.
! WARNING ! WARNING ! WARNING ! FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN RESULT IN PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH.
! WARNING ! WARNING ! WARNING ! DO NOT PROCEED WITH INSTALLATION UNTIL THE INSTALLER HAS READ THE MANUAL IN ITS ENTIRETY. © Copyright 2007 National Oilwell Varco, all rights reserved.
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Installation and Operation Manual Reset Relief Valve –C 34000 Publication date: August 7, 2007 All other product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. All rights reserved. This publication is the property of, and contains information proprietary to National Oilwell Varco. No part of this publication may be reproduced or copied in any form, or by any means, including electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of National Oilwell Varco. Information in this manual is subject to change without notice.
Warranty National Oilwell Varco (NOV) warrants that, for a period of one year from the date of delivery equipment of manufacture, the Equipment shall be free of defects in materials and workmanship under normal use and service, and provided the Equipment is used and maintained in accordance with instructions supplied. This is a sole and exclusive warranty. If a defect in the Equipment appears within one year from the date of shipment, and Purchaser has given written notice of such defect within thirty days from the discovery thereof, NOV will repair or replace the part, at its option, by shipping a similar part FOB shipping point or, at its option, refund an equitable portion of the purchase price. NOV may require the return, to a designated location, of the defective part, transportation prepaid to establish Purchaser's claim. No allowance will be made for repairs undertaken without NOV’s written consent or approval. This warranty applies only to equipment manufactured by NOV. Warranties on equipment manufactured by others, if any, are assigned to Purchaser by NOV (without recourse) at time of delivery. Any description of Equipment, drawings, specifications, and any samples, models, bulletins, or similar material, used in connection with this sale are for the sole purpose of identifying the Equipment and are not to be construed as an express warranty that the Equipment will conform to such description. Any field advisory or installation support is advisory only. The foregoing warranties are in lieu of all other warranties, whether oral, written, express, implied or statutory. Implied warranties or merchantability and fitness for a particular purpose will not apply. NOV's warranty obligations and purchaser's remedies there under are solely and exclusively as stated herein. Purchaser's sole and exclusive remedy, whether based upon warranty, contract or tort, including negligence, will be to proceed under this warranty. All liability of NOV shall terminate one year from the date of delivery of the Equipment.
Intended audience Conventions Notes, cautions, and warnings Notes Cautions Warnings Illustrations
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Safety requirements Personnel training Recommended tools Genera system safety practices Replacing components Maintenance Proper use of equipment
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Intended audience This manual is intended for use by field engineering, installation, operation and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. National Oilwell Varco company (NOV), will not be held liable for errors in this material, or for consequences arising from misuse of this material.
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000
Notes, cautions, and warnings Notes, cautions, and warnings appear throughout this manual to provide you with additional information, and to advise you to take specific action to protect personnel from potential injury or lethal conditions. They may also inform you of actions necessary to prevent equipment damage or conditions that may void your warranty. Please pay close attention to these advisories. Notes The note symbol indicates that additional information is provided about the current topic. Cautions The caution symbol indicates potential risk of damage to equipment or injury to personnel. Follow instructions explicitly and take extreme care. A caution symbol may also indicate a condition that voids your equipment warranty. Warnings The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures is likely to result in serious or fatal injury to personnel, significant property loss or significant equipment damage. Illustrations Figures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For more specific component information pertinent to your rig configuration, see the technical drawings included with your National Oilwell Varco documentation. Safety requirements
Safety requirements Personnel training NOV equipment is installed and operated in a controlled drilling rig environment involving hazardous operations and situations. Proper service and repair is important for safe and reliable operation. Operation and service procedures provided by NOV manuals are the recommended methods of performing those operations. Figures provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For more specific component information pertinent to your rig configuration, see the technical drawings included with your National Oilwell Varco documentation. All personnel performing installation, operation, repair or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on shop safety, tool operation, and maintenance. Contact the NOV Valve training department for more information about equipment operation and maintenance training. Recommended tools Service operations may require the use of tools designed specifically for the purpose described. When stated, use only these tools. General system safety practices Avoid performing maintenance or repairs while the equipment is in operation. Wear proper protective equipment during equipment installation, operation, maintenance, assembly/disassembly or repair. Local codes may apply. Please consult them prior to performing any operation. The presence of a NOV Valve representative at the site does not relieve the owner/ operator of responsibility to follow published installation, operation, and maintenance instructions. Replacing components Verify that all components are tagged and labeled during disassembly and reassembly of equipment.
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Installation and Operation Manual Reset Relief Valve –C 34000 Replace failed or damaged components with NOV genuine certified parts. Failure to do so could result in equipment damage or personal injury. Maintenance Equipment must be maintained on a regular and routine basis. See the Maintenance and Repair chapter of this manual for maintenance recommendations. Proper use of equipment NOV equipment is designed for specific functions and applications, and should be used only for its intended purpose.
Introduction Features
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Introduction A pressure relief valve is a self operating valve that is installed in a process system to protect against over pressurization of the system. The NOV Reset Relief Valve is designed to keep pressure from exceeding a preset valve, which will in turn protect the liners and other internal components of a typical mud pump. There are a wide variety of valve designs, but most valves of this type incorporate one or more helical compression springs which are used to maintain constant force acting on the backside of a piston, causing the valve to be normally closed. When the force exerted by the process stream (i.e. fluid pressure) against the piston is greater than the constant force exerted by the spring, the valve "trips" open (the piston moves to its fully open position) and allows process fluid to exit the valve and pass through a discharge line to a mud tank or pit. This valve actually utilizes a balance beam whereby the piston force acts on a short moment arm while the spring force acts on a longer moment arm. The NOV Titan Class "C" Valve utilizes the 34000 series part number. Various dash numbers may be added to indicate the type of piping adapters supplied with the valve or any other auxiliary items. Please refer to the bill of material and drawing sections to determine the complete valve assembly number. Features Unlike its predecessor, which utilized an elastomeric cushion ring, the Titan Class “C” valve incorporates a pressure balance chamber, similar to the original RX valve. The opening movements of NOV's patented piston ports (U.S. Patent 5,715,861) are hydraulically cushioned by throttling fluid from the balance chamber to the discharge side of the valve. The butt weld flanges or 3”-1502 unions provide excellent connection integrity. There is no load bearing threaded connections exposed to the flow media (such as line pipe threads). The 4-bolt inlet and discharge flanges allow for easy access to the body and internal parts. The entire valve can be replaced with all adjacent piping in place. The valve is 100% adjustable to provide any relief pressure setting within the particular pressure range of the valve. The relieving pressure set point may be altered easily by turning a single adjusting nut; adjustment may be made while pressure is in the valve however, is limited to increasing the setting only. The accuracy of the relief valve is not affected by continuous pressure surges or vibration. The valve is easily reset by operating a single lever; no replacement shear pins are required and little, if any, down time is encountered in resetting the valve. Once properly calibrated, the accuracy of the valve is maintained over numerous valve “trips”. The valve may be manually discharged at any time, regardless of line pressure, by striking the “release button” provided on the valve. The “open” or “set” position of the valve piston is indicated by the position of the “release button”. When the button is away from the side of the bonnet, the valve is “set”. When the button is adjacent to the side of the bonnet, the valve is “open”. The valve’s internal linkage is fully enclosed and protected from debris and corrosion. The release shaft retainer has been redesigned for greater safety.
Inspection Installation
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Installation and Operation Manual Reset Relief Valve – C 34000 Storage Recommended procedure for extended storage
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Inspection Installation Prior to setting up and operating a new Reset Relief Valve, inspect the goods as received from the shipping company. A claim for damage or loss should be reported immediately to the carrier and to the Valve Division. Also, check the bill of lading for any separately shipped items, including manuals and CDs. Once it is confirmed the order has been received complete in undamaged condition, installation may begin. The Titan “C” Reset Relief Valve may be installed in any position but it is generally easier to operate and maintain with the bonnet in a vertical position together with a horizontal discharge line. The valve is outfitted with (A) a pair of 6-bolt butt weld flanges (one on the inlet and one on the outlet) that have to be fitted, tacked, welded, and stress relieved in accordance with ASME Section IX and/or ASME B31.1 specifications PRIOR to bolting the valve in place for operation or (B) adapter flanges which go from a 6-bolt pattern (to match the body) to 3”-1502 male and female union connections. Material certificates for these components are available and (for the butt weld components) include heat treating times and temperatures which may be used to write a proper weld procedure for valve installation (WPS or PQR). Due to the service encountered and pressure rating of this equipment, the integrity of all welding, which may be required for the installation of this valve, should be volumetrically inspected 100% using appropriate X-ray procedures. Assemblies including component parts with butt weld ends requiring welding must follow the same procedures described above. The dimensions of the “window” required for valve installation are shown in the assembly drawing. It is recommended that the pipe I.D. be no smaller than that of a 3” Schedule XXH pipe (2.300 I.D.) for the upstream and downstream piping. Figure 3-1 exhibits the correct setup of the upstream and downstream piping. A 3 degree minimum downward slope must be maintained on piping.
! WARNING ! WARNING ! WARNING ! NEVER ATTEMPT TO MAKE UP OR BRAKE OUT UNION CONNECTIONS WITH ANY INTERNAL PRESSURE IN THE VALVE. REPLACE ALL WORN OR DAMAGED UNION COMPONENTS WITH ORIGINAL NOV PARTS. The dimensions of the “window” required for valve installation are shown in the assembly drawing. It is recommended that the pipe I.D. be no smaller than that of a 3” Schedule XXH pipe (2.300 I.D.) for the upstream and downstream piping. Figure 3-1 exhibits the correct setup of the upstream and downstream piping. A 3 degree minimum downward slope must be maintained on piping. Note: Sufficient size piping and schedule are required for operating conditions including containing working pressure, handling cyclic nature of the pump pressures, and staying within the erosional velocity limits of the pipe for the expected discharge fluid volumes of drilling mud and the related fluid velocity within the pipe. The discharge line should slope gradually downwards from the valve outlet to the mud pit or holding tank. This insures any fluid remaining in the line will self-drain.
! WARNING ! WARNING ! WARNING ! IN FREEZING ENVIRONMENTS, FLUID REMAINING IN THE DISCHARGE LINE COULD FREEZE AND PREVENT DISCHARGE FROM THE VALVE. THIS COULD BE DETRIMENTAL TO THE VALVE, PIPING AND PUMP. Due to thrust loads at the time of discharge, adjacent piping for a relief valve installation requires all piping be properly braced, anchored and supported to prevent unnecessarily high stresses from damaging the valve or any adjacent connectors. 5 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000
! WARNING ! WARNING ! WARNING ! AVOID MOUTING THE VALVE ON A TALL RISER UNLESS THE RISER IS WELL BRACED, ANCHORED AND SUPPORTED. FAILURE TO DO SO COULD CAUSE SEPERATION OF PIPING AND/OR CONNECTIONS AT THE TIME OF DISCHARGE, WHICH COULD LEAD TO SERIOUS INJURIES.
Figure 3-1. Recommended downstream setup
Note: Refer to the Parts and Drawings Section when item numbers are referenced. Standard butt weld hubs normally supplied with this valve when requested (p/n 31953), are for mating up with 3-1/2”SCH. XXH (4.000” O.D. x 2.728” I.D.) piping. Torque the (6) flange bolts (item 50) gradually in a crossing pattern so that the adjacent sealing faces of the flange and body remain parallel. This will also prevent flange separation and the resulting flange-to-body seal failure. The adjusting nut (item 32) moves the upper spring retainer (item 34) thereby increasing or decreasing the amount of spring compression and thus spring force against the arm of the crank. The correct position of the adjusting nut is shown by an indicator (item 33) mounted on the upper spring retainer and the calibration plate (item 36) mounted adjacent to the indicator on the bonnet cover (item 29). It is generally undesirable to bring a mud pump on-line with the valve at an abnormally low pressure setting. Such a practice could cause inadvertent opening of the valve. Always verify the pressure setting by examining the indicator and calibration plate prior to placing the valve in service. In some operating conditions, the valve may appear to discharge at a lower (or higher) pressure than indicated by the valve setting. This phenomenon may sometimes result from (1) a lag between the actual system pressure and the pressure gauge reading, especially for gauges with dampening devices, (2) pressure pulsations, especially when inadequate or poorly operating pulsation dampeners are installed, (3) inaccurate or improperly calibrated gauges, or (4) an improperly maintained valve. The release of drilling mud, especially at high pressures, can be very destructive to internal valve parts. Operators are advised to always try to isolate and shut down a pump as quickly as possible when the relief valve for that pump discharges. Doing so can help to increase the life of the valve and its internal parts. 6
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000
Note: Back pressure on the valve (usually due to hydrostatic head pressure from a column of fluid in the discharge line) is usually undesirable. However, due to the balanced design of the Titan “B”, back pressures less than 100 psig will have little if any affect on the operational accuracy of the valve
! CAUTION ! CAUTION ! CAUTION ! DO NOT ATTEMPT TO RESET THE VALVE WHILE THE PUMP IS IN OPERATION.
Storage Recommended procedure for extended storage Relief Valve should be stored inside a cool, controlled environment. Valve should be stored in an upright position, protecting the piston and internal parts. Internal parts should stay lubricated with synthetic grease, Mobil SHC 220, Mobilith or equal. If the valve is in storage more than 6-15 months, the valve should be disassembled, the bonnet pulled and the piston cap seal and o-ring inspected and changed. Clear all debris from internal parts, lubricated with recommended lubricant. For assembly procedures, see Section 6. If additional information is needed, please contact your sales representative or call the location shown on the cover of this manual.
Field Setting Procedure Valve “Calibration” The “zero setting” The “Span” setting Hydrostatic Pressure Testing (in plant only)
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Field Setting Procedure Valve “Calibration” The valve adjusting nut (item 32) should be tightened (rotated clockwise looking at the top of the bonnet) to increase the compression on the load springs and thus increase the setting indicated by the calibration plate. Likewise, the nut should be loosened to lower the set pressure. Going from a higher setting to a lower setting with pressure on the valve could inadvertently cause the valve to “trip”. Increasing the set point with pressure on the valve is generally not a problem. Although all NOV Reset Relief Valves are calibrated at the factory, because of the variety of mud types, it is important to verify the operating characteristics of the valve in a particular system and with the mud being used to determine if any additional adjustments are needed. Please refer to the section on valve calibration in this section. The valve should be bench tested on a regular basis to verify proper calibration and accuracy. As mentioned, NOV can provide a complete portable test unit for a modest price. For calibration purposes, an accurate “test” gauge should be used (usually plus or minus 1/4% of the full scale reading). The gauge should be connected so that it indicates pressure in the lower end of the valve. If any gauge with a built-in dampening device is used, the line pressure should be built up slowly to allow for the actual system pressure and gauge pressure to stabilize. If possible, the system pressure should be built up slowly and gradually with little or no pressure pulsations. Remove the adjusting nut (item 32), upper spring retainer (item 34), two load springs (item 37), four socket head cap screws (item 50) and the bonnet cover (item 29) so that the lower spring retainer can be lifted and turned. Drive out the ¼” Spirol Pin (item 40) from the back side (bonnet side) of the lower spring retainer. Replace the bonnet cover using new NOV socket head cap screws. Replace the remaining components. The “zero setting”: Adjust the valve to its minimum pressure setting as indicated by the calibration plate and indicator. Operate the reset lever to “set” the valve (close the piston). Slowly increase internal pressure until the valve operates (“trips”), noting the 7 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000 gauge pressure indicated. If the valve “tripped” before the gauge reached the pressure indicated on the calibration plate, the valve “Zero setting” is low (too little initial spring compression). In order to correct the zero setting, the two flats on the lower end of the load screw (item 38) will be used to change the initial compression on the load springs. If the valve “tripped” early, more initial spring compression is required and vice versa. Use a 3/8” open end wrench to tighten the load screw further into the lower spring retainer if the valve “tripped” early. Looking down on the upper face of the lower spring retainer, a clockwise rotation of the wrench will drive the load screw farther into the lower spring retainer. The amount of change will vary somewhat between valves but a half turn of the load screw should cause approximately a 50 psig (higher or lower depending on the direction of rotation) change in the “tripping” pressure of the valve. Because it will be locked in place by the 1/4” Spirol pin upon successful completion of the calibration procedure, the load screw may only be adjusted in half-turn increments (with the flats on the load screw left perpendicular to the lower spring retainer). Once the “zero” setting is close, it is time to check the “span” or upper setting. The “Span” setting: Hydrostatic Pressure testing (in plant only) Tighten the adjusting nut until the indicator points precisely to the highest setting on the calibration plate. Reset the valve and slowly increase internal pressure until the valve “trips”. Note the pressure on the gauge at this point. For example, let’s assume that we are working with a typical 1500-5000 PSI valve assembly. If the valve initially “tripped” at 1400 PSI for the “zero” setting and then “tripped” at say 4900 PSI for the “span” setting, it is possible to bring both values closer to the desired setting. In other words, by going back to the “zero” setting and increasing the initial spring compression, the valve may be made to “trip” at exactly 1500 PSI or plus 100 PSI. As such, we will expect the valve to “trip” at an additional 100 PSI on the high end (span setting), very close to the desired 5000 PSI. We will rerun the span procedure to confirm. However, if the valve “trips” at 1700 PSI at the low end and at 5300 PSI at the high end, you can not perform the basic calibration procedure to make the valve more accurate. If we increase the initial spring compression, when testing the high setting, to make the valve “trip” right at 1500 PSI we could expect the valve to “trip” at around 8600 PSI which would be totally unacceptable. In short, both settings (low and high) may be either increased or decreased but they may not be moved closer together or farther apart. Valves which do not calibrate properly may have one or more faulty load springs, a worn upper link pin (which most often causes erratic valve behavior), excessive seal friction due to corrosion, a faulty main crank, or binding linkage. If the operator is unable to achieve satisfactory performance from the valve after following normal calibration procedures, contact the factory. If the valve is within acceptable tolerances at both the low and high set points, secure the load screw with the Spirol pin (item 40) by driving it into the lower spring retainer (against the bonnet) until the end is flush with the outboard side of the lower spring retainer. If the valve is not within acceptable tolerances, replace the load springs or look for mechanical problems. Repeat this entire procedure after reworking valve. For Titan Class “C” valves, any in-plant or customer-witness hydrostatic pressure testing will be limited to the following maximum values: 5000 PSIG WORKING PRESSURE, 7500 PSIG TEST PRESSURE Acceptable Tolerance, Set Point vs. Actual Valve “Trip” Pressure Pressure Range 1500-5000, psig Acceptable Tolerance +200 psig
If the valve is within acceptable tolerances at both the low and high set points, secure the load screw with the Spirol pin (item 40) by driving it into the lower spring retainer (against the bonnet) until the end is flush with the outboard side of the lower spring retainer. If the valve is not within acceptable tolerances, replace the load springs or look for mechanical problems. Repeat this entire procedure after reworking valve. Hydrostatic Pressure testing (in plant only) For Titan Class “C” valves, any in-plant or customer-witness hydrostatic pressure testing will be limited to the following maximum values: 5,000 PSIG WORKING PRESSURE 7,500 PSIG TEST PRESSURE (Test pressure applies to the sub-assembly: valve body with sub, seat insert, and related seals only.) With the valve in the “set position” and springs compressed for maximum pressure setting, slowly increase internal pressure to that of working pressure, hold hydrostatic pressure for 3 minutes and check for leakage, bleed pressure to zero. Re-pressurize valve to the specified pressure required and hold for 15 minutes. Check for leakage. If no leakage is observed outside the valve and if no apparent leakage is visible from monitoring the gauge, the test is successful. Bleed pressure to zero. Test is complete.
Reset Relief Valve Troubleshooting Guide
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000
Reset Relief Valve Troubleshooting Guide NOV Reset Relief Valves are fairly easy to operate and are reliable and stable when properly used and maintained. The success and performance of the valves rely on links inside that connect the piston to the bonnet. The links must be in a straight line (3O off center) for the valves to hold pressure. Once the joint is out of line, the links retract (due to exceeding set pressure) and the valve trips. Valves must be reset in a straight line to work properly. When pushing the handle forward to reset the valve, a lever inside the reset crank pushes the links into alignment. There is a stop inside the valve when the links are in the correct position, the links will be straight and the piston will be down. When the valve is fully reset, the reset button on the backside of the bonnet sticks out approximately 3/8 inch. When the reset relief valve seals are new, more effort to reset the valve may be required. New seals are stiff and tight. Troubleshooting Problem Solution If the valve cannot be fully reset even when using an extension wrench check the pump to see if it’s turned off and there is no back pressure on valve. Check for foreign substance in the valve that’s blocking the piston from resetting. Make sure the reset crank handle pin is tight. Check if the crank is not bent; also check if the inner stem seal is installed properly and has not rolled up on piston stem, preventing the valve from resetting. Sometimes the pressure activated lower piston seal may be swollen preventing the valve from resetting; in this case, drain all the fluid out and replace the lower piston seal. This seal can be used again when it shrinks back to original shape after drying for few minutes. If the valve does not hold pressure, check piston seal for wear and insure links are fully reset (the reset button should be extended 3/8 inch). Check piston and body for wear. If the valve calibration has changed, replace the load springs if they are shorter than 7 inches. Inspect links and link pins for wear or bent. Follow calibration procedures. If valve is leaking on outside between bonnet and body remove stem bushing seals. If fluid is leaking through discharge side remove the flange/discharge line on valve outlet side and clean the inside of the valve from the discharge side. Use a flashlight and check for fluid leaks. If the fluid is leaking from bottom i.e. between piston cap and insert, turn off the pump and drain all the fluid from the valve body, push the reset button in and reset the valve 2-3 times. If the valve is still leaking, replace the lower piston cap seals. If fluid is leaking from top, remove the bonnet assemble and replace the upper piston – shoulder seal. Before reinstalling the bonnet assembly, check the inner valves of the body for rust, pitting or scarring. The inner surface where the seal seats must be clean and smooth or the valve will leak. If there is more than surface/superficial rust proceeds to send the valve body to NOV facility for further evaluation. If you have any more problems contact NOV service guys or NOV facility for repair.
Assembly / Disassembly Procedures Lower Piston Disassembly Bonnet & Linkage Disassembly Lower Body Disassembly Lower Body Assembly Bonnet and Linkage Assembly Body Flange/Adapter Assembly
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Assembly / Disassembly Procedures Lower Piston Disassembly Note: Replacement of the lower piston seal ring (item 7) or any of its associated components requires that the bonnet assembly first be removed from the body. The steps required to accomplish this task are as follows: Danger Failure to safely bleed off internal pressure prior to bonnet or flange removal could cause serious bodily injury or even death. 1. After removing ALL internal pressure from the body, loosen all four bonnet socket head cap screws (item 54) about 3 turns. Pull up on the bonnet until the bonnet flange is again in contact with the face of the screws. Verify that the stem 9 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000 bushing seal (item 14) has disengaged its respective seal bore in the body. Only then the (4) cap screws may be completely removed from the body along with the bonnet sub-assembly. 2. Clean the upper bores of the body with a soft cloth. Verify that the seal bores in the upper end of the body are free of marks, scratches, dings, and corrosion prior to reinstalling a cleaned up or rebuilt bonnet assembly. Also, clean and inspect the seat insert (item 2) in the lower end of the body. DO NOT attempt to repair a leaking valve by merely replacing the lower piston seal when the seat insert is also damaged. 3. holding the bonnet firmly loosen and remove the piston cap (item 4) from the piston body (item 3). Remove the outboard seal retainer (item 8), the lower piston seal (item 7) and the inboard seal retainer (item 8) from the piston body. Inspect the piston cap face seal (item 11) for damage and replace as required. Replace item 7, (Never reuse the lower piston seal (item 7)) along with two of item 8 if necessary, and reassemble the lower end of the piston. Note the orientation of all components for correct assembly of the piston. 4. Inspect the outer stem bushing seal (item 14) for damage and replace if required. Verify that the piston slides freely in and out of the stem bushing. If not, there could be damage to the inner stem bushing seal (item 10) or excessive corrosion on the internal bore of the stem bushing (item 6). Correcting this problem will require complete removal of the piston sub-assembly from the bonnet. See the "Bonnet & Linkage Disassembly" 5. Verify that the piston shoulder seal (item 9) is in good condition. If not, it will require replacement. Again, correcting this problem will require complete removal of the piston sub-assembly from the bonnet. See the "Bonnet & Linkage Disassembly" 6. Using high quality synthetic grease, lubricate the upper end of the body as well as the lower and upper end of the piston, particularly all sealing elements. 7. Again, contingent upon the inspection performed in step 2, the bonnet sub-assembly may be reinserted into the body. Lubricate the threads and collars of four NEW cap screws (item 54) with a nickel base anti-seize compound and using a crossing pattern, torque the screws to specification, see the "Torque Chart"
! CAUTION ! CAUTION ! CAUTION ! NEVER REUSE BONNET CAP SCREWS (ITEM 54).
Bonnet & Linkage Disassembly Note: This procedure assumes that the bonnet sub-assembly has been safely removed from the body following the procedure in step 1 of "Lower Piston Disassembly" 1. Completely remove the adjusting nut (item 32) and lift off and remove the upper spring retainer (item 34) and the two load springs (item 37). Check the load springs for yielding. If either spring is less than 7.00” in overall length, replace both springs and re-calibrate the valve. 2. If the adjusting stud (item 35) must be replaced, punch out the ¼” Spirol Pin (item 40) in the bonnet cover and unscrew the stud. Note the amount of stud protruding from the cover so that the replacement part may be reinstalled properly as before. 3. Remove and discard the four cover cap screws (item 50) from the bonnet cover (item 29), lift off and remove the cover. 4. If the reset roller (item 31) must be replaced, punch out the 1/8” Spirol Pin (item 44) and slide the roller from the reset crank. Replace the roller with a new one and install a new pin. 10
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000
5. If the reset crank (item 30) or the reset handle (item 16) must be replaced, punch out the 5/16” Spirol Pin (item 24). Slide the reset handle off of the reset crank, remove the shaft seal o-ring (item 43) and pull the reset crank out of the bonnet cover. 6. If the cover bearing (not ballooned) is damaged, it may be pressed out of the bonnet cover (with the proper tooling) and replaced with a new one. 7. Remove the spring guide rod (item 28) along with the reset spring (item 23) and the keeper (item 27) from the bonnet. 8. Using a pair of needle nose pliers, carefully remove the two “clock” or linkage springs (item 25). Examine both springs for damage. The tabs which hold the spring in place (one on the inside and one on the outside) should be in alignment with each other. If the outer tab is more than 30 degrees out of alignment with the inner tab, replace both springs with new NOV parts. 9. With the remaining bonnet assembly resting above the piston (item 3) which is to be positioned firmly on a flat surface, rotate the upper link (item 21) into a horizontal position (as if the valve had “tripped”). Punch out the 1/8” pin (item 19) in upper link. Note: Pulling back on the release button and locking it in the retracted position with a small block (or other item which may be used temporarily as a spacer) during this operation will keep the inboard end of the release shaft (item 45) from interfering with the removal of the pin (item 19). Remove the top crank pin (item 26). 10. If the crank (item 22) must be removed, lift lower spring retainer and turn it so that the ¼” diameter pin can be driven out from side adjacent to the bonnet. Rotate the load screw (item 38) CCW to remove it from the lower spring retainer (item 39). Lift the load screw up through the crank for complete removal from the bonnet. Punch out the 1/8” pin (item 44) from the crank to remove the crank pivot pin (item 41). The crank may now be lifted out and completely removed from the bonnet. 11. If required, the bearing (item 15a) may be removed from bonnet (item 15) with a 19/32 punch. Again, this is a somewhat tedious task and replacement of the bonnet sub-assembly is generally the better choice. 12. If it is necessary to remove the release shaft (item 45), hold the inboard end from rotating with a drift pin while rotating the release button (item 47) CCW. With the release button removed, push the release shaft inboard until it clears the notches in the release shaft retainer (item 46). A large slotted screw driver may be used to loosen and remove the release shaft retainer (item 46). Now the release shaft and release shaft spring may be easily removed from the bonnet. 13. The piston along with the linkage may now be carefully pulled out of the lower end of the bonnet. 14. Disassemble upper link and lower links by punching out four 1/8” pins (item 19) and removing the two link pins (item 18). 15. Remove the stem bushing by sliding it off of the small end of the piston. Inspect both the bushing outer seal (item 14) and the bushing inner seal (item 10) for wear or damage. Clean and inspect both glands for damage or corrosion. 16. If required, the bearing (item 21a) may be removed from upper link (item 21) with a 15/32 punch. Again, this is a somewhat tedious task and replacement of the upper link sub-assembly is generally the better choice. Note Usually, while the valve is completely disassembled, it is always a good practice to replace any and all worn, damaged, or otherwise questionable parts. 17. Check lower links for straightness and/or ovaling of the link pin holes. Check straightness by laying a straight edge against the end flat on each side of the link. If either link is distorted, always replace both lower links—never just one. Check the small pads on one side of each lower link for damage from contacting the pad on the main crank. It is important to note the position and orientation of the pads on both lower links. These pads MUST be placed in the same 11 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000 position during assembly (the pad end of the lower link is to be farthest away from the bonnet flange while both pads are to face towards the release shaft button). 18. Check all link pins and crank pins for straightness. If a pin is not straight or shows signs of wear, it should be replaced. A worn pin may show cracks or dings in the surface or may no longer be perfectly straight and or round. 19. Check all pressed-in bushings. If a bushing is loose, has chipped or otherwise damaged edges, or is wallowed out, it should be replaced with a new NOV part. 20. Check the outside diameter of the piston and all sealing surfaces for signs of wear, corrosion, or other damage that might impair the effectiveness of a new seal. Lower Body Disassembly 1. Removal of the sub (item 5) can be difficult at times. It will require using the special sub wrench listed in the tool section. We will assume that the valve assembly has been removed from the line and that the bonnet/piston assembly has been removed from the valve. 2. If the valve was supplied with butt weld flanges and the body is out of the line, the 6-bolt flange will have already been disconnected. If the valve was supplied with 1502 connections (see section 8), the inlet adapter will need to be removed. Using a 12-point socket or box end wrench, loosen and remove all 6 flange cap screws from the valve inlet. 3. Carefully remove the inlet flange adapter from the body and set aside. Clean and inspect the union components for damage. Clean and inspect the face seal groove for damage or corrosion and inspect the seal. 4. It is best to carefully anchor the body when removing the sub. This may be done by using a minimum of 2 bonnet cap screws to bolt the body to a work table. Holes will have to be drilled in the table to match the bonnet bolt pattern. Flip the body upside down (bonnet end down) and attach it to the work table using discarded bonnet cap screws or place the body (in a similar position) securely in a large vice. 5. Insert the lugs of the sub wrench into the sub. Looking at the inlet of the body, rotate the sub counter clockwise to loosen and remove the sub from the body. In some cases, applying penetrating oil or similar substance to the sub may help with its removal from the body. 6. Clean the sub (item 5) and inspect it for damage, especially in the threaded area, the radial seal groove, and the sealing faces on the inboard and outboard ends. 7. Remove the seat insert (item 2) from the body along with the insert face seal (item 13). Carefully clean and inspect the insert for damage, especially the internal seal surface (I.D.) and the face seal groove. 8. Clean and inspect the lower valve body internals, especially the threads and the seal bore for the sub seal (item 12). Lower Body Assembly Use the procedure described in "Lower Body Disassembly" on page 6-4 for mounting and holding the valve body while working on the lower end of the valve. 1. If the body (item 1), sub (item 5), seat insert (item 2) are all cleaned and free of damage, they may be reassembled. Always use new sealing elements when reassembling this valve. 2. Use a nickel base anti-seize compound to lubricate the threads and sealing surfaces of the lower end of the body prior to assembly. Also lubricate the threads and inboard face and radial sealing surfaces of the sub prior to assembly. 3. Install a new sub seal (item 12) into its groove in the sub. Install a new seat insert face seal (item 13) into its groove in the insert. As mentioned in step 1, with the bonnet side of the valve body facing downwards, place the seat insert into the lower body cavity, face seal side up. Verify that the insert shoulder is fully seated against the step in the body. 12
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000 4. Place the sub into the lower body cavity, threaded end last. Make up the sub into the body by hand. If this is not possible, check the body and sub for thread damage. Continue making up the sub until it bumps against the seat insert. 5. Using the pipe wrench, torque the sub to 800-1000 ft.-lbs. protect the outboard sealing face of the sub when flipping the body over for bonnet assembly.
Bonnet and Linkage Assembly 1. Lubricate and install new seals (items 10 and 14) in the stem bushing (item 6). Note that the inner seal (item 10) MUST be installed with the seal lip energizer facing the large end of the stem bushing. Failure to install this seal properly could cause the seal to leak and fail. Place the stem bushing sub-assembly aside. Do not proceed with bonnet and linkage assembly, unless all parts have been cleaned, inspected, and are found in good condition. Do not reuse Spirol pins 2. Assemble the piston body (item 3) with items 4, 7, 8 (2x), 9, and 11. Place the face seal (item 11) into its gland in the piston cap (item 4). Place the first seal retainer (item 8) over the nose of the lower end of the piston as shown in the assembly drawing. Carefully place the piston seal (item 7) over the nose of the lower end of the piston and against the first seat retainer. Place the second seal retainer (item 8) over the piston seal. Screw the piston cap (item 4) into the lower end of the piston. Be sure that the face seal (item 11) remains fully in its groove during make up. Torque the cap to 80-100 ft.-lbs. install a (lubricated) shoulder seal (item 9) into its gland on the upper end of the piston. Again, orientation of this seal is critical. The spring energizer MUST be oriented towards the upper end of the piston as shown. The piston sub-assembly is now complete. Take care not to damage piston seals (items 7 and 9) during assembly. 3. Slide the stem bushing sub-assembly (from step 1) over the lubricated end of the piston, large end first. Carefully slide the bushing down towards the big end of the piston, as far as it will go. Do not force. 4. Assemble the two lower links (item 20) to the upper end of the piston with the first link pin (item 18). Orientation of both links is critical. The links should have side bosses facing the same direction (away from the piston centerline). The link bosses should also be oriented away from (not adjacent to) the bushing in the piston. Secure links with two 1/8” Spirol Pins (item 19). 5. Assemble the “thick” end of the upper link (item 21) between the upper end of the lower links with the second link pin (item 18) and again secure with two 1/8” Spirol pins (item 19). Upper and lower links should fit snugly with the link pins but both link pins should turn freely in their respective bushings. 6. Slide the release shaft (item 45) into its respective hole in the side of the bonnet (big end first). Slide the release shaft spring (item 48) over the threaded end of the release shaft. Slide the release shaft retainer (item 46) over the release shaft, notched end last. Apply several drops of non-permanent thread locking compound to the threads of the release shaft retainer prior to making it up fully into the bonnet. With no other components yet attached to the bonnet, the release shaft may be pushed towards the middle of the bonnet to allow for use of a large slotted screw driver to make up the release shaft retainer. 7. Push the release shaft towards the outboard side of the release shaft hole in the bonnet so that the threaded section protrudes from the bonnet. Screw the release shaft button on to the release shaft. Use a few drops of non-permanent thread locking compound to secure the release shaft button. Alternatively, the threaded end of the release shaft may be pined with a center punch to prevent inadvertent loosening of the release shaft button. 8. Place the crank assembly (item 22), with its two bushings, into the cavity in the top of the bonnet. Slide the middle section of the crank over the bushing in the top of the bonnet. Align the small end of the crank over the hole for the load screw. Align the crank assembly hole with the bonnet bushing and insert the crank pivot pin (item 41). Note that the transverse hole in the crank pivot pin must be oriented with respect to the matching hole in one side of the crank assembly. Rotate and slide the crank pivot pin so that the transverse hole is in line with its respective hole in the crank assembly. Drive the Spirol pin (item 44) through the hole to secure the crank assembly. The end of the pin should be flush with the outer surface of the crank as shown in the assembly drawing.
13 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000 9. Insert the linkage (attached to the piston) through the bottom of the bonnet with side bosses of lower links facing release shaft hole. Again, orientation of the bosses on the lower links is CRITICAL to proper valve operation. Align the hole in the upper end of the upper link with its respective hole in the crank assembly. Slide the top crank pin through the hole. 10. With the lower end of the piston resting on a flat surface, steady the bonnet while rotating the top crank pin with respect to the upper link. When the transverse slot in the top crank pin is aligned with the hole through the upper link, place a 7/64 drift through the upper link to hold both members in place. Now allow the bonnet to move downwards and the upper link to move to the near horizontal position until the parts rest against each other. (The piston is now basically in the “tripped” position). Carefully remove the drift and, without disturbing the related parts, drive one 1/8” Spirol pin through the hole in the upper link. Tap the pin carefully until it passes the top crank pin. 11. Lay the bonnet assembly on its side with the piston extended in the “set” position. Both lower links should be against the side of the bonnet. Place one linkage (or “clock”) spring (item 25) over each end of the top crank pin. The inner tab of the spring should slide into the slot in both ends of the top crank pin. Use a pair of needle nose pliers to grab the outer tab of the spring to wind it “tighter” approximately 90 degrees and slip it into the slot in the crank. The short crook or bend in the very end of the outer end of the spring should face towards the release shaft button. Press against the outboard side of the spring to assure that it is fully against the side of the crank and fully engaging both slots. 12. Insert the load screw (item 38), threaded end first, through the hole in the crank assembly and out through the lower side of the bonnet. 13. Drive a 1/4” Spirol pin (item 40) about 1/4 to 3/8” into one side of the lower spring retainer (item 39), just to hold it in place. With the spring guide nubs facing upwards and the Spirol pin facing away from the bonnet, make the load screw up into the lower spring retainer. The end of the load screw should protrude from the lower side of the lower spring retainer by about 1/4”. 14. Slide the reset roller (item 31) over the small end of the “Z” or reset crank (item 30) and secure it with one 1/8” Spirol pin (item 44). Insert the large end of the reset crank through its respective hole in the bonnet cover from the inside. Place the weather seal o-ring (item 43) over the reset crank shaft from outside the bonnet cover. 15. Place the reset handle (item 16) over the reset crank shaft with the large chamfer facing the o-ring (and cover). Align the hole in the reset crank with the hole in the handle and secure both parts with a 5/16” spirol pin (item 24). 16. Screw the adjusting stud (item 35) into the bonnet cover (milled notch end first) until the end is flush with inside surface of the cover. Rotate the stud in or out slightly to allow the notch to align with the hole through the end of the cover. Secure the stud by driving one ¼” spirol pin (item 40) through the cover until the outer end is flush with the outer surface of the cover. 17. Place reset spring (item 23) over the spring guide rod (item 28) and insert one end of the rod into the shallow hole (or divot) inside of the bonnet. Rotate the reset crank to allow the spring keeper (item 27) to be inserted into its hole in the reset crank (from the outboard side). Position the cover (item 29) over the bonnet, tilt it back to view the keeper, and guide the keeper over the end of the spring guide rod prior to placing the cover fully against the top of the bonnet. Secure the bonnet cover using only New NOV cap screws lubricated with a nickel base never seize compound. Tighten all four screws in a crossing pattern according to the "Torque Chart" on page 16 18. Set both load springs (item 37) on the lower spring retainer (item 39) and place upper spring retainer (item 34) over the top of the adjusting stud and allow it to move downwards until it engages both springs. Screw the locknut (item 32) on the adjusting stud until a minimum amount of compression is placed on the springs to hold them in place. 19. Orient the reset handle so that it is opposite the discharge side of the valve body. After lubricating the body bores and piston seals stab the piston carefully into the upper end of the body. Press downwards on the bonnet until the bonnet flange mates with the body. Secure the bonnet using only New NOV cap screws lubricated with a nickel base never seize compound. Tighten all four screws in a crossing pattern according to the torque shown in "Torque Chart" on page 16. The valve is now ready for calibrating. 14
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000
Body Flange/Adapter Assembly 1. Adapter flanges, 6-bolt x 3-1/2”-XXH butt-weld, 6-bolt x 3”-1502 female, or 6-bolt x 3”-1502 male may be attached to or removed from the body of the “RX” valve assembly. When attaching these flanges, it is important to first install the flange face seal (item 53) into its face groove in the flange. It is also important to make up all six 12-point flange cap screws (item 51) with their respective helical lock washers (item 52) to the hand tight position prior to applying torque. Torque all six cap screws in each flange little by little in a crossing pattern so that the flange face does not become cocked with respect to the face of the mating body. Cocking of the flange will lead to early failure (blow our or extrusion) of the flange face seal. Torque all twelve screws (6 on the inlet flange and 6 on the outlet flange) to the torque prescribed in the "Torque Chart" on page 16. 2. On assemblies with the 3”-1502 union connections, care must be taken to protect the threads and sealing surfaces of these unions at all times when the valve is removed from the line. Using worn or damaged union parts can cause failures which could lead to serious bodily injury. Union hammer nuts should always engage their mating parts using hand force. Never try to start a thread using a hammer. After the union is mostly made up by hand, it may be tightened using a hammer. Usually, a 4 to 8 pound hammer is sufficient. Three to four blows on the nut member after initial rotation has ceased should suffice to achieve the proper preload. Correct calibration - The relief pressure indicator should accurately indicate the actual relief pressure. When the valve has been completely torn down and reassembled, it will be necessary to re-calibrate the valve, even if no new components have been installed. Binding or interference between parts, any and all moving parts, especially parts associated with the linkage assembly, will cause the valve to operate improperly.
34000 Series Titan Class “C” Valve Assembly Table Assembly P/N
Item No
Special Parts
34000-01
36 37
111342 20805-03
34000-02
36 37
34000-03
36 37
Pressure Range
Connection Outlet 3” SCH XXH BUTWELD
750 - 2500 PSI
Inlet 3” SCH XXH BUTWELD
111342 20805-04
3” SCH XXH BUTWELD
3” SCH XXH BUTWELD
1500 - 5000 PSI
31591 20805-03
3” SCH XXH BUTWELD
3” SCH XXH BUTWELD
400 - 1500 PSI
Complete Bonnet Assembly Kits Assembly P/N
Pressure Range
34011 34012 34013
750-2500 PSI 1500-5000 PSI 400-1500 PSI
Seal Kit Assembly P/N
Pressure Range
34005
All (3) Pressure Ranges
15 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000 Maintenance Torque Inspection Tools Required Replacement Seal Kit Bushings
7-1 7-1 7-2 7-2 7-2 7-3
Maintenance The Titan Class “B” Reset Relief Valve has been designed to require a minimum amount of maintenance. The recommended maintenance for the valves involves removing the bonnet assembly (refer valve disassembly procedure) every 2-4 weeks and flushing out the valve body and cleaning any debris. Then you would need to apply grease to the inner walls of the valve body where the upper shoulder seal on the piston seals and also apply grease through the grease fitting on the bonnet assembly itself until it is completely full of grease (from the factory it should be full of grease). The grease will act as a rust inhibitor and this will protect against the corrosion. Flange screws, bonnet retaining screws, and cover retaining screws should be checked for proper torque periodically. Please refer to the torque chart. Note: Recommended Lubricant P/N 2560 Upper Bonnet Assembly Parts (Top Works): Maxi Glide Teflon Gel Lubricant or Equal P/N 3015 Piston, Body I.D. and Seals: Synthetic Lubricant Grease or Equal. Torque Chart Size. Part No. 1/2”-13 SH Cap 204044-10-14 5/8”- 11 SH Cap 063150-10-15 1”-8 12-pt. Cap 111676
Quantity Where Used
Torque, Ft.-lbs--N-m
(4) Cover (4) Bonnet (8) Flange Adapters
85+9 115+12.2 169+17 229+23 420+31.5 569.5+42.7
Due to the variations in pulsation dampening from rig to rig and the resulting effect on component fatigue life, it is recommended that the 1/2” and 5/8” socket head cap screws not be reused but rather replaced with new cap screws when servicing the valve. Verification of the valve accuracy should be done on a regular basis. After all, this is a piece of safety equipment and it should be operated and maintained accordingly. It is recommended that the valve be calibrated every 6 months as a minimum. For calibrating the valve in the field, NOV may provide a portable manual pump with a proper test gauge (1/4% full scale) to aid the operator (reference part number 32590). If a pressure gauge with a built-in dampening device is used, the line pressure should be built up slowly to allow the actual system pressure and gauge pressure to stabilize. If possible, the line pressure should be built up slowly and gradually with little or no pressure pulsations.
Inspection To inspect visually, with no pressure in the valve, reset button pushed in, remove (4) Bonnet Bolts. Pull Top Work up vertically; inspect piston seal and the body ID. Wash any debris from the body and re-lube body and piston. Reassemble. Valve is ready for reset. Tools Required 1.3/32 to 7/64 inch diameter x 1 inch (min.) long straight shank punch (for items 19 and 44) To perform service work on the Titan Class “B” Reset Relief Valve, the following tools will be required: To inspect visually, with no pressure in the
16
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000 valve, reset button pushed in, remove (4) Bonnet Bolts. Pull Top Work up vertically; inspect piston seal and the body ID. Wash any debris from the body and re-lube body and piston. Reassemble. Valve is ready for reset. 2. 7/32 to 15/64 inch diameter x 1-3/4 inch (min.) long straight shank punch (for item 40) 3. 1/4 to 19/64 inch diameter x 1-3/8 inch (min.) long straight shank punch (for item 24) 4. Small hammer 5. 3/8 inch hex Allen or internal hex wrench (for item 50) 6. 1/2 inch hex Allen or internal hex wrench (for item 54) 7. 3/8 open end wrench (for item 38) 8. Large slotted screwdriver (for item 38) 9. 1-1/4 6pt. or 12 pt. box end or socket wrench (for item 32) 10. Needle nose pliers (for item 25) 11. 1”-12 pt. socket and torque wrench (for item 51) 12. Sub wrench assembly, NOV p/n 31873 (for item 5) 13. Release Shaft Retainer Spanner, use large slotted screw driver (for item 46) 14. 15/16 open end wrench or open end adjustable wrench (for item 4) 15. O-ring pick In addition to these tools, a supply of new NOV spare parts should be available and on hand in order to speed the repair process. Replacement Seal Kit for P/N 34005 Item
Qty
Part No
7
1
32501-2
9
1
31914
10
1
31909
11
1
702640-03-20
12
7
02640-24-31
13
1
32519
14 43
1 1
702640-23-01 702640-21-01
53
2
702640-23-71
Spirol Pins The minimum number of Spirol Pins required for complete replacement of all pins in the valve is shown on the bill of materials and in the chart below: Item
Qty
Part No
Basic Size
19
5
20712-02
1/8 x 5/8
24
1
20712-13
5/16 x 1-3/8
40
2
20712-04
1/4 x 1-1/2
44
2
20712-03
1/8 x 7/8
NOTE Refer to the Drawings and Parts List at the end of this manual for NOV part numbers and usage. The bushings shown in the chart below are not specifically “ballooned” on the assembly drawing but they are called out on the bill of material under the main item in the sub-assembly where they are used.
17 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000 Bushings Item
Qty
Part No
3a
1
13229-10
Basic Size I.D. x O.D. x Length 3/8 x 1/2 x 23/32
15a
1
13229-08
1/2 x 5/8 x 1/2
21a
1
13229-13
3/8 x 1/2 x 5/8
22a
2
13229-13
3/8 x 1/2 x 5/8
29a
1
13229-12
3/4 x 7/8 x 1-1/8
Unitized connector assemblies Titan Class “C” W/3” –XXH Butt-weld Connections Drawing Titan Class “C” W/3” –XXH Butt-weld Connections Parts List Class Type “C”W/3”-1502 Connection Drawing Class Type “C”W/3-1502 Connection Parts List
8-1 8-2 8-3 8-4 8-5
Unitized connector assemblies Item
Description
1
Flange 1002 Female Connector Detachable Nut Nitrite Seal Ring Male Half (Butt Weld Prep Piece)
2 3 4
Part No. 31892 31881 31884 31880
Figure 8-1-1. 1002 - Hammer Union, Part No. 31893 (Flange 1002 Female) Item 1 2 3 4
Description Flange 1002 Male Connector Detachable Nut Nitrile Seal Ring Female Half (Butt Weld Prep Piece) Retainer Segments (3 ea. included) Retainer Ring
5 6
Part No. 31891 31881 31884 31871 31926 31927
Figure 8-1-2. 1002 - Hammer Union, Part No. 31894 (Flange 1002 Female) Item
Description
1 2 3 4
Flange 1002 Female Connector Detachable Nut Nitrite Seal Ring Male Half (Butt Weld Prep Piece)
Part No. 31930 31925 31884 31931
Figure 8-1-3. 1502 - Hammer Union, Part No. 31885 (Flange 1502 Female) 18
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000
Item
Description
1 2 3 4 5 6
Flange 1002 Male Connector Detachable Nut Nitrile Seal Ring Female Half (Butt Weld Prep Piece) Retainer Segments (3 ea. included) Retainer Ring
Part No. 31929 31925 31884 31932 31926 31927
Figure 8-1-4. 1502 - Hammer Union, Part No. 31886 (Flange 1502 Female)
Titan Class “C” W/3” –XXH Butt-weld Connections Drawing
19 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000
Titan Class “C” W/3” –XXH Butt-weld Connections Parts List
ITEM
PART NO.
DESCRIPTION
QTY
1
34001
BODY, MACHINE 3" TITAN “C” SEAT, INSERT,TITAN
1
PISTON BODY, SUBASS’Y., TITAN BUSHING, F/ PISTON
1 1
CAP, FOR PISTON
1
SUB, M2 / TITAN CLASS STEM BUSHING
1
SEAL, PISTON, LOWER SEAL, RETAINER
1
SEAL, UPPER PISTON (SHOULDER) SEAL,STEM BUSHING, INNER(VITON) O-RING, PISTON CAP,FACE SEAL O-RING, SUB TO BODY SEAL, FACE (F/INSERT) O-RING, STEM BUSHING OUTER BONNET, SUBASS’Y,TITAN “C” BUSHING, BONNET
1
*
1
*
1
*
1
*
1
*
1
*
1
2
32524 2 3
33003-01
3a
13229-10
4
3250002/M2 31948/M2
5
31900 6 7
32501-2
8
32512
9
31914
10
31909
11
70264003-20 70264024-31 3251
12 13 14 15
70264023-01 34020
15a
13229-08
16
30377
17
32025-2
SPARES
*
1 *
2
1 1
23545
HANDLE, RESET, MACHINED NAMEPLATE,F/ BONNET (SMALL) PIN, LOWER LINK
18 19
20712-02
PIN, SPIROL
5
20
20786
LINK, LOWER
2
21
31977
UPPER LINK SUBASS’Y.
1
1
20
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MANUAL: M-34000
Installation and Operation Manual Reset Relief Valve – C 34000 ITEM
PART NO.
DESCRIPTION
QTY
13229-13
2
38161
BUSHING F/ UPPER LINK CRANK, SUB-ASS’Y.
21a
SPARES
1
22 13229-13
BUSHING, F/ CRANK
2
22a 23
30391
1
24
20712-13
SPRING, RESET CRANK PIN, SPIROL
25
20791
SPRING, LINKAGE
2
26
31975
TOP CRANK PIN
1
27
30380
KEEPER, SPRING
1
30387
ROD, SPRING GUIDE
1
38159
COVER, SUB-ASS’Y.
1
13229
BUSHING, F/ COVER
1
30373
RESET CRANK
1
30388
1
20798
ROLLER, RESET CRANK NUT, AJUSTING, SELF-LOCKING INDICATOR, SET PRESSURE RETAINER, UPPER SPRING STUD, ADJUSTING
1
30389
SEE CHART CAL. PLATE SEE CHART SPRING, LOAD SCREW, LOAD
1
20712-04
RETAINER, LOWER SPRING PIN, SPIROL
30381
PIN, CRANK PIVOT
1
5929-02
FITTING, ALEMITE, 1/4” MALE NPT O-RING, RESET HANDLE PIN, SPIROL
1
1
28 29 29a 30 31 5953-34 32 30379 33 30385 34
1 1 1 1
35 36 37
2 1
38 30382 39
2
40 41 42 43
70264021-01 20712-03
1 2
44 21 MANUAL: M-34000
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Installation and Operation Manual Reset Relief Valve –C 34000 ITEM
PART NO.
DESCRIPTION
QTY
30397
SHAFT, RELEASE
1
32052
RETAINER, THREADED RELEASE BUTTON, RELEASE
1
SPRING, RELEASE BUTTON SCREW U-DRIVE
1 16
SCREW, SH CAP, ½
4
CAPSCREW, FERRY HEAD 1” LOCK WASHER 1”
8
O-RING, FLANGE
2
SCREW, SH CAP, 5/8
4
NAMEPLATE, F/RRV COVER (LARGE) NAMEPLATE,TITAN CLASS FLANGE, WELD NECK F/3"-C
1
SPARES
45 46 47
30396
48
31868
49
111656
50 51
20404410-14 111676
52
111680
53
55
70264023-71 06315010-15 32025-1
56
32025-3
57
31852
54
1
8
1 2
22
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MANUAL: M-34000
Class Type “C”W/3”-1502 Connection Drawing
Installation and Operation Manual Reset Relief Valve – C 34000 Class Type “C”W/3-1502 Connection Parts List
ITEM
PART NO.
DESCRIPTION
1 2 3 3a 4 5 6 7 8 9 10 11 12 13 15 15a 16 17 18 19 20 21 21a 22 22a 23 24 25 26 27 28 29 29a 30 31 32 33 34 35 36 37
34001 32524 33003-01 13229-10 32500-02/M2 31948/M2 31900 S 32501-2 32512 31914 31909 702640-03-20 702640-24-31 32519 34020 13229-08 30377 32025-2 23545 20712-02 20786 31977 13229-10 38161 13229-13 30391 20712-13 20791 31975 30380 30387 38159 13229-12 30373 30388 5953-34 30379 30385 20798
BODY, MACHINE 3" TITAN “C” SEAT, INSERT, TITAN PISTON BODY, SUB-ASS’Y., TITAN BUSHING, F/ PISTON CAP, FOR PISTON SUB, M2 / TITAN CLASS TEM BUSHING SEAL, PISTON, LOWER SEAL, RETAINER SEAL, UPPER PISTON (SHOULDER) SEAL, STEM BUSHING, INNER (VITON) O-RING, PISTON CAP, FACE SEAL O-RING, SUB TO BODY SEAL, FACE (F/INSERT) BONNET, SUB-ASS’Y, TITAN “C” BUSHING, BONNET HANDLE, RESET, MACHINED NAMEPLATE,F/ BONNET (SMALL) PIN, LOWER LINK PIN, SPIROL LINK, LOWER UPPER LINK SUB-ASS’Y. BUSHING F/ UPPER LINK CRANK, SUB-ASS’Y. BUSHING, F/ CRANK SPRING, RESET CRANK PIN, SPIROL SPRING, LINKAGE TOP CRANK PIN KEEPER, SPRING ROD, SPRING GUIDE COVER, SUB-ASS’Y. BUSHING, F/ COVER RESET CRANK ROLLER, RESET CRANK NUT, AJUSTING, SELF-LOCKING INDICATOR, SET PRESSURE RETAINER, UPPER SPRING STUD, ADJUSTING SEE CHART CAL. PLATE SEE CHART SPRING, LOAD
QTY 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 5 2 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2
SPARES * *
* * * * * *
1 MANUAL: M-34000
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Class Type “C”W/3-1502 Connection Parts List (Continue)
ITEM
PART NO.
DESCRIPTION
38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
30389 30382 20712-04 30381 5929-02 702640-21-01 0712-03 30397 32052 30396 31868 111656 204044-10-14 111676 111680 702640-23-71 063150-10-15 32025-1 32025-3 31930 1502 31929 1502 31884 31925 31931 31932 31926 31927
SCREW, LOAD RETAINER, LOWER SPRING PIN, SPIROL PIN, CRANK PIVOT FITTING, ALEMITE, 1/4” MALE NPT O-RING, RESET HANDLE PIN, SPIROL SHAFT, RELEASE RETAINER, THREADED RELEASE SFT. BUTTON, RELEASE SPRING, RELEASE BUTTON SCREW U-DRIVE SCREW, SH CAP, ½ CAPSCREW, FERRY HEAD 1” LOCK WASHER 1” O-RING, FLANGE SCREW, SH CAP, 5/8 4 NAMEPLATE, F/RRV COVER (LARGE) NAMEPLATE,TITAN CLASS FEMALE FLG CONNECTOR MALE FLG CONNECTOR SEAL RING, F/1002 & 1502 UNIONS NUT, DETACHABLE 3” 1502 SUB, 3” 1502/1002 MALE X 3” XXH BW SUB, 3” 1502 FEMALE X 3” XXH BW SEGMENTS (3-PC) SET RETAINER RING 10/1502
QTY 1 1 2 1 1 1 2 2 2 2 2 16 4 8 8 2 1 1 1 1 2 2 2 2 2 2
SPARES
*
