1

TABLE OF CONTENTS 1. Introduction

Topic This manual covers the Series 1800 line of

Pressure Relief Valves which encompasses differ-

ent model types of similar design. It contains suffi-

cient information to allow trained maintenance per-

sonnel to properly repair valve types 1850, 1850H,

1852, 1852H, 1855, 1856M, 1890, 1892, 1895

and 1896M.

1. Introduction

,Page

1

2. Disassembly

Series 1850, 1852, 1855 and 1856M

.page

2

All of the assembly and disassembly instructions

refer to types with plain screwed caps. When

repairing types with either open or packed lifting

levers refer to Section 3 which describes the

removal of the appropriate lever assembly.

Series 1890,1892,1895 and 1896M

.Page

3

3. Lifting Lever Assemblies

Open Ufting Lever

.Page

4

Packed Lifting Lever Page 4If a valve repair requires replacement parts, only

factory supplied components shall be used. Use of

parts from other than the original manufacturer is

not recommended because it will lead to potentially

dangerous operating conditions. If faced with

repairs exceeding the scope of this manual, we

suggest you contact the Farris Factory.

.Page

54. Lapping Procedure.

5. Assembly

Series 1850,1852,1855 and 1856M

.Page

6

Series 1890,1892,1895 and 1896M

,Page

6

6. Testing and Setting

.Page

7

...,~ TELEDYNE FLUID SYSTEMSFams EngineeringAppendix A: Critical Seat Dimensions Page 8

400 COMMERCIAL AVENUEPALISADES PARK, NEW JERSEY 07650PHONE (201) 944-6300FAX (201) 944-4315

PRESSURE RELIEF VALVESAND TESTING EQUIPMENT

2Fig. 2.2

1855_6

c--14

-3

-4_1

_6

_15

-10

-3---4Series 1850. 1852.1855 and 1856M (Fig. 2.1-2.3)

Mount valve vertically in a vise utilizing the flats inthe body.

2. Remove wire seal. Unscrew cap by turningcounterclockwise. Remove cap gasket. (Foropen lever and packed lever cap construction,refer to the section on Lifting Lever Assemblies.

Fig. 2.31856M

3. Measure the distance from the top of the springadjusting screw to the top of the bonnet. Usethis measurement when reassembling the valveto approximately duplicate the original set pres-sure.

Bill of Materials

4. Using a smooth jaw wrench hold the springadjusting screw on wrench flats and loosen thejam nut.

SA-4791Ype31681 81.

OrSA-3S1. Gr

Cf8M 51. 51.

ASTM 816HH 8rass~

Body Or ASTM B62 Bronze

SA-216 G( I SA-351 G( ~MA1262 Bonnet Y«:B Carb. 51 CFBM 51. 51 I CIS Cast Iron

3 Disc 316 51 51

51. 51

ASTM B16HH. Brass

OrASTMB62

Bronze

ASJM 862 ,Bronze

5. Relieve the spring compression by turning thespring adjusting screw counterclockwise.

316 5t 51 Brass

Brass

Iron

St St

Brass

Brass

Brass

:. I 316 St St-~~~! 316StSt

Blass

Bronze

Brass

Brass

Brass

~ BIow riI7N!, Ring

5 Cap

6s.m ! 316 51 516. Thread a pipe into the outlet and turn the bonnet

counterclockwise. Uft the bonnet out to exposeinternal sub-assembly.

I 7 ISpringAdj Screw i ~St. St

131651 51

~

I 31651. 51.I Carbon 51.

f:g316 51. 51. AuSI Proofed 51. 51. Carbon 51.

Ausr PrOOled 51. 51

FlexibleGraDhile

7. Remove the upper spring button, spring andlower spring button from the stem. Flexible

GraphiteFlexibleGraphite316 51. 51

31651.51

31651 51

;;;

8a. (1850, 1852, 1856M open lever, 1856Mpacked lever only) Lift the stem with stemretainer, lockwasher and disc attached.Unscrew the stem retainer from the disc.Remove lockwasher.

51 51

1 17 I Nameplate(not shfNIn)

18 I SDrin-;;-

-~ II -I

Stainless 51..1 WOe/lead Seal

Stainless Sleel

Lap Joint Stub I $A-403, G;T":SA:403 Gr.End ilnlet) WP316 SI-St I WP316 St SI8b. (1855 only) Lift the stem with the disc attached.

Remove the groove pin. Lift the stem from thedisc.

SA-234 I SA 403 Gr.Carbon SI. WP316 SI. SI.

N0 ! Lap Joint StubT ~nd (Outlet)

E Lap Joint flange I SA-181 or T SA-182 Gr(Inlet) SA-105CarbSt f316 St St

1 IUPJointflange ~~ (Outletl F316 S~

NOTE: 1 Applicable to the F 1850 Series (lianged)

SA.181 orISA.105CarbStSc. (1856M plain cap only) Lift the stem from the

disc. Remove the disc.

9. Unscrew the blowdown ring from the body.

10. Clean all parts and threaded surfaces thor-oughly. Replace all gaskets. Lap the bodyseat and disc surfaces. (See the section onLapping for details.)

TELEDYNE FLUID SYSTEMSFarris Engineering

When a valve is first received in the shop it shouldbe given a visual inspection to note its conditionwhen removed from service. The valve should thenbe carefully dismantled. Proper facilities and toolsshould be available. At each stage In the dismao-:tling process, visually inspect all parts of the valvefor evidence of wear and corrosion. If parts areworn, replace them.

3Series 1890. 1892. 1895 and 1896M (Fig. 2.4)

1. Mount valve vertically in a vise utilizing the flats inthe body.

2. Remove wire seal. Unscrew cap by turningcounterclockwise. Remove cap gasket. (Foropen lever and packed lever cap construction,refer to the section on Lifting Lever Assemblies.)

3. Measure the distance from the top of the springadjusting screw to the top of the bonnet. Usethis measurement when reassembling the valveto approximately duplicate the original set pres-sure.

Bill of Materials4. Using a smooth jaw wrench hold the springadjusting screw on wrench flats and loosen thejam nut.

SA.479 Type I SA-419 Type

316 St. 51 316 51. 51.

5. Relieve the spring compression by turning thespring adjusting screw counterclockwise.

316 St SI I 316 SI. St

316 SI. St.StSt.CaIIIon St.

St. St.St 51

1 I!Orjy

",," ,2 Bonnet

~~~-, ~~

3 ~ c

4 Glide St St.

5 ~, Plain ~ CaIIIon St.

6 Sf8m St. St.

7 Sprilg Adj. Screw St. St.

8 SpIi1O BIIt1On ..-c

9 Jam Nut St St

10 Smm ShOtJkIer St St

11 Body Gasket =~

12 Cap GasI<et =I:e

13 Lift Slop Ring St St

14 Relainmg Ring- St StStem SOOWder .

15 Wire Seal

16 Namepmm(not shown)

17 Spring

lap Joint Stub EndN (In~)

0 Lap Jamt Stub End ~234T (OUllet) Carbon St

E Lap JoHrt Range ~181 or ~105(Inlet) Carbon Steel

1lap Joint Flange ~181 Qr SA-105(O.l1et) CarbQrJ St

6. Thread a pipe into the outlet and turn the bonnetcounterclockwise. Lift the bonnet out to exposeintemal sub-assembly.

7. Uft the stem with spring and buttons attached.Remove upper spring button, spring and lowerspring button.

8. Remove the lift stop ring.

9. By inverting the assembly, remove the disc fromthe guide.

~. Gr SA-4O3 GrWP316 51 51 WP316 5t St.

SA-403 GrWP316 St. St.

SA-182 Gr.F316 St 5t.

SA-152 Gr.F316 5t. 5t.

NOT AVAILABLE

10. Unscrew the guide from the valve body.Remove body gasket.

General Noles:1 Items not shown are applicable to the F 1890 Series (Flanged).

11. Clean all parts and threaded surfaces thorough-ly. Replace all gaskets. Lap the body seat anddisc surfaces. (See the section on Lapping for

details.)

Valve No.18901892

1890/841892/84

18951896M

Spring Material

Stainless

SteelHigh Temp. Alloy, Rust Proofed

316 Stainless SteelHigh Temp. Alloy, Nickel Pltd.Stainless

SteelStainless Steel

TELEDYNE FLUID SYSTEMSFanis Engineering

4

B. PACKED LIFTING LEVER

There are several designs of packed cap constructions.Refer to the appropriate section below for your particular capconstruction.

(a) Fig. 3.2

1 .Remove groove pin from lever and slide lever off the cam

2. Remove gland from gland nut. Unscrew gland nut frombonnet and remove packing ring and cam. If any signs ofleakage exist, replace packing ring.

3. Break wire seal and unscrew cap from bonnet. Holdingthe stem with pliers, remove stem jam nut and stem testwasher.

4. Reassemble in reverse order making sure the cam lobe is

pointing down. The stem test washer should be adjusted

to ensure the cam will make contact with the stem test

washer and lift the stem when the lever is actuated.

(b) Fig. 3.3

1 .Remove groove pin from lever and slide lever off the cam shaft.

2. Complete disassembly is only required if the packing ring is

to be replaced or intemal inspection is required. To remove

assembly, rotate the leve, down and unscrew the cap.

3. To complete disassembly, remove the gland packing ring

and retaining ring.

4. Pull the cam shaft from the cap. The cam can then be

removed through the bottom of the cap.

5. Remove the stem jam nut and stem test washer.

6. Reassemble in reverse order making sure the cam rests

beneath the stem test washer.

(c) Fig. 3.4

1. Remove lever jam nut and washer. Slide lever off the cam

shaft.

2. Follow steps 2 to 6 in section (b).

STEil JAIl NUT

STEil TEST WASNER

CAIISHArT

STEIl

GlAND

CRDDV-PlN

PACKING RING

CLAND NUT

TEST LEYER

BONNET

SPRING ADJUSTING SCREW

SEAL

CAP

CAP GASKET

Figure 3.2 Packed Lifting Lever (a)

STEM TEST -.sHEW

CAM mu

ST[W JAW WUT

!T[W ftST WASHER

CAP

CAW~

STEW

CAP CASK£T 111 i

~NN£T./

CAP GAS«[T---:'" ~ i !-_MET /" .

rm l£VtR \Q)

Figure 3.4 Packed Lifting Lever (c)

TEST l£VER ~

Figure 3.3 Packed Lifting Lever (b)

TELEDYNE FLUID SYSTEMSFarris Engineering

A. OPEN LIFTING LEVER (Fig. 3.1)

1. Remove wire seal and cotter pin. Slide out button head

rivet to release lever from cap.

2. Remove set screw from base of cap and lift cap off bonnet.

3. Remove stem jam nut and stem test washer from the stem.

4. Clean all parts and reassemble in reverse order. Adjust

stem test washer so there is 1/8" clearance between test

lever fulcrum and stem test washer.

5

4. Lapping Procedure(For metal seats only; does not apply to a-ring seat seal valve)

1. The finish on the body seat and disc are critical to seattightness. After the parts have been cleaned both partsshould be lapped to remove all blemishes and scoremarks. This can be done on an automatic lappingmachine or by hand using a cast iron lapping block orPyrex lapping glass which is known to have a perfectlyflat surface.

that has been lapped off from the body seat in order tomaintain the critical parts respective relationship.

5b. (1890/95/96M only) Remove the same thickness ofmaterial from the bottom face of the guide as that hasbeen lapped off from the body seat.

PYREX LAPPING PLATES:

PART NO. MAT. CODE SIZE THICKNESS 6. Carefully clean compound from all parts. Failure to do somay foul the seat and disc surfaces. When reinstallingthe parts in the valve and/or in assembling the disc in theguide, be careful not to scratch or score either surface.

76887689

164164

1-1;2'2-1f4-

1;4"

%"

7. Check Appendix A for critical seat dimensions. Replaceany parts that have dimensions smaller than the minimum

required.

2. Use Farris 1200 lapping compound. When lapping thedisc, operate with a light figure eight motion over entireblock surface. In this way complete contact will be made.With this motion the complete surface of the part will beevenly lapped and you will avoid wearing a groove in theblock.

3. Lap the disc until all blemishes and score marks havebeen removed. As the figure eight motion is executed,frequently lift the disc away from the block to get a freshbite on the compound. Most importantly, do not contam-inate compounds with dirt. Store lapping blocks and lap-ping glass in a clean, dust-free area.

4. Measure and record the body seat height. Follow thesame procedure for lapping the body seat. When lappingbodies the body can be placed on a table and a lappingblock placed on the body. Be sure that the lapping blockdoes not tip over the side of the body (which would causerounding of the edges). Use a light, rapid figure eightstroke, lifting the block from the body occasionally.

5a. (1850/55/56M only) Remove the same thickness ofmaterial from the bottom face of the blowdown ring as

TELEDYNE FLUID SYSTEMSFarris Engineering

6

Series 1890. 1892. 1895 AND 1896

1. Refer to Figure 2.4 for construction details.2. Visually inspect all parts to be assembled. Replace

gaskets, a-rings, and any parts that are worn.Lubricate all threaded and mating surfaces with BostikNever Seez (or equivalent).

2. Visually inspect all parts to be assembled. Replaceall gaskets. Lubricate all threaded and mating sur-faces with Bostik Never Seez ( or equivalent.).

3. Examine seat of body and disc for any marks that maycause leakage. Refer to the section on lapping ifrelapping is necessary.

3. Examine seat of body and disC for any marks or sur-face imperfections that may neduce seat tightness.If relapping is necessary, refer to the section on lap-

.Iping. !

4. (O-ring Seat Only) Refer to Fig. 5.1. Position thedisc on a flat surface with the O-ring groove facingup. Insert O-ring into the disc groove. Insert theO-ring retainer on the disc, ensuring the O-ring iscentered. Lock the O-ring and retainer to the diskwith the hex nut.

4a.(Metal Seat Only) Loosely assemble body andguide. Insert disc in guide and verify that guideturndown from disc contact is 1/16 to 1/4 turn.For set pressure under 100: PSIG, 1/8 turndownmaximum is required. Remo~e disc.

4b.(O-Ring Seat Only) It is ~ecommended that

O-ring/disc sub-assembly be replaoed rather thanattempt removal of retainin~ ring. Do not use ametal seat guide in O-ring se~t seal valves.

5. Tighten the blowdown ring to the body.

6a. (1850, 1852, 1856M open lever and 1856M packedlever only) Place stem retainer over stem. Screwstem retainer to disc.

5. Tighten guide to body with 11/4" dia. bar insertedthrough guide exit holes with qpproximate torque of20 ft. Ibs.

6. Insert disc and install lift stop.disc lift is greater than .085".

Verify that available

6b. (1855 only) Place stem into the disc. Drive groove pin

through the disc into the stem.

6c. (1856M Plain cap only) Insert retaining ring into the

stem groove. Place stem into disc.

7. Place disc- stem assembly over the body, making sure

that the disc and body seats are aligned. 7. Place stem shoulder over retaining ring. Installspring and spring buttons on $tem and insert entireassembly into bonnet/spring ~djusting screw sub-assembly. The lower sub-a~sembly with bonnetgasket can then be assembled and tightened toapproximately 40 ft. Ibs. torque.

8. Install lower spring button, spring and upper springbutton on stem.

9. Place bonnet over the assembled parts and screwdown onto the body.

8. Hand tighten adjusting screw until slight springcompression occurs.

10. Thread the jam nut onto the spring adjusting screw.

11. Thread spring adjusting screw into bonnet to the posi-

tion recorded during disassembly.

12.The valve is now ready to be removed for testing.

Fig. 5.1 1850 Series O-Ring Seat Construction Fig. 5.2 1890 Series O-Ring Seat Construction

TELEDYNE FLUID SYSTEMSFarTis Engineering

Series 1850. 1852. 1855 AND 1856M

1. Refer to Figures 2..1- 2.3 for construction details.

7

WATER -Before starting the seat tightness test, the outletbody bowl shall be filled with water, and the valve shall beallowed to stabilize with no visible flow from the valve outlet.The valve shall be observed for "1 minute at the test pressure.There shall be NO VISIBLE LEAKAGE at the valve outlet.

Soft Seated Valves

Soft seated valves shall be tested at 95% of set pressurewhen set above 100 psig; they shall be tested at 5 psigbelow set pressure when the set pressure is less than orequal to 100 psig.

8l8: There shall be NO LEAKAGE (ZERO BUBBLES) usingthe test method outlined above.

STEAMgng WATER: There shall be NO VISIBLE LEAKAGEat the valve outlet.

2. If any valve fails to meet leakage requirements it shall bereworked.

3. Assemble appropriate CAP CONSTRUCTION after leaktightness has been verified. If valve type is OPEN LEVER,no back pressure test is required. PLAIN CAP andPACKED LEVER valves must be back pressure tested asoutlined in the next section.

BACK PRESSURE TEST

1. This test applies to all valves designed for discharge to aclosed system (PLAIN or PACKED LEVER CAP CON-STRUCTION) with inlet sizes larger than 1" NPS.

2. The secondary pressure zone of the valve shall be testedwith air or other suitable gas at a pressure of at least 30psi. The valve should be pressurized at the outlet withshop air or other means. A soap solution or other suitablesolution shall be applied to all connections which are

potential leakage paths (i.e., body/bonnet connection,cap/bonnet connection, packed lever assembly/cap con-nection). No leakage is acceptable.

3. If leakage is detected at any location the valve shall bereworked.

~~ TELEDYNE FLUID SYSTEMSFarTis Engineering

TESTING AND SETTING PROCEDURE:

1. Mount the valve on the test stand. Use air as the testmedium for air, gas and vapor or flashing service appli-cations. Set valves for saturated steam service on satu-rated steam. Valves for steam service set with airshould include temperature compensation. The name-plate provides "Cold Differential Set Pressure." Setvalves for liquid service on water.

2. Hold the STEM tightly and tighten (turn clockwise) theSPRING ADJUSTING SCREW to increase the springforce. Make sure the stem does not rotate while load-ing the SPRING.

3. Slowly raise the test drum pressure and observe theopening point. The set pressure on air or steam is the"pop point" while on water it is the first continuous flow.

4. If necessary reduce the test drum pressure and adjustthe SPRING ADJUSTING SCREW. Repeat this until thevalve opens at the required pressure, designated as"Cold Differential Set Pressure." At the desired setting,torque the JAM NUT to 25 FT. LBS. and assemble CAPand GASKET for tightness testing. Check set point oncemore after locking JAM NUT.

NEVER ADJUST THE SPRING SETTING WHEN THEPRESSURE UNDER "THE VAL VE IS NEAR ITS POPPINGPOINT; AS THE BODY SEA T AND DISC SEA T MIGHTSCORE AND/OR GALL. ALWAYS LOWER THE PRES-SURE IN THE VALVE AT LEAST 25 PERCENT BELOWPOPPING PRESSURE BEFORE MAKING ADJUST-MENTS. THIS WILL PUT A LOADING ON THE SEA TfNGSURFACES, THUS PREVENTING ROTATION AND DAM-AGE. SEAT TIGHTNESS TESTING

SEAT TIGHTNESS TESTING

NOTE: The valve must be checked for seat leakage after theset pressure has been checked. Excessive leakage couldlead to fouled or inoperable valves, serious product loss andcould be hazardous to personnel and equipment.

1. The valve can be tested for tightness on the test stand byincreasing vessel pressure to the required test pressureand observing the valve outlet for evidence of leakage.The following is an overview of the test procedures used.

Metal Seated Valves:

Metal seated valves shall be tested at 90% of set pressurewhen the set pressure is greater than 50 psig; they shall betested at 5 psig below set pressure when the set pressure isless than or equal to 50 psig.

A!B -A 5/16' 0.0. x 0.035' wall thickness copper tube orequivalent immersed no more than 1/2" deep in water shallbe connected to the valve outlet. See Figure 6.1. Seal allother potential leakage paths with suitable fixtures (i.e., cap,plugs) so that seat leakage can be detected at the outlet.Before starting the bubble count, test pressure shall beapplied for a minimum of 1 minute. The valve shall then beobserved for leakage for at least 1 minute. The leakage rateshall not exceed 40 bubbles per minute.

STEAM -Test pressure shall be applied for 3 minutes beforethe seat tightness test. The valve shall be observed for leak-age for at least1 minute. There shall be NO VISIBLE LEAK-AGE at the valve outlet.

8

CHAMFER .005 X 45"

~

L:=

MIRROR FINISH

,

MIN.

Body #1 Body #2

I ,040 MIN,.MIRROR FINISH

CHAMFER ,010 X 45'DiSC 1*1

~~ TELEDYNE IFLUID SYSTEMSFarris Engineering

TELEDYNE FLUID SYSTEMSFarris Engineering

400 COMMERCIAL AVENUE

PALISADES PARK, NEW JERSEY 07650PHONE (201) 944-6300

FAX (201) 944-4315

PRESSURE RELIEF VALVESAND TESTING EQUIPMENT

Printed In USA