CROSBY SERIES HSJ SAFETY VALVES

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Before installation, these instructions must be carefully read and understood.

SERVICE RECORDS Contract management

Emerson will combine a group of services to
Service records should be completed before satisfy your special maintenance needs.
a valve is returned to service. These records
are important and will provide guidance on Emerson’ full-spectrum service
establishing time intervals between repairs as • Valve repair
well as providing the historical record of repairs • Field service
and service conditions. Well kept records will • Replacements parts
be useful in predicting when to retire a valve • Contract management
and which spare parts should be maintained in • Training
inventory to ensure uninterrupted plant operation. • Testing
• Contract
WARNING
The safety of lives and property often depends
on the proper operation of the safety valves.
Consequently, the valves should be kept clean and
should be tested periodically and reconditioned to
make sure they function properly.

EMERSON FIELD SERVICE AND REPAIR

PROGRAMS

Field service
OVERVIEW Emerson field service provides on-site, in
line testing and repair capability for all types
Series HSJ is a full nozzle reaction type safety of pressure relief devices. It is strongly
valve designed for saturated and superheated recommended that on new installations, a
steam service on drums, superheater outlets, Emerson service engineer be present for
reheater inlets and outlets and economizer assembly and testing of safety valves.
applications. Increasing operating efficiency
through the use of the FLEXI-DISC™ seat Parts
design. The FLEXI-DISC™ seat design is Emerson will help you establish the right mix
recessed for pressure and temperature of on-site spares with our own distribution and
equalization, ensuring a flat and tight seal. manufacturing support.

SPARE PARTS Training

Emerson offers intensive factory or on-site
Emerson recommends spare parts as shown training seminars to improve maintenance
on the outline drawing Figure 1. When ordering and application skills.
spare parts, the valve size, style and assembly
number and/or serial number should be Testing
given together with set pressure, part name, Emerson has the capability to evaluate safety
and reference number from Figure 1. The valve operability either in the field or at various
valve assembly number is shown on the valve Emerson facilities. Special qualification
nameplate as 'Shop No'. Spare parts may be programs may also be conducted in our
ordered from any Emerson regional sales office laboratories.
or representative.

Engineering Doc. #IS-V3146

Emerson.com © 2017 Emerson. All Rights Reserved. VCIOM-01062-EN 22/04

CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 1 VALVE NAMEPLATE

Seal and
wire

NOTES NOTES
1. Consumable spare parts: soft goods (gaskets, On Series HSJ with closed bonnet option
etc.) which should be replaced as part of any (except Series HSJ-DOW) the bonnet vent
disassembly, and disk inserts which must be MUST REMAIN OPEN. Keeping the bonnet vent
replaced if seats are damaged. open is essential for proper valve operation.
2. Repair spare parts: goods exposed to wear and/
or corrosion during normal operation. They are in On Series HSJ-DOW (for organic fluid vaporizer
fluid flow paths and may require replacement as generator applications) use a closed bonnet having
part of any repair. the bonnet vent plugged and Type A screwed cap.
Seal and wire 3. Insurance spare parts: hard goods exposed to
process or environmental wear and/or corrosion
and may require replacement as part of a major
repair.
Emerson recommends that sufficient inventory
of spare parts be maintained to support process
requirements.
Always be sure to use genuine Emerson parts to
ensure continued product performance and warranty.

PARTS LIST
Material and maximum temperature
Part No. Part name 750°F (399°C) 1000°F (538°C) Spare parts designation (See notes 1, 2, 3)
1 Body Carbon steel Alloy steel
ASME SA-216 Gr. WCB ASME SA-217 GR. WC6
2 Nozzle Stainless steel Stainless steel 3
3 Nozzle ring Stainless steel Stainless steel 3
4 Nozzle ring set screw Stainless steel Stainless steel 3
5* Disk holder Nickel alloy Nickel alloy 2
6* Disk insert Stainless steel Stainless steel 1
6A* Disk Stainless steel Stainless steel 1
7* Disk insert cotter Stainless steel Stainless steel 1
8 Guide Nickel alloy Nickel alloy 3
9 Guide ring Stainless steel Stainless steel 3
10 Guide ring set screw Stainless steel Stainless steel 3
11 Spindle assembly Stainless steel Stainless steel 3
12 Spring Alloy steel Alloy steel 3
Corrosion resistant coating Corrosion resistant coating
13 Spring washers Steel Steel 3
14 Bonnet Carbon steel Alloy steel
ASME SA-216 Gr. WCB ASME SA-217 GR. WC6
15 Bonnet stud ASME SA-193 Gr. B7 ASME SA-193 Gr. B7
16 Bonnet stud nut ASME SA-194 Gr. 2H ASME SA-194 Gr. 2H
17 Adjusting bolt Stainless steel Stainless steel 3
18 Adjusting bolt nut Steel Steel 3
19 Cap lever assembly Steel/iron Steel/iron
Gaskets Organic fiber non asbestos Organic fiber non asbestos 1

* One piece disk (6A) replaces part reference numbers 5, 6 and 7 in orifice sizes F, G, H, and J for CL 150, CL 300 and CL 600.

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 2 Fixed support anchored to building structure NOTES

* Refer to ASME boiler code section 1, pg-71.2
** Allow sufficient space to prevent bottoming or side binding of the drip
pan to the discharge pipe under maximum conditions of expansion
Seal wire
Ring positions
stamped here

Discharge pipe

Drip pan

Wire and
seal Drain

Drain

See note **

Shortest Recommended minimum diameter -

possible ½” larger than valve inlet
length*

Boiler drum

Rounded smooth length

CAUTION 2 STORAGE AND HANDLING

The valve should never be lifted or handled using
the lifting lever. Often, valves are on hand at the job site months
before they are installed. Unless stored and
WARNING protected properly, valve performance may be
To have trouble-free performance be sure to affected adversely.
clean the inlets and outlets of valves thoroughly Rough handling and dirt may damage or
before installing. All dirt, sediment and scale in cause misalignment of the valve parts. It is
the protected vessel and piping must be removed recommended that the valves be left in their
completely before installation (foreign material original shipping containers and that they be
entering the valve may cause seat leakage, stored in a warehouse or at a minimum on a
plugging and valve malfunction). dry surface with a protective covering until they
are used.
1 INTRODUCTION

Crosby Series HSJ safety valves have been

selected because of their performance features,
reliability and ease of maintenance. Adherence
to the installation and maintenance procedures
specified herein will provide the utmost in safety, a
minimum of maintenance and a long service life.
Crosby Series HSJ safety valves are manufactured
in accordance with the requirements of Section
1, Power Boilers, and Section VIII and Section XIII,
Unfired Pressure Vessels, of the ASME Boiler and
Pressure Vessel Code.

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

3 INSTALLATION The precise nature of the loading and

the resulting stresses will depend on the
Rigging configuration of the valve and the discharge
Safety valves must be handled carefully and piping. This must be taken into consideration
never subjected to sharp impact loads. While by those responsible for the installation of the
in the shipment case or when uncrated they safety valve and associated vessel or piping.
should not be bumped or dropped. Rough Determination of outlet reaction forces is the
handling may alter the pressure setting, deform responsibility of the designer of the vessel and/
valve parts and affect seat tightness adversely. or piping.
When it is necessary to use a hoist, a sling Many valves are damaged when first placed
should be placed around the valve body and into service because of failure to clean the
bonnet in a manner that will ensure that connections properly when installed. It is
the valve is in a vertical position to facilitate essential that the valve inlet, the vessel and the
installation. line on which the valve is mounted be cleaned
Flange protectors should remain in place until thoroughly of all foreign material. The inlet
the valve is ready to be installed on the system. connection bolts or studs should be tightened
uniformly to avoid straining or distorting the
Inspection valve body.
Safety valves should be inspected visually
before they are installed to ensure that no Outlet piping
damage has occurred during shipment or while Discharge piping should be simple and direct.
in storage. All protective material, sealing plugs Where possible, a short vertical pipe connected
and any extraneous material inside the valve through a long radius elbow discharging
body or nozzle must be removed. directly into the atmosphere is recommended.
The valve nameplate and other identifying tags Discharge piping should be designed so as not
should be checked to ensure that the particular to impose any loading on the valve. Excessive
valve is being installed at the location for discharge piping may cause seat leakage or
which it was intended. The seals protecting the faulty valve operation. The inside diameter of
spring setting and ring adjustments should be the discharge pipe must never be less than that
intact. If seals are not intact, the valve should of the valve outlet.
be inspected, tested and new seals installed Valve effluent must discharge to a safe disposal
before use. area.
Valve bodies are provided with pipe thread
Inlet piping openings for drains. These should be connected
Safety valves should be mounted in a vertical to prevent any accumulation of fluid in the
position, directly on the pressure vessel; the valve body. In addition, it is recommended that
nozzle should have a well-rounded approach discharge piping also be drained to prevent any
that provides smooth, unobstructed flow accumulation of fluid. Care must be observed
between the vessel and the valve. A safety valve to ensure that the drains are directed or piped
should never be installed on a fitting having to a safe disposal area.
an inside diameter smaller than the inlet
connection of the valve as restricted flow can
cause faulty valve operation.
Inlet piping (nozzles) must be designed to
withstand the total resultant forces due to the
valve discharging at the maximum accumulated
pressure and the expected piping loads.

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

CAUTION 7 ADJUSTMENT
Gags should not be used when inlet pressures are
more than 10% greater than the safety valve set Set pressure adjustment
pressure. Damage to the valve may result. Before making any adjustments, reduce the
system pressure under the valve 10% to 20%
4 HYDROSTATIC TESTING below the set pressure stamped on the valve.
This will prevent damage to internal parts and
When a hydrostatic test is made on the system, minimize the chance of an inadvertent valve
it is recommended that blank flanges be used opening.
in preference to gagging of the safety valves. For parts identification see Figure 1 on page 2:
Excessive tightening of the gag (test rod) may a. Remove the cap (19) and lifting lever device
damage or bend the valve spindle. However, (if any) following the instructions on page 8.
when the valves are to be gagged for a b. Loosen the adjusting bolt nut (18).
hydrostatic test, a gag as shown in Figure 4 on c. Turn the adjusting bolt (17) clockwise to
page 10 should be used. increase set pressure or counterclockwise
Blank flanges must be removed and the safety to reduce set pressure.
valve reinstalled before the vessel is placed in d. Retighten the adjusting bolt nut (18)
service. following each adjustment.
When test rods are used, care must be e. Once the set pressure has been established
exercised to prevent overtightening that could replace the cap (19) and lifting lever device
damage the spindle and valve seats. Generally, (if any) following the instructions on page 9
a test rod which is finger tight will provide and install a new seal and wire.
sufficient force to hold the valve closed.
After the hydrostatic test, the test rod (gag) Nozzle ring and guide ring adjustment
must be removed and replaced by either a cap The nozzle ring (3) and guide ring (9)
plug or a cap not fitted with a test rod. adjustment is made at the factory and resetting
in service seldom is necessary.
5 TESTING SAFETY VALVES Should it be necessary to change blowdown
or reduce valve simmer, the following steps
Before a new boiler is put in service all safety should be taken:
valves should be tested. Each valve has been set
and tested at the factory but service conditions Whenever ring adjustments are changed, a
differ and it is sometimes necessary to make record should be kept of the number of notches
adjustments. Safety valves may be tested by and the direction in which the ring was moved.
raising the system pressure and popping the This will make it possible to return to the
valve. All safety valves on the system with lower original setting in case of error.
set pressures should be gagged.
IMPORTANT
6 DESCRIPTION OF OPERATION Crosby steel safety valves have the shipment ring
settings stamped on the machined surface on the
The valve will open with a sharp pop at the bonnet directly under the cap. See Figure 2.
pressure for which it is set and remain open,
relieving full capacity at 3% overpressure. As CAUTION
pressure decays below the popping pressure, Should any ring adjustments be made while the
the valve will remain open until the blowdown valve is installed on a pressurized vessel, the
pressure is reached. The valve will close sharply. valve should be gagged. Care must be exercised
to prevent excessive tightening of the gag that
could damage the valve spindle and valve seats.
However, sufficient force must be applied to the
gag to prevent the valve from lifting.

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Guide ring adjustment b. Remove the nozzle ring set screw (4). Check
The guide ring (9) is the principal blowdown the nozzle ring setting by turning the nozzle
control ring in the valve. To change the guide ring (3) to the right and counting the number
ring position, remove the guide ring set screw of notches turned until it makes contact with
(10) and insert a screwdriver to engage one of the disk holder assembly (5). Record the
the notches. Turning the guide ring to the right number of notches. This location is given as
raises it and decreases the blowdown. Turning minus (-) notches from this contact position.
the guide ring to the left lowers the ring, Remove the guide ring set screw (10). Check
thereby increasing the blowdown. the guide ring setting by returning the guide
The guide ring (9) should never be moved more ring (9) to its level position. The guide ring
than ten notches either way without retesting is in level position when the bottom face
the valve. After each adjustment always of the guide ring is level with the bottom
replace, tighten and seal wire the set screw face of the disk holder assembly (5). The
being careful that its point fits in the notch in guide ring should be turned to the right or
the ring without making contact with the ring or left, whichever is necessary to return it to
bearing on top of a tooth. its level position. The guide ring position is
recorded as minus (-) (down) or plus (+) (up)
Nozzle ring adjustment notches from this level position.
The nozzle ring adjustment is determined c. Before releasing the spring load, measure
carefully by factory test and resetting in and make note of the height of the adjusting
service is seldom necessary. Should it be bolt (17) over the top of the bonnet (14). This
necessary, the nozzle ring (3) is adjusted by information will help when reassembling the
removing the nozzle ring set screw (4) and valve to its approximate original setting.
inserting a screwdriver to engage the ring d. Loosen the adjusting bolt nut (18). Count the
notches. Turning the ring to the right raises number of turns required to remove the spring
it and results in a strong 'pop' action that will load by rotating the adjusting bolt (17) in a
increase blowdown. Moving the ring to the left counterclockwise direction.
lowers the ring, decreasing the blowdown and e. Loosen and remove bonnet stud nuts (16).
may result in warn or simmer if lowered too far. f. Carefully lift the bonnet (14) straight up to
The range of adjustment of this ring is limited clear the spindle (11) and valve spring (12).
and it should not be moved more than one Exercise care when lifting the bonnet as the
notch at a time from its set position. The valve spring and spindle will then be free to fall
performance should be checked after each aside.
adjustment. After each adjustment always g. Lift the spring (12) and spring washers (13) off
replace, tighten and seal wire the set screw (4), the spindle. The spring and spring washers
being careful that its point fits in the notch are fitted together and must be kept together
without making contact with the ring or bearing as a subassembly. Spring washers are not
on top of a tooth. It is very important not to let interchangeable between ends of the spring.
the valve pop before the nozzle ring set screw h. The disk holder assembly (5) or disk (6A) and
has been reinstalled and tightened. spindle (11) can now be removed from the
valve body (1) by lifting the spindle.
Restamping i. Remove the guide (8) and guide ring (9) from
If different ring locations are obtained after the body (1) as an assembly and unscrew the
testing, restamp the valve bonnet with the new guide ring from the guide.
(tested) ring settings. j. If the valve has a 2-piece disk design
(insert and holder), remove the disk insert
8 VALVE MAINTENANCE cotter pin (7) and the disk insert (6) from the
disk holder assembly (5).
The functioning and service life of a safety k. Remove the spindle (11) from the disk holder
valve depends primarily on methods used in assembly (5) or disk (6A) by pulling up on
its maintenance. For this reason, the following the spindle rod to engage the spindle point
maintenance procedures are recommended: threads in the disk/holder. Turn the spindle
counterclockwise while holding the disk/
Disassembly holder still and remove the spindle rod.
When possible, remove the valve from the l. Unscrew the nozzle ring (3) from the nozzle (2).
system before dismantling. There should be m. Unscrew the nozzle (2) from the body (1).
no system pressure when a valve is either
dismantled in place or removed for shop repair. CAUTION
For parts identification, see Figure 1 on page 2: Nozzle and guide ring set screws are custom
a. Remove the cap (19) and lifting lever device fitted to each valve and are not to be interchanged.
(if any) following the instructions on page 8.
CAUTION
Never loosen bonnet stud nuts before completely
releasing spring tension with the adjusting bolt.

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Repair procedure Lapping procedure

All the parts should be cleaned thoroughly. Unless the seats have been damaged badly
Guiding surfaces may be polished using a fine by dirt or scale, lapping the seating surfaces
emery cloth. All parts should be examined to should restore them to their original condition.
determine their condition. Inspection of valve Never lap the disk insert or disk against the
components is important to ensure proper nozzle.
valve performance. Lap each part separately against a cast iron
Damaged valve parts must be repaired or lapping block of the proper size. These blocks
replaced. Parts identification may be found in hold the lapping compound in their surface
Figure 1 on page 2. pores and must be reconditioned frequently.
Lap the block against the seat. Never rotate
Lapping or refurbishing of valve seats the block continuously, but use an oscillating
Good seating surface on the nozzle (2) and disk movement. Extreme care should be taken
insert (6) or disk (6A) are of the greatest throughout to make certain that the seats are
importance when reconditioning the safety valves. kept perfectly flat.
The seats should be flat and free from surface If considerable lapping is required, spread a
scratches. thin coat of medium coarse lapping compound
on the block. After lapping with this compound,
Lapping block lap again with a medium grade compound. The
Lapping blocks are made of a special grade of first step can be omitted unless much lapping
annealed cast iron. There is a block for each is called for. FIGURE 3
orifice size. Each block has two perfectly flat Next, lap again using a fine grade compound. Top lapping
working sides and it is essential that they retain When all nicks and marks have disappeared surface
this high degree of flatness to produce a truly remove all the compound from the block and Motion shown
flat seating surface on the disk, or disk insert seat. Apply polish compound to another block by dotted lines
and/or the nozzle. and lap the seat.
Before a lapping block is used, it should be As the lapping nears completion only the
checked for flatness and reconditioned after compound left in the pores of the block
use on a lapping block resurfacing plate. The should be present. This should give a very
block should be lapped in a figure eight motion, smooth finish. If scratches appear, the
applying uniform pressure while rotating the cause is probably dirty lapping compound.
lapping block against the plate as shown in These scratches should be removed by using
Figure 3. compound free of foreign material.
Lapping blocks and lapping block resurfacing Disks and disk inserts should be lapped in the
plates are available from Emerson sales, same way as nozzles. The disk insert must be
service and distribution centers. removed from the holder before lapping. Before
Bottom rough Lapping block
the disk insert is placed back in the holder all surface do not use to be squared up
Lapping compounds foreign material should be removed from both
Experience has proven that medium coarse, parts. The insert must be free when in the
medium, fine and polish lapping compounds holder. If the disk insert is damaged too badly
will condition any damaged safety valve seat to be reconditioned by lapping, it should be
properly except where the damage requires replaced. Remachining the insert will change
machining. The following lapping compounds, critical dimensions, affect the action of the
or their commercial equivalents are suggested: valve and is not recommended.

TABLE 1 Machining of nozzle seats

Grit compound no. Description If machining of the nozzle seat or other major
320 Medium coarse repairs are necessary it is recommended that
400 Medium the valve be returned to a Emerson authorized
600 Fine facility for repair. All parts must be machined
900 Polish accurately per Emerson specifications. No Lapping block resurfacing plate
safety valve will be tight, nor will it operate
properly unless all parts are correctly
machined. If unable to a return to a Emerson
authorized repair facility for remachining, use
of a reseating machine is recommended.

Lapping block

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

If a reseating machine is not used, the most b. Screw the nozzle ring (3) onto the nozzle (2). i. Screw the bonnet stud nuts (16) onto the
satisfactory way to machine a nozzle is to Note: The top of the nozzle ring should be bonnet studs (15) and tighten down evenly
remove it from the valve body. However, it may approximately one ring revolution above to prevent unnecessary strain and possible
also be machined while assembled within the the nozzle seating surface. misalignment.
valve body. In any event it is vitally important c. Thread the spindle assembly (11) into the j. Lift the disk insert slightly by lifting the spindle
that the seating surfaces run absolutely true. disk holder (5) or disk (6A). Turn the spindle rod. Lower the nozzle ring (3) below the seats.
Machining dimensions for Crosby Series HSJ until it drops off the internal threads and Release the spindle slowly to permit the
valves are shown in Figure 5. Remove only contact is made between the spindle ball disk insert to contact the nozzle seat gently.
enough metal to restore the surface to its and the disk or disk holder bushing. Check that the nozzle ring moves freely.
original condition. Turning to the smoothest Note: If spindle does not thread into disk, k. Screw the adjusting bolt (17) and nut (18)
possible finish will facilitate lapping. check the design version number in the into the top of the bonnet (14) the same
The nozzle must be replaced when the model number for compatibility. Do not number of turns originally required to
minimum face to seat dimension is reached. force the spindle to thread into the disk. remove the spring load. The original set
This critical dimension is shown in Table 2. Reference Section 10 for more detail on pressure can be approximated by screwing
the design version numbers and contact the adjusting bolt down to the height above
Machining of disk and disk insert seats Emerson to get the correct disk and spindle. the bonnet measured during disassembly.
When the damage to the disk or disk insert d. If the valve has a 2-piece disk design l. Move the nozzle ring (3) up until it touches
seat is too severe to be removed by lapping, (insert and holder), place the disk insert (6) the disk holder (5). From this position
the disk or disk insert should be replaced. into the disk holder (5). Turn the insert until lower it to the original recorded position
Remachining of the disk or disk insert seat is alignment is achieved between the hole in (paragraph b. page 6). Move the guide ring
not recommended. the button end of the insert and the hole in (9) until the bottom of the guide ring is at
The disk or disk insert seating surface may be the bottom end of the holder. Insert disk the same level as the bottom face (6A) of the
lapped provided that the minimum overall disk insert cotter (7) to hold in place. disk or disk holder assembly (5). If the guide
height shown in Figure 6 is maintained. e. Thread the guide ring (9) onto the guide (8). ring position originally recorded is a positive
f. Valves with Type A/B and D/E caps require number, raise the guide ring by the number
CAUTION two guide gaskets (not shown), one above of notches indicated; if a negative number,
Care should be used in this assembly operation to and one below the guide (8). Valves with lower the ring that number of notches.
prevent damage to the valve seating surfaces. Type C caps do not include guide gaskets. Rings are moved up by turning them to the
If supplied, place one guide gasket on top of right and lowered by turning them to the left.
Assembly the body (1). Install the guide (8) and guide
All components should be clean. ring (9) assembly into the top of the body.
Before assembling the following parts, The guide of Type C valves should be seated
lubricate with pure nickel 'Never-Seez' or directly on the top surface of the valve
equivalent. body. Maintain proper alignment between
- Nozzle and body threads the guide (8) and the body (1) to ensure that
- Nozzle and body sealing surfaces the guide is seated correctly in the body.
- All stud and nut threads g. Lower the spindle (11) and disk (6A) or disk
- Spindle bearing surfaces and threads holder assembly (5) into the guide (8) and
- Set screw threads onto the nozzle (2).
- Spring washer bevels h. Place the second guide gasket of Type A
- Adjusting bolt and bonnet threads and D valves on top of the guide (8). Place
the spring (12) and washers (13) assembly
For parts identification, refer to Figure 1 on onto the spindle (11). Lower the bonnet (14)
page 2: over the spindle and spring, onto the bonnet
a. Before installing the nozzle (2), lubricate studs (15) in the body (1). In closed bonnet
the flange surface in contact with the valve valves, the bonnet vent should be aligned
body (1) and on the nozzle threads. Then with the valve outlet. Position the bonnet
screw the nozzle (2) into the valve body (1) counter bore on the O.D. of the guide (8) and
and tighten until the nozzle flange is seated lower the bonnet onto the guide.
fully against the valve body.

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

m. Place the set screw gaskets (not shown) Type D 10 VALVE DESIGN VERSION AND
onto the set screws (10, 4). Screw the set Install the cap gasket on the bonnet. INTERCHANGEABILITY
screws into the body (1) engaging both the Screw the spindle nut onto the spindle. Place
nozzle ring (3) and guide ring (9). Both rings the dog in the cap and install the dog shaft so The design version number is used to
should move back and forth slightly after that the dog is horizontal and the square on distinguish specific versions of the HSJ valve
the set screw is tightened. the end of the dog shaft has a corner on top. design where the updated parts are not
n. The valve is now ready for testing. After With the dog shaft in the position above, scribe interchangeable with the previous version. The
testing, the following steps should be taken: a horizontal line on the end of the dog shaft. design version number is needed for reference
- Be sure that adjusting bolt nut (18) is locked. This line must be horizontal when the lifting when ordering spare parts and servicing the
- Install the cap assembly (see below). gear is installed finally on the valve. Install the valve. If the design version does not match the
- Seal wire the cap and set screws to prevent dog shaft O-ring in the dog shaft bearing and current design version, new spare parts may
tampering. place the dog shaft bearing gasket on the dog not be compatible in the valve, and the valve
shaft bearing. Screw the dog shaft bearing into may need to be upgraded to the new version.
9 ASSEMBLY OF CAP AND LIFTING LEVER the cap. Rotate the dog shaft so that the dog
DEVICES is pointing down and install the cap assembly The design version number will be at the end of
onto the bonnet. the model number, and any model number with
Series HSJ safety valves are furnished with Rotate the dog shaft so that the dog contacts no design version number will be considered
several different caps and lifting lever devices. the spindle nut. With the scribed line horizontal, "-01".
The following describes assembly of the remove the assembly and adjust the position of
available types of construction the spindle nut. Repeat the operation until the Reference Table 3 for current version of HSJ
(disassembly is the reverse of assembly). scribed line is horizontal when the dog contacts design.
For part identification refer to Figure 4. the spindle.
Remove the assembly and install the spindle
Type A nut cotter pin. Install the lifting gear assembly
Install the cap gasket and screw the cap onto onto the bonnet and secure it with cap studs
the top of the bonnet. Tighten the cap with a and nuts.
strap wrench. For Type D lifting levers that have two part
caps (cap and cap top), the above procedure
Type B is accomplished more easily. After the cap is
Install the cap gasket and screw the cap onto screwed to the bonnet, the positioning of the
the top of the bonnet. Tighten the cap with a dog shaft is the same as above except that the
strap wrench. Install the cap plug gasket and positioning of the spindle nut is performed last
screw cap plug into the cap. The test rod is through the open end of the cap.
installed only during system hydrostatic testing. With the dog in the horizontal position, screw
Never install the test rod unless performing the spindle nut onto the spindle until it contacts
system hydrostatic testing. the dog.
Install the spindle nut cotter, cap top gasket
Type C and screw the cap top into the cap.
Screw the spindle nut onto the spindle.
Place the cap on the bonnet. Install the forked Type E
lever and forked lever pin. Attach the lever to Assembly of Type E lifting lever is identical
the cap using the lever pin and secure with the to Type D with the addition of the cap plug
lever pin cotter. Adjust the spindle nut until gasket and cap plug. The test rod is installed
there is a 1/16 inch minimum of play between only during system hydrostatic testing. Never
the forked lever and the spindle nut. The install the test rod unless performing system
spindle nut may be adjusted by removing the hydrostatic test.
forked lever pin, forked lever and cap. When
the spindle nut is in proper adjustment, install
the spindle nut cotter pin. Replace the cap and
forked lever and install the forked lever pin
and forked lever pin cotter. Position the lever
opposite the valve outlet and install the four cap
set screws and tighten them against the groove
in the top of the bonnet.

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 4
Cap and lifing levers
Cap plug Test rod Cap
Cap Cap Spindle nut
Cap plug gasket

Forked lever Cotter pin

Seal and wire Cotter pin

Screwed cap and test rod type B

Pin
Cap gasket
Screwed cap type A
Pin

Lever nut Cap set screw

Lever
Lever
Lockwasher
Dog shaft bearing Regular lifting lever type C
Dog shaft
Gasket
O-ring

Cap Cap plug

Test rod
Dog Cap plug gasket

Cap top
Valve spindle

Packed lifting lever type D Cap top gasket

(Top view)

Packed lifting lever and test rod type E

Cap top Cap

Cotter pin

Cap top gasket

Spindle nut
Dog

Test rod
Cap
Dog shaft

Cap stud Spindle

Adjusting bolt
Cap stud nut
Adjusting bolt nut

Type C Gagged construction

Additional cap furnished for gagging
Seal and wire purposes only when requested and ordered
Cap gasket
by customer

Packed lifting lever type D

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

TABLE 2 - MINIMUM NOZZLE FACE TO SEAT DIMENSIONS in inches (mm)

Valve type
Orifice 16 26 36, 37 46, 47 56 57 66, 67 76, 77
F 4.021 - - 4.021 - - 4.021 4.646
(102.133) - - (102.133) - - (102.133) (118.008)
G 4.115 - - 4.115 - - 4.115 5.115
(104.521) - - (104.521) - - (104.521) (129.921)
H 3.897 - 3.897 3.897 4.834 4.834 4.834 -
(98.984) - (98.984) (98.984) (122.784) (122.784) (122.784) -
J 4.646 4.646 4.678 5.427 6.761 5.427 6.761 -
(118.008) (118.008) (118.821) (137.846) (171.729) (137.846) (171.729) -
K 5.068 - 5.068 6.193 6.193 6.193 6.193 -
(128.727) - (128.727) (157.302) (157.302) (157.302) (157.302) -
L 5.350 - 5.350 5.568 6.256 6.256 - -
(135.890) - (135.890) (141.427) (158.902) (158.902) - -
M 5.881 - 5.881 5.881 6.693 6.693 - -
(149.377) - (149.377) (149.377) (170.002) (170.002) - -
N 6.990 - 6.990 6.990 - - - -
(177.546) - (177.546) (177.546) - - - -
P 6.303 - 8.053 8.053 - - - -
(160.096) - (204.546) (204.546) - - - -
Q 7.178 - 7.178 7.178 - - - -
(182.321) - (182.321) (182.321) - - - -

TABLE 3 - DESIGN VERSION TABLE

Orifice
Pressure Class F G H J K L M N P Q
150# 02 02 02 02 01 01 01 01 01 01

300# 02 02 02 02 01 01 01 01 01 01
600# 02 02 02 02 01 01 01 01 01 01
900# 01 01 01 01 01 01 01 - - -
1500# 01 01 01 01 01 - - - - -
2500# 01 01 - - - - - - - -

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CROSBY SERIES HSJ SAFETY VALVES
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FIGURE 5
Nozzle seat critical dimensions in inches
.010 .010 Mach.
A .001 TIR Mach.
.014 .014
Ω
1 B .001
II B .001 (.203 mm) (.102 mm)
.001 .008 min. .004 min.
after lapping after lapping

Minimum face to
seat dim.
+1-1/2°
-0 45°
1-1/2°

-B-
.001
-A-
B .001

FIGURE 6
Disk insert minimum heights
F, G, H and J orifice
CL150, CL300 and CL600

F through Q orifice 'B' min.

after lapping

'B' min.
after lapping

See 'orifice' table

'B' DIMENSIONS
Orifice NPS DN
F .002 .051
G .003 .076
H .003 .076
J .004 .102
K .005 .127
L .006 .152
M .007 .178
N .008 .203
P .009 .229
Q .012 .305

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