Anderson Greenwood Series 500 POSRV

Installation and Maintenance Instructions

ANDERSON Before installation these instructions must

be fully read and understood.
GREENWOOD

1.1 Operation 1.2 Installation

The Anderson Greenwood Pilot Operated Either or both inlet and outlet may be standard ANSI flanges and the valve should be
Safety-Relief Valves utilize the principle installed in accordance with accepted piping practices.
of pressurizing the top, or large area, of a
When remote pressure pick-up is used the pilot supply tube is connected to a remote
differential area piston with line pressure to
location rather than to the inlet neck of the valve. If a block valve for shut-off is used in the
hold the piston closed up to set pressure.
remote pilot supply line, be sure it is opened before pressurizing the system or opening the
At set pressure the pilot valve relieves,
isolating block valve, where installed.
partially evacuating the dome (volume
above piston) and the piston lifts permitting NOTE: Remote pressure pick-up piping must have the equivalent flow area of 1/2” tubing for
discharge from the main valve. When the lengths up to 20 feet. For lengths greater than 20 feet, larger tubing or pipe should be used.
pilot reseats, line pressure is diverted to the
dome closing the main valve. 1.3 Start-Up
The set pressure range is 15 psig to 720 There must be pressure at the valve inlet to establish a differential in force across the piston
psig. and “load” it in the closed position. Pressure must pass through the pilot supply tube and
pilot, and exert force on the top of the piston. On normal plant start-up, the valve loads itself
without incident as plant pressure increases. It is not uncommon that slight leakage past the
main seat occurs until system pressure reaches five to ten pounds. This amount of pressure
is sometimes needed to form the Teflon® seat to nozzle surface.
Block valves are often used under safety valves in order to isolate them when maintenance
is required. When putting the safety valve in service be sure the block valve is fully opened. If
the block valve is opened after system start-up, the safety valves may briefly vent to the
atmosphere past the main seat before the dome gets pressurized-it will then close off
positively. To minimize this venting, open the block valve slowly.

Teflon® is a registered trademark of E.I. duPont de Nemours Company.

Flow Control
Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Table of contents

1.0 General valve description and start-up ................................................ 1

2.0 Main valve maintenance ...................................................................... 3

3.0 Pilot maintenance ................................................................................. 8

4.0 Pilot set pressure adjustment ............................................................. 11

5.0 Testing complete valve assembly........................................................ 13

6.0 Pilot set pressure field test procedure ................................................ 14

7.0 Soft goods repair kits .......................................................................... 16

8.0 Pilot conversion kits ............................................................................ 16

Pilot valve

Field test connection

Supply tube
Outlet
Remote sense

Main valve

Inlet

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

2.0 Main valve maintenance

2.1 Disassembly
Remove the cap from the body. Remove the piston and liner. A cap bolt may be threaded into
hole in top of piston to aid in removal. Through holes in seat retainers 2”, 3” and 4” sizes are
threaded to assist in disassembly. Remove the soft goods from the piston. If the piston is
equipped with a wedge ring, clean and retain it for use during assembly. The dipper tube is
swaged in place and no attempt should be made to remove it. Refer to Figure 1 for parts
description and location. The nozzle and nozzle seal should not be removed unless the
nozzle is damaged or the seal is leaking.

2.1.1 Nozzle and nozzle seal disassembly

Refer to Figure 2 for parts description and location.
1. Place liner in body and piston, without seat or seat retainer, into liner and on top of nozzle.
2. Place appropriate spacer (see Table I) on top of piston and then the cap over the spacer.
3. Thread the appropriate number of cap bolts (see Table I) into threaded holes on top of
body. If two bolts are used, they should be 180° apart. When using four bolts, they should
be 90° apart.
4. Tighten cap bolts evenly to the torque listed in Table I to compress nozzle seal.
5. Use a punch or bar with a light hammer and tap on the nozzle retainer teeth to loosen the
nozzle retainer. Unthread nozzle retainer approximately 1/2 turn.
6. Loosen cap bolts to remove load from nozzle. Remove components from main valve.

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

2.2 Main valve nozzle rework

Should the main valve nozzle seating face become nicked or scratched such that the main
valve seat does not seal, the imperfections can be removed by polishing the nozzle face with
400 grit sandpaper on a flat surface plate. Certain critical nozzle dimensions and finishes
must be maintained and those are shown in the figure and table below.

Valve Size and Type Min. Nozzle

Projection Height
(in)
1.5” Type 546 .045
2” Type 546 .055
3” Type 546 .055
4” Type 546 .055
6” Type 546 .070
8” Type 546 .070
1.5” Type 566 .055
2” Type 566 .055
3” Type 566 .055
4” Type 566 .070
6” Type 566 .070
8” Type 566 .070

32
.010
R.020
32

Minimum projection

Dir: H/MGarza/05-9040-272Fig0.dwg

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

2.3 Assembly

2.3.1 Nozzle and nozzle seal installation

1. Place nozzle seal and nozzle in body.
2. Place nozzle retainer over nozzle and thread into body until it stops on nozzle shoulder. Do
not lubricate nozzle retainer threads or mating body threads.
3. Repeat steps 1 through 4 of disassembly procedure to compress nozzle seal. Thread
nozzle retainer into body as seal is compressed to keep nozzle retainer from binding
against piston.
4. Use a punch or bar with a light hammer and tap on the nozzle retainer teeth to snug the
nozzle retainer threads.
5. Loosen cap bolts to remove load from spacer and remove spacer from valve.
Replace seat, piston and liner seal. Apply a light coat of Dow Corning #33 silicone lubricant
on all threads after cleaning. Do not use any lubricant on the soft goods.
When installing the cap, make sure it is seated squarely into body. Torque cap bolts uniformly
so as not to “cock” cap. See Table II for torque values. Such a condition may result in leakage
at the liner seal or cause the piston and liner to bind.

Table I
Valve Size and Type Spacer P/N Cap Bolt # Cap Cap Bolt
Thread Bolts To Torque
Use (ft-lb)
1.5x2/3 Type 546 (G and H Orifice) 06.5612.003 .500-20 UNF 2 41
1.5x2/3 Type 546 (G and H Orifice) 06.5612.003 .625-18 UNF 2 51
2” Type 546 06.5612.005 .500-20 UNF 4 27
3” Type 546 06.5612.007 .500-20 UNF 4 35
4” Type 546 06.5612.008 .750-16 UNF 4 130
6” Type 546 06.5612.009 .750-16 UNF 2 82
6” Type 546 06.5612.009 .875-14 UNF 2 95
8” Type 546 06.5612.010 .875-14 UNF 4 123
8” Type 546 06.5612.010 1.000-14 UNS 4 140
1.5” Type 566 06.5612.005 .500-20 UNF 2 19
2” Type 566 06.5612.007 .500-20 UNF 2 31
3” Type 566 06.5612.008 .750-16 UNF 2 113
4” Type 566 06.5612.011 .625-18 UNF 2 63
6” Type 566 06.5612.012 .750-16 UNF 2 88
8x10 Type 566 06.5612.014 1.125-12 UNF 10 89

Table II
Bolt Size Torque Value
(ft-lbs)
1/4 7
5/16 12
3/8 21
7/16 33
1/2 45
9/16 59
5/8 97
3/4 130
7/8 202
1 271
11/8 408

Engineering Doc. #05.9040.272 Rev. E

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Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Item Description Item Description Notes

1 Body 10 Piston Seal(2) (1) Do not replace unless required.
(2) Recommended spare parts for repair.
2 Piston 11 Nozzle Seal(1)
(3) Used on 4” sizes and larger Type 546 and 3”
3 Liner 12 Liner Seal(2) and larger Type 566.
4 Nozzle(1) 13 Retaining Ring See page 16 for soft goods repair kit part
number.
5 Seat(2) 14 Cap Bolt
6 Seat Retainer 15 Lock Washer
7 Seat Retainer Bolt 16 Dome Spring
8 Cap 17 Nozzle Retainer
9 Dipper Tube 18 Wedge Ring(3)

14
12 8

13
10
16
1
18
10

13
5

18

15
6 7 2
17
11/2” thru 4” size
5

11

4 6 15 7 9

6” and 8” size

Dir: H/MGarza/05-9040-272Fig1.dwg

Figure 1

Engineering Doc. #05.9040.272 Rev. E

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Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Cap bolt

Cap

Spacer

Body

Liner

Piston

Nozzle retainer

Nozzle

Nozzle seal

Dir: H/MGarza/05-9040-272Fig2.dwg

Figure 2

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

3.0 Pilot maintenance

3.1 Disassembly
To facilitate assembly, place all parts removed in an orderly arrangement so that the correct
parts can be assembled in the proper sequence. Refer to Figure 3 for parts description and
location.
NOTE: If pilot is equipped with a lift lever, the lift lever handle assembly must be unscrewed
from cap before continuing with disassembly. Hold lift lever in position shown in Figure 8,
unscrew bushing (Item 14) from cap and remove handle assembly (Items 13, 14, 15, 32,
and 45).
Unscrew and remove cap. Loosen jam nuts and release spring compression by backing out
adjusting screw. Remove bonnet, spring and spring washer. Remove lift lever adapter, rod
and support spring where used.
Loosen spindle nut before loosening jam nuts. The spindle jam nuts serve as wrench flats on
the spindle. Remove remainder of accessible parts except spindle. Remove nozzle with a 3/8”
square drive socket extension. Remove the spindle assembly by pushing it up through the
body.

3.2 Assembly
Assemble pilot in reverse order of disassembly. Take care not to scratch the sealing face of
the seat or nozzle. If scratched or nicked, it must be replaced or lapped to prevent leaking.
Lubricate all screw threads and bearing end of spring washers with NG-165 Never Seez
lubricant. Use Dow Corning No. 33 Silicone grease on all surfaces of the spring washer
bearing if installed. Lubricate the sealing flange of the nozzle to prevent galling. Do not
lubricate spindle, lower end of spindle seat, nozzle face, or Teflon® seals.

3.3 Pilot diaphragm assembly

3.3.1 Boost diaphragm

Install boost diaphragm (Item 55) over spindle on top of the lower diaphragm shield, with
spindle gaskets (Item 56) and diaphragm gaskets (Item 54 or 57) on both sides of the
diaphragm. For pressure below 120 psi, use a Teflon® diaphragm with FEP diaphragm
gaskets. For pressure between 121 psi to 180 psi, use a Hastelloy® diaphragm with FEP
diaphragm gaskets. For pressure above 180 psi, use a Hastelloy® diaphragm with PEEK
diaphragm gaskets. Install upper diaphragm shield on top of diaphragm.

3.3.2 Sensing diaphragm

Install sense diaphragm (Item 55) on top of spacer ring, with a diaphragm gasket and a
spindle gasket below the diaphragm. For set pressure up to 30 psi, use a Teflon® diaphragm
with a FEP diaphragm gasket. For pressure between 30 psi to 180 psi, use a Hastelloy®
diaphragm with a FEP diaphragm gasket. For pressure above 180 psi, use a Hastelloy®
diaphragm with a PEEK diaphragm gasket.

3.4 Bolt make-up (item 38)

Tighten the six 3/8” case bolts alternately opposite each other to approximately 32-36 ft-lb.

Hastelloy® is a registered trademark of Haynes International.

Engineering Doc. #05.9040.272 Rev. E

Copyright © 2003 Tyco Flow Control. All rights reserved. ANGMC-6022

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Item Description
1 Body 41 12
2 Nozzle
3 Spindle 14 17
4 Seat Socket
32 18
5 Diaphragm Support
6 Spacer Ring 13 25
7 Sense Plate
8 Boost Plate 45 21
9 Diaphragm Shield, Lower
40
10 Bonnet 15
11 Spring Washer 24
31
12 Lift Lever Cap(1)
13 Lift Lever Cam(1) 11
52
14 Lift Lever Bushing(1)
10
15 Lift Lever Handle(1) 51
16 Lift Rod Bushing(1) 22
16
17 Lift Lever Rod(1)
18 Lift Lever Nut(1) 3
34, 41
21 Pressure Adjustment Screw
22 Lift Lever Coupling 30
24 Bonnet Screw
26 33
25 Retaining O-ring(1)
30 Boost Plate Seal 38
7
31 Spring
57, 54, 55
32 Cam Spring(1) 56
33 Bonnet Vent 5
34 Lockwasher 8
35 Shim Washer 39
36 Seal Retainer
6
38 Bolt
39 Diaphragm Shield, Upper 57, 54, 55
40 Jam Nut
41 Jam Nut 9
56
45 Spring Pin(1)
35
46 Seat 36
47 Ball 27
46
51 Nameplate
52 Drive Screw 4 A A
54 Diaphragm Gasket-FEP
55 Diaphragm 47
56 Spindle Gasket
1
57 Diaphragm Gasket-PEEK
(1) Use with lift lever option only. 2 Dome

Note Dir: H:/MGarza/05-9040Fig3.dwg

Refer to page 10 for Section A-A and 276-720
psig. Figure 3
15-275 psig

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Item Description
2 Nozzle
3 34
3 Spindle
4 Seat Socket
55 7
5 Diaphragm Support

26 5
7 Sense Plate
8 Boost Plate
39 30 9 Diaphragm Shield, Lower
19 Blowdown Needle
55 8 20 Blowdown Bushing
23 Inlet Screen
9 35 26 Bonnet Seal
27 Spindle Seal
43 4 28 Bushing Seal
29 Needle Seal
27 47
30 Boost Plate Seal
34 Lockwasher
46 2
35 Shim Washer
276-720 psig 37 Needle Retainer
39 Diaphragm Shield, Upper
42 Jam Nut
37
50 43 Screw
49 46 Seat
47 Ball
20 49 Tubing
50 Elbow Connector
53 Pipe Plug
29
55 Diaphragm

19

42

28

53

Auxiliary Dome 23

Exhaust Supply

Dir: H:/MGarza/05-9040-272SecAA.dwg

Section A-A

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

4.0 Pilot set pressure adjustment

4.1 General
Two adjustments are provided; one for varying the pressure at which the pilot opens and one
for varying the pressure at which the pilot closes. The first adjustment controls the “set”
pressure; the second the “reseat” or “blowdown” pressure.

4.2 Set pressure

Set pressure is that supply pressure where the dome pressure is reduced to 70% ± 2% of
the supply. This corresponds to the initial audible discharge of gas or first steady stream of
liquid from the main valve.
To adjust the set pressure, a test set up similar to that shown in Figure 4 should be used.
The set pressure adjustment screw should be turned IN most of the way. Increase the supply
pressure to the nameplate setting and slowly back the adjustment screw out until the dome
pressure is 70% ± 2% of the supply pressure and supply pressure meets the required set
pressure tolerance of paragraph 4.5. Lock the adjusting screw with the jam nut and cycle the
pilot several times to make sure the setting is correct.

4.3 Reseat pressure

Reseat pressure is that supply pressure where the dome pressure increases to 75 ± 2% of
supply.

4.3.1 Reseat pressure – modulating action

The reseat pressure should be adjusted with the pilot flowing. Increase the supply pressure
until the pilot opens and steady flow is obtained. With the blowdown adjustment screw turned
in, slowly decrease the supply pressure to 97% to 100% of set. Turn the blowdown
adjustment screw OUT until the pilot reseats. Lock the adjusting screw with the jam nut and
cycle the pilot several times to make sure the setting is correct. A small interaction between
set pressure and blowdown may occur. If so, re-adjust set pressure. NOTE, if the blowdown
adjustment screw is backed out more than necessary to obtain 0% blowdown, pilot action
will become more sluggish and pilot crack to main valve opening pressure spread will
increase.

4.4 Adjustment tolerances

All pilots can be adjusted ± 5% beyond the nameplate setting for set pressures above 275
psig and ± 10% for set pressures 275 psig and below.

4.5 Range of adjustment

Cracking pressure: 95% of specified set pressure
Set pressure: ± 3% of specified set pressure above 70 psig set
± 2 psig for 70 psig and below
Reseat pressure: Specified as a percent of set pressure
modulating action (0-3%)

4.6 For steam service pilots

Set on steam, check the case bolts (Item 38) again for tightness at zero pressure. Retighten
to 35-39 ft-lbs of torque, as required. Check set pressure again if bolts are retightened.

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Pilot exhaust Set pressure adjustment

(backside) (turn in to increase set pressure)
(turn out to decrease set pressure)

Blowdown adjustment
(turn in to increase)
(turn out to shorten)

Dome Bonnet vent

pressure
gauge
Bleed Pilot inlet (backside)
valve

Inlet supply pressure gauge Elbow

Cross Flexible supply hose

Pipe Street Valve “A”

Union nipple elbow
Valve “B” Mounting stud

Accumulator
(approx. 1/4 cu ft)

Flexible supply hose Vent valve “C”

Dir: H:/MGarza/05-9040-272Fig4.dwg

Figure 4

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

5.0 Testing complete valve assembly

5.1 General
The complete valve assembly should be tested for internal and external leakage and to verify
main valve function using a test set-up similar to that shown in Figure 5.

5.2 Low pressure leakage check

Slowly increase the inlet pressure to 30% of the set pressure. Check for main valve nozzle,
seat, and piston seal leakage at the main valve outlet. No visible leakage shall occur in one
minute. To help in seating the valve seat and piston seal, the valve may be actuated several
times.

5.3 High pressure leakage check

Apply pressure to the inlet equal to 90% of the set pressure. Check for leakage at the main
valve outlet. Using a suitable gas or air leak detector solution, check for leakage at the cap
seal and other pressure connections. No leakage shall occur at the valve outlet and no
visible leakage shall be detected at the cap seal or other pressure connections in one
minute.

5.4 Main valve function check

CAUTION: This test must be performed at a slow rate of pressure increase to ensure that the
main valve does not go into full lift. The pressure applied to the inlet is not to exceed 105% of
nameplate set pressure.
After completing the high pressure leakage check of paragraph 5.3, verify main valve
opening as follows. Remove the leakage test device from the outlet flange. Slowly increase
the inlet pressure above 90% of set pressure. Continue increasing inlet pressure until an
audible discharge at the valve outlet verifies main valve opening.

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

6.0 Pilot set pressure field test procedure

NOTE: EXTREME CAUTION and appropriate safety procedures should always be utilized
when testing or servicing a safety relief valve. Any compressible fluid under pressure is
dangerous.

6.1 General
The pilot set pressure can be checked in the field by applying an external test pressure to
the pilot through the Field Test Hand Valve as shown in Figure 6. This applies only to valves
without a condensate drain in the main valve.
The pilot set pressure on a valve set for modulating action is best determined when the main
valve dome pressure is measured. From the discussion in Section 4.0 Pilot Adjustment, set
pressure is defined as that process pressure where the dome pressure is 70% of the supply
pressure. Frequently this measurement can not be made since access for measuring this
pressure is not available without depressurizing the dome and installing special fittings.
All valves with a factory installed Field Test accessory contain an Actuator Indicator. When a
test set-up similar to that shown in Figure 6 is used, set pressure of the valve is where the
actuator button retracts or moves in.
NOTE: Use extreme caution when testing to prevent injury should the main valve open and
discharge product on personnel. If the main valve must remain closed, temporarily replace
the pilot exhaust vent with an orifice plug having an orifice diameter of .040”/.060”. This
orifice must be removed on completion of field testing as it prevents the Main Valve from
opening.

External sensitivity adjustment

1/4” O.D. X .028 wall tube

.10 Inlet pressure

Supply
Ported blind flange

Figure 5

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

6.2 Procedure
A. Connect test gas bottle as shown in Figure 6.
B. Close vent valve “C”.
C. Open field test valve “B”. Test gauge will read process pressure.
D. Open block valve “A” SLOWLY to increase pressure until pilot opens or until the actuator
indicator button moves in. The pressure will be the pressure indicated on the test gauge at
the time of pop.
E. To remove test set up, close valves “A” and “B”, open valve “C”.

Indicator position
“out” - valve closed
“in” - valve open

Indicator assembly

Field test
valve “B”
A A
View A-A

Vent “C”

Block valve “A”

Dir: H:/MGarza/05-9040-272Fig5.dwg

Figure 6

Engineering Doc. #05.9040.272 Rev. E

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 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

7.0 Soft goods repair kit

The kits listed below are available from stock. To order, specify the base number and select
the last three digits from the following tables. To ensure the purchase of the correct soft
goods kits, the order should specify the valve model number and serial number.

Kit base number: 06.3366.XXX

Type 546 main valve kit

Set
Press. (psig) 11/2 x 3 2x3 3x4 4x6 6x8 8 x 10
Teflon® All 001 002 003 004 005 006
PEEK 276-720 010 011 012 013 014 015

Type 566 main valve kit

Set
Press. (psig) 11/2 x 2 2x3 3x4 4x6 6x8 8 x 10
Teflon® All 002 003 004 007 008 009
PEEK 276-720 011 012 013 016 017 018

Kit base number: 04.4959.XXX

Pilot kit
Description With or Without
Lift Lever
Standard Soft Goods 212
NACE Soft Goods 213
Nozzle 106

Accessory kit
Description All Pressures
Field Test
w/Indicator 192
Soft Goods
Backflow Preventer 390
Soft Goods
Supply Filter
Soft Goods and 417
Filter Screen

8.0 Pilot conversion kits

8.1 Lift lever conversion kit

Pilot Set Pressure Kit Part No.
All Pressures 06.3416.007

Engineering Doc. #05.9040.272 Rev. E

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Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Engineering Doc. #05.9040.272 Rev. E

Copyright © 2003 Tyco Flow Control. All rights reserved. ANGMC-6022

17
 Anderson Greenwood Series 500 POSRV
Installation and Maintenance Instructions

Tyco Valves & Controls

www.tycovalves.com

Tyco Flow Control (TFC) provides the information herein in good faith but makes no representation as to its comprehensiveness or accuracy. This IOM is intended only as a guide to TFC products and services.
Individuals using this IOM must exercise their independent judgment in evaluating product selection and determining product appropriateness for their particular purpose and system requirements. TFC MAKES
NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
WITH RESPECT TO THE INFORMATION SET FORTH HEREIN OR THE PRODUCT(S) TO WHICH THE INFORMATION REFERS. ACCORDINGLY, TFC WILL NOT BE RESPONSIBLE FOR DAMAGES (OF ANY
KIND OR NATURE, INCLUDING INCIDENTAL, INDIRECT, OR CONSEQUENTIAL DAMAGES) RESULTING FROM THE USE OF OR RELIANCE UPON THIS INFORMATION.
Patents and Patents Pending in the U.S. and foreign countries. Tyco reserves the right to change product designs and specifications without notice.

Engineering Doc. #05.9040.272 Rev. E

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