LIBRARY OF THE UNIVERSITY OF CALIFORNIA. GIFT OF VeJlv-t Class Consolidated Pop Safety Valves . v^ 1910 ^ Consolidated Safety Valve Co General Offices: 85, 87 and 89 Liberty St., New York Western Offices: 111, 113 and 115 North Canal St., Chicago Factory, Bridgeport, Conn. Copyright, 1909, The Consolidated Safety Valve Company, New York , Introduction THE Consolidated Safety Valve Company has within the last two years inaugurated two exceedingly important movements in the safety valve practice of this country movements which are causing universal modifications of design, and, for the first time in the history of engineering, are putting the methods of safety valve rating and specification upon a sound basis. This has, of course, required exhaustive testing and research, in conducting which this Company has spared no expense, deliberately adopting the policy of giving the results freely to the engineering public. This policy has obtained for the Company in this work the co-operation of railroads, of station- ary and marine interests, and of eminent engineers, adding much to the broad application and value of the results obtained. The movements referred to are : first, for the rating and specifying of safety valves according to their actual relieving capacities ; and, second, for increasing their efficiency by modifications in design which make possible the obtaining of larger capacities, and a cleaner, more positive action. ^%. X ITY] y Safety Valve Capacity A" J account of certain of the elaborate tests and extensive research work, conducted by this Company, showing the apparatus developed, the methods employed and results obtained, has been published in a pamphlet entitled " Safety Valve Capacity," which will be sent upon application to anyone interested in this subject. Because of this supplementary publication, the following account of the work will be brief. The function of a safety valve is to prevent the pressure in the boiler, to which it is applied, from rising above a definite point ; to do this automatically, and under the most severe conditions which can arise in service. For this the valve, or valves, must have a reliev- ing capacity at least equal to the boiler evaporation, under these con- ditions. If it has not this capacity, the boiler pressure will continue to rise, although the valve is blowing, resulting in strain to the boiler and danger of explosion, consequent to over-pressure. Thus, with the exception of a requisite mechanical reliability, the most vital factor in a safety valve is its capacity. Two factors in a safety valve geometrically determine the area of discharge and hence the relieving capacity. These are the diame- ter of the inlet opening at the seat, and the valve lift. The former is the nominal valve size; the latter is the amount the valve disc lifts vertically from the seat when in action. The rules for calculating the size of valves to be placed on boilers, which do not include a term for this valve lift, or an equivalent (such as a term for the effective area of discharge) assume, in their derivation, a lift for each size valve. Nearly all existing rules and formulae are of this kind, which rate all valves of a given nominal size as of the same capacity. To find what lifts valves^ actually have in practice, and thus test the truth or error of this assumption, that lifts are approximately the same for the same size valve, an apparatus has been devised by us upon which tests of different designs of valves have been conducted. With this apparatus, not only can a valve lift be read, at any moment, to thousandths of an inch, but an exact permanent record of the lift, 3 189830 Consolidated Pop Safety Valves SECTION OF TESTING" LABORATORY AT THE PLANT OF THE CONSOLIDATED SAFETY VALVE COMPANY, BRIDGEPORT, CONN. Consolidated Pop Safety Valve ED CENTER SHAFT DRIVEN BY A SMALL PAPER SPOOL APER DRUM DRIVEN :Y MOTOR THROUGH THE: WORM AND WHEEL CONNECTION TAPPED INTO DIFFERENT PLACES IN VALVE CASE EXHAUST PIPE ETC TO DETERMINE BACK PRESSURE CONNECTION TO BOILER JCE 3-HX ^ra&l^ fittmf I Wyi W------fci-.------^L I CONNECTED TO BOILER AS IN SERVICE SAFETY VALVE LIFT RECORDING APPARATUS 5 Consolidated Pop Safety Valves during the blowing of the valve, is obtained. This record resembles a steam engine indicator card in appearance, and is of similar use and value in analyzing the action of the valve. As appears in illustrations on pages 4 and 5, the valve under test is mounted upon the boiler in the regular manner, and a small rod is tapped into the top end of its spindle. This rod connects the lifting parts of the valve directly with a circular micrometer gauge and a recording gauge above. The steam pressures are noted and read from a large test gauge, graduated in pounds per square inch, and an electric spark device makes it possible to spot the chart at any point in its travel. In our tests, this was done as each pound pressure mark was reached, during the blowing of the valve. The actual lift equivalents of the pencil heights upon the chart are carefully calibrated in order that the record may be accurately measured to thousandths of an inch. With this apparatus, investigations and tests were started upon seven different makes of 4-inch stationary type safety valves, and these Lifts, Discharge Areas, Etc., of different makes of Safety Valves Size Popping Pressure Lifts Effective area of discharge with opening lift Per cent of largest area valve Opening Closing Lbs. per square inch Inches Inches Inches Square inches Iron Body Stationary Types 4 200 .06 4 .024 .568 46.6 4* 200 .031 .017 390 3'-4 4 200 .056 .032 .496 40.8 4 200 OQ4 .039 .834 68.5 4 200 .094 055 .834 68.5 4 200 .082 .054 .727 59-7 4 200 137 .088 1.22 100. Locomotive Muffler Types 3% 200 .0/2 .027 559 51-4 3 180 .045 .027 .300 3 J /2* 200 .040 .023 .440 39-8 3% 200 .076 .041 .590 54-4 3^ 200 .065 .034 .505 46.4 3Y2 200 .OC.I .030 .396 36.4 4 200 .058 .042 .515 4 200 .086 .039 .764 3 1 A 200 .140 .102 1.09 100. Flat Seat, other valves, 45 degree seat. Consolidated Pop Safety Valves LIFT APPARATUS AS ERECTED FOR LOCOMOTIVE TESTING AT BURNSIDE, ILLINOIS tests were followed by similar ones upon nine makes of muffler loco- motive valves, six of which were 3^- inch. All these valves were designed for and tested at 200 pounds steam pressure. The stationary valve tests were made upon a 94 horse-power Babcock & Wilcox Company water-tube boiler. The locomotive valve tests were made upon locomotive No. 900 of the Illinois Central Railroad, the valve being mounted directly upon the top of the main steam dome. Al- though a great amount of additional valve lift experimental work has been conducted, the above two series only, will be quoted here. The record of lifts, given in table on page 6 shows (with exception of a small preliminary simmer, which some of the valves have) an abrupt opening to full lift and an almost equally abrupt closing, when a cer- tain lower lift is reached. Both the opening and closing lifts are significant of the valve action. THi ete IT V Consolidated Pop Safety Valves The great variation 300 per cent in the lifts of these standard valves of the same size is startling. Its real significance is apparent, when it is realized that under existing official safety valve rules, these valves, some of them with less than one-third the lift and capacity of others, receive the same rating and are listed as of equal relieving value. There are other defects in existing rules, as indicated in the pamphlet above referred to. For example, in these rules, the assumed lift varies as the valve diameter, while in reality, with a given design, the lifts are more nearly the same in the different sizes, not varying nearly as rapidly as the diameters. And further than this the lifts assumed in these rules, for the larger valves, are nearly double the average actually obtained in practice. The direct conclusion is this: that existing rules and statutes are not safe to follow. Some of these rules were formulated before spring safety valves were invented and at a time when 1 20 pounds was con- sidered high pressure. They have not been modified since. None of them takes account of the different lifts which exist in the various makes of valves of the same nominal size. It would therefore seem the duty of all who are responsible for steam installation and opera- tion, to investigate for themselves and no longer leave the determina- tion of safety valve size and selection to such statutes as may happen to exist in their territory. The elements of a better rule for determining safety valve size exist in Napier's formula for the flow of steam, combined with the actual discharge area of the valve, as determined by its lift. By sub- stituting the value of the effective area of discharge, with a 45 degree seat, into Napier's formula, the following is obtained E = 1 14 x L x P x D, in which E is the valve relief or capacity in pounds of steam per hour; L is the vertical lift of valve in inches; P is the boiler steam pressure (absolute) in pounds per square inch ; D is the nominal diameter of the valve in inches, i.e., the diameter of the inlet opening. The uncertainty of the coefficient of flow, that is, of the exact value of the constant in this formula, when applied to the irregular steam discharge passages of safety valves, has probably been largely responsible for the fact that this method of obtaining valve capacities has not been more generally used. To determine what this constant, 8 Consolidated Pop Safety Valves or coefficient of flow, is and how it is affected by variations in valve design and adjustment, the Consolidated Safety Valve Company has recently conducted an extended series of tests at the Stirling Depart- ment of the Babcock & Wilcox Company at Barberton, Ohio. A 373 horse-power Stirling boiler was used, its water feed being measured in calibrated tanks and the entire steam discharge from the boiler being through the valve under test. Three sizes of stationary type and three of locomotive, the latter with and without mufflers, all being Consolidated designs, were used in this work. There were run 29 separate tests, most of which were of three hours duration. Much information concerning the design, action and theory of safety valves, was obtained from these tests. The most important application of the results, however, was in determining directly from actual tests upon safety valves themselves, a value for the constant in the capacity formula already indicated. This value obtained from these tests is 105, giving as the capacity formula E = 105 x Lx P x D or transposed E To make the use of the rule more direct, where the evaporation of the boiler is only indirectly known, it may be expressed in terms of the boiler heating surface or grate area. This modification consists merely in substituting for the term E (pounds of total evaporation), a term H (square feet of total heating surface) multiplied by the pounds of water per square foot of heating surface which the boiler will evapor- ate. Evidently the value, of such modified forms of the formula, depends upon the proper selection of average boiler evaporation figures for different types of boilers and also upon the possibility of so grouping these boiler types that average figures can be satisfactorily selected. Such values have been suggested and are given in our book entitled " Safety Valve Capacity." In locomotive practice, special conditions, as the relation of the required safety valve capacity to the maximum evaporative capacity of the boiler, make the form of the rule, based upon heating surface, more serviceable than the above more direct form. In the first place, the Consolidated Pop Safety Valves maximum evaporation of a locomotive is only possible with the maxi- mum draft obtained when the cylinders are exhausting up the stack, at which time the throttle is necessarily open. The throttle, being open, is drawing some of the steam and therefore the safety valves on a loco- motive can never receive the full maximum evaporation of the boiler. Just what percentage of this maximum evaporation the valve must be able to relieve under the most severe conditions, can only be determined experimentally. A large number of service tests have been conducted to determine the constant in this formula. The size valves upon a locomotive have been increased or decreased until one valve would just handle the maxi- mum steam generation, and the locomotive heating surface being known, the formula was figured back to obtain the constant. Other special conditions were considered, such as the liability, in locomotive practice, to a not infrequent occurrence of the most severe conditions; the exceptionally severe service which locomotive safety valves receive; and the advisability on locomotives to provide a substantial excess valve capacity. The rule, thus selected for determining the proper safety valve equipment for locomotives, is : D= .055 - H L x P in which D is the nominal valve diameter in inches; H is heating surface in square feet ; L is the safety valve lift in inches ; P is boiler pressure (absolute) in pounds per square inch. Two direct results have issued from the extended investigations, briefly indicated above. ist. The complete redesign of the entire line of Consolidated Safety Valves. 2nd. The possibility of incorporating, in this catalogue, tables giving the relieving capacities of each valve. These capacities are stamped upon the valves, and constitute the Company's guarantee of their relief. In presenting them, the Consolidated Safety Valve Com- pany takes the lead in giving to designing engineers the first reliable data upon which to base safety valve specifications, thus starting a new era in the history of safety valve practice. 10 Consolidated Safety Valve Designs THE feature which has predominated in the redesigning of Con- solidated Safety Valves is the large and generous spring. With each type of valve, a spring of suitable proportions, having de- sirable values for both fiber stress and compression under the highest steam pressures, was first calculated and the valve case was then built up around this spring. Steam pressures have outgrown the spring spaces available in valve cases not recently enlarged. Only by a com- plete redesign, such as that undertaken by the Consolidated Safety Valve Company, can the unavoidable, extreme values for these two spring factors, which result from the limitations of a contracted spring chamber, be remedied and values, efficient at the steam pressures of present practice, be maintained. The policy of Consolidated spring design is for comparatively large spring diameters, which design gives springs of more mechanical stability than those of long slender propor- tions, and makes possible the maintenance of lower fiber stresses for given compressions. An absolutely central thrust of the spindle upon the valve feather (or disc) and freedom of the spring from the least tendency to cramp or bind the spindle have been obtained by the exceptionally flexible method of mounting the spring to the end of the compression screw above and to the spindle below. This consists of two ball and socket bearings of the same size (making the top and bottom spring washers interchangeable) which allows the spring ends to freely assume their normal positions. A distinguishing feature of the valve feather is the fact that its upper trunk overlaps the outside of the spring case. This leaves practically no area upon the top of the feather exposed to exhaust steam pressure, the principal advantage of which is that it makes the feather entirely independent of pressure conditions within the valve case. This construction, which will be found in all forms except H to O inclusive, also gives an exceptionally effective protection to the spring and makes possible a more compact spring case. Another exclusive feature of Consolidated valves is the balled Consolidated Pop Safety Valves seat, included in each of the designs. The seats are hand ground with a spherical balling tool which maintains a perfect bearing at the seat despite any axial change of the feather position. This construction is largely responsible for the exceptional tightness of Consolidated valves. The long broad faced wings of the feather below the seat and the ample bearing of its trunk on the spring case above, together with the unusually low bearing of the spindle upon the feather, make the lift- ing of the valves smooth and free and give them their characteristic, clean, positive action. The blow back adjustment of all Consolidated valves is obtained by means of the original device for this purpose, the Richardson Ad- justing Ring. Many equivalent devices for this purpose have from time to time been introduced, but none has ever equalled, either in effi- ciency of regulation or simplicity of construction, this Richardson ring, the invention of which marked the origin of pop safety valve design. It not only gives a definite, positive control of the blow back adjust- ment for close or wide regulation, but forms an important factor in obtaining the large relieving capacities of these valves. The arrangements of the lock up, lifting lever and pressure adjust- ment are all of newly patented design. They are very compact, simple, and at the same time, effective. The relief nut upon the top of the stationary valve spindle makes it possible to take apart the valves for regrinding or inspection, without disturbing either adjustment of the valve a detail of great practical advantage in service. In each type of Consolidated valve, analysis will show an absolutely minimum number of parts, which is due to the consistent following of the simplest and most straightforward design. The materials of construction employed have, in each case, been selected for the particular service which the part will receive. All springs are of the best grade crucible spring steel. In form A, casings and covers are of iron, the bushings and other mountings of special bronze composition, except the seat which is, in all cases, of nickel a metal which has proven itself pre-eminently satisfactory for this pur- pose, being absolutely non-corrosive and capable of withstanding the severest oxidizing action. I 2 Consolidated Pop Safety Valves Stationary type, form B, has casing of steel, bushing and other mountings of nickel. This metal is especially suitable for use with steel in this high temperature service as it maintains its tensile strength and has, besides its non-corrosive properties, a coefficient of expansion very close to that of steel. This feature is very necessary at high temperatures to prevent the loosening of the seat and cover bushings. All nickel mountings in form B valves are securely locked in place by spinning, which acts as a further preventative against these parts becoming loose under high temperatures. Locomotive valves, forms R and S, are built entirely of a high grade of bronze, except the springs and spindles, which are of steel. Specifications for each valve type give the material of each part in detail. All valves before leaving the factory are thoroughly tested, ad- justed, ground in and set under the same pressure conditions of service they are designed for. Consolidated Pop Safety Valves Stationary Type For Saturated Steam Form A This type of valve is designed for general stationary work on saturated steam, except for low pressure house heating and other small boilers where the lighter design, forms M or O, can be used, or for portable and exposed boilers where the composition body forms H, 1 or K, should be selected. Lock up The lock-up attachment of each valve is sealed with a brass tag on which its guaranteed capacity, in pounds of steam per hour, is stamped. See cut, page 72. Consolidated o p Safety Valves Stationary Type For Saturated Steam Relieving Capacities Form A Pounds of Steam per Hour She Valve Gauge Pressures ( Ibs. per sq. in. ) 20 40 60 80 100 120 140 160 180 200 ! 220 240 260 280 300 2 880 1390 1890 2400 2900 3400 3900 4410 4910 5420 5920 6430 6930 7430 7940 2^ I1CO 1730 2360 3000 3620 4250 4880 55oo 6140 6760 7400 8030 8650 9300 9900 3 1430 2250 3070 ! 3890 4700 5530 i 6350 7170 i 8000 8800 i 9620 10400 1 1 200 I2IOO 12900 3^ i 1810 2830 3860 4880 5910 6950 7960 9020 10000 II 100 I2IOO 13100 14200 15200 16300 4 2060 3240 4410 5580 6770 7950 9120 10300 11500 12600 13800 15000 i6200 17300 18500 4H 2480 3900 5310 6730 8150 9570 1 1 000 12400 13800 15200 16700 18100 19500 20900 22400 5 2940 4620 6300 7970 9650 H330 13000 14700 16400 18100 19700 21400 23100 24800 26500 | These capacities are stamped upon brass tags, with which the valve lock- up attachments are sealed and constitute the Company's guarantee of their relief. Divide the above figures by 30 to obtain the approximate horse-power equivalents. See the section (page 3 of this catalogue) on Safety Valve Capacity. Prices Form A SIZE -Inches . . . . 2 2^ 3 3^ 4 \ l /2 5 Prices $50.00 $6o.OO $70.00 $85.00 $100.00 $130.00 $160.00 Diameter Base Flange ^i/ Inches 1% 8X 9 IO 10*4 ii Outlet Screwed Iron Pipe ~ Thread Inches . . 2 2 ^ 3 ^ 4 \ l /2 Flanged 10 Diam. When ordering valves, specify plainly: ist, form letter of valve; 2nd, size of valve; 3rd, pressure at which valve is to be set to blow. Unless otherwise ordered, flanged valves will be furnished with our stand- ard dimension flanges, given in above table. An additional charge will be made for flanges of dimensions other than above standard. When specified, flanges will be drilled to standard template for our regular flanges, without extra charge. 15 Consolidated Pop Safety Valves Stationary Type For Saturated Steam Sectional Form A Specifications Valve base and cover, iron ; seat, nickel ; feather, compression screw and other mountings, bronze composition ; spring, crucible spring steel ; spindle, steel ; lever and cap, malleable iron. Dimension specifications, see page 73. Repair Parts For price list of parts, see opposite page. Description See section, page n, on Consolidated Safety Valve Designs, for a descrip- tion of the general features of this valve. 16 Consolidated Pop Safety Valves Stationary Type For Saturated Steam Parts In ordering repair parts, number and popping pressure state plainly name of part, size, form letter, serial of valve for which they are required. Price List Form A See sectional cut on opposite page VALVE SIZE -INCHES PART NAME 2 T.% 3 3** 4 4/2 5 Base, including seat bush, and nickel ring inserted . $19-10 $23.10 $27.00 $33.00 $39.00 $50.00 $63.00 Cover, including cover ring attached 5.15 6.40 7.30 9-00 IO.4O 14.80 16.90 Compression Screw . . . 1. 80 2.10 2.50 3.00 3-50 4.60 5 .60 Adjusting Ring .... 1.70 2.00 2.30 2.8o 3-30 4.50 5-30 Ring Pin 30 30 .40 .48 .60 .67 1. 00 Cap .40 .50 .60 i .60 .90 .90 1.40 Compression Screw Nut 35 .40 .50 .60 .70 .90 1. 10 Lever 45 .50 .60 .60 1. 00 1. 00 1.30 Spindle 2.00 2.40 2.80 3-40 4.00 5.20 6.40 Release Nut 45 .60 -70 .80 95 1. 20 1.50 LeveriRest .28 .28 38 38 .50 .50 .70 Spring Washers, each . . .60 .70 .80 95 1-13 i-43 1. 80 Lever Spring .40 -40 .40 .40 .40 .40 .40 Lever Pin .10 .10 .10 .10 .20 .20 .21 Release Nut Pin .... .05 .05 .05 .05 .05 .05 .05 Cover Bolts, per set ... -4 2 .42 . .42 54 i -54 .72 54 Cover Bolts, each .... .07 .07 .07 .09 .09 .09 .09 Feather 11.80 14.20 16.70 20.50 23.70 3I.OO 38.00 Spring 4.00 4-80 5.60 6.80 8.00 10.50 13.00 Lever Rest Washer . . . .05 .05 .05 .05 Springs should not be used for pressures over ten pounds above or below that for which they are designed. See page 28 for instructions covering installation, adjustment and repairs of these valves. Consolidated Pop Safety V v e s Stationary Type For Superheated Steam Form B This type of valve is especially designed for service under superheated steam. It has an exceptionally large spring to meet the higher temperature conditions of superheat practice and should be selected in all cases where there are steam temperatures above 42oF. It can also be used advantageously for high pressure service under saturated steam. A superheat safety valve should be applied to every superheater, in order to maintain a flow of steam through it when the main feed is suddenly checked ; otherwise the superheater becomes a dead end, and under such conditions it is in danger of serious damage by the excessively high temperatures. Lock up The lock-up attachment of each valve is sealed with a brass tag on which its guaranteed capacity, in pounds of steam per hour, is stamped. See cut, page 72. 18 v y VLiFO*X Consolidated Pop Safety Valves Stationary Type For Superheated Steam Relieving Capacities Form B Pounds of Steam per Hour Gauge Pressures ( Ibs. per sq. in. ) 40 60 80 100 120 140 160 200 220 240 260 280 300 i y?. 660 1040 1420 1 1800 1 2180 2550 i 2 960 1500 2050 | 2600 3I4O 3700 lY-2. 1290 2020 2760 \ 3500 4230 4970 3 1650 2600 3540 4500 5440 6380 3^ 2060 3230 4400 5590 6770 ' 7950 4 2500 3920 j 5350 6800 j 8220 I 9650 4^ | 2980 4680 | 6380 | 8080 9800 11500 2 93 33 3680 j 4060 4440 ! 4820 5200 5570 5950 4240 4780 5330 5860 6420 ! 6970 7500 8060 8600 5700 6430 7170 7900 8640 9400 ioi oo 10800 11600 7330 8270 9220 10200 11100 12000 13000 13900 14900 9100 10300 11500 12600 13800 15000 16200 17300 18500 1IIOO 12500 ! 13900 | I540O 1680O ! l8200 : 19700 2IIOO 22500 I 13200 14900 : 16600 | 18300 200OO ! 2I70O 23400 25000 26800 These capacities are stamped upon brass tags with which the valve lock-up attachments are sealed and constitute the Company's guarantee of their relief. Divide the above figures by 30 to obtain the approximate horse-power equivalents. See the section (page 3 of this catalogue) on Safety Valve Capacity. Prices Form B SIZE Inches . . . . l l /2 2 2^ 3 3^ 4 4^ Prices $65 oo $8000 &QZ. oo $1 IO.OO $120.00 $n;.oo $150.00 Diameter l.ase Flange Inches $y* 6^ 7 1 A 8X 9 10 io)4 Outlet Screwed Iron Pipe Thread Inches . . 2 1 l /2 3 3^ 4 4 1 A When ordering valves, specify plainly: ist, form letter of valve; 2nd, size of valve; 3rd, pressure at which valve is to be set to blow. Unless otherwise ordered, flanged valves will be furnished with our standard dimension flanges, given in above table. An additional charge will be made for flanges of dimensions other than above standard. When specified, flanges will be drilled to standard template for our regular flanges, without extra charge. '9 Consolidated Pop Safety Valves Stationary Type For Superheated Steam Sectional Form B Specifications Valve base and yoke cover, steel ; seat bushing, feather and cover ring, nickel ; compression screw and other mountings, bronze composition ; spring, crucible spring steel ; lever and cap, malleable iron. Dimension specifications see page 74. Repair Parts For price list, see opposite page. Description See section, page 11, on Consolidated Safety Valve Designs, for a descrip- tion of the general features of this valve. Consolidated Pop Safety Valves Stationary Type For Superheated Steam Parts In ordering repair parts, state plainly name of part, size, form letter, serial number, and popping pressure of valve for which they are required. Price List Form B See sectional cut on opposite page VALVE SIZE -INCHES"" Ifc 2 2^ 3 3 1 A 4 4 1 A Base, including bushing in- serted ' $26.70 33-15 $3940 $45-55 $49.70 $5570 $61.70 Yoke cover, including cover ring attached II.80 14.60 17.20 20.00 22.00 24.30 27.20 Compression Screw . . . .90 I.OO 1.20 1.45 1.70 2.00 2.50 Adjusting Ring .85 1. 00 1.20 1.40 i-53 1.70 1.90 Ring Pin .20 .25 30 35 38 40 45 Cap 15 15 15 23 23 34 34 Compression Screw Nut .20 .23 .26 -30 32 32 32 Lever .25 .25 .25 3i 35 54 54 Spindle 1. 00 1.25 1.46 1.70 1.90 2.10 2.30 Release Nut .19 .25 33 .40 44 55 .70 Lever Rest .10 15 15 .20 .20 30 30 Spring Washers, each . . 45 .56 .70 .78 85 -95 1.05 Lever Spring .20 .20 .20 .20 .20 .20 .20 Lever Pin 05 .05 .05 05 .05 .10 .10 Release Nut Pin .... .05 .05 .05 .05 .05 05 05 Cover Bolts, per se . . . .16 .20 .20 .20 .20 40 .40 Cover Bolts, each .... .05 .05 .05 .05 .05 5 05 Feather 18.00 22JO 26.40 30.40 33-oo 37-30 41.40 Sorins" 3.30 4.00 4.80 5.60 6.00 6.80 7.50 Lever Rest Washer . . . .05 05 Springs should not be used for pressures over ten pounds above or below that for which they are designed. See page 28 for instructions covering installation, adjustment and repairs of these valves. 2 i Consolidated Pop Safety Valve Board of Trade, Marine Type Single Pattern Form C This marine type of valve fulfills the requirements of the U. S. Board of Supervising Inspectors, and has additional features adapting it to marine work for which it should be selected. The single type valve shown above should be used in preference to a duplex type, whenever possible. Lock up Lock-up attachment of each valve is sealed with a brass tag on which its guaranteed capacity, in pounds of steam per hour, is stamped. See cut, page 72. Consolidated Pop Safety Valves Board of Trade, Marine Type Single Pattern Relieving Capacities Form C Pounds of Steam per Hour HIM! Valve H Gauge Pressures ( Ibs. per sq. in.) . 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 2 880 1390 1890 2400 2900 3400 3900 4410 4910 5420 5920 6430 6930 743o 7940 2^ 1 100 1730 2360 3000 3620 4250 4880 5500 6140 6760 7400 8030 1 8650 9300 9900 3 1430 2250 3070 3890 4700 5530 6350 7170 8000 8800 9620 10400 11200 12100 12900 3^ 1810 2830 3860 4880 S9 10 6950 7960 9020 1 0000 I 1100 12100 13100 14200 15200 16300 4 2060 3 2 40 4410 5580 6770 7950 9120 10300 11500 12600 13800 15000 16200 : 17300 18500 4^ 2480 3900 53io 6730 8150 9570 IIOOO 12400 13800 15200 16700 18100 19500 2C900 22400 ; 2940 4620 6300 7970 9650 H330 13000 14700 16400 18100 19700 21400 23100 24800 26500 These capacities are stamped upon brass tags with which the valve lock-up attachments are sealed, and constitute the Company's guarantee of their relief. Divide the above figures by 30 to obtain the approximate horse-power equivalents. See the section (page 3 of this catalogue) on Safety Valve Capacity. Prices Form C SIZE Inches 2 2^ 3 3^ 4 4^ 5 Prices . $60 oo $70 oo SSooo $100 oo S 1 20 oo $150 oo ^190 oo Diameter Base Flange Inches 6^ rA 8X 9 10 io# ii Diameter Outlet Flange Inches 6 7 7X 8^ 9 9 1 / 10 When ordering valves, specify plainly : ist, form letter of valve ; 2nd, size of valve ; 3rd, pressure at which valve is to be set to blow. Unless otherwise ordered, flanged valves will be furnished with our standard dimension flanges, given in above table. An additional charge will be made for flanges of dimensions other than above standard. When specified, flanges will be drilled to standard template for our regular flanges, without extra charge. 23 Consolidated Pop Safety Val Board of Trade, Marine Type v e s Single Pattern Sectional Form C Specifications Valve base and cover, iron ; seat , nickel ; feather, compression screw and other mountings, bronze composition; spring, crucible spring steel ; spindle and key, steel; lever and cap, malleable iron. Steel or bronze composition valves furnished to order. Regularly made with cam levers, as shown in cut. Dimension Specifications see page 75. Repair Parts For price list, see opposite page. Description See section, page 11 on Consolidated Safety Valve Designs, for a descrip- tion of the general features of this valve. 24 Consolidated Pop Safety Valves Board of Trade, Marine Type Single Pattern Parts In ordering repair parts, state plainly name of part, size, form letter, serial number, and popping pressure of valve for which they are required. Price List Form C See sectional cut on opposite page PART NAME VALVE SIZE INCHES 2 2^ $23.10 3 3 1 A 4 4 1 A $39-00 i $50.00 5 $63.00 Base, including seat bush, and nickel ring inserted . $19.10 $27.00 $33.00 Cover, including cover ring attached and lever bushings 6.88 7-30 7.70 II. 10 13-74 15.04 21.10 Compression Screw . 4-20 4.80 5.50 690 8.30 IO.3O 13.10 Adjusting Ring .... 1.70 2.00 2.30 2.80 3.30 4.50 5-30 Ring Pin 30 32 .40 .50 .60 .70 1. 00 Cap 1.70 2.OO 2.50 2.50 3-40 4.80 4.80 Compression Screw Nut .65 .80 .90 1. 10 1.30 1. 60 2.10 Lever, upper, including bush, inserted .... 1.40 1. 60 1. 80 2.25 2.70 340 4-30 Lever, cam, including bush. .86 1. 00 1. 10 1.30 i. 60 2.00 2.00 Spindle 2.90 3-40 3-90 4.90 5.80 7-30 9-3 Cap and Key .08 .IO .10 .14 .20 .24 .24 Spring Washers, each . .60 .70 .80 95 i- r 3 i-43 1. 80 Feather 14.90 1740 19.90 24.90 29.90 37-30 47.20 Feather Pin .05 .06 .08 .09 .10 .12 .16 2 Feather Split Pins . . . .05 .05 .05 .05 .05 .06 .08 Spring 340 4.OO 4.50 5.70 6.80 8.60 10.90 Cover Bolts, per set .42 42 .42 54 54 .72 54 Cover Bolts, each .07 .07 .07 .09 .09 .09 .09 Upper Lever Pin .08 .10 .10 .14 .18 .20 30 4 Lever Split Pins . .05 .05 .05 .05 .05 .06 .08 Cam Lever Pin . . . . -O8 .10 .10 .14 .18 .20 30 Springs should not be used for pressures over ten pounds above or below that for which they are designed. See page 28 for instructions covering installation, adjustment and repairs of these valves. Consolidated Pop Safety Valve Board of Trade, Marine Type Duplex Pattern Encased Spring Form D ("With Rockershaft Levers) Made of iron, bron/e or steel. Prices on application. State plainly, in inquiry, full specifications. 26 Consolidated Pop Safety Valves Board of Trade, Marine Type Duplex Pattern Exposed Spring Form E (With Independent Cam Levers) Made of iron, bronze or steel. Prices on application. State plainly, in inquiry, full specifications. Consolidated Pop Safety Valves Stationary and Marine Types Instructions Installation, Adjustment and Repairs These instructions apply to valves, forms A, B, C, D and E, and are sub- stantially as given upon an instruction tag which is wired to each of these valves when it leaves the factory. Directions for Installation The valve must be connected directly to the boiler with a close nipple or short steam noz/le of the full valve size, or larger. Under no conditions should there be any stop valve, fitting or extra piping between it and the boiler. In applying valve, strain up the flange bolts evenly. Carelessness in this, or in handling the valve, may distort its seat and make valve leak. New boilers should be thoroughly blown out before the safety valve is used, or chips, red lead, cement, etc., will ruin the valve seat. The valve should be properly gagged, during hydraulic and other testing, instead of screwing the spring down to the high pressures required. Directions for Adjustment All valves are accurately adjusted and tested, before leaving the factory, and should not be altered until necessary. Popping Pressure First: Remove the cap and lever. To do this, if a form C, Dor E valve, with- draw the cap key, lift off the cap and remove the lever. If a form A or B valve, take out the lever pin and lever, turn the cap a quarter turn and lift it off ; remove the cotter pin and unscrew the release nut from the spindle. Then loosen the check nut on the compression screw and turn the screw down (right handed) to increase, and up (left handed) to decrease the popping pressure. A quarter turn of the compression screw will change the popping point 5 to 10 pounds. The check nut should be tightened and valve blown, to determine the result, and after the correct setting is obtained the cap and lever should be replaced. On the form A and B valves, however, before replacing the cap, the castellated release nut should be screwed down on to the spindle until there is about -jVinch clearance between it and the top of the compression screw, where it should be carefully pinned with the cotter pin. Especial care must be taken that this clearance between the release nut and the top of the compression screw be maintained, for if this nut touches the compression screw the valve will be held open and leak. Note. The valve spring is designed for the pressure stamped on the brass tag wired to the valve. If valve is to be set at a pressure over ten (10) pounds above or below this pressure a new spring should be furnished. Blowdown To change this, remove the hex. head lock screw in the side of the base casting, insert any pointed tool and turn the slotted or notched adjusting ring 28 Consolidated Pop Safety Valves Stationary and Marine Types Instructions Continued down (right hand rotation) to decrease, and up (left hand rotation) to increase the blow down, between the popping and the closing pressures. Replace the lock screw and tighten it before blowing the valve, being sure, before inserting it, that a notch of the ring, to receive its point, comes opposite the center of the hole. The screw should always shoulder at its head and not bear upon the ring. In setting the ring, move it only two or three notches at a time. If the valve does not pop cleanly or shows a tendency to rumble, the ring is too low and should be screwed up (left hand rotation). It is not advisable to set the valve to blow down less than four (4) pounds, and if it does blow down less, the ring should be put up to prolong the life of the valve. Directions for Repairs Before taking the valve apart, if it is a form A or B, remove the cap, and screw the release nut down on spindle until it bears upon the top of the com- pression screw. If a form C, D or E valve, leave the cap and key in place. Then, upon removing the valve cover bolts, the cover, spring, spindle, etc., may be removed together, without releasing the spring or disturbing its adjustment. In regrinding these valves, remember they have balled and not straight taper seats, and therefore do not machine the seats unless absolutely necessary. Grind the valve with No. ^ pulverized quartz and heavy machine oil, using a coarser grade, about No. i l / 2 , at first, if the surfaces need to be considerably cut down, and finish with the No. l / 2 . Be sure the seats are wiped clean after grinding. If the valve needs repairs further than regrinding, it should be sent to the factory, if possible. If not, special instructions should be requested from The Consolidated Safety Valve Company, 85-89 Liberty Street, New York. 29 Consolidated Pop Safety Valves Portable Types These valves are made entirely of special high grade bronze composition, with the exception of the spring, spindle, washers and lever. They are especially adaptable to out-door service on portable boilers, hoisting, farm and steam fire engines, road rollers, steam launches, etc. They have the same adjustments and general structural features throughout as the iron and steel body types previously described. These features are : large diameter spring, the ball bearing spring washers, the low spindle bearing on the feather, the long wing bearings and the Richardson Adjusting Ring. These valves are made with three different types of outlet or exhaust, the designs being exactly similar with this exception. The parts are interchangea- ble. They are made in all pipe sizes from %"-inch to 3-inch. See section, page 11, on Consolidated Safety Valve Designs, for a descrip- tion of the general features of these valves. Relieving Capacities Forms H, I, and K Pounds of Steam per Hour Gauge Pressures ( Ibs. per sq. in. ) Valve In. 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 % 160 260 35o 450 540 640 730 830 920 1020 11 10 12 10 1300 1390 1490 290 460 630 800 970 1130 1300 1470 1640 l8lO 1980 2150 2310 2480 j 26$0 1* 370 580 790 IOOO 1210 1420 1630 1840 2050 2260 2470 2680 2890! 3100 3310 ifc 55o 870 1180 1500 1820 2130 2450 2760 3080 3390 3700 4020 4340 4650 4960 2 730 1160 1580 200O 2420 2840 3260 3680 4100 4520 4940 5350 5770 6200 6600 2^ 1 100 1730 2360 3000 3620 4250 ! 4880 5500 6l50 , 6770 ] 7400 8030 8650 | 9300 j 9900 3 1320 2080 : 2840 3590 4350 ^lOO 5860 6600 7370 j 8120 8900 9650 10400 j moo 11900 The portable types should be selected for all out-door service and may further be specified wherever the conditions make the use of a composition body valve desirable. Form H should be selected wherever it is unnecessary to muffle or pipe away the steam exhaust. Form I should be selected if it is desired to pipe away the exhaust steam, or deflect it in any given direction. Form K should be selected wherever it is unnecessary to pipe away the ex- haust but desirable to diminish the noise of its discharge. 3 Consolidated Pop Safety Valve Portable Types Lock-up Attachment A compact and neat lock-up attachment for application to any of the port- able designs, forms H, I and K, will be furnished when ordered. As shown in above cut, this attachment consists of a simple bronze collar, of but two parts, which covers the base of the valve cap, making it impossible, when locked, to remove the cap. It thus effectually protects the compression screw and its pressure adjustment beneath. This attachment will be furnished with either plain seal or bronze case pad- lock as specified. It may be ordered either with the valve or separately for application to valves already in service. In the latter case, it is necessary merely to specify the size of the portable valve for which it is desired. Prices Lock-up Attachment SIZE-Inches .... X i ix .* 2 I 2y 2 3 With Plain Seal .... $1.00 $2.20 $1.10' $1.25 $1.30 $1.45 $1.60 $1.70 With Padlock $2.30 $2.45 $2.50 $2.65 $2.80 $2.90 Consolidated Pop Safety Valves Portable Type With Top Outlet Form H Prices Form H SIZE Inches .... H i iX i* 2 2*4 3 Prices . ... $8.00 $10.00 $15.00 $20.00 $30.00 $40.00 $60.00 When ordering valves, specify plainly : 1st, form letter of valve ; 2nd, size of valve; 3rd, pressure at which valve is to be set to blow. A brass tag, on which is stamped the guaranteed capacity, in pounds of steam per hour, is attached to every valve when it leaves the factory. See cut, page 72. 32 Consolidated Pop Safety Valves Portable Type With Top Outlet Sectional Form H Specifications Base, case, feather, adjusting ring, compression screw and cap, bronze composition; spring, crucible spring steel; spindle, steel; lever and spring washers, malleable iron. Lock up ; for description, see page 31. Repair parts ; for price list, see page 39. 33 Consolidated Po Safety V a 1 v e s Portable Type With Side Outlet Form I Prices Form I SIZE Inches .... X . .X iX 2 2^ 3 Prices . $8.00 $10.00 $15.00 $20.00 $30.00 $40.00 $60.00 When ordering valves, specify plainly ; ist, form letter of valve ; 2nd, size of valve; 3rd, pressure at which valve is to be set to blow. A brass tag, on which is stamped the guaranteed capacity, in pounds of steam per hour, is attached to every valve when it leaves the factory. See cut, page 72. 34 Consolidated Pop Safety Valves Portable Type With Side Outlet Sectional Form I Specifications Base, case, feather, adjusting ring, compression screw and cap, bronze com- position ; spring, crucible spring steel ; spindle, steel ; lever and spring washers, malleable iron. Lock up ; for description, see page 31. Repair parts ; for price list, see page 39. 35 (UN k - i*.. * OF THfc UNIVERSITY] Consolidated Pop Safety Valves Portable Type With Muffler Form K Prices Form K SIZE Inches X . iX *# 2 2^ 3 Prices $12.00 $15.00 $20.00 $30.00 $40.00 $55-oo $75-oo When ordering valves, specify plainly: ist, form letter of valve; 2nd, size of valve ; 3rd, pressure at which valve is to be set to blow. A brass tag, on which is stamped the guaranteed capacity, in pounds of steam per hour, is attached to every valve when it leaves the factory. See cut, page 72. 36 Consolidated Pop Safety Valves Portable Type With Muffler Sectional Form K Specifications Base, case, feather, adjusting ring, compression screw, cap and muffler shells, bronze composition ; spring, crucible spring steel ; spindle, steel lever and spring washers, malleable iron. Lock up ; for description, see page 31. Repair parts ; for price list, see page 39. 37 Consolidated Pop Safety Valves Portable Types Instructions Installation, Adjustment and Repairs These instructions apply to valves, forms H, I and K,and are substantially as given upon an instruction tag, which is wired to each of these valves when it leaves the factory. Directions for Installation These valves should be connected to the boiler as directly as possible. Under no conditions should there be any stop valve, fitting or extra piping be- tween it and the boiler. New boilers should be thoroughly blown out before the safety valve is used or chips, red lead, cement, etc., will ruin the valve seat. Directions for Adjustment All valves are accurately adjusted and tested before leaving the factory, and should not be altered until necessary. Popping Pressure To change the pressure at which the valve pops or opens, remove the cap and turn the compression screw down (right handed) to increase, and up (left handed) to decrease the popping pressure. Blow Down To change this, remove the hex. head lock screw in the lower part of the case, insert any pointed tool and turn the slotted or notched adjusting ring down (right hand rotation) to decrease, and up (left hand rotation) to increase the blow down between the popping and closing pressures. Replace the lock screw and tighten it before blowing the valve, being sure, before inserting it, that a notch of the ring, to receive its point, comes opposite the center of the hole. The screw should always shoulder at its head, and not bear upon the ring. In setting the ring, move it only two or three notches at a time. Directions for Repairs In taking these valves apart, first remove the lever pin, lever and cap. The hole at the top of the lever handle is threaded to fit the top of the spindle. Screw it down on the spindle until it bears upon the top of the compression screw, thus locking the spring compression. Then remove hex. head adjusting ring lock screw and unscrew the case from the base, using the lugs provided. The valve may be reground, assembled and the lever removed from the spindle, leaving both the popping pressure and blow down adjustments un- altered. In regrinding these valves, remember that they have balled and not straight taper seats, and therefore do not machine the seats unless absolutely necessary. Grind the valve with No. > pulverized quartz and heavy machine oil, using a coarser grade, about No. \ l / 2 , at first, if the surfaces need to be con- siderably cut down, and finish with the No. l / 2 . Be sure the seats are wiped clean after grinding. 38 Consolidated Pop Safety Valves Portable Types Parts In ordering repair parts, state plainly name of part, size, form letter, serial number and popping pressure of valve for which they are required. Price List Forms H, I and K See sectional cuts on pages 33, 35 and 3 7 PART NAME VALVE SIZE INCHES Vi, i iK i$* 2 2^ 3 Base $ 1.90 $ 2.30 $ 3.60 $ 4.60 $ 6.90 $9.30 $13.90 Case 2.05 2.70 4.10 5.40 8.00 10.80 16. 10 Compression Screw . .40 5 .70 .90 1.40 1.90 2.80 Adjusting Ring . . 30 .40 .60 .80 1.20 1.70 2.50 Ring Pin .14 .14 .14 30 30 .60 .60 Cap 34 34 55 .80 i-34 1-34 2.30 Spindle, including collar . .70 .90 i-34 i. 80 2.70 3.60 5.40 Spring 1. 00 1.25 i. 80 2.50 3-75 5-00 7.50 Spring Washers, each . 17 .21 34 45 .70 .88 1.43 Lever .08 .IO .14 .18 .27 .36 .60 Lever Pin .05 05 .05 .08 .14 14 .24 Feather -7O .90 1.30 1.74 2.60 3-50 5.20 Inner Muffler Shell ... I-3O 1-70 1.70 3-30 3-30 5.00 5.00 Outer Muffler Shell ... 2.70 3 3 3-30 i 6.70 6.70 10.00 10.00 39 Consolidated Pop Safety Valve Water Relief Type Form L This type of valve is designed for general service in relieving the pressure of any liquid which is not injurious to bronze composition, of which certain of the interior parts are constructed. It meets the requirements of the Associated Factory Mutual Fire Insurance Companies and the National Board of Fire Underwriters. It is specially adapted for use in connection with steam pumps of all kinds, pipe lines, water works, etc. 4 Consolidated S a f e t V v e s Water Relief Type In the water relief valve, form L, will be found certain changes in details of construction, from those in the various types of Consolidated Safety Valves designed for service under steam. These variations, as well as other features of this valve, are very clearly shown in sectional view on page 42. These details of construction, which are peculiar to the form L valve, are necessary to perfectly adapt the valve to the work required of it. As indicated on page 40, we have combined in this valve features, which not only fit it for the general service required of valves of this character, but which make it fully meet the requirements of the underwriting boards. As will be seen from the sectional view, the most important variation in construction is the design of the feather. It will also be noted that the adjust- ing ring which is employed in practically all of the other types, has been omitted in the form L. Prices Form L SIZE Inches 2 2^ 3 3^ 4 \y* 5 6 Prices $50.00 $60.00 $70.00 $85.00 $100.00 $130.00 $160.00 $225.00 Diameter Base Flange Inches (When Flanged base is ordered) 6^ 7^ W 9 10 lO l /2 ii I2# Inlet Screwed Hex. Base Inches 2 2^ 3 3K A \% 5 6 Outlet Screwed Iron Pipe Thread Inches 2 2^ 3 3 l /2 4 M Flanged 10 inch diameter Flanged it inch diameter Prices on valves, for pressures higher than 300 pounds, furnished on appli- cation. When ordering valves, specify plainly : ist, form letter of valve ; 2nd, size of valve ; 3rd, pressure at which valve is .to be set to blow. Unless otherwise ordered, screwed hex. base will be furnished on these valves. When flanged base is specified, flanged valves will be furnished with our standard dimension flanges, given in above table. An additional charge will be made for flanges of dimensions other than above standard. When speci- fied, flanges will be drilled to standard template for our regular flanges, without extra charge. This valve is regularly made with minimum collar to prevent the valve's being set to relieve at lower than a certain specified pressure. When ordered, a maximum collar will be furnished without extra charge, to prevent the valve's being set at higher than a given specified pressure. Consolidated Pop Safety Valves Water Relief Type Sectional Form L Specifications Valve base, cover and hand wheel, iron ; seat, feather and compression screw, bronze composition; spring, crucible spring steel; spindle, steel ; lock nut and spring washers, malleable iron. Valves are regularly furnished with hand wheel. When specified, there will be furnished in place of wheel, a square on compression screw for application of wrench. Repair Parts For price list, see opposite page. 4? Consolidated Pop Safety Val v e s Water Relief Type Parts In ordering repair parts, state plainly name of part, size, form letter, serial number and popping pressure of valve for which they are required. Price List Form L See sectional cut on opposite page II PART NAME VALVE SIZE INCHES 2 ^iS.QO 2.% 3 $26.65 3^ $32.65 4 $38.50 4^ 5 $62.00 6 $87.00 Base, including bushing in- ! serted $22.95 $49.30 Cover . 340 440 4.90 5.70 6.80 9-00 11.00 I5-30 Compression Screw . 3.62 3-90 4.70 5-5 6.60 8.70 10.30 14.90 Lock Nut 32 35 45 55 .66 .80 1. 00 1.50 Spindle i-75 2.OO 2.50 3.00 3-50 4.50 5.50 8.00 Upper Spring Washer . .85 1. 00 1.20 1.50 1.70 2.30 2.80 3-90 Lower Spring Washer . .65 .80 .90 1. 12 1.30 1.70 2.10 3-oo Cover Bolts, per set 30 42 42 54 54 .72 54 .72 Cover Bolts, each . . . 5 .07 .07 .09 .09 .09 .09 .09 Feather 12.40 I4.60 17. SO 2I.OO 24.80 32.50 40.00 55.40 Spring | 4.60 540 6.50 8.00 9.20 I2.OO 14.40 20.70 Hand Wheel ': 265 3-50 3-50 4.50 5-30 7-00 8.50 11.90 Hand Wheel Washer . . |i 30 36 44 50 .60 .80 1. 00 1.50 Hand Wheel Cap Screw . ' .10 .14 .14 .18 .20 .28 36 .48 Hand Wheel Key . . . .16 .18. .20 .26 30 .40 .50 .70 See page 44 for instructions covering installation, adjustment and repairs of these valves. 43 Consolidated Pop Safety Valves Water Relief Type Instructions Installation, Adjustment and Repairs These instructions apply to valves, form L, and are substantially as given upon an instruction tag, which is wired on each of these valves when it leaves the factory. Directions for Installation Connections to these water relief valves must be arranged so that the sup- ply of liquid will not be throttled or restricted by small piping, excessive length of pipe or by too many or restricted fittings between the valve and its source of pressure. In case of flanged valves, the bolts should be tightened up evenly. Care- lessness in this, or in handling the valves previous to application, may distort the bodies and seats and cause the valves to leak. All connections should be blown out and cleaned before the valves are connected, otherwise, in new work especially, pipe cement, scale or dirt may work into the valve openings, become lodged between the seats and cause leakage. Directions for Adjustment Arrows on the handwheel indicate the proper rotation of same to open valve or reduce the popping pressure. Reverse motion of handwheel will close the valve or increase the popping pressure. The pronged lock nut directly under the handwheel should be loosened before attempting to move the handwheel and well tightened after adjustments are made. Directions for Repairs To grind these valves, back out the spring compression screw by turning the handwheel in the direction of the arrows on same. Back out the cover bolts and remove the cover. All this can be done without disturbing the pipe connections. Grind the valve with No. y 2 pulverized quartz and heavy machine oil, using a coarser grade, about No. I ^ at first, if the surfaces need to be consider- ably cut down, and finish with No. Yz. Be sure the seats are wiped clean after grinding. If repairs other than grinding are needed, send the valves, if possi- ble, to the factory. If not, special instructions should be requested from The Consolidated Safety Valve Company, 85-89 Liberty Street, New York. 44 Consolidated Pop Safety Valves Consolidated Y Base For Pop Safety Valves I The fitting shown above is regularly made in iron and with all connections flanged. It is adapted for use in connection with all styles of flanged base valves. Prices Consolidated Y Base Size of Valves Inches . . 2 2> 3 3^ 4 4 5 Prices $23 oo $25.00 $28.00 $16.00 $45.00 $54.OO $63.00 Diameter Top Flanges Inches 6^ I 7^ 8* 9 10 .0^ ii Thickness Top Flanges- Inches % i i% I%6 iX I%6 1/8 Diameter Inlet Hole Inches 3 3/^ 4K 5 6 6 7 Diameter Bottom Flange 8X 9. lO l /2 ii I2> I2# 14 Thickness Bottom Flange Inches I 5 /16 1* I%6 I 7 /16 ix An extra charge will be made for bases of dimensions other than above standards. When specified, flanges will be drilled to standard template for above dimen- sions, without extra charge. Special prices on bronze composition or steel bases, on application. 45 Consolidated Pop Safety Valves House Heating Type Form M The above type valve should be selected generally for service on heating boilers where the steam pressure is 30 pounds or below. Lock up When specified, the form M valve will be furnished, with arrangement for sealing the adjustment of popping pressure, without extra charge. Note. In Massachusetts the law requires a special type of valve for service on certain low pressure boilers. See pages 50-53 inclusive, for descrip- tion, prices, etc., on these valves, form O. 46 C o n s o 1 i ate op S a f e t Val v e s House Heating Type While the form M valve is adapted for low pressure work only, it is a high grade valve in every respect, having a design which makes it particularly well suited for service on low pressure boilers. The materials employed in its manu- facture are exactly the same as are used in our high pressure bronze valves. It has a liberal capacity and clean blow which are characteristic of Consolidated Pop Safety Valves. It likewise closes sharply, not simmering along indefi- nitely as many valves of this character do. Although the form M valve is extremely simple in construction, it is of such design that it has a perfect pop safety valve action. The cap enclosing the compression screw is also the check nut. The spring has ball bearings at both ends. This feature, together with a substantial weight feather and a generous length of feather wings, is peculiar to the Consolidated Valve and is an especi- ally advantageous one for low pressures where the least cramping or drag will prevent uniform valve action. The seat is the bevelled 45 degree type, which always insures a tight valve and prevents its sticking. The inside attachment of the lifting lever allows an exterior finish of the entire valve, making a much more attractive appearance than where there is an unfinished band on the outside. The special design of feather in the Consoli- dated Valve gives an action exactly the same in principle as the Consolidated high pressure valves. This valve is very readily taken apart for grinding or repairs. Unscrewing the case by means of the hex. nut on its top, exposes the entire interior of the valve. The lower spring ball, being part of the feather casting, forms a convenient handle when grinding. The adjustment of popping point is very easily accomplished. No special tools are required and there are no small pins or screws to lose. A monkey wrench and screw driver are all that are needed to connect the valve, adjust or take it apart. Prices Form M SIZE -Inches .... X i* i* 2 2/ 2 3 Finished Brass .... $IO.CO $I2.0Q $15.00 $20.00 $30.00 $50.00 $65.00 Nickel plated $1200 $1400 $17.50 $23.50 $35.00 $57.00 $75.00 47 Consolidated Pop Safety Valves House Heating Type Sectional Form M Specifications Base, case, feather, compression screw, spring washers and cap, bronze composition ; spring, crucible spring steel ; lever, malleable iron. Repair Parts For price list, see opposite page. 48 Consolidated Pop Safety Valves House Heating Type Parts In ordering repair parts, state plainly name of part, size, form letter, and popping pressure of valve for which they are required. Price List Form M See sectional cut on opposite page PART NAME VALVE SIZE INCHES 3 A i \y* i l A 2 2 y 2 | 3 Base $ 2 -75 $ 3-3 S 4- IQ $ 5.00 S 8.20 $13.70 '$17.70 Case ' 3.70 4.30 5.50 7-3 11.00 18.30 23.90 Feather 2.00 240 3.15 4.10 6.2O 10.30 13.50 Lever .10 .13 .16 .22 35 .58 .75 Cap .70 .92 .92 I.9O 1.90 3.20 4.10 Spring .30 .34 .40 5 .80 1.34 1.70 Spring Washers, each . .10 .15 .17 .22 35 .58 .7 Compression Screw ... .15 .18 .25 30 5 .84 1. 10 Lever Pin .10 .13 .18 .24 35 58 -75 Add to above prices the following amounts, for nickel plated parts PART N 4MF VALVE SIZE INCHES % I i& I 1 A 2 2 1 A 3 Base $ -75 $ -75 S -94 $ 1.30 $ 1.92 $ 2.8o $ 3.70 Case i. oo i. oo 1.30 i-75 2.60 3.60 5.60 Lever .03 .03 .04 .05 .08 .10 .10 Cap .22 .22 .22 .40 -40 .50 .60 49 Consolidated Pop Safety Valves Massachusetts Police Type Form O The form O valve has been designed to meet the specifications of the Massachusetts District Police, and conforms fully to their requirements. It should be selected for service on all boilers of 8 horse-power, or over, carry- ing a steam pressure of 15 pounds or less, where no licensed engineer or fire- man is employed. Lock up This type of valve is regularly furnished with lock-up attachment, together with padlock. 50 Consolidated Pop Safety Valves Massachusetts Police Type The general construction of this valve is similar to the regular house heat- ing type valve, form M, as will he seen by the sectional views on pages 48 and 52. While this valve is adapted to all pressures up to 30 pounds, practically all valves of this type furnished are set at 15 pounds or less, as 15 pounds is the maximum allowed under the above law. In the form O valve will be found the same liberal capacity and clean blow which are peculiar to the regular house heating type valve, form M. These valves close sharply without any simmer whatever. They are designed to withstand the highest working pressure under which valves of this type are used and also the hard usage which they often receive while being connected to the boiler. The form O valves are so designed that all the requirements of the law are met by a valve which is symmetrical and compact in design and of a size which is in proportion to the boiler on which it is installed. This type of valve can very easily and quickly be taken apart for grinding or repairs. To accomplish this, unscrew the case, using the hex. nut on base, and thereby expose the entire interior of the valve. The lower spring ball, being part of the feather casting, forms a convenient handle when grinding. The adjustment of the popping point is very similar to that em- ployed in the regular house heating type, form M. In the form O valve, how- ever, this cannot be accomplished without first removing the padlock which secures the cap to case of valve. No special tools are required to change the popping point. A monkey wrench and screw driver are all that are needed to connect the valve, adjust or take it apart. Prices Form O SIZE Inches . . . . 2 lYi 3 3'A Prices $30.00 . $50.00 $65.00 $85.00 Consolidated Pop Safety Valve Massachusetts Police Type Sectional Form O Specifications Base, case, feather, compression screw, spring washers and cap, bronze composition ; spring, crucible spring steel ; spindle, steel ; lever, malleable iron. Repair Parts For price list, see opposite page. 5 2 Consolidated Pop Safety Valves Massachusetts Police Type Parts In ordering repair parts, state plainly name of part, size, form letter, serial number, and popping pressure of valve for which they are required. Price List Form O See sectional cut on opposite page VALVE SIZE INCHES rs\K.i r\ rt ivj. n, 2 2^ 3 3^ Base $ 70 $11.90 $15.50 $20.00 Case 9.IO 15.90 20.70 26.50 Feather .... 5-30 8.70 11.70 15.50 Lever .... .60 1. 00 1.30 1.70 Cap 2-45 4-3 5.70 8.25 Spring .... .85 1.40 i-75 2.50 Spring Washers, each 30 5 .65 .90 Compression Screw 1.20 2.IO 2.85 3.80 Lever Pin 35 55 75 1.05 Lock 2.25 2.25 2.25 2.25 Spindle .... 45 .70 .90 1.20 Spindle Pin . 15 .20 30 45 53 Consolidated Pop Safety Valves Ashcroft Micrometer Lift Gauge For the quick and convenient determination of the lift of safety valves, this device has been designed. The instrument consists of an indicating dial, graduated in hundredths and half hundredths, starting at zero and extending through a range of twenty-five hundredths of an inch. The hundredth divisions are plainly numbered and spaced one-quarter of an inch apart. The dial and indicating hand, with the gauge movement, are enclosed in a brass case having a removable glass front. The gauge case is attached to a frame which is equipped with set screws. This frame can very readily be fitted to the top part of safety valve, and in a position which places the gauge case directly over the top of the center of the valve. From the gauge case a rod is extended so that it may be brought to bear upon the top of the valve spindle or other lifting valve parts. This rod is ad- justable so that a zero reading may be obtained on the dial by means of a thread- ed sleeve clamped with a thumb screw. This device is small and compact and can conveniently be added to an in- spector's kit. Price, $50.00 54 Locomotive Types L) CO MOTIVE service presents peculiar conditions which re- quire special features in safety valve design. During their application, locomotive valves are frequently in almost contin- ual action. The boilers are quick steamers, the load fluctuating and the valves are apt to receive repeatedly the most severe conditions possible. All locomotive apparatus, especially in bad water districts, is necessarily subjected to frequent inspection and should therefore be designed with reference to the usual round house facilities for this work. For such reasons the locomotive forms, R and S, while in- corporating the general construction of all Consolidated Valves (see page 11) have special features, designed to meet the exacting require- ments of locomotive service and to facilitate their inspection and repair. The encased valve, form R, and the muffler, form S, have identi- cally the same construction, all parts being interchangeable except for the two muffler shells, which are added to the open valve in making the muffler. The practical advantage of this feature, which is found only in the Consolidated Valve, is evident. The same gauge, instruc- tions or set of repair parts apply to both valves. In fact a muffler valve can be converted into an encased one by merely removing its muffler shells. Another equally important advantage results from this form of construction. When it becomes desirable to clean the muffler shells of lime or other sediment, either by reaming out the holes or by im- mersion in an acid bath, it is not necessary, as is the case with all other muffler valves, to remove the valve from the locomotive, or even to alter either of its adjustments. The outer muffler shell is merely un- screwed, both shells lifted off and taken to the bench for cleaning. This removing of the muffler may, of course, be done while the engine is under steam. In fact, if it is not convenient to clean the shells at once, the engine can make a trip or two with them off. The valve will work perfectly as an encased valve, under these conditions, until the shells are ready to be replaced. 55 Consolidated Pop Safety Valves The open construction of compression screw and check nut at the top does away with the cap of other designs. These caps are incon- venient and unnecessary. They restrict the amount of metal upon the top hex of the compression screw and also its length, at the top, avail- able for taking up wear. Further they must be taken completely off and replaced whenever adjusting the valve. As a result round-house men generally remove them or turn off their tops. In adjusting the Consolidated Valve, on the other hand, it is merely necessary to loosen the check nut a fraction of a turn. This nut cannot be lost or removed over the top of the compression screw for the screw has a large heavy hex. head that will stand, without crushing, the rough usage it is apt to receive. Also the threaded part of the screw above the check nut, available for taking up wear, has been left exceptionally long. The steam discharge from these valves is all vertically upwards, there being no side blow or spreading out of the steam to cloud the cab windows. This desirable result is obtained by placing the spring case vent holes at the top of the case instead of at the side and by drilling the outer muffler shell in a special jig, by which the direction of the holes is kept nearly vertical. If damage to the valve seat, due to a chip or other cause, makes it necessary to reseat the valve, the shape of the disc has been so sim- plified, that a single lathe cut across the horizontal surface, just out- side the seat, is all that is required to properly maintain its shape. Grooving of the steam across the valve seats at a point opposite the wings of the feather or disc, a very common difficulty, has been com- pletely overcome in this design by milling the wing faces to a point at their top just beneath the seat. The construction of Consolidated Locomotive Valves throughout is of the simplest, most straightforward design giving an absolutely minimum number of parts, there being a total of but twelve parts to the encased valve and but three more to the muffler. Although the preceding paragraphs have merely enumerated some of the mechanical details of the forms R and S valves, the funda- mental principles of Consolidated design and action are all incorporated in them. The principal of these features are the exceptionally large springs with their correspondingly low fibre stresses ; the flexible 56 Consolidated Pop Safety Valves mounting of both ends of the spring with top and bottom washers, which are interchangeable and bear each upon a sensitive balled joint at the center ; the long, broad-faced wing guides of the valve feather, or disc ; the low spindle bearing upon feather ; the outside overlap of the feather trunk upon the case above, over, instead of into which joint the steam discharge flows. This construction leaves no area, upon the top of the disc or feather, exposed to the steam in the valve case. The action of the valve is clean and positive and its capacity ap- proximately double that of average types. The closing is especially characteristic, it taking place from nearly the full lift of the valve, bit- ing off the steam sharply and thus protecting the seats from the wire drawing action of a low settling close. 57 Consolidated Pop Safety Valves Locomotive Types Standard Equipments As indicated in the section of this catalogue on Safety Valve Capacity (pages 9 and 10), two peculiar conditions of locomotive service necessitate in the capacity formula, a special constant, based on heating surface. A value for this constant has been experimentally determined after exhaustive service tests, upon locomotives of different types and sizes, on various railroads. Using the capacities of Consolidated Pop Safety Valves, Locomotive Types, the following table of locomotive safety valve equipments has thus been com- piled. When Consolidated Valves, forms R or S, are applied in accordance with this table, it will not be possible to force the boiler pressure above the popping point of the highest set valve. Standard equipment of Consolidated Pop Safety Valves, Locomotive Types, for various sizes of locomotives. Forms R and S. Based upon Heating Surface Total Heating Surfaces Locomotive Boiler Pressures Pounds per Square Inch 100 120 140 160 180 200 220 Sq. Ft. No. of S B - Valves c/5 '- 1 No. of g c - Valves c/5 1 - 1 No. of S B - Valves BS^ No. of ^ -INo. of ^ Valves ~ Valves ^ No. of ^ c - Valves c/5 1 - 1 No. of ^ Valves c/5^ 700 2 \% 2 1/^2 1% 2 I ^ ! 2 \V 2 2 1^ 2 1% 800 2 2 3 '/^ 2 1* 2 1^ 2 ^ 2 1^2 2 ^ 2 1^ 900 2 2 3 1% 2 2 3 I& 2 I* 2 1^ 2 1* 2 1^-2 2 1% 1,000 2 2 3 1% 2 2 3 I 72 2 2 3 t/^ 2 1^ 2 1^ 2 , 2 1^ 1,100 3 2 2 22 2 3 i%. 3 ^A 2 2 3 '/^ 2 I 2 \% 2 1 1 A 1,200 2 2^ 3 2 2 2 3 ' T2. 2 2 2 2 3 1^ 2 2 3 i^ 2 l 2 1% 1,300 2 2^ 3 2 3 2 2 2 2 3 '^ 2 2 2 2 3 15* 2 1 2 & 1,400 3 2 2 2 2y 2 3 2 2 2 o | i/ 2 2 3 1^ 2 2 3 '^ 2 2 2 l l /z i, Soo 2 3 3 2 2 2% 2 2% 3 2 2 2 2 2 2 2 2 2 3 ^A i, 600 2 3 3 2% 3 2 3 2 2 2% 3 2 2 2 3 ^/2 2 2 3 T^ 2 2 3 & 1,700 2 3 23 22% 3 2^3 2 2 2^ 3 2 2 2 3 ~L l /2 2 2 2 2 3 1^2 i, 800 3 i 2322^ 3 2^ , 3 2 3 2 2 2 2% 3 2 2 2 3 i^ 2 2 3 '* 1,900 3 2% 2 3 3 2^ 2 3 3 2 2 2 l /2 3 2 2 2% 3 2 2 22 2 3 i^| 3 ifc 2,000 7 2^ 2 3 3 2^ 2 3 3 2 3 2 2 2 2% 3 2 3 2 2 2 2 Consolidated Pop Safety Valves Locomotive Types Standard Equipments Continued Total Heating Surfaces Locomotive Boiler Pressures Pounds per Square Inch 100 120 140 160 180 200 220 jNo. of No. of g j Sq. Ft. 'Valves u5~|Valves ~ No. of g d Valves ~ No. of g s -.No. of g c - Valves cn^ 1 Valves en" No. of g d Valves en "" No. of g c - Valves c/5 M 2,100 2 35* 3 3 2 35* 3 2J 2 3 3 2% 2 3 3 2 2 2^ 3 2 2 2^ 3 2 2 2^* 3 2 2,200 2 4 3 3 2 35* 3 2J/2 2 3 3 2^ 2 3 3 2 2 2fc 3 2 2 2^ 3 2 2 2^ 3 2 2,300 2 4 3 3 2 35* 3 2Y 2 2 3 3 25* 2 3 3 2 2 3 3 2 2 2Y 2 3 2 2 2^ 3 2 2.400 2 4 3 3 2 35* 3 3 2 35* 3 2^ 2 3 3 2y 2 2 3 3 2 2 2 1/ 2 3 2 2 2% 3 2 2,500 2 4 3 3 2 35* 3 3 2 35* 3 2^ 2 3 3 2y 2 2 3 3 2 2 2^ 3 2 2 2^ 3 2 2,600 2 4 3 3 2 4 3 3 2 3 1 A 3 2^ 2 3 3 2y 2 3 i* 2 3 3 2 2 2^ 3 2 2,700 2 4 3 3 2 4 3 3 2 35* 3 2y 2 2 35* 3 2^ 2 3 3 2% 2 3 3 2 2 2^ 3 2 2,800 3 35* 2 4 3 3 2 356 3 3 2 3^ 3 2^ 2 3 3 2% 2 3 3 2 2 2^ 3 2 2,900 3 35* 2 4 3 3 2 4 3 3 2 35* 3 2% 2 3 3 afc 2 3 3 2 1 A 2 3 3 2 3,000 3 35* 2 4 3 3 2 4 3 3 2 35* 3 2J6" 2 3^ 3 2^ 2 3 3 2fc 3 i 3,200 3 35* 3 35* 2 4 3 3 2 35* 7 2 356 3 2y z 2 3 3 25* I i 3,400 3 4 3 35* 2 4 3 3 2 4 3 3 2 35* 3 2 K2 2 35* 3 25* ? IK 3,600 3 4 3 3X 2 3 35* 2 4 3 3 2 3^ 3 3 2 3>* 3 2/2 s i 3,800 4 35* 3 4 3 3% 2 4 3 3 2 4 3 3 2 354 3 ^ 2 35* 3 25* 4,000 4 35* 3 4 3 3% 3 35* 2 4 3 3 2 35* 3 3 2 3^* 3 2^* 4,200 4 35* 3 4 3 3/2 3 3/2 2 4 3 3 2 4 3 3 2 35* 3 2Y 2 4,400 4 4 4 35* 3 4 3 35* 3 3 2 4 3 3 2 35* 3 3 4,600 4 4 4 35* 3 4 3 35* 3 3^ 3 3 2 4 2 4 3 3 4,800 4 4 4 35* 3 4 3 356 3 354 3 3 2 4 3 3 5,000 4 4 4 3% 3 4 3 4 3 35* 3 35* 2 4 3 3 5.200 5 3^2 4 4 4 35* 3 4 3 35*! 3 3^ 2 4 3 3 5,400 5 35* 4 4 4 35* 3 4 3 3 1 A 3 35* 3 35* 5,600 5 4 4 4 4 35* 3 4 3 4 3 35* 3 35* 5,800 5 4 4 4 4 35* 3 4 3 4 3 35* 3 35* 6,000 5 4 5 35* i 4 35* 4 35* 3 4 3 35* 3 35* Note. The Locomotive equipments shown in the table give the option of using either 2 or 3 standard size valves, except for the larger heating surfaces where more than 2-4 inch, or for the smaller, where less than 3-1 5* inch valves, are requ red. 59 Consolidated Pop Safety Valves Locomotive Type Encased Form R Prices Form R SIZE Inches ' \i/ 2 2 2>^ 3 3^ 4 *>ioo oo When ordering valves, specify plainly ; ist, form letter; 2nd, size of valve ; 3rd, pressure at which valve is to be set to blow. See further instructions on opposite page. 60 ' Consolidated Pop Safety Valves Locomotive Type Encased Relieving Capacities Form R Pounds of Steam per Hour Size Valve in. Gauge Pressures (Ibs. per sq. in.) 20 40 60 1300 80 100 120 140 2690 160 180 200 220 240 260 280 300 \% 600 950 1650 2000 2340 3030 338o 3720 4070 4410 4760 5110 5470 2 2^ 880 1 100 1390 1730 1890 2360 2400 3000 2900 3620 3400 4250 3900 4880 4410 5500 4910 6140 5420 6760 5920 7400 6430 8030 6930 8650 7430 9300 7940 9900 3 i43o 2250 3070 3890 4700 5530 6350 7170 8000 8800 9620 10400 1 1 200 I2IOO 12900 3^ 1810 2830 386o 4880 5910 6950 7960 9020 10000 1 1 100 12100 13100 14200 15200 16300 4 2060 3240 4410 5580 6770 7950 9120 10300 11500 12600 13800 15000 16200 17300 18500 Valve Bases The standard threading of Consolidated Locomotive Valve Bases is given below. Except in the i l / 2 inch valve, the threads are straight (not taper). The valve bases bottom on a shoulder of the spud bushing and the threading is al- ways female in the valve base. VALVE SIZE Inches . ! I j 2 2^ 3 3/2 4 Standard \% Threads per inch .... inch pipe thread Htf Htf n l A 10 10 Outside diam. of Thread Inches 2^ VA 3tt 3^ 4/2 For Spud Thread Height Inches n /16 "Ae 13 /16 13 /16 7 /s Unless otherwise ordered, the above threading is always furnished. Bushings Bushings or spuds for connecting form R valves to boilers will be furnished, when specified. Our standard bushings are threaded at the top end to fit the standard threading of valve bases given in above table. If special threading is ordered for valve base, bushings wilTbe threaded to fit same, and in this case a male thread gauge should be furnished so as to insure that this special thread- ing of bases properly fits the railroad standard. Lower end of bushing will be threaded with male pipe thread of size corresponding to nominal valve size. Special bushings, threaded to other than our standard or left blank for turning to make press fit, will be furnished when specified, it being our practice, in case bushings are to be pressed into dome, to leave the lower end rough turned slightly larger than the specified size so that the final fit may be made in the railroad shop. 61 Consolidated Pop Safety Valves Locomotive Type Encased Spindle Upper Spring /g Washer ^J^ Case Lower Spring Washer ompression Scre\ heck Nut ather Adjusting Ring | V-Ring Pin Sectional Form R Specifications Valve base, case, feather, adjusting ring, spring washers, compression screw, bushing and other mountings, bronze composition ; spring, crucible spring steel ; spindle, steel. See section, page u, on Consolidated Safety Valve designs, for a descrip- tion of the general features of this valve. 62 Consolidated Pop Safety Valves Locomotive Type Encased Parts In ordering repair parts, state plainly name of part, size, form letter, serial number and popping pressure of valve for which they are required. Price List Form R See sectional cut on opposite page PART N4ME SIZE INCHES j % 2 2^2 3 3/2 4 " Base i $<^ .50 $6.00 $8. 2O $13.00 $18.00 $25.00 Case L .60 7.60 10.00 14-5 21.30 27.00 Feather 3.50 4.80 6.80 8.80 1370 20.0O Adjusting Ring .... .60 .90 i 20 1.40 1.70 2.30 Ring Pin .10 .10 20 .20 30 3 Spring Washers, each . . .70 1.05 i. 35 1. 60 I 90 2.45 Compression Screw . . . .60 .90 i. 40 1. 60 I.9O 2.30 Check Nut 30 .30 40 40 .40 .70 Spring i .90 2.20 2. 40 2.80 340 5.40 Spindle j .30 1. 80 2.20 2 5 2.90 340 Bushing 2 .20 3.30 4 50 6.60 7 .60 8.70 Springs should not be used for pressures over ten pounds above or below that for which they are designed. See page 68 for instructions on the adjustment and repairs of these valves. Consolidated Pop Safety Valves Locomotive Type With Muffler Form S Prices Form S SIZE Inches Prices 30.00 I $40.00 S55-00 $70.00 $90.00 $120.00 When ordering valves, specify plainly; ist, form letter ; 2nd, size of valve; 3rd, pressure at which valve is to be set to blow. See further instructions on opposite page. 64 Consolidated Pop Safety Valves Locomotive Type With Muffler Relieving Capacities Form S Pounds of Steam Per Hour Size < Gauge Pressures ( Ibs. per sq. in. ) 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 boo 950 1300 1650 2000 2340 2690 33 338o 3720 4070 4410 4760 5no 5470 2 880 1390 1890 ; 2400 2900 3400 3900 4410 4910 5420 5920 6430 6930 7430 7940 2^ i 100 1 1730 2360 3000 ! 3620 4250 4880 $500 6140 6760 7400 8030 8650 9300 9900 3 1430 2250 3070 3890 4700 5530 6350 7170 8000 8800 9620 10400 1 1 200 I2IOO 12900 y-A 1810 2830 3860 4880 5910 6950 7960 9020 10000 1 1 100 I2IOO I3IOO 14200 15200 16300 4 2060 3 2 40 4410 S58o 6770 795o 9120 ! 10300 11500 12600 13800 15000 16200 17300 18500 Valve Bases The standard threading of Consolidated Locomotive Valve Bases is given below. Except in the I ^4-inch valve, the threads are straight (not taper). The valve bases bottom on a shoulder of the spud bushing and the threading is al- ways female in the valve base. VALVE SIZE Inches . 2 2^ 3 3^ 4 Threads per inch .... Standard i 1 /? inch pipe thread 11* ii# ii* IO IO Outside Diatn. of Thread- Inches ^ 1% 3 3 /8 3% 4^ For Spud Thread Height Inches /l. U /16 13 /16 13 /16 Unless otherwise ordered, the above threading is always furnished. Bushings Bushings or spuds for connecting form S valves to boilers will be furnished, when specified. Our standard bushings are threaded at the top end to fit the standard threading of valve bases given in above table. If special threading is ordered for valve base, bushings will be threaded to fit same, and in this case a male thread gauge should be furnished so as to insure that this special thread- ing of bases properly fits the railroad standard. Lower end of bushing will be threaded with male pipe thread of size corresponding to nominal valve size. Special bushings, threaded to other than our standard or left blank for turning to make press fit, will be furnished when specified, it being our practice, in case bushings are to be pressed into dome, to leave the lower end rough turned slightly larger than the specified size so that the final fit may be made in the railroad shop. 65 Consolidated Pop Safety Valves Locomotive Type With Muffler Spindle mpression Screw Upper Spring Washer Outer Muffler Shell Jnner Muffler/ Shell Case Locking Screw Lower Spring Washer Sectional Form S Specifications Valve base, case, feather, adjusting ring, spring washers, compression screw, bushing, outer muffler shell, inner muffler shell and other mountings, bronze composition; spring, crucible spring steel; spindle, steel. See section, page 11, on Consolidated Safety Valve designs, for a descrip- tion of the general features of this valve. 66 Consolidated Pop Safety Valves Locomotive Type With Muffler Parts In ordering repair parts, state plainly name of part, size, form letter, serial number and popping pressure of valve for which they are required. Price List Form S See sectional cut on opposite page SIZE -INCHES PART N4.ME 2 2^ 3 lYz 4 ii Base $3-50 $6.00 $8.20 $13.00 $l8.00 $25.00 Case 4.60 7.60 10.00 14.50 2I.3O 27.00 Feather 3-5 4.80 6.80 8.80 13.70 20.00 Adjusting Ring .... 60 .90 1.20 1.40 1.70 2.30 Ring Pin . TO .10 .20 .20 30 30 Spring Washers, each . . ,70 1.05 1.35 1. 60 1.90 2.45 Compression Screw ... _6o .90 1.40 1. 60 1.90 2.30 Check Nut ! .30 .30 .40 .40 .40 .70 Spring j.QO 2.2O 2.40 2.80 3.40 5.40 Spindle 1.30 I.8o 2.20 2.50 2.90 340 Bushing 2 2O 3-30 4.50 6.60 7 .60 8.70 Outer Muffler Shell . . .' 7.40 7.40 9.90 9.90 9.90 12.90 Inner Muffler Shell . . . 2.50 2.50 5.00 5.00 5.00 7.00 Muffler Shell Locking Screw H .10 .IO .IO .IO .10 .10 Springs should not be used for pressures over ten pounds above or below that for which they are designed. See page 68 for instructions on the adjustment and repairs of these valves. 67 Consolidated Pop Safety Valves Locomotive Types Instructions Adjustment and Repairs Taking Apart If the safety valve is fitted with the muffler, be sure to remove the locking screw in the lower rim of the outside muffler shell before attempting to unscrew the shell from the valve case. Note on the lower part of the muffler shell that there are lugs, which should be used when unscrewing the muffler shell. When it is desired to remove the case from the base, remove the ring pin and unscrew the case, using the lugs provided. If the holes in the muffler shells are filled with lime, scale or dirt, they should be thoroughly cleaned by scraping, or by immersion in a suitable bath, the nature of which depends upon the kind of scale to be cut and dissolved. See that the drainage holes in the feather or disc, in the adjusting ring, case and inner muffler shell are clean and free. Repairs In order that the safety valve, when repaired, may be maintained in the same condition as when new, a seating gauge and cutter (6") and a feather or disc gauge (F) should be used. Valve Seat If the valve seat needs re-seating, it should be done by the use of the seat gauge G. This gauge has a hardened edge, and by clamping it to a flat tool can itself be used as a cutting tool for truing up the valve seat. A very light cut should be taken. If the valve seat needs any great amount of facing, the seat should be faced with a regular tool and finished with the seat gauge G. The seat gauge G is of the exact radius desired for the seat, and care should be taken when using it as a cutting tool that it is held central, to give the seat a true radius. When the seat is recut it will, of course, increase the width of the seat, and a cut should be taken off the top of the base to reduce the seats to the following widths : Size of Safety Valve, inches i* 2 2^ 3 3>^ 4 Width of Seat, inches . . '/64 5 /32 3 /16 7 /32 17 /64 19 /64 Feather or Disc This seldom needs any repairing further than regrinding and no machine work should be done upon it unless absolutely necessary. If, however, its seat has become marred and must be refaced, chuck the feather and follow opera- tions in 3rd, 4th, 5th and 6th sections on opposite page. If in addition the feather wings are found to have worn to more than .05 inches or .06 inches diameter play, then follow all the operations given. 68 Consolidated Pop Safety Valves Locomotive Types Instructions Continued It is very important in making repairs that the feather or disc have the same dimensions when repaired as when new, and the following should be care- fully adhered to : ist. Pein out the feather wings not striking on the broad bearing faces (a) but on the web within (b). 2nd. Chuck the feather by the thread on its top (e) and take a cut off the face of the wings (a), truing these up until they fit into the base with about .01 inch diameter play. 3d. Take a light cut from (c), just enough to true it up, and take an equal cut from the bottom of the wings (d). The feather gauge (F) is made to register along the face of the feather wings (a) and should be used in the following operations ; great care should be taken in repairing the feathers to bring them exactly to gauge. 4th. Using position No. I, square off the surface (f) to the proper height from surface (c). 5th. Turn off seat (g) to gauge position No. 2. 6th. Turn the outside bevel (h) to the diameter and angle to suit gauge position No. 3, the notch of the gauge seating down on surface (f). Feather and Seat Gauges for Types R and S Feather Gauge (F) Seat Gauge (G) Prices Each Net PART SIZE OF SAFETY VALVE INCHES X 2^ . 30 I/ J/2 A Feather Gauge (F) . . . $2.25 $2.25 $2.25 $2.25 $2.25 $2.25 Seat Gauge (G) .... $1.65 $1.75 Si.75 $2.05 $2.20 $2.30 69 Consolidated Pop Safety Valves Locomotive Types Instructions Continued Grinding in the Seat Grind the valve with No. % pulverized quartz and heavy machine oil, using a coarser grade, about No. i^, at first, if the surfaces need to be considerably cut down, and finish with the No. y z . After it is ground, wipe the surfaces per- fectly clean and rub them together dry. The polished surfaces, which are the true bearings, should start from the bottom edge of the seat and appear about 3 /32 inch wide in valves 2^ inches and larger. The bearings in i^ inch and 2 inch valves should be about Vie inch wide. To insure a clean working valve, this seat must be kept down to the loca- tion indicated, and if any bearing points appear above the given location, they must be removed with emery cloth, being careful not to round the upper corner of the seat. Assembly In putting the valve together, the adjusting ring should be placed so that its top horizontal surface is about X f a turn below the top of the base, closer adjustment to the desired blowdown being made by trial after the valve is under steam. Setting Valve For Popping Point In adjusting the popping point of the valve, loosen the check nut and turn the compression screw down to increase and up to decrease the popping point. The spindle should be free,!, e., central in the top of the compression screw. If it bears upon one side, it should be driven to the center, which can be very readily done. Be sure to tighten the check nut as soon as the correct popping adjustment is made. For Blowdown For this adjustment, the hex. head adjusting ring lock screw near the bottom of the case is removed and a pointed tool of any kind used to move the slotted ring. The adjusting ring thread is right-handed, and to increase the blowdown (between the opening and closing pressures of the valve) the ring is screwed up; to decrease the blowdown the ring is screwed down. Before replacing the lock screw, be sure that the ring is left with a slot opposite the center of the hole, otherwise the screw may strike a land before seating. This screw should always shoulder at its head and not bear upon the ring, to insure a tight valve. In setting the ring, move it only a few (4 to 5) notches at a time. If the valve does not pop cleanly or if it shows a tendency to rumble, the ring is too low to control the valve and should be screwed up. It is not advisa- ble to set the valve to blow down less than 3 to 4 pounds, and if it does blow down less the ring should be put up. 70 Consolidated Pop Safety Valves Muffler Head This muffler is made in iron body with bronze composition cover. It is for application to the exhaust piping of safety valves and is made with screwed hex. base only, threaded-for standard iron pipe. Prices SIZE- Inches j 2 2^ ' 3 i 3/2 4 4/2 5 6 Prices, each $15.00 $17.50 $20.00 $24.00 $28.00 $34.00 $52.00 $68.00 Consolidated Pop Safety Valve Capacity Tag To each Consolidated Pop Safety Valve, forms A, B, C, D, E, H, I and K, is attached a tag same as shown in cut on this page. On this tag will be found the guaranteed capacity of the valve in pounds of steam per hour. This is the capacity which this company guarantees for the valve in question. The figures given on this tag have been arrived at by actual capacity tests and can be absolutely relied on by any engineer drawing specifications or operating the valves. Testing Lugs Testing lugs will be furnished with safety valves, forms A, B, C, D and E, when specified. These testing lugs or clamps will prevent any strain on the spring and liability of injury to it, when boilers are being tested. Price, each $1.00 72 Consolidated Pop Safety Valves Dimension Specifications Form A SIZE OF VALVE Inches 2 2 l / 2 T, 3*/2 4 4^ B Extreme Height Inches A 11% 13 i6& i7 T 5 5 18% 20^ 23/8 Height from Face of Inlet to Center of Outlet In. B M 63/ 8 7X 8/8 9 10/8 n% Center of Valve to Face of Outlet Inches . . . C V/2 3 7 /a 4 5 A 5 A 5M 6 7 1 A Diameter of Inlet Flange Inches D 6y 2 7 1 A VA 9 10 10^ ii % i l l /S IT% iJi I T 5 T5 i% Diameter of Neck at Bottom Inches .... F 3X 3H 4 3 /4 5% 6 6,% 7& Center of Valve to End of Lever Inches ... G sy s 85/ R v>X 10 % iiK 1134 15 Standard Pipe Thread Inches . . . . . H 2 2 l /2 3 3 1 A 4 4^ 8ee Note Across Flats of Hex. Base Inches I 3& \ l /i 5r 3 B SX 63/ 8 7% 7% Diameter of Bolt Circle Inches J 5 5% 6^8 7K 7/8 *y 2 9% Diameter of Bolt Holes Inches K % % 3 /4 3 /4 /8 % % Number of Bolts 4 8 8 8 8 Size of Bolts Inches . y* 3/r y M 3/ 3/ YA. Note i. On 5 inch valves, outlet is flanged 10 inch diameter by };? inch thick, and standard drilling for this flange is 8-% inch holes for $/ s inch bolts on 8% inch circle. Note 2. Flanges are not drilled unless specified. Bolt holes, if specified, will be drilled off centers, unless other instructions are given. Consolidated Pop Safety Valves Dimension Specifications Form B Extreme Height Inches . A 1 9^ i2/j i5M l 7 5/ 8 I9J4 21 X 23^ Face of Inlet to Center of Outlet Inches B ! 2 34i | 4& 4 1 A 4& 5H 6% Center of Valve to Face of Outlet Inches C 33 9 5 4l 3 g ^j^ S/8 6 6yg j 7ll5 Diameter of Inlet Flange Inches . . ! D ' M 6^ i 7 l / 2 8K 9 10 lO 1 ^ Thickness of Inlet Flange Inches . . E % % : I 1/8 I TB ^YA I T 5 g Diameter of Neck at Bottom Inches . F I 1 23/s 3& 3M 4% VA : 5% 6/8 Center of Valve to End of Lever Inches . G | 6^ 8/8 8^8 io/^ loJi 11% nK Standard Pipe Thread Inches .... H \% 2 ' 2^ 3 3% ' 4 4!4 Diameter of Bolt Circle Inches . I 4K 5 ' 5/8 6/8 7^ 7/8 8^ Diameter of Bolt Holes Inches T 3/ M % % y\ y& : H Number of Bolts ' 4 4 ! 4 8 8 8 i 8 Size of Bolts Inches c/ ! \\ $4 s/ & -y^ H H H M Across Flats of Hex. Base Inches K 2^ 8 S/8 1 63^ 7/8 Note. Inlet flanges are not drilled unless specified. Bolt holes, if specified, will be drilled off centers, unless other instructions are given. 74 Consolidated Pop Safety Valves Dimension Specifications Form C SIZE OF VALVE Inches 2 2% , 3 c O/ . 'r *f /2 j Extreme Height Inches . A 73/ 16 20 21% 23J/8 x _ 283/ Face of Inlet to Center of Outlet Inches . . B 1% 6% IX 8/8 9 10/8 11^ Center of Valve to Face of Outlet Inches C 4 4 l /2 5 5^ ; 6 6K 7 1 A Diameter of Inlet Flange Inches D 6^ 7% 8/ 9 10 10^ II Thickness of Inlet Flange Inches E % i lYs 1 TS T-% I T 5 B 1% Diameter of Neck at Bottom Inches . . . . F V/\ 3H \y\ 5% 6 6i 9 B 7/ Center of Valve to end of Lever Inches G 4TB 5 7 7 8 8% 9^ Diameter of Outlet Inches .... H 2 2^ 3 3^ 4 4^ 5 Thickness of Outlet Flange Inches . I y* % ii fs ; % % ii Diameter of Outlet Flange Inches J \ 6 7 7/2 8^ 9 9/i 10 Diameter of Bolt Holes(Inlet ) Inches . K y\ % ' y H % % % Diameter of Bolt Circle (Inlet) Inches fc . . . L 5 5% 6% 7% l 7% 8^ 9 Number of Bolts (Inlet) 4 4 8 8 8 8 8 Size of Bolts (Inlet) Inches H % i H H ! M M M Diameter of Bolt Holes (Outlet) Inches . . . M y z H y s y% y % % Diameter of Bolt Circle (Outlet) Inches . . . N 4% M ' 6 7 ! 7^ 7% 8^ Number of Bolts (Outlet) i 4 4 i 4 8 8 Size of Bolts (Outlet) Inches | y i y ^ ^ 5 /8 ^ Note. Flanges are not drilled unless specified. Bolt holes, if specified, will be drilled off centers, unless other instructions are given. 75 Consolidated Pop Safety Valve Dimension Specifications Form R ACROSS Tuyrs P-TiTCH SIZE OF VALVE Inches Extreme Height Inches Bottom of Valve to Top of Case Inches. . . . Top of Case to Top of Compression Sc. Inches Bottom of Valve to Bottom of Case Flange Inches Bottom of Valve to Bottom of Case Inches . . . Diameter of Base Thread Inches Diameter of Bottom of Base Inches Across Corners of Hex. Base Inches . Diameter at Case Lugs Inches Depth of Threading Inches Across Flats of Hex. Base Inches Diameter of Case Flange Inches Diameter of Top of Case Inches Pitch of Thread . jl^Pipe m 2 9T5 7H 2*/2 2% 9 9i 9 s 2 | J Ji 4& j 5 lH 2/j 3/3 I 3% 3% i 4 4/8 O/! 3H 3^ I 4 I3r5 Mrs 2% 2}i 3% ' 4% 4 5 A i BT T S 4% 76 Consolidated Pop Safety Valves Dimension Specifications Form S SIZE OF VALVE Inches \y 2 2 2 1 A 3 3% 4 Extreme Height Inches A 7& 9T 7 H II 11% i3A I4T S B Bottom of Valve to Top of Case Inches . . : . . B 64i 711 9 9, 9 B HT 3 S 12}i Top of Case to Top of Compression Sc. Inches . . C i& 1% 2 i*i 1% 2 T ' B Bottom of Valve to Bottom of Case Flange Inches . D 3K 3H 4 1 / 5 5M OT% Bottom of Valve to Bottom of Case Inches .... E i& IT 9 * 1% 2/8 2% 2H Diameter of Base Thread Inches . . - F I ^ Pipe 2^ 3/8 3% 3% 4% Diameter of Bottom of Base Inches G 2A 2% 3% 4 4^ 5A 2|f 3M 4M 4% 5% 6 T 7 B Diameter at Case Lugs Inches I 3A 4K 5 5H 6*i 7X Depth of Threading Inches J T 9 S H % U 1 i Across Flats of Hex. Base Inches K 2 T ' S 3 3% 4/8 4 3 /i 5T 9 6 Diameter at Muffler Shell Lugs Inches N 4,3 tJL 6,3 6ts 7H 8fg Diameter of Muffler Shell Inches O 3% 4iS 5K 6% 7A 8/8 Pitch of Thread P 11% n% n% 10 10 77 Contents Introduction 2 Safety Valve Capacity 3-10 Consolidated Safety Valve Designs, Description 11-13 Consolidated Pop Safety Valves Stationary Type for Saturated Steam, Form A Illustration 14 Relieving Capacities 15 Price List 15 Sectional View i 6 Specifications 1 6 Parts 17 Stationary Type for Superheated Steam, Form B Illustration I 8 Relieving Capacities 19 Price List 19 Sectional View 20 Specifications 20 Parts 21 Board of Trade, Marine Type, Single Pattern, Form C Illustration 22 Relieving Capacities 23 Price List 23 Sectional View 24 Specifications 24 Parts 25 Board of Trade, Marine Type, Duplex Pattern, Form D 26 Board of Trade, Marine Type, Duplex Pattern, Form E 27 Instructions Stationary and Marine Types 2829 Portable Types, Forms H, I and K Relieving Capacities 30 Lock-up Attachment 31 Top Outlet, Form H Price List 32 Sectional View 33 Specifications 33 Side Outlet, Form I Price List 34 Sectional View 35 Specifications 35 Muffler, Form K Price List 36 Sectional View 37 Specifications 37 Instructions 38 Parts 39 Water Relief Type, Form L Illustration 40 Description 41 Price List 41 Contents Continued Consolidated Pop Safety Valves Continued Pa g es Water Relief Type, Form L Continued Sectional View 42 Specifications 42 Parts 43 Instructions 44 House Heating Type, Form M Illustration 46 Description 47 Price List 47 Sectional View 48 Specifications ' 48 Parts 49 Massachusetts Police Type, Form O Illustration 50 Description 51 Price List 51 Sectional View 52 Specifications 52 Parts 53 Locomotive Types, Forms R and S Description 5 5-56-5 7 Standard Equipments 5 8- 59 Locomotive Type, Encased, Form R Illustration 60 Price List 60 Relieving Capacities 6 1 Bases and Bushings 6 1 Sectional View 62 Specifications 62 Parts 63 Locomotive Type with Muffler, Form S Illustration 64 Price List 64 Relieving Capacities 65 Bases and Bushings 65 Sectional View 66 Specifications 66 Parts 67 Instructions, Forms R and S . 6870 Consolidated Y Base . 45 Ashcroft Micrometer Lift Gauge 54 Muffler Head 71 Capacity Tag 72 Testing Lugs 72 Dimension Specifications Form A 73 Form B 74 Form C 75 Form R 76 Form S 77 Ro gei*s & Comp ELTK^ Chicago - New York UNIVERSITY OF CALIFORNIA LIBRARY Due two weeks after date. 30m-7,'12