Baker Hughes Mooney 20 Series Bedienungsanleitung

Mooney™

Series 20 Relief Valve

Instruction Manual (Rev.C)

Baker Hughes Data Classication : Public

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PRO-

JECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S

NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTE-

NANCE PHILOSOPHIES VARY, BAKER HUGHES COMPANY (AND ITS SUBSIDIARIES AND AF-

FILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BA-

SIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDER-

STANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELEC-

TRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE

INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE

SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR RE-

QUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN

EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CON-

NECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFOR-

MATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COV-

ERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD

BE REFERRED TO BAKER HUGHES.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE CUSTOMER/

OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT

RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR

WARRANTIES BY BAKER HUGHES REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN

OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO AS-

SIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIP-

MENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART

WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.

Mooney Series 20 Relief Valve Instruction Manual | 1

If and when required, appropriate safety labels have been included in the rectangular

margin blocks throughout this manual. Safety labels are vertically oriented rectangles

as shown in the representative examples (below), consisting of three panels encircled

by a narrow border. The panels can contain four messages which communicate:

• The level of hazard seriousness

• The nature of the hazard

• The consequence of human, or product, interaction with the hazard.

• The instructions, if necessary, on how to avoid the hazard.

The top panel of the format contains a signal word (DANGER, WARNING, CAUTION

or ATTENTION) which communicates the level of hazard seriousness.

The center panel contains a pictorial which communicates the nature of the hazard,

and the possible consequence of human or product interaction with the hazard. In

some instances of human hazards the pictorial may, instead, depict what preventive

measures to take, such as wearing protective equipment.

The bottom panel may contain an instruction message on how to avoid the hazard. In

the case of human hazard, this message may also contain a more precise definition

of the hazard, and the consequences of human interaction with the hazard, than can

be communicated solely by the pictorial.

I. Product Safety Sign and Label System

Do not remove bolts if

pressure is in the line, as

this will result in severe

personal injury or death.

Know nuclear "health

physics" procedures,

if applicable, to avoid

possible severe personal

injury or death.

Wear necessary protec-

tive equipment to pre-

vent possible injury

Do not drop or

strike.

DANGER — Immediate hazards

which WILL result in severe per-

sonal injury or death.

WARNING — Hazards or unsafe

practices which COULD result in

severe personal injury or death.

CAUTION — Hazards or unsafe

practices which COULD result in

minor personal injury.

ATTENTION — Hazards or unsafe

practices which COULD result in

product or property damage.

Improper use or re-

pair of a pressurized

device may result in

severe personal injury

or death.

Heed all container

label Warnings

II. Safety Alerts

Read - Understand - Practice

1. DANGER: It is the end users responsibility to ensure proper

installation and the associated risks in accordance with API

520 Part 2.

2. DANGER: High temperature/pressure can cause injury.

Be sure all system pressure is absent before repairing or

removing valve.

3. DANGER: Don’t stand in front of valve outlet when

discharging. STAND CLEAR OF VALVE to prevent exposure

to trapped, corrosive media.

4. DANGER: When inspecting a pressure relief valve for

leakage. BE VERY CAREFUL!

1. WARNING: Taking the appropriate actions to ensure

that site personnel who are performing installation,

commissioning, and maintenance have been trained in

proper site procedures for working with and around GE

supplied equipment, per Safe Site Work Practices, are the

end users responsibility.

2. WARNING: Allow the system to cool to room temperature

before cleaning, servicing or repairing the system. Hot

components or fluids can cause severe personal injury or

death.

3. WARNING: Always read and comply with safety labels on

all containers. Do not remove or deface the container. Do not

remove or deface the container labels. Improper handling or

misuse could result in severe personal injury and/or death.

4. WARNING: Never use pressurized fluids/gas/air to clean

clothing or body parts. Never use body parts to check for

leakage or discharge rates of areas. Pressurized fluids/gas/

air injected into or near the body can cause severe personal

injury or death.

5. WARNING: It is the responsibility of the owner to specify

and provide guarding to protect persons from contact with

pressurized or heated parts. Contact with pressurized or

heated parts can result in sever personal injury or death.

6. WARNING: Do not allow anyone under the influence of

intoxicants or narcotics to work on or around pressurized

systems. Workers under the influence of intoxicants or

narcotics are a hazard to both themselves and other

employees and can cause severe personal injury or death

to themselves or others.

7. WARNING: Incorrect service and repair could result in

product or property damage and/or serve personal injury or

death.

8. WARNING: Use of improper tools or improper use of the

right tools could result in personal injury and/or product or

property damage.

9. WARNING: Any and all lines and fittings shall be properly

connected and secured, and as required anchored to restrict

movement.

10. WARNING: Proper Lockout/Tagout of energy sources

prior to maintenance, per Safe Site Work Practices, is the

end users responsibility. This includes any potential control

signals or circuits that may have a remote or automated

control function over any product.

Do not remove bolts if

pressure is in the line,

as this will result in

severe personal injury

or death.

XXX

Provide and use

guarding to prevent

contact with heated

and/or pressurized

parts.

Do not work with valves

while under the inu-

ence of intoxicants or

narcotics.

Mooney Series 20 Relief Valve Instruction Manual | 3

Improper tools or im-

proper use of the right

tools could result in

personal injury or

product damage.

All potential hazards

may not be covered in

this manual.

II. Safety Alerts (Contd.)

Heed all service manual

warnings. Read installa-

tion instructions before

installing valve(s).

Wear necessary pro-

tective equipment

to prevent possible

injury

Know nuclear "health

physics" procedures,

if applicable, to avoid

possible severe per-

sonal injury or death.

Always use appropriate

restoration procedures.

11. WARNING: After installation or maintenance, it is the end

users responsibility to ensure the equipment has been

properly inspected and returned to proper condition before

being returned to service.

12. WARNING: It is the end users responsibility to ensure

properly loaded and/or supported piping to avoid undesired

stresses on the product which may result in damage to the

product, loss of containment, or loss of functionality and

resulting unsafe states or conditions.

13. WARNING: It is the end users responsibility to correctly

identify end locations and place product in areas that do not

contain explosive atmospheres.

14. WARNING: The failure of properly following the test,

installation, maintenance and/or disassembly/assembly

instructions may result in a compromised product which

in turn could result in an uncontrolled/unexpected loss of

containment and release of pressure and heated flammable

gas. It is the responsibility of the person conducting the tasks

listed above to take great care in following such procedures.

15. WARNING: For products installed in areas with explosive

media in the surrounding environment, it is the end users

responsibility that only properly trained personnel evaluate,

install, and work on such installations, and in accordance

with safe site work practices.

16. WARNING: It is the end users responsibility to recognize

and safely contain any leak. Failure to do so could result in

injury or death..

1. CAUTION: Heed all service manual warnings. Read

installation instructions before installing valve(s).

2. CAUTION: Ensure proper Personal Protective Equipment

is available and used.

3. CAUTION: Wear hearing protection when testing or

operating valve(s).

4. CAUTION: Wear appropriate eye and clothing protection.

5. CAUTION: Wear protective breathing apparatus to protect

against toxic media.

6. CAUTION: Proper lifting techniques / equipment / procedures

(refer to O&M manual for additional information), per Safe

Site Work Practices, are the end users responsibility.

7. CAUTION: During assembly or maintenance and under

operation in some conditions the operators or technicians

should be alert and aware of all possible pinch points or

areas where there are moving or sliding components.

Scope

This manual includes instructions for the installation, operation and maintenance of the Mooney Series 20 Relief Valve. For questions

concerning any details of this manual, please contact the manufacturer’s representative or the factory.

Table of Contents

Product Introduction.................................................................................................................5

Specications ............................................................................................................................5

Nameplate Information..............................................................................................................6

Principle of Operation...............................................................................................................7

Installation..................................................................................................................................8

Remote Sensing ........................................................................................................................8

Startup and Operation...............................................................................................................9

General Planning for Maintenance ..........................................................................................9

Disassembly of the Mooney Series 20 Relief Valve ...............................................................10

Cleaning.................................................................................................................................11

Inspection of the Main Valve ....................................................................................................11

Reassembly................................................................................................................................11

Reassembly of Pilot to Main Valve.........................................................................................13

Mooney Series 20 Pilot .............................................................................................................13

Product Description................................................................................................................13

General Description ...............................................................................................................13

Pilot Markings (Figure 12)......................................................................................................15

Maintenance...............................................................................................................................15

Pilot Disassembly......................................................................................................................16

Pilot Assembly...........................................................................................................................16

Hydrostatic Testing ...................................................................................................................18

Accessories ...............................................................................................................................18

Mooney Series 20 Relief Valve Instruction Manual | 5

Product Introduction

Figure 1

Mooney Series 20 Relief Valve.

The Mooney Series 20 Relief Valve included in this manual is an

over-pressure protection device designed to be used with a self-

contained pilot valve system. This device is intended for use on

DOT regulated applications and shall NOT be used to meet the

requirements for ASME Section VIII.

The Mooney Series 20 Relief Valve consists of five main

components (Figure 1):

A. Main valve

Available in inlet sizes 1.5” through 8”, with a full-bore

orifice, the main valve contains a seat O-Ring to maintain

a bubble tight seal and a nozzle O-Ring to isolate the dome

from the inlet and outlet ports. Assembly and disassembly

of the main valve are accomplished through top entry. When

there is no pressure in the system, routine maintenance,

such as replacement of O-Rings and seals, may be done

with the main valve in place.

B. Mooney Series 20 or 20H Pilot in Back Pressure (BPV)

Mode

The Series 20 Pilot is an independent pneumatically

operated flowing auxiliary device intended for controlling the

main valve. While the Series 20 Pilot is able to be configured

in either pressure reducing or back pressure (BPV) modes,

it should only be used in the back pressure (BPV) mode

when installed on the Consolidated* main valve assembly.

C. Mooney Type 25 Restrictor

Designed exclusively for the Mooney Series 20 Relief Valve,

the Type 25 Restrictor has a variably controlled orifice with

a range setting of ‘0-5’. Adjustment of the restrictor affects

the response rate, stability, and sensitivity of the valve.

Smaller restrictor openings result in higher gain (sensitivity)

and slower closing speeds. Larger openings result in lower

gain (greater proportional band), greater stability and

faster closing speeds. The Type 25 Restrictor is required

for normal valve operation. The recommended and factory

setting for optimal performance is ‘2’.

D. Inline Filter

A 15 micron inline filter is recommended on all Mooney

Series 20 Relief Valves. This inline filter serves to limit debris

particles from entering the supply line of the pilot.

E. Field Test Connection

A field test connection is recommended for the Mooney

Series 20 Relief Valve. This allows the stroking of the valve

with an auxiliary media, e.g. air or nitrogen in order to

establish the desired pressure set point. An internal check

valve is present in the field test connection isolating the inlet

media from the test media and at the same time, allowing

the valve to open normally in the event of a system over

pressurization during a field test.

Specications

Specifications

Main Valve Orifice Full-bore

Sizes 1.5” (40mm) through

8” (200mm) inlet

Body Style 1.5” through 4” Inlet – Single Outlet

6” through 8” Inlet – Dual Outlet

Inlet Ratings ASME/ANSI Class 150 through 300

Outlet Ratings ASME/ANSI Class 150

Temperature Range -20°F to 150°F (-29°C to 66°C)

Pressure Range 15 psig to 740 psig

End Connections Raised-face flanges

Materials Carbon Steel or 316 SST Main Valve

Brass or SST Pilot

Table 1

Nameplate Information

Designation Definition

Blank Box CE Marking

S/N Serial Number

Size Line Size of the Valve (Inlet X Outlet)

RV- Figure Number

ANSI/ASME CL Inlet Class flange rating

Max Inlet Maximum Operating Inlet Pressure (psig)

YR Year Manufactured

S/O Sales Order Number

Max Temp Maximum Operating Temperature

Bolt Torq Recommended Cover Plate Bolt Torque

Table 2

Figure 2

Nameplate of Mooney Series 20 Relief Valve

Mooney™Series 20 Relief Valve

Mooney Series 20 Relief Valve Instruction Manual | 7

Principle of Operation

The Mooney Series 20 Relief Valve controls system pressure

upstream of the valve. When system pressure is less than

the pilot set point, the pilot venting port is closed, and system

pressure from the main valve inlet is fed through the pilot to

equalize with the dome pressure. Since the area above the

main valve disc is larger than the area of the main valve seating

surface, the difference in area causes a net downward force,

keeping the main valve closed.

As system pressure increases, system media pushes against

the main pilot spring in the pilot sense chamber. The pilot opens

and relieves the dome pressure from the relief valve to the outlet

faster than is flowing into the dome through the restrictor. As the

dome pressure decreases the main valve disc begins to lift with

the inlet pressure force. The force balance at this moment is

equal between system pressure in the sense chamber and the

main pilot spring. As the pressure increases or decreases within

this balance, the pilot’s control of flow opens and closes and the

dome pressure decreases and increases, respectively, the valve

disc responding sensitively to the flow demand.

As inlet pressure increases further, the net upward force on the

main valve disc increases, allowing the main valve to relieve

more pressure. The disc obtains full lift (full capacity) at 1.5 psig

or 5% above set point, whichever is greater.

When discharging, the valve reduces system pressure below

the set point, allowing the pilot to reclose. The system pressure

continues to flow through the restrictor to equalize with the

pressure in the dome above the main valve disc. The downward

force created by the difference in areas of the disc allows the disc

to close. The disc obtains full reseat at 1.5 psig or 5% below set

point, whichever is greater.

Figure 3

Closed Position

Figure 4

Partially Open Position

Installation

Figure 5

Mounting Option A

Figure 6

Mounting Option C

1. The Filter connects to the Main Valve Inlet Supply via the

Inlet Supply Guide

2. Tubing splits from the Filter outlet to the Field Test Connection

(if applicable) and Type 25 Restrictor

3. The Field Test Connection (if applicable) connects to the

Pilot Sense port

4. The Type 25 Restrictor connects to the Pilot Inlet port

5. The Pilot Loading port connects to the Main Valve Dome

port

6. The Pilot Outlet connects to the NPT tapped main valve

outlet port

7. Connect the flanged inlet system piping to the upstream

inlet flange

8. Connect the flanged outlet system piping to the downstream

outlet flange

Remote Sensing

The Mooney Series 20 Relief Valve ships standard from the

factory with the sense line connected to the main valve inlet

supply guide. If the pressure drop between the source of pressure

in the system or equipment to be protected and the pressure at

the relief valve inlet exceeds 3%, the sensing line to the pilot

valve can be connected directly to the process system rather

than to the main valve. Pipe connections are ¼” NPT, and tubing

connections are 3/8” OD Seamless Stainless Steel.

ATTENTION: For remote sensing, 3/8” (9.5 mm) OD tubing is

adequate for distances up to 10 feet (3m). Sense line locations

should be away from turbulent areas (elbows, valves, reducers,

etc.) and have full opening into the pipe free from burrs, drill

peels, and weld slag. Shut-off valves are not required, but if

used, should be full-bore.

Mounting Option A (Figures 5 & 7)

1. Remove tubing between the Field Test Connection (B) and

the filter (E), leaving NPT connections in place.

2. Connect the filter (E) and the restrictor (A) via new

tubing (D).

a. Elbow fitting the Type 25 Restrictor must be rotated

180° to perform this action.

Figure 7

3. Place a tubing plug on one of the open tubing connections

on the tubing tee above the Field Test Connection (B).

4. Connect remote sense location upstream of the valve to the

Field Test Connection (B) via new tubing (C).

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