GE Valve Regulators Mooney_Flowgrid_iom Technical Specifications
Contents
1. 4 Check for pilot vent port blockage The regulator will not regulate to set point or droops off 1 Check for proper sizing The regulator may be running out of capacity during peak demand periods 2 Adjust the restrictor to a higher gain smaller setting Refer to page 11 The regulator fails open or fails closed 1 Refer to the table below to diagnose failure modes Table 7 Failure Mode Problem Fail Fail Open Closed Damage to the flexible element X X Damage to the flexible element on the X upstream side less likely Damage to the flexible element on the X downstream side more likely Debris between the flexible element and X the seat Blockage of pilot supply pressure Blockage of the restrictor Blockage of the pilot supply line X X X X Loss of the sense line PRV pilot Loss of the sense line Relief Pilot Blockage of pilot discharge Pilot diaphragm rupture if PRV pilot X Pilot diaphragm rupture if BPV relief pilot X Blockage of pilot orifice Blockage can be caused by debris hydrates freezing or damage to the component involved 15 Limited Warranty Seller warrants that Products shall be delivered free from defects in material workmanship and title and that Services shall be per formed in a competent diligent manner in accordance with any mutually agreed specifications The warranty for Products shall expire one 1 year from first use or eighteen 18 months from del2. Pilot Sense Connection Pilot Supply Restrictor KS VVI Pilot Loading Connection Pilot Outlet Connection Figure 7 Back Pressure Configuration Partially Open A back pressure regulator or relief regulator controls upstream pressure instead of downstream pressure The control action in the pilot is the reverse of a pilot for a pressure reducing regulator increasing pressure in the sense chamber opens the pilot regulator At no flow when the inlet pressure is less than the set point of the pilot regulator the pilot is closed and full inlet pressure loads the spring case through the pilot loading connection In this condition the diaphragm is closed tightly against the throttle plate The pressure differential across the outlet half of the diaphragm adds to the spring force in closing the Flowgrid regulator Refer to figure 6 As inlet pressure increases above the set point of the pilot regulator it will open and start bleeding pressure out of the spring case faster than it can enter through the restrictor Reducing the pressure above the dia phragm allows inlet pressure to progressively Hydrostatic Testing All Flowgrid regulators are hydrostatically tested at the factory prior to shipment according to ISA S75 19 1989 and MSS SP 61 standards If it is necessary to retest the regulator follow one of the procedures listed below to prevent damage to the diaphragm Option 1 1 Disconnect and remove all con
3. This will improve the shutoff of the second stage regulator Maintenance Regulator parts are subject to normal wear and must be inspected and replaced as necessary The frequency of inspection and replacement of parts depends on severity of service conditions or the requirements of local state and federal regulations Be certain that the name plates are updated to accurately indicate any field changes in equipment materials service condi tions or pressure settings Before disassembly make sure the regulator has been isolated from the process by closing block regulators on the inlet and outlet sides of the regulator Safely release pressure and process fluid from body and pilot system Failure to complete these steps can result in personal injury and property damage 13 14 Maintenance cont d Assembly L Disconnect control lines s and pilot supply line from pilot system Loosen main spring case nuts In a crisscross pattern The main spring will lift the spring case as the nuts are removed Remove spring diaphragm throttling element spacer throttle plate and O rings in that order Inspect all parts for wear and damage Replace as necessary NOTE The periphery of the downstream outlet portion of the throttling plate is the primary shutoff surface and should be inspected most closely for wear and damage Nicks and or wear on the support ribs will usually not affect shutoff The outside rib on the
4. 1 801 487 2225 F 1 801 487 2587 mooney inquiries ge com Visit us online at www ge com energy 2012 General Electric Company All Rights Reserved Trademarks of General Electric Company GEA 19583 Mooney Flowgrid IOM Manual Rev 08 2012
5. 4 ALL 125 169 28 6 CL 150 amp CL 300 Flanged 125 169 28 6 CL 600 Flanged 200 270 86 10 CL 150 amp CL 300 Flanged 125 169 28 10 CL 600 Flanged 200 270 86 12 CL 150 amp CL 300 Flanged 125 169 28 12 CL 600 Flanged 200 270 86 All Flowgrid Pilots 10 13 54 Refer to WARNING below WARNING Lubricating and or overtightening the bolting can damage the Diaphragm in the 1 and 2 sizes of the Flowgrid regulator WARNING DO NOT replace the studs or nuts with any bolt or stud and nut combination that does NOT have an SAE Grade 7 or ASTM Grade B7 rating 3 Reconnect the pilot system Follow Start up procedures when returning to operation Troubleshooting First Steps 1 Verify the regulator specifications fit the application conditions Min max inlet pressure control pressure range amp min max operating differentials should be checked to make sure the regulator and pilot are designed to operate in the present conditions 2 Verify the regulator is piped correctly Even though the regulator may have operated in the past check that current piping connections match recommendations on pages 7 10 3 Verify the regulator is sized correctly Regulators operating below 10 or above 80 of their maximum capacity given current application conditions tend to have more problems Consider reduced capacity trim or a larger regulator in these cases Potential Issues Regulator
6. amp Gas Figure 3 Flowgrid Nameplate Table 3 Flowgrid BLANK SN FG SIZE END CONN ANSI CL MAX INLET PRESSURE YR DIFF MIN MAX MAX F TEMPERATURE BOLT TORQ FT LBS n m Registered name of regulator CE Marking Serial number assigned to regulator Flowgrid Model description Line size of bogy an type of end connection American National Standards Institute pressure class Maximum inlet pressure psig bar Year manufactured Minimum differential required to fully open regulator Maximum allowable operating pressure differential psig bar Maximum Operating Temperature in degrees Fahrenheit Recommended bolt torque for spring case in foot pounds Principles of Operation Pilot Sense Connection Pilot Supply Restrictor G Vv VS Pilot Loading Connection Pilot Outlet Connection Outlet Figure 4 Pressure Reducing Configuration Fully Closed At no flow when the outlet pressure is greater than the set point of the pilot regulator the pilot is closed and full inlet pressure loads the spring case through the pilot loading connection In this condition the diaphragm is closed tightly against the throttle plate The pressure differential across the outlet half of the diaphragm adds to the spring force in closing the Flowgrid regulator Refer to Figure 4 As demand for flow occurs in the downstream system the outlet pressure drops causing the pilot r
7. and a consistent minimum differential regardless of temperature It also provides a positive closing force which is important in monitor regulation applications The spring case 6 is shaped to retain the main spring It provides a low volume cavity where loading pressure from the pilot system is placed on top of the diaphragm to control flow through the regulator Regulator Markings Front View Figure 2 Regulator Markings S Oy Se et NY Back View Top View American National Standards Institute ANSI pressure class rating of the regulator Line size of body ANSI pressure class rating of the flange Indication that the regulator has been hydrostatically tested according to code requirements The serial number is stamped on the spring case spacer and body The Nameplate location The flow direction is marked on the spring case INLET or OUTLET Proper alignment assures that the diaphragm guide on the Spring Case is aligned toward outlet side of the regulator The Capacity tag indicates the capacity of the throttle plate 100 75 50 amp 35 in the regulator NOTE On all 1 regulators and 2 standard regulators the throttle plate itself is stamped Nameplate Information U S Pat Nol 4 659 062 Mooney Flowgrid Regulator 659 Canadian Pat No 1 250 207 Salt Lake City UT USA S EAO O Size Ends M ANSON ey VR A O gt O aed EAO O O GE Oil
8. downstream side of the throttle plate is where shutoff takes place in the Flowgrid Regulator NOTE Nitrile O rings can swell after disassembly of a regulator that has been in service due to gas permeating the nitrile rubber This does not necessarily mean they must be replaced Set O ring aside for several hours and it will gradually return to normal size Placing the O ring s on ice will speed the process considerably Before placing the O ring back into service inspect for defects Cleaning 1 DO NOT clean O ring grooves with sharp metal tools The bottom of the groove must have a smooth finish to prevent leakage The mating surface of adjacent parts must also be smooth to prevent leakage Assembly NOTE Do not lubricate diaphragm sealing surface 1 Reassemble parts on the body per the assembly drawing in the parts supplement for the particular regulator size NOTE Both the throttle plate and the diaphragm can be rotated 180 degrees not turned upside down to renew the shutoff capability if the inlet side is in better condition than the outlet 2 Tighten main bolts in increments using a crisscross pattern Torque bolting as indicated on regulator nameplate or refer to Table 6 Bolting Torque Values Clean Dry Bolts Non Lubricated Table 6 Ft Lbs n m Flowgrid 250 20 27 09 1 ALL 25 33 86 2 x 1 ALL 25 33 86 2 ALL 60 81 26 3 ALL 125 169 28 4 x 3 ALL 125 169 28
9. joined to Tee B Tee connected to loading connection on spring case C Outlet of Tee connected to outlet connection on regulator Installation 1 PERSONNEL Installation of the Flowgrid regulator should be made by qualified personnel familiar with high pressure piping and pilot operated regulators WARNING Personal injury equipment damage or leakage due to explosion of accumulated gas or bursting of pres sure containing parts may result if this regulator is overpressured or is installed where service conditions could exceed the limits given in the specification of this manual or on the nameplate or where conditions exceed any ratings of the adjacent piping or piping connections Verify the limitations of both regulator and pilot to ensure neither device is overpressured To avoid such injury or damage provide pressure relieving or pressure limiting devices as required by Title 49 Part 192 of the U S code of Federal Regulations by the National Fire Codes of the National Fire Protection Association or applicable codes to prevent service conditions from exceeding those limits Additionally physical damage to the regulator regulator could break the pilot off the main regulator causing personal injury and or property damage due to explosion of accumulated gas To avoid such injury and damage install the regulator in a safe location 2 PRIOR INSPECTION Inspect the main regulator pilot and tubing fo
10. our commitment to quality and safety The certification was awarded by DVGW the German Technical and Scientific Association for Gas and Water one of the world s most recognized industry certification bodies and the largest gas and water industry certification agency in Europe GE Oil amp Gas has also secured the following verifications ISO 9901 ISO 14001 CRN along with others ensuring the safety and quality of the Mooney regulator Table 1 Materials of Construction Body amp Spring Case ASTM A 216 WCB Carbon Steel Spacer ASTM A 216 WCB Carbon Steel Throttle Plate 17 4PH Stainless Steel Diaphragm Nitrile Nylon Optional Viton Nylon O Ring amp Seals Nitrile Optional Viton Bolting ASTM 193 GR B 7 or Equal Spring 301 Stainless Steel 4 Figure 1 Flowgrid Parts All Mooney Flowgrid regulators have six main parts excluding bolting and O rings the body throttle plate spacer diaphragm main spring and spring case Although parts vary in size and design all regulators share the same principle of operation The body 1 is constructed with a single port sizes less than 10 and a dual port sizes greater than 10 The dual port design can provide redundant control if equipped with dual pilots or be used with a single pilot for maximum capacity The throttle plate 2 supports the diaphragm and provides a machined surface that the diaphragm seals against for bubble tight shutoff Restricted c
11. pilot restrictor for stability and performance as follows a If the system is stable adjust the pilot restrictor to a more closed position towards MIN setting Change the flow rate or increase the pilot setting to check the operation of the system during an upset b If the system is stable repeat step a until the system is unstable oscillating c Now readjust the restriction to a more open position towards MAX setting where the system is stable d Vary the flow rate over as wide a range as possible to make sure the system will be stable under all flow conditions NOTE Adjustment of the restrictor affects the response rate stability and sensitivity of the regula tor CLOSING the pilot restrictor moving adjustment towards MIN setting will result in higher gain narrow the proportional band more sensitivity and slower closing speeds OPENING the pilot restrictor moving the adjustment towards MAX setting will result in less gain widen the proportional band less sensitivity and faster closing speeds 8 Slowly increase the pilot spring setting until the desired downstream pressure is achieved 9 Slowly close the downstream block regulator or vent to check the Flowgrid regulator for lockup shut off 10 Slowly open the downstream block regulator to begin normal operation Back Pressure Regulator or Relief Regulator 1 Adjust the pilot restrictor to an intermediate opening a 4 setting on the
12. regulator 6A Outlet port of Series 20 Pilot connected to downstream piping 7 Pilot cartridge in PRV mode 8 Pilot supply from inlet connection on regulator body to Type 30 Filter inlet 9 Pilot supply from outlet connection on Type 30 Filter to Type 24 Restrictor inlet 10 Type 24 Restrictor mounted to Inlet port of Series 20 Pilot 11 Loading Port of Series 20 Pilot connected to Loading connection on Spring Case of Flowgrid regulator 12 Sense line connecting Sense port on Series 20 Pilot to downstream piping 13 Outlet port of Series 20 Pilot connected to Outlet connection of Flowgrid regulator 14 Pilot cartridge in PRV mode ot Dr ee a I 10 Piping Schematics cont 9 Working Monitor Refer to schematic on page 13 General recommendations To reduce the adverse m Gas velocity should be less than 100 ft sec 30m sec effects on the sense signal due to high gas velocity and m Sense connections should be 8 10 pipeline diamters turbulence away from turbulent areas m Pipeline diameters may need to be increased in pipe m Follow EN12186 piping specification sections containing sense connections Pilot 1 Pilot 2 p 1st Stage Regulator ABO Our nE DIA Mere 15 4 D 2nd Stage Regulator 1st Stage Regulator 810p 1 Filter supply connected from inlet connection on regulator body to Type 30 Filter inlet Plameters 2 Pilot supply from outlet connection on Type 30 Filter to Type 24 Restri
13. GE Oil amp Gas Mooney Flowgrid Regulator Installation Operation and Maintenance Manual Scope This manual provides installation operation and maintenance instructions for the Mooney Flowgrid regulator Instructions for the Mooney Series 20 Pilot will be found in a separate manual Table of Contents Product SSC OOM saeia acted nt teatee 1 Regulator MONS assnnesssensne sis 3 Nameplate INFOrMation wuu ccsecsssssssssssssssssesssssssseecsessseeessesssseeseessseees 3 Principles of OD CLOG 1 ccessccscstctecsectevsoteetecdatideteeasmbtietterupsteciesiaats 4 Hydrostatic TESUNG sisseseade 5 ITS CU cece E E ENE EE A ETT 6 Product Description The Mooney Flowgrid regulator is an easy to maintain regulator designed to be used primarily with a self contained pilot system The Flowgrid regulator has several unique features that add to its versatility such as m n line maintenance m Replaceable trim m Reversible trim parts m Non stretching fabric reinforced diaphragm for stability and fast response at all temperatures m Positive spring shutoff m Two stage pressure drop to minimize noise and provide cavitation protection imagination at work PIV Detall susene SOn upand OO ei AN ssn 11 PGA VNC E aE craeeeacceeetseette aerate L5 TOUDE NO ONG seei E 15 4 6 6 AEE E E E N EA 16 Poduri 8 6 6 g a 16 GE Oil amp Gas has secured global PED EN 334 certification for its Mooney Flowgrid regulators demonstrating
14. Mooney Type 24 Restrictor 2 Increase pilot spring compression to maximum or some margin above desired setting 3 If installed open hand regulators s in the control line s and the pilot supply line 4 Check that the Flowgrid regulator is vented to atmosphere or the downstream system is ready to accept flow 5 Open the downstream block regulator or open vent in piping downstream of the Flowgrid regulator 6 Slowly open the upstream block regulator to pressur ize the Flowgrid regulator and pilot system The Flowgrid regulator should lock up shut off with zero pressure downstream 7 Slowly decrease the pilot spring setting until some flow is achieved The flow may only be through the pilot system 8 Adjust the pilot restrictor for stability and performance as follows a If the system is stable adjust the pilot restrictor to a more closed position towards MIN setting Change the flow rate or increase the pilot setting to check the operation of the system during an upset b If the system is stable repeat step a until the system is unstable oscillating c Now readjust the restriction to a more open position towards MAX setting where the system is stable d Vary the flow rate over as wide a range as possible to make sure the system will be stable under all flow conditions NOTE Adjustment of the restrictor affects the response rate stability and sensitivity of the regulator CLOSING the p
15. apacity plates of 35 50 and 75 are available The spacer 3 creates a space between the throttle plate and the diaphragm which forms a flow path inside the regulator Table 2 Specifications Sizes 1 12 DN 25 DN300 Body Style Single Port 10 inch and 12 inch Dual Ports Screwed Socket Weld Flanged Flangeless amp Buttweld 20 F to 150 F 29 C to 66 C 40 F to 175 F 40 C to 79 C 800 psi 55 16 bar End Connections Temperature Min Max Temperature Maximum Operating Differential Maximum Emergency 1000 psi 68 9 bar Differential unless limited by body rating Minimum Differential Refer to individual product specification sheets Cracking Differential Refer to individual product specification sheets 1480 psig 102 1 bar limited by flange or pilot rating Maximum Inlet Pressure Outlet Pressure Range Limited by pilot Bi Directional 1 4 18 NPT Flow Direction Body Taps 1 Reverse flow by changing pilot connections and reversing spring case The fabric reinforced diaphragm 4 is the main working part of the Flowgrid regulator The diaphragm functions as both an actuator and the regulator throttling element It is designed to provide stability rangeability and fast response without stretching It will not take a set and is thick for durability and wear resistance The main spring 5 provides high frequency response proportional action for stability
16. ay from air intakes or any hazardous location The vent lines and stacks must be protected against condensation and clogging 7 PILOT SUPPLY LINES Run a 3 8 or 1 2 pilot supply line from the regulator body connection on the inlet side of the Flowgrid regulator to the pilot supply Filter or directly to the pilot Restrictor NOTE A shutoff regulator is not required in the supply to the pilot but if one is installed it should be a full opening ball regulator type 8 A TYPE 30 FILTER in the pilot supply line is recom mended to clean dirt and other particulates that could affect the restrictor or variable orifice in the pilot Use a 1 4 nipple to mount the filter to the body tap on the Flowgrid regulator 9 FILTER OUTLET Run 3 8 tubing or 1 4 pipe from the filter OUTLET port to the INLET side of the restric tor in the pilot system of the regulator The TYPE 30 30A 30S FILTER has two OUTLET ports for ease of tubing Block the other port with the plug provided or mount a gage to monitor inlet pressure if desired NOTE To avoid galling when stainless steel to stain less steel connections are made use a lubricant such as NEVER SEEZ by Bostik For best results Lightly lubricate the female threads Mixing the lubricant with pipe dope is also acceptable Do not exceed more than 1 4 turn past the point the threads start to bind 10 PILOT GAS HEATERS OPTIONAL Pilot supply gas can be heated to prevent the formation of i
17. ce plus the pres sure differential across the outlet half of the throttling element closes the diaphragm against the throttle plate shutting off the flow Refer to Figure 6 Adjustment of the restrictor affects the response rate stability and sensitivity of the regulator Smaller restric tor 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 Option 2 1 Disconnect and remove all control line s and pilot from the Flowgrid regulator 2 Pipe regulator with the inlet outlet and loading connections all common so that pressure is equalized in the entire regulator during the hydrostatic test See Figure 8 3 Refer to Table 4 for Maximum hydrostatic test pressure of each Flowgrid regulator 4 After hydrostatic test is completed follow the Disassembly Cleaning and Assembly procedures in the Maintenance section of this manual Table 4 Maximum Hydrostatic Test Pressures End Connection Max Hydrostatic Test Pressure Screwed amp Socket Weld 2225 psi 153 41 bar 150 Flange amp Flangeless 450 psi 31 02 bar 300 Flange amp Flangeless 1125 psi 77 56 bar 600 Flange amp Flangeless 2225 pis 153 4 bar Flowgrid 2501 375 psi 25 86 bar 1 The Flowgrid 250 is a ductile iron construction j Figure 8 Flowgrid Tee Connections A B A Inlet connection on regulator body
18. ce or hydrates in the pilot system Pilot supply gas heaters should be connected after the pilot filter if one is used Do not directly heat to entire Flowgrid regulator to prevent freezing internal rubber components can be heated beyond their max temperature rating causing potential damage 11 SENSE LINES CONTROL LINES Sense lines should be run from the pilot mounted on the Flowgrid regulator to a point 8 to 10 pipe diameters away from the regulator Refer to Piping Schematics Use Table 5 as a guide for the ideal tubing to use Reduce as necessary to connect to the pilot Table 5 Outlet Pressure Outlet Pressure Pilot Regulator Less than 2 psi 2 5psil0 14 Greater than with 0 14 bar 0 35 bar 5 psi 0 35 bar Static Sense Line 1 2 Pipe minimum 1 2 Tubing 3 8 Tubing No Flow Sense Line w Flow 3 4 1 Pipe 1 2 Pipe 1 2 Tubing The Flowgrid Series 20 Pilot has a static sense line NOTE The Sense line control line connection should be 8 10 pipe diameters away from areas of turbulence such as regulators reducers and elbows and should have a full opening into the pipe free from burrs drill peels and weld slag Shutoff regulators are not required in the control line s but if installed they should be of the full opening type Gas velocity at the sense line connection should not exceed 100 ft sec 30m sec 12 PILOT discharge Run 3 8 inch tubing from the pilot OUTLET port to the dow
19. ctor inlet 3 Type 24 Restrictor mounted to Inlet port of Series 20 Pilot 1 4 Loading Port of Series 20 Pilot 1 connected to Loading connection on Spring Case of the Flowgrid regulator 5 Outlet port of Series 20 Pilot 1 connected to Inlet port of the monitor Series 20 Pilot 2 6 Sense line connecting sense port on Series 20 Pilot to interstage piping 7 Sense line connecting sense port on the monitor Series 20 Pilot 2 to downstream piping 8 Outlet port of Series 20 Pilot 2 connected to Outlet connection of Flowgrid regulator 9 Loading port on the monitor Series 20 pilot 2 is plugged 10 Pilot cartridges in PRV mode 2nd Stage Regulator 11 Filter supply connected from inlet connection on regulator body to Type 30 Filter inlet 12 Pilot supply from outlet connection on Type 30 Filter to Type 24 Restrictor inlet 11 Pilot supply tubing from inlet connection on regulator body to Type 24 Restrictor inlet 13 Type 24 Restrictor mounted to Inlet port of Series 20 Pilot 3 14 Loading Port of Series 20 Pilot 3 connected to Loading connection on Spring Case of the Flowgrid regulator 15 Outlet port of Series 20 Pilot 3 connected to Outlet connection of Flowgrid regulator 16 Sense line connecting Sense port on Series 20 Pilot 3 to downstream piping 17 Pilot 3 cartridge in PRV mode NOTE In a working Monitor system with less than 25 psig 1 72 bar differential across the second stage regulat
20. does not shut off 1 Refer to the failure mode chart to diagnose potential causes 2 Clean or replace regulator and pilot components as necessary Erratic Control 1 Check for damage debris in the restrictor and control pilot Replace clean and lubricate compo nents as necessary Consider pilot supply filtration Type 30 Filter 2 Check for the potential of hydrate formation or freezing liquids in the pilot system If liquids are pres ent consider gas conditioning before the pilot and or regulator heating the supply gas to the regulator or heating the pilot supply gas pilot gas heater 3 Check the sense line location and assure it is away from turbulent locations Moving the sense line to a new location often solves control problems 4 Check to make sure needle regulators are not used on any pilot system connections Full opening type such as ball regulators are recommended 5 Check for pilot vent port blockage Instability amp Speed of response issues 1 Change restrictor setting Refer to page 11 2 Check the sense line location and assure it is away from turbulent locations Moving the sense line to a new location often solves control problems Factory recommendation is 8 10 pipe diameters away from sources of turbulence such as tee s elbows reducers regulators etc 3 Check to make sure needle regulators are not used on any pilot system connections Full opening type regulators are recommended
21. egulator to open and start bleeding pressure out of the spring case faster than it can enter through the restrictor Reducing the pressure above the diaphragm allows the inlet pres sure to progressively lift the diaphragm off the throttle plate opening the regulator and satisfying the demand for flow in the downstream system Refer to Figure 5 Pilot Sense Connection Pilot Supply Restrictor S Pilot Loading Connection Pilot Outlet Connection Outlet Figure 6 Back Pressure Configuration Fully Closed Pilot Sense Connection Pilot Supply Restrictor VVI Pilot Loading Connection Pilot Outlet Connection Outlet Figure 5 Pressure Reducing Configuration Partially Open When demand for flow ceases or is reduced the downstream pressure increases causing the pilot regulator to close Inlet pressure continues to pass through the restrictor until the control pressure equals the inlet pressure The spring force plus the pressure differential across the outlet half of the diaphragm closes the diaphragm against the throttle plate shutting off the flow Refer to Figure 4 Adjustment of the restrictor affects the response rate stability and sensitivity of the regulator Smaller restric tor 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
22. he Series 20 Flowgrid pilot equipped with Type 24 restricting regulator amp Type 30 Filter Consult factory for installation schematics of other manufacturer s pilot on the Flowgrid regulator 2 Single Regulator Single Pilot Back Pressure Regulator y Filter supply connected from inlet connection on regulator body to Type 30 Filter inlet Pilot supply from outlet connection on Type 30 Filter to Type 24 Restrictor inlet Type 24 Restrictor mounted to Inlet port of Series 20 Pilot Loading Port of Series 20 Pilot connected to Loading connection on Spring Case of Flowgrid regulator Sense line connecting Sense port on Series 20 Pilot to upstream BPV or downstream PRV piping Outlet port of Series 20 Pilot connected to Outlet connection of Flowgrid regulator Pilot cartridge in PRV mode pressure reducing BPV back pressure relief mode SDr ee a hy eS Piping Schematics cont 3 Dual Port Single Pilot Pressure Reducing Regulator 4 Dual Port Single Pilot Back Pressure Regulator 5 Dual Port Dual Pilot Pressure Reducing Regulator NOTE The dual port regulator offers redundant control with two separate control loops Ports 1 amp 2 are piped identically 1 Filter supply connected from inlet connection on regulator body to Type 30 Filter inlet 2 Pilot supply from outlet connection on Type 30 Filter to Type 24 Restrictor inlet 3 Type 24 Restrictor mounted to Tee connection 3A Type 24 Restrictor moun
23. ilot restrictor moving adjustment towards MIN setting will result in higher gain narrow the propor tional band more sensitivity and slower closing speeds OPENING the pilot restrictor moving the adjustment towards MAX setting will result in less gain widen the proportional band less sensitivity and faster closing speeds 9 Slowly adjust the pilot spring setting until the desired upstream pressure relief setting is achieved 11 Standby Monitor NOTE When the set point of the Operating Regulator NOTE This procedure is based on the 1st Regulator becomes less than the set point of the Monitor being the operating regulator and the 2nd regulator regulator the interstage pressure will drop from being the monitor regulator approximately full inlet pressure to 5 10 psi 0 35 oe 0 68 bar above the outlet pressure at low flow rates 1 Set operating pilot 1 spring at the MAXIMUM setting Checking Standby Monitor Operation 2 Set monitor pilot 2 spring to the MINIMUM zero 1 With flow going through the station slowly increase setting the setting of the Operating Regulator When 3 Purge station and open outlet regulator or vent to the pressure reaches the setpoint of the Monitor allow flow through the station Regulator the monitor should take control and the interstage pressure should increase to almost full 4 Slowly open inlet block regulator Full inlet pressure inlet pressure should be present at the Monito
24. ivery whichever occurs first except that software is warranted for ninety 90 days from delivery The warranty for Services shall expire one 1 year after performance of the Service except that software related Services are warranted for ninety 90 days If Products or Services do not meet the above warranties Buyer shall promptly notify Seller in writing prior to expiration of the warranty period Seller shall i at its option repair or replace defective Products and ii re perform defective Services If despite Seller s reasonable efforts a non conforming Product cannot be repaired or replaced or non conforming Services cannot be re performed Seller shall refund or credit monies paid by Buyer for such non conforming Products and Services Warranty repair replacement or re performance by Seller shall not extend or renew the applicable warranty period Buyer shall obtain Seller s agreement on the specifications of any tests it plans to conduct to determine whether a non conformance exists Buyer shall bear the costs of access for Seller s remedial warranty efforts including removal and replacement of systems structures or other parts of Buyer s facility de installation decontamination re installation and transportation of defective Products to Seller and back to Buyer The warranties and remedies are conditioned upon a proper storage installation use operation and maintenance of Products b Buyer keeping accurate and complete records of
25. nstream piping or to the connection provided on the outlet of the Flowgrid Piping Schematics 1 Single Port Regulator PRV Single Port Regulator BPV Dual Port Regulator Single Pilot PRV Dual Port Regulator Single Pilot BPV Dual Port Regulator Dual Pilot PRV Dual Port Regulator Dual Pilot BPV OF ge J SY 1 Single Regulator Single Pilot Pressure Reducing Regulator 2 regulator as shown in the piping schematics Refer to pages 7 10 STANDBY MONITOR NOTE To ensure full capac ity of a Standby Monitor regulator station it is important that the pilot discharge of the upstream regulator be connected downstream of the station if the minimum pressure drop across the entire station is below 60 psig 4 13 bar Refer to page 9 and page 12 13 VENT REGULATORS AND GAUGE CONNECTIONS Vent regulators and gauge connections are recom mended in the inlet and outlet piping to the Flowgrid regulator A gauge connection may be installed on the loading pressure connection to the Spring Case of the Flowgrid regulator These would be a great convenience during start up maintenance and operation 14 INTERSTAGE PIPING WORKING MONITOR Please refer to page 10 for interstage piping and sense line connection recommendations 7 Standby Monitor with differential greater than 60 psig 4 13 bar 8 Standby Monitor with differential less than 60 psig 4 13 bar 9 Working Monitor All drawings show installations with t
26. operation and maintenance during the warranty period and providing Seller access to those records and c modification or repair of Products or Services only as authorized by Seller in writing Failure to meet any such conditions renders the warranty null and void Seller is not responsible for normal wear and tear The above sets forth the exclusive remedies for all claims based on failure of or defect in Products or Services regardless of when the failure or defect arises and whether a claim however described is based on contract warranty indemnity tort extra contractual liability including negligence strict liabil ity or otherwise The warranties provided above are exclusive and are in lieu of all other warranties conditions and guarantees whether written oral implied or statutory NO IMPLIED OR STATUTORY WARRANTY OR WARRANTY OR CONDITION OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE APPLIES Product Support Local support is available through our manufacturers representative and distributor network Contact the factory or refer to our web site for your support representative contact information Factory support is available from 8 00 AM to 4 30 PM MST Monday through Friday Limited after hours support is also available Complete product specifications parts lists and flow calculation software Is available on our web site www ge com energy 1 801 487 2225 USA GE Oil amp Gas 2822 S 1030 West Salt Lake City UT 84119 T
27. or the pilot supply 11 may be connected to the piping upstream of the first stage regulator This will improve the shutoff of the second stage regulator Start up and Operation The following procedures are suggested for start up of the Flowgrid regulator Start up of the Flowgrid regulator should be made by qualified personnel familiar with high pressure systems and pilot operated regulators WARNING The instruction manual for the PILOT S being used should be consulted to ensure that the installation and start up instructions for the pilot are followed Some pilots can be damaged if not installed and put into operation correctly Pressure Reducing Regulator 1 Adjust the pilot restrictor to an intermediate opening a 4 setting on the Mooney Type 24 Restrictor 2 Back off on the pilot adjusting screw to fully relieve all the spring compression 3 If installed open hand regulator s in the control line s and the pilot supply line 4 Slightly open downstream block regulator or open vent in piping downstream of the Flowgrid regulator 5 Slowly open the upstream block regulator to pres surize the Flowgrid regulator and pilot system The Flowgrid regulator should lock up shut off with zero pressure downstream 6 Use vent in the downstream piping or slowly open the outlet block regulators 7 Slowly increase the pilot spring setting until some flow is achieved through vent or into downstream system Adjust the
28. r Regulator and the Monitor Regulator should be closed 2 Reduce the setting of the Operating Regulator back to the required outlet pressure The interstage pressure should drop to 5 10 psi 0 35 0 68 bar above the outlet pressure as the Operating Regulator takes control 5 Increase the pilot spring setting of the Monitor Regulator until the desired monitor override setting is reached Lock in pilot setting 6 With some flow going through the station begin to lower the operating pilot setting of the Operating Regulator until the desired outlet pressure is NOTE When the differential across the entire station P1 P2 is less than 60 psig 4 13 bar then alternate outlet piping as shown below is recommended for achieved added station capacity This applies to the Series 20 Pilot only consult with GE for applicability to other manufacturer s pilots Legend Inlet a O Outlet I Alternate Outlet S Sense See Note L Loading Pilot 1 Series 20 Pilot Restrictorg Restrictor Pilot 2 Series 20 Pilo Operating Regulator Monitor Regulator Figure 9 Standby Monitor Schematic Standby Monitor Working Monitor 1 Purge station and open outlet regulator or vent to allow flow through the station Set pilot 3 to a high setting above desired setpoint Set pilot 1 to a high setting above desired setpoint Set the Monitor pilot 2 at a zero setting Set restrictor on Pilo
29. r any damage that might have occurred in shipping Make sure the body pilot lines and inlet piping are clear and free from foreign material 3 ORIENTATION The Flowgrid regulator may be installed in any position the best position being one that provides easiest access for pilot adjustment and regulator maintenance 4 SCREWED END REGULATORS Apply pipe compound to the male threads starting one or two threads back from the end prior to assembling the joint 5 FLANGED END REGULATORS Use suitable line gaskets and good bolting practices with flanged bodies A crisscross pattern of incrementally tightening the line bolts is recommended 6 WELD END BODIES Remove the Spring Case and all trim parts including diaphragm and O rings before welding a buttweld and or a socket weld end Flowgrid regulator Electric arc welding is recommended to minimize heat build up on the body assembly Reassemble regulator refer to the Maintenance section of this manual for Disassembly and Assembly procedures and pressurize with air to check for leaks prior to putting the regulator in Service WARNING Gas Regulators installed in confined or enclosed spaces should be provided with adequate ventilation to prevent the possibility of gas buildup or accumula tion from leaks and venting Leaks or vented gas may accumulate causing personal injury death or property damage Pilot spring cases and the regulator enclosure should be vented to a safe area aw
30. t 1 at an intermediate opening a 4 setting on the Mooney Type 24 Restrictor 6 Slowly open the inlet block regulator to station The 1st Stage Regulator should remain closed as a result of the Monitor Pilot 2 being set to zero 7 Increase the setting of the Monitor Pilot 2 to the desired pressure setting If the regulator is unstable increase the restrictor opening until it becomes stable a Pi Legend Inlet O Outlet S Sense L Loading fs 1st Stage Regulator Figure 10 Working Monitor Schematic Pilot 2 Monitor 8 Lower the setpoint of the 2nd stage regulator Pilot 3 to the desired outlet pressure setting Tune the restrictor on Pilot 3 at this time The 1st stage regulator should open or begin to control the inter stage pressure at the setpoint of Pilot 1 9 Adjust the setpoint of Pilot 1 to achieve the desired Interstage pressure Tune the restrictor on Pilot 1 at this time 10 Raise the setpoint of Pilot 3 to verify the setpoint of the Monitor Pilot 2 Adjust if necessary Check for system stability and adjust the restrictor on Pilot 1 if required 11 Return setpoint of Pilot 3 to maintain the desired outlet pressure 2nd Stage Regulator NOTE In a working Monitor system with less than 25 psig 1 72 bar differential across the second stage regulator the pilot supply may be connected to the piping upstream of the first stage regulator
31. ted to Inlet port of Series 20 Pilot 4 Tee mounted to Inlet Port of Series 20 Pilot 5 Loading Port of Series 20 Pilot connected to Loading connection on Spring Case Port 1 of Flowgrid Regulator 6 From Tee to Spring Case Port 2 of Flowgrid regulator 7 Outlet port of Series 20 Pilot connected to Outlet connection of Flowgrid regulator 8 Sense line connecting Sense port on Series 20 Pilot to downstream PRV or upstream BPV piping 9 N Pilot cartridge in PRV mode pressure reducing BPV back pressure relief mode OTE Dual port regulators in 1 8 sizes have been discontinued Schematics for reference only Piping Schematics cont 7 Standby Monitor with Differential Pressure Greater than 60 psi 4 13 bar L r pia ao S 4 Operating Regulator Monitor Regulator i 8 43 8 Standby Monitor with Differential Pressure Less than 60 psi 4 13 bar Operating Regulator Monitor Regulator D amp Filter supply connected from inlet connection on regulator body to Type 30 Filter inlet Pilot supply from outlet connection on Type 30 Filter to Type 24 Restrictor inlet Type 24 Restrictor mounted to Inlet port of Series 20 Pilot Loading Port of Series 20 Pilot connected to Loading connection on Spring Case of Flowgrid regulator Sense line connecting Sense port on Series 20 Pilot to downstream piping Outlet port of Series 20 Pilot connected to Outlet connection of Flowgrid
32. trol line s and the pilot from the Flowgrid regulator 2 Loosen main spring case nuts in a crisscross pattern The main spring will lift the spring case as the nuts are removed 3 Remove main spring and diaphragm from regulator For all 1 2 4 6 and 10 V6 Flowgrid Regulators 4 Replace diaphragm with a used diaphragm that has the thick padded area cut out leaving the outer sealing surface see below This area removed For 3 and 4 x 3 Flowgrid Regulators 4 Remove diaphragm but leave diaphragm O ring in place Make sure O ring is properly seated 5 Reassemble spring case on Flowgrid regulator 6 Tighten main bolts in increments using a crisscross pattern Torque bolting as indicated on regulator nameplate or refer to Table 6 Page 14 7 Plug spring case loading port pilot inlet and outlet taps on Flowgrid regulator 8 Refer to Table 4 for the maximum hydrostatic test pressure of each Flowgrid regulator 9 After hydrostatic test is completed follow the Dissassembly Cleaning and Assembly procedures in the Maitnenace section of this manual lift the throttling element off the throttle plate opening the regulator and satisfying the demand for flow in the upstream system Refer to Figure 7 When upstream pressure decreases causing the pilot regulator to close pilot supply pressure continues to pass through the restrictor until the control pressure equals the inlet pressure The spring for
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