GE Baker Hughes Masonelian BR200, Baker Hughes Masonelian BR400 Instruction Manual

Masoneilan*

BR200/BR400

High Capacity Volume Booster Relays

Instruction Manual (Rev. B)

BHGE Data Classication : Public

2 | BHGE

© 2019 Baker Hughes, a GE company. All Rights Reserved.

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC
REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND
MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BHGE (BAKER
HUGHES, A GE COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE
SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE
OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL 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 REQUIREMENTS 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 CONNECTION WITH INSTALLATION,
OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR
PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES
THE MATTER SHOULD BE REFERRED TO BHGE.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE 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 BHGE REGARDING THE EQUIPMENT OR ITS USE
ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.

THESE INSTRUCTIONS CONTAIN PROPRIETARY INFORMATION OF BHGE, AND ARE FURNISHED TO
THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR
MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE
OR IN PART NOR SHALL ITS CONTENTS BE DISCLOSED TO ANY THIRD PARTY WITHOUT THE WRITTEN
APPROVAL OF BHGE.

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 3

Product Description

BHGE’s Masoneilan BR400 and BR200 are high capacity volume boosters for applications that require fast
stroking speeds using pneumatic actuators. Stable operation over a wide range of actuator sizes can be obtained
by adjusting the bypass valve on the booster to modify the dynamic response. The models BR200 and BR400 are
equally suitable for use on diaphragm or piston actuators.

Features and Benefits

• Flow characteristics suitable for control valves

• Short stroking times with consistently stable operation for use on high-volume actuators or on very

demanding stroking time control valve applications

• Built-in bypass valve with locking screw to adjust sensitivity and dynamic response

• Filter on the supply port to protect instrument from particles in air supply

• Corrosion resistant finish and stainless assembly hardware to permit use in corrosive atmosphere

Principle of Operation

The input signal pressure is applied to the upper diaphragm to produce a force that is opposed in a 1:1 ratio by
the output pressure acting on the lower diaphragm through the seal plate orifice. An increase in the input signal
pressure will depress the top diaphragm and open the pilot valve, allowing supply pressure to the output until the
output pressure action on the lower diaphragm re-balances the forces. Conversely, a decrease in the input signal
pressure allows the exhaust valve to open until the output pressure falls to the same value as the input signal

pressure.

A bypass valve allows a controlled flow of input signal direct to the output to obtain stable control for small or
slow changing input signals.

4 | BHGE

Figure 1 - Cut-away View of BR400 Booster Relay

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Pneumatic Supply

The BR400 and BR200 Booster Relays require a source of clean, dry, oil-free, instrument grade air to ANSI/
ASA-57.3 1975 (R1981) or ISA-S7.3-1075 (R1981).

Maximum Supply Pressure 150 psi (10.3 bar)

Dew Point At least 18°F (10°C) below minimum anticipated ambient temperature.

Particulate Matter Filtered to below 5 microns.

Oil Content: Less than 1 ppm w/w or v/v.

Contaminants

Free of all corrosive contaminants and hazardous gasses, flammable or
toxic.

Pneumatic Connections

The pneumatic connection locations are shown on Figure 1 and are also stamped on relay body. The supply and
output connections are 1/4" NPT and the signal connection is 1/4" NPT. The supply and output tubing should be a
minimum of 1/2". Blow out all piping prior to connecting to booster. Use of a soft setting anaerobic hydraulic seal,
such as Loctite Hydraulic Seal 542 is recommended on the male threads of all connections.

Do not use an excessive amount of hydraulic sealant as it will

not set and may migrate into the pneumatic passages.

Do not use pipe thread sealant tape on pneumatic fittings, as
it tends to shred small particles which can cause instrument
malfunction.

Installation

The booster relay should be close coupled to the actuator. Use of a short ½" pipe nipple between the relay output
and the actuator provides both the pneumatic connection and mounting means. The preferred orientation is with
the exhaust openings pointing down; however horizontal mounting is acceptable.

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 5

Specifications

Features Specifications

Maximum Cv (supply) 1.2 (BR200) and 2.6 (BR400)

Maximum Cv (exhaust) 1.2 (BR200) and 2.4 (BR400)

Maximum Signal Pressure 150 psi (10.3 bar)

-30ºC to +83ºC (-22ºF to +181ºF)

Operating Temperature Limits

Input / Output Ratio 1:1

Supply and Output Connections 1/4” NPT or Rc (BR200) and 1/2" NPT or Rc (BR400)

Signal Connection 1/4" NPT or Rc

Approximate Weight 0.7 kg (1.5 lbs) for BR200 and 1.4 kg (3 lbs) for BR400

Low Temperature: -55ºC to +60ºC (-67ºF to +140ºF)
High Temperature: 0ºC to +100ºC (32ºF to +212ºF)

Table 1 - Specifications

Flow Characteristics

6 | BHGE

Figure 2 - Flow Characteristics

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Operation

Prior to applying supply pressure to the relay, open the bypass needle valve approximately one turn. After
applying pressure, note response of actuator to open and close commands from the positioner. If excessive
overshoot or hunting is seen, open needle valve until stable operation is obtained. If valve is sluggish, close needle
valve until unstable operation occurs, then back off until stable operation is obtained.

Turning valve clockwise (closing) speeds response but can lead to instability. Turning valve counterclockwise aids
stability but will slow down the actuator's response. Proper setting provides stable operation and acceptable

response time.

Bypass valve

Safety screw

Safety screw

Bypass valve

Bypass valve adjustment on BR200 model

Figure 3

Bypass valve adjustment on BR400 model

Figure 4

Break loose of bypass valve:
Completely loose small screw and turn bypass valve near the
fully opened position may cause bypass valve to break loose by

internal pressure

Adjustment of bypass valve during plant operation:
Adjusting bypass value when control valve is in service may

generate sudden valve opening change or oscillation.

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 7

Maintenance

The BR400 Booster Relays do not require any routine maintenance. If a contaminated air supply has been used,
then there may be need to clean the filters or disassemble the relay to clean the supply and exhaust seats and

valves.

Troubleshooting

If the output pressure does not respond to changes in the input pressure, check that supply pressure is at proper
value and that signal and supply filters are not plugged with foreign matter. Check also that supply and exhaust

valve seats are clean.

If output pressure is not stable or is slow to respond, check setting of bypass needle valve. See bypass valve
setting procedure under "Operation".

8 | BHGE

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Material of Construction and Dimensions

Model BR200

No. Part Standard Material

ø86mm (3.4")

2

14

3

17

4

5

7

9

15

10

82mm (3.3")

Figure 5 - BR200 Construction and Dimensions

13

1

6

8

12

11

57mm
(2.2")

79.5

mm

(3.1" )

1 Body Aluminium Alloy Die Casting

2 Case Aluminium Alloy Die Casting

3 Upper Diaphragm Chloroprene / Polyester

4 Lower Diaphragm Chloroprene / Polyester

5 Lower Diaphragm Plate Aluminium Alloy Plate

6 Exhaust Seat Copper Alloy

7 Seal Plate Austenitic Stainless Steel

8 Exhaust Seal Guide Copper Alloy

9 Seal Plate Gasket

10 Plug Cap Copper Alloy

11 Coil Spring Austenitic Stainless Steel

12 Plug Austenitic Stainless Steel

13 Bypass Valve Plug Austenitic Stainless Steel

14 Piston

15 Supply Filter Austenitic Stainless Steel

16 Signal Filter Austenitic Stainless Steel

17 Bleed Ring Aluminium Alloy Die Casting

Note: model BR400 is available in stainless steel for marine
offshore applications.

Inorganic Fiber/Oil Resistant
Synthetic Rubber

Glass Fiber Reinforced
Thermoplastic Polyester

Model BR400

14

3

17

4

5

7

9

15

10

ø127mm (5")

87mm (3.4")

16 2

13

1

6

8

12

11

90mm

(3.5")

119mm

(4.7 ")

Figure 6 - BR400 Construction and Dimensions

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 9

Notes

10 | BHGE

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Notes

© 2019 Baker Hughes, a GE company. All Rights Reserved.

Masoneilan BR200/BR400 High Capacity Volume Booster Relays | 11

DIRECT SALES OFFICE LOCATIONS

AUSTRALIA
Brisbane:
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Fax: [phone]

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BRAZIL
Phone: [phone]

CHINA
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Fax: [phone]

FRANCE
Courbevoie
Phone: [phone]
Fax: [phone]

GERMANY

Ratingen

Phone: [phone]
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INDIA
Mumbai
Phone: [phone]
Fax: [phone]

New Delhi
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JAPAN
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THE NETHERLANDS
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RUSSIA
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UNITED STATES
Jacksonville, Florida
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Deer Park, Texas
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Houston, Texas
Phone: [phone]
Fax: [phone]

valves.bhge.com

*Denotes a trademark of Baker Hughes, a GE company, LLC.

Other company names and product names used in this document are the registered trademarks or

trademarks of their respective owners.

© 2019 Baker Hughes, a GE company LLC - All rights reserved.

Baker Hughes, a GE company, LLC and its aliates (“BHGE”) provides this information on an “as is”
basis for general information purposes and believes it to be accurate as of the date of publication.
BHGE does not make any representation as to the accuracy or completeness of the information and
makes no warranties of any kind, specic, implied or oral, to the fullest extent permissible by law,
including those of merchantability and tness for a particular purpose or use. BHGE hereby disclaims
any and all liability for any direct, indirect, consequential or special damages, claims for lost prots,
or third party claims arising from the use of the information, whether a claim is asserted in contract,
tort, or otherwise. The BHGE logo is a trademark of Baker Hughes, a GE company LLC. GE and the GE
monogram are trademarks of the General Electric Company used under trademark license.

GEA30642B 05/2019