GE Valve Regulators Mooney_Flowgrid_iom Technical Specifications
GE Oil & Gas
Mooney
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 Description ............................................................................1
Regulator Markings .............................................................................3
Nameplate Information .................................................................... 3
Principles of Operation ...................................................................... 4
Hydrostatic Testing .............................................................................5
Installation ............................................................................................... 6
Flowgrid* Regulator
Piping Details .......................................................................................... 7
Start-up and Operation .................................................................. 11
Maintenance ....................................................................................... 13
Troubleshooting ................................................................................. 15
Warranty ................................................................................................ 16
Product Support ................................................................................. 16
*
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:
■
In line maintenance
■
Replaceable trim
■
Reversible trim parts
■
Non stretching fabric reinforced diaphragm for
stability and fast response at all temperatures
■
Positive spring shutoff
■
Two-stage pressure drop to minimize noise and
provide cavitation protection
GE Oil & Gas has secured global PED EN 334 certification
for its Mooney Flowgrid regulators demonstrating 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 & 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
Table 2
Materials of Construction
Body & Spring Case
Spacer
Throttle Plate
Diaphragm
O-Ring & Seals
Bolting
Spring
425
3
Figure 1 - Flowgrid Parts
ASTM A 216 WCB Carbon Steel
ASTM A 216 WCB Carbon Steel
17-4PH Stainless Steel
Nitrile/Nylon (Optional - Viton/Nylon)
Nitrile (Optional - Viton)
ASTM 193 GR B-7 or Equal
301 Stainless Steel
6
1
Specifications
Sizes
Body Style
End Connections
Temperature
Min/Max Temperature
Maximum Operating
Differential
Maximum Emergency
Differential
Minimum Differential
Cracking Differential
Maximum Inlet Pressure
Outlet Pressure Range
Flow Direction
Body Taps
1
Reverse flow by changing pilot connections and reversing spring case.
1” - 12” (DN 25 - DN300)
Single Port
10 inch and 12 inch Dual Ports
Screwed, Socket Weld
Flanged, Flangeless & 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)
1000 psi (68.9 bar)
(unless limited by body rating)
Refer to individual product
specification sheets
Refer to individual product
specification sheets
1480 psig (102.1 bar)
(limited by flange or pilot rating)
Limited by pilot
Bi-Directional
1/4” - 18 NPT
1
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 capacity
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.
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 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.
2
Regulator Markings
Front View
Figure 2 - Regulator Markings
Back View
Top View
1. American National Standards Institute (ANSI) pressure class rating of the regulator.
2. Line size of body.
3. ANSI pressure class rating of the flange.
4. Indication that the regulator has been hydrostatically tested according to code requirements.
5. The serial number is stamped on the spring case, spacer1, and body.
6. The Nameplate location.
7. 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.
8. The % Capacity tag indicates the capacity of the throttle plate (100%, 75%, 50%, & 35%) in the regulator.
1
NOTE: On all 1” regulators and 2” standard regulators the throttle plate itself is stamped.
Nameplate Information
Table 3
Item Definition
Mooney™ Flowgrid™ Regulator
Salt Lake City, UT USA
S/N
Size/Ends
ANSI Cl
YR
Max
Temp
°F/°C
Diff
Min/Max
Max
Inlet
psi
Bolt Torq
Ft-lbs/Nm
U.S. Pat. Nol 4,659,062
Canadian Pat. No. 1,250,207
FG-
psi
bar
Flowgrid
BLANK
SN
bar
FG
SIZE/END CONN
Registered name of regulator
CE Marking
Serial number assigned to regulator
Flowgrid Model description
Line size of bogy an type of end
connection
ANSI CL
American National Standards Institute
pressure class
MAX INLET
Maximum inlet pressure (psig)/(bar)
PRESSURE
Figure 3 - Flowgrid Nameplate
YR
Year manufactured
Minimum differential required to fully
DIFF/MIN/MAX
open regulator
Maximum allowable operating pressure
differential (psig)/(bar)
MAX F
TEMPERATURE
BOLT TORQ
FT-LBS/n-m
Maximum Operating Temperature in
degrees Fahrenheit
Recommended bolt torque for spring
case in foot pounds
3
Principles of Operation
Pilot Supply Pilot Sense
Restrictor
Pilot Loading
Connection
Inlet Outlet
Figure 4 - Pressure Reducing Confi guration Fully Closed
Connection
Pilot Outlet
Connection
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 regulator 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 pressure 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 Supply Pilot Sense
Restrictor
Pilot Loading
Connection
INLET
Inlet Outlet
Figure 5 - Pressure Reducing Confi guration Partially Open
Connection
Pilot Outlet
Connection
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 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.
Pilot Supply Pilot Sense
Restrictor
Pilot Loading
Connection
Inlet Outlet
Figure 6 - Back Pressure Confi guration Fully Closed
4
Connection
Pilot Outlet
Connection
Pilot Supply
Restrictor
Pilot Loading
Connection
Inlet
Figure 7 - Back Pressure Confi guration Partially Open
Pilot Sense
Connection
Pilot Outlet
Connection
Outlet
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 diaphragm allows inlet pressure to progressively
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 force, plus the pressure 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 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.
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 control 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
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 & Socket Weld 2225 psi (153.41 bar)
150# Flange & Flangeless 450 psi (31.02 bar)
300# Flange & Flangeless 1125 psi (77.56 bar)
600# Flange & Flangeless 2225 pis (153.4 bar)
Flowgrid 250
1
The Flowgrid 250 is a ductile iron construction.
1
375 psi (25.86 bar)
Figure 8 - Flowgrid Tee Connections
A. Inlet connection on regulator body joined to “Tee”.
B. “Tee” connected to loading connection on spring case.
C. Outlet of “Tee” connected to outlet connection on
regulator
5
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