This document provides maintenance instructions for a pilot operated safety relief vent with a non-flowing modulating pilot (Series 9200). It describes general safety precautions, storage and handling guidelines, and procedures for replacing major components like the main seat and diaphragms. The valve uses a pilot to pressurize a large diaphragm area to hold the main seat closed until set pressure. When pressure reaches the set point, the pilot actuates to reduce dome pressure and allow the main seat to lift and relieve tank pressure.
This document provides maintenance instructions for a pilot operated safety relief vent with a non-flowing modulating pilot (Series 9200). It describes general safety precautions, storage and handling guidelines, and procedures for replacing major components like the main seat and diaphragms. The valve uses a pilot to pressurize a large diaphragm area to hold the main seat closed until set pressure. When pressure reaches the set point, the pilot actuates to reduce dome pressure and allow the main seat to lift and relieve tank pressure.
This document provides maintenance instructions for a pilot operated safety relief vent with a non-flowing modulating pilot (Series 9200). It describes general safety precautions, storage and handling guidelines, and procedures for replacing major components like the main seat and diaphragms. The valve uses a pilot to pressurize a large diaphragm area to hold the main seat closed until set pressure. When pressure reaches the set point, the pilot actuates to reduce dome pressure and allow the main seat to lift and relieve tank pressure.
This document provides maintenance instructions for a pilot operated safety relief vent with a non-flowing modulating pilot (Series 9200). It describes general safety precautions, storage and handling guidelines, and procedures for replacing major components like the main seat and diaphragms. The valve uses a pilot to pressurize a large diaphragm area to hold the main seat closed until set pressure. When pressure reaches the set point, the pilot actuates to reduce dome pressure and allow the main seat to lift and relieve tank pressure.
TYPE 9200 POSRV WITH NON-FLOWING MODULATING PILOT The intent of these instructions is to acquaint the user with the storage, installation and operation of this product. Please read these instructions carefully before installation.
WARNING Removal of the seal wires in an attempt to adjust and/or repair this product by unauthorized or unqualified persons voids the product warranty and may cause damage to equipment and serious injury or death to persons. The product is a safety related component intended for use in critical applications. The improper application, installation or maintenance of the product or the use of parts or components not manufactured by Anderson Greenwood Crosby may result in a failure of the product. Any installation, maintenance, adjustment, test, etc. performed on the Product must be done in accordance with the requirements of all applicable Anderson Greenwood Crosby Procedures and Instructions as well as applicable National and International Codes and Standards.
SAFETY PRECAUTIONS When the pressure/vacuum relief valve is under pressure never place any part of your body near the pilot exhaust nor the outlet of the main valve. The main valve outlet should be piped or vented to a safe location. Always wear proper safety gear to protect head, eyes, ears, etc. anytime you are near pressurized valves. Never attempt to remove the pressure/vacuum relief valve from a system that is pressurized. Never make adjustments to or perform maintenance on the pressure/vacuum relief valve while in service unless the valve is isolated from the system pressure. If not properly isolated from the system pressure, the pressure/vacuum relief valve may inadvertently open resulting in serious injury. Remove the pressure relief valve prior to performing any pressure testing of the system. The safety of lives and property often depends on the proper operation of the pressure/vacuum relief valve. The valve must be maintained according to appropriate instructions and must be periodically tested and reconditioned to ensure correct function.
STORAGE AND HANDLING
Pressure/vacuum relief valve performance may be adversely affected if the valve is stored for an extended period without proper protection. Rough handling and dirt may damage, deform, or cause misalignment of valve parts and may alter the pressure setting and adversely affect valve performance and seat tightness. It is recommended that the valve be stored in the original shipping container in a warehouse or as a minimum on a dry surface with a protective covering until installation. Inlet and outlet protectors should remain in place until the valve is ready to be installed in the system.
ANDERSON GREENWOOD CROSBY
REPORT NUMBER 05.9040.171
1.0
Page 4
Rev. E
GENERAL VALVE DESCRIPTION
1.1
Operation The 9200 Pilot Operated Safety Relief Valve uses the principle of pressurizing a large diaphragm area, referred to as dome, with tank pressure to hold the main valve seat closed up to set pressure. At set pressure the pilot actuates to partially reduce the pressure in the dome, and the downward force acting on the main seat. The seat then lifts to relieve tank pressure. When the tank pressure is reduced, the pilot actuates to repressure the dome with tank pressure to close the main valve.
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Rev. E
Installation Inlet flanges are designed for use with 150 class ANSI flanges. Installation of studs is required in the base of the vent. Remote pressure pickup is mandatory on all pressure/vacuum or vacuum only units. Internal sense is standard on pressure only units.
1.3
Start-Up There must be pressure at the vent inlet to establish a closing force across the main vent element. Pressure must pass through the pilot supply tube and pilot and exert force on the main diaphragm. On normal plant start-up the vent loads itself without incident as tank pressure increases. It is not uncommon that slight leakage past the seat occurs until system pressure reaches the dome chamber. If block valves are used under the safety vent, be sure all block valves are open. If block valves are opened after system start-up the safety vents briefly vent to the atmosphere past the main seat before the dome gets pressurized. It will close off positively once dome pressure has been established. Open the block valve slowly to minimize venting.
2.0
MAIN VALVE MAINTENANCE (Refer to Figure 1)
2.1
General Since the Series 9200 vent can be either a pressure only, a vacuum only, or a pressure/vacuum relieving device, it is built in a modular fashion. The standard single diaphragm unit will function on pressure and vacuum, however opening under very low vacuum requires use of the auxiliary diaphragm chamber. The vent can also be repaired in a modular fashion. The seat can be replaced without complete disassembly of the diaphragm cases. Selective repair can be performed as required.
2.2
Main Seat Replacement
--
Remove bolts (41) that connect the main diaphragm case to the vertical column supports (38).
--
Remove the operational assembly including diaphragm cases
(1)(23), shield (26), and seat plate assembly (Details "D" & "E") as a single unit. NOTE: Use a hoist on large sizes.
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REPORT NUMBER 05.9040.171
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--
While holding the shield (26) up, unscrew the seat plate assembly from the shaft (18). This is normally a hand operation, however a 9/16" (14.3 mm) wrenching flat is provided on the seat hub (52) if required. The connecting thread will run free then tighten and run free again as it disengages from a locking helicoil in the vertical shaft (18).
--
Refer to Figures 3, 4 and 5, Details D and E for the
appropriate valve seat plate size, material and pressure range. Remove the seat jam nut (50) and screws (31) and nuts (28) or seat band clamp (56). Remove the seat retainer (37). Remove seat film (29).
--
Install new seat film (29) and reassemble hub (52) in
accordance with Detail "D". NOTE: On reassembly pay special attention to the stack-up sequence to make sure the parts are assembled properly.
--
Install seat retainer (37) over new film per Detail "E" and cross tighten seat screws (31) and nuts (28) until secure.
--
On the stainless steel seat plate with band clamp
tighten clamp before tightening seat jam nut (50).
--
Reinstall seat plate assembly to main shaft (18).
NOTE: Shield (26), tube (22), and seal (30) must be in place before installation of seat assembly.
--
The thread on the seat plate assembly will at first run free then tighten then run free again. The seat plate assembly is then in place and will swivel to assure good seat contact on the nozzle (33). NOTE: Seat hub (52) must not be tightened to shoulder tightly on the shaft (18).
(56),
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Rev. E
Diaphragm Replacement 2.3.1
All Dual Diaphragm 9240C Models (Refer to Figure 2)
--
Remove the pilot and tubing from the auxiliary
diaphragm case.
--
Remove the upper auxiliary diaphragm case (1).
--
Install a small retaining wire in the lift rod
(17) as shown in Figure 6, Detail "C" to retain the lift rod.
--
Lift the auxiliary and main diaphragm assemblies
to the full open position using the auxiliary vacuum plate (5). The open dome port can be temporarily capped to hold the main diaphragm assembly up.
--
Remove nut (3) and O-Ring (4), Figure 6, Detail
A.
--
The lift rod (17) is attached to the auxiliary
plate bushing (46) with threads. See Figure 6, Detail "A". Unscrew the lift rod (17) from the plate bushing (46) by rotating the rod. The rod will unscrew from the bottom of the assembly. An extension on the upper end of the rod has been provided if wrenching is required. The Auxiliary diaphragm assembly can now be removed to replace the auxiliary diaphragm (6). NOTE: On 2" and 3" valves with aluminum internals or low pressure stainless steel internals, a diaphragm reinforcement (63) is used under the auxiliary diaphragm and should also be replaced.
--
Remove the jam nut (42) on the auxiliary
diaphragm assembly and replace diaphragm (6) and diaphragm reinforcement (63), where used. NOTE: See Figure 6, Detail "A" and pay special attention to the stack-up sequence on reassembly.
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REPORT NUMBER 05.9040.171
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--
Remove the main diaphragm case bolts (41). Remove
the studs (13) from the column supports (38). Remove the lower auxiliary diaphragm case (12) and the upper main diaphragm case (14) as a unit, assembled to the diaphragm case adapter (11). Allow the lift rod (17) to slip from the center hole and lift items (12), (14) and (11) upwards as one unit.
--
Remove the main diaphragm assembly, lower main
diaphragm case (23) and seat plate assembly from the base. NOTE: On the 2" and 3" valves a reinforcement diaphragm (62) is used between the main diaphragm (15) and the lower main diaphragm case (23). It should be replaced also.
--
See Figure 6, Detail C. Remove jam nut (42) and
disassemble. Replace main diaphragm (15) and diaphragm reinforcement (62), where used. NOTE: Pay special attention to stack sequence shown.
--
Remove the O-Ring (58) from the upper end of the
adapter bore (11). Lubricate O-Ring with Dow Corning FS3451 or equivalent when the new one is installed. NOTE: For oxygen service valves, use only lubricants suitable for this service, such as Krytox 240AC.
--
If cap gaskets (16) are to be replaced, apply
Teflon gasketing to upper diaphragm cases (1, 14) only as shown in Figure 7.
--
Reassemble in reverse order. Apply a
of Dow Corning No. 33 silicone equivalent to all threaded parts. oxygen service valves, use only suitable for this service, such as LG-160.
light film grease or NOTE: For lubricants Fluorolube
ANDERSON GREENWOOD CROSBY
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Rev. E
All Single Diaphragm 9240P Series (Refer to Figure 1)
--
Remove pilot and tubing from the diaphragm case.
--
Remove the upper main diaphragm case (14).
--
Remove the main diaphragm assembly, lower main
diaphragm case (23) and seat plate assembly from the base (34). NOTE: On the 2" and 3" valves, a reinforcement diaphragm (62) is used between the main diaphragm (15) and the lower main diaphragm case (23).
--
See Figure 6, Detail C. Remove jam nut (42) and
disassemble. Replace main diaphragm (15) and diaphragm reinforcement (62), where used. NOTE: Pay special attention to stack sequence shown.
--
Remove remaining internal assembly as a unit
including lower diaphragm case (23), and internal assembly.
--
If cap gasket (16) is to be replaced, apply
Teflon gasketing to upper diaphragm case (14) as shown in Figure 7.
--
Reassemble in reverse order. Apply a light film
of Dow Corning No. 33 silicone grease or equivalent to all threaded parts. NOTE: For oxygen service valves, use only lubricants suitable for this service, such as Fluorolube LG-160.
Nozzle Replacement (Refer to Figure 1 or 2)
--
Remove nozzle retaining screws (36) and gently tap nozzle
(33) with soft face mallet.
--
NOTE: Inspect nozzle seating surface for nicks or scratches. If they cannot be removed with crocus cloth or fine sandpaper, the nozzle must be remachined.
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REPORT NUMBER 05.9040.171
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--
Nozzle face can be remachined.
.060" (1.52 mm) of material.
Do not remove more than
--
If nozzle gaskets (32, 35) are to be replaced, install
Teflon gasketing as shown in Figure 7.
--
Reinstall nozzle and retaining screws.
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REPORT NUMBER 05.9040.171
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Rev. E
PARTS LIST MAIN VALVE ITEM
DESCRIPTION
ITEM
DESCRIPTION
CASE-UPPER,AUXILIARY DIAPHRAGM
34
BASE-FLANGE
NUT
35
GASKET-NOZZLE, LOWER
NUT
36
SCREW-NOZZLE RETAINER
O-RING/TEFLON
37
RETAINER-SEAT
PLATE-AUXILIARY VACUUM
38
COLUMN-SUPPORT
DIAPHRAGM-AUXILIARY
39
BUSHING SUPPORT
PLATE-AUXILIARY PRESSURE
40
SCREEN-SEAT
SCREEN-LOWER AUXILIARY CASE
41
BOLT-CASE
RING-SNAP
42
NUT-JAM
10
SCREW
43
WASHER
11
ADAPTER
44
WASHER
12
CASE-LOWER, AUXILIARY DIAPHRAGM
45
GASKET-PLATE
13
STUD
46
BUSHING-AUXILIARY DIAPHRAGM
14
CASE-UPPER, MAIN DIAPHRAGM
47
GASKET-ADAPTER
15
DIAPHRAGM-MAIN
48
BUSHING-GUIDE
16
GASKET-DIAPHRAGM CASE
49
BUSHING-ROD RETAINING
17
ROD, LIFT
50
NUT-JAM, SEAT
18
SHAFT, SEAT PLATE ASSEMBLY
51
BUSHING-SEAT
19
PLATE-MAIN VACUUM
52
HUB-SEAT
20
SCREEN, LOWER MAIN CASE
53
O-RING-SEAT
21
PLATE-MAIN PRESSURE
54
SPACER-SEAT
22
TUBE THRUST
55
GASKET-PLATE
23
CASE-LOWER, MAIN DIAPHRAGM
56
CLAMP-BAND, SEAT
24
SLEEVE-GUIDE
57
WASHER-SEAT (PRIOR TO 1990 ONLY)
25
PLATE-SEAT
58
O-RING, LIFT ROD
26
SHIELD
59
BUSHING, ADAPTER
27
PROTECTOR-PLATE
62
DIAPHRAGM, REINFORCEMENT, MAIN
(LOW PRESSURE 2" & 3" VALVE SIZE)
28
NUT-LOCK
63
DIAPHRAGM, REINFORCEMENT, AUXILIARY
(LOW PRESSURE 2" & 3" VALVE SIZE)
29
SEAT-FILM
30
SEAL-WEATHER
31
SCREW-SEAT
32
GASKET-NOZZLE, UPPER
33
NOZZLE
64
NUT-COLUMN RETAINING
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Rev. E
PILOT MAINTENANCE (Refer to Figure 8)
The pilots used for the 9240P Positive Relief Valve, for the 9240C Positive and Negative Pressure Relief Valve and the 9204V Negative Pressure Relief Valve are shown in Figures 8 and 9. Both pilots have the same construction, except for the location of the connections to the main valve diaphragm actuators, or the connections for the pressure sense. For either the positive or positive and negative pressure relief valve, the pilot controls only the positive pressure relief. The negative pressure relief is controlled by the weight of the parts that move in the main valve when it opens. For the negative pressure relief valve, the pilot controls the negative pressure relief. 3.1
Disassembly --
Remove cap (5), loosen lock nut (7), back out adjusting screw (6) to relieve spring tension, remove nuts (11) and bonnet (4). NOTE: To make it easier to reassemble the pilot, arrange parts in an orderly sequence on a work table when disassembling.
--
Push down on spool retaining nut (30) to engage spool
anti-rotation pin (21) and remove nut. Remove spindle spring (31), case bolts (13) and nuts (17) and upper case (3). Internals are now accessible for removal.
--
Remove the internals and disassemble the sense diaphragm
(34) and feedback diaphragm (19), spindle (24) and lantern ring (35) from the spool (36). The outlet seat (the lower O-Ring, 32) must be removed from spindle before the spindle can be removed from the spool.
--
Remove the lower case (2) from the body (1).
--
Remove the inlet connector (27) and screen (41).
--
Clean all metal parts.
and seals.
Throw away all gaskets, diaphragms
ANDERSON GREENWOOD CROSBY
REPORT NUMBER 05.9040.171
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Rev. E
Assembly --
Assembly is done in the reverse order of disassembly.
Lubricate all O-rings, sliding surfaces, screw threads and spring washer pivot points with Dow Corning No. 33 silicone grease or equivalent. NOTE: For oxygen service valves use only lubricants suitable for this service, such as Krytox 240 AC.
--
The spindle O-ring (23) and bearing surface should
lubricated with Dow Corning FS 3451 or equivalent.
--
Assemble the lower case (2) to the body (1). NOTE: Pilots with Kalrez O-rings use two Teflon Gaskets between the case and body.
--
Assemble the inlet screen (41) to the inlet connector (27)
and the inlet connector to the body (1).
--
Assemble the inlet seat (upper O-ring, 32) and the spindle O-ring (23) to the spindle.
--
Assemble the spindle to the spool and install the outlet
seat (lower O-ring, 32) to the spindle.
--
Install the spool (36) with spindle (24) in the body.
Position the spool to engage the anti-rotation pin (21).
--
Install a diaphragm case gasket (15) on the lower diaphragm
case (2) and the feedback diaphragm support plate (14). NOTE: Install the support plate (14) with the rounded edge up towards the feedback diaphragm (19).
--
Install a diaphragm case gasket
diaphragm support plate (14).
(15)
on
the
be
feedback
ANDERSON GREENWOOD CROSBY
REPORT NUMBER 05.9040.171
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Rev. E
Install the following parts in the order listed on the
spool. 1. 2. 3. 4. 5.
Feedback diaphragm slipper (38)
Feedback diaphragm (19) Lantern ring (35) Sense diaphragm (34) Sense plate (33) NOTE: Install the sense plate with the round edge towards the sense diaphragm (34).
--
Install the upper diaphragm case (3) and case bolts (13), washers (16) and nuts (17).
--
Install the spindle spring (31) and spool retainer nut
(30). Push down on the retainer nut to engage the antirotation nut and tighten to 10 foot-pounds. Do not overtighten, the diaphragms may be damaged.
--
Pretest pilot function by depressing spindle/diaphragm
assembly stack downward. The spindle spring (31) should return the stack assembly to the upward position.
ANDERSON GREENWOOD CROSBY
REPORT NUMBER 05.9040.171
Page 22
PARTS LIST PILOT
ITEM
DESCRIPTION
ITEM
DESCRIPTION
BODY
27
CONNECTOR-INLET
CASE-DIAPHRAGM, LOWER
28
BOLT
CASE-DIAPHRAGM, UPPER
29
VENT SCREEN
BONNET ASSEMBLY
30
NUT-SPOOL RETAINER
CAP-BONNET
31
SPRING-SPINDLE
SCREW-PRESSURE ADJUSTMENT
32
O-RING-(-014)
NUT-LOCK
33
PLATE-SENSE
WASHER-SPRING
34
DIAPHRAGM-SENSE
SPRING
35
RING-LANTERN
10
WASHER-PLAIN
36
SPOOL
11
NUT
37
GASKET-BODY
12
GASKET-BONNET
38
SLIPPER-FEEDBACK DIAPHRAGM
13
BOLT
39
FERRULE-TUBING
14
PLATE-DIAPHRAGM SUPPORT
40
RETAINER-DOME TUBING
15
GASKET-DIAPHRAGM CASE
41
SCREEN-INLET
16
WASHER-LOCK
42
PLUG-PIPE
17
NUT
43
STUD-BONNET
18
O-RING (-022)
44
BUSHING
19
DIAPHRAGM-FEEDBACK
51
PLUG
20
BOLT
52
INSERT
21
PIN-GROOVE
53
O-RING
22
BUSHING-GUIDE
54
SEAL-THREAD
23
O-RING (-013)
24
SPINDLE
25
FERRULE-TUBING
26
RETAINER-INLET CONNECTION
Rev. E
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PILOT ADJUSTMENT 4.1
Set Pressure To adjust the set pressure, a test set-up similar to that shown in Figure 10 should be used. The set pressure adjustment screw (6) should be turned IN most of the way. Increase the supply pressure to nameplate setting and slowly back this adjustment screw out until flow through the pilot exhaust begins. Continue to back screw out until the dome pressure is 70% of the supply pressure.
4.2
Range of Adjustment All pilots can be adjusted +/- 10% of the set pressure value stamped on the nameplate with the spring supplied with the pilot. Consult the factory to determine if the spring in the pilot can be adjusted more.
4.3
Adjustment Tolerances Set Pressure + 3% Crack Pressure 98% of set Reseat Pressure 96% of set
4.4
Definitions Set Pressure is defined as that supply pressure when the dome pressure is 70% of the supply pressure. Crack Pressure is defined as the supply pressure where gas flow begins at the pilot outlet. Reseat Pressure is defined as that supply pressure when the dome pressure is 75% of the supply pressure.
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LEAK TESTING THE ASSEMBLY
5.l
General
Page 27
Rev. E
The complete valve assembly should be leak tested for internal
and external leaks using a pressure equal to 30% and 90% of set. 5.2
Internal Leak Test
Spray leak test solution around nozzle/seat area to locate a leak. Seat leakage may be caused by a damaged nozzle seat or seat film. Pilot internal leakage may be checked by blocking one pilot exhaust vent and using a leak test bubble bottle on the other.
5.3
External Leak Test
Apply leak test solution to all joints and seals. or fittings as required.
6.0
Tighten bolts
FIELD TEST INSTRUCTIONS-POSITIVE PRESSURE PILOT
An optional field test accessory is available for checking the positive set pressure without removing the valve from service. The field test accessory consists of a 3-way ball valve to allow the pilot to sense pressure from either the process or from the test gas source. A standard bottle of nitrogen equipped with a pressure regulator, block valve, pressure gage, and convenient length of high pressure flexible hose is recommended for testing. A set-up similar to that shown in Figure 11 should be used. Such a test kit is available from Anderson, Greenwood & Co. under the part number 04-4812-001 plus additional dash numbers for the pressure gages required.
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REPORT NUMBER 05.9040.171
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PROCEDURE A. B. C. D. E. F.
G.
Connect gas bottle as shown in Figure 11.
Close vent valve "C". Open block valve "B" to supply regulator (regulator pressure should be set at zero). Connect bubble tester bottle to pilot exhaust vent and block the second pilot vent if the pilot is equipped with one. Increase pressure at field test port to slightly above tank pressure by slowly increasing regulated pressure. Open field test valve "A" and slowly increase regulator pressure until bubbles are seen in the bottle. That pressure will be within 3 percent of the set pressure. To remove the test set-up, close valves "A" & "B" and open valve "C".
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REPAIR KITS Soft goods repair kits contain all the diaphragms, seals, and seats to repair a valve. To order a kit, specify the base number and select the last three digits from the following tables. To ensure the purchase of the correct repair kit, the order should specify the valve model and serial number. For chloride rich environments, the bolts in the main valve and pilot exposed to the environment should be replaced during routine maintenance or at least every five years. PILOT REPAIR KITS
