MERCER 9100 Series Manuel utilisateur

Before installation of a Mercer Valve Co., Inc. Pressure Relief Valve, all sections of this document and all

regulatory authority codes must be read and understood. Failure to do so voids all warranties.

ENG-502000

9100 SERIES

DIRECT SPRING OPERATED PRESSURE

RELIEF VALVE

INSTALLATION, OPERATION, &

MAINTENANCE MANUAL

REV ECN DATE

J 3152 23-July-2020

Table of Contents

1. Scope.................................................................................................................................................4

2. Definitions.........................................................................................................................................5

3. Handling and Shipping .....................................................................................................................7

4. Unpacking and Storing......................................................................................................................8

5. Installation.........................................................................................................................................9

6. Operation.........................................................................................................................................13

7. Maintenance....................................................................................................................................14

8. Inspections ......................................................................................................................................16

a) Visual Inspection ............................................................................................................................16

b) Set Pressure Inspection ...................................................................................................................18

c) Leak Inspection...............................................................................................................................19

9. Test Equipment...............................................................................................................................21

a) In Situ Testing.................................................................................................................................21

b) Offsite Testing ................................................................................................................................22

c) Mobile Test Units ...........................................................................................................................23

d) Test Gauges.....................................................................................................................................24

e) Lift Checking..................................................................................................................................24

10. Tester Qualifications.......................................................................................................................25

11. Tool List..........................................................................................................................................26

a) Valve...............................................................................................................................................26

b) Miscellaneous .................................................................................................................................26

12. Disassembly....................................................................................................................................28

a) 1” Body - Bottom Entry..................................................................................................................28

b) 2” Body - Bottom Entry..................................................................................................................31

c) Top Entry........................................................................................................................................34

d) Lift Levers – Bottom Entry.............................................................................................................37

e) Lift Levers – Top Entry ..................................................................................................................40

13. Component Inspection ....................................................................................................................43

14. Reassembly.....................................................................................................................................46

a) Cleaning & Lubrication ..................................................................................................................46

b) Valve Reassembly...........................................................................................................................46

i) 1” Bodies – Bottom Entry...........................................................................................................46

ii) 2” Bodies – Bottom Entry...........................................................................................................50

iii) Top Entry....................................................................................................................................54

c) Lift Levers – Bottom Entry.............................................................................................................58

d) Lift Levers – Top Entry ..................................................................................................................60

15. Valve Setting Procedure..................................................................................................................61

a) Cold Differential Set Pressure (CDTP)...........................................................................................61

b) Setting the Valve.............................................................................................................................61

16. Tag Information ..............................................................................................................................62

17. Product Number System .................................................................................................................63

a) Valve Product Numbering ..............................................................................................................63

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 3

b) Repair Kit Product Numbering.......................................................................................................65

18. Exploded Views..............................................................................................................................66

19. Cutaway View.................................................................................................................................70

20. Trouble Shooting Guide..................................................................................................................74

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 4

1. Scope

This document is used for the installation, operation, and maintenance of a Mercer Valve Co., Inc.

9100 Series pressure relief valve. This document should be read and understood before the valve

is installed, put into service, or maintained. Failure to do so can result in improper operation that

could result in damage to equipment or affect the safety of individuals around the equipment. The

recommendations in this document should be used in conjunction with all regulatory bodies and

all end-user company policies.

Proper safety precautions must be followed during all procedures indicated in this document. This

document does not cover these precautions or the required safety equipment.

Additional information on installation, operation, and maintenance can be found in the following

specifications. These specifications should be used in addition to this document but are not limited

by it.

American Petroleum Institute:

API 510 – Pressure Vessel Inspection Code

API RP 520 Parts I & II – Sizing, Selection, and Installation of Pressure-Relieving Devices in

Refineries

API RP 521 – Guide for Pressure-Relieving and Depressuring Systems

API STD 526 – Flanged Steel Pressure Relief Valves

API STD 527 – Seat Tightness of Pressure Relief Valves

API RP 576 – Inspection of Pressure-Relieving Devices

API STD 598 – Valve Inspection and Testing

American Society of Mechanical Engineers:

ASME PTC 25 – Pressure Relief Devices

ASME Boiler and Pressure Vessel Code Section VIII, Division 1 – Unfired Pressure Vessels

ASME B16.5 – Pipe Flanges and Flanged Fittings

National Board of Boiler Inspectors:

NB-18 – Pressure Relief Valve Certifications

NB-23 – National Board Inspection Code

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 5

2. Definitions

Accumulation is the amount of pressure increase above the MAWP of the system that is allowed.

Accumulation is set from the applicable codes.

Backpressure is the amount of pressure on the outlet side of the pressure relief valve. This is

pressure downstream of the nozzle of the pressure relief valve. It is a combination of superimposed

and built-up backpressures.

Blowdown is the reclosing point of the pressure relief valve. It can be expressed as a pressure but

is most commonly expressed as a percentage of the set pressure.

Built-up Backpressure is pressure on the outlet of the pressure relief valve that is caused by the

flow of the pressure relief valve. Piping size, length of outlet pipe, fittings, or other flow friction

producing items all affect the built-up backpressure.

Capacity is the flow rate as required by the applicable code.

Cold Differential Test Pressure (CDTP) is the pressure at which the pressure relief valve is

adjusted to open on the test stand. The CDTP includes corrections for the service conditions of

backpressure and/ or temperature.

Conventional Pressure Relief Valve is a direct spring operated valve where the spring tension is

used to hold the disk closed. The operational characteristics of the valve are directly affected by

changes in the backpressure. These characteristics include opening pressure, closing pressure,

relieving capacity, and valve function. This is also referred to as a spring operated pressure relief

valve (SOPRV).

Inlet Size is the nominal pipe size (NPS) of the inlet of the pressure relief valve.

Leak Test Pressure is the pressure below the set pressure that the leak test is to be performed.

This pressure is often calculated as a percentage of the set pressure.

Lift is the amount of travel of the disk from the fully closed to the fully open position when the

valve is relieving.

Maximum Allowable Working Pressure (MAWP) is the pressure rating the system can

withstand at a specific temperature. The MAWP is often used as the setting of the pressure relief

valve.

Outlet Size is the nominal pipe size (NPS) of the outlet of the pressure relief valve.

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 6

Over Pressure is the amount of pressure increase above the set pressure allowed for the pressure

relief valve to achieve full lift and full flow. Set pressure plus over pressure should never exceed

MAWP plus accumulation, but they will often be equal.

Pressure Relief Valve (PRV) is a pressure relief device designed to open and relieve excess

pressure and to reclose and prevent the further flow of fluid after normal conditions have been

restored.

Set Pressure is the pressure on the inlet of the pressure relief valve that the valve is set to open.

Each pressure relief valve manufacturer will define this setting based on how their valve is to act.

Set pressure definitions for each manufacturer’s series can be found in NB-18.

Simmer or Warn is the audible or visual release of test fluid from between the disk and seat prior

to opening of the valve. This is caused by the force holding the disk closed and the inlet pressure

force equalizing just before the valve begins to open at the set pressure.

Superimposed Backpressure is the pressure on the outlet of the pressure relief valve that is

caused by a closed discharge system. This type of backpressure is present before the valve begins

to open. It can be constant or variable. Superimposed backpressure can affect the set pressure of a

conventional spring operated PRV.

VR is an accreditation the National Board offers to organizations/ facilities that have been shown

to independently operate and repair pressure relief valves sufficiently within codes and regulations.

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 7

3. Handling and Shipping

Mercer Valve Co., Inc. produces a very durable pressure relief valve. Even though these valves

are able to take some abuse, it is recommended that they are handled and shipped with care. This

will help prevent damage prior to their installation. These PRVs are safety devices and are the last

line of defense when a system over pressures. An impaired PRV could leave the system

unprotected.

A PRV should be carried by a structural part, such as the body, flange, or eye bolts. If the valve is

dropped, it should be checked to assure it is still functioning properly. Any damage to the

connections (flanges, threads, etc.), such as denting and scratching, may cause a leak or inhibit

proper installation. All precautions should be taken to ensure no valve damage occurs.

During shipping, all open ports of the PRV should be sealed to prevent the ingress of dirt and

moisture. Proper precautions to prevent rust should be taken. All flanges and threads should be

covered with protectors to prevent damage. The valve should be sealed in a plastic bag.

The valve may be placed in a shipping container upright or on its side, however, it should be

packed so that it cannot move within. Movement can cause the valve to become damaged during

the shipping process. The proper shipping container should be chosen for the size and weight of

the valve. After being packaged, the shipping container should be handled with care.

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 8

4. Unpacking and Storing

A PRV should be installed immediately after being removed from the storage/ shipping box when

possible. When the valve cannot immediately be installed, certain storage precautions should be

taken to keep it functioning properly until it is installed. Following these recommendations will

encourage proper function of the valve prior to installation. These recommendations only apply to

Mercer Valve Co., Inc. manufactured pressure relief valves. Other valve brands can have different

requirements and their manufacturer should be contacted for information.

The PRV should be stored in a dry, indoor environment at temperatures between 50ºF (10ºC) and

90ºF (32ºC). The inlet and outlet of the valves should be protected from any possible damage.

Threaded valves should have thread protectors installed. Flanged connections should be covered

to protect their raised faces from scratches and dents. The protectors should also seal the openings

so that foreign materials cannot ingress.

PRVs are usually stored vertically to keep parts aligned, however, this isn’t required for Mercer’s

PRVs. Although vertical storage can help with initial startup in certain circumstances, these valves

may be stored horizontally.

Before installing a valve that has been stored, it should be visually inspected for any damage. It is

recommended to test the valve before installation if it has been stored for more than one (1) year.

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 9

5. Installation

Proper installation of a PRV is mandatory to ensure safe and accurate operation. Incorrect

installation can cause failures that result in damage or destruction to the equipment and also

possible injuries or even death to anyone around the equipment.

Before installation, the valve should be visually inspected for any damage that occurred during

shipping and storage. If any damage is found, do not install and immediately contact Mercer Valve

Co., Inc.

Always remove all thread and flange protectors from the inlet and outlet before installing. These

protectors can stop pressure from entering or exiting the PRV and this may result in malfunction.

Make sure that a test gag is not engaged when the valve is in operation. Test gags are only used in

controlled over pressures situations, such as hydrostatic testing of the system.

The set pressure should be tested before installation if the valve has been shipped great distances

or has been in long term storage. This verification helps to confirm proper valve function and

correct settings.

It is also important to check that the backpressure and temperature of the application are within

the valve’s ratings and limitations. There are two types of backpressure: superimposed and built-

up. Each type of backpressure affects the valve differently. Superimposed backpressure can come

in two forms, constant and variable. The correct form of backpressure must be considered during

the sizing and selection of the valve. If the wrong type of back pressure is assumed, the valve may

not operate properly. Built-up backpressure should not exceed the allowable overpressure for

conventional PRVs. The PRV’s seat and o-rings have pressure-temperature limitations. Using

these materials outside their limitations will cause issues. Contact Mercer Valve to find the

limitations of the valve.

Compatibility, in terms of reactivity and corrosion, between the system media and the materials

used within the valve must be considered. Appropriate material selection is the responsibility of

the end user/ purchaser of the valve.

The nameplate information should be verified for the service conditions of the application before

the valve is installed. The fluid state, capacity, service temperature, set pressure, and backpressure

can all be found on the PRV’s nameplate, which is also called the tag. If the information indicates

improper settings or the wrong service conditions, the valve should not be installed. The service

temperature listed is not the temperature limit. It is important that the set pressure is examined

against the system’s MAWP. It should also be noted that the capacity on the tag is not specific to

the application. A gas valve will have a tag capacity in SCFM of air at 60ºF (16ºC) and standard

atmospheric conditions. A liquid valve will have a tag capacity in GPM of water at 60ºF (16ºC)

and standard atmospheric conditions.

MERCER VALVE COMPANY, INC.

9100 SERIES DIRECT SPRING OPERATED PRESSURE RELIEF VALVE

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

MERCER VALVE CO., INC. RESERVES THE RIGHT TO CHANGE

PRODUCT DESIGNS AND SPECIFICATIONS WITHOUT NOTICE.

Rev.: J

Date: 23-July-2020

ECN: 3152 Page | 10

The PRV should be oriented in a vertical position with its inlet pointing downwards and its outlet

pointing in a horizontal direction. Mercer Valve Co., Inc. must be contacted to ensure proper

operation if the valve cannot be installed in this orientation.

Use a suitable sealing mechanism (PTFE pipe tape, gasket, etc.) when installing a PRV on a

system. When screwing a threaded valve onto inlet piping, always use the wrench flats on the inlet

connection. See Figure 1. Use a square jaw type of wrench. Do not put a wrench on the PRV’s

body or bonnet during installation. Tighten 1.5 to 3 turns past finger tight for national pipe threads.

Flanged valves require the correct amount, type, and size of bolts and the correct type of gasket to

be used. Flange information can be found in ASME B16.5.

Figure 1: 9100 Series Threaded Valve Wrenching Flats

One common cause of early PRV failure is debris trapped on the valve’s seat, resulting in a leak.

Weld slag and pipe tape are among the more common items that cause this. It is recommended that

all piping and tank systems are cleaned prior to the initial installation of the PRV.

A pressure relief valve should be attached to the system with the shortest amount of piping

possible. All piping leading to the PRV must be equal to or larger than the PRV’s inlet pipe size;

it must never be smaller. Any restriction within the inlet lines can cause valve chatter, which can

result in serious damage to the valve. It is recommended that any pressure drop created from inlet

piping is less than 3% of the set pressure. Piping restrictions can also reduce the relief capacity of

the valve, which can leave the system under protected.

Outlet piping should be as short and direct as possible to keep built-up backpressure to a minimum.

For spring operated PRVs, built-up backpressure should never exceed the allowable over pressure.

For most but not all cases, the allowable over pressure is 10% of the set pressure. It is

recommended that the outlet piping be less than 4 ft (1.2 m) in total length. Its nominal size should

be equal to or greater than the outlet size of the PRV. Increasing the outlet piping size will reduce

the built-up backpressure potential and enable longer lengths. Long runs, additional fittings and

bends, and small diameter pipes will increase the propensity of valve chatter. Valve chatter can

DO NOT USE BODY

FOR INSTALLING

Appropriate

Wrenching Flats

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