9100 Series IOM Manual

ENG-502000
9100 SERIES
DIRECT SPRING OPERATED PRESSURE
RELIEF VALVE
INSTALLATION, OPERATION, &

MAINTENANCE MANUAL
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.
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
b) Repair Kit Product Numbering ....................................................................................................... 65
18. Exploded Views .............................................................................................................................. 66
19. Cutaway View ................................................................................................................................. 70
20. Trouble Shooting Guide .................................................................................................................. 74
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
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

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 4
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.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 5
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.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 6
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.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 7
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.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 8
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.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 9
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.
DO NOT USE BODY

FOR INSTALLING
Appropriate
Wrenching Flats
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

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 10
have damaging effects and can reduce the relieving capacity, which potentially leaves the system
under protected.
Special consideration should be made when multiple relief valves are installed on a system with a
common discharge header. The size of the header should be based on the sum of the discharge
areas for each relief valve and any pressure loss. The built-up backpressure still cannot exceed the
allowable overpressure. When greater built-up or variable superimposed backpressure exists, a
9100 Series valve may not be suitable and Mercer Valve Co. should be consulted prior to
installation.
PRVs must be braced and supported for reaction forces, vibrations, weight, and other external
forces applied during operation. These and all other loads must be considered when installing the
valve and adding bracing.
See Figure 2 for an example installation of a pressure relief valve.
PIPING SIZE AT LEAST AS WEATHER

LARGE AS OUTLET; 4ft CAP
(1.2m) OR LESS LENGTH
PIPING SUPPORT TO
LONG RADIUS
RESIST WEIGHT AND
ELBOW
REACTION FORCE
LOW POINT
DRAIN/WEEP
HOLE
INLET CONNECTION SIZE

NOT LESS THAN VALVE
INLET SIZE; NON-
RECOVERABLE PRESSURE
LOSS NO MORE THAN 3%
Figure 2: Typical Recommended Installation of a PRV
Excessive vibrations can cause a PRV to open below its intended set pressure. Vibrations apply
acceleration to the internal movable parts and create an upward force. When this force is added to
the force balance within the valve, the required pressure to open the valve is lowered. When the
operating pressure is close to the set pressure and vibrations exist, premature relieving can occur.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 11
Extreme caution is required regarding the outlet piping if liquid can be present. The presence of
liquid can increase the required force the valve needs to open and this alters the actual relief
pressure. At low temperatures, the liquid can freeze and form an ice block in the discharge piping
or valve body that restricts the relief flow. Discharge lines should be weather capped and provided
with a drain hole to prevent liquid from collecting. If these precautions are not taken, the valve
may not be able to adequately protect the system.
DO NOT BREAK THE SEAL WIRE. Breaking the seal wire invalidates the manufacturer’s
warranty to repair or replace the valve. If resetting is required in a field emergency situation,
qualified personnel with calibrated instrumentation should perform it. A PRV with a broken seal
wire is not considered to be an ASME coded valve until it has been repaired by a VR Certified
repair shop.
Important installation information is contained in Paragraph UG-135 and Appendix M of the

ASME Boiler and Pressure Vessel Code and in API RP 520 Part II. Other standards and codes
may be applicable depending on the jurisdiction and area of use.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 12
6. Operation
The Mercer Valve 9100 Series is an ASME Section VIII, Division 1 certified PRV for gas/ vapor
and liquid applications. It has a set pressure definition for both gas/ vapor and liquid applications
of a “POP.” When the valve reaches set pressure, the disk will open, creating a “POP” sound. The
valve could exhibit simmer or warn before its set pressure but this is not considered the set point.
The valve will open to full lift at set pressure.
The 9100 Series is a direct spring operated PRV. The valve uses spring compression to keep the
valve closed. The inlet pressure opens the valve. In normal operation, the spring compression has
been adjusted to achieve the set pressure setting of the valve. The spring tension pushes down on
the disk, which presses against the nozzle subassembly. The disk seals against the seat within the
nozzle subassembly. The pressure on the inlet pushes up on the disk through the nozzle. At set
pressure, the force generated by the inlet pressure exceeds the spring’s force. This makes the disk
rise up, letting the inlet pressure escape past the seat. The disk stem is guided by the adjustment
screw’s bore, which keeps the disk aligned with the nozzle subassembly during this movement.
The disk rises until it reaches a mechanical stop located on the adjustment screw. At this point, the
valve is at full lift and will flow the media at its discharge coefficient rating. The PRV’s orifice
should be sized so its capacity rating, at the allowable overpressure, exceeds the maximum flow
capacity the system will produce. Sizing information can be found in ASME Boiler and Pressure
Vessel Code (BPVC), Section VIII, Division 1, Appendix 11 and in API RP 520 Part I. Additional
requirements by local authorities also need to be considered. Since the PRV’s flow capacity will
exceed the required capacity of the system, the system pressure will drop. The valve will reclose
when the inlet pressure has dropped enough to allow the spring force to push the disk back down
against the seat. The disk will reset against the seat, stopping any further flow and the valve will
be ready for the next overpressure event.
Best performance is usually obtained on a system where the operating pressure is at least 15% or
20% less than the valve’s set pressure for gas or liquid service applications, respectively.
Performance improves with greater margin between the operating and set pressures. A larger
margin helps with the reclosing of the PRV and reduces the chance of inadvertent opening from
system characteristics, such as pressure pulses, vibration, temperature, etc. ASME’s BPVC and
API’s standards require that the set pressure does not exceed the MAWP of the system.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 13
7. Maintenance
For dependable performance, PRVs must be maintained regularly. Mercer Valve Co., Inc.
recommends its PRVs are inspected and tested annually. After the valve has been installed and
a service history has been established, the testing and inspection frequency may be adjusted. Some
guidelines for testing frequencies can be found in NB-23, API 576, and API 598. Additionally,
government jurisdiction should be reviewed. When maintenance is done, qualified repair personnel
should perform it. Qualified repair personnel conducting the annual inspection and testing may
alter the maintenance schedule based on the service conditions.
During the inspection, a visual inspection, a set pressure verification, and a leak check should be
completed. These tests can be performed while the PRV is installed on its system or when it’s on
a testing bench. The PRV can only be tested while on its application if there is a method and
procedure to apply a controlled pressure to the PRV’s inlet without exceeding any limits of the
system.
A visual inspection is used to identify if the PRV is installed properly, is correct for the application,
and doesn’t have any apparent problems. Check the nameplate information to verify that the valve
is installed on the proper service. A missing nameplate requires immediate addressing. If the valve
is installed on gas/ vapor service, the nameplate’s capacity will indicate an air capacity in SCFM
at 60ºF (16ºC) and standard atmospheric conditions. If the valve is installed on liquid service, the
nameplate’s capacity will indicate a water capacity in GPM at 60ºF (16ºC) and standard
atmospheric conditions. Check the seal wire. A broken seal wire indicates that an unqualified
person has adjusted the set pressure; this also voids any warranty the valve may have had. The
valve should be inspected for damages. If there is damage to the valve, it may not operate properly.
Look for potential issues that would keep the valve from opening or would inhibit flow. Rust or
dirt accumulation, insect or animal nests, and pooled water are just some of the things that can
restrict the flow or stop the valve from opening. If any problems are found during the visual
inspection, the valve must be repaired by a qualified person or replaced with an equal.
When verifying the set pressure, the appropriate fluid should be used. Gas/ vapor PRVs should
only be tested with a gas, usually air or nitrogen. Liquid PRVs should only be tested with a liquid,
usually water. Testing a pressure relief valve with the incorrect fluid will cause inaccurate readings.
The set pressure of the pressure relief valve, in accordance with the ASME Boiler and Pressure
Vessel Code, has a tolerance of ±3% of the specified set pressure or ±2 psi (±15 kPa), whichever
is greater. If the examined set pressure is not within this tolerance, the PRV should be reset or
possibly repaired by qualified repair personnel. A PRV’s set pressure definition will depend upon
its manufacturer and will be listed in NB-18 if it is ASME certified. NB-18 can be found at
http://www.nationalboard.org/.
After the set pressure has been verified, the valve is leak checked. The valve is checked for any
leaks coming from its seat. Leak checks are usually performed at 90% of the set pressure or 5 psi
(34.5 kPa) below set pressure, whichever is greater. The valve must be actuated and reseated to

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 14
perform this test. The pressure is then brought up to and held at the leak check pressure. If the
valve does not pass a leak check, it will need to be repaired by a qualified person or replaced with
an equal.
Start of Service Period

In many codes and standards, there is ambiguity about when the PRV’s inspection interval begins
for newly constructed equipment. When a governing code or standard has defined this start date
specifically, then it should be followed. When the start date is not specified, the following is what
Mercer Valve Co. recommends for its products, which will clarify this ambiguity should the user/
owner of the PRV adopt it to their standards. This recommendation is irrespective of the warranty
Mercer Valve Co. has for its goods.
Contingent that proper storage and transportation of the PRV was accomplished, the start time for
the inspection interval, otherwise known as service life, is the PRV’s commissioning date not
exceeding one year after it was manufactured; the manufactured date is listed on the PRV’s
nameplate. Commissioning is defined as the first time the equipment is operated with the PRV
installed.
This recommendation is based on Mercer Valve’s storage policy. Mercer Valve recommends
testing a valve only if it has been in storage for more than a year. Testing of the valve should be in
accordance with NB-23 standards and with a clean, inert media. The testing must not excessively
exercise the valve. The valve should not have any wear or damage prior to the commissioning
date.
Additional maintenance instructions can be found in API RP 576, ASME Boiler and Pressure
Vessel Code Section VIII, Division 1, and the National Board Inspection Code.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 15
8. Inspections
Pressure relief valves are used to help with safe operation of the system that they are installed on.
They are designed to stop excessive over pressure scenarios. More information on causes of over
pressure can be found in API 521. If a PRV fails during an over pressure scenario, the system can
increase to an unsafe pressure. These over pressure situations can exceed the MAWP and result in
failures. These failures can be catastrophic in nature and result in damages to the system or even
destruction of the equipment. The safety of people around the system will be affected as well.
Because of the gravity of these types of failures, keeping pressure relief valves in proper working
order is essential. Regular inspections must be conducted to assure a properly functioning PRV.
These inspections are used to verify if the PRV is suitable for the service conditions it is installed
in. If the PRV is not correct for the conditions, it may not be able to protect the system properly
and this could result in failures.
The inspection of the PRV can be done while in place, in the field, or offsite within a repair shop.
During the inspection, three tests should be performed: a visual inspection, a set pressure test, and
a leak test. Using these three inspections can help determine the functionality of the valve or if
repair or replacement is required.
Relief valves can generate an enormous amount of noise and pose other hazards to personnel
during its operation. Appropriate personal protective equipment must be worn and other safety
standards must be followed when working with pressure relief valves.
a) Visual Inspection
During the visual inspection, the pressure relief valve is checked for any potential issues that may
restrict the operation of the valve. This inspection will be performed with the valve still assembled
but the valve should not be pressurized for the safety of the person performing the inspection.
Corrosion and damage to the valve are some of the common problems found in the visual
inspection. Some of the items that should be checked in the visual inspection are as follows:
 Cap and Seal Wire – The valve cap and seal wire should be checked first on all inspections.
These parts prevent adjustment tampering. On the seal wire, there is a pressed security seal
that has an impression on it to indicate the certified company that last adjusted the set point
of the valve. When this seal wire is cut or removed, it indicates that someone may have
adjusted the set point or altered the valve. This voids any warranty the valve had. See Figure
3.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 16
Cap Seal Wire
Pressed Security Seal
Figure 3: Typical Cap and Seal Wire
 Flanged Connections – The flanges should be checked for wear, such as pitting, and any
reduction in width that would cause improper sealing and reduction in pressure rating.
Proper fastening should also be checked.
 Threaded Connections – The threads on the threaded connections should be checked for
any damage that could potentially compromise the sealing of the threads or the strength of
the connection.
 Outlet – The valve’s outlet should be inspected to make sure there is not any corrosion or
other debris accumulation within that could inhibit the operation of the valve.
 External Surface – The valve should be checked for any damage that has occurred that
could restrict or impair the operation of the valve. Tubing lines, bent piping, and other
external attachments are commonly damaged and can cause malfunction.
 Valve Tag – The tag information should be inspected and verified to the service conditions.
Some of the items on the tag that are to be verified are the set pressure, CDTP, and capacity
in appropriate unit of measure for the service fluid. If any of the tag information is found
to not correspond to the conditions of the system, the valve should be removed and replaced
with an appropriate one. A missing tag also warrants further inspections.
If, for any reason, the valve has failed the visual inspection and the valve is deemed to be dangerous
to test, the set pressure inspection and the leak inspection should not be carried out. Valves that
fail visual inspection should be replaced or repaired immediately.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 17
b) Set Pressure Inspection
During the set pressure inspection, the set pressure is verified in accordance with the ASME
BPVC. For all valves set 70 psi (500 kPa) and above, the set pressure has a tolerance of ±3% of
the set pressure. For all set pressure below 70 psi (500 kPa), the tolerance is ±2 psi (±15 kPa). If
the valve has a CDTP associated with it due to temperature and/ or backpressure, the test pressure
is checked to the CDTP. Even with a CDTP, the set pressure tolerance is calculated based on the
actual nameplate set pressure. The set pressure test should be performed before and after any
repairs.
The set pressure is inspected to the definition listed in NB-18, a publication by the National Board
of Pressure Vessel Inspectors, which is found at http://www.nationalboard.org/. This publication
lists all ASME BPVC certified pressure relief valves. It indicates the correct set pressure definition
and other characteristics of a valve. The set pressure has been defined to achieve particular
operational characteristics. If the wrong set pressure definition is used in the inspection test, the
valve’s set pressure will not be accurate and it may not operate appropriately.
The correct fluid for testing has to be used to achieve accurate results. For gas/ vapor service,
nitrogen or compressed air is used as the test fluid. For liquid service, water is used as the test
fluid. If the incorrect fluid is used during the testing, the test’s results will be inaccurate. Depending
on the size of the valve and its set pressure, the set pressure discrepancy can vary outside of ASME
tolerances.
Setting procedures should be in accordance with ASME PTC 25. The rate of the system pressure
increase should be slow when the pressure is within 15% of the set pressure. Within this range, the
rate should never be more than 2 psi/sec (15 kPa/sec). Ideally, each pressure increment on the
pressure gauge should be clearly read as the pressure is increased. Slow pressure increase helps to
accurately read the pressure gauge.
The procedures for testing set pressure are as follows:
1. Check the set pressure definition from NB-18. For Mercer 9100 Series valves, a crisp “pop”
is the definition of set pressure for both gas/ vapor and liquid valves.
2. Rigidly connect the valve to a test fixture.
3. Slowly increase the pressure on the inlet side until the valve opens. This will be the set
pressure of the valve. If the pressure reaches more than 1.5 times the expected set pressure
and hasn’t opened, do not proceed with the test. The valve is considered stuck closed and
has failed.
4. Verify the set pressure 2-3 more times. Verification relief should be no more than ±1% or
±0.5 psi (3.5 kPa), whichever is greater, from the average of all verifying pops.
If the test equipment is not adequate, the results can produce a false reading. Refer to section 9 on
proper test equipment.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 18
Common Set Pressure Definitions
-POP – A crisp “pop” sound from the valve. The “pop” sound is made from the rapid increase in
the lift of the disk, allowing more flow out of the valve.
-1st Audible Sound – The 1st sound heard from the outlet of the valve. This definition is usually for
gas service.
-1st Steady Stream – A continuous stream from the outlet of the valve. This stream should flow out
from the outlet and not dribble down the outlet. This definition is usually for liquid service.
c) Leak Inspection
After the set pressure is verified, the valve undergoes a leak inspection. This is performed to verify
the disk and seat are sealed to a degree appropriate for the type of pressure relief valve being tested.
Leak tests are always performed below the set pressure of the valve, usually at a certain percentage
of the set pressure. The leak check is usually performed at 90% of the set pressure or 5 psi (34.5
kPa) below the set pressure, whichever is greater. If the valve has a CDTP, the leak test pressure
will be below the CDTP in lieu of the set pressure. Mercer Valve Co., Inc. should be contacted for
proper leak pressure and specification for the valve. In the tests, the pressure is held steady for a
length of time and the valve is observed for any leakage. Before this test is performed, the valve
must have had its set pressure examined.
There are several methods used in testing for leakage. All of the tests can indicate a leak at the seat
but some of the tests are more sensitive to leakage than others.
One common test for gas valves is listed in API STD 527. In this test, the outlet is blocked with a
tube coming out of it into a cup of water. See Figure 4. The tube and water are observed for any
bubbles developing in the water from the tube’s end. This test has specific requirements for its
apparatus, pressure, and duration of observation. This specification should be reviewed before
testing the valve. For soft seated valves, such as the 9100 Series, zero bubbles must be observed
for one minute to pass leak inspection per API 527.
Figure 4: API 527 Leak Check Apparatus

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 19
Flow gauges can also be used to check for leakage. These tests are similar to the API 527 test
except a flow gauge is attached to the outlet instead of a cup of water.
Soap film test is another common method for leak testing. In this test, the valve’s seat and disk are
sprayed with a soap and water mixture. The mixture is then observed for any growth of bubbles.
Another simple test is to apply a membrane, a wet paper towel for example, onto the outlet. This
membrane seals the outlet. If there is any leakage, the pressure will push the membrane out,
causing it to bulge.
Sometimes, there is not a way to access the outlet due to outlet piping when a valve is left on the
unit. In these cases, the valve cannot be leak checked by normal means. One method of checking
for a seat leak is by maintaining a blocked-in pressure in the valve’s inlet. In this test, a block valve
must be installed below the pressure relief valve and it must be closed during the test. It is
important to make sure that the gas used to pressurize the valve does not react with the system
fluid in these tests. If the pressure remains stable during the test, there are no leaks present. If the
pressure is not stable, there is a potential leak and the valve should be removed for further testing.
Even though the test indicates a leak, it doesn’t guarantee that it’s from the valve. It could be in
the connections on the inlet or the block valve. This is why the valve should be removed and
rechecked on a test stand if it fails using this method.
Backpressure Testing
The purpose of backpressure testing is to check for leaks in the secondary pressure zone (the outlet
side of the pressure relief valve). This includes the body, bonnet, outlet flange, and all parts
included in the upper valve assembly. Backpressure testing is not required by ASME for field
repair. If this is conducted, it should be performed before the valve’s seal wire has been attached.
The backpressure test is performed after the valve has been assembled and set to the correct set
pressure. The test is performed by attaching a sealed and controlled pressure to the outlet and then
entirely submerging the valve in a solution of water treated with rust inhibitor. The pressure in the
secondary pressure zone is brought to 30 psig (200 kPa) at a minimum. For PRVs installed on
systems with superimposed backpressure, this test should be performed at the backpressure of the
system. This is the pressure required by the ASME BOILER AND PRESSURE VESSEL CODE,
SECTION VIII, PART UG-136(d) “Production Testing by Manufacturers and Assemblers”. The
valve is then visually inspected for any leaks by checking for bubbles coming from any part of the
valve.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 20
9. Test Equipment
Testing and inspections can be performed in multiple locations. They can be performed onsite in
place (in situ testing), onsite on a mobile test unit, or offsite in a shop or test facility. Each
environment offers its own advantages and disadvantages.
a) In Situ Testing
Testing and inspecting in place eliminates the laborious task of removing and handling the valve.
This is especially desirable with large PRVs. Additionally, not disturbing the existing connections
reduces the chance of compromising the existing seals. This type of testing is very useful when a
system cannot be shut down for long lengths of time. However, there are disadvantages. The
inspection process is more difficult because the accessibility of the valve is reduced. The outlet
pipe is often still attached and the internal parts are not observable for the visual inspection. This
can also make it difficult to leak check. Different methods for leak checking are required. In
addition, the set pressure testing process is difficult. Block valves are mandatory to be able to
properly test the set pressure. Even with a block valve under the valve, the volume under the valve
may not be sufficient to accurately test the set pressure. A heavy warn or simmer can cause false
readings as a result of insufficient test volume. Gauge placement is critical to get an accurate
pressure reading. If the gauge is placed too far away from the valve or the line has too many
restrictions, there will be pressure loss. When this happens, the pressure gauge will indicate a
pressure that includes the pressure loss. This is an inaccurate reading compared to the actual
pressure at the valve’s inlet. The supply pressure can also be a factor. Usually, the pressure source
in these types of tests is far away from the actual valve. Compressed air or nitrogen bottles are
heavy and usually a line is run from the bottles to the valve. The length of this line can create a
pressure drop. This will usually mean that additional pressure in the bottles will be required to
properly test the set pressure of the valves. Typical testing apparatus can be seen in Figure 5 and
Figure 6.
Figure 5: Diagram of Proper In Situ Testing Apparatus

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 21
Figure 6: Picture of Typical In Situ Testing
b) Offsite Testing
Offsite testing allows for the most thorough and accurate testing and inspection. The valves are
removed from the units and brought to a shop. In the shop, a valve can be completely tested and
inspected. The shop environment gives the technician the most advantages because more tools are
available, there is adequate space to work, and test benches enable accurate results. All of the same
concerns in testing are still present in offsite testing as in situ testing. The volume of pressure,
valve simmer, pressure losses to the gauges, and supply line pressure are all factors in getting an
accurate result. Proper assembly of a test bench is crucial in limiting these effects. The main
disadvantage in offsite testing is time. A valve must be removed from the unit and then transported
to the shop. After testing, it is transported back to the field to be installed. This time frame can be
long and cause delays.
For gas/ vapor valves, there should be approximately ¼ ft3 (7 liters) or more capacity below the
valve when setting. This volume is sufficient to test the set pressure for most 4 x 6 M orifices and
smaller valves accurately. To see other valve characteristics (e.g. blowdown), a larger vessel is
required. If excessive warn is observed during the test, a larger volume is required. See Figure 7
for an example.
Figure 7: Typical Gas/Vapor Test Stand

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 22
For liquid testing, the test bench, at a minimum, should have enough volume to perform 5 to 10
consecutive set pressure tests before the test stand has to be refilled with liquid. Approximately 2
ft3 (60 liters) of volume is required for most valves. The larger the volume, the more accurate the
settings will be. To see other valve characteristics (e.g. blowdown), a larger vessel is required. The
test bench must be set up so that liquid is present at the nozzle each time the PRV is opened. This
can be accomplished with a J-tube design or a down tube that is completely submerged into the
liquid. See Figure 8 for an example. In both styles, gas pressure is used to push the liquid through
the valve’s inlet, generating continuous liquid flow absent of any gas.
Figure 8: Typical Liquid Test Stand Setups
c) Mobile Test Units

Mobile testing units are similar to offsite testing. The valve is removed from the application. This
enables a thorough inspection. Mobile testing units can save time because transporting the valve
isn’t necessary. Mobile test units are often not setup to test all types and sizes. The testing
equipment on a mobile test unit can vary. Some mobile test units have test stands similar to an
offsite test stand, allowing for larger valves to be tested accurately. Other mobile test units are
setup only for smaller valves. In each case, the limitations of the test stand should be documented
and the test stand should only be used for the sizes and pressure that it is designed for. See Figure
9 for an example.
Truck Bed Mounted Test Trailer Mounted Test
Bench (Small PRVs) Bench (Larger PRVs)
Figure 9: Typical Mobile Test Stand Setups

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 23
d) Test Gauges
When testing the set pressure or leak checking, it is recommended that two pressure gauges are
used. This enables quick identification if they are reading incorrectly. If the gauges are not reading
identical values within their respective tolerances, it is an indication that at least one gauge is
inaccurate and both should be checked to make sure they are calibrated correctly. At least one of
the gauges should be an analog (dial) gauge that is not liquid filled. This type of gauge responds
to pressure quickly and gives accurate readings. Digital gauges can be used for the second gauge,
if desired. Digital gauges have to be used carefully because quick pressure increases are not always
seen on the gauge readings. The test gauges should have at least 0.25% accuracy over their full
scale. The portion of the gauge used should be selected so that the tolerance of it is more stringent
than the set pressure’s tolerance. For analog gauges, only the middle 1/3 or less of the gauge should
be used; it is the most accurate portion of the gauge. Each gauge should be calibrated using a dead
weight tester. Monthly calibrations of the gauges are recommended.
e) Lift Checking
The lift of the PRV is checked by seeing how much the disk subassembly moves from the closed
position to the opened position. Figure 10 depicts a typical apparatus for checking the lift of a
PRV. To use the standard lift check setup, the PRV is placed in an arbor press upside down; the
PRV’s set spring must initially have tension. A rod is placed through the inlet and it touches the
disk. The rod should be sized to fit in the inlet base without damaging the seat or touching the side
walls of the nozzle insert. The lift is the measurement of the displacement of the disk from the
closed position to the mechanical stops at the fully open position. The shaft of the arbor press will
press against the rod sticking out of the valve inlet base. To find the lift, a slight force is applied
by using the arbor press. A dial indicator is placed on the arbor press so that it can measure the
displacement of the arbor press shaft. This measurement will be the PRV’s lift. The minimum lift
for certified PRVs can be found in NB-18 publication, which is located on the National Board
website www.nationalboard.org. If the PRV doesn’t meet the minimum lift, there is something
wrong and the valve must be reexamined.
Figure 10: Lift Checking Apparatus

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 24
10. Tester Qualifications
Only qualified individuals should perform PRV tests and repairs. They should be trained to test
and calibrate pressure relief valves. They should understand how to properly operate the equipment
and know the hazards involved. They should be familiar with the specific PRV being tested and
know how it functions and operates. It is recommended that the individual attend factory approved
training class for each type of valve worked on.
The end user’s company will have additional requirements for the individual conducting the PRV
inspection. These requirements should be checked before any PRV work is carried out.
Government authorities can also have requirements for the individual. For every PRV installment,
regional specifications that apply should be reviewed.
It is recommended that the individual be qualified in a program similar to US DOT OPS Operator
Qualification. This is a qualification program for pipeline operators. Operator Qualification (OQ)
Rules can be found in 49 CFR Part 192, Subpart N; and 49 CFR Part 195, Subpart G.
It is also recommended that any company that repairs PRVs is VR certified through ASME and
The National Board of Boiler and Pressure Vessel Inspectors. VR is an accreditation program
administered by the National Board for the repair of pressure relief valves. A PRV repair is any
process or operation that affects the valve’s flow passage, capacity, function, or pressure-retaining
integrity; this includes cleaning. VR companies are certified to work on all types of pressure relief
valves.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 25
11. Tool List
The following Tool List shows the recommended tool to be used with an associated component.
The list is not exhaustive and more tools that are not listed may be necessary.
a) Valve
Table 1: Tools Used on 9100 Series PRVs
Tool Where it is Used
Cutter Dikes Seal Wire
11/16” Open End Wrench Lock Nut
7/8” Open Wrench Lock Nut and Center Nut (2” Bodies)
15/16” Open Wrench Lock Nut
7/32” Allen Wrench Adjustment Screw (Bottom Entry Valves)
7/16” Open Wrench Adjustment Screw
1/2” Open Wrench Adjustment Screw
9/16” Open Wrench Center Bushing (2” Bodies)
Adjustable 1-1/8” to 5-5/8” Hex/ Straight Jaw Inlet Base (Bottom Entry Threaded Valves)
Wrench and Bonnet (H Orifice)
Flange Wrench Inlet Base (Bottom Entry Flanged Valves)
1-1/6” Open Wrench Bonnet Bolts (J-K-L-M Orifice)
1/2” Wrench/ Socket Inlet Keeper Screw (Bottom Entry Valves)
1” Open End Wrench Nozzle/ Seat Subassembly (C-D-E Orifice)
Special 1” Flat Socket (optional) Nozzle/ Seat Subassembly (C-D-E Orifice)
1-3/4” Open Wrench Nozzle/ Seat Subassembly (F-G Orifice)
Special 1-3/4” Socket (optional) Nozzle/ Seat Subassembly (F-G Orifice)
2” Hex Socket* Nozzle/ Seat Subassembly (H Orifice)
2-1/2” Hex Socket* Nozzle/ Seat Subassembly (J Orifice)
2-3/4” Hex Socket* Nozzle/ Seat Subassembly (K Orifice)
3-1/2” Hex Socket* Nozzle/ Seat Subassembly (L Orifice)
4” Hex Socket* Nozzle/ Seat Subassembly (M Orifice)
Nozzle/ Seat Subassembly and Bonnet
5/16” Allen Wrench
Sleeve Bolts (N-P Orifice)
Pick O-Ring (Removal)
Torque Wrench Nozzle/ Seat Subassembly (Installation)
(refer to section 14 for the required torque range)
*Large sized hex sockets that can be used for nozzle removal/installation are similar to “Truck Wheel Bearing Locknut Sockets.”
b) Miscellaneous
Table 2: Miscellaneous Items Used
Nickel Based Anti-Seize (similar to Loctite® LB 771TM)
Medium Strength Thread Retainer (similar to Blue Loctite® 242®)
High Strength Thread Retainer (similar to Red Loctite® 271®)

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 26
Fine Grade Abrasive Hand Pad (similar to Scotch-Brite™ 7447®)
Phenyl-Methyl Silicon Grease (similar to Molykote® 33)
Water Resistant NLGI #2 Grease (similar to Aqua Lube Marine Grease)

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 27
12. Disassembly
The following general procedure is recommended for the disassembling of a 9100 Series PRV.
Non-standard or “special” configurations are possible and these instructions may not be reflective
of them; a special configuration is indicated by a special code at the end of the PRV’s part number.
See section 17. Always make sure there is no pressure in the system prior to removing a PRV.
The 9100 Series contains several different orifice sizes. For most C to G orifices, the valves are
bottom entry type with the bonnet integral to the body cavity. These valves have a removable inlet
base. Larger orifice sized valves are top entry types and have removable bonnets.
These instructions are divided into three sections: 1” Body-Bottom Entry, 2” Body-Bottom Entry,
and Top Entry. See Figure 11 to identify the difference in appearance. Each type may have either
flanged or threaded connections.
Top Entry
2” Body
1” Body
Figure 11: Different Sized Valve Bodies
a) 1” Body - Bottom Entry

1. Cut and remove the seal wire and unscrew the cap to expose the adjustment screw. See Figure
3.
i) Go to section 12 d) if the valve is a lift lever configuration.
2. Loosen the lock nut from the adjustment screw. See Figure 12.
Adjustment Screw
Washer Lock Nut
Bonnet/Body
Figure 12: 1” Body Upper Bonnet Components

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 28
3. Relieve the compression on the spring by turning the adjustment screw counter clockwise. This
is important so that components will not spring out and pose a hazard. If the adjustment screw
begins to appear as receding back into the bonnet during the relieving of the preload, then the
spring compression has been completely removed and the adjustment bushing is beginning to
re-compress the spring.
4. Remove the inlet base:
a) For threaded valves,
i) Rigidly support the body to prevent movement during disassembly.
ii) Unscrew the inlet using the appropriate wrenching flats. See Figure 1.
b) For flanged valves,
i) Make an identifiable reference mark on the valve body and inlet base. The two marks
should be aligned on both parts prior to disassembly. This mark will be used as a
reference during reassembly.
ii) Rigidly support the body to prevent movement during disassembly.
iii) Unscrew the inlet using a flange wrench.
5. Remove the set spring and discard the disk subassembly. See Figure 13.
i) A replacement disk is included in the repair kit.
6. Remove and discard the inlet base seal. See Figure 13.
i) A replacement base seal is included in the repair kit.
Set Spring
Nozzle Subassembly
Disk Subassembly
Inlet Base
Inlet Base Seal
Figure 13: Bottom Entry Thread Inlet Base Components
7. Rigidly support the inlet base to prevent movement during disassembly.

8. Unscrew and discard the nozzle subassembly using the appropriate tool. See Table 1. The
nozzle will have thread retainer on its thread.
i) A replacement nozzle subassembly is included in the repair kit.
9. Remove and discard the nozzle base o-ring. See Figure 14.
i) A replacement o-ring is included in the repair kit.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 29
Nozzle
Nozzle Base O-ring

Inlet Base
Figure 14: Nozzle/Seat Subassembly of Bottom Entry Valve
10. Remove the lock nut and washer. See Figure 15.
a) If the valve is a lift lever and the center bushing is being removed, the lift lever lock nut is
unscrewed as well.
Lock Nut
Washer
Figure 15: 1" Body Upper Bonnet Components
11. Push downwards on the adjustment screw and center bushing to remove them from the bonnet.
12. Disassemble the center bushing from the adjustment screw if they are still together. See Figure
16.
13. Remove and discard the o-ring located on the center bushing.
a) Older models have two o-rings located on the center bushing
i) Two replacement o-rings are included in the repair kit.
14. Remove and discard the o-ring located on the adjustment screw. See Figure 16.
Center Bushing
Center Bushing O-Ring
Adjustment Screw O-Ring
Adjustment Bushing Adjustment Screw
Figure 16: 1" Body Inner Bonnet Components

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 30
15. Unscrew the adjustment bushing from the adjustment screw. The adjustment bushing has left
handed threads. See Figure 16.
16. PRV is disassembled.
b) 2” Body - Bottom Entry

3.
i) Go to section 12 d) if the valve is a lift lever configuration.
Adjustment Screw
Center Bushing
Lock Nut
Center Nut
Bonnet/Body
Figure 17: 2” Body Outer Bonnet
4. Remove the inlet base:
a) For threaded valves,
ii) Unscrew the inlet using the appropriate wrenching flats. See Figure 1.
b) For flanged valves,
i) Flanged valves will have a flange keeper that must be removed before the inlet base
can be unscrewed. See Figure 18. Remove the flange keeper by unscrewing the keeper
bolts first.
ii) Remove the keeper.
Inlet Keeper
Keeper Bolts
Figure 18: Inlet Keeper

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 31
iii) Rigidly support the body to prevent movement during disassembly.

iv) Unscrew the inlet using a flange wrench.
5. Remove the set spring and lower spring guide (if one is present) and discard the disk
subassembly. See Figure 19.
a) Not all 9100 Series valve configurations have a lower spring guide. This component is used
to guide the bottom of the spring on the top side of the disk.
Set Spring
Lower Spring Guide
Disk Subassembly
Figure 19: Body Internal Components
6. Remove and discard the inlet base seal. See Figure 13.
i) A replacement base seal is included in the repair kit.
7. Rigidly support the inlet base to prevent movement during disassembly.
8. Unscrew and discard the nozzle subassembly using the appropriate tool. See Table 1. The
nozzle will have thread retainer on its thread.
10. If not already done, unscrew the lock nut and set it aside. See Figure 20.
Lock Nut
Center Nut
Figure 20: 2" Upper Bonnet Components
11. Push downwards on the adjustment screw to remove inner bonnet components.
12. Remove and discard the adjustment screw o-ring. See Figure 21.
13. Unscrew the adjustment bushing. This has left handed threads.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 32
Adjustment Screw
Adjustment Screw O-ring
Adjustment Bushing
Figure 21: 2" Body Inner Bonnet Components
If the center bushing is being removed, continue with the following. Otherwise, skip to step 19.
14. If necessary*, the center bushing can be removed by using wrenches on the center nut and the
flats of the center bushing. One wrench should remain stationary while the other is applied on
the other component to break the two parts loose.
a) *These components do not have to be disassembled unless the center bushing o-ring is
suspected to be leaking. This o-ring must be specially ordered and is not included in the
repair kit. The center nut will likely become damaged by removing it; this can be specially
ordered as well. Removing these parts is not recommended.
b) These parts are used to lock in the index bracket.
c) The center bushing has high strength thread retainer on its threads.
d) If the valve has a lift lever, this step has already been completed in section 12 d).
15. Once loose, unscrew the center nut from the center bushing if not already done so. Set aside
the center nut. See Figure 22.
Center Nut
Center Bushing
Figure 22: 2" Body Center Nut and Bushing
16. Push downwards on the center bushing to remove.

17. Remove and set aside the index bracket. See Figure 23. Be careful not to bend the index
bracket.
18. Remove the center bushing o-ring. See Figure 23.
i) A replacement o-ring is not included in the repair kit.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 33
Index Bracket Center Bushing O-Ring
Center Bushing
Figure 23: 2" Body Index Bracket

c) Top Entry
3.
i) Go to section 12 e) if the valve is a lift lever configuration.
Adjustment Screw
Washer Lock Nut
Bonnet/Body
Figure 24: Top Entry Upper Bonnet
4. Remove the bonnet:
a) H Orifice - The 9100 Series H orifice has a threaded bonnet.
ii) Unscrew the bonnet from the body using the wrenching flats. The wrench flat width is
3-1/4”. See Figure 25.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 34
Wrenching Flats
Figure 25: 9100 Series Threaded H Bonnet
b) J Orifice and Larger – The 9100 Series J orifice and larger has a bolted bonnet.
i) Loosen each of the bonnet bolts in an alternating “star” pattern.
ii) Remove and set aside all the bonnet bolts.
5. Remove the set spring and lower spring guide (if one is present) and discard the disk
subassembly. See Figure 26.
a) Not all 9100 Series valve configurations have a lower spring guide. This component is used
to guide the bottom of the spring on the top side of the disk.
Set Spring
Disk Subassembly
Figure 26: Top Entry Internal Components

(Lower Spring Guide Not Shown)
6. Rigidly support the body to prevent movement during disassembly.

7. Unscrew and discard the nozzle subassembly from the body cavity using the appropriate tool.
See Table 1 and Figure 27.
a) H though M orifice sizes will have a nozzle subassembly that is screwed into the body.
b) N and P orifice sizes will have a nozzle subassembly that is bolted to the body.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 35
Nozzle Subassembly
(Screwed In Type)
Nozzle Base O-Ring
Valve Body
Figure 27: Top Entry Inner Components
9. Remove and discard the bonnet o-ring. This is located on the bottom side of the bonnet. See
Figure 28.
i) A replacement bonnet o-ring is included in the repair kit.
Bonnet O-Ring
Figure 28: Bonnet O-Ring
10. In some N and P configurations, there may be a guide sleeve bolted to the bonnet that must be
removed to service the adjustment screw and bushing. See Table 1.
11. Remove the lock nut and washer. See Figure 29.
Lock Nut
Washer
Bonnet
Figure 29: Top Entry Upper Bonnet Components
12. Push downwards on the adjustment screw to remove from the bonnet.
13. Remove the adjustment screw o-ring and discard. See Figure 30.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 36
Adjustment Screw O-Ring

Bonnet
Figure 30: Top Entry Adjustment Screw O-Ring
14. Unscrew the adjustment bushing from the adjustment screw. The adjustment bushing has left
handed threads. See Figure 31.
Adjustment Bushing
Adjustment Screw
Figure 31: Adjustment Screw and Adjustment Bushing
d) Lift Levers – Bottom Entry

The 1” and 2” bodies have identical lift lever designs. Conduct the following steps to remove the
lift lever and then continue with the aforementioned instructions to complete the disassembling.
1. Cut and remove the seal wire. See Figure 32.
Seal Wire
Lift Lever Cap

Subassembly
Figure 32: Lift Lever Cap – Bottom Entry

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 37
2. Bend straight and pull out the cotter pin. See Figure 33. Set it aside.
i) A replacement cotter pin is not provided in the repair kit.
3. Unscrew and remove the stem lift nut. See Figure 33.
Lift Rod
Stem Lift Nut Cotter Pin
Figure 33: Upper Portion of Lift Lever Cap
4. Loosen the three lift lever cap set screws. See Figure 34. These must be unscrewed enough so
that they no longer engage the lift lever lock nut.
Lift Lever Cap Set Screw x3
Figure 34: Lift Lever Cap Set Screws
5. Raise the entire lift lever cap to remove it from the bonnet.
6. Unscrew and remove the seal adjustment nut. See Figure 35.
a) If the valve has a closed lift lever configuration, there will be an o-ring under this nut.
Remove and discard this o-ring.
b) If the valve has an open lift lever configuration, there won’t be an o-ring.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 38
O-Ring
(Closed Lift Lever) Seal Adjustment Nut
Lift Lever Lock Nut
Lock Nut
Figure 35: Removed Lift Lever Cap
7. Loosen the lock nut by using two additional jam nuts on the adjustment screw to prevent it
from turning. See Figure 36.
i) The additional jam nuts are not included in the repair kit.
Jam Nuts
7/16”-20 UNF
Lock Nut (not provided)
Figure 36: Jam Nuts Used on Adjustment Screw
8. Turn the adjustment screw counter clockwise to remove the spring load. Use the jam nuts to
apply torque to the adjustment screw.
9. Remove the jam nuts.
If removing the center bushing, continue with the following. Otherwise, skip to step 11.
10. If necessary*, the lift lever lock nut may be removed by using a wrench on the flats of the
center bushing and a pipe wrench on the lift lever lock nut. One wrench should remain
stationary while the other is applied on the other component to break the two parts loose.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 39
a) *These components do not have to be disassembled unless the center bushing o-ring is
suspected of leaking. Removing these parts is not recommended.
b) This lock nut has high strength thread retainer applied and can be difficult to remove.
Center Bushing
Wrenching Flats Lift Lever Lock Nut
Apply Pipe Wrench
Figure 37: Lift Lever Lock Nut Removal
11. The disassembly is now typical of the process described for non-lift lever configurations.
Return to step 4 in the aforementioned instructions.
e) Lift Levers – Top Entry

1. Cut and remove the seal wire. See Figure 38.
Seal Wire
Lift Lever Cap

Subassembly Attachment Bolts
Pivot Block
Subassembly
Figure 38: Lift Lever Cap - Top Entry
2. Unscrew the four bolts attaching the pivot block subassembly to the lift lever cap. See Figure
38.
3. Remove the pivot block. There will be an o-ring between the pivot block and the cap. Remove
this o-ring and discard. See Figure 39.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 40
a) A replacement o-ring is included in the repair kit.
O-Ring
Figure 39: Pivot Block O-ring
4. Unscrew and remove the bolts attaching the lift lever cap to the bonnet. See Figure 40.
Attachment Bolts
Figure 40: Lift Lever Cap Mounting Bolts
5. Remove and set aside the cap. There will be an o-ring under the cap. Remove and discard
this o-ring. See Figure 41.
a) A replacement o-ring is included in the repair kit.
Stem Lift Nut

Cotter Pin
Lift Rod Adjustment Screw

(Flush with Jam Nut)
Jam Nuts
O-Ring
Lock Nut
Figure 41: Removed Lift Lever Cap

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 41
6. Bend straight and pull out the cotter pin. Figure 41. Set it aside.
i) A replacement cotter pin is not provided in the repair kit.
7. Unscrew the stem lift nut from the lift rod. See Figure 41.
8. Loosen and remove the lock nut by using the two jam nuts on the adjustment screw. Hold the
jam nuts with one wrench and use another wrench on the lock nut. This will prevent the
adjustment screw from turning.
9. Turn the adjustment screw counter clockwise to remove the spring load. Use the jam nuts to
apply torque to the adjustment screw.
10. Remove the jam nuts.
11. The disassembly is now typical of the process described for non-lift lever configurations.
Return to step 4 in the aforementioned instructions.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 42
13. Component Inspection
The following general procedure is recommended in the inspection of a 9100 Series PRV. New
parts should be inspected.
1. Inspect the seat for cuts and abrasions. The seat is the non-metallic element in the nozzle
subassembly.
a) If there are only minor scratches or abrasions, the seat may be polished and restored.
b) Polish the seat area lightly with a fine grade abrasive pad. Be careful not to damage the soft
seat.
c) If the seat is damaged with deep abrasions and cuts, it should be replaced.
2. Referring to Figure 42, measure the diameter, 𝐷 , of the nozzle. This diameter must be in the
range of values listed in Table 3.
Figure 42: Critical Seat Dimension
Table 3: Critical Seat Dimension Values

NOZZLE DIAMETER Ds, in (mm)
ORIFICE SIZE
MINIMUM MAXIMUM
C 0.335 (8.51) 0.337 (8.56)
D 0.478 (12.14) 0.480 (12.19)
E 0.620 (15.75) 0.622 (15.80)
F 0.778 (19.76) 0.780 (19.81)
G 0.914 (23.22) 0.916 (23.27)
H 1.243 (31.57) 1.246 (31.65)
J 1.599 (40.61) 1.603 (40.72)
K 1.899 (48.23) 1.903 (48.34)
L 2.394 (60.81) 2.398 (60.91)
M 2.676 (67.97) 2.680 (68.07)
N 2.930 (74.42) 2.940 (74.67)
P 3.580 (90.93) 3.590 (91.18)
3. Inspect the disk subassembly. Especially examine the spherical surface portion that engages
the seat; this surface must be clean and smooth.
a) This surface may be polished with a fine grade abrasive to restore the disk if only minor
imperfections exist. Any form of heavier cutting must not be done.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 43
b) If the spherical surface is damaged or scratched, the disk needs to be replaced.
4. Referring to Figure 43, measure the diameter, 𝐷 . This diameter must be within the range of
values listed in Table 4.
Figure 43: Critical Disk Dimension
Table 4: Critical Disk Dimension Values

DISK DIAMETER Dd, in (mm)
ORIFICE SIZE
MINIMUM MAXIMUM
C 0.329 (8.36) 0.333 (8.46)
D 0.472 (11.99) 0.476 (12.09)
E 0.614 (15.60) 0.616 (15.65)
F 0.768 (19.51) 0.771 (19.58)
G 0.904 (22.96) 0.906 (23.01)
H 1.228 (31.19) 1.231 (31.27)
J 1.580 (40.13) 1.583 (40.21)
K 1.876 (47.65) 1.880 (47.75)
L 2.372 (60.25) 2.376 (60.35)
M 2.650 (67.31) 2.655 (67.44)
N 2.895 (73.53) 2.900 (73.66)
P 3.540 (89.91) 3.545 (90.04
5. Check the portion of the disk stem that slides inside the adjustment screw bore. Verify that its
surface is smooth. The surface must not have severe wear. See Figure 44 for an example.
Figure 44: Example of Severe Wear on a Disk Stem

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 44
6. Inspect the set spring for damage. Clean or replace the spring, if necessary. Check that the
spring appears square. A spring with too much curvature can cause the valve to leak.
7. Verify that the correct spring is being used for the intended service and set pressure. This is
checked by measuring the wire diameter and the inside diameter of the spring. Cross reference
these values to the spring chart. This is a separate document.
8. Swab out the internal bore of the adjustment screw to ensure that it is clean and free from
obstructions, such as dirt or grease. Also, examine for severe wear within this part.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 45
14. Reassembly
The following general procedure is recommended for the reassembling of a 9100 Series PRV.
Parts should not be difficult to put back together and excessive force should never be used.
a) Cleaning & Lubrication

Cleaning:
 All of the valve’s parts except the o-rings and nozzle subassemblies may be cleaned using
a solvent bath. Remove all soft goods before applying solvent.
 An abrasive pad may be used to clean dirty surfaces. Always rinse off parts after using
Scotch-Brite™.
 All parts shall be drained and dried before reassembly.
 Parts should never be media blasted. This process leaves beads/ sand in the valve, which
can cause improper function. It may also ruin a required surface finish condition.
 After parts have been cleaned, they may be re-lubricated.
Lubricating:
 All o-rings should be lubricated with silicone grease similar to Molykote® 33 grease.
 The adjustment screw threads should be lubricated with a small amount of anti-seize,
preferably a nickel base type. A good method for doing this is to apply a small line of anti-
seize on the upper half of the adjustment screw threads. When the adjustment bushing is
threaded on, the anti-seize will be spread. This prevents using too much.
 The adjustment bushing should be greased on the outer cylindrical area with a water
resistant lubricant similar to Aqualube.
 Never apply grease, oil, or other lubricants on seats, seal faces, or sliding components.
b) Valve Reassembly
i) 1” Bodies – Bottom Entry
1. Lightly apply a small amount of anti-seize to the threads of the adjustment screw. See Figure
45.
2. Thread the adjustment bushing onto the adjustment screw. This has left handed threads. Screw
the adjustment bushing down onto the adjustment screw until approximately 2 threads of the
adjustment screw are visible from the top. See Figure 16.
3. Lightly lubricate the outer surface of the adjustment bushing. See Figure 50 or Figure 54.
4. Lightly lubricate the adjustment screw o-ring.
5. Carefully place the adjustment screw o-ring onto the adjustment screw, making sure not to cut
the o-ring. The o-ring should reside in a notch groove below the upper threads of the adjustment
screw. See Figure 45.
If the valve has a lift lever, go to section 14 c).

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 46
Apply Anti Seize Here

O-Ring Notch
Figure 45: Adjustment Screw O-Ring Notch
6. Lightly lubricate the center bushing o-ring.

a) Older 9100 Series may have two o-rings and two notches on the center bushing.
7. Carefully place the center bushing o-ring onto the center bushing. The o-ring should reside in
a notch on the center bushing. See Figure 46.
O-Ring Notch
Figure 46: Center Bushing O-Ring Notch
8. Install the center bushing over the top of the adjustment screw. See Figure 16 for the proper
orientation.
9. Carefully slip fit the adjustment screw and bushing into the bore of the bonnet by aligning the
index pin of the body with the notch of the adjustment bushing. The center bushing should end
against the top of the inner bonnet.
a) The adjustment bushing must slip into the valve bore freely but with little radial play.
b) Remove and inspect/ re-clean parts if the fit is not correct.
c) DO NOT FORCE THE ADJUSTMENT BUSHING INTO THE VALVE BODY. Forcing
the parts may restrict valve lift and cause serious malfunction.
10. Place the washer over the top of the bonnet and onto the adjustment screw with the rounded
edge side of the washer away from the body (towards the top of the valve). See Figure 12.
11. Thread on the lock nut over the top of the bonnet and onto the adjustment screw.
a) DO NOT fully tighten. The lock nut just needs to be finger tight at this point, as it is only
to retain the inner bonnet components.
b) The lock nut will be tightened once the setting process is completed.
12. Lightly lubricate the nozzle base o-ring.
13. Install the nozzle base o-ring into the lower corner of the nozzle pocket. See Figure 47.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 47
Nozzle Base O-Ring Apply Anti Seize Here
Figure 47: Nozzle Pocket of Bottom Entry Valve
14. Put a dot of medium strength thread retainer onto the bottom of the threads of the nozzle. See
Figure 52.
15. Thread the nozzle subassembly into the nozzle base.
a) Do not put any lubricant on the seat.
16. Rigidly hold the inlet base.
17. Tighten the nozzle to the appropriate value as shown in Table 5.
Table 5: Nozzle Torque Values

Nozzle Orifice Torque, lbf-ft (N-m) ± 5%
C to G 100 (136)
Conversion Adapter (C, D, E) 100 (136)
E orifice 316 SS (see section 17) No Torque – use channel lock pliers to snug down
H 250 (339)
J 350 (475)
Conversion Adapter (J) 250 (339)
K 400 (542)
L 500 (678)
M 600 (813)
N & P (Nozzle and Guide Sleeve Bolts) 50 (68) per bolt
18. Hold the valve body upside down.

19. Before reinstalling the spring, insert the disk subassembly’s stem into the bore of the
adjustment screw and simulate the valve opening operation. The disk stem must slide freely
within the bore of the adjustment screw.
20. Remove the disk subassembly.
21. Check and make sure the set spring slides over the disk freely without sticking.
22. Install the spring over the adjustment screw so it is resting on the lower portion of the
adjustment bushing.
23. Install the disk subassembly into the adjustment screw and spring.
a) Do not put any lubricant on the disk or disk stem.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 48
24. Place the base seal onto the inlet base. See Figure 13.
25. Put a small amount of anti-seize on the threads of the inlet base that get screwed into the body.
See Figure 47.
26. While still holding the body of the valve upside down, finger tighten the inlet base subassembly
threads into the body while making sure all internal parts remain aligned. Also, make sure that
the inlet base seal is centered on the inlet base and body and is not getting bent or caught on
the inlet threads.
27. Tighten the inlet base to the body:
a) For threaded valve bodies,
i) Tighten the inlet base to the appropriate value as shown in Table 6.
Table 6: Inlet Base Torque Values

Body Size (Thread Size) Torque, lbf-ft (N-m) ± 5%
1” (1-1/2”-12) 350 (475)
2” (2-3/8”-12) 450 (610)
b) For flanged valve bodies,

i) Tighten the inlet flange into the valve body so that the reference marks made in section
“12 Disassembly; a) 1” Body - Bottom Entry; 4.b)” are aligned. Or, tighten to the
proper flange timing/ alignment.
28. Turn the valve upright.
29. If any pipe plugs/ fittings were removed, wrap their threads with 3 wraps of PTFE pipe fitting
tape, reinstall them, and then tighten them approximately 2-3 turns past finger tight.
30. Turn the adjustment screw clockwise until resistance is felt; the spring is engaged. Turn the
adjustment screw an additional 4-5 more times. This is increasing the compression on the
spring.
a) If the PRV has a lift lever option, utilize two jam nuts to turn the adjustment screw. See
Figure 36. The jam nuts are tightened against each other to 100 lbf-ft (136 N-m).
31. Check the lift of the valve. Refer to section “9 Test Equipment e) Lift Checking”. The
measured lift of the PRV should meet or exceed the minimum lift denoted in the NB-18
publication. If valve does not meet lift, disassemble and inspect parts.
32. Adjust the set pressure of the valve. See section “15 Valve Setting Procedure”.
33. Tighten the lock nut to the appropriate value listed in Table 7. Tighten by utilizing two
wrenches, one on the lock nut and the other on the adjustment screw (or jam nut). The wrench
on the adjustment screw (or jam nut) should be held stationary during tightening so that the
adjustment screw does not turn and alter the spring compression.
a) If the PRV has a lift lever and jam nuts were used to turn the adjustment screw, the jam
nuts will be removed once set pressure adjustment is finalized.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 49
Table 7: Lock Nut Torque Values
Orifice Sizes Torque, lbf-ft (N-m) ± 5%
C to G Lock Nut 25 (34)
1” & 2” Body Center Nut (Lift 80 (108)
Lever Lock Nut)
Top Entry - Short Bonnet Lock Nut 35 (47)
Top Entry - Tall Bonnet Lock Nut 50 (68)
N & P Lock Nut 90 (122)
34. Re-check the set pressure to verify set pressure is still as intended.
35. Conduct a leak check. See section “8 Inspections; c) Leak Inspection”.
36. Install cap and seal with lock wire. See Figure 3.
a) If the PRV has a lift lever option, use the instructions listed in 14 c) step 9.
37. Reassembly is complete.
ii) 2” Bodies – Bottom Entry

48.
3. Lubricate the outer surface of the adjustment bushing. See Figure 50.
5. Carefully place the adjustment screw o-ring onto the adjustment screw, making sure not to cut
the o-ring. The o-ring should reside in a notch groove below the upper threads of the adjustment
O-Ring Notch
Apply Anti Seize Here
Figure 48: 2” Body Adjustment Screw O-Ring Notch
If center bushing was removed, continue with the following. Otherwise, skip to step 10.
If the valve has a lift lever, go to section 14 c).
6. Place the index bracket over the center bushing. The bracket should be pointing downwards.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 50
8. Carefully place the center bushing o-ring onto the center bushing making sure not to cut the o-
ring. The o-ring should reside in a notch on the center bushing. See Figure 49.
O-Ring Notch
Figure 49: Center Bushing O-Ring Notch
9. Install the center bushing and index bracket over the top of the adjustment screw. The center
bushing should be oriented with its wrenching flats towards the top of the adjustment screw.
The angle portion of the index bracket should be pointed downwards and be aligned with the
notch of the adjustment bushing. The current subassembly should look like Figure 50.
Center Bushing
Center Bushing O-Ring
Index Bracket
Adjustment Bushing
Apply Grease Here
Adjustment Screw
Figure 50: 2" Inner Bonnet Components
10. Carefully slip fit the adjustment screw and other parts into the bore of the bonnet so that the
center bushing is against the top of the inner bonnet.
a) The adjustment bushing must slip into the valve bore freely.
If the center bushing was removed, continue with the following. Otherwise, skip to step 13.
11. Apply a small amount of high strength thread retainer on the threads of the center bushing only
if it was removed during disassembly. See Figure 51.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 51
Apply Thread Retainer Here
Figure 51: Thread Retainer on Center Bushing
12. Tighten the center nut against the center bushing. When tightening, use the flats on the center
bushing to stop the center bushing from turning. Tighten to the appropriate value shown in
Table 7.
13. Thread the lock nut onto the adjustment screw finger tight against the center bushing. Do not
tighten fully.
16. Put a dot of medium strength thread retainer onto the bottom threads of the nozzle. See Figure
52.
Apply Thread Retainer Here
Figure 52: Thread Retainer Location on Nozzle
17. Thread the nozzle subassembly into the nozzle base.

a) Do not put any lubricant on the seat.
18. Rigidly hold the inlet base.
19. Tighten the nozzle to the appropriate value as shown in Table 5.
20. Hold the valve body upside down.
21. Before reinstalling the spring, insert the disk subassembly’s stem into the bore of the
adjustment screw and simulate the valve opening operation. The disk stem must slide freely
within the bore of the adjustment screw.
23. Check and make sure the set spring slides over the disk or lower spring guide freely without
sticking.
24. Install the spring over the adjustment screw so it is resting on the lower portion of the
adjustment bushing.
25. Place the lower spring guide on top of the disk subassembly if the configuration has a lower
spring guide.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 52
26. Install the disk subassembly into the adjustment screw and spring.
27. Place the base seal onto the inlet base. See Figure 53.
Apply Anti Seize Here Inlet Base Seal
Figure 53: Bottom Entry Inlet Base
28. Put a small amount of anti-seize on the threads of the inlet base that get screwed into the body.
See Figure 53.
29. While still holding the body of the valve upside down, finger tighten the inlet base subassembly
threads into the body while making sure all internal parts remain aligned. Also, make sure that
the inlet base seal is centered on the inlet base and body and is not getting bent or caught on
anything.
30. Tighten the inlet base to the body:
a) For threaded valve bodies,
i) Tighten the inlet base to the appropriate value as shown in Table 6.
b) For flanged valve bodies,
i) Tighten the inlet flange into the valve body to the point where the notch in the body for
the inlet flange keeper aligns with the center of the inlet keeper holes in the inlet base.
The inlet base seal should be getting squeezed between the body and inlet base at this
point.
ii) Install the inlet keeper onto the inlet base.
iii) Screw in and tighten the two keeper bolts into the inlet keeper and inlet base. If the
keeper bolts do not easily fit into the keeper, then the inlet flange alignment may still
be askew. These bolts are tightened to the value shown in Table 8.
Table 8: Keeper Bolt Torque

Part Torque, lbf-ft (N-m) ± 5%
Keeper Bolt 25 (34)
31. Turn the valve upright.

spring.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 53
a) If the has a lift lever option, utilize two jam nuts to turn and adjust the adjustment screw.
See Figure 36. The jam nuts are tightened against each other to 100 lbf-ft (136 N-m).
measured lift of the PRV should meet or exceed the minimum lift denoted in the NB-18
nuts are removed once set pressure is finalized.
nuts will be removed once set pressure is finalized. See Figure 36.
37. Re-check the set pressure to verify set pressure is still as intended.
a) If the PRV has a lift lever option, use the following instructions listed in 14 c) step 9.
iii) Top Entry

45.
Apply Grease Here Adjustment Bushing
Adjustment Screw
Figure 54: Adjustment Screw and Adjustment Bushing
3. Lightly lubricate the outer surface of the adjustment bushing. See Figure 54.
4. Carefully, slip fit the adjustment screw subassembly into the bore of the bonnet by aligning the
index bracket (or pin) of the body with the notch of the adjustment bushing. The top shoulder
of the adjustment screw should be against the top of the inner bonnet.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 54
a) The adjustment bushing must slip into the valve bore freely but with little radial play.
6. Carefully place the adjustment screw o-ring onto the adjustment screw making sure not to cut
the o-ring. The o-ring should reside in a notch on the bonnet. See Figure 55.
O-Ring Notch
Figure 55: Top Entry Adjustment Screw O-Ring Notch
7. Place the washer over the top of the bonnet and onto the adjustment screw with the rounded
edge side of the washer away from the body (towards the top of the valve). See Figure 24.
8. Thread the lock nut onto the adjustment screw finger tight against the washer. Do not tighten
fully.
9. Lightly lubricate the bonnet o-ring.
10. Place the bonnet o-ring over the bonnet. Be careful to not cut the o-ring. The o-ring should
reside in a notch towards the bottom of the bonnet. See Figure 56.
Threaded Bonnet Bolted Bonnet
O-Ring Notch
Figure 56: Top Entry Bonnet O-Ring Notch
11. If there was a guide sleeve removed during the disassembly of an N or P, this would need to
be reattached to the bonnet.
a) Align the bolt holes of the guide sleeve and bonnet.
b) Apply a small amount of medium strength thread retainer to each mounting bolt.
c) Finger tighten all the guide sleeve bolts into the bonnet.
d) Tighten the guide sleeve bolts in an alternating star pattern to the appropriate value shown
in Table 5.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 55
12. If you are converting from a K orifice to a J orifice, a conversion adapter will be required. This
will need to be purchased separately and requires a special tool.
a) Apply a drop of high strength thread retainer to the outside threads of the conversion
adapter.
b) Tighten the adapter to the appropriate value as shown in Table 5.
Nozzle Base O-Ring Location
Figure 57: Top Entry Nozzle Base O-Ring Location
15. Lubricating the nozzle:

a) Threaded Nozzle – Put a small amount of anti-seize onto the bottom of the threads of the
nozzle. See Figure 58.
b) Bolted Nozzle – Apply medium strength thread retainer to the bottom threads of each
nozzle mounting bolt.
Apply Grease Here

Figure 58: Anti-Seize Location on Nozzle
16. Installing the nozzle:

a) Threaded Nozzle – Finger tighten the nozzle into the nozzle base.
b) Bolted Nozzle – Place the nozzle into the nozzle base and align the mounting holes. Finger
tighten each nozzle mounting bolt into the aligned holes.
17. Rigidly hold the body.
18. Tighten the nozzle:
a) Threaded Nozzle – Tighten the nozzle to the appropriate value as shown in Table 5.
b) Bolted Nozzle –Tighten each bolt in a star pattern to the appropriate value as shown in
Table 5.
19. Hold the valve bonnet upside down.
20. Insert the disk subassembly’s stem into the bore of the adjustment screw and simulate the valve
opening operation. The disk stem must slide freely within the bore of the adjustment screw.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 56
22. Check and make sure the set spring slides over the disk or lower spring guide freely without
sticking or binding.
23. With the body positioned upright, place the disk subassembly on the nozzle subassembly
within the body cavity. The spherical portion of the disk should be in contact with the seat.
24. Place the lower spring guide on the disk (if one is present).
25. Place the set spring over the disk subassembly or lower disk guide.
26. If the bonnet is threaded type, place a small amount of anti-seize on the bonnet threads, which
are used to connect the bonnet to the body. If the bonnet is bolted, skip this step.
27. Place the bonnet subassembly over the top of the body, making sure that the disk stem is
inserted into the bore of the adjustment screw and the set spring is located around the
adjustment screw. All parts should be axially aligned.
28. Attach the bonnet to the body.
a) Threaded Bonnet:
i) Finger tighten the bonnet to the body.
ii) Tighten the bonnet using the wrenching flats to the torque value specified in Table 9.
Table 9: Threaded Bonnet Torque Value

Orifice Sizes Torque, lbf-ft (N-m) ± 5%
H 500 (678)
b) Bolted Bonnet:
i) Align the bolt holes of the bonnet and body.
ii) Apply anti-seize to each mounting bolt.
iii) Finger tighten all the bonnet bolts into the bonnet and body.
iv) Tighten the bonnet bolts in an alternating star pattern to the appropriate value shown in
Table 10.
Table 10: Bonnet Bolt Torque Values

Bolt Size Torque, lbf-ft (N-m) ± 5%
5/8”-11 93 (126)
1”-8 287 (389)
If the valve has a lift lever, go to section 14 d).
spring. Use the flats of the adjustment screw to turn it.
a) If the PRV has a lift lever option, utilize two jam nuts to turn and adjust the adjustment

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 57
measured lift of the PRV should meet or exceed the minimum lift denoted in NB-18
34. Re-check the set pressure to verify that the set pressure is as intended.
If the valve has a lift lever, go to section 14 d) step 3.
c) Lift Levers – Bottom Entry

If the center bushing was removed, begin with step 1. Otherwise, skip to step 5.
1. Place the index bracket over the center bushing. The bracket should be pointing downwards.
a. This only applies to 2” bodies.
3. Carefully place the center bushing o-ring onto the center bushing, making sure not to cut the
o-ring. The o-ring should reside in a notch on the center bushing. See Figure 49.
4. Install the center bushing and index bracket (for 2” bodies) over the top of the adjustment
5. Carefully, slip fit the adjustment screw and other parts into the bore of the body.
a. The adjustment bushing must slip into the valve bore freely.
b. Remove and inspect/ re-clean parts if the fit is not correct.
c. DO NOT FORCE THE ADJUSTMENT BUSHING INTO THE VALVE BODY. Forcing
If the center bushing was removed, continue with step 6. Otherwise, skip to step 8.
6. Apply a small amount of high strength thread retainer on the threads of the center bushing
only. See Figure 51.
7. Install and tighten the lift lever lock nut against the center bushing. When tightening, use the
flats on the center bushing to stop the center bushing from turning. Tighten to the appropriate
value shown in Table 7.
8. Thread the lock nut onto the adjustment screw finger tight against the center bushing. Do not
tighten fully.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 58
Continue with assembling the bottom portion of the PRV in section 14 b)i) step 12 for 1” and in
section 14 b)ii) step 14 for 2” bodies.
To install a lift lever cap, the PRV must have its set pressure adjusted first. Remove any jam
nuts used.
9. Remove the two jam nuts.

10. Lubricate and place the seal adjustment nut o-ring over the lift lever rod. See Figure 59. If the
valve has an open lift lever configuration, this step is omitted since there will not be an o-ring
used.
O-Ring
Figure 59: Lift Lever O-ring
11. Slip the seal adjustment nut over the lift rod and thread it onto the adjustment screw. The seal
adjustment nut should be finger tightened so that the adjustment screpw does not get turned.
12. Place the lift lever cap subassembly over the adjustment screw and lift lever lock nut with the
orientation shown in Figure 60.
13. Insert and tighten the three lift lever cap set screws to the value listed in Table 11. See Figure
34.
Table 11: Lift Lever Cap Set Screw Torque

Torque, lbf-ft (N-m) ± 5%
1/4”-20 Lift Lever Cap Set Screw 6.3 (8.6)
14. Thread the stem lift nut on the lift rod until its pin hole is aligned with the lift rod’s pin hole.
It will be in light contact with the lift lever. Once installed, the lift lever should have some play
in its action.
15. Insert the cotter pin through the two pin holes.
16. Slightly bend the end of the cotter pin so that it is captured within the lift rod and stem lift nut
assembly.
17. Attach the seal wire through the small unused hole of the lift lever cap as shown in Figure 60.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 59
Hole Used for Lock-Wire
Figure 60: Lift Lever Orientation and Lock Wire
d) Lift Levers – Top Entry

1. Screw the two jam nuts onto the lift rod until the upper jam nut is flush with the top of the lift
rod. See Figure 41.
2. Tighten them together by using two wrenches, one on each jam nut. Tighten these against
each other to approximately 100 lbf-ft (136 N-m).
Return to section 14 b)iii) step 28.
3. Screw the stem lift nut onto the lift rod so that the cross holes of the lift rod and the stem nut
are aligned.
4. Insert the cotter pin through the aligned hole and bend the sharp edge of the pin. See Figure
41.
5. Lubricate and place the lift cap o-ring over the lift rod and other parts so that it rests on top of
the bonnet. See Figure 41.
6. Carefully, place the lift lever cap over the lift rod and other parts so that the o-ring and the
bolt holes are all aligned with the cap.
7. Install the lift cap mounting bolts and tighten to the appropriate value shown in Table 12. See
Figure 40. Apply anti-seize to each mounting bolt.
Table 12: Lift Lever Mounting Torque

Torque, lbf-ft (N-m) ± 5%
1/4”-20 Mounting Bolts 6.3 (8.6)
8. Lubricate and place the pivot block o-ring in the lift lever cap as shown in Figure 39.
9. Carefully, place the pivot block on the lift cap by aligning the bolt holes.
10. Install the pivot block bolts and tighten to the appropriate value shown in Table 12. See
Figure 38. Apply anti-seize to each mounting bolt.
11. Attach the lock wire and seal through the small holes as shown in Figure 38.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 60
15. Valve Setting Procedure
a) Cold Differential Set Pressure (CDTP)
High temperatures cause materials to relax and results in a set pressure change. Additionally,
because the 9100 Series PRV is a conventional design, superimposed backpressure affects its set
pressure. The Cold Differential Test Pressure (CDTP) is a compensation made to the set pressure
for the temperature and any constant superimposed backpressure of the application’s conditions.
The CDTP is the pressure that the valve will open at when it’s not exposed to the backpressure
and temperature conditions, i.e. when the valve is being set on a test stand. The PRV will open at
its set pressure in the service conditions. Variable superimposed backpressure cannot be accounted
for with a CDTP.
The CDTP will be listed on the PRV’s nameplate for the original set pressure conditions. If the
valve’s service has changed, the CDTP might need to be recalculated. For more information on
calculating CDTP, contact Mercer Valve. When examining and calibrating the set pressure on a
test bench, the CDTP is used. If the CDTP line on the nameplate is blank, there is not a CDTP for
that PRV and it should be calibrated to its set pressure.
b) Setting the Valve

Setting procedures should be in accordance with ASME PTC 25. The rate of the system pressure
increase should slow when close to set pressure (within 15-20% of the set pressure). Within this
range, the rate should never be more than 2 psi (15 kPa)/sec. Ideally, each pressure increment on
the pressure gauge is clearly read as it changes. Slow pressure increase help to accurately read the
pressure readings.
1. Rigidly connect the valve to a test fixture.

2. For Mercer 9100 Series PRVs, a crisp “pop” is the definition of set pressure for both liquid
and gas/ vapor valves.
3. Increase the spring tension by turning the adjustment screw in the clockwise direction.
4. Slowly increase the pressure on the inlet side until it reaches the bench test pressure. If the
valve pops before the bench test pressure is reached, increase the spring tension and again
increase the pressure to the bench test pressure.
5. Slowly reduce the spring tension by turning the adjustment screw counter clockwise while
keeping the system pressure at the bench test pressure. Turn until the valve “pops”.
6. Verify the bench test pressure 3-4 more times, making any adjustments as needed. Verifying
each “pop” should be no more than ±1% or ±0.5 psi (3.5 kPa), whichever is greater, of the
average of all the verifying pops.
7. While holding the adjustment screw still, tighten the locknut to the appropriate value listed in
Table 7.
8. Re-verify the setting after the locknut has been tightened. Make any adjustments, as needed.
Install the cap and seal wire after leak check and back pressure checking.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 61
16. Tag Information
Information and identification about the valve can be found on the tag, also called the nameplate.
This information can be used to verify if the valve is installed in the proper service. It also can be
used to get an appropriate replacement. A PRV’s original nameplate must always remain attached.
If changes are made that would alter its information, such as the part number, the original
information should be crossed out but left legible. The updated information should either be
stamped on the original or on an attached repair nameplate. The information on the tag is as
follows:
• Product Number (PN) – This indicates the series and identifies the configuration of the
valve.
• Serial Number (Serial No.) – This will be a unique identifier to the valve and provides a
means of traceability through Mercer Valve Co., Inc.
• Set Pressure (Set P.) – Identifies the set pressure of the valve while in its service conditions.
• Cold Differential Test Pressure (CDTP) – This indicates the bench test pressure that was
used to compensate for temperature and/ or backpressure of the service conditions.
• Backpressure (Back Press.) – This indicates possible pressure in the valve’s outlet.
• Valve Capacity (CAP. Air/ Water) – This indicates the capacity of the valve at standard
atmospheric conditions of air for gas service valves or water for liquid service valves.
• Service Temperature (Service Temp.) – This indicates the valve’s normal operating
condition. It is not a temperature limit.
• Size – This indicates the nominal inlet size of the valve.
• Repair Kit (Repair Kit No.) – This designates the associated repair kit for the product
number.
• Date – This indicates the month and year the valve was made.
• CRN – This is the Canadian Registration Number.
Figure 61: Example Tag

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 62
17. Product Number System
Not all code combinations are valid product numbers. Not all possible configurations are shown. Consult Mercer Valve Co., Inc. for any
questions on valid product number configurations.
a) Valve Product Numbering

9100 Series Threaded

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 63
9100 Series Flanged

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 64
b) Repair Kit Product Numbering
Parts Included in Repair Kit:

1. Nozzle Subassembly
2. Disk Subassembly
3. Base Seal (Bottom Entry Only)
4. O-ring Set
Parts Not Included in Repair Kit:

 Socket for installing/ removing nozzle subassembly
o This may be specially ordered.
 Lubricants and adhesives

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 65
18. Exploded Views
Bottom Entry - 1” Body
Figure 62: Exploded View of 1" Body
See Table 13 for part identification.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 66
Figure 63: Exploded View of 2" Body

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 67
Top Entry – Threaded Bonnet
Figure 64: Exploded View of Top Entry Threaded Bonnet

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 68
Top Entry – Bolted Bonnet
Figure 65: Exploded View of Top Entry Bolted Bonnet

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 69
19. Cutaway View
Figure 66: Cutaway View of 1" Body
Table 13: Part Identification of 1” Body

ITEM NO PART NAME ITEM NO PART NAME
1 CAP 9 ADJUSTMENT SCREW
2 LOCKNUT 10 SET SPRING
3 WASHER 11 DISK SUBASSEMBLY
4 BONNET/BODY 12 NOZZLE/SEAT SUBASSEMBLY
5 CENTER BUSHING O-RING 13 NOZZLE BASE O-RING
6 CENTER BUSHING 14 INLET BASE SEAL
7 ADJUSTMENT BUSHING 15 INLET BASE
8 ADJUSTMENT SCREW O-RING

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 70
Figure 67: Cutaway View of 2" Body
Table 14: Part Identification of 2" Body

1 CAP 9 ADJUSTMENT SCREW O-RING
2 LOCKNUT 10 ADJUSTMENT SCREW
3 CENTER NUT 11 SET SPRING
4 BODY/BONNET 12 DISK SUBASSEMBLY
5 INDEX BRACKET 13 NOZZLE/SEAT SUBASSEMBLY
6 CENTER BUSHING O-RING 14 NOZZLE BASE O-RING
7 CENTER BUSHING 15 INLET BASE SEAL
8 ADJUSTMENT BUSHING 16 INLET BASE

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 71
Top Entry – Threaded Bonnet
Figure 68: Cutaway View of Top Entry Threaded Bonnet
Table 15: Part Identification of Top Entry Thread Bonnet

1 CAP 8 ADJUSTMENT SCREW
2 LOCKNUT 9 SET SPRING
4 ADJUSTMENT SCREW O-RING 11 NOZZLE/SEAT SUBASSEMBLY
5 BONNET 12 NOZZLE BASE O-RING
6 BONNET O-RING 13 BODY
7 ADJUSTMENT BUSHING 14 BODY PLUG

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 72
Top Entry – Bolted Bonnet
Figure 69: Cutaway View of Top Entry Bolted Bonnet
Table 16: Part Identification of Top Entry Bolted Bonnet

1 CAP 9 SET SPRING
2 LOCKNUT 10 LOWER SPRING GUIDE
4 ADJUSTMENT SCREW O-RING 12 NOZZLE/SEAT SUBASSEMBLY
5 BONNET 13 NOZZLE BASE O-RING
6 BONNET O-RING 14 BODY
7 ADJUSTMENT BUSHING 15 BODY PLUG
8 ADJUSTMENT SCREW 16 BONNET BOLTS

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 73
20. Trouble Shooting Guide
The following describes some, but not all, problems that could occur in PRVs. This list is not
exhaustive. Complicated problems and causes may exist, which require more involved solutions.
 Always take the proper safety precautions when working with PRVs.
 Always work on the valve within a controlled environment, not on an active pressurized
system.
1) Symptom
a) Possible Cause (ordered by priority)
i) Solution (ordered by priority)
1) There is a leak coming from the valve.

a) The disk is not initially fully seated against the nozzle.
i) Check for debris between the seat and disk.
b) The soft seat or disk is damaged.
i) Inspect the disk and seat for any signs of abrasions or damages. Repair or replace, as
necessary.
ii) Check media-material chemical compatibility.
c) The nozzle base o-ring is leaking.
i) Disassemble and inspect the nozzle/ seat subassembly. Replace, as necessary.
d) Valve is beginning to open (warning) because the operating pressure is approaching the set
pressure.
i) Check the operating conditions.
2) The valve is relieving at a pressure lower than the set pressure tolerance allows.
(Tolerance: -2 psi/ 15 kPa or -3% of set pressure, whichever is greater).
a) The valve’s settings are not correct.
i) Re-check the set pressure and adjust accordingly.
b) The valve’s seat is leaking.
i) Inspect the disk and seat for damages. Replace or repair, as necessary.
c) Pressure pulses/ spikes are causing the valve to relieve.
i) Check and make sure the operating conditions are suitable for the valve.
d) Vibrations are causing the valve to relieve.
3) The valve is relieving at a pressure higher than the set pressure tolerance allows.
(Tolerance: +2 psi/ 15 kPa or +3% of set pressure, whichever is greater).
a) The valve’s settings are not correct.
i) Re-check the set pressure and adjust accordingly.
b) The disk’s movement is being impeded.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 74
i) Inspect the inside of the valve, the set spring, and the bore of the adjustment screw for
build up or damages.
c) Superimposed back pressure is causing the valve to remain closed.
4) The valve is remaining open after it relieves and won’t return to the operating pressure.
a) Check and make sure the operating conditions are suitable for the valve. The recommended
target maximum operating pressure is 15% below set pressure for gas service and 20%
below for liquid service.
b) The disk’s movement is being impeded.
i) Inspect the inside of the valve, the set spring, and the bore of the adjustment screw for
debris build up or damages.
c) The disk or seat is damaged and is allowing large amounts of leakage.
i) Inspect the disk and seat for damages. Replace or repair, as necessary.
5) Valve is chattering.
a) Restrictions in either the inlet piping, outlet piping, or a combination of both are causing a
pressure drop or build up.
i) Check and make sure that there are no restrictions within the inlet piping that would
cause a pressure loss greater than 3% of the set pressure.
ii) Check and make sure that there are no restrictions within the outlet piping that would
cause a pressure build up greater than the allowable over pressure of the valve.
6) Set pressure has too much variation.

a) Valve’s components are dimensionally out of tolerance.
i) Check the critical dimensions.
ii) Check the spring to make sure it is correct for the set pressure and orifice.
b) Test equipment is providing false pressure readings.
i) Make sure the pressure gauges are calibrated.
ii) Verify that the test equipment is producing correct results. Consult NB23, Part 4,
section 3.2.5.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 75
CORPORATE HEADQUARTERS
9609 NW 4th STREET
OKLAHOMA CITY, OK 73127
1-800-833-6402
PHONE: (405) 495-6533, FAX: (405) 495-8728
[email protected]
FOR MORE INFORMATION PLEASE VISIT OUR WEBSITE AT
WWW.MERCERVALVE.NET
Other company names and product names used in this document are registered trademarks or tradenames of their respective owners.

Rev.: J
Date: 23-July-2020
ECN: 3152 Page | 76

9100 Series IOM Manual

Uploaded by

Copyright:

Available Formats

9100 Series IOM Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

9100 Series IOM Manual

Uploaded by

Copyright:

Available Formats

ENG-502000

INSTALLATION, OPERATION, &

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

American Petroleum Institute:

American Society of Mechanical Engineers:

National Board of Boiler Inspectors:

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

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

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

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

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

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

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

DO NOT USE BODY

Figure 1: 9100 Series Threaded Valve Wrenching Flats

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

See Figure 2 for an example installation of a pressure relief valve.

PIPING SIZE AT LEAST AS WEATHER

INLET CONNECTION SIZE

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

Important installation information is contained in Paragraph UG-135 and Appendix M of the

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

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

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

Start of Service Period

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

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

Cap Seal Wire

Pressed Security Seal

Figure 3: Typical Cap and Seal Wire

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

The procedures for testing set pressure are as follows:

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

Figure 4: API 527 Leak Check Apparatus

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

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

Figure 5: Diagram of Proper In Situ Testing Apparatus

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

Figure 6: Picture of Typical In Situ Testing

Figure 7: Typical Gas/Vapor Test Stand

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

Figure 8: Typical Liquid Test Stand Setups

c) Mobile Test Units

Figure 9: Typical Mobile Test Stand Setups

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

Figure 10: Lift Checking Apparatus

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

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

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

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

Figure 11: Different Sized Valve Bodies

a) 1” Body - Bottom Entry

Figure 12: 1” Body Upper Bonnet Components

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

Figure 13: Bottom Entry Thread Inlet Base Components

7. Rigidly support the inlet base to prevent movement during disassembly.

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

Nozzle Base O-ring

Figure 14: Nozzle/Seat Subassembly of Bottom Entry Valve