GE Masoneilan 77-6 User manual

GE Oil & Gas
GE Data Classification : Public
Masoneilan*
77-6 Model
Air Lock-up Valve
Instruction Manual

© 2016 General Electric Company. All rights reserved.
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE
INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE
PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY
AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO
PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE
REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY
HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN
CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR
REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO
PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION
OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE
WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE
REFERRED TO GE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO
THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL
REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY
THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION,
TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE
REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE.
2 | GE Oil & Gas

© 2016 General Electric Company. All rights reserved.
Safety Information
Important - Please Read Before Installation
These instructions contain DANGER, WARNING, and
CAUTION labels, where necessary, to alert you to
safety related or other important information. Read the
instructions carefully before installing and maintaining
your control valve. DANGER and WARNING hazards
are related to personal injury. CAUTION hazards involve
equipment or property damage. Operation of damaged
equipment can, under certain operational conditions,
result in degraded process system performance that
can lead to injury or death. Total compliance with all
DANGER, WARNING, and CAUTION notices is required
for safe operation.
CAUTION
CAUTION
WARNING
DANGER
This is the safety alert symbol. It alerts you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not
avoided, could result in serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
CAUTION
CAUTION
WARNING
DANGER
When used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided,
could result in property damage.
Note: Indicates important facts and conditions.
About this Manual
• The information in this manual is subject to change
without prior notice.
• The information contained in this manual, in whole or
part, shall not be transcribed or copied without GE’s
written permission.
• Please report any errors or questions about
the information in this manual to your local supplier.
• These instructions are written specifically for the 77-6
Model Air Lock-up valve control valves, and do not
apply for other valves outside of this product line.
Warranty
Items sold by General Electric are warranted to be free
from defects in materials and workmanship for a period
of one year from the date of shipment provided said
items are used according to GE recommended usages.
GE reserves the right to discontinue manufacture of
any product or change product materials, design or
specifications without notice.
This instruction manual applies to the 77-6 Model Air Lock-
up valve control valves.
Note:
• The 77-6 air lock-up valve MUST BE installed,
put into service and maintained by qualified and
competent professionals who have undergone
suitable training.
• Changes to specifications, structure, and
components used may not lead to the revision
of this manual unless such changes affect the
function and performance of the product.
• All surrounding pipe lines must be thoroughly
flushed to ensure all entrained debris has been
removed from the system.
• Under certain operating conditions, the use of
damaged equipment could cause a degradation of
the performance of the system which may lead to
personal injury or death.
CAUTION
CAUTION
WARNING
DANGER
Masoneilan 77-6 Model Air Lock-up Valve Instruction Manual | 3

© 2016 General Electric Company. All rights reserved.
Please read these instructions carefully BEFORE this
instrument is installed or maintained.
These converters are intended for use in industrial
compressed air systems only. Ensure that adequate
pressure relief provision is installed if application of system
supply pressure could cause downstream equipment to
malfunction. Installation should be in accordance with
local and national compressed air and instrumentation
codes.
Products certified for use in explosion-proof or intrinsically
safe installations MUST:
a) Be installed in accordance with local and national codes
for hazardous area installations, and in accordance
with this manual.
b) Only be used in situations which comply with the
certification conditions stated in this handbook.
c) Only be maintained by qualified personnel with
adequate training on hazardous area implementation.
Before using these products with fluids other than air or
for non- industrial applications consult GE.
Installation
Do not use for air pressures exceeding 250 psi.
Prior to installing, clean all lines thoroughly to remove
all dirt, scale or other foreign matter. Install the lock-up
valve in the controller output line as near to the control
valve diaphragm chamber as possible, holding the
number of connections to a minimum—so that the air
flows through the body in the direction indicated by the
words INLET and OUTLET marked on the underside of
valve body.
The signal pressure line should be connected upstream
of the air supply regulator to provide effective response
of the lock-up valve in the event of air failure. Be sure all
pipe connections are tight.
Do not install this Air Lock-up Valve in air lines
which exceed 250 psi (1.72 MPa, 17.2 bar) pressure.
CAUTION
CAUTION
WARNING
DANGER
CAUTION
CAUTION
WARNING
DANGER
Adjustment
The lock-up valve is normally factory set (i.e., 20 psi for
3-15 psi operation or 35 psi for 6-30 psi operation) and
should not require adjustment. If, however, it becomes
necessary to adjust the setting an air supply, with a
gauge and regulator, should be piped to the signal
pressure connection after: (1) relieving compression on
the range spring of the lock-up valve; and (2) connecting
the instrument output line to the inlet connection of the
lock-up valve.
Instrument output pressure need be sufficient only to
determine the open and closed position of the lock-up
valve. Turn the air supply pressure on until the pressure
gauge indicates the desired set pressure, then turn the
adjusting screw down until no air pressure may be felt
coming from the outlet of the lock-up valve. The valve
will be fully closed at this point.
Finally, tighten the adjusting screw locknut and connect:
(1) the lock-up valve outlet connection to the control valve
diaphragm chamber; and (2) the signal pressure line to
the signal pressure connection of the lock-up valve. Turn
on and set the air supply to operating pressure. Be sure
that all pipe connections are tight.
4 | GE Oil & Gas

© 2016 General Electric Company. All rights reserved. Masoneilan 77-6 Model Air Lock-up Valve Instruction Manual | 5
Maintenance
Due to their design and intended application,
maintenance difficulties are not expected to be
encountered with these valves. If they fail to perform in
a satisfactory manner, it may be due to accumulation
of dirt in one or more of the parts. If necessary to
disassemble, proceed as follows, after: (1) shutting off
supply pressure; and (2) relieving spring compression by
backing off the adjustment screw.
Remove the four body cap screws (16); body cap (15),
body cap O-ring (14), range spring (3), upper spring
button (2) and spring case (9) will come free from body (7).
To free diaphragm S/A (10) and inlet valve S/A (12) from
the body, place the wrench on the insert retainer (13) and
unscrew from the body insert (5). Remove the body insert
O-ring (6) and slide the diaphragm S/A, the body insert
and the inlet valve S/A from the body. Holding the inlet
valve from turning, unscrew inlet valve locknut (4) and
remove diaphragm S/A from the inlet valve. Turn the inlet
valve out of body insert.
Check all ports to be sure they are clear of dirt. Inspect
the diaphragm S/A for rupture or for damage around the
edge. If necessary, install a new diaphragm S/A. Check
the inlet valve for wear. If the inlet valve is roughed-up or
pitted, replace with new one.
To reassemble the lock-up valve, perform all operations
in reverse order to that used in disassembly. Note: The
O-ring on the inlet valve stem should be lubricated before
the inlet valve is reassembled in the body insert.
Note: Considering the high labor costs involved in
replacing internal parts, it may be more economical
to stock complete units.
Prior to performing maintenance on the Air Lock-up
Valve, shut off the supply pressure and remove the
spring compression by backing off the adjustment
screw.
It is recommended that the Air Lock-up Valve be
removed from the line for repairs.
Ref. Qty Part Name Ref. Qty Part Name
1 1 Adjusting Screw 9 1 Spring Case
2 1 Upper Spring Button 10 1Diaphragm S/A
3 1 Range Spring 11 1 Inlet Valve O-Ring
4 1 Inlet Valve Locknut 12 1 Inlet Valve S/A
5 1 Body Insert 13 1Insert Retainer
6 2 O-Rings 14 1Body Cap O-Ring
7 1 Body 15 1 Body Cap
8 1 Locknut • 16 4 Body Cap Screws
• Not visible in cutaway view.
Signal Pressure
16

© 2016 General Electric Company. All rights reserved.
6 | GE Oil & Gas
Notes

© 2016 General Electric Company. All rights reserved. Masoneilan 77-6 Model Air Lock-up Valve Instruction Manual | 7
Notes

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*Denotes a trademark of the General Electric Company.
Other company names and product names used in this document are
the registered trademarks or trademarks of their respective owners.
©2016 General Electric Company. All rights reserved.
GEA31168A 09/2016
www.geoilandgas.com/valves