SALES PURCHASING

(800) 833-6402 Post Office Box 270970 (405) 789-2994

(405) 495-6533 Oklahoma City, Oklahoma 73137 (405) 789-0664
FAX # (405) 495-8728

ACCOUNTING ENGINEERING
(405) 495-7178 (405) 495-3274

MERCER VALVE COMPANY, INC.

9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INSTALLATION The safety relief valve should always be installed on a tank or piping run in the
vertical position with the valve outlet pointing in a horizontal direction. When
screwing the valve into the inlet piping, always use the wrench flats on the inlet
connection. Never put a wrench on the relief valve body.

One of the most common causes of early failure of relief valves is dirt trapped on
the valve seat. Welding slag and/or piping Teflon tape are among the more
common items that cause difficulty. It is recommended that all piping and tank
systems be cleaned prior to installation of the relief valve.

A relief valve should be connected with the minimum amount of piping between
the tank and valve. Further, all piping used must be equal or larger than the inlet
pipe size of the relief valve, never smaller. Any restriction of the inlet to a relief
valve may cause unusual valve chatter, which could result in serious damage to
the valve. Piping restrictions can also can also cause the valve to not relieve its
full capacity causing the valve not to be able to reduce the pressure increase.
Outlet piping from the relief valve should be less than four (4) feet in length and
never of a pipe size smaller than the outlet pipe size of the relief valve. Long runs
of small diameter pipe on the outlet side of a relief valve will create valve chatter
and a capacity reduction that can cause the system to not be protected.

Extreme caution is required in the outlet piping if installed where liquids, if

present, could form an ice block in the piping of the relief valve body in below
freezing conditions. Discharge lines must be “weathered capped” and provided
with a drain hole to prevent any liquid collection in the relief valve body or outlet
piping. This liquid can freeze and cause the valve to not open or reduce the
capacity of the valve. If these precautions are not taken the valves will not protect
the system.

Additional, important installation information is contained in Paragraph UG-135,

Section VIII of the ASME Code.

REVISION B PAGE 1 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

OPERATION For best performance in process work is usually obtained by setting the safety
relief valve to open at least 15% above the operating pressure where possible. A
greater margin is desirable. However, this setting must not exceed the maximum
working pressure of the vessel. All Mercer 9100 Series Safety Relief Valves are
checked for bubble-tight per API 527.

In Addition to checking the set pressure versus the maximum allowable working
pressure of the vessel, also check to insure that back pressure and temperature
limitations of the process are consistent with valve ratings. The fluid state,
capacity, temperature, set pressure, and back pressure can all be found on the tag
of the valve. Pressures and Temperatures outside the normal ranges require
special materials. Further, carefully check the process fluid input capacities to
insure that the relief valve capacity is greater than the process capacities.

DO NOT BREAK THE SEAL WIRE Breaking the seal wire invalidates the
manufacture’s warranty to repair or replace the valve. If resetting is required in a
field emergency situation a qualified personnel with calibrated instrumentation
should perform it. With a broken seal wire this valve will be considered a non
ASME code valve until it has been repaired by a VR certified repair shop.

REVISION B PAGE 2 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

DISASSEMBLY: The following general procedure is recommended in disassembly inspection

and cleaning of the relief valve:

1. Cut the wire seal and unscrew the cap to expose the adjustment screw.
2. Loosen the lock nut and relieve the tension on the spring by turning
the adjustment screw counter clockwise. This will relieve the spring
tension.
3. Secure the valve body so that it will not move
For orifice sizes C to G, unscrew and remove the inlet base
For orifice size of H, unscrew and remove the bonnet
For orifice sizes J and K, unbolt and remove the bonnet
4. Inspect the replaceable seat for cuts and abrasions. If there are only
minor scratches or abrasions on the seat, polish the seat area lightly
with Scotch-Brite #7447. Be careful not to damage the soft seat. If
the seat is damaged with deep abrasions and cuts, replace the
nozzle/seat subassembly.
5. Refer to Figure 1 and measure the diameter of Ds with a precision
caliper. This diameter must be in the range of values listed in Table 1.
If this is not the case, replace the nozzle/seat subassembly.
TABLE 1

DIAMETER Ds (INCHES)
ORIFICE
SIZE MINIMUM MAXIMUM
“C” .335 .337
“D” .480 .482
“E” .620 .622
“F” .778 .780
“G” .914 .916
“H” 1.242 1.2465
“J” 1.599 1.6025
“K” 1.899 1.903

REVISION B PAGE 3 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6. Remove and inspect the disk subassembly, especially the spherical surface
portion that engages the seat. This surface must be clean and smooth.
Polishing this surface with Scotch-Brite #7447 may restore the disk if it has
only minor imperfections. If the spherical surface is damaged or scratched,
replace the disk subassembly

7. Refer to Figure 2 and measure the diameter of Dd with a precision caliper.

This diameter must be within the range of values listed in Table 2. If this is
not the case, replace the disk subassembly.

TABLE 2
DIAMETER Dd (INCHES)
ORIFICE
SIZE MINIMUM MAXIMUM
“C” .331 .333
“D” .474 .477
“E” .614 .616
“F” .768 .771
“G” .904 .906
“H” 1.228 1.231
“J” 1.580 1.583
“K” 1.876 1.880

8. Check the disk stem of the disk subassembly to insure that the surface is
smooth. Polish the stem if necessary with Scotch-Brite or fine emery. If the
stem is galled, replace the disk subassembly.
9. Remove the spring and inspect for wear or damage. Clean and replace the
spring if necessary. Be sure the spring is straight and square. If not replace
the spring.
10. Remove the adjustment screw and guide bushing by tapping on the top of the
adjustment screw with a “soft” drive rod. The guide bushing is designed to
“slip fit” into the internal machined bore of the body. This “slip fit” must be
maintained by cleaning the outside diameter of the guide bushing and internal
bore of the valve body.
11. Replace the o-ring found on the adjustment screw stem.
12. DO NOT REMOVE THE CENTER NUT OR INDEX BRACKET
SUBASSEMBLY. They are permanently installed at the factory. The
purpose of the index bracket subassembly is to prevent rotation of the guide
bushing. A body side pin is used in the 9100 “C” AND “D” orifices in place
of the index bracket.
13. Lubricate the outside diameter of the adjustment screw thread, outside
diameter of the guide bushing, the adjustment screw o-ring and the internal
upper machined bore of the valve body with a good lubricating grease.

REVISION B PAGE 4 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

REASSEMBLY: The following general procedure is recommended in reassembly and setting of the valve:

1. Before reinstalling the adjustment screw and guide bushing, position the
adjustment screw with the upper end of the thread protruding 1/8” from the
end of the guide bushing. Carefully “slip fit” this assembly into the body,
fitting the index bracket leg or body side pin into the slotted portion of the
guide bushing. Note that the guide bushing must slip into the valve bore
freely but with little radial play. Remove and reclean parts if the parts do
not easy fit in. DO NOT FORCE THE GUIDE BUSHING INTO THE
VALVE BODY. Forcing the parts may restrict valve lift and cause serious
malfunction.
2. Swab out the internal bore of the adjustment screw to insure that is is clean
and free from obstructions like dirt and grease.
3. Before reinstalling the spring, insert the disk subassembly 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.
4. Reinstall the spring and the disk subassembly. The spring should slide over
the disk freely without sticking. Make sure the correct spring is installed.
5. Install the nozzle subassembly into the inlet base or body, for whichever
applies.
6. For bottom entry valves reinstall the inlet base subassembly using a new
base seal. Caution, the inlet base must be tight against the base seal and
body.
For top entry valves reinstall the bonnet subassembly.
Make sure the disk and nozzle are aligned.
7. Check the lift of the valve by inhering a properly shaped drive rod in an
arbor press into the internal bore of the inlet base and pressing on the nose
of the disk subassembly. Apply a slight spring tension to the valve disk.
Measure the “lift” of the valve with a dial indicator. The minimum lift can
be found in NB-18 on the National Board website www.nationalboard.org.
8. Reinstall the lock nut and the valve is ready for setting. Valve setting at all
pressures is dangerous. All eye and ear safety precautions should be
observed.
9. Resetting should be performed using the correct fluid. Gas/Vapor valves
should be set with air and liquid valves should be set using water. Mercer
Valve recommends that for gas/vapor valves there be approximately (1)
cubic foot capacity below the valve when setting. To see other valve
characteristics a larger vessel may be required. The test gauges should be at
least .25% accuracy and be currently calibrated using a dead weight tester.
10. Repeated “popping” at set pressure is recommended. The valve should be
popped approximately five (5) to ten (10) times during the setting process
allowing full blowdowns.
11. A slight audible warning action is to be expected, starting approximately 5%
below the set pressure.
12. All valves should be bubble tight at 10% below set pressure in accordance
with API 527.
REVISION B PAGE 5 3/13/05
 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

13. When the valve is set, tighten the lock nut securely so at least 1/4” of the
stem is exposed above the lock nut. The adjustment screw must not turn
when the lock nut is tightened. This will affect the set pressure. Pop the
valve once more after the lock nut is tightened to verify the set pressure.
14. Reinstall the cap and a new lockwire. Close the lockwire and crimp the lead
seal.

REVISION B PAGE 6 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

BACK PRESSURE TESTING The purpose of back pressure testing Mercer Safety Relief Valves is to
check for leaks in the secondary pressure zone (the outlet side of the relief valve).
This includes the body, bonnet, outlet flange and all parts included in the upper
valve assembly. This is best performed before the valve seal wire has been
attached.

The back pressure test is performed after the valve has been assembled and set to
the correct set pressure. The test is performed by attaching a pressure source to
the outlet of the valve and submerging the valve in a solution of water treated
with rust inhibitor. The pressure in the secondary pressure zone is then brought to
30 psig or to what the back pressure the valve will see. 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. If any part of the valve is producing bubbles, the
valve is disassembled, repaired and the valve is reassembled and retested. If no
leaks are detected, the valve is stamped with the appropriate set pressure, the
valve then goes to the finishing department to be painted, tagged, and prepared for
shipping.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THE

PRECEDING PROCEDURES, FEEL FREE TO CONTACT THE FACTORY
AT (405) 495-6533 or 800-833-6402. Phones are answered 24 hours a day.

REVISION B PAGE 7 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

“C”, “D”, AND “E” ORIFICE STANDARD BILL OF MATERIALS

“C” ORIFICE DIAMETER: .281 In.
“C” ORIFICE AREA: .062 Sq.In.
SET PRESSURE RANGE: 15-2999 PSI

“D” ORIFICE DIAMETER: .394 In.

“D” ORIFICE AREA: .122 Sq.In.
SET PRESSURE RANGE: 15-2999 PSI

“E” ORIFICE DIAMETER: .520 In.

“E” ORIFICE AREA: .212 Sq.In.
SET PRESSURE RANGE: 15-2400 PSI

“C”, “D”, AND “E” ORIFICE

“C”, “D”, “E”
ITE “D” & “E” STD
PART “C” ORIFICE STD MTRLS OPTIONS
M MTRLS
NAME “C” TRIM CODE “U”, “L”, “N”, OR “B”
NO. “I” TRIM CODE
CODE
Carbon Steel or 316 Carbon Steel or 316 Carbon Steel or 316
1 Inlet Base
Stainless Steel Stainless Steel Stainless Steel
Carbon Steel or 316 Carbon Steel or 316 Carbon Steel or 316
2 Base Seal
Stainless Steel Stainless Steel Stainless Steel
3 O’Ring Viton Viton Viton
Nozzle 17-4 Stainless Steel 17-4 Stainless Steel 316 Stainless Steel
4
Subassy with Soft Seat with Soft Seat with Soft Seat
Disk
5 440C Stainless Steel 17-4 Stainless Steel 316 Stainless Steel
Subassy
WCB Carbon Steel or WCB Carbon Steel or WCB Carbon Steel or
6 Body
CF3M Stainless Steel CF3M Stainless Steel CF3M Stainless Steel
17-7 Stainless Steel or
7 Spring 17-7 Stainless Steel 17-7 Stainless Steel
Inconel X-750 (NACE)
Adjustment 300 Series Stainless 300 Series Stainless
8 300 Series Stainless Steel
Screw Steel Steel
Adjustment 300 Series Stainless 300 Series Stainless
9 300 Series Stainless Steel
Bushing Steel Steel
10 O’Ring Buna N Buna N Buna N
Center 300 Series Stainless 300 Series Stainless 300 Series Stainless
11
Bushing Steel Steel Steel
12 O’Ring Buna N Buna N Buna N
13 Washer Carbon Steel Carbon Steel Carbon Steel

14 Lock Nut Carbon Steel Carbon Steel Carbon Steel

15 Cap Anodized Aluminum Anodized Aluminum Anodized Aluminum

REVISION B PAGE 8 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

“F” AND “G” ORIFICE STANDARD BILL OF MATERIALS

“F” ORIFICE DIAMETER: .655 In.
“F” ORIFICE AREA: .337 Sq.In.
SET PRESSURE RANGE: 15-2400 PSI

“G” ORIFICE DIAMETER: .775 In

“G” ORIFICE AREA: .472 Sq.In.
SET PRESSURE RANGE: 15-2000 PSI

“F” AND “G” ORIFICE

ITE PART “F” AND “G” ORIFICE STD MTRLS “F” AND “G” STD MTRLS
M NAME “U”, “L”, “N”, OR “B” TRIM CODE “C” TRIM CODE (High Pressure)
NO.
1 Inlet Base Carbon Steel or 316 Stainless Steel Carbon Steel or 316 Stainless Steel
2 Base Seal Carbon Steel or 316 Stainless Steel Carbon Steel or 316 Stainless Steel
3 O’Ring Viton Viton
Nozzle
4 316 Stainless Steel with Soft Seat 17-4 Stainless Steel with Soft Seat
Subassy
Disk
5 316 Stainless Steel 440C Stainless Steel
Subassy
WCB Carbon Steel or WCB Carbon Steel or
6 Body
CF3M Stainless Steel CF3M Stainless Steel
17-7 Stainless Steel or
7 Spring 17-7 Stainless Steel
Inconel X-750 (NACE)
Adjustment
8 300 Series Stainless Steel 300 Series Stainless Steel
Screw
Adjustment
9 300 Series Stainless Steel 300 Series Stainless Steel
Bushing
Index
10 300 Series Stainless Steel 300 Series Stainless Steel
Bracket
Center
11 300 Series Stainless Steel 300 Series Stainless Steel
Bushing
12 O’Ring Buna N Buna N
13 Center Nut Carbon Steel Carbon Steel
14 O’Ring Buna N Buna N
15 Lock Nut Carbon Steel Anodized Aluminum
16 Cap Anodized Aluminum Anodized Aluminum

REVISION B PAGE 9 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

“H” ORIFICE STANDARD BILL OF MATERIALS

“H” ORIFICE DIAMETER: 1.050 In.
“H” ORIFICE AREA: .865 Sq.In.
SET PRESSURE RANGE: 15-2000 PSI

“H” ORIFICE
ITE PART “H” ORIFICE STD MTRLS “H” ORIFICE STD MTRLS
M NAME “U”, “L”, “N”, OR “B” TRIM “C” TRIM CODE (High
NO. CODESteel or
WCB Carbon Pressure)
WCB Carbon Steel or
1 Body
CF3M Stainless Steel CF3M Stainless Steel
2 O’Ring Viton Viton
Carbon Steel or Carbon Steel or
3 Drain Plug
Stainless Steel Stainless Steel
Nozzle 17-4 Stainless Steel
4 316 Stainless Steel with Soft Seat
Subassy with Soft Seat
Disk
5 316 Stainless Steel 440C Stainless Steel
Subassy
17-7 Stainless Steel or
6 Spring 17-7 Stainless Steel
Inconel X-750 (NACE)
7 O’Ring Buna N Buna N
Adjustment
8 300 Series Stainless Steel 300 Series Stainless Steel
Screw
Bonnet Carbon Steel or Carbon Steel or
9
Subassy 316 Stainless Steel 316 Stainless Steel
Adjustment
10 300 Series Stainless Steel 300 Series Stainless Steel
Bushing
11 O’Ring Buna N Buna N

12 Washer 300 Series Stainless Steel 300 Series Stainless Steel

13 Lock Nut 18-8 Stainless Steel 18-8 Stainless Steel

14 Cap Anodized Aluminum Anodized Aluminum

REVISION B PAGE 10 3/13/05

 MERCER VALVE COMPANY, INC.
9100 SERIES THREADED SAFETY RELIEF VALVES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

“J” AND “K” ORIFICE STANDARD BILL OF MATERIALS

“J” ORIFICE DIAMETER: 1.350 In.
“J” ORIFICE AREA: 1.430 Sq.In.
SET PRESSURE RANGE: 15-1800 PSI

“K” ORIFICE DIAMETER: 1.625 In.

“K” ORIFICE AREA: 2.074 Sq.In.
SET PRESSURE RANGE: 15-1500 PSI

“J” AND “K” ORIFICE

ITEM PART “J” AND “K” STD MTRLS “J” AND “K” STD MTRLS
NO. NAME “U”, “L”, “N”, OR “B” TRIM “C” TRIM CODE (High Pressure)
CODESteel or
WCB Carbon WCB Carbon Steel or
1 Body
CF3M Stainless Steel CF3M Stainless Steel
2 O’Ring Viton Viton
Carbon Steel or Carbon Steel or
3 Drain Plug
Stainless Steel Stainless Steel
Nozzle 17-4 Stainless Steel
4 316 Stainless Steel with Soft Seat
Subassy with Soft Seat
Disk
5 316 Stainless Steel 440C Stainless Steel
Subassy
17-7 Stainless Steel or
6 Spring 17-7 Stainless Steel
Inconel X-750 (NACE)
7 O’Ring Buna N Buna N
Alloy Steel B7 or Alloy Steel B7 or
8 Bonnet Bolt
Stainless Steel B8M Stainless Steel B8M
Adjustment
9 300 Series Stainless Steel 300 Series Stainless Steel
Screw
Adjustment
10 300 Series Stainless Steel 300 Series Stainless Steel
Bushing
Bonnet Carbon Steel or Carbon Steel or
11
Subassy 316 Stainless Steel 316 Stainless Steel
12 O’Ring Buna N Buna N

13 Washer 300 Series Stainless Steel 300 Series Stainless Steel

14 Lock Nut 18-8 Stainless Steel 18-8 Stainless Steel

15 Cap Anodized Aluminum Anodized Aluminum

REVISION B PAGE 11 3/13/05