History of Mooney Controls
• Founded by Dick Mooney in 1984
• Pilot added ~ 1990
• Acquired by Dresser 1998
• FlowMax added ~ 2001
• FlowTap added ~ 2005
• Acquired by GE in 2011
FLOWGRID REGULATORS
FlowGrid Design Goals
• Easy and Fast In-line Maintenance
• Consistent Low Minimum Differential
• Non Stretching Fabric Reinforced Diaphragm
Throttling Element
• High Frequency Response and Turndown Ratio
• Redundancy or Increased Capacity with Dual
Port Body
Components of the Flowgrid Regulator
Restrictor
Pilot
Loading Line
Sense Line
Outlet
Inlet Supply Line or
“Dump” Line
Filter Regulator Body
Basic Components
Cap Screws
Spring Case
Main Spring
Diaphragm
Throttle Plate
Body Seal
Body
Basic Components
Body
• A216 Grade WCB Steel
• Bi-directional
• Flanged, NPT, SWE, Buttweld,
Flangeless, and Dual Ports
Spring Case
• A216 Grade WCB Steel
• Directional (1”, 2”, 3” sizes only)
• Recessed spring pocket
Basic Components
Spring
• Bias to aid in Shutoff
• Adds Support to Diaphragm
• Stainless Steel Construction
• Low differential model available
Diaphragm
• Fabric reinforced construction
• Nitrile rubber (Buna-N) w/ Nylon fabric
• Design flexes, does not stretch
• Available materials:
• 60D / 75D Nitrile
• 80D Hi-ACN & Lo-ACN Nitrile
• Viton (limited sizes)
Diaphragm (Boot)
• Fabric reinforced construction consisting of Nylon
Fabric and Nitrile (Buna N) rubber.
• Diaphragm Flexes, Does not Stretch
• 4 Durometers of Material available
– 60 Durometer
– 75 Durometer
– 80 Durometer Hi-ACN
– 80 Durometer Lo-ACN
Throttle Plate
• Standard Construction - 17-4PH Stainless Steel
• Available Restrictions
– 35%
– 50%
– 75%
• Reversible and Bi-directional
• Drilled hole Throttle Plates available for high differential
applications (greater than 400 psid). Standard in 600 CL Flanged
and 8”, 12” regulators.
Seals
• Nitrile rubber
• Reusable
• “D” Seal is proprietary
• O-ring Seals are standard Parker seals
– 3 Middle numbers represent the Parker seal
number
Series 20 Pilot Connections
Supply to Pilot INLET
OUTLET port to outlet tap on
FlowGrid® valve
Sense SENSE port 10 pd downstream
of valve
Restrictor
LOADING port to top of
diaphragm
* Note that during static conditions inlet port
pressure, loading port pressure, and upstream
pressure P1 are the same.
Inlet Loading
Outlet
Series 20 Pilot Components
• Materials
– Brass
– Stainless Steel
• Spring Housing
• Body
• Insert Assembly
Modes of Operation
• Pressure Reducing (PRV)
• Back Pressure (BPV)
• Change made by reversing stem
Pilot with Cartridge removed
Pilot with Adjusting Spring Removed
Springs
Series 20 High Pressure Pilot
• Conversion pieces include
• High pressure Diaphragm
• Spacer Plate
• Diaphragm Plate
• Springs
Series 20L Low Pressure Pilot
• Bronze or Aluminum Construction
• Max. Inlet Pressure: 750 psi
• Uses the standard Series 20 cartridge
Series 20 Pilot Performance
MOONEY CONTROLS SERIES 20 PILOT PRESSURE REDUCING MODE RESTRICTOR SET AT 4
LOCK-UP DROOP (PSI) @ BOOST @ CONSTANT
SPRING RANGE COLOR
(PSI) MAX CAPACITY FLOW (PSI)
3-12 RED 1.0 0.3 0.7
10-40 CADMIUM 1.0 0.3 0.7
25-90 BLUE 2.0 0.6 0.7
60-200 PURPLE 2.0 1.30 0.7
100-260 BLACK 5.0 2.00 0.7
200-450 GREEN 10.0 4.00 0.7
Type 24 Restrictor
• Fixed orifice in the Pneumatic amplifier package
• Higher setting signifies less gain/less responsive
Tuning the Flowgrid Regulator
Restrictor Adjustment
• Larger setting for greater stability.
• Larger setting for faster shut-off.
• Smaller setting for increased sensitivity and
accuracy.
• Leave margin of safety.
• Adjust setpoint last.
Accessories - Type 30 Filter
• Aluminum, Steel, or Stainless Steel
• 1/4” NPT connections
• Porous Polyethylene element
• 10 micron rating for air/gas service
Applications
• District Regulator
• Monitor Regulator
• Relief Valve (BPV)
• Compressor Fuel Gas
• Co-Generation Fuel Supply
• Boiler Fuel Gas
Control Limitations and Criteria
Minimum Differential
• See Differential Chart - Color Brochure pg.6
Maximum Differential
• 800 psid (1000 psid for 1”)
Sense Line Placement
• 8 to 10 Pipe Diameters from Regulator
Gain/Proportional Band
TYPICAL REGULATOR DROOP
OUTLET PRESSURE (PSIG)
140
130
120 LOCKUP IDEAL
110 REGULATOR
100
90
DROOP
80
70
60
0 20 40 60 80 100
% CAPACITY OF REGULATOR
Flowgrid Applications
Pressure Reducing Systems
• Single Regulator
• Standby Monitor
• Working Monitor
Back Pressure / Relief Systems
• Single Regulator
Principle of Operation of Pilot Operated
Regulators with Unloading Type Pilot
Systems
Combination of Components
Basic Components
• Pilot & restrictor work together
• Pilot (Variable Orifice) to form a pneumatic amplifier.
• Restrictor (Fixed Orifice) • Unloading type system.
• Regulator (Control Element)
Variable Orifice
Fixed Orifice (Pilot)
(Restrictor)
P1 PL P2
Loading pressure
Upstream pressure Downstream pressure
Control Element
(Regulator)
Principle of Operation of Pilot Operated
Regulators with Unloading Type Pilot
Systems
Amplification From Difference In Discharge Rates
When the variable orifice discharge rate is greater than
the fixed orifice recharge rate we have amplification.
The greater the difference between the fixed orifice and
the variable orifice, the greater the amplification.
Reducing the fixed orifice size magnifies this effect.
Variable Orifice
Fixed Orifice (Pilot)
(Restrictor)
P1 PL P2
Loading pressure
Upstream pressure Downstream pressure
Control Element
(Regulator)
Principle of Operation of Pilot Operated
Regulators with Unloading Type Pilot
Systems
Decreasing fixed orifice size increases gain. Higher gain
means greater “accuracy” or ability to maintain downstream
pressure. However, higher gain also increases sensitivity to
instability.
Pilot
Restrictor (Variable Orifice)
(Fixed Orifice)
P1 PL P2
Loading pressure
Upstream pressure Downstream pressure
Regulator
(Control Element)
Pressure Reducing Application - Single Regulator
Fully Closed Partially Opened
Principle of Operation
Pressure Reducing Configuration (PRV)
Closed Position
• Outlet pressure above pilot set point.
• Pilot Closed.
• Full inlet pressure loads valve main
spring case.
• Pressure forces valve diaphragm
tight against valve outlet.
100 psi 10 psi
Outlet pressure
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
As downstream demand occurs
• Outlet pressure drops.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
As downstream demand occurs
• Outlet pressure drops.
• Pressure below pilot diaphragm is
reduced.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
As downstream demand occurs
• Outlet pressure drops.
• Pressure below pilot diaphragm is
reduced.
• Spring force above pilot
diaphragm overcomes pressure
below.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
As downstream demand occurs
• Outlet pressure drops.
• Pressure below pilot diaphragm is
reduced.
• Spring force above pilot
diaphragm overcomes pressure
below.
• Pilot begins to open, releasing
pressure from valve spring case.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
As downstream demand occurs
• Outlet pressure drops.
• Pressure below pilot diaphragm is
reduced.
• Spring force above pilot
diaphragm overcomes pressure
below.
• Pilot begins to open, releasing
pressure from valve spring case.
• Valve diaphragm begins to open.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…as demand
continues
• Pilot bleeds gas out of valve
spring case faster than it can enter
through restrictor.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…demand increases
• Reducing loading pressure above
valve diaphragm allows inlet
pressure differential to lift valve
diaphragm off throttle plate.
• Valve will remain open as long as
needed to satisfy demand.
100 psi 9 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…as demand is
satisfied
• Outlet pressure increases.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…as demand is
satisfied
• Outlet pressure rises.
• Pressure below the pilot
diaphragm builds and overcomes
pilot spring force.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…as demand is
satisfied
• Outlet pressure rises.
• Pressure below the pilot
diaphragm begins to build
overcoming spring force.
• Pilot begins to close, no longer
releasing pressure from valve
spring case.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…pilot begins to close
• Gas now enters through restrictor
faster than it can escape through
the pilot orifice.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…pilot begins to close
• Gas now enters through the
restrictor faster than it can escape
through the pilot orifice.
• Pressure builds above the valve
diaphragm forcing the diaphragm
toward the throttle plate.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…pilot closes.
• Outlet pressure reaches pilot set
point.
100 psi 10 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…pilot closes.
• Outlet pressure reaches pilot set
point.
• Pilot Closed.
100 psi 10 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…pilot closes.
• Outlet pressure reaches pilot set
point.
• Pilot Closed.
• Full inlet pressure loads valve
main spring casing.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Principle of Operation
Pressure Reducing Configuration (PRV)
…pilot closes.
• Outlet pressure reaches pilot set
point.
• Pilot Closed.
• Full inlet pressure loads valve
main spring casing.
• Pressure differential forces
diaphragm tight against throttle
plate stopping flow.
100 psi 9.5 psi
Fundamentals of Pressure Regulators
Pressure Reducing Application -
Standby Monitor
Fundamentals of Pressure Regulators
Confidential
Pressure Reducing Application -
Standby Monitor
Principle of Operation
Closed Position
• When outlet pressure is less than the set point of monitor regulator, monitor remains
wide open.
Set point Set point
35 psi 30 psi
100 psi 30 psi
Monitor Worker Fundamentals of Pressure Regulators
Confidential
Pressure Reducing Application -
Standby Monitor
Principle of Operation
Closed Position
• When outlet pressure is less than the set point of monitor regulator, monitor remains
wide open.
• Worker regulator is closed because outlet pressure is greater than or equal to set
point
Set point Set point
35 psi 30 psi
100 psi 30 psi
Monitor Worker Fundamentals of Pressure Regulators
Confidential
Downstream Demand
• When demand occurs outlet pressure begins to drop, opening
worker pilot, allowing worker regulator to open and satisfy
demand
• Monitor regulator remains open because downstream pressure
is below set point.
Set point Set point
35 psi 30 psi
100 psi 29 psi
Monitor Worker Fundamentals of Pressure Regulators
Confidential
Worker Regulator Failure
• Worker regulator loses ability to control sending high pressure
gas downstream.
• Monitor regulator senses the increase in downstream pressure
and takes control at 35 psi.
Set point Set point
35 psi 30 psi
100 psi 35 psi
Monitor Worker Fundamentals of Pressure Regulators
Confidential
Standby Monitor Advantages
• Normally lower ΔP across monitor reduces wear in
monitor.
• Upstream worker may catch debris before monitor.
• Downstream worker more accurate and responsive.
• Lower flow of gas through monitor pilot system.
• Low cost build.
• Monitor always in position to take over control.
Note: Token relief is recommended on all short or dead end systems.
Fundamentals of Pressure Regulators
Pressure Reducing Application -
Working Monitor System
Fundamentals of Pressure Regulators
Confidential
Pressure Reducing Application -
Working Monitor System
“Working” Monitor
“Worker”
Monitor
Override Pilot
Fundamentals of Pressure Regulators
Confidential
Pressure Reducing Application -
Working Monitor
Principle of Operation
1st stage Cut / Monitor 2nd Stage Cut
Fundamentals of Pressure Regulators
Confidential
Pressure Reducing Application -
Working Monitor
Principle of Operation
S
Set Point
Set Point
90 psi
95 psi
S
O
Set Point
350 psi
600 psi 350 psi 90 psi
1st stage Cut / Monitor 2nd Stage Cut
Fundamentals of Pressure Regulators
Confidential
Pressure Reducing Application -
Working Monitor
Should 2nd Stage regulator fail the 1st stage regulator can handle the
complete load requirements
2nd Stage Failure!
Set Point
Set Point
S 90 psi
95 psi
S
Set Point
350 psi
600 psi
95 psi
350 psi 95
90 psi
1st stage Cut / Monitor 2nd Stage Cut
Fundamentals of Pressure Regulators
Confidential
Working Monitor Advantages
• 2-stage pressure cut reduces stress on regulators by
distributing workload.
• Distributed workload reduces system maintenance
frequency.
• Reduced system noise for same mass flow.
• Performance of each regulator can be continuously
monitored.
• Condition of monitor regulator can be determined before
emergency condition arises.
• Cost effective long term.
Note: Token relief is recommended on all short or dead end systems.
Fundamentals of Pressure Regulators
Back Pressure Application - Single Regulator
Fully Closed
Back Pressure (BPV) Application -
Single Regulator
For gas relief
Principle of Operation applications P2 is
often vented to
Closed Position atmosphere
• Inlet P1 pressure below pilot set
point.
• Pilot closed.
• Full inlet pressure loads
regulator spring case and
diaphragm.
• Pressure forces diaphragm tight
against throttle plate.
P1
Fundamentals of Pressure Regulators
Confidential
As upstream pressure increases …
• Pressure below pilot diaphragm increases.
P1
Fundamentals of Pressure Regulators
Confidential
As upstream pressure increases …
• Pressure below pilot diaphragm increases.
• Pressure below diaphragm overcomes
spring force above diaphragm.
P1
Fundamentals of Pressure Regulators
Confidential
As upstream pressure increases …
• Pressure below pilot diaphragm increases.
• Pressure below diaphragm overcomes
spring force above diaphragm.
• Pilot opens releasing pressure from
regulator spring case.
P1
Fundamentals of Pressure Regulators
Confidential
As upstream pressure increases …
• Pressure below pilot diaphragm increases.
• Pressure below diaphragm overcomes
spring force above diaphragm.
• Pilot opens releasing pressure from
regulator spring case.
• Valve diaphragm lifts off throttle plate
allowing gas to flow.
P1
Fundamentals of Pressure Regulators
Confidential
As upstream pressure decreases …
• Inlet P1 pressure drops below
pilot set point.
• Pilot closed.
• Full inlet pressure loads
regulator spring case and
diaphragm.
• Pressure forces diaphragm tight
against throttle plate.
• Flow stops.
P1
Fundamentals of Pressure Regulators
Confidential
Advantages of Monitor vs. Relief
Advantages
• No gas is vented to atmosphere.
• Gas is continuously supplied to system at a safe level.
• Easy maintenance.
• Accurate control.
• Reduced noise with monitor (should relieve blow).
• Public is unaware the monitor takes over control.
• Accurate sizing is not required.
• Very cost effective.
