Pressure regulatorsPressure regulators

PRESSURE REGULATORS INTRODUCTION

FUNCTIONThe function of a pressure regulator is to reduce a pressure and to keep this pressure as constant as possible while the inlet pressure and the flow may vary.

HOW DOES IT WORKA pressure regulator has a sensing element (piston, diaphragm or bellows) which is on oneside subject to loadforce (Fs) created by a spring or a gaspressure. On the other side thesensing element is subject to the force (F) of the controlled fluid. When the loadforce (Fs) ishigher than force (F) the valve will open until the two forces are in balance. As soon asforce (F) is equal to or slightly higher than force (Fs) the valve will close. At this point therequired outlet pressure has been reached.

INSTALLING A REGULATORlt is advisable to use a good filter close to the inlet of the regulator. Swarf, burrs, wire etc.may cause valve leakage. Therefore, before installing the regulator, clean all pipes andconnections. Avoid the use of teflon tape on pipe threads and be careful with anaerobic(loctite type) sealing compounds which may get into the regulator and lock moving parts.

HOW TO OPERATE A REGULATOR– Fully unwind the controlknob anti-clockwise.– Apply pressure to the regulator inlet. There should be no flow from the outlet port.– Wind the knob clockwise. The outlet pressure will continue to rise until the knob

adjustment stops. At any outlet pressure there should be no tendency to creep upwards.

– Wind the controlknob until the desired outlet pressure has been reached.Open the downstream valve to obtain flow through the system.You will now observe a small drop in the outlet pressure, which recovers when the flowstops.

TROUBLE SHOOTINGThe most common problem is rise in outlet pressure, which is almost invariably caused by a damage seat .

Seat damage: Quite often the seat is damaged by pieces of swarf – from welding or fitting – which bed in the seat causing leakage.

Remedy: Use a proper filter on the inlet of the pressure regulator.

Effect Causes Remedy

• Rise in outlet pressure 1. Damaged main valve seat Fit a new valve/seat2. Dirty main valve or seat Clean main valve3. Broken valve spring Renew spring4. Damaged O-ring on valve assembly Replace O-ring

• Continual bleed of media 1. Relief stem wrongly adjusted Readjustfrom vent port 2. Damaged relief valve of seat Replace(outlet pressure drops) 3. Relief valve spring broken Replace

4. Piston or piston plate O-ring damaged Replace O-ring

• lnability to control Broken main spring Replace

REGULATOR FEATURES• Balanced valve

In many of our regulators the valve is balanced so that inlet and outlet pressure have little influence on the position of the valve.Because of this variation in inlet pressure has little influence on the outlet pressure.

• Leaktightness on the seatOur manufacturing techniques guarantee leaktight shut-off ≤1x10-4 mbar l/sec.of the valve under no-flow conditions. However, a pressure regulator is nota stopvalve.Stopvalves should be installed upstream and downstream of a pressure regulator.

• Internal relief valveSome of our regulators have built-in relief valve (sometimes adjustable). This allows reducing of the outlet pressure in a no-flow situation by simply turnìngthe controlknob anti-clockwise.Note: This type of relief valve is not a safety valve!!

• Outlet pressure rangeAlways try to select the outlet pressure range in such a way that the maximum required pressure in your system lies close to the maximum pressure ofthe selected range. Regulators should not be used in the lower 10% of the outlet range.

HOW TO SIZE A PRESSURE REGULATORThe following information is required to select the most suitable regulator.– the maximum and minimum inlet and outlet pressure– the fluid– the flow requirement– the temperature– materials of construction

The next step is to calculate the:– seat orifice area (A1): the flow area between a valvestem and the seat with the valve fully opened.– outlet port area (A2): the area of the internal passage in the regulator outlet connection.

SIZING FOR GASPlease note that the following formula are used to determine the flow of air through a regulator. Correction factors for other gases are shown on the page.

Calculating the seat orifice area (A1)Use the formula: 0,67x A1x P1 = Q1

Calculating the outlet port area (A2)Use the formula:0,10 x A2 x P2 = Q2 (assuming a velocity in the downstream piping of 30 M/sec.)0,18 x A2 x P2 = Q2 (assuming a velocity in the downstream piping of 50 M/sec.)0,30 x A2 x P2 = Q2 (assuming a velocity in the downstream piping of 75 M/sec.)

A1 = seat orifice area in mm2

A2 = outlet port area in mm2

P1 = inlet pressure in bar absP2 = outlet pressure in bar absQ1 = flow of air in Nm3/hour through the seat orifice areaQ2 = flow of air in Nm3/hour through the outlet port area

Non-choked orificesA non-choked situation occurs when the outlet pressure (P2) is more than half the inlet pressure (P1).To make sure that the sizing is correct multiply flow Q1 by correction factor Y.

Correction factor YP2 (in bar abs.) Multiplyer YP1 (in bar abs.)

0,975 0,10,95 0,31 Formula: 0,67 x A1 x P1 x Y =Q10,925 0,520,9 0,60,85 0,710,8 0,80,75 0,860,7 0,910,65 0,950,6 0,980,55 0,990,5 1The maximum flow through a regulator is always the lesser of the calculated flows Q1 and Q2.

Correction for other gasesMultiply the maximum airflow through the seat area (Q1) by the following factors to obtain the specific gasflow.

Hydrogen : 3,81 Nitrogen : 1,02Oxygen : 0,95 Helium : 2,695Argon : 0,85 Neon : 1,28Carbon dioxide : 0,8 Carbon monoxide : 1,0Ammonia : 1,27 Methane : 1,8Acetylene : 1,05 Chlorine : 0,64Ethane : 1,0 Etylene : 1,03Hydrogen suiphide : 0,93 Nitrous oxide : 0,83Propane : 0,82 Sulphur dioxide : 0,68Lpg : 0,8 Natural gas : 1,30Correction of the flow through the outlet port area (Q2) is not required.

SIZING FOR LIQUIDSTo find the maximum water volume flow which will pass through the seat orifice area (A1) at a prevailing pressure drop use the formula:0,525 x A1 x √∆P = Q1To find the flow of water through the outlet port area (A2) use the formula:0,275 x A2 = Q2Q = flow in L/min. waterThis formula is based on a velocity (V) = 4,5 M/sec.The maximum flow possible through a regulator is the lesser flow of Q1 and Q2.

IR4000 Parker Hannifin Corporation’s Veriflo Division introduces the IR4000 Series internally threadless pressure regulator for instrument/analyzer and semiconductor applications.Instrument applications include gas management in refineries and process analyzer systems.Semiconductor applications for use on general purpose gas management – Air, Condensed Dry Air (CDA), and Plant Nitrogen –.The IR4000 is a high pressure regulator that can be ordered with a variety of options to meet a range of system design requirements.

Product Features and Benefits• Unique patented compression member loads the seal to the body without requiring a threaded nozzle

or additional seals to atmosphere.• Selection of seat materials for media compatibility and temperature applications.• Meets NACE standard MR0175.• Cleaned for Oxygen Service.• Fully swept design.• Internally threadless seat design to promote long seat life.• Convoluted, Hastelloy C-22® diaphragm provides high corrosion resistance and increased cycle life.

• Positive upward and downward diaphragm stops increases cycle life by preventing over stroking of the diaphragm.

• Minimize internal volume reduces cycle time to the analyzer.• Captured bonnet allows for safety venting.

• Standard units can be dome loaded.• The use of Inconel®, Hastelloy® and Elgiloy® provide superior corrosion resistance and high repeatability.• Close tolerances and tight alignment of moving components minimizes hysteresis.• Unique carrier design disperses gas uniformly through the regulator to improve purging.

IR6000Parker Hannifin Corporation’s Veriflo Division introduces the IR6000 Series internally threadless pressure regulator for pressure reducingindustrial/analytical applications including cylinder and calibration gases.The IR6000 is a high pressure regulator that can be ordered with a variety of options to meet a range of system design requirements.

Product Features and Benefits• Unique patented compression member loads the seal to the body without requiring a threaded nozzle or additional seals to atmosphere.• Selection of seat materials for media compatibility and temperature applications.

• Meets NACE standard MR0175.• Compression member for low internal volume.

• Fully swept design.• Internally threadless seat design to promote long seat life.• No threads in the wetted area minimizes potential particle generation that causes seat damage.

• Convoluted, Hastelloy C-22® diaphragm provides high corrosion resistance and increased cycle life.

• Positive upward and downward diaphragm stops increases cycle life by preventing over stroking of the diaphragm.

• Minimize internal volume reduces cycle time to the analyzer.• Captured bonnet allows for safety venting.

• The use of Inconel®, Hastelloy® and Elgiloy® provide superior corrosion resistance and high repeatability.• Close tolerances and tight alignment of moving components minimizes hysteresis.

• Unique carrier design disperses gas uniformly through the regulator to improve purging.

IR5000Parker Hannifin Corporation’s Veriflo Division introduces the IR5000 Series high pressure regulator. Veriflo Division continues the internally threadless design of the IR4000 family of products.Instrument applications include gas management for analyzer systems and other industrial processes. Semiconductor applications include general purpose gas management – Air, Condensed Dry Air (CDA), and Plant Nitrogen – Systems.The IR5000 is a high pressure regulator that can be ordered with a variety of options to meet a wide range of system design requirements.

Product Features and Benefits• Unique patented compression member loads the seal to the body without requiring a threaded nozzle

or additional seals to atmosphere.• Selection of seat materials for media compatibility and temperature applications.• Meets NACE standard MR0175.• Cleaned for Oxygen Service.• Fully swept design.• Internally threadless seat design to promote long seat life.• Convoluted, Hastelloy C-22® diaphragm provides high corrosion resistance and increased cycle life.• Positive upward and downward diaphragm stops increases cycle life by preventing over stroking of the diaphragm.• Minimize internal volume reduces cycle time to the analyzer.• Captured bonnet allows for safety venting.• Standard units can be dome loaded.• The use of Inconel®, Hastelloy® and Elgiloy® provide superior corrosion resistance and high repeatability.• Close tolerances and tight alignment of moving components minimizes hysteresis.• Unique carrier design disperses gas uniformly through the regulator to improve purging.

XPRVeriflo Division of Parker Hannifin Corporation introduces the XPR Series HighPressure Regulator. The new regulator safely reduces pressure from 10,000 psig(6,000 psig Brass) inlet down to as low as 50 psig by utilizing seven different ranges.The new self relieving feature comes standard with all XPR Series regulators.

Features• Bonnet assembly allows easy changeout.• Self relieving adjustment with allen wrench.• Self relieving allows downstream pressure to be vented through regulator.• Optional “T” handle.• Seven range assemblies available.• Non-self relieving option available.• Available for Panel Mounting (panel mount ring sold separately).• Bottom mounting holes (mounting bracket sold separately).

APR 66The APR-66 Series is a high pressurereducing single-stage regulatordesigned to operate at inletpressure up to 6000 psig.

Features• Piston sensing.• Thrust bearing allow low

actuating torque and precisesetability

• Optional self relieving feature allowsuser to decrease outlet pressure in closed systems (feature is actuatedby turning the adjusting knobcounterclockwise).

• Low friction adjusting screw sleeveprovides smooth operation.

NOTE: For safety purposes, the optional selfrelieving feature is not recommended for toxicor flammable gases of liquids.

ChangeOver SystemVeriflo’s ChangeOver System is a compact turnkey module designed for continuous gas and fluid management.The ChangeOver System combines the IR Series pressure reducing regulator with the NOVA Series diaphragm valves to create a compact gas delivery system for continuous gas or fluid applications.

This unique device directs the flow of gas from two separate sources to the user’s application.When one source empties, the ChangeOver System automatically draws from the secondsource. The first source can then be changed without flow interruption.

Features• Prevent unnecessary downtime by providing continuous uninterrupted gas flow.• Convoluted diaphragm provides outlet pressure stability with changes in flow.• Integral diaphragm stop provides excellent leak integrity.• Valve controlled high pressure purge allows user to clean or purge lines before adding a new cylinder.• Quick changeover control enhances safety by minimizing exposure to toxic and flammable media.• Designed for easy change of sources while in operation.• Separate gauges to monitor both inlet sources.• Available in Nickel Plated Brass or 316L Stainless Steel.• Alarm sensor port for systems integration allowing user to monitor gas consumption.• Optional outlet regulator maintains constant outlet pressure.• All Stainless Steel panel and trim designed available.• Especially suited for continous on-stream analyzers.

Quantum 959Veriflo Division’s Quantum 959 is a high purity, high pressuretied diaphragm regulator.The 959 regulator controls pressure flows accurately and predictably without changing the liquids or gases and without adding particles or ions to the flowing material.

Features• ”VeriClean”, Veriflo’s low

sulfur high purity 316L CAR, Stainless Steel enhances electropolishing, welding, and corrosion resistance.

• Subatmospheric pressure control available with the NPR959.

• Unique patented compression member loads the seal to thebody without requiring a threaded nozzle or additional sealsto atmosphere.

• Internally threadless nozzle assembly.• Metal-to-metal diaphragm to body seal assures high leak

integrity and lifetime bonding.• Aerodynamic, smooth flow passages.• Minimal particle generation and entrapment.• High cycle life.• 100% Helium leak tested.

LABORATORY REGULATORSSmall stainless steel regulators for low flow laboratory and instrumentation applications.• material ss 316L• gases and liquids• inlet pressure up to 400 bar• elastomer, pfe or metal

diaphragms

DOMELOADED REGULATORSThese are domeloaded or airloaded regulators with integral springloadedpilot regulators or with integral proportional pilot regulators:The latter is really an electropneumatic PID controller. With pressure transducers a closed loop system can be created.• operates on shop air• millisecond response• no worries about droop or dependancy• manual, remote or computerised control of pressure• sizes 1/2” - 3”

SPRINGLOADED REGULATORSThis family of springloaded pressure regulators comprises 1/2” to 3” models.• available in brass and ss 316L• bsp, flanges to DIN or ANSI, weld connections• pressure ranges 70 bar - 400 bar• suitable for gases and liquids• internal filtration

LOW PRESSURE REGULATORSMedium to high flow regulators for low pressureindustrial applications such as bollers, furnaces and ovens.• material ss 316L• outlet pressures as low as 100 mbar• sizes 3/4” - 3”• direct acting or pilot-operated

PRESSURE REGULATORS FOR TANKBLANKETINGRHPS supplies a complete program of regulators for tankblanketing pressure control, such as pressure

reducing regulators, backpressure regulators,vacuumbreakers, differential pressureregulators etc.We specialise in stainless regulators for relatively small flows used in chemical and pharmaceutical batch processes.• material ss 316L, exotic alloys• 1/2”, 1”, 2” bsp connections or flanges

to DIN or ANSI• angle pattern

BACK PRESSUREREGULATORS

These springloaded backpressureregulators are the big brothers

of the Blue Knob Line.• available in 1” - 3”

• bsp connections, flanges to DIN or ANSI• set pressures up to 70 bar

THE BLUE KNOB LINE• available in brass and ss 316L• bsp connections, flanges to DIN or ANSI• set pressures up to 400 bar