Professional Documents
Culture Documents
Balanced
Changes in inlet pressure do not change outlet pressure
Company Confidential Rev. 1/2006, Pg. 6 - JRA
P1 0 P2
P1 0 P2
P1 0 P2
The surface area of the valve plug equals that of the balancing diaphragm surface area.
Balancing diaphragm
Valve plug
Company Confidential Rev. 1/2006, Pg. 8 - JRA
Set: P1= 50 psig P2= 6" w.c. Q=500 scfh 0.6 gas 10.0 20 psig 50 psig 9.0 99 psig
Farm Taps High pressure drops Small diaphragm area Minimal boosting Low to High Setpoints
Commercial Service Low pressure drops Large diaphragm area High boosting Low Setpoints
Company Confidential Rev. 1/2006, Pg. 9 - JRA
8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0 500 1000 1500
2000
2500
3000
3500
4000
4500
Boosting
Stem
Vent
Lever
P1
Company Confidential Rev. 1/2006, Pg. 11 - JRA
P2
Stem
Lever
P1
Company Confidential Rev. 1/2006, Pg. 12 - JRA
P2
What happens when: P1 = P2 Control line break Pilot failed open Restrictor plugged Main spring broken Diaphragms broken No pilot P1 pressure Control line closed
Restrictor
PL P1
Spring open or spring closed design?
Company Confidential Rev. 1/2006, Pg. 13 - JRA
P2
Flow to open or close design?
Pilot
What happens when: P1 = P2 Control line break Pilot failed open Restrictor Plugged Main spring broken Diaphragms broken No pilot P1 pressure Control line closed
Bleed/Sense Line
PL
Spring
Diaphragm/Plug
P1
P2
Spring open or spring closed design?
Debris in gas stream, damaged boot fails High cycling damaged boot, heat related Constant flow rate and boot takes a set Wide open flow condition High pressure drops Gas entrainment into the rubber Bubba uses to much grease in upstream plug valve(dirt collector) Aromatics
Company Confidential Rev. 1/2006, Pg. 15 - JRA
Dirt/Poor Filtration
Dirty gas blew the inlet filter and destroys diaphragm and plugs cage
Cage erosion
P2
Lockup
Reseat
SYSTEM DEADBAND
Droop
Regulator
0
Q = FLOW
Temperature Changes
Example:
Regulator set at 7 WC Relief set at 14 WC Gas temperature = 50 degrees F
Apply General Gas Laws
P1abs* V1 /T1R = P2abs* V2/T2R Pipe heats up to 150oF at no flow conditions
Downstream Gas Temp Increase = 100oF Downstream Pressure goes to 3.18 PSIG
GasTemp = 50oF
Company Confidential Rev. 1/2006, Pg. 22 - JRA
Bubbas BBQ
Joe Morris Proprietor
7 wc
Regulator Freezing
Every 15 psi of pressure drop equals 1 degree F of cooling To avoid freezing the following can be done:
Heat the gas stream Heat the pilot supply Remove moisture from gas stream Inject antifreeze in pilot supply line
Company Confidential Rev. 1/2006, Pg. 24 - JRA
Installation Problems
Regulator vent locations Control line placement Tubing incorrect Needle Valves Environment susceptible to corrosion
Icing/Freeze Ups
Vent Piping
Restricted vent piping can cause the following:
Slow speed of response Instability Reduced IRV capacity
Vent Pipe Guidelines w/IRV Use same diameter pipe as vent Increase 1 pipe size for every 10 1 pipe elbow equals 3 of straight pipe Vent Pipe Guidelines wo/IRV Use same diameter pipe as vent Increase 1 pipe size for every 50 1 pipe elbow equals 3 of straight pipe
1 inch pipe
1 inch vent
Company Confidential Rev. 1/2006, Pg. 29 - JRA
TYPE 1805
Solution:
Plan the installation ahead of time using these guidelines:
Make the control line as short and straight as practical. Connect the control line 6 to 10 pipe diameters downstream of a turbulence generator (valve, tee, elbow, swage). Connect the control line to the point where the pressure is to be controlled.
Company Confidential Rev. 1/2006, Pg. 32 - JRA
Regulator In Swages
A B
RIGHT WRONG PRESSURE MAY BE LOWER IN THE SMALLER PIPING DUE TO HIGHER VELOCITY
Company Confidential Rev. 1/2006, Pg. 33 - JRA
A B
RIGHT WRONG PRESSURE MAY BE LOWER IN THE CONNECTING PIPING DUE TO HIGHER VELOCITY
Company Confidential Rev. 1/2006, Pg. 34 - JRA
Connect the control line at a location that is expected to be relatively free of turbulence.
A B
WRONG TOO CLOSE TO REGULATOR OUTLET CORRECT CONNECTION IS 6 TO 10 PIPE DIAMETERS DOWNSTREAM OF THE REGULATOR
Company Confidential Rev. 1/2006, Pg. 35 - JRA
Connect the control line at a location that is expected to be relatively free of turbulence.
A B
WRONG PIPE SIZE CHANGE (SWAGE) CAUSES TURBULENCE CORRECT CONNECTION IS 6 TO 14 PIPE DIAMETERS DOWNSTREAM OF THE SWAGE
Company Confidential Rev. 1/2006, Pg. 36 - JRA
CORRECT CONNECTION IS 6 TO 10 PIPE DIAMETERS DOWNSTREAM OF THE REGULATOR WRONG TOO MUCH TURBULENCE AT AN ELBOW CORRECT CONNECTION IS 6 TO 10 PIPE DIAMETERS DOWNSTREAM OF THE SECOND ELBOW. WITH THE CONNECTION AT THIS POINT, THE REGULATOR WILL COMPENSATE FOR PRESSURE LOSS THROUGH THE TWO ELBOWS.
Company Confidential Rev. 1/2006, Pg. 38 - JRA
B C
PROBLEM:
CONTROL LINE LOCATION APPEARS TO BE GOOD BUT REGULATOR CHATTERS.
SOLUTION:
THROTTLE THE NEEDLE VALVE SO THE REGULATOR IS NOT SUBJECTED TO TRANSIENT PRESSURE SPIKES. (DO NOT CLOSE THE VALVE)
THE FIRST CHOICE IS NOT TO INSTALL A VALVE IN THE CONTROL LINE THERE IS A SMALL FLOW (PILOT BLEED) DOWN THE CONTROL LINE. A RESTRICTION IN THE CONTROL LINE RESULTS IN A PRESSURE BUILD UP UPSTREAM OF THE RESTRICTION THIS RESULTS IN A FALSE PRESSURE SIGNAL TO THE PILOT AND ALSO CAN CAUSE CYCLING. IF A VALVE MUST BE INSTALLED, IT SHOULD HAVE A LARGE PORT AND BE IN THE FULL OPEN POSITION WHEN OPERATING.
Company Confidential Rev. 1/2006, Pg. 40 - JRA
P1
P2
P1
If common tap point is used, increase tubing diameter at least 2 pipe sizes to prevent interaction between pilot sensing and bleed.
Corrosive Environment
Casting Porosity
Noise is common when: Cap removed Flapper valve broken High P1 with orifice to large for inlet
Restricted piping
Too many valves, orifices, small diameter piping before the load
Turbulent Piping
Swages, elbows, meters can interject backpressure
Load Dynamics
Fast changing loads burners, furnaces, etc. Low flows turndown requirements High flow excessive turbulence, some regulators will close at higher flows over what is published
Boiler Loads
Use self operated whenever possible for maximum stability When using pilot operated, use a quick dump bleed pilot.
Quick dump bleed
Conclusion
Basic troubleshooting of any regulator will require a working knowledge of how regulators operate and how to apply them effectively.