Regulator Selection Practices

and Mistakes to Avoid

Presenters

Vince Mezzano

Keith Erskine

Introduction
The purpose of this presentation is to provide an overview of Pressure Regulator operation, discuss selection criteria, and dispel common misconceptions which may lead to suboptimal selection and performance.

Sample Data Sheet

Sample Data Sheet

Sizing and Selection Information

Required
Process Data
P1, P2, Fluid Properties, Temperature, Flow Rate

Piping Specs
Materials, Connection Type and Size, ANSI Rating, Design Pressure and Temperature

Functionality
Back Pressure or Pressure Reducing Minimum Accuracy Requirements

Definitions:
Upstream pressure is P1. Downstream pressure is P2. Differential Pressure is the difference between upstream and downstream pressure.
PCV

Set @ 10 psig

Upstream Pressure (P1) Delta Pressure

Downstream Pressure (P2)

What is a Pressure Regulator?

A pressure regulator is a device that matches the downstream flow demand while maintaining the downstream pressure constant.

The simpler a system is the better it is. Regulators are simpler devices than control valves Performs the function of a VALVE, ACTUATOR, CONTROLLER, AND PRESSURE TRANSMITTER in one device Process-powered (does not need external power sources, its WIRELESS!) Field Adjustable Normally No Feedback (technology exists to communicate with BPCS strictly position feedback only) Regulators can be more cost effective than Control Valves.

Types of Regulators
ISA Symbols S5.1

Pressure Reducing Regulator, Self Contained

Pressure Reducing Regulator with External Pressure Tap

Differential Pressure Reducing Regulator with Internal and External Pressure Taps

Backpressure Regulator, Self Contained

Backpressure Regulator with External Pressure Tap

Specific Regulator Types / Definitions:

Pressure Regulators can be used to control downstream pressure, upstream pressure, or differential pressure. Pressure Regulators that control upstream pressure are typically referred to as backpressure regulators. (Relief Valves not ASME certified) Pressure Regulators in differential pressure service monitor both upstream and downstream pressure and hold a constant pressure differential. There are two types of pressure regulators: Direct-Operated and Pilot-Operated.SelfOperated regulators are mounted in-line and do not have any external to the process. A Pilot-Operated regulator is mounted in-line and has a sensing line connected to the process.

Direct-Operated Regulator

Also called Self-Operated Pressure Regulator (Vince Mezzanos First Choice)

Three Essential Components

1. Restricting Element (a valve, disk, or plug) 2. Measuring Element (a diaphragm) 3. Loading Element (a spring)

Self-Operated Regulator
Regulator has three basic components:
Loading - Spring

Sensing - Diaphragm

Restricting - Valve

Force Balance
1. Pressure = Force/Area (lb/In)
1 Inch Ad=10 in FS = 100 Lb FD = 100 Lb

2. Force = Pressure*Area (lb) 3. Spring Force (Fs)= K*X (lb)

K= spring rate (lb/In) X= Compression (In). Fs=Spring Force (lb) Fd= Diaphragm Force (lb)
P1 = 100 Psig Q = 50 SCFH P2 = 10 Psig

Fs = 100 lb/in x 1 in = 100 lb Fd = 10 psig x 10 in = 100 lb At Equilibrium

Increasing Demand
As flow demand increases, downstream pressure decreases. Fs= K * X (lb)
0.90 Inch FS= 90 Lb FD= 90 Lb P1=100 Psig P2 = 9 Psig Q = 200 SCFH

.1

Valve travels = 0.10 in

Actual Performance Droop/Offset

Droop is the amount of deviation from the set point at a given flow, Expressed as a percentage of set point.
P2 10% Psig 11 10 9 8 Ideal
20%

Actual

P1 = 100 psig

0 50

200

300

500

Flow scfh

Droop due to Diaphragm Effect

Assume:At rest Fs=Fd=100 lb & Ad=10 in Fs=P2(Ad), Solve for P2 P2=Fs/Ad=100 lb/10 in P2=10 lb/in Diaphragm area increases from 10 in to 11 inas it travels downward. P2=99 lb /11 in P2=9 lb/in

Spring Effect Reduces P2 furthermore

Recall: 1) The effective diaphragm area is 10 in at rest. 2) The Spring Force is 100 lb. 3) P2 desired is 10 lb/in. Now assume that the diaphragm travels downward 0.10 in to open the valve fully. The effective area of the diaphragm increases from 10 in to 11 in. In order to load the regulator with 100 lbs of downward pressure, the spring must be compressed 1 in, if the spring has a rate (K) of 100 lbs/in. Fs=K(X) Fs=100* (1-0.1)= 90 lbs. Solve for P2 by equating Fs=Fd Fs=P2(Ad) P2=90 lbs/11 in=8.2 lbs/in due to the diaphragm and spring effects.

Light Spring Rate Improves Accuracy

A light spring rate of 50 lb/in will open twice as far as it did with a heavy spring rate of 100 lb/in. For example#1 using heavy spring rate of K=100 lb/in, Solve for compression X, initially Fd=P2(Ad)=10(10) lb Fs=K(X) X=Fd/K X=100/100 = 1 in When P2 dropped from 10 psig to 9 psig. Fd=P2(Ad)=9(10) lb Fs=K(X) X=Fd/K

X=90/100 = 0.90 in

For example#2 using light spring rate of K=50 lb/in, Solve for compression X, initially Fd=P2(Ad)=10(10) lb Fs=K(X) X=Fd/K X=100/50 = 2 in When P2 dropped from 10 psig to 9 psig. Fd=P2(Ad)=9(10) lb Fs=K(X) X=Fd/K

X=90/50 = 1.80 in

Therefore, a spring with a range of 2 to 10 psig is more accurate than a spring with a range of 9 to 20 psig. If the set pressure of the PCV is 10 psig, the 2 to 10 psig spring will provide better accuracy or less droop.

Spring Effect on Accuracy

P2 Psig 11 10 9 8 Ideal Light spring Heavy spring
10% Offset 300 scfh

P1 = 100 psig

0-50

200

300

400

500

Flow scfh

Pilot-Operated Regulator

Loading Style (two-Path Control)

The pilot is simply a pressure amplifier. It detects a small change in downstream pressure and it increases the Loading Pressure 20 times as much. The pilot regulator uses upstream pressure as its supply, reduces this pressure, and loads the main regulator diaphragm with sufficient pressure to compress the main spring and open the regulator up to full travel. Use Pilot Pressure Regulators on large flow capacity and clean service.

Question #1
The upstream pressure (P1) is 100 psig and a differential pressure is 20 psid. What is the downstream pressure (P2) of a pressure regulator? a) 120 psig b) Delta Pressure = P1-P2 c) 20 psig d) None of the above Solve for P2=80 psig

Regulator Sizing

The manufacturers formulas and tables shall be used to size and select pressure regulators. The regulator shall be sized no more than 10% droop at maximum flow. Regulators should never be used in cavitating or flashing liquid service.

Regulator Applications & Typical Sizes

Pressure Reducing Back-Pressure/Relief Differential Pressure Sizes 1 to 8, up to ANSI 600 Where? - Boiler/Furnace/Burners Fuel Gas - Nitrogen Tank Blanketing - Instrument Air Supply - Compressor Fuel Gas - Water Systems - Natural Gas Distribution - Steam Supply - Lube Oil Systems, Pipelines, Farmtaps, Residential

Why Use a Pressure Regulator?

Non-critical applications Quick speed of Response Economic solution No external energy source required Low maintenance device Reliable solution to control pressure

Question #2
True or False. Heavy spring rate provides the most accuracy (least droop) than light spring rate. a) False b) True

Backpressure Regulators

A backpressure regulator maintains a desired upstream pressure by varying the flow in response to changes in upstream pressure. A pressure relief valve limits pressure buildup (prevents overpressure) at its location in a pressure system. The relief valve opens to prevent a rise of internal pressure in excess of a specified value. The pressure at which the relief valve begins to open pressure is the relief pressure setting. Relief valves and backpressure regulators are the same devices. The name is determined by the application. Back pressure regulators (relief applications) are not ASME safety relief valves.

Backpressure Regulator Selection Backpressure regulators control the inlet pressure rather than the outlet pressure. The selection criteria for a backpressure regulator is exactly the same as for a pressure reducing regulator.

Question #3

Which of the following answer reflects the ISA symbol of the Pressure Regulator? a)Self-Operated PCV with internal tap. b)Self-Operated PVC with external tap. c)Backpressure PVC with external tap. d)Backpressure PCV with internal tap. e)None of the above.

General Sizing Guidelines:

Pressure Ratings: Remember regulators can have different ratings between upstream and downstream. Make sure not to exceed the rated casing pressure. Spring selection: Choose the spring with the lowest spring rate that covers the required pressure range. Orifice diameter: Choose the smallest diameter that will handle the required flow.

Common Misconceptions
Pressure regulators control pressure; they do NOT regulate flow. Flow rate and controlled pressure are linked together; thus change in flow change in pressure. Regulators are best used in systems where flow changes are small. Regulators are NOT shut off devices.
All regulators with elastomeric seats are bubble tight, but wear or damage to seats could increase leakage.

Common Misconceptions
DO NOT hydrostatically test a regulator. Reducing regulators, in most cases, have two separate pressure/temperature ratings for the inlet and outlet. Failure Mode Depends on the component that fails
No air or power failure basis

Control Valve or Regulator?

Regulator Advantages
Self Contained Faster Speed of Response Less Complicated Lower Installed Cost Ease of Maintenance Flow Turndown

Control Valve Advantages

Larger Size, Pressure, and Temperature Capabilities Trim Selections (Severe Service) Material Selection Fluid Versatility Remote Interface and Feedback

Question #4
Upstream pressure = 200 psig. Differential pressure = 50 psig. What is the set point of a pressure regulator?
PCV

Set @ xx psig

Upstream Pressure (P1) Delta Pressure

Downstream Pressure (P2)

a)150 psig b)200 psig c)250 psig d)None of the above

Fuel Gas Compression Package

First Cut

Instrument Supply
source: SEC caterpillar compressor skid

Instrument Supply

Question #5
For Vapor Service, how does one know if the valve is in a Cavitation or Flashing Service? a) Downstream pressure is greater than Vapor Pressure. b) Upstream pressure is greater than Vapor Pressure. c) Downstream pressure is less than Vapor Pressure. d) Upstream pressure is less than Vapor Pressure. e) None of the above.

Summary:
Pressure Reducing Regulators a) Direct-Operated b) Pilot-Operated Backpressure Regulators (Relief Valves not ASME certified) Three Components on Pressure Regulators 1) Loading (Spring) 2) Sensing (Diaphragm) 2) Restricting (Valve or Plug) Droop, Proportional Band, or Offset.

Contd Summary -Self-Operated Regulator

Simplest and most cost effective final control element Offer the fastest speed of response Used on applications that require low flow capacity. 10%-20% Droop.

Contd Summary - Pilot-Operated Regulator

Fast speed of response Handles high flow capacity Larger body sizes, up to 8x6 More economical option to valve-actuator controller 1-3% Droop.

More Information

Website: http://www.fisherregulators.com/ Contact your local Emerson Local Business Partner