Module 11 - Pressure Regulators, Overpressure Protection, Meters, and Fuel Containers2

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GAS TRADE TRAINING UNIT 11

October 2019
Title: Pressure regulators , overpressure protection, meters , and fuel containers
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GAS TRADE TRAINING UNIT 11
Pressure regulators, overpressure
•
protection, meters, and fuel
•
containers
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Pressure regulators, overpressure protection, meters, and fuel
GAS TRADE TRAINING UNIT 11 containers
Contents
Overview .................................. ..................................... ..................................... ......................... 7
Purpose ......................... ................................. .................................................... ............ 7
Objective s .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ..... .. ... .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. ... .. .. 7
Gas trad e trainin g and Red Seal alignm e nt ............... ................................... ................. 7
Pressure regulators .................... ................................... ................................. ........................... 9

Overvi ew .................. ................................... ........................................ ............................ 9
The need for pressure regulators ............ ................... ................................... ............... 10
Basic operation of a regulator ............. ................................................... ................. ...... 14
Codes ............. ....................................... ............... ......................................................... 29
Different types of regulators .................. .......................... ................................ ............. 34
Selection requirem ents ............ ....................................... ......................................... ..... 52
Location and piping practice ............................... ............... ....................................... .... 60
Troubleshooting of regulators ............. ....................... ......................................... .......... 61
Appendix : Typical regulat or se lection guide and capacity tables ................................. 64
Overpressure protection ................ ................... ...................... ................................................ 76

Overv iew ......................................... .................................................................. ............ 76
Introduction .................. ................... ........... ........................ ........................................... 76
Relief va lves ...................................... ....................................... ............... ..................... 78
Pressure limitin g regulator system s ........... ....................................... ........................... 85
Automati c shut-off ................................. ............. ........................ ................................... 89
Meters ................................ ............................................................................................. ........... 91

Overvie w ......................... ...................... ............................ ............. ............................... 91
Types of meters ........... ....................................... ................... ................................... .... 92
Determining flow rates .................... ...... ................................... ............... ............... ....... 9 7
Fuel containers ....... .. ............ .. ......... ....... ... .. .. . ...... ... .. .. ....... ....... ... .. .. ....... ... .... ....... ....... ... .. .. .. 107
Ove rview ...... ....... ....... ....... ....... ....... ..... .. ....... ............................................................. . 107
Cylinders , tanks , and accessori es ........ .............. ................................... ..................... 107
Sizing and installing cylinders and tank s ................................... ................................. 123
Appendix A: vapouri zation rates for tanks and cylinders ........................................... 133
Appendix B : Install ation clearances for tank s and cy linders ...................... ............... 135
Figures
Figure 1-1 - Propane installatio n ...................... ............................ ............................ ............... 12
Figure 1-2 - Natural gas installation showing loc ation of service regulat or and line pressure
regulators ....... ............... ....................................... ......................................... ....... 13
Figure 1-3 - Direct-operated regulator ............... ......................................... ............. ................ 14
Figure 1-4 - Graph depicting the performance of a typical regulat or ...................................... 17
Figure 1-6 - Regulator thre aded remova ble orifi ce ................................................................. 20
Figure 1-7 - Adjusting regulat or ................... ....................... ................ ..................................... 2 1
Figure 1-8 - Ve nt limiting orifice .......................................................... ....................... .............. 22
October 2019 1
Figure 1-9 - Vent limiting orifice accessory ............................................................................. 23

Figure 1-10- Leak limiting devices ................ .......................................................................... 24
Figure 1-11 - Multi position 2 psi regulator ................................................. ............................. 25
Figure 1-12 - Pitot tube and lever features ................. ....................................... ...................... 26
Figure 1-13 - Regulator with internal relief valve ..................................... ................................ 26
Figure 1-14 - Regulator with overpressure shut-off and two-way stabilizer vent
valves ................................................................................................................. 28
Figure 1-15-Allowed locations for vent terminations per Table 5.2 of CSA B149.1 .............. 33
Figure 1-16 - Low capacity appliance regulator ...................................................................... 35
Figure 1-17 - High input boiler valve train ............................................................................... 36
Figure 1-18 - Appliance regulator in a combination gas valve ................................................ 36
Figure 1-19 - Combination gas valve with servo-operated regulator ...................................... 37
Figure 1-20- Combination gas valve with servo-operated regulator (open) .......................... 38
Figure 1-21 - Electronic modulating servo-regulated combination gas valve ......................... 39
Figure 1-22 - Combination gas valve ...................................................................................... 40
Figure 1-23 - Single-ported balanced regulator ...................................................................... 41
Figure 1-24 - Double-ported balanced regulator ..................................................................... 42
Figure 1-25 - Zero governors .................................................................................................. 43
Figure 1-26 - Zero governor .................................................................................................... 44
Figure 1-27 - The combination gas valve on a Viessmann matrix burner incorporates a
zero governor ..................................................................................................... 45
Figure 1-28 - Air/gas ratio regulator on a nozzle mix burner ................................................... 46
Figure 1-29- Gas/air ratio controller on a Lochinvar modulating condensing boiler .............. 47
Figure 1-30 - Typical first- and second-stage propane regulators .......................................... 49
Figure 1-31-A typical high to low twin-stage propane regulator ............................................
50
Figure 1-32- Two-stage regulator installation ......................................................................... 51
Figure 1-33- Single-stage regulator ....................................................................................... 51
Figure 1-34- Rego automatic changeover regulator .............................................................. 52
Figure 1-35 - Itron regulator on line sizing application - Parameters screen .......................... 56
Figure 1-36 - Itron regulator on line sizing application - Results screen ................................. 56
Figure 1-37 - B42 14" w.c. outlet pressure capacity table ....................................................... 56
Figure 1-38 - B42 spring selection chart ................................................................................. 57
Figure 1-39 - Performance curve for a twin-stage regulator ................................................... 59
Figure 1-40 - Regulator with bottom plug ................................................................................ 62
Figure 2-1 - Pressure buildup .................................................................................................. 79
Figure 2-2 - Pop-type relief valve .................. .......................................................................... 79
Figure 2-3 - Direct operated relief valve .................................................................................. 81
Figure 2-4 - Pitot tube operated relief valve ............................................................................ 82
Figure 2-5 - Internal relief valve ............................................................................................... 84
Figure 2-6 - Manufacture 5 psi line pressure regulator assembly ........................................... 85
Figure 2-7 - 2 psi meter set ..................................................................................................... 86
Figure 2-8 - Monitor regulator system ..................................................................................... 87
Figure 2-9 - Maxitrol 5 psi line pressure regulator assemble .............................. .................... 88
Figure 2-10- Series regulation system schematic .................................................................. 88
Figure 2-11 - Working monitor ................................................................................................. 89
Figure 2-12 - Fisher CSB600 series regulator ........................................................................ 90
Figure 2-13- Token relief releasing gas .................................................................................. 90
Figure 2-14 - Slam-shut activated ........................................................... ..................... ........... 91
Figure 3-1 - Diaphragm meter ................................................................................................. 93
2 October 2019
Figure 3-2 - Curved bimetallic temperature correction device ................................................ 94

Figure 3-3- Rotary meter ........................................................................................................ 94
Figure 3-4 - Cross-section of rotary meter shows two stages of impeller movement ............. 95
Figure 3-5 - Orifice meter with differential press ure measured on a manometer ................... 96
Figure 3-6 - Orifice flow meter ................................................................................................. 97
Figure 3-7 - Gas meter displays .............................................................................................. 99
Figure 3-8 - Electronic rotary meters ....................................................................................... 99
Figure 3-9 - A dial-type gas meter ......................................................................................... 100
Figure 3-10 - Electronic volume device for a gas rotary meter ............................................. 104
Figure 3-11 - TCI temperature displays .......... ....................................................................... 105
Figure 3-12 - EVC pressure factor display ............................................................................ 105
Figure 3-13 - Live corrected flow rate in cu ft/h ..................................................................... 106
Figure 4-1 - Typical propane cylinder markings .................................................................... 108
Figure 4-2 - Overfill prevention device (OPD) ........................................................................ 110
Figure 4-3- Sizes of propane cylinders .................................................................................. 110
Figure 4-4 - Typical ASME propane storage tank nameplate ................................................ 112
Figure 4-5 - Stationary cylinder valves ................................................................................... 114
Figure 4-6 - POL thread for vapour service ............................................................................ 115
Figure 4-7 - Acme service valve ............................................................................................. 116
Figure 4-8 - CGA thread for liquid service .............................................................................. 116
Figure 4-9 - Auto changeover valve ....................................................................................... 117
Figure 4-1O -A pigtail .............................................................................................................117
Figure 4-11 - Double back-check filler valve ..........................................................................118
Figure 4-12 - External safety relief valve ................................................................................ 118
Figure 4-13 - Float gauges ..................................................................................................... 119
Figure 4-14 - Fixed liquid level gauge ................................................................................... 120
Figure 4-15 - Excess flow valve ............................................................................................. 120
Figure 4-16 - POL combination valve .................................................................................... 121
Figure 4-17 - OPD valve ........................................................................................................ 122
Figure 4-18 - Combination valve for liquid service ................................................................ 123
Figure 4-19 - Propane vapourization point ............................................................................ 124
Figure 4-20 - Liquid propane boiling inside pressurized chamber ........................................ 125
Figure 4-21 - Propane direct fire vapourizer ......................................................................... 132
Figure 4B-1 - Installation clearances for aboveg round ASME tanks .................................... 135
Figure 4B-2 - Installation clearances for underground ASME tanks ..................................... 136
Figure 4B-3- Installation clearances for DOT/TC cylinders ................................................. 137
October 2019 3
Acknowledgements
The Manager , Gas Information Products , CSA , wishes to acknowledge the following individuals
who contributed as members of a review panel during the development of the original edition of
these materials . In addition, British Columbia Institute of Technology (BCIT) is acknowledged for
its work in the technical development and editing of the original edition.
Contributors and members of the review panel
Individual Organization
Frank Boone Apprenticeship Gas Technician Instructor ,
NSCC
Barry Bowman Instructor,
Conestoga College
Joel Crook JTAC/U .A. Local 787
Eli DiCredico Coordinator, Engineering Technologies ,
St. Clair College

Steve Holt Enbridge Gas Diistribution Inc.
David Kerr TS Technical Training

Dan Mailloux Professor , Heating , Refrigeration & Air Conditioning
Technician School of Skilled Trades ,
St. Clair College

Shane McCarthy Training Director ,
Joint Training and Apprenticeship Committee
Refrigeration Workers Local 787

Neil McPherson TSSA
Bill Norris Technical Trainer,
Direct Energy
Ellie Oldacre Team Leader , Technical Training Dept.,
Direct Energy
Steve Perdeaux Training Supervisor,
Enbridge Gas Diistribution Inc.
(Continued)
October 2019 5
(Continued)
Individual Organization
Clarke Petty Technical Coordinator, Oxford County Division,
Fanshawe College
Gary Prentice Instructor,
Fleming College , McRae Campus

Robert Sist Gas and Hydronic Training Programs ,
Georgian College
Greg Taylor Senior Facilitator ,
HVAC Training Academy

Bob Visentin Coordinator , HVAC Centre for Advanced Building Technologies ,
George Brown College

Dave Watkins Professor ,
Durham College
6 October 2019
Pressure regulators, overpr essure pro tection, meters, and fuel
Overview
Purpose
Before the installation of any piping and appliance systems inside a building , gas technicians/
fitters must plan the location of gas meters, propane storage containers , and gas pressure
regulators. These are key elements in the supply of fuel gas to the installation and will determine
many important aspects of the work that follows. This unit deals with the nature of these items
and the installation and maintenance procedures that apply to them .
Objectives
At the end of this unit, you will be able to :
• choose and install the correct gas pressure regulator for a system ;
• explain the need for overpressure protection and how to achieve this;
• read and clock meters ; and
• identify and plan for the correct use of propane cylinders and tanks.
Gas trade training and Red Seal alignment

You can use the CSA Group Gas Trade Training materials as resources to help you prepare for
the Red Seal Gasfitter - Class B exam. For more information on how these material s align with
the 2014 national standard for the occupation of Gasfitter - Class B, please review an expanded
reference matrix at httQs://store .csagrouQ.orgL
October 2019 7
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tl 2019 Canadian Standards Association . All Rights Reserv ed.
8 October 2019
Pressure regulators
Overview
Purpose
Pressure regulators are installed in a gas piping system to reduce and maintain the downstream
pressure and flow rate that allow downstream appliances to operate safely and efficiently. A
thorough understanding of the principal elements of pressure regulators and their operation is
necessary in order to properly install and service gas equipment.
Objectives
At the end of this chapter, you will be able to :
• describe the need for pressure regulators ;
• describe the basic operation of a regulator;
• locate the codes and regulations pertaining to regulators ;
• distinguish between the different types of regulators ;
• describe the selection requirements ;
• describethe locationand pipingpractices; and
• troubleshoot common regulator problems.
Terminology
Term Abbreviation Definition
(Symbol)
An air/gas proportioning Is similar to a zero regulator , except that air
regulator (ratio regulator) pressure is applied to the vent opening on the
spring side of the diaphragm through a sensing
line connected to an air supply line delivering
co mbustion air to the nozzle mix burner
Droop and offset The downstr eam pressure drop below setpoint
Lockup The pressure above setpoint that is used to shut
the regulator off tight
Servo A mechanism set in operation by other
mechanisms
Setpoint Th e desired outlet pressure
Zero governor (regulator) Designed to deliver an outlet pressure
equivalent to atmospheric pressure
October 2019 9
The need for pressure regulators

Gas pressures in supply mains (natural gas) and from storage containers (propane) are higher
than the maximum allowed inlet pressure of connected appliances . For this reason , gas
pressures must be controlled to fall within an appropriate pressure range , depending on the
operating characteristics of installed appliances .
Purpose
Gas pressure regulators have two main purposes, namely:
• reduce and maintain a safe operating pressure for the building and/or connected appliances
regardless of changes in the gas flow or upstream pressure ; and
• provide a means by which the pressure to connected appliances or burners can be adjusted ,
set , and maintained .
If .. . Then .. .
The inlet pressure to the regulator is The regulator must provide an additional function to
over 0.5 psi (3.5 kPa) act as a positive shut-off device to ensure that
downstream pressure does not build up to unsafe
levels under no flow conditions.
A gas appliance receives too much It will overtire .
fuel because the gas pressure is too
great
If the gas appliance receives too little It will underfire .
fuel
If an appliance is overtired or • It will produce too much (overtired) and too little
underfired (undertired) heat.
• Combustion characteristics could change , resulting
in carbon monoxide generat ion.
• The appliance may not work properly or efficiently.
Main categories
There are four categori es of gas pressure regulators that a gas technician/fitter encounters, each
used to serve a specific purpose :
10 October 20 19
Category Description
First-stage regulators • Used in all permanently installed propane systems to
reduce the propane container pressure to service line
pressure delivered to the second stage regulator
• See Figure 1-1
Service regulators (commonly • Used in both natural gas and propane systems to
called second-stage regulators in reduce the service line pressure to building line pressure
propane systems)
at the gas meter set
• See Figure 1-2
• Commonly called second-stage regulators in line
propane systems
• See Figure 1-1
Line pressure regulators • Used to reduce the building line pressure in a branch
line where the pressure required by appliances or
equipment on that branch line is less than the pressure
in the main building line
• See Figure 1-2
• Referr ed as "syste m regulat ors" in the Gas Code, prior
to 2005
Appliance regulators • Used to reduce low (max 0.5 psi) building or branch line
pressure to the pressure required by the appliance
• Often built into a combination control
Also see the definitions provided in the CSA B 14'9.1, Natural gas and propane installation code.
October 2019 11
Figure 1-1
Propane installation
First-stage regu lato r
Service regulator
Propane (also called second-
container stage regu lato r)
12 October 2019
Figure 1-2
Natural gas installation showing location of service regulator and line pressure
regulators
Service/
regulator
Line pressure
regulato r Appliances
Service regulator
Building
wall ,......,P,.,,:..,,,g,.....-1:K:1-----::-
7-,-in-w-
.c-..... (§
Meter
60
ps1g
7 inw.c.
2
7 inw.c.
Direction of flow
When installing a pressure regulator , the direction of gas flow is critical for proper operation of the
regulator . An arrow on the regulator casing indicates the direction of flow . Be certain that you
install the regulator so the flow arrow points in the direction of flow . (Direction of flow will be
covered in more detail later in this chapter.)
Knowing these two commonly used terms is important since they are used often to exp lain where
to place appliances. These refer to the placing of an item in the system according to the flow of
the gas:
• downstream; and
• upstream.
October 2019 13
Flow Description
Gas downstream of the Refers to the gas flow after it has passed through the regulator
regulator
Gas upstream of the regulator Refers to the gas flow before it passes through the regulator
Most pressure regulators are either pilot-operated or direct-operated . Pilot-operated regulators

consist of two regulators with the same essential components as direct-operated units. The pilot
can simply and effectively be considered a second regulator , providing additional control to the
main regulator , improving overall sensit ivity and, ultimately, accuracy. Pilot-operated regulators
are used for high-capacity applications to supply gas to commercial , institutional , and industrial
buildings.
This level of training focuses on the operation of direct operated regulators , although , it covers
servo regulation , which by definition is a type of pilot operated control , as it applies to the
appliance regulators built into combination gas valves .
Basic operation of a regulator

Most service , system, and appliance regulators are direct-operated regulators that work in
basically the same way.
A direct-operated regulator is defined as any self-contained valve and actuator combination that
automatically adjusts the flow in direct response to changes in downstream pressure , thereby
matching the gas demand . Figure 1-3 illustrates a direct-operat ed regulator .
Figure 1-3
Direct-operated regulator
Loading
eleme nt
Measuring
element
Restrict ing
element
As shown in Figure 1-3, these regulat ors have four essential elements.
14 October 2019
Element Description
Loading element Usually a spring
Measuring element Usually a diaphragm
Restricting element An orifice and valve seat
Atmospheric vent A vent on the atmospheric side of the
diaphragm
Here is how a regulator works:

1) When the appliance shuts off, the pressure increases under the diaphragm (or measuring
element), pushing it up with greater force than the spring (or loading element) is exerting
downward. As a result, the valve closes against the orifice (in a configuration known as the
restricting element). Air exiting the vent allows the diaphragm to move freely.
2) When the appliance starts, the loss in pressure downstream causes the spring to overcome
the downstream pressure exerted on the measuring element. As a result, the diaphragm
moves downward, thus opening the valve. Air entering the vent allows the diaphragm to
move freely.
3) The balancing of forces acting on the measuring element determines the position of the
valve in relation to the orifice. The diaphragm and valve stabilize when the force under the
diaphragm equals the force exerted by the spring. At this point, the regulator has found its
point of equilibrium and the flow rate and pressure downstream match that which is required
by the system.
If additional appliances start or an increase in firing rate occurs, the diaphragm moves
downward and the valve stabilizes in a new position in relation to the orifice, allowing more
gas flow at the same pressure.
If gas demand decreases , the diaphragm moves upward and the valve stabilizes in a new
position in relation to the orifice, allowing less gas flow at the same pressure. Air entering
and exiting the vent allows the diaphragm to move freely.
Note: The closing force in a regulator is the downstream gas pressure.
The loading element

The loading element is used to counterbalance the downstream pressure. It is usually a spring.
The amount of spring pressure on the diaphragm determines the position of the restricting
element.
Changing the spring load can adjust the amount of flow through the regulator.
The following terms relate to flow and pressure regulation.
October 2019 15
Flow and pressure Description

regulation
Setpoint • The desired outlet pressure is known as the setpoint.
• A perfect regulator could maintain downstream pressure equal to
setpoint under all flow rates , but in reality , as flow rate increases , the
downstream pressure decreases .
Lockup • Lockup is the pressure above setpoint that is used to shut the
regulator off tight. In many regulators, the orifice has a machined
edge , while th e disk is made of a soft material. To make a tight seal,
the regulator must increase the downstream pressure to force the
disk onto the machined edge . This extra amount of pressure required
is called the lockup pressure .
• Regulators that have an inlet pressure over 0.5 psi (3.5 kPa) must
provide a positive shut-off when there is no gas demand
downstream . These regulators usually lock up to within 10% of the
original outlet pressure setting .
Droop and offset • Droop and offset describe the downstream pressure drop below
setpoint. At this point , the valve is fully open , and there is an
increased gas demand downstream . Droop can be expressed as a
percentage of setpoi11tpressure . Manufacturers publish regulator
capaciti es according to their amounts of droop . These are generally
for 10% droop and 20 % droop. The accuracy of a regulator is
determined by the amount of flow it can pass for a given amount of
droop. The closer the regulator is to setpoint, the more accurate it is.
• If the performan ce of a typical regulator is plotted on a graph (), the
graph will show how the flow rate of gas drops off drastically as the
gas flow increases above its designed droop or offset.
16 October 20 19
Figure 1-4
Graph depicting the performance of a typical regulator
,----- Lockup
, ''
'
Setpoint
Droop
(offset)
...
CV
::,
VI
VI
...
CV
a.
E
n:J
...
CV
....
VI
C
Wide open
~
0
Cl
Flow rate
The measuring element

The measuring element is usually a diaphragm. It is used to measure the changes in the
downstream pressure .
The diaphragm is attached by a stem to the restricting element so that they both move together .
Made of neoprene , it is extremely flexible and usually is supported by a metal plate that allows
downstream pressure to act upon the diaphragm evenly.
The diaphragm is slightly permeable to gas , so it is not unusual to detect a slight odour of gas at
the vent opening . Howeve r, a significant odour around the regulator may indicate a damaged
diaphragm . Diaphragms do wear out and may crack or tear due to age or exposure to chemi cals .
The restricting element

When the downstream pressure changes, the restricting element moves in response to the
movement of the measuring element.
Usually , the restricting element is a valve and orifice that together control the amount of flow
through the orifice opening.
It is important that the orifice and seat are properly maintained. They must be smooth and
undamaged so that the seat may seal the orifice. If dirt such as pipe dope or tape or metal
cuttings from threading operations lodges between the orifice and the valve seat , the regulator
ca nnot shut off.
Upstream pressure will leak downstream when the appliances are shut off. This may damage
downstream components or ca use gas to escape through burners and build up in the heat
exchanger and vent.
October 2019 17
Pressure regulators , overpressure protection, meters, and fuel
The dirt may also damage the soft valve seat.
The atmospheric vent

The atmospheric vent (regulator vent) is an essential part of the regulator. It allows the air above
the diaphragm to escape or enter as the diaphragm moves up or down. If the vent is blocked or
restricted , the diaphragm will not be able to move properly. For example , if the vent was
completely blocked, it would cause the air above the diaphragm to become locked in and prevent
the diaphragm from raising enough to close the restricting element. This would lead to the rise of
the downstream pressure above the required setpoint.
If the vent were partially blocked or restricted, the air movement would be delayed as the
diaphragm attempts to force air out and pull air through the vent opening. This would in turn
cause wide swings in downstream pressure above and below the setpoint known as "hunting or
cycling".
Most small appliance regulators vent to the indoors through a very small (#78 drill size) opening
that is considered safe and acceptable by appliance standards as long as the regulator is located
in a ventilated area.
Older appliances may have the appliance regulator vented into the appliance combustion
chamber adjacent to the continuous pilot.
Newer appliances are usually vented outdoors or have the vent equipped with a leak limiter as
discussed later in this section.
The vent also allows gas to escape if the diaphragm ruptures or an internal relief valve (installed
in some regulators) opens. Safety measures are required to control this escaping gas as
discussed later in this section .
Performance characteristics
The amount of flow it can pass for a given amount of droop determines the accuracy of a
regulator. The closer the regulator is to setpoint, the more accurate it is. The following four factors
mainly affect droop:
• spring rate;
• diaphragm area;
• orifice size; and
• inlet pressure.
Spring rate
The control springs for regulators are rated by the amount of force required to compress it one
inch. For example, a spring with a rate of 25 pounds per inch (lbs/in) needs 25 pounds of force to
compress it one inch , 50 pounds of force to compress it two inches , etc. This force is opposing
the total force created by the setpoint pressure spread over the area of the diaphragm.
Adjustable regulators usually have a selection of springs to choose from in order to achieve the
desired setpoint for each application . The spring ranges often have overlap within the range of
settings each can deliver. Since a lighter spring is more sensitive to changes in downstream
pressure , choosing the lightest available spring rate causes the least droop and the most
accurate pressure control.
18 October 2019
For example, in the spring chart shown in Figure 1-5, there are several spring ranges available
for this model of regulator . If our system required a setpoint of 12 inches water column (w.c.), the
spring with a pressure range of 4 - 12 inches w.c would be more accurate for our application and,
therefore , has less droop than the spring with a pressure range of 10 - 22 inches w.c .
Figure 1-5
Spring selection chart
model Part number Colour code Outlet Approximate Approximate

pressure inner length
Adjustable models : (in w.c.) diameter
325-3 R325C10 -2 6 Plated 2.0 to 6.0 5/8" 1 3/4"
R325C10 - 59 Plated 5.0 to 9.0 2 5/16"
R325C10-412 * Violet 4 .0 to 12 1 3/4"
R325C10- 711 White ?.Oto 11 2 5/8"
R325C10 - 1022 Red 10 to 22 2 1/8"
R325C10 - 1530 Yellow 15 to 30 2 5/16"
R325C10 - P12 Tagged 1 psi - 2 psi 2 5/16"
Diaphragm area
Because a larger diaphragm area produces more force change for a given change in
downstream pressure (F = P x A ), larger diaphragms are often used in applications that require
minimum droop and, therefore , better accuracy.
Orifice size
As shown in Figure 1-6, moving the valve disc away from the orifice increases the flow rate of the
regulator only to a certain point. Once the restrict ing element is wide open (when the disc clears
the orifice by a distan ce equal to 1/4 of the orifice diameter) , the orifice size and the pressure
difference on either side of the orifice dictate the maximum flow capacity of the regulator . In many
models of service and line pressure regulators , you can change the flow capacity by changing the
orifice size .
October 2019 19
Figure 1-6
Regulator threaded removable orifice
Courtesy of Camosun College , Rodney Lidstone , licenced under CC BY
When changing the orifice size, you must be careful not to oversize it, as this can lead to unstable
operation and faster wear.
Inlet pressure
As mentioned , the orifice size and the pressure difference on either side of the orifice dictate the
maximum flow capacity of the regulator. The pressure differen ce is determined by the outlet
pressure and the operating inlet pressure . It is important when selecting a regulator that its
maximum capacity be determined by analy zing the minimum inlet pressure . The minimum inlet
pressure will be during operation and will be a result of the piping pressure losses at maximum
design conditions .
Adjusting pressure on non-utility regulators

There are three main types of regulators when it co mes to adjusting the pressure , namely:
• non-adjustable regulators ;
• minimal adjustment regulators; and
• fully adjustable regulators.
Unless a gas technician/fitter is authorized to do so by the distributo r, the Gas Code prohibits a
gas technician /fitter from working on a servi ce regulator that is part of the distributor 's system.
Before beginning any adjustments on non-utility regulators , consult the manufa cturer 's
instructions for the regulator and for the appliance(s) served by the regulator , and take note of the
following:
• Adjustments should only be made to meet appliance manufactur er's pressure specifications
using the adjustment method recommended by the regulator manufacturer.
20 October 2019
• Always use the proper tools and make sure that your pressure measurement instrument has
the proper range and accuracy for the job .
Adjusting pressure
If the pressure from the regulator is too high or too low, use the following procedure to change the
pressure setting:
1) Turn off the gas.
2) Install the pressure test equipment to sense downstream pressure.
3) Remove the regulator adjusting screw cap.
4) Turn on the gas.
5) Turn the equipment on, allowing the gas to flow.
6) Look at the pressure and make the appropriate adjustment (Figure 1-7).
Figure 1-7
Adjusting regulator
If... Then ...

The pressure is too • Turn the adjusting screw counter-clockwise. Doing this will
high reduce the spring tension.
• Keep turning the screw until the correct pressure is achieved .
The pressure is too low • Turn the adjusting screw clockwise. Doing this will increase
the spring tension .
• Keep turning the screw until the correct pressure is achieved .
7) Replace the cap.
8) Shut off the gas.
9) Remove the test equipment.
10) Properly plug any test points.
11) Turn on the gas
October 2019 21
12) Leak test the test points .

13) Check the operation of the appliances or burners downstream of the regulator to ensure that
they are in safe operating condition.
Safety features
A number of safety devices form part of the regulator.
Vent limiting orifice

Regulators on smaller input appliances are usually constructed with a vent opening that has an
integral orifice , usually a #78 drill size , to limit the escape of gas from the upper diaphragm
chamber [Figure 1-8(a)] . The vent opening is threaded to enable it to be piped to away if the
regulator is installed in a non-ventilated space .
If the diaphragm ruptures , the leakage is limited to less than 1 ft3/h (0.02832 m3/h) at 7 inches w.
c. (1.74 kPa) gas pressure . The vent opening (especially on combination gas valves) is usually
covered by a loose-fitting cap to prevent dirt from plugging the opening [Figure 1-8(b ) and (c)].
Figure 1-8
Vent limiting orifice
Regulalor blee d ve nt dust caps
(a) lntegral vent orifice (b) Dust cap partiall y remo ved for viewing (c) Vent dust cap
As the regulator size increases, the larger diaphragm will need to move more air through the vent
opening , and an integral orifice restriction will affect the reactions time of the regulator . In some
cases , the manufacturer may offer a fixed orifice accessory that can be installed , but the
individual load capacity of the regulator will need to be reduced. Figure 1-9 shows a fixed vent
limiting orifice accessory sitting on the regulator , the orifice opening is difficult to see as it is on
the side of the body under the hex head. You can also see that the bleed vent hole in the
regulator is much larger than the #78 integral orifice . If this regulator was required to respond at
its full capacity for a single applian ce, then the vent limiting orifice could not be used and the vent
would need to terminate outside or use an automati c vent leak limiting device.
22 October 20 19
Figure 1-9
Vent limiting orifice accessory
Leak limiting device

In certain regulators , such as 2 psig (14 kPa) line pressure regulators, a leak limiting device can
be installed in the threaded vent opening (Figure 1-10) .
In this device , a ball check or disc check allows free movement of air at atmospheric pressure
above the diaphragm to ensure fast regulator response . However , if the diaphragm ruptur es, the
high pressure flow of gas causes the ball check or disc check to limit the flow of gas to a
maximum flow rate of 2.5 ft3/h (0.0706 m3/h) for natural gas or 1 ft3/h (0.02832 m3/h) for propane ,
as allowed by the Gas Code. In most cases, the opening in the leak limiter is a #78 drill size.
A regulator equ ipped with a leak limiter must be in a ventilated space. Keep the small opening on
the leak limiter free of dirt or paint. Do not use vent limiting devices outdoors; if they are exposed
to the environment, they may become clogged by moisture or insects. You can only install vent
limiters in regulators for which they are certified. Install them directly into the vent connection of
the regulator without intermediate pipe or fittings . Manufacturers may have more than one lea k
limiter available that fits the regulator . It is important that you use the proper model specified by
the manufacturer.
October 2019 23
Pressure regulators , overpress ure protection , meters, and fuel
GA S TRADE TRAINING UNIT 11 containers
Figure 1-10
Leak limiting devices
Courte sy of Maxitrol Company
2 psig regulato r
Leak limi ting

device
• ~
."
f
l
f
12A09 12A3
9 12A49
Wh en using ball check vent limiters, mount the regulator in the horizo ntal position to keep the
ve nt limiter in the ve rtical up position. Some manufa cturers have regulator des igned with two ve nt
co nnections that enable the regulat or to be installed either ve rtically or horizo ntally using th e
appropri ate location for the ve nt limiter and a plug in the other (Figure 1-11 ).
24 October 2019
Figure 1-11
Multi position 2 psi regulator
Performance features
Besides the four performance factors previously mentioned , there are additional features that are
used to improve regulator performance . Two common ones (Figure 1-12) include :
• pitot tubes; and
• levers .
The pitot tube design is used to decrease regulator droop. Inside the regulator , the pitot tube
connects underside of the diaphragm to an area called the vena contracta, which has a lower
pressure when exposed to increased gas velocity. By sensing the setpoint pressure at this point ,
the diaphragm will be tricked into opening wider, therefore , responding quicker to increase
demands. This phenomenon - the reverse of droop - is called boost.
Lever controlled regulators provide increased force necessary for lockup against higher inlet
pressures. The extra mechani cal force also keeps the disk in a stable position, thereby opposing
tendencies of the disk to cycle or buffet.
October 2019 25
Figure 1-12
Pitot tube and lever features
Diaphragm
Lever
Pitot tu be
Internal safety relief

Some regulators with an inlet pressure over 0.5 psi (3.5 kPa) are equipped with internal relief
valves. This kind of valve usually consists of a second spring mechanism acting against a valve
opening between the diaphragm and its supporting metal plate (Figure 1-13) .
The internalrelief valve only opens if downstreampressureexceedsa set amount and

automatically resets when the pressure drops below the setpoint. The relief valve will then open
to allow the overpressure to escape through the vent. This escaping gas must be piped to a safe
location outdoors.
Figure 1-13
Regulator with internal relief valve
Tamper-resistant nut holds
designed tens ion on the
relief valve spring
Vent must
termi nate
elief valve
outdoors
Outlet ~ ~ Inlet
26 October 2019
The set pressure for the relief cannot be adjusted and is an important factor in selecting a
regulator . Under full flow cond itions from the relief valve and relief piping , the regulator outlet
pressure must never exceed the pressure rating of the weakest component downstream .
Review manufacturer 's specifications for both the regulator and the downstream components
when determining if the relief capacity is sufficient. Remember that the piping attached to the
relief vent must never reduce the relief capacity or exert back-pressures on the regulator .
Where large volume relief of gas pressure is required to protect components, a separate relief
valve may be installed on the piping system. These automatically reset valves function in the
same way as the internal relief device in regulators . Set pressures are established by a spring
holding down a valve seat. Within the range of the valve, the set pressure can be adjusted to
relieve pressure before damage occurs to the downstream components .
Overpressure shut-off (OPSO)

OPSO is used on some service regulators and on line pressure regulators where it is impractical
or undesirable to pipe the vent outdoors . A reverse-acting pressure-activated device closes ,
shutting off the flow of gas through the regulator if the outlet pressure is too high . Under these
conditions , the OPSO locks off and must be manually reset (Figure 1-14) .
October 2019 27
Figure 1-14
Regulator with overpressure shut-off and two-way stabilizer vent valves
OPSO
Main gas pressure regulator
Two-way stabilizer
vent with flappers Relief valve stem
closed
Turbo-booster tube
Internal relief
Reset pin
Two-way stabilizer vent valve

A two-way stabilizer vent valve provides quick but controlled reaction to rapid downstream
pressure changes. As the diaphragm responds to rapid changes, the increase or decrease in
pressure above the diaphragm must overcome the spring pressure located above and below the
stabilizer vent valve (Figure 1-14 ). The stabilizer valve is closed during equilibrium.
Materials of construction
Regulators are made from corrosion-resistant materials. Typical construction materials are
shown in Table 1-1.
28 October 2019
Table 1-1
Typical regulator construction materials
Part Material
Body Cast aluminum
Cast iron
Steel
Spring case, lower diaphragm casing, union ring, seat ring, Aluminum
disk holders
0-ring , disks , diaphragms Nitrile
Closing cap gasket , relief valve pad Neoprene
Diaphragm head , adjusting screw Delrin™
Aluminum
Relief/monitor piston ring Graphite
Vent flappers CycolacTM
Nylon
Other metal parts Aluminum
Brass
Cast iron
Monel TM
Steel
Stainless steel
Zinc
Codes
The applicable code requirements for regulators are in the Natural gas and propane installation
code (CSA 8149.1) and the Propane storage and handling code (CSA 8149 .2). This section
identifies the key requirements and explains some of the reasons for these requirements. Unless
otherwise stated, code references are to the most current version of CSA 8149.1. Refer directly
to the Clauses identifi ed since the prese ntation usually paraphras es the Code and it is important
that you become familiar with the layout of the Code.
Prohibited work
Clause 4 .6.2 states that no person other than an employee or person authorized by the supplier/
distributor shall perform work on the supplier/distributor system. The service regulator on natural
gas systems is part of the supplier/distributor system.
October 2019 29
The system regulator (or second stage regulator) and the first stage regulator may be considered
part of the propane supplier /distributor system in some areas . Check with the propane distributor
and/or authority having jurisdiction before working on these regulators.
Pressure inside buildings

Most of the requirements applicable to regulators are found in Clause 5 of the CSA B 149.1 Code .
Table 5.1 sets maximum levels for the gas pressure inside buildings. Higher gas pressures are
permitted in certain areas in buildings (such as a central boiler or mechanical room) because
problems that may be caused by leaking gas are reduced in these areas .
For natural gas installations , the distributor determines and sets the building pressure in
compliance with Table 5.1. For propane systems where the first and/or second stage regulators
are not considered part of the distributor's system, it is the responsibility of the gas technician /
fitter to set the building line pressure so it meets appliance requirements but does not exceed the
maximum pressures set in Table 5.1.
In both natural gas and propane systems , the maximum pressures allowed by Code are seldom
employed for safety reasons .
General requirements for regulators

The following requirements apply to both natural gas and propane regulators .
Clause 5.2.1 .1 contains some relatively new requirements that first appeared in the 2007
Supplements to the CSA B 149.1 Code . Although it has always been required that a regulator be
certified and be of sufficient size to provide the required flow of gas at the extremes of inlet
pressures to which the regulator can be exposed , the reference to three recognized standards is
new. When installing a new regulator that is not approved as part of the appliance approval ,
check that it is certified to a recogn ized standard .
A pressur e regulator shall not be bypassed (Clause 5.2 .1.3).
Any regulator in the gas supply line shall not be installed in any of the following three locations
(Clause 5.2.1 .6):
• where it is inaccessible for repair , replacement , servi cing, or inspection ;
• in a concealed location ; or
• where it could be reasonably expected to be subject to physical or chemical damage .
Clauses 5.2 .1.5 and 6.18.2 require that pressur e regulators have a manual shut-off valve
install ed upstream. This valve is necessary for servicing and for emergency response .
Line pressure regulators

Line pressure regulators are defined in the Code as a gas pressure regulator intended for
installation in a gas distribution system between th e utility service regulator or 2 psi propane
regulator and gas utilization equipment.
These regulators are only used on piping systems where the building pressure exceeds 0.5 psi
(3.5 kPa). As such , the code requirement (Clause 5.2 .1.4) stating that a line pressure regulator
30 October 20 19
with an inlet pressure over 0.5 psi (3.5 kPa) be a positive shut-off type applies to all line pressure
regulators.
Clause 5.2.1 .5 requires that a line pressure regulator be equipped with a line relief device or an
overpressure protection device. However , an exception is allowed in Clause 5.2 .2.4 for propane
systems and in Clause 5.2.3.1 for natural gas systems when the line pressure regulator is
equipped with a leak limiting device (as discussed previously) .
For piping systems with a supply pressure over 2 psi , a line pressure regulator must be equipped
with either a line relief device or an overpressure protection device (see definition in the CSA
B149.1 Code). These devices are covered in the Overpressure protection> Relief valves section .
Additional requirements for propane regulators

The CSA B149.1 Code specifies additional requirements in Clause 5.2.2 that apply onl y to
propane regulators . Under this Clause , propane regulators must:
• be firmly secured to the container valve or the regulator bracket on the wall or hood; or
• be secured in some other appropriate manner .
When installed outdoors and subject to inclement weather , the regulator has to be protected as
necessary from exposure to weather conditions. A regulator installed outdoors or in an unheated
area must be positioned so that the bonnet vent opening discharges vertically downward. Clause
5 .2.2.3 allows two exceptions to this requirement.
All permanent propane installations must employ two-stage regulation (see Figure 1-1 ).
Reducing container pressure in two stages ensures a much more consistent delivery pressure to
appliances compared to single-stage regulation . It also reduces the chan ce of internal freeze-ups
caused by large drops in pressure through the small orifice required in a single-stage regulator.
As previously discussed , line pressure regulators on a piping system operating at 2 psi (14 kPa)
or less do not have to be vented outdoors if the regulator is equipped with a leak limiter . In the
case of propane systems , the leak limiter must limit escaping gas from a ruptured diaphragm to
no more than 1 ft 3/hour (0 .0283 m3/h). Clause 5.2.2.4 requires that a regulator with a leak limiter
be installed in a ventilated space only.
A hydrostatic relief device is required on liquid propane systems where the propane can be
trapped between two valves. If liquid propane is trapped between two closed valves in piping or a
hose, it will expand as its temperature increases . The hydrostatic relief device relieves this
pressure , thus preventing the piping from bursting. The minimum relief pressur e setpoint is 375
psi (2500 kPa) and the maximum is 500 psi (3500 kPa) . See Clause 5.4 .1 of the CSA B149 .1
Code.
Additional requirements for natural gas regulators

Clause 5.2.3 establishes additional requirements that apply only to natural gas regulators . Leak
limiters are also allowed in place of a vent on natural gas piping systems operating at 2 psi (14
kPa) or less. However , the natural gas leak limiter must limit escaping gas from a ruptured
diaphragm to no more than 2.5 ft 3/hour (0.0706 m 3/h).
There is a Claus e in the CSA B149 .1 Code that allows the use of leak limiters on natural gas
systems operating above 2 psi , provided that the system has an overpressure prote ction device
October 2019 31
set to a pressure either below 2 psig (14 kPa) or 2 times the delivery pressure on the system and
that the regulator is certified to ANSI Z21.80/CSA 6.22, Line pressure regulators. There is no
similar allowance for propane systems operating above 2 psi.
Venting of regulators
When venting a regulator vent outdoors , a techn ician/fitter must pay special attention to Clause
5.5 of the CSA B149.1 Code. It specifies the material that can be used for the vent , the size of
single and combined vents , and the permissible locations for vent terminations. Compliance with
the regulator manufacturer's instructions is also required.
The vent line shall be made of steel pipe , copper, seamless aluminum, or steel tubing that meets
the standards specified in Clause 6.2. However, aluminum vents are not allowed on combined
vent systems with an inlet pressure over 0.5 psi (3.5 kPa).
For dedicated vents serving a single regulator, the vent size must be at least that of the nominal
pipe size of the vent outlet of the pressure regulator, but its inside diameter must not be less than
0.25 inches (6 mm). Individual vent lines may be connected to a single vent line, but the size of
the common vent depends on the types of devices that are common vented and the inlet
pressure to these devices; refer to Clauses 5.5.3 to 5.5.5.
If specific manufacturer's instructions are not provided giving details on the sizing of the vent line,
increase the vent line by one pipe size diameter for every 50 ft (15 m) or part thereof that the vent
line extends beyond the initial 50 ft (15 m). This increase must be made at the regulator vent
outlet.
The Code also defines how and where the vent terminates outdoors.
The vent must terminate outdoors pointing downwards and have a means to prevent the entry of
water, insects, or foreign material.
Clauses 5.2.1.2, 7.4.4, and 7.5.2 and Table 5.2 require that a regulator vent terminating outside
be at least 3 ft (1 m) from the moisture exhaust duct of a domestic clothes dryer and at least 10 ft
(3 m) from the moisture exhaust duct of a commercial clothes dryer. This requirement applies to
gas-fired and electric clothes dryers and is intended to prevent the moist air from the dryer from
damaging the regulator or freezing on the regulator vent screen.
Figure 1-15 provides a visual representation of the vent termination requirements established in
Table 5.2. The overpressure protection device described in the first column of the table are of the
OPSO type. These installations have lesser clearance requirements, as the device will be
completely shutting of the flow of gas when activated.
32 October 2019
Figure 1-15
Allowed locations for vent terminations per Table 5.2 of CSA 8149.1
Clearances from j : ; : : : : : : : : : j : j : j : : : : : : : : : j : j
Mecha nical air intake 3 ft
vent termination Appliance air intake 1 ft
for nat ural gas
relief devices from
OPSOregulators
Appliance vent out let 1 ft 0
having a relief
A/C~
capacity of unit~
50 scf/h or less openi ng
1 ft
Regulato r vent clearance
j : i :::::::j : j : j : j : j : : : : : j : j : j
Appliance air int ake 3 ft Mechanical air intake 10 ft
Clearances from
vent ter mination
Appliance vent out let 3 ft @
for nat ural gas
relief devices
EE Buildi ng
open ing 3 ft
Regulator vent c earance

Source of ignition 3 ft
Propane
Clearances from
vent termination
for propane
relief devices
Regulator vent clearance
Appliance and pilot regulators

Although most of the requirements regarding appliance regulators and pilot regulators are found
in the Standard to which the applian ce was built and certified, the CSA B149.1 Code provides a
few additional requirements in Clause 5.6.
Propane appliances must have an appliance regulator and a separate pilot regulator when the
supply pressure to the appliance could be subjected through supply pressure , design , creepage,
or fluctuation to propane pressure in excess of that for which the appliance is rated.
Since older propane appliances may not have a11appliance regulator , a gas technician/fitter must
ensure that either the second-stage regulator provides a consistent pressure within the pressure
October 2019 33
rating of the appliance or appliance and pilot regulators are installed in accordance with Clauses
5 .6.1.1 and 5.6.1.2 .
To comply with the code requirements that apply to regulators, a technician/fitter must fully have
a sound understanding of how regulators work .
Different types of regulators
Appliance regulators
The appliance regulator works on the same principle as all other regulators . Appliance regulators
are designed to reduce the inlet pressure of an appliance to the appropriate manifold pressure for
proper burner operation. Most natural gas appliances require a manifold pressure of 3 - 4 inches
w .c. while propane appliances typically require 10 - 11 inches w.c. The appliance regulator
typically has a maximum inlet pressure of 0.5 psi. The appliance input determines the type of
appliance regulator required.
There are three types of appliance regulators . They are :
Regulator Description
Low-capacity-type • Used to provide safe and uniform gas pressure to residential gas
appliance regulator appliances.
• May be used on smaller input appliances for supplying gas to either
the main burner or pilot burner or both burners.
• Usually have a high resistance to flow through the regulator but
provide fine pressure control.
High-capacity-type • Used on larger residential and commercial appliances.
appliance regulator
• Are only used to regulate the gas pressure to higher input burners .
• Usually have a low resistanc e to flow through the regulator by
employing a large orifice in the restricting element or a straight-
flow-through design .
Regulator component • Performs the same fun ction as a low capacity type appliance
of a combination gas regulator except that it forms part of the combination control valve .
control valve
• May be a simple direct-a cting regulator or a servo regulat or.
• A combination gas valve usually consists of a manual shut-off
valve, pilot gas control devi ce, main gas pressure regulator , as well
as one or two automatic safety shut-off valves .
• Gas flow to the pilot burner is controlled by a throttling valve
(needl e valve) , sometimes called the B cock .
34 October 20 19
Low capacity appliance regulator

Low capacity appliance regulators are typically less than 250 MBH and are typically designed to
give fine pressure control to both the main burner and the pilot burner . Some manufacturers
include a code on the label to indicate whether or not the regulator can regulate pilot flow, as
indicated in Figure 1-16 by the letter P in a circle .
Figure 1-16
Low capacity appliance regulator
Courtesy of Camosun College, Rod Lidstone CC BY
High capacity appliance regulator

Appliances with larger inputs require an appliance regulator with low internal resistance to flow to
deliver the higher volumes of gas with relatively little pressure differential across the restricting
element. High capacity appliance regulators are not used to regulate the gas pressure to the pilot
flame , only to the main burner . If the appliance has a pilot flame , there will typically be a separate
pilot gas line, control valve, and pilot regulator as shown in Figure 1-17.
October 2019 35
Figure 1-17
High input boiler valve train
Courtesy of Camosun College , Rod Lidstone CC BY
Separatelow
capacity pilot
regulator
Combination gas valve appliance regulators

For appliances with inputs less than 400 MBH , the appliance regulator is usually included as part
of a combination gas valve. These combination valves often employ servo-operated regulators
(Figure 1-18 ).
Figure 1-18
Appliance regulator in a combination gas valve
Servo
appliance
regulator
Here is how a servo regulator works.

1) When the bleed valve is in the off position , there is no call for heat. The bleed valve operator
on a servo valve can be electromagnetic, hydraulic , or bimetal.
36 October 2019
2) Inlet gas pressure passes through the restrictor and down the bleed line to build pressure
under the main valve diaphragm . The gas pressure is equal above and below the
diaphragm.
3) The force of the spring and the fact that the area of the lower diaphragm surface is greater
keep the valve closed .
Figure 1-19
Combination gas valve with servo-operated regulator
Bleed valve Regulator
(closed) adjustmen t screw t
5ervo regu 1a or
Bleed valve
operator I valve (wide open)
Regulator vent
(leak limited)
Inlet
Main valve
(closed)
4) When there is a call for heat, the bleed valve operator opens the bleed valve. This allows gas
from below the main valve to escape through the servo regulator restricting element , which is
wide open because there is no downstream pressure . As a result, the main gas valve starts
to open allowing gas to the burner (Figure 1-20) .
5) As gas pressure downstream of the main valve starts to build (due to restrictions in flow
through the orifice and burner ports), this back-pressure acts upon the diaphragm in the
servo regulator , causing it to move upward and reducing the flow rate through the servo
regulator 's restricting element. The upstream gas pressure that cannot pass through the
servo regulator again starts to flow into the chamber below the main valve, causing it to
close.
6) The servo regulator restricting element stops moving when the force of the downstream gas
pressure equals the force of the spring in the servo regulator. This maintains the main valve
in a position necessary to reduce the upstream gas pressure (usually 7 inches. w.c. for
natural gas systems and 13 inches w.c . for propane systems) to the manifold pressure
(usually 3.5 inches w.c. for natural gas systems and 11 inches w.c. for propane systems).
Essentially , the servo regulator causes the main valve to act as a restricting element to
regulate gas pressure to the burner .
October 2019 37
Figure 1-20
Combination gas valve with servo-operated regulator (open)
Bleed valve
operat or
Restrictor
Inlet
7) When the call for heat is satisfied, the bleed valve operator closes the bleed valve and the
upstream pressure flows only to the chamber below the main valve, causing it to close . Most
combination gas valves have a second solenoid operated main valve for added safety.
A gas technician/fitter can adjust the spring on the servo regulator to increase or decrease
downstream pressure to meet the appliance ma11ufacturer's specifications. Like most small input
regulators , servo regulators cannot be repaired. If they fail , the entire combination gas valve must
be replaced.
Some modulating appliances achieved their firing rate modulation by way of connecting an
electronic stepper motor at the servo regulator adjustment screw. This motor operator rece ives a
signal from the controller and adjusts the setting of the servo regulator to the required manifold
pressure. These valves ca n achieve a full range of modulation from 35 - 100% with 1%
increments .
38 October 2019
Figure 1-21
Electronic modulating servo-regulated combination gas valve
Servo regulator with referenced connection

Proper manifold pressure is critical to ensure the correct amount of gas flow through the burner
orifices . For older style appliances , the combustion chamber pressure was atmospheric, so the
manifold pressure was to sole force affecting the flow of gas through the burner orific es . But for
most high efficiency appliances, the combustion chamber is sealed and the pressure in the
burner enclosure can flu ctuate depending on venting conditions. These pressure fluctuations on
the discharge side of the burner orifice would affect the flow of gas if the appliance regulator did
not make adjustments . In order for these adjustments to be automatically compensated for , a
burner enclosure reference tube is connected into the appliance regulator vent outlet (Figure 1-
22). The pressure within the co mbustion chamber is now applied to the top of the diaphragm,
causing an adjustment to the loading element. For example, if the regulator spring was set at 3
inches w.c., and the burner enclose was experiencing a positive pressure of 1inch w.c., the
appliance regulator would set the manifold pressure at 4 inches w.c. This is also called a
referenced pressure of 3 inches w.c.
October 2019 39
Figure 1-22
Combination gas valve
Balanced regulators
A balanced-type regulator is designed to have the inlet pressure acting in two opposing directions
on the orifice seat(s) , thus producing a balancing effect that prevents an increase in set pressure
through an increase in the inlet pressure .
Large changes in the inlet pressure make it difficult for a regulator to maintain constant
downstream pressure . Many regulators therefore add a second diaphragm or port to create a
balanced regulator. Balanced regulators are classified as :
• single-ported; and
• double-ported.
Single-ported balanced regulator

Single-ported balanced regulators have the four basic elements common to all regulators . The
regulator is also equipped with a pitot tube and a balancing diaphragm , as shown in Figure 1-23.
40 October 2019
Figure 1-23
Single-ported balanced regulator
Loading
element
Vent
Measuring
element
Balancing
diaphragm
Pitot tube
Disk
and seat ~
Inlet
Double-ported balanced regulator - Basic type

Double-ported regulators have the same four basic elements of all regulators, except that the
restricting element has two disks and seats (Figure 1-24 ). The equal port diameters balance the
opposing forces across the valve disks, resulting in minimum lockup with either high or low inlet
pressures.
October 2019 41
Figure 1-24
Double-ported balanced regulator
--==-- /D ust cap
Adju sting
Vent nut
Measuring
element
Sense line
Double seat
connectio n
and disks
The shaft connecting the two disks or plugs to the main diaphragm is sealed with an O-ring where
it passes through the valve body . The double-ported regulator does not use a pitot tube to sense
outlet pressure . Instead , a tapping is provided under the main diaphragm , which must be
connected to the downstream piping.
Balanced regulators allow for more stable operation and precise control of pressure.
Zero governors
Zero governors , or regulators , are designed to deliver an outlet pressure equivalent to
atmospheric pressure. They are normally double-diaphragm units equipped with an O-ring seal
diaphragm (balancing diaphragm), as shown in Figure 1-25. This isolates the inlet gas pressure
from the lower chamber of the main control diaphragm.
The balancing diaphragm is set so that its effective area equals the effective area of the valve
disk .
The spring of these regulators counterbalances the weight of the internal parts. This provides just
enough additional tension to close the valve.
42 October 2019
Figure 1-25
Zero governors
Measuring
element
Balancing
diaphragm
Pitot
tube
c:::::>
Inlet 7\i~t
LJ Restricting
element
As the spring always just counterbalances the inte rnal parts, the outlet pressure of the governor
will always be the same pressure that is applied to the top side of the main diaphragm . Since the
vent above the diaphragm is open to the atmosphere (Figure 1-25) , the zero governor is also
called an atmospheric regulator . It can be adjusted to provide gas pressure at a slight negative or
slight positive pressure , but is usually employed for supplying gas at atmospheric pressure . If you
look closely at the regulator shown on the right of Figure 1-25, you can see that this manufacturer
has simply taken their balanced diagram design and added a counterbalance spring to the
underside of the valve.
A zero governor is connected to an air-gas mixer in a burner system that employs a mechanical
device (i.e., blower) to deliver air under pressure . The blower or a venturi-type mixer creates
suction on the outlet of the atmospheri c regulato r. This suction on the bottom of the main
diaphragm causes it to open the regulator and try to bring the outlet pressure back up to zero.
The more suction applied to the outlet, the more the regulator opens to increase the flow .
October 2019 43
Figure 1-26
Zero governor
Courtesy of Fives North American Combustion Inc.
Contro l
valve
Air_____.
Air and gas
mix in ventur i
Gas Mixer _
Built-in
limit ing
orifice
~ Atmospheric
"" Drip
leg
(0) pressure
Air/gas ratio
regulator
Courtesy of North American Mfg. (Canada) Inc.
By changing the air flow through the blower or mixer, the gas flow through the zero governor
changes automatically. These systems are ideal for modulating premix burner systems. Although
Figure 1-26 shows a large zero governor normally used on industrial appliances , a zero governor
can be incorporated into a combination gas valve for smaller input premix modulating burners, as
shown in Figure 1-27.
44 October 2019
Figure 1-27
The combination gas valve on a Viessmann matrix burner incorporates a zero
governor
Air/ gas proportioning regulators

An air/gas proportioning regulator (often called a 1:1 pressure ratio regulator) is similar to a zero
regulator , except that it delivers a pressure that matches the air pressure. Similar to the
referenced pressure connection shown earlier, the air pressure is applied to the vent opening on
the spring side of the diaphragm through a sensing line connected to an air supply line delivering
combustion air to the nozzle mix burner (Figure 1-28) . The outlet pressure from the ratio regulato r
changes automatically whenever changes are made to the air flow pressure .
October 2019 45
Figure 1-28
Air/gas ratio regulator on a nozzle mix burner
Air---e►
Manua l
valve
valve
Burner
4 pipe
Gas dia. (min.) Limit ing
10 pipe orifice va Ive
dia. (min .)
Ratio
regulato r
Alth ough Figure 1-28 shows a ratio regulator arrangement normall y used on industri al
appliances , a gas/a ir ratio regulator can be incorporated into a combination gas valve for small er
input premix modulating burners, as shown for the boiler burner in Figure 1-29 .
46 October 2019
Figure 1-29
Gas/air ratio controller on a Lochinvar modulating condensing boiler
Propane regulator systems

A big difference between natural gas systems and propane gas systems is that natural gas
system pressures in serv ice piping usually do not experience the same change in pressures that
propane systems do.
Propane storage container pressures may vary from as low as 8 psig (55 kPa) in winter to as high
as 220 psig (1500 kPa) in summer due to changes of temperature around the container.
The propane regulator system must compensate for this variation and deliver a steady pressure.
The regulator must also be able to handle the problems that result from the intermitten t use of the
appliances attached to it.
Although single-stage regulator systems are still used on portable propane appliances or on older
permanent installations, the Code has required all permanent installations use two-stage
regulator systems since 1995.
Two-stage regulator systems have a numb er of advantages over single-stage systems, including
the following :
• They deliver a more uniform appliance pressure because the second-stage regulator receives
a relatively uniform gas flow from the first-sta gie regulator .
October 2019 47
• They reduce the possibility of internal freeze-ups caused when moisture in the gas is emitted
as water and freezes as it drops in pressure (and therefore temperature) through the small
orifice of a single-stage regulator . Two-stage regulator systems have larger orifices and lower
pressure drops through each orifice compared to single-stage systems .
• There is an economy of installation since the li ne between the first- and second-stage
regulators is much smaller than in single-stage systems .
• The allowance for future appliances is enhanced , as additional second-stage regulators may
be added if the first-stage regulator still has additional capacity .
These systems should also be used in non-permanent installations to get full and proper use
from the connected appliances .
Two-stage regulator system

The following are two options for a two-stage pressure regulation system :
• A first-stage high pressure regulator [Figure 1-30(a)] with an inlet from the storage container
and an outlet to a second-stage low pressure regulator [Figure 1-30(b )]. This second-stage
regulator acts as a service regulator to the building .
• An integral twin-stage regulator that performs both of thes e functions internally . An ex ample is
shown in Figure 1-31. Use these when piping distances are 30 ft (9 m) or less . A big
advantage is that the regulator is compact , allowing it to be used easily in mobile homes, on-
site filling , and in average size domestic installations .
48 October 20 19
Figure 1-30
Typical first- and second-stage propane regulators
(a) High pressure first-stage regulator (b) Low pressure second-st age regulator
Copyright Engineered Controls International Inc. (RegO"}

Reproduced with permission
October 2019 49
Figure 1-31
A typical high to low twin-stage propane regulator
Copyright Engineered Controlls International Inc. (RegO)
Clause 5.1.2 of the CSA B149.1 Code requires that the outlet pressure of the first-stage regulator
shall not exceed 1O psi (70 kPa) when supplying a residential installation. However , this
maximum allowed pressure should be reduced to 5 psi in colder climates, such as in Northern
Ontario, to prevent the vapour from changing into liquid when the temperature is low .
The maximum allowed outlet pressure of the second-stage regulator is given in Table 5.1 of the
Code. Although the maximum building pressure allowed inside a residence is 2 psi, most
residential systems are provided with 11 inches w.c. (2 .7 kPa} , except in recreational vehicles
where the pressure must be maintained at 13 inches w.c. (3.25 kPa) in accordance with the CSA
2240 RV Series.
Typical installation of two-stage regulator system

Figure 1-32 shows a typical two-stage regulator installation . The first stage of the system supplies
a nearly constant inlet pressure of 8 to 10 psig (55 to 70 kPa) to a second-stage regulator . This
means that the second-stage regulator does not have to compensate for as much variance in
inlet pressures. Any pressure loss through the pipe or tubing can be corrected by the second-
stage regulator at the building being served. Smaller piping can be used between the first- and
second-stage units because of the higher pressure .
50 October 2019
Figure 1-32
Two-stage regulator installation
First-stage
regulat or
Second-stage
0000
regulato r
□
Usually
10 psig
Single-stage regulator
A single-sta ge regulator is used to reduce tank or cylinder pressures to applian ce inlet pressure
- usually 11 inches w.c. (2.7 kPa). A typical singl e-stage regulator is shown in Figure 1-33. As
previously mentioned , the use of a single-stage regulat or is only allow ed on portable propane
appliance s.
Figure 1-33
Single-stageregulator
Travel stop on closing
cap opens interna l relief
valve in emerg ency
Large 3/4 inch NPT Internal relief valve

drip-lid reduces keeps downstrea m
chance of blockage pressure below 2 psig
by freezing rain
Diaphragm
~
Inlet
Orifice t ube wi t h
straight-through
flow design
Copyright Fisher Controls International Inc.
Reprinted with permission
October 2019 51
Automatic changeover regulators

Automatic changeover regulators (Figure 1-34) are two-stage regulators that are suitable for
homes , mobile homes , and portable two-cylinder installations .
They automatically change the supply over from the "service" to the "reserve" cylinder when the
"service" cylinder is empty. This happens without interruption to the flow.
These regulators also allow the refilling or replacement of the empty cylinders without interruption
of the supply to the system. They come with indicators that let you know the status of the tank the
arrow is positioned to and also allows the reserve cylinder to supplement the flow of gas from the
in-service cylinder during extreme load of severe cold conditions.
Figure 1-34
Rego automatic changeover regulator
Courtesy of Rego Products
Selection requirements
Selecting the correct gas regulator depends upon a number of factors. The main factors relate to
the rate of flow , type of gas, maximum and minimum gas inlet pressu res, outlet gas pressure , and
pipe or tubing size. These factors need to be taken into account before choosing a regulator .
Selection factors
Before you can select a regulator for a particular application, take into account the following
factors relating to the piping system. First , complete and size a sketch of the piping system, then
get the following information:
52 October 2019
Information Description
Rate of flow The rate of flow through the regulator is determined by the
number of appliances connected to the downstream piping
system . This flow rate is usually expressed in standard cubic
feet per hour or standard cubic metres per hour.
The type of gas Ensure that the regulator is designed for use with the intended
fuel gas (natural gas or propane) as the flow rate is effected by
the specific gravity of the gas.
Inlet gas pressure Regulators are manufactured with a maximum and minimum
inlet pressure rating. Select the regulator that is designed to
handle the possible range of inlet pressures. The maximum inlet
pressure is a factor in determining overpressure protection
requirements . The minimum available inlet pressure is an
important factor in determining the rate of flow (capacity) the
regulator can deliver.
Outlet gas pressure The outlet gas pressure is the downstream system-operating
(setpoint) pressure. This pressure is usually adjustable within a small
range and is necessary to select the proper spring. Outlet
pressure is also a factor that effects the flow rate through the
regulator, as the difference between it and the operating inlet
pressure determine the allowable pressure drop through the
regulator.
Piping or tubing size The inlet and outlet pipe or tube size is a factor in determining
how to select the regulator body size .
Sizing factors
The following are general guidelines for sizing regulators. When sizing any regulator, always
consult experienced personnel or the manufacturer.
Body size The regulator body size should never be larger than the pipe
size. However , a properly sized regulator can be one or two
sizes smaller than the pipe.
Construction The regulator should be constructed from materials compatible
with the nature of the gas, the gas flow, and the temperature
used. Also ensure that the regulator is available with the desired
end connections.
Pressure ratings Pressure-reducing regulators are sized by using minimum inlet
pressure to ensure that they can provide full capacity under all
conditions. It is also very important to take note of the maximum
inlet and outlet ratings. Downstream pressures significantly
higher than the regulator pressure setting may damage soft
seats and other internal regulator parts.
October 2019 53
Spring pressure range If two or more springs have pressure ranges that include the
desired pressure setting, use the spring with the lower range for
more accuracy.
Spring performance The full published range of a spring can generally be used
without sacrificing performance or spring life .
Orifice diameter The recommended orifice size is the smallest diameter that
handles the flow. This benefits operation by:
• avoiding instability and premature wear;

• allowing for smaller relief va lves; and
• reducing lockup pressures .
Wide-open flow rate The capacity of a regulator when it has failed wide open is
usually greater than the regulating capacity. Use the regulating
capacities when sizing regulators and the wide-open flow rates
only when sizing relief valves.
Accuracy Evaluate the need for accuracy with each installed regulator.
This is expressed as droop, which was discussed in the previous
section.
Inlet pressure losses The regulator inlet pressure used for sizing should be measured
directly at the regulator inlet. Measurements at any distance
upstream from th,e regulator are suspect because line loss can
significantly reduce the actual inlet pressure to the regulator .
During the design stage, this measurement is not available;
therefore, the best practice is to select an operating inlet
pressure based on the maximum allowable pressure loss criteria
that was used for sizing the piping system. For example, a 5-psi
system is sized based on a 2.5 psi pressure drop; therefore, the
operating inlet pressure for the line pressure regulator would be
2.5 psi.
Turn-down ratio Within reasonable limits, most soft-seated regulators can
maintain pressure down to zero flow. Therefore , a regulator
sized for a high flow rate usually has a turn-down ratio sufficient
to handle pilot-light loads during periods of low demand.
Speed of response Direct-operated regulators generally have faster response to
quick flow changes than pilot-operated regulators.
Overpressure protection Evaluations for overpressure protection should also be made at
the time of regulator selection. As discussed previously, if the
service or line pressure regulator has a system pressure of 2 psi
or less and is equipped with a vent limiter , overpressure
protection is not required. If the system pressure is greater than
2 psi then either; internal relief, line relief valve, or another
approved method of overpressure protection (OPP) would be
required.
54 October 2019
Most regulator manufacturers offer a range of models to supply the required flow rate depending
on inlet pressures and outlet pressures. Larger regulators may have the option of replaceable
orifices and a range of springs that may be selected for each model of regulator depending on the
particular application. When you are to make choices, always select the smallest orifice size that
will provide the required flow rate, largest practical diaphragm, and the lightest spring rate. These
guidelines will provide the best regulator performance.
Selection guides, tables, and online programs

Regulator manufacturers offer a variety of models to accommodate the wide range of job
applications. Although their sizing tables may have different formats between the various
manufacturers, the required information needed to select an appropriate regulator and its
components is the same for all manufacturers. An example of a typical model selection guide and
some product catalogues are included in the appendix.
The selection process can seem very complexed if you were to try and look at all of the
specifications for each model of regulator available. To streamline the process, the first step is to
narrow the choices down to a few models by applying the selection factors related to your piping
system. You can apply these factors to a Model Selection Guide or what is more commonly used
today is an online sizing program. Figure 1-35 shows a snapshot of the computer screen in which
the initial section factors have been inserted into the appropriate fields of the Itron online
program.
Figure 1-36 shows the on line software results for the information that was given. If you were to
compare with the charts supplied in the appendix, you would get a similar result. In Figure 1-37, a
portion of the B-42 capacity table is shown. Since this table does not include an inlet pressure of
2.5 psig, you should use the 2-psi column to ensure that you do not undersize the regulator.
According to the tables, this regulator is supplied with a 5/16-inch orifice and 385 SCFH of natural
gas. This is lower than what the online software predicted but do remember that the online
software enables us to use a higher inlet of 2.5 psig.
Notice that the left side of the chart also indicated the standard spring supplied (Silver). If we look
at the spring selection chart (Figure 1-38) for this regulator, you will see that the blue spring is the
lightest spring that will achieve the desired setpoint off 14" w.c., which is consistent with the
online results.
The model ending in the Letter "R" would be chosen as it has the necessary internal relief.
October 2019 55
Figure 1-35
Itron regulator online sizing application - Parameters screen
Courtes y of Itron Inc.
Step 2: Parameters
SCf~ N:m.ra l caw •
[1111l1WC.;•
,..,,mun, lnr1tPNsswe
,,
M-AXfflllffllftilt PrfflUN
Mu Alowi1bla ouu,t PreHUl'9 ilt FilJIUn (O pttoni11)

2u l1n Cl't°\~ •
Figure 1-36
--
Itron regulator online sizing application - Results screen
Courtesy of Itron Inc.
Selected Regulators
Cldt tier• 1Dr ._,.
""""' ,.,.
i,IJDnn.aDon
Odnce :
'!OSC>C
H(N_ G,,i ___ __,
1'Jlio,ctW\.
BIUF
Y'M• Open flow, ; 19!Ni sc r H fN,H.u(•ICAI) ,1101Sprma:
Spring R;)nge; uu10 ,.a.uInct wt:
Ill Ft-MMIZI
Figure 1-37
B42 14" w.c. outlet pressure capacity table
Courtes y of Itron Inc.
B42 Series commercial regulator , models N and R
14" w.c. (34 mbar) capacity table (2" droop) ,¾" outlet valve bodies
Capacities in SCFH of 0.6 S.G. gas ; base condit ions of 14.7 PSIA and 60°F.
Typical capacity info.
Manufa cturer I Itron
56 October 2019
Type and model B42 N, R

Regulator
Inlet size ¾"NPT
Outlet size ¾"NPT
Spring colour Silver
Inlet pressure Orifice size

PSIG BAR 1/8" 1/8" X 3/16 " ¼" 5/16 " 3/8" 1/2" 1/2" X
3/16" 9/16 "
1 0.069 - - - 105 270 230 365 420 (
(3 .0) (7.6) (6.5) (10 .3) 11.9)
2 0.1 - 100 220 300 385 450 550 ( 590
(2.8) (6.2) (8.5) (10.9) (12.7) 15.6) (16.7)
3 0.2 95 110 270 445 445 515 ( 650 ( 720 (
(2.7) (3.1) (7.6) (12.6) (12.6) 14.6) 18.4) 20.4)
5 0.4 150 280 390 540 625 740 ( 880 ( 930
(4.2) (7.9) (11.0) (15.3) (17.7) 21.0) 24 .9) (26.3)
10 0.7 360 390 570 820 960 1100 1225 1270
(10.20 (11.0) (16.1) (23 .2) (27.2) (31.1) (34 .7) (36.0)
Figure 1-38
B42 spring selection chart
Spring data , spring colour outlet pressure range
Colours Outlet pressure range* *
Standard spring data
Green 5 - 7" w.c.
Brown 6 - 8" w.c.
Blue 8 - 14" w .c.
Silver 12 - 28" w .c.
Yellow /Black 1 - 2 PSIG
Purple 1.5 - 2 .25 PSIG
Alternate spring data
Orange 5.5 - 9" w .c.
Dark green 4 - 9" w.c.
High pressure spring data
October 2019 57
Yellow 2 - 4 PSIG
White 4 - 5 PSIG
Relief spring data
Purple 7" w .c. above set point
Orange 5" w.c. above set point

Red 6" w .c. above set point
Black 9" w.c. above set point
Additional issues for propane regulators

Follow a systematic approach when sizing propane regulator systems. First, determine the
lowest operating temperature for the storage containers serving the installation.
Table 1-2 lists the approximate vapour pressures corresponding to a range of temperatures.
Table 1-2
Approximate vapour pressures of propane
Temperature °F (°C) Approximate pressure psig (kPa)

-40 (-40) 1.3 (9)
-3 0 (-3 4) 5.5 (38)
- 20 (- 29) 10.7 (73.8)
- 10 (- 23) 16.7 (115)
0 (-18) 23.5 (162)
10 (-12) 31.3 (216)
20 (-7) 40.8 (282)
30 (-1) 51.6 (356)
40 (4) 63.3 (437)
50 (10) 77.1 (532)
60 (16) 92.5 (638)
70 (21) 109.3 (754)
80 (27) 128.1 (884)
90 (32) 149.3 (1030)
100 (38) 172.3 (1189)
110 (43) 197.3 (1361)
58 October 2019
If using propane for space heating , select the lowest temperatures the storage containers are
likely to be exposed to over a 24-hour period. Consult with the local propane distributor for a
reasonable design temperature that reflects past experience.
It is also important to check the maximum temperature so that the full range of storage container
vapour pressure is known.
Next , determine the maximum load in Btu/h (or kW) by adding all the inputs from all of the
appliance rating plates connected in the system. Also take into account seasonal demands.
Always use the peak demand.
Now use a regulator manufacturer's performance curves to select the appropriate first- and
second-stage , or integral twin-stage regulators. shows a typical performance curve for an integral
twin-stage regulator.
Figure 1-39
Performance curve for a twin-stage regulator
1
14 _150 ps\g (1030 kPa) inl~t
C:
-
_In iti al setting I I I
I 100 psig (690 kPa) inl et _
... E::,
QI 13 '
'I
~ 8 12 , .I /
7
75 psig (515 kPa) inlet
~ ai 11 - ~ • I
-- • ,,
~
C.
~ ~ 10,(.:; ~ -- --- l L)
QI
=>
....
0
V, 9
~ - I
~~ I
I
I 50 ps1g{345 KPaJinlet
~ 8 L 10 ps1g 69 KPa) niet
I
cu ft/h 50 100 150 200 250 (:.)300 350 400 450 500
I I I I I
MBtu/h 250 500 750 1000 1250
~ Range of acceptable
de livery pressure
The following are the three steps in using the performance curve:
1) Start at the bottom of the chart, using the maximum connected load from appliances and
equipment. In the above chart , a maximum load of 700 000 Btu/h has been assumed (point 1
on the graph) .
2) Draw a line straight up that intersects the lowest expected vapour inlet pressure. In this case,
the 75-psig inlet pressure curve was used (point 2) based on the lowest expected tank
operating temperature of 1O °C.
3) Draw a horizontal line from this intersection point to the delivery pressure scale at the left
side of the chart (point 3). In this case, a delivery pressure of 10.5 inches w.c. results , which
is within the acceptable range of 8 to 11 inches w.c .
The process is similar when first- and second-stage regulators are being sized. The first-stage
regulator is sized the same way as the twin-stage regulator. The second-stage regulator is sized
using the delivery pressure from the first-stage regulator as its inlet pressure.
Once again, always make use of the manufacturer's literature.
October 2019 59
Location and piping practice
Preliminary planning
Make sure that the regulator is properly installed the first time.
To ensure that the regulator is installed properly, properly plan the installation process .
If all the steps are planned properly, the installation process will usually proceed smoothly.
On-site considerations
First , make sure that you have chosen the correct regulator for the system. It must have the
correct orifice and control spring .
Read the manufacturer 's guidelines for installing the type of regulator chosen . As part of the
process of choosing the correct regulator , use a sketch of the piping system . This sketch will also
help to determine what supplies , equipment , and tools you need to complete the job .
When arriving at the site , check the sketch to ensure that the intended location of the regulator is
suitable.
Regulator location
Place the regulator so that it can be easily serviced . There must also be enough room above the
regulator to allow for the removal of the actuator or the spring casing from the body.
Finally , ensure that there is enough room to install a vent and sensing line if they are required .
Details on the location of the pressure regulator are in the Code .
Piping, tubing, and hose systems

The piping, tubing , and hose systems provide the link between the gas supply , the regulator , and
the applian ces .
Check the following items to ensure that the basic requirements for the piping have been met:
• Approved materials have been used for the piping .
• The piping is in an appropriate location.
• The sizing is adequate for present and future applianc es.
Extensive details on approved piping , tubing , and hose systems are in the Code .
Piping connections
1) First , check that there are no misaligned piping conn ections that produ ce strain on th e body
of the regulator . This could crack or warp the body of the regulator and prevent it from
operating corre ctly or cause it to leak gas. Ensure that the piping has proper support so that
it is properly align ed and does not put stress on the regulator .
60 October 20 19
2) Use threaded fittings on pipe sizes up to 2 inches to connect a regulator to the piping . On
larger pipe sizes, use flanged connections.
3) If using threaded joints, clean the pipe threads and apply pipe lubricant sparingly to male
threads, being careful to start a few threads from the end of the pipe.
a) Do not tighten the piping into the regulator body so that it causes stress on the regulator .
b) Do not over tighten the pipe threads into the regulator, as this can damage the regulator
body.
Direction of gas flow

The direction of flow through a regulator is critical for its proper operation .
The flow direction is shown by an arrow or by the words "inlet" and "outlet" at each end of the
regulator .
If ... Then .. .
A regulator is installed Full inlet pressure will enter the diaphragm casing and will
backwards hold seat closed resulting in no flow .
This pressure is high enough The diaphragm casing may rupture , causing regulator
failure, damage to downstream equipment , and possib ly a
fire and explosion.
Service valve and pressure regulator leakage

For information on service valve and pressure regulator leakage , refer to Unit 8 Introduction to
piping and tubing systems > Code requirements for testing.
Troubleshooting of regulators
Most troubleshooting depends on the type of regulator and is normally covered in the
manufactur er's literature . Never repair or change parts in a regulator unless specifically allowed
in the manufa cturer's certified instructions . Always use the manufacturer's approved
replac ement parts.
Before beginning any tests, check that the regulat or is installed in the line properly and that the
pressure conditions and flow rates are within the design limitations of the regulator. Many
problems may also result from misalignm ent of parts due to the rough handling of the regulator.
If the regulator has a bottom plug (Figure 1-40), remove it and work the valve mechanism up and
down with your finger . The valve should move freely .
October 2019 61
Figure 1-40
Regulator with bottom plug
Some common problems and their solutions are listed below .
Problem Solution
Obstructed vents Clear obstructions.
Foreign material lodged between the seat Remove the material and clean.
and disk
Wrong regulator installed for the Replace the regulator .
application
Failure of mechanical parts due to Replace the parts if allowed by the manufacturer's
corrosion certified instructions. Most residential and light
commercial regulators are non-repairable and
must be replaced.
Table 1-3
Troubleshooting pressure regulators
Symptom Possible causes Test Remedy

Outlet pressure too Incorrect spring Remove seal cap. Adjust for proper
high adjustment tension.
In order to check Ruptured Apply soap solution to vent Replace
outlet pressure , the diaphragm outlet - bubbles indicate diaphragm .
appliance must be leaky diaphragm.
operating. Under
conditions of no flow , Flow rate too low Check orifice size to Replace regulator
pressure on the outlet on main burner determine flow (should not with one of smaller
side of the straight- regulators be less than 5% minimum size.
through-flow models ,
(Continued)
62 October 2019
Table 1-3 {Concluded)

will be equal to the main burner regulation
pressure on the inlet capacity) .
side .
Use a manometer Gas turned on Close control valve before This is a temporary
downstream of the upstream with opening manual valve condition and will
regulator to measure control valve open upstream. Wait 30 s, then rectify itself in less
the pressure . A open control valve . than 30 s.
manometer gives a
very accurate Stretched spring Manually turn off gas . Replace with new
reading. Remove seal cap and spring.
adjusting screw. If
spacings between spring
turns are not uniform,
spring has probably been
stretched.
Outlet pressure too Incorrect spring Re move seal cap. Adjust spring to
low adjustment proper tension .
Inlet pressure too Remove spring. Hold Check for
low diaphragm down with obstructions in
screwdriver. If there is no system upstream of
rise in the outlet pressure , regulator.
the inlet pressure is too
low.
Regulator See that the arrow on the If incorrect , install
improperly bottom of the regulator regulator properly .
installed points in the direction of
the gas flow .
Wrong spring Remove spring. Hold Replace with
diaphragm down with correct spring .
scr ewdriver. Rise to correct
outlet pressure indicates
stronger spring is required .
Inlet pressure too Regulators for domesti c If inlet pressure is
high servi ce are not expected to greater than 28
perform accurately if inlet inches w .c. (7 kPa) ,
pressure is greater than 28 consult
inches w .c. (7 kPa). manufacturer for
special
applications .
Regulator responds Obstruction in vent Inspect vent opening on Free vent hole with
but action slow or causing limited top cover of regulator. In small wire. Be
sluggish diaphragm the event the regulator is careful not to
movement vented to the combustion puncture
chamb er or some other diaphragm .
(Continued)
October 2019 63

remote location , be sure
that the venting tube is free
of dirt, ice, or other
obstructions .
Regulator Remove surge arrester Check that orifices
equipped with from vent to see if in surge arrester
surge arrester for regulator response is are clean and not
purposes of restored . blocked. Check with
improving manufacturer if the
combustion surge arrester is
characteristics properly sized for
the application.
Sensing hole at This condition occurs very Remove regulator
base of threads on rarely , but when it does from line, clean
outlet side of valve exist it will always be sensing hole, and
chamber blocked detected at time of original re-install.
by excessi ve pipe installation .
dope
Regulator formerly Change inlet Remove spring. Hold Check for
operating pressure diaphragm down with obstructions in
satisfactorily , will no conditions screwdriver. If there is no system upstream of
longer maintain rise in the outlet pressure , regulator.
outlet pressure the inlet pressure is too
low.
Regulators for domestic If inlet pressure is
service are not expected to greater than 28
perform accurately if inlet inches w.c. (7 kPa),
pressure is greater than 28 consult
inches w.c. (7 kPa). manufacturer for
special
applications.
Loss of flexibil ity of n/a Replace
diaphragm diaphragm .
Appendix: Typical regulator selection guide and

capacity tables
The following tables are examples of typical manufacturer 's regulator selection guides. Select
pages from different manufa cturers catalogues have been provided here courtesy of Itron Inc.,
Maxitrol Company Inc., and Pietro Fiorentini S.p,a .. Additional factors may have to be considered
when selecting a regulator , as discussed in the Selection requirements section.
64 October 2019
Itron Regulator Quick Reference Model Selection

Guide
Max Fl ow Yilllve Body Size Mu Inlet Outlet Pren ure Model
Rat e CFH (ln lnc hu} PrH sure 1.W. C. PSIG
PSIG (max. )
, 'l'ln In , 11.1 • 1 • 1 1)4 11~ B-42-N-R
?.<nn IM -1(4 • I • I 1),1 125
"'"" sn B-42-HP-N-R
2 500 In - J/4 · I· I 114 125 Yes B-Jl •N•R•lM-IMV
2 500 tn -3M· I · 1 114 125 20 B 31 HP•N R-IM CMV
2~0 l/2-3( .t.J . t l/4 125 Yes B-57-N-R
, 'l'ln In . 1(4 . 1 • 1 11<1 11~ 1n B-57-HP-N-R
, <nn ,n . 11.1 . 1 . 1 11<1 17~ v- ~-58-N-R
2 500 tn -3f4 · I · I 114 125 20 B-58-HP-N-R
3 500 I tn - 2 125 Yes 3-34-S-N-R
3 500 I tn - 2 125 20 ~-34-SHP-N-R
1n nnn I 10.? 17~ v- B-'.H-N-R-O-M-IM-lMV
20000 I 1/2 · 2 150 50 l-34-N-R-D-M-IM-IM\I
n oon 114 • I lOOO 1~n n B-35-N-R
10 000 'l/4-l-11/ 4 175 600 B-36R
,0 000 I 1/2 -2 100 Yes 3-38-NR lM·IMV
~6nnn l 1/'l . 1 ,nn \n B-38-N·R·Il~-IMV
S 000
gn nnn
innnnQ
I l/2 · 2
2- ~-4
2-l - ~
125
11'i
l'.l~
..
Yes
...,,
2.0
so
B-531-N-R-IM-IMV
B-838-N-R-O-M
3-838-N-R-D-M
50 000 1 - 3- 4 m Yes B-838-IM IMV
56 000 2-3- 4 m S.O B-838-tM-UIAV
A mn 1/d . 1 . 11/4 11< 190 CL-31~"R-IM-IMV
7 'l'ln 1 1/d . I ln.7 17~ 2nn "L2J l-N-R
20000 I 1/2 • 2 150 50 :'.:1,-34-1
D-M-IM-NV
80 000 I tn - 2 150 600 ~1,-3~.2 D-M-IM-NV
40 000 I tn -2 !50 50 " L-'l8-I D-M-IM-IMV
~nnnn I 1/'l.? ,<n ~11n □ -38-lD·M·IM·LvlV
itnnnn l- 3 - 4 1<n ~n '.:1-838-1 D-M-IM-CMV
130.D0
O 2- 3-4 150 300 Cl,.838-l D-M-IM-CMV
600D0O 2-] 275 ]0 0 :W 4000Sc:ne
s
I00D0O I In 230 "'""
Ye:1 ]60 ~ 1700Se:1es
Itron Is a regjst.8'edtrademal1<of Itron. In: @ Itron, Inc NI rights reserved30 September2015

For techl"lc:,jsupport. COJ\t:ocluronsupportSer.tees Teoriee pn01e:877-487-6602
Email: support@ltron com l DC-0919-001
October 2019 65
B42 Series Regulator

ResidentialcKldLight CommercialRegulator
"Pie B42 is a spr ng 1oads<jself-operatedregula:orwith internalrsief opt on. The 842 lea:Jres a molded
diaphragm,6:1 leverratioand one nd'l vent. Tne benefit s a hghte<r>'orecompact LA'lt tnat providesthe
pol'.rer,capacty and re 1elperformanceof largerregu ators.
APPLICATIONS 842A COMPACT

SIZE
fUf
Con~l(ft p·f;t;~t.. rudx:.i:..11 ol WJ..., • ltv; U4lH I& L'191''11''1.i ·.Jl81(HJ
,WJOO ,..,..,if! 1hr.mr.de. fl4?is =, ~
ice, oorr sstic ard l9ht commerc1BI
tyJ:? r:Jlhs 842 Series. ,ie la,ge 1' r terral :h.n :rad tiara regJlatars it was sleo
.ip;,u,bo<t;:I rei,ei val'l9 P'O'IOQ,SQKCCp\lorJ rellOI ~•1ooc to r-(.OI cus1cmorsxpocldlOl1$
capac i·y. lor SBE')' a'l:J ong field lie 'Iha 842 1s
OPTIONDESIGNATIONS to =ollckltn prcdrt l.f'..a
O'JfJll)ooc no
N ~ lnle<nllR,sl,ef DESIGNED
TOINCREASE
VOUP. b• bo1hresdna l ano 1g~:commercol
P hturoJ 11::
lir;f CUSTOMER'SSATISFACTION
ANO ow l~a1◊'IS
REDIJCEYOURTOTALCOSTS
HP A•,alg~,e - S99 ,rprt~ char .
'Iha "'°"" ,s
842 uniqw,fy con;:ructc-d FEATURES
842N 1(1 ~~I.It) lo!<~'.JlOo,:~'J""-~ nooo ll ,Tl • ln"3'Chargeab e a/un1,,m c rifice
1ncreas,'1QIYcc,npex ana ::ompetitb-e
• r"° B42N :. a SO<K'O 100<.lod. scN ·2.s ~a ~-o· dJP"r~~ :rro
rrnuk~,Iliac" I " 11100.,1842 wu;uls
coarat!>dregula·or w 1hno nlrr\a Mclced ceep 001111Clut01
oiaplYa!Jn
YI th OAllflfilRcl «171!,
f\Slt-.ty. flAl'lY'"', H1':A,
rcI10· (NJ vo1•19,T•usroo1aI c.'ln bo '"1th:J rn·u~u l
erd cost. '1B i:;£2 aloo o'la-s "h 119
used on low or ,nl&!med ate irilet
P"\ISS<, res wtlv·oan lntllrral relo' <r
P'"''
co, necnon,--ers1oos dirg 11,-., • Flateds·;;al G:I !Ewer
i,oato,;I flE~1bl ly lo, yov rGQul.i.10,s • Orr.prcomc11<1c.11'11,n;I\ ~1',,() se<il
ct'lil' type ol a.,.1-pr.ss .re Pf• :ecliar
reeds. n addllY.lr.-d11e
ro ,nventtlr\- • Oelrin• ,,ant "11."'8
«11tt,Bune-N aaa1
c,:,,ee Is n~trQQ uo•~J.
ard "'"ruluc U1irr9 ont-u,00---0·11<;
Sprlro-,o.:)duc lntw"liJ rsli!,l •t<li'lfl
•his proauct :er :>edalrvered ,,,;:h
842CASTIRON ass,;mt~/
u-para l r;lac :;peed ard ,;ciscu1ng
• ol'e 34:>Cast -oo e e vasicn ol the 1342 do~r.n:hhh ·t " ar,J .,, lh~J.O'.,J 1/Cl't •1,1lhStlO •;S:.
w th a ::o5t l•oo dai:t"t·.:mcaoo tn.:.tc-..r steel acraen
b6 uSEd r a ct c, cub vault a::iphcaticn
• Fot.r..;,~:,;;rvr.rur~~uµ.,lyu~~ •(.I •J >Ca
cap w1h rteg·al relia1•;al/8 atoo
• r0011intmh argtJOt,,oo-ti.siJ'TlerYt-:o,11J
• 1 ••
SP[CrrlCATIONS
66 October 2019
B42 SERIES RESIDENTIALREOULATOR, MODELS NANO R

i' w .c. (17 mbarl Capacity Table (1" Oroop•I , 314" Outlet Valve Bodies
ti~ in SCFH ~mM,r) of 0.6 S ,G. n : b,~c-condDano;Qf 1~.7 PSl<\■nc61Y F.
C.:.,::111.::i
Typ ical Capacity Info . Inlet Pressure OrtlioeSize
Manufacturer In-on PSIG BAR 118" 1/8x3M6'' 3/16" 114" ~ 16'' 318" ·1/2" 112x 9t16''
Type and model 942 R 0.5 0.038 55 [1.6) 60(17) 70 (2 OJ 80(2 .3) 95 (2.7) 210 (59) 270 (7 6) 280 (7 9)
Regu lator 0.069 60 :1 .7) 80 (2 3) 65 (2 4) 200 (5.7) 275 [7.8) 3 00 [8 5) 360( 10.2) Z85 (10 9)
lnlot SIZO. 3/4" I\ PT 2 0.1 60( 2.3) 95 (2 7) 225 (6.A) 250 (7. 1) 365 (10.3) 425 (12.0) 495 (14.0) 485 (13. 7)
Outlet size 314" NPr 3 0.2 105 (3,0) 225 (6.4) 290 (8.2) 350 (9.9) 470 (13.3) 525 (14.9) 595 (16.S) 595 (16.S)
Spr ng oolnr RrO\'-"l 5 03 2 10 (5 9) 280 fl !'I) 4:0 (11 3) r,r.o (14 2l 600 (17 0) 7 15 (?O?) 805c;,:;>II) 830 (73 5)
Position 5 10 0.7 340 (9.6) 390 :11.0) 6:lO (17.0J 850 (24 .1) 940 (26.6) 1085 [30. 7) 1300 (36.8) 13 10 [37. 1)
15 1 .0 425 (12.0 ) 470{13 .J ) 6-"'0 (24. 1) 1 100(31 1) 130 0 (36.8) 1415 (40. 1)
20 550 [15.6) 550 15.6) 1 5( 6
30 21 700 (19.8) 700 (19 .8) 1400 (39 6) 1 soo(45 3)

40 2.8 850 (24 .1) 8 70{2 4 .6) 170 0 (4!! 1) 100 0 (538)
50 3 .5 1000 (26 .3) 1020 (26 .9) 100 0 (63 8)
60 1 1150 (32 . ) 1 ! (33 7) 0 (56

80 5.5 1500 (42.5) 1475 (41.8) 2200 (62 3)
100 6 .9 1800 {51.0) 1•175 {41.ll) 2000 (5'5 6)

125 B6 2150 (6: 3) 1475 (41 B) 200 0 (56 6)
In let E:llect A (on;;hesw.c.) 01 0.2 O.~ 0.4 0.4 0.6 0.6 1.0
Loci< Up B (incheswc.j 04 0.4 0.4 0.5 0.6 06 09 , 1
Not!>S·
A. Charigein outet pressure'or 10 PSIG ,nletpressurechange
8 . Outlet pressure inc rease required for oc< up
•1ndiv idual reg ulatc· performance M.li' vary 'ror, data sh:,w•1.
- 0o not cpa,rale Cllllce ,n shaded mlat p 1ess u1e «rea .
,
/Iron I B42 Senes Res.denta l Regulator 7
October 2019 67
B42 SERIES COMMERCIAL REGULATOR, MODELS NANO R

14" w.c . (34 mbar) Capacity Tabl1>(2" Droop•) , 314" Oull1>t Valw Be d ies
c. ,,., ;, scrn c,1
0.es G ~~. t:e~~ ca, citicn~ r:114 .7 P.ClA.zu d 80" F.
Inlet Ol'lllCOSIZ<l
Typical Capac ity Inf o .
Prossuro
Manut.icruror Itron PSI BAR 118" 118x 3116
" 3116"' 114" 51'16" 318'' 1/Z' 112x9116'
'
Typ e and mo de l ~2 N. R 0.06 9 10!>(30} 2/ 0 (7.6} 23 0 (8.!l) 385 (10 .3) 4 20 ( 11 .9)
Regulato r 2 0 .1 100 (2.8) 220 (62) 300 (8.$) 385 (10.9) 4 50 ( 12.7) 550 (15.6) 590 (18 .7)
lnle:sze 314 NPT 3 0 .2 95 (2.7) 110(3 .1) 270 (7.6) •1<15(12.6) 4<15 (12 .6) 5 15 (14 .6) 600 (18 .4) 720(20 .4)
O ut et size Jl<l"NP T 5 0 .4 100 (4 .2) 280 (7.9) 390 (1 1 0) 5 40 (15.3) 625 (17.7) 7<10 (21 .0) aoo12<1.9) 930 (26 .J)
Son ng colo r Silv er 10 0.7 360 (10 .2) 390( 11 0) 570 (161) 820 (23-2) 960 (27.2) 1 100 (3 1 ") 122:3 (34 7) "27 0 (350)
Pc:sition 5 15 1 .0 460 (13.0) 500 (14 2) 780 (221) 1070 (30 .3) 1250 (35.4) 1550 (38 .2)
20 1.4 560 (15.9) 590 (18 7'J ,coo(28 3) 1320 (374) 1425 (.:0.4) 1575 (44 .6)
30 2. 1 740 (21.G) 750 (2 1 2)
.:o 2 .8 9 10 (25 .8) 920 (26.1) 1 600 (45.3) 19SC (55 .2)
50 3.5 1050 (29 .7) 1100 (31 1) 1800(51 1) 2080 (589)
60 4 .1
80 5 .5 1500 (4 3.9) 1550 (43.9} 2000 (56 .6)
100 6 .9 1640 (46.4) 1!!60 (5:J.2} 2C00 (56.6)
125 8 .6 2100 (609) 2150 (60 9) 2 150 (60 9)
Inlet El'fecl A (i ncr ..s w .c .) 0.2 0.4 04 05 0.7 0. 7 2.3 2.3
Lock Up B [inches 1•1.c.] 0.6 0.6 07 08 0.9 1.0 1.3 1.3
A Cn ange in ouflel press ure l or 10 P9 G inlet pressure ch ange .

e Outtd p·e,,""Sure increase required tor lo~k up.
• I-idi, idual ·egu l3X>r peio r,n ance may vary from d 31a sho'l,n .
- Do not opera:eorifice 11 st>acled inlet preSS1J

re area
Itron I 842 Series Reside'llia l Reguhstor 11
68 October 2019
SPRING DATA, SPRING COLOR OUTLET PRESSURE RANGE

Colors Outlet ~ure Range-
srancial'dSpringDa ta
Green
Brrn.•m 6-S"w .c
B lue 8 -~ 4" w.c.

Silver 12 - 20"w .c.
YellO',•IBlack 1 - 2PSIG
Pu rple 125-2.25PSG
Alte rn ate Spring Data
Orange 55 - 9"w .c .
Da rk Green 4 .Q"•,v .c
Hlgn PrKsur& spnngData
2-4 PSG
\'Vhi:e 4- 5 PSW
Relief Spring Data
Pu rple 7" w.c. aboveset point
Orange 5" w .c . abo,.•e set poi nl
6'' e,.c. above sol [X)lnl
'Note Ranges a re approximations. Pleese oontad msnufsc:urer to ob:ai n tt-e b est spri ng for your app liostion.
"'Vl/arrung A<l_u&na nl son rigs aro nol ,ntorch angoa b lo bot.•.oon 8 42 a"d e42HP.
ORIFICE DATA , WIDE OPEN FLOW COEFFICIENTS AND MAXIMUM PRESSURES
EmergencyOutlet?tes,;ure (PSIO)
Orifice Si,., ( incJie,;) K - Factor MAOP Emergency Inlet Pressure(PS IGJ
"'°damage++ Contl ln ment++
118 3D 125PS IG 300 30 60
1/8 X 3/16 30 125PS IG 300 30 &J
3116 7"1 125PS IG 200 30 00
114 127 SOPSIG 1:iJ 30 trJ

5116 100 35 PSIG 100 30 $)
3/ll 200 20PSIG 75 30 00

112 416 10PSIG 40 30 00
112•9 f16 416 10PSIG 40 30 &J
+ B42 cast iron ro9ulatoI have a MAOP hrnrtod to 90 PSIG.

++ Fo r maximum pressu ·es , see the /Iron Ragvlata< Pressur e Rst111gsbrochure (TDC -0988-XXX) .
OPERATING TEMPERATURE RANGE
-20'T to 150 "r

• S ilicone valve seat,; ••,,.; able for ap plicatio n s below -20 '•F
ADD ITIONAL SPECIFICATIONS
Avai labl e Vent S izes 1" NPT. '3.U

." NPT
Other Ava il able Options Se3 -,.areto in d ic:ate umpproved tam p eri ng
118'' r, pe plug t;lp on n e t side of •••a Ive body

118" r, pe plug mp on out let side of vo've body
/Iron I 842 Se ries Res idenfa l 'legulator 3
October 2019 69
325-LSERIES
LeverActingDesignfor 2 psiPipingSystems
M axilrof·s us . L Seri~ fin<-pr('s.~ur('
t('gul,11ois ,UP 1012 psi
riping sy<tf'tn< 12, SPrif'< rf'j\1Jl.1•or< ilff' ior l,<f'<Jn r..s;<lpn ti,11,
, ctmmrrt·1,1I, ,1ncfinrfu~rn,1
1ap p :.c:,1~um<.
.
11,e 325 St•rie, fo,1lu1L-,,

d lri,;h bt•rdge li11
~d);<' d>"-'mbly lo
<leliver P<)"it ne de;id end lockup. Tt,e r~u!.ltors are capable
ul prt•Li,e rL-i;uldlirri;t:urrlrul .rum full lluw UU\\·11lu p :lu; fluw.
325-ll
Specifications
PipeSi7l'S............................. "Ill:!"tn 2" thrP.ir!P<IrnnnP<"tirm, wnh 'IP I or IS07 I th•i>,iri<.
Opt ional ...... ... . •............ 1/8" ,'IPT outlet pre«ure IJP' on 325.7, 325-9, and 325-1 r
Housing Material ................. ..... ll.'>-.Jl. 12~-.'>L.J.l5 -7AL, .IL5-'J l : nlu111inun

1.
Mourlling ............................. ..... Suit.iblterur 1111..lli-µu,it
io11~I1l1ou11lini:.lifJ.1IIt:ht:d<vt:ntliir1ili1l!',
dt"viLt' i> in~l.il[t:tl,1nuur1l
irr ,111upr i~ht pmilion uni)'·
NOTE:All Maxilro'.gas pressure reeulalo~ ~hoold be inslllleclJild operated ill accordance
,1,ilhMaxitrol Saie1ywaming ln~ruclions (see GPR_CSA...2rsu,1u:-. fR ,.
..............................J25-Jl, 325-Sl, J25-7Al, 325-9l, 325-1 '1l : A 'I Si Z21.80lCSA6.22 l ine f>re:;s:ire
Certific.1tioos Reguk,tor).
G:lsTypes .................................. Suilolbleior na1U1,1

I, mJnul,1c:ured,mixedg,1ses.liquetic-dpetroleumg,:ise,,,,nd LPIJilS.-Jir
rrlix:un~.
Rated Inlet Pressure ........... ....... 2 JJ>i(13.8 kPJi
M.ui tro l Raled ......................... 10 p, i th'J k~dl
Emergency Exposure Li,nits... .... . 65 psi t43il kP.ii :i,dd , it.le or ,I) ,
M.uimom lndi., id ual load ........ ldri,e,I ~i11gh• l liy lh1• n'l!ulJlur: 125-Jl: 140,000 BII.Jh;
"flfll1dr11.eS<'M:<
l.l C,-·,L: 42,.UUO fltu,11;IL, •7;\L: 1,L,U ,UOORtu1l1; ur,.<Jl: .1.,.1.C,0,0l)!I
RIL./h;
i2 5- 11: ·1,-150,000 R11,.'h
Capa(ily ....... ................... .... ..... lr>:dl ln,1cfoi mu:1rplP.app liEtnc:Pcomh:n P.d
.1}5-.!I rva~,If)"); }50,000 IH1Jh;
315-5L ( 1/2";, 300,000 llt:.i/h: 325-SL 0/1", l '1: 600,000 lltlL'h;
32S-7Al (I l/4", I 1irJ: 1,250,000 B:ull·; 323-9 l :11/2", 2"1:2,250,COOBl~1h:325-11
4.450,CCOOluih
NOTE: C1p~nt i>< ,1•p ;i,.,cf Ill rll'!PrrriN' :hf' m~xcmum muhcplP applian<"Plmrl. Thf' IM};i>'I
sin~lt>ap 11:iJr<:e serve<!O}' tbe r~u:Jtor , bou:d not t'~l"t'<:'<Ithe m ,1x1mu'll indrv ·dua[ load
sl)('lified above,
Ambient Temperature Ranges . -40 10 205 F •:-40to 96 'C
...............Sui1,1bleior pilot flow ,,pplic,1tionc ®
Min imum Regul,1tio11 :o rd<' r110.1 ~ CFH NGi
lmbl ue Technology'' ........... ..... .lH- IL, ·u 5-Sl. !!5-7:\ l. l.!5-'JLmCld d~ m,))' b<.-orckt<YI w ill ' hrblUC' -:-cchnologyr., .. lmb lu<,
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whPn or rfpnnq .
46
Courtesy of Maxitrol Company Inc
70 October 2019
LINE
REGULATORS
Capacities
Capacil 1e. exp1 essedin CFH (m•,11_1~ 0.64 sp gr gas
- - -
Op erat ing Inlet Pn.-ssure
OuU P-1 fN-liCiilU rf'
Moru-1 Pi)ll' Si>I' .5 ps i .75 p,i 1 psi 1., psi 2 psi
S..t P,1int
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: llxrrP.s~rnd (m3/ hl al O.G4sp 9rnas
dl'I l\ uniher
MA> J .0* \\'. C. (1. , lrf'a) .5 l'"i (3 .4 l<Pa
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12.5-7,'\ L bl.S 12 ~ IJ IM'J l.ll.5' • 111!5 ,.1·, .~,
- -- - --
-- $25-'•L
U5-' l l
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111.i [.) lt _fft
-l:l'.!IJ· 119 S'

-- - 1SSi" ,;,1 11
511U I' I'>.I I

---
- ---
Spring
Selection
O ullei Pressure Range (JIImodels)
( e11if i,.rf ~prirr, . . ..... ..... .. ....... 7" tn I I " w.c. : I .7 tn ·•.7 k~)
NOTE:See to pagt>S56 5~ io<aimplt>teSpr 1·g ~lecTion Chm.
mAXIT'RC>L.: 47
Courtesy of Maxitro l Compa ny Inc
October 2019 71
SPRING
SELECTIUN
CHART
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mAXITROL: 57
Courtesy of Maxitro l Company Inc
72 October 2019
GOVERNOR Pietro
Standard Model Fiorentini~
CAPACITY IN C FH FOR .60 SPECIFIC GR AVITY GAS WITH FILTER (CAPAC ITY INITHCUTFILTER I\J BRACK ET S)
1 PSIO 2rs 1n
306 (JOO) !152 (649) 78 !1 ~23)
218 (255) 511 (00 11 788 (827)
369 (450) 665 (612) 946 (1,154)
263 ;321) 616 (?51) 950 (1,158)
496 :5e5J 893 (1.055) 1,270 (1,500)
3:sl (4 11) 826 (fifl7) 1,214 [1,500]
675 ~6St\} 1.218 (1,;>43! 1,731 (2. 1913)

11· w.c . !60~) 1,7l)ij [2,?0·)
..
481 1,127 ( ',4261
i';"•IJ.C 789 i".080) 1;421 (1,949) 2,020 (2,77")
11· ·.\·/:. 561 (770) 1,315 (1,6J3) 2,028 f2,78')

.. ,.,
P.' V•/C. 990 (1, 2a3) 1.786 (2314) 2.540 (3,200)
11' -.NC. 706 (Sl14) 1,6!53 (:>,14?-j 2,549 [3,300)
G' \•1/( .. 2 ,071 (3,062) 3,735 (5,522) !1,31 1 i/,ll:,•1
1 ,476 (2. 183) 3,457 (5 ,110) 5,330 (7,880)
2,!167 (3.197) 4 ,629 (5,700) 6,!181 (8,197j
1 1. \'1i/.:. 1.829 (22/ij ) 4 .284 c::.~oJ 6,605 (6,228)
• ~
~· ~..-
•/.(', S.179 (5854) 9.339 (10,557) 13.278 (1::,,OJ9;
3 .691 (4.173) 8 .643 (9.770) 13.327 (15 ,0:35)
6.530 (7.431) 11 ,775 (13,'.39~} 16.741 ( 19,05"}
4.at.e (5.,97 ) 10,898 c1:>,4 n1} 16,803 (19.121)
7.205 (9 007) 12.993 (1i3,242) 18.473 (23,09::)
5.1a4> (6,240) 12,025 (15,032) 18.~ 2 (23,1 77)
12 ,835 (15 762) 23,145 (28.~24) 32 ,906 (40 ,•W }
9,149 (11,236) 21 ,4 20 (26,300) 33 ,027 {40.~60)

NOTE: Flow rates are actua l s tat ed recommende d capa cit ies, for o ptimal performance .
h11arlrlil irtU:ll-,;i.1:
i11
q , ,,t;it VIW'II.Ga.SIOSl(/1:
.COm • 888.618.8/IJI 5
Courtesy of Piertro Fiorentini S.p.a
October 2019 73
PSIG
Over Pressure Device (C.PD)Model
MainFeatures
■ \•\lorker & Monnor !or adc,;c Saf,aty
■ CSA Certifed 6.22a -2005 ANSI Z21 .80.A2005 Oa% I fo1outlet Ov!lrProssuro Oovico [CPO} Model
lnla:t=-'t"t~l•''" P.;v1!l•
>: 7 · Vt/.c': tv :;P61G
t fl'£GGu1es uµ tu 5 PSIG
01essur;,s up In 1,\ ' 'IN.C c.l'<Jh119
■ CSA CeM6ed S 22E-20'.l5 Al\ SI Z21 BCA2005 Class I for outl;;t
pre-3sL-re3up to 1 !"S IG a~d irlet p•es3ures up too 1-'SIG
■ lntegra Vent Umi:er
■ CSA ;ippr o',oo Extcr!'al Vent Li1"1
rtcr 10 ·,unt line rc,quroo-
■ Pusit r, a '00% bubble liflh l lock1..1
p
■ In let·RM O,Jll,;f fe<d rorts
■ 5CO lo 1 - urnd own
Specflcatloos
■ Sultc1ble for use ·.-Atn\latu ,al 3as,
LPG. <1J1,; ct~er ncn-,;01rc<:: r-,-e, clwn gas
Ven:Slz.es
■ 1/4" NP- 11?" -1 ·
■ Ir.et PrsssJ·a : 7 ' W.C. to 5 PStG CS;l,.~pp-oved
■ 1/2" NP- 1 1.h ' - 4"
■ lo/bx. Inlet 7,25 F-31~for non-CSA
■ Outlet prero ure: 2 · 1N,C. to · 4" WC. fo• CS/1Class I Outlet Spring Range
Outlet p i;w u1e: 2 ' W.C. lo • PSIG 1or CSA Clw,;,,;II
■ Gree11 2" W C. to 6: " WC.'
Outlet prescure: 2' W .C. to 4 25 PSIG for 1,)1-CSA
■ Red 2.7:5"'I·,'.c. to 7.87'' W,G'
■ TeP1perature raf(le -40' F I<• 1[-O"F ■ Bl.:.J<6''1N.C. bJ 14' W.C.'
■ Gonnecli om : ,., .. thru 4"
■ Yellcw 9 8" W.C. tc, 27 :3" V• ! .C.'
■ t•1tlximu11::me-gency Inlet Expo~ure: P·essure: 80 PSIG ■ Vc 'ot 23 .6" WC. to :,,rw.c.Of 0.8:0 to 2 • 3 PSIG •
■ Suiwble for l~ooo r or Gv tcoo r lri;ta .ation ■ Ora,~G t,:, ' w.c. to • • 8" \IV C. 0' 2 to 4 .2 6 PSIG
•• Bmss Ven1li miters must be remove d for outdoor ·~ !"'

rinJ i!tC;~ ·., . t ~- r:,~~: ,:11
1 ·;. r.~· ";
i 11
stallation ..
(j "As A/Jlm)vcdby Local Cod<J
S ilfla Sr11od11rr.is
74 October 2019
GOVERNOR Pietro
Over Pressu re Device {OPD) Model Fiorentini•
C APACITY IN CFH FOR .60 SPECIFIC GRAVITY GAS WITH f ll TE R (CA 0 ACI-Y W ITHOUT FILTER N BRACKETS }
:., f~31:., "'~ -~(;

fl' \'i.C. 785 (~2~l 78S [9Zs)
11' W C. 7S 8 (927) 788 (927)
790 (930) 7'90 [9~0)
9'16 (1,15 4] 94 6 (1, 154)

950 ( 1,158) 950 (1.15-5)
9!3 (1,163) 9:i8 (1,163)
1,270 (1 !iOn) 1,270 ( 1 SOJ)

1,274 ( 1,006) 1 ,274 ( 1,500)
1,279 (1.~ 12) 1,279 ( ' ,512)
1.731 (2," 9:l} 1,731 (~. 1,3;

11 '\ ,.....
:.;,. 1,738 (2,2C1} 1,738 (2, 201:
14 '\',•,:;, 1,744 {2,2CP} 1,744 (2,239;
fl' \'i.<:. 2 ,020 (2,771} 2,020 (2.771;

1 I 'V •/ .C. 2.02e (2.7~1 } 2,02.8 ( 2,781'.
2,035 (?,791) 2,03 5 (2.79 1;
·,
2,540 {3,2QO) 2.~ {J.2 90;
1 1'W. O. 2,549 {3,302} 2,549 ( :J,::s:.12
;
14. \'•:.:.;. 2,!168 (3,3 14) 2,55 8 (3,3 14;
• 5,3 11
!\' l l.f':1
5.3 11 (7,851) (7,9 51;
I lt"l.,V.C. 5,330 {7,880) 5,330 (7 ,ijijO;
14''{ ,:.:.:,,
. s.sao (7,9C9,\ 5,35 0 (7_939;
!I' W.<:. 6,581

•(6 ,197 ) 6,581 (8,197)
11\ 'NC . 6,60S {B,226} 6,605 (l:l,226;
1-1·w .:.:. 6,629 (6,253) 6,629 (8,258:
• t.\" V\•,<.:. 13,27S [15 oo<l) 13,278 [15 009)
1 I ''l,.•·_:.;,_ 13,3 27 (15 005'1 13,327 (15 005)
13,375 (1~:w) 1:),875 (15 1Xl)
16,74 1 (19,051) 16,741 ( 19,051)

16.803 (19 ,121) 16,803 (19,12 1)
16,86!5 (19, 1!!1) 16,965 (19.' R1)
18,473 (23,002) 18,473 IZ3,W2J

1 1 '\"\•.G. 18,.542 123, 1 / /I 18,!!42 (23 .' 77)
14'W.<:. 18.610 (23~2) 18,6 10 [Z.,262)
!\' W.<:. 32,906 (4C.'-1 ') 32,906 '.40 4 11)

11" v-.:
.e. 83,027 (~0.550} 33,027, ;40 ~'33)
.,..,..,/\'.C 33, 149 (40,709; 33, 149 :40 709)
NOTE:Flow rates are act ual stated reco mmended capac ities, for opti mal performance.
I-or add ilb r".~!ii.!ing •1i,il1vmv.Ga,;/mii<fr.
, i;om • 888.618.8787 7
October 2019 75
Overpressure protection
Overview
Purpose
An overpressure condition occurs when the pressure downstream of a regulator exceeds the
maximum pressure rating of any downstream components. If the pressure regulator should
happen to fail , components downstream that are not rated for the pressure upstream could be
damaged . Due to the importance of protecting the system , overpressure protection should be a
primary consideration in the design of any piping system.
Objectives
• describe overpressure protection ;
• describe relief valves;
• describe the function and types of pressure limiting systems; and
• describe security shut-off systems.
Terminology
(symbol}
Pressure buildup over For the relief valve to fully open, the pressure
setpoint (buildup) must build up to some level above the setpoint
of the relief valve.
Introduction
Overpressure occurs when pressure downstream of a regulator exceeds the maximum pressure
rating of any downstr eam component. It indicates a failure in the system that could result in a
dangerous condition. Overpressure protection is a primary consideration in the design of any gas
piping system.
The objective in providing overpressure protection is to maintain the pressure downstr eam of the
regulator at a safe maximum value. This means ident ifying the weakest part in the pressure
system, then limiting overpressure to that component's maximum pressure rating .
To identify the most vulnerable components, examine:

• the maximum pressure rating of downstr eam equipment;
• the low-pressure side rating of the main regulator; and
76 October 2019
• the piping.
The lowest maximum pressure rating of any of these components is the maximum allowable
pressure .
The worst-case conditions of regulator failure are those in which the regulator fails in either a fully
closed or wide-open position .
Position Description
A fully closed regulator • Produces an underpressure condition .
• This is not damaging to equipment but may create
dangerous conditions in the combustion chamber .
• This condition can be detected with pressure switches that
will shut the equipment down until gas pressure is restored .
A fully open regulator • Causes excessive pressure conditions that are damaging to
equipment and create a potentiall y dangerous situation.
• These conditions can be controlled by using some form of
overpressure protection .
Types of overpressure protection include :

• pressure relief using relief valves ;
• pressure limiting; and
• automatic shut-off .
There are three selection criteria to evaluate the various methods of overpressure protection:
Selection criteria Description

Continuity How important is uninterrupted downstream flow?
Where the excess flow is Is the excess flow directed to the atmosphere, or is it contained
directed in the system?
System failure warning How is it indica ted that the system has failed and is operating
on the safety system?
With this in mind , briefly examine the advantag es and disadvantages of the three methods of
overpressure protection as shown in Table 2-1.
October 2019 77
Table 2-1
Advantages and disadvantages of different methods of overpressure protection
Method Relief valve Pressure limiting Automatic shut-off

Continuity Provides continuity of Provides continuity of Does not provide
service service as one continuity
regulator takes over
when another fails
Excess flow Normally released to No gas vented to the Any excess gas
the atmosphere atmosphere pressure contained in
the system
Depending on the
nature of the gas and
the location of the
valve, this can be
dangerous. It can also
be noisy and create
unpleasant odours.
Failure warning Often given by the Not very clear, as the Very clear since the
noise and odours as the bac kup regulator will system shuts down
gas vents to maintain system
atmosphere pressure so no effects
are sensed
This may go unnoticed downstream
in isolated areas .
Visual inspection and
slightly higher pressure
are indications .
Relief valves
Relief valves maintain the pressure downstream of a regulator at a safe maximum value using
any device that vents fluid to a lower pressure system (often the atmosphere). They are
considered to be one of the most reliable types of overpressure protection available and are
popular for several reasons, including the following:
• They do not block the normal flow through a line .
• They do not decrease the capacities of regulators they protect.
• The noise and the odour act as an alarm if they vent to atmosphere.
Pressure buildup
A relief valve has a setpoint at which it begins to open.
For the valve to fully open, the pressure must build up to some level above the setpoint of the
relief valve. This is known as pressure buildup over setpoint, or more simply , buildup (Figure 2-1 ).
78 October 2019
Figure 2-1
Pressure buildup
Pressure
buildup
Relief valve
_______________________ • setpoint
~
::I
"'
"'
...
Q)
Cl.
- - - - - - - - - - - - - - - - - - - - - - - Regulator
setpoint
Lockup Droop
Flow
Relief valves are generally available in four types , namely:

• pop-type;
• direct operated;
• pilot operated; and
• internal relief valves.
Pop-type relief valves

Pop-type relief valves are essentially on-off devices. They generally operate in either the closed
or wide-open position, as shown in Figure 2-2.
Figure 2-2
Pop-type relief valve
Loading
spring
Poppet
Seat
ring
Closed Wide -open

position position
October 2019 79
Operation
Pop-type designs register pressure directly on a spring opposed poppet , as shown in Figure 2-2 .
The poppet assembly includes a soft disk for tight shut-off against the seat ring.
When the inlet pressure increases above the relief valve's set pressure , the poppet assembly is
pushed away from the metal seat. As the poppet rises , pressure registers against a greater
surfac e area of the poppet. This dramatically increases the force on the poppet , so the poppet
tends to travel to th e fully open position until the overpressure condition is reduced.
This style of relief valve does not throttle the flow over a pressure range. Because of its on/off
nature , it may create pressure surges in the downstream system .
If the relief valve capacity is significantly larger than the failed regulator's capacity , the relief valve
may overcompensate each time it opens and closes, causing downstream pressure to become
unstable.
Setpoint
The setpoint of a pop-type valve cannot be adjusted by the user. This is a safety measure that
prevents tampering with the relief valve setpoint. A pinned spring retainer, initially loaded by the
manufacturer , keeps the spring in position.
Application
This type of relief valve is almost exclusively used by natural gas distributors upstream of the
building meter set where venting to the atmosphere is acceptable and where relief pressure
variations are allowable . It is low in cost and its small size allows installation where space is
limited .
Direct operated relief valves

Direct operated relief valves provide throttling action and require less pressure buildup to open
the relief valve .
This relief valve looks like an ordinary direct operated regulator , except that it senses upstream
pressure rather than downstream pressure . It also uses a spring close action and contains the
same essential elements as a direct operated regulator (Figure 2-3) :
Element Description
Diaphragm Measures the system pressur e
Loading spring Provid es the initial load to the diaphragm and is used to
establish relief setpoint
Restri cting element Throttles the flow
80 October 20 19
Figure 2-3
Direct operated relief valve
Diaphragm
Valve
ow<;>
D System pressure
D
Lower-pressure area
(usually atmosphere)
Pi tot tube relief valve

While some direct operated relief valves require significant pressure buildup to achieve maximum
capacity, others with the pitot tube can often pass high flow rates with minimum pressure buildup
(Figure 2-4 ).
The pitot tube can decrease pressure buildup over setpoint.

• When the valve is opening, high fluid velo city through the seat ring creates an area of
relatively low pressure .
• Since the low-pressure area is located near the end of the pitot tube, fluid will be drawn out of
the volume above the diaphragm, which helps to open the valve.
• The result is increased relief valve capacity and reduced pressure buildup.
October 2019 81
Figure 2-4
Pitot tube operated relief valve
Loading
Diaphragm
Adjusting the setpoint

The setpoint of the direct operated valve can be adjusted by removing the cap and turning the
adjusting nut clockwise to increase , and counterclockwise to decrease, the relief pressure.
Application
Direct operated relief valves are commonly used in natural gas systems supplying commercial
enterprises like restaurants and laundries , and in industrial furnaces.
Internal relief valves

Regulators that include internal relief valves may eliminate the requirement for external
overpressure protection.
An internal relief valve contains:
Element Description
Loading element Its own light-loading spring
Measuring element Shares the main measuring diaphragm
Restricting element Located in the centre of the main measuring diaphragm
The restricting element is composed of the main diaphragm

and the relief valve seat, which are pressed together by the
relief valve loading spring.
82 October 2019
Operation
When no gas is flowing and the downstream pressure is normal, both the internal relief valve and
the valve disk are closed (Figure 2-Sa).
During normal operation of the regulator , the underside of the main diaphragm senses
downstream pressure , while the main loading spring applies a loading force to the top side . The
small loading spring of the relief valve has no effect on normal regulator operation.
Changes in downstream pressure alter the force applied to the underside of the main diaphragm.
This produces movement in the position of the diaphragm and a corresponding change in the
position of the disk and seat in the restricting element.
Overpressure conditions develop when the downstream pressure increases above the setpoint of
the regulator . This is usually a result of dirt lodging between the disk and seat , or of internal
component failure. When an overpressure condi tion develops , the downstream pressure lifts the
main diaphragm until the relief valve seat com es in contact with the pusher post (Figure 2-Sb). At
this point , any increase in downstream pressure compresses both the main and relief loading
springs. When sufficient force is applied, the main diaphragm and the relief valve seat separates
and allows gas flow to pass through the centre opening in the diaphragm to the relief valve
opening.
The amount of pressure buildup over setpoint depends on the spring rate of the relief valve spring
and the size of the main regulator orifice . Remember that to keep pressure buildup to a minimum ,
the main regulator orifice should be the smallest size that maintains the maximum required flow
rate .
October 2019 83
Figure 2-5
Internal relief valve
Diaph ragm
Int ernal relief Valve
valve disk
Pusher pos
Seat ring
(a) With gas not flowing and downstream

1f
pressure normal
1f
(b) Internal relief in operation due to high
downstream pressure
Copyright Fisher Controls International Incorporated

Reprinted with permission
Adjusting the setpoint

The loading for ce of the relief valve loading spring is not adjustable. The relief va lve setpoint is
determined by the combin ed spring rates of th e re lief va lve and regulat or springs. This design
generally requires signific ant pressure buildup to reach its maximum relief flow rate .
Application
Internal relief valves are used in se rvice regulat ors, line pressur e regulat ors, and appliance
regulators for industrial equipment.
84 October 2019
Sizing relief valves

The size of the relief valve depends on the system . Relief valves are made for different
applications and operate in different ways . They also handle different pressure ranges .
Once the type of system and the pressure ranges that the system can safely handle are
established , consult manufacturers ' tables before choosing a relief valve.
Note: You should be able to set the pressure on a pressure relief valve at a higher value than the
pressure on the regulator, but it should still be in the range of downstream pressure limitati ons.
Venting relief valves

Some aspe cts of venting gas pressure systems are discussed in the Pressur e regulators chapter .
Vent ing of relief valves is also covered extensive ly in the Code . Check the Code for all the
relevant regulations before planning a venting system for a pressure relief valve .
In particular , sizing relief valve vents are covered in Clause 5.5 of the CSA B149 .1 Code . The
manufacturer's rule of thumb for sizing relief valve vents is that it must be the size of the outlet if
the termination point is less than 1Oft (3 m) away from the relief valve . For every addit ional 1Oft
(3 m) farther away it is, the vent outlet must increas e one size . A 90° elbow has an equivalent
length of 3 ft (1 m). For long lengths , conta ct the manufacturer or the authority having jurisdiction.
Pressure limiting regulator systems

Pressure limiting is overpressure control by containment. Pressure limiting regulators are listed
as an acceptable overpressure protection device and are commonly used as preassembled units
for 5 psi line pressure regulators (Figure 2-6) . They are also used at service meters with the
additional protection of a relief valve to ensure reliable prote ction (Figure 2-7) .
Figure 2-6
Manufacture 5 psi line pressure regulator assembly
Courtesy of Pietro Fiorentini S.p .a.
October 2019 85
Figure 2-7
2 psi meter set
There are three types of pressure limiting regulator systems:

• wide-open monitors ;
• series regulation; and
• working monitors .
Wide-open monitors
Wide-open monitor regulator systems are simply a pair of regulators piped in series , with both
regulators sensing pressure downstream of the second regulator , as shown in Figure 2-8.
86 October 2019
Figure 2-8
Monitor regulator system
Monitor Wor ker

regulato r regulato r
Worker Monitor
regulator regulato r
(b)
One of the regulators is known as the monitor and the other as the worker. Under normal
operating conditions, the monitor regulator is always wide open because the monitor regulator
setpoint is slightly higher than the worker regulator setpoint. The monitor regulator only starts
regulating if the worker regulator fails.
Wide-open monitor regulator systems may be referred to as either:

• upstream wide-open monitor ; or
• downstream wide-open monitor.
The terms refer to the location of the monitor regulator in reference to the worker regulator.
Figure 2-7(a) shows an upstream wide-open monitor, and Figure 2-6(b) shows a downstream
wide-open monitor .
Systems can be changed from upstream to downstream mon itors and vice versa, simply by
reversing the setpoints of the two regulators.
A disadvantage of wide-open monitoring systems is that the monitor is rarely exercised. As a

result, it may become bound, sluggish, or damaged in such a manner that it cannot provide tight
shut-off when required . Series and working monitors minimize these problems by taking the
pressure reduction in two cuts and allowing both regulators to operate .
October 2019 87
Series regulation
Series regulation is also known as two cut systems (Figure 2-10) . Like the monitor system, they
have two regulators set in the same pipeline and are available as preassembled units for 5 psi
line pressure regulators (Figure 2-9).
Figure 2-9
Maxitrol 5 psi line pressure regulator assemble
Courtesy of Maxitrol Company
325-3L47
The first unit maintains an inlet pressure to the second valve that is within the maximum allowable
operating pressure of the downstream system. Under this setup, if either regulator should fail , the
resulting downstream pressure maintained by the other regulator would not exceed the safe
maximum pressure.
Figure 2-10
Series regulation system schematic
_ ± _____.____
I J: _____.___I
__
Working monitors
Working monitors use design elements from both series regulation and wide-open monitors . In a
working monitor installation , the two regulators work continuously as series regulators to take two
pressure cuts (Figure 2-11). Because both regulators are working, both are less likely to become
clogged , sluggish, or stuck.
88 October 2019
Figure 2-11
Working monitor
orker
pilot
p int-ermediate
The worker pilot is connected as in series regula tion and controls the intermediate pressure . Its
setpoint is at some intermediate value that allows the system to take two pressure drops .
The monitor pilot is in series ahead of the worker pilot and is connected so that it senses
downstream pressure . Its setpoint is set slightly higher than the required pressure.
When both regulators are performing properly , downstream pressure is below the setting of the
monitor pilot, so it is fully open , trying to raise system pressure. Standing wide open, the monitor
pilot allows the worker pilot to control the intermediate pressure. As demand changes, the
downstream regulator adjusts flow and causes some change in the intermediat e press ure. The
worker pilot on the upstream regulator senses the change in the intermediate pressure and
ca uses a repositioning of the upstream regulator. In this way, both regulators can work in
response to changes in the pressure demand.
Automatic shut-off
Also known as overpressure shut-off (OPSO) or slam-shut (Figure 2-12), this devi ce was
previously introduced in the "Safety features " section of the previous chapter.
As with pressure, limiting the shutoff device also accomplishes overpressure protection by
containment. In this case, the gas is shut off completely until the cause of the malfun ction is
determin ed and the device is manually reset. Many gas distribution companies use this as an
added measure of protection for places of public assembly such as schools, hospitals , churches ,
and shopping centers . In those cases, the shutoff device is a secondary form of overpressure
protection . Shutoff valves are also commonly used by boiler manufactur ers in combustion
systems .
October 2019 89
Figure 2-12
Fisher CS8600 series regulator
Courtesy of Emerson Automation Solutions
The regulator typically has a token internal relief to avoid nuisance trips of the slam-shut
mechanism due to a small pressure increase from minor orifice damage or a small obstruction
(Figure 2-13) .
Figure 2-13
Token relief releasing gas
The integral slam-shut trips in the event of overpressure conditions. The safety plug is forced
onto the slam-shut seat, providing complete shutoff of the gas flow to the downstream system
(Figure 2-14) .
90 October 2019
Figure 2-14
Slam-shut activated
Some models also slam-shut if an under pressure condition occurs . This is referred to as under
pressure cut-off (UPCO)
Meters
Overview
Purpose
A gas technician /fitter routinely measures gas flow rates to determine inputs . Calculating flow
rates accurately requires a thorough knowledge of gas meter types , their operation, gas
measurement standards, and correction factors .
Objectives
• describe types of meters ; and
• determine gas flow rates .
October 2019 91
Terminology
(Symbol}
Burner input See Firing rate (e.g ., Btu/h , kW)
Clocking a meter Using a meter to determine the input of a gas
appliance
Firing rate Amount of heat in the combustion chamber
Standard cubic foot SCF Quantity of gas contained in a cubic foot at the
base temperature of 60 °F and base pressure of
14 .73 psia
Standard cubic metre SCM The quantity of gas contained in a cubic metre
at the base temperature of 15 °F and base
pressure of 101.325 kPa
MBH Thousands of BTUs per hour
Types of meters
Each piece of gas equipment is designed to produce a specific amount of heat in the combustion
chamber. This amount of heat is called the firing rate or burner input.
Gas regulations require that the burner input be checked to ensure that it conforms to the
equipment manufacturer's specifications. These are found on the rating plate attached to the
appliance.
The common meters used in gas measurement may be grouped into two categories:
Meter Description
Displa ce ment • Measure the total quantity, or volume, of gas that has passed
meters through the meter at the time of the reading
• Can be adapted to provide rate of flow
Rate of flow meters • Measure the instantaneous gas flow rate
• Can have totalizers to provide total volume flow
Displacement meters
Displa cement meters operate on the principle of positive volumetric displa cement. A precise
volume of gas passing through the meter is meas ured.
Two common types are used in the residential and commercial markets. These are:
• diaphragm (bellows) meter ; and
• rotary (geared or lobed impeller) meter.
92 October 2019
Diaphragm gas meter

The diaphragm gas meter (Figure 3-1) is the most frequently used gas meter at residential and
light commercial installations . It provides highly accurate readings over most of its range .
Two bellows alternately fill and empty as the gas flows through the meter. The movement of the
bellows is transferred through a series of linkages and gears that record the move ment as a
volume of gas on the display.
Diaphragm meters have capacities of up to 10 500 cu ft/h (300 m3/h) when the piping system
operates at less than 10 inches w.c. (2.5 kPa).
Figure 3-1
Diaphragm meter
Inlet
A temp erature co rrection device (Figure 3-2) monitors the temperature of the gas flowing through
the meter and causes the display dials to move slower in response to thinner hot gas or faster in
response to denser cold gas, such that the end result is that the reco rded gas volume is
corrected to standard conditions of 1 ft3 at 60 °For 1 m3 at 15 °C.
October 2019 93
Figure 3-2
Curved bimetallic temperature correction device
Rotary gas meter

This displacement type of meter, shown in Figure 3-3, is mainly used by commercial or industrial
customers. Rotary meters are available with pressure ratings of up to 1450 psig (10 000 kPa) and
volume ratings of 175 to 105 000 cu ft/h (50 to 3000 m3/h} .
Figure 3-3
Rotary meter
Figure 3-4 shows the cross-section of a rotary meter at two stages of impeller movement. The
two impellers are synchronized to rotate within a close-fitting housing. As the impellers turn , they
displa ce a fixed volume of gas with each revolution , causing a slight differential pressure across
the rotor. This allows a measured volume of gas to be discharged through the bottom of the
meter.
94 October 2019
A gear train transmits the number of rotations to a dial that displays the gas volume discharged.
Figure 3-4
Cross-section of rotary meter shows two stages of impeller movement
Inlet Inlet
Measuring
Lobed compartment
impeller
(a) (b)
Rotary meters are oil filled , and the oil must be changed at least every two years.
Rate of flow meters

Rate of flow meters are referred to as "inferential '' meters because the quantity of flow is
determined by inference from interaction of the flowing stream and a primary element, such as an
orifice plate , venture tube, ultrasonic device, turbine , or impeller inserted in the stream. The y are
non-pos itive displacement meters as such will have an accuracy flow range and cannot be used
to sense very low flow such as leak testing or pilot flow. They are mostly used by utilities to
measure how much gas is being generated or transferred at different stage of the distribution
chain.
Orifice meters
Orifice meters can be used for measuring air and gas flows on large commercial and industrial
appliances . They simplify th e combustion setup adjustments made on nozzle mixing burners.
The meter consists of the primary flow element and a differential flow transmitt er. The primary
element in these meters is an orifice plate in the pipe, which creates a differential pressure that
varies in relation to the rate of flow (see Figure 3-5) as per Bernoulli 's principle.
October 2019 95
Figure 3-5
Orifice meter with differential pressure measured on a manometer
--~
__________
---- --=
----- -- --
~
-
A differential pressure flow transmitter converts the differential pressure across the ports into an
electronic signal (Figure 3-6). To obtain an accurate reading , there should be a suitable
straightening of the gas flow upstream of the orifice .
96 October 2019
Figure 3-6
Orifice flow meter
Determining flow rates

Meters are used to determine flow rates , and so it is important to know how to read the meters in
order to check the gas input. The Code requires that each piece of equipment be checked and
adjusted to the correct firing rate. Inputs to gas appliances are based on standard temperature
and pressure conditions. The measured volume of gas flowing through the meter may have to be
corrected to standard conditions in order to determine the actual heat energy entering the
combustion chamber.
Gas meters are usually rated in metric or imperial units , and a gas technician/fitter should be able
to convert between the two.
Being able to read and understand the reading on the meter gives the technician/fitter an
indication as to whether the appliance is operating properly.
October 2019 97
To make accurate calculations of the quantity of heat in the combustion chamber , identify the
calorific value of the gas in the piping system . If the calorific value is unknown , contact your local
gas utility company .
The gas industry usually accepts the following calorific values for the three main fuel gases :
• natural gas -1000 Btu/cu ft or 10.35 kW/m 3
• propane - 2520 Btu/cu ft or 26 kW/m3
• butane - 3260 Btu/cu ft or 33.7 kW/m 3
Reading the meter

There are two types of meter reading displays (Figure 3-7):
Display Description
Dial-type • The dial type meters are read according to the manufacturer's design
of the display to determine the overall consumption of gas through
the meter.
. However, there are one or two additional test dials located on dial-
type meters that a gas techni cian/fitter can use to check the piping
system for leaks and check the input of individual appliances .
• The latter procedure is often called "clocking the meter " .
Direct reading-type • Direct reading type of meters are easier to read than dial types
because the actual reading is displayed as a number indicating cubic
meters or cubic feet of gas .
• However, like the dial-type meter , the diaphragm direct reading type
of meter has one or two test dials on it that a gas technician /fitter can
use to check th e piping system for leaks and check the input of
individual appliances .
Information on reading the meters is available from the local gas utility .
98 October 20 19
Figure 3-7
Gas meter displays
1 B 7 S X 10 0 •
Modern rotary meters typically have an LED direct read display with multiple readout screens for
different functions . Instead of test dials , the scroll pushbuttons are used to access the flow rate
screen . Figure 3-8 shows the consumption screen on the left and the flow rate screen on the
right.
Figure 3-8
Electronic rotary meters
Dial-type meter
There are two types of dials on a dial-type gas meter :
October 2019 99
Dial Description
Consumption dials Indicate the amount of gas that has been consumed and provides
information to the gas utility for billing purposes
Test dials Are used to determine the input to appliances and to indicate if there
are any downstream leaks in the gas line
Figure 3-9 shows a typical dial-type gas meter and how the dials are read .
Note: Figure 3-9 show s a meter that measures in cubic feet. Meters may also measure in cubic meters.
Figure 3-9
A dial-type gas meter
1.,00 0
~ Consumption
v.-dials
l>f "' P. t. ~
0
CUBIC
FEET
TEMPERATURE
COMPENSATED
~ ------ Test dials
On the meter shown in Figure 3-9:

• every complete revolution that the test dial on the left makes represents half a cubic foot of
gas ;
• the dial on the right measures two cubic feet of gas with every revolution ; and
• check once again to see the units of measure ment.
Calculating flow rates through meters

Using a meter to determine the input of a gas appliance is often called "clocking a meter" . The
following steps can be employed:
1) Make sure that the applian ce being clocked is the only appliance in operation. If necessary,
shut off the gas flow to all other appliances.
2) Make sure that the appliance is firing continuously throughout the clocking period. Avoid
taking measurements immediat ely after start-up.
3) Take readings after about 5 minutes of continuous operation .
4) Record the time it takes for one complete revolution of the test dial that is moving at a
reasonable speed (i.e., if the dial with the smallest scale is moving too fast to clock , use the
dial with the larger scale.). Clock this two or three times and use the average.
5) Check the units of measur ement of the meter.
100 October 2019

6) Using the Imperial or metric formula given below , determine the volume of gas that would
pass through the meter in one hour . Convert this volume to the amount of Btu/h that would
be produced by that type of gas (i.e ., multiply by 1000 Btu/ft3 for natural gas or 2500 Btu/ft3
for propane) and compare this to the input rating of the appliance given on the rating plate .
The measured input of an appliance should not exceed the rated input or be less than 90% of its
rated input.
Unit Measured input

Imperial j6(Jll,v,cn11,: .• ,/;mur
X /J .!7
,.
Q~
f • f' J
.~:2.; t
. B / .J
>< ~ fl.J jT - Bn; I h i11pur
J£
.vec,mJ\·/ ,.~voluriou ·
Metric .i "ij.\',l.\r : •-~ l t l i11:1o1·

x l~".''fl diol 'Ii:~ Ill] x ~ J:,.;.,,-1
= !tW inp11l
"f,IJV(lft,•:,/ ,'t ••r./1,,:,;;:
For example , if the average time for one revolution of a 0.5 ft3 natural gas meter dial was 30
seconds , the imperial formula is:
Imperial and metric conversions

Gas appliances are clocked in either Imperial or metric units . When both the meter and the
appliance rating plates are expressed in the same measurement unit , calculations are
straightforward.
At other times, an appliance rated in Btu may be connected to a meter showing its gas flow in
cubic meters - or vice versa. In such cases , you use conversion factors to determine burner
input in Imperial or metric values . Table 3-1 shows the Imperial and metric equivalences used in
converting between the measurements.
Table 3-1
Equivalences
Measurements Imperial Metric

For gas flow 35.31 cu ft 1 m3
For burner input 3412 Btu/h 1kW
Based on natural gas having a calorific value of 1000 Btu per cu ft , Table 3-2 shows conversion
factors used in calculating burner input.
Table 3-2
Burner input conversion factors
Btu/h kW
1 cu ft/h 1,000 0 .293
1 m3/h 35 ,310 10.35
October 2019 101

Flow rates with pressure (volume) compensation

When gas pressures exceed 0.5 psig (3.5 kPa) , the flow rates indicated by the meter's test dials
may require correction for pressure to show the true flow rate . Use the following formula to
calculate the flow rate as corrected for pressure:
Where Description
Q Flow rate (cu ft/h or m3/h)
3600 Seconds per hour (constant)
V Volume of test dial (cu ft or m3)
t Time per revolution of test dial (in seconds)
Pa Local atmospheric pressure (psia or kPa)
Pw Working pressure of gas in meter (psia or kPa)
Ps Standard pressure (14.73 psia or 101.325 kPa)
Example
The 2 cu ft test dial takes 18 seconds to complete one revo lution.
Calculate the flow rate to a burner in standard cubic feet if the working pressure in the meter is 5
psig and the local atmospheric pressure is 14.35 psia.
Solution
0=[36 00><2c:u ji- - 14.35psi(J+5p.~ig
- 18 .~l!c _ l 14.73psia
: 400 c:uji/hx 1.313

= 515,-14Clf ft/ h
Flow Rates with Pressure (Volume) and Temperature

Compensation
As the temperature of a gas increases, the volume of the gas increases , unless it is restricted in a
container; in that case, the pressure in the container increases .
Most gas meters are equipped with temperature compensating dev ices to correct the actual
volume of gas that passes through the meter to a standardized volume measurement at a
standardized temperature (1 cubic foot at 60 °For 1 cubic metre at 15.4 °C).
When temp erature is a factor in measuring flow rate with gas pressures over 0.5 psig , and the
meter is not corrected, use the following formula to calculate the flow rate.
102 October 2019

Where Description
Ts Base temperature (60 °F or 15 °C in absolute units)
T Temperature of gas at meter in absolute units
Example
A 5 cu ft test dial takes 20 seconds to complete one revolution.
The local atmospheric pressure is 14.55 psia and the pressure of the gas in the gas meter is 10
psig.
The temperature of the gas in the meter is 45 °F.
Calculate the rate of flow to the burner in standard cubic feet.
Solution
) = [3600 x .fou Ji- - 14.55psw + 10psig ] 60 " F + 460)p R
{ 20 sec _ 14.73 f!.~ia 45 " F + -160r R
=900 c:uji/hxJ.66xJ,(i2
= 154-1
.49 Sid rn.f(/h
The local weather bureaus generally report barometric pressures that are corrected to sea level.
In the above equation, the actual barometric pressure must be used . This can be obtained from
the weather bureau.
Electronic correctors
Electronic metering systems do all the things mechanical devices do (Figure 3-10) , plus they
have many more features such as continuous temperature , pressure , correction factor readouts,
indications of gas flow conditions , and storage of load survey data. Some of this information can
be accessed by the gas fitter using the scroll buttons , whereas more detailed information requires
a computer connection with the appropriate software. The amount of information that can be
accessed depends on the type and complexity of the device.
Octob er 2019 103

Figure 3-10
Electronic volume device for a gas rotary meter
Electronic metering devices are typically found on large commerc ial and industrial installations .
Electronic correctors employ a magnetic sensing device to sense each rotation of the meter that
represents the non-compensated (UNG-un corrected) meter gas volume . The volumetric input
pulses are also converted to base measurement conditions (CCR-corrected) .
Two common electronic correcting systems are :

• electroni c temperature compensating index (TCI); and
• electronic volume corrector (EVC).
A TCI converts gas volume from operating condi t ions to reference temperature conditions . The
temperature is measured by a temperature sensor located in the temperature well of the meter . A
pressure transducer is also mounted inside the meter or as a separate piping connection .
An EVC converts gas volume from operating conditions to reference pressur e and temperature
conditions. The temperature is measured by a temperature sensor located in the temperature of
the meter . A pressure transducer is also mounted inside the meter or as a separate piping
connection.
The pressure and temperature correction factors are calculated by the same formulas previousl y
mentioned . Depending on how the utility has set up the meter display, there are many parameters
that could be viewed . Figure 3-11 shows the gas temperature and the calculated correction factor
for a TCI. Because this meter is located indoors , the gas temperature is above the 15 ° C base
conditions; therefore, the correction factor is less than one. Notice that the temperature correction
factor is quite small unless the temperatures are very extreme .
104 October 20 19
Figure 3-11
TCI temperature displays
Courtesy of Camosun College, Rodney Lidstone , licenced under CC BY
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In Figure 3-12, the two screens of an EVC unit show the absolute pressure on the left and the
pressure correction factor on the right.
Figure 3-12
EVC pressure factor display
Courtesy of Camosun College, Rodney Lidstone, licenced under CC BY
R
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When using EVC unit for clocking purposes, the test dial display, also known as the live flow rate ,
may or may not be corrected depending on the parameter settings. You may have to contact the
utility or meter manufacturer to verify which parameters are being displayed. The meter shown in
October 2019 105

Figure 3-13 is displaying the live corrected flow rate in cu ft/h for a 55 MBH appliance . This is
useful for checking the appliance input , as there is no need to clock the meter or perform any
correction factor calculations. You only need to multiply the flow rate by the appropriate CV of the
gas for that area. Be aware that the utility could have the meter set up to display the live flow rate
as cu ft/h or m3/h.
Figure 3-13
Live corrected flow rate in cu ft/h
i
L td .
ANADA
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Using a meter to leak test piping systems

A diaphragm or bellows meter can also be used for leak testing a piping system at working
pressure . Rotary meters and orifice meters are not considered sufficiently accurate at measuring
small volumes of gas to be reliabl y used for this purpose.
Condu ct the following steps to use a diaphragm meter to leak test a piping system:
1) Turn off all gas consuming devices (appliances and pilots) as close to the appliance as
possible.
2) Mark the position of both test dials on the meter display using a non-p ermanent marker. See
Figure 3-9.
3) After waiting at least ten minutes, check to see if either dial has moved from the marked
position.
Movement of the test dials indicates that gas has passed through the meter and is leaking from
the pipe (if all gas-consuming devices have been completely shut off). The source of the leak
must be inve stigated and corrected.
106 October 2019

Both test dials are marked during the meter leak test in case one dial moves back to its original
position at the end of the test. Since the two dials are moving at different speeds , they are
unlikely to both return to their original position.
Fuel containers
Overview
Purpose
Propane gas equipment is normally supplied from either a cylinder or a tank . To ensure a steady
supply of gas , the container and accessories must be sized and installed to meet the appliance
needs under all temperature and weather co nditions.
Objectives
• describe cylinders , tanks , and accessories ; and
• describe how to size and install cylinders and tanks .
Terminology
(Symbol)
Prestolite threaded POL Fitting unique to vapour service that cannot
connection accidentally be connected to a liquid line
Service con nection Outl et of the service valve
Wetted surface area Specific area of the tank that comes in contact
with the propane liquid
Cylinders, tanks, and accessories

A major difference between natural gas and propane is how the fuel is supplied.
Natural gas is normally suppli ed from a natural well. It trav els from the well through a large
pipeline to a city or town gate station operated by local utility . From here it is distributed to each
building via service piping. It passes through a meter set before it reaches the consumer. A
steady supply of natural gas is ensured if the piping and tubing systems, as well as th e required
pressure regulators, are operating correctly .
October 2019 107

For propane , sufficient storage capacity is required to meet the total demand of installed
appliances and equipment , especially during cold weather. It is thus extremely important to select
the correct propane container .
Propane companies normally lease propane tanks and cylinders to customers and then provide a
filling service for the tank and an exchange service for the cylinder .
Propane cylinders are intended for transportation both empty and filled, and tanks are intended to
remain stationary once they are placed in service and filled.
Due to the need for safety , a number of standards and regulations that govern the type , location ,
and size of propane storage containers are in place. Refer to CSA B149 .2 , Propane storage and
handling code , for these requirements .
Cylinders
The CSA B149.2 Code states that all cylinders must be fabricated , tested , inspe cted , and legibly
marked in accordance with CSA B339 , Cylinders , spheres , and tubes for the transportation of
dangerous goods , and the Transportation of Dangerous Goods Regulations from Transport
Canada (www.tc.gc .ca) .
Refillable cylinders will have the important information shown in Figure 4-1 stamped on their
protective collar .
Figure 4-1
Typical propane cylinder markings
A B C D
---
F SJN - 1234 21.6 L
G I, I ACM E CO. T8.4 0 KG E
H I 04 0 4
\.. RETEST
Additional information regarding these markings is provided below .
108 October 20 19
Construction Standard Only TC standards are currently acceptable in Canada. However ,
older cylinders may reference CTC or DOT (e.g. , CTC/DOT 240
4BA) .
Note: "M" at the end indicates metr ic units.
Manufacturer 's name Such as : Worthington , Manchester , etc .
Date of manufacture Such as : 1210 or Dec 10
Date of re-inspection Cylinders with a water capacity of 240 lb or less must be recertified
within 10 years of the date of manufacture or date of re-inspection .
The cylinder recertification facility must stamp the collar with the
cylinder's identifi cation number and date of recertification (e.g.,
MO311096).
Note: Prior to June 1994 , it was acceptab le to simply stamp the date of re-
inspecti on followed by an "E" meaning visual re-inspection.
Capacity The volume of the cylinder is given in pounds or kilograms of water

at 130 °F (e.g., WC 240#) . This is the capacity of the cylinder when
filled with water. From this , you can quickly determine how much
propane can be safely stored in the container by multiplying by .42
(since propane is .51 the weight of water and the cylinder must only
be filled to the 80% capacity to allow for expansion) . Therefore , a
240 lb w.c. cylinder can safely hold 100 lb of propane .
Note: The largest cylinder that is made has a capacity of 1000 lb of water
(420 lb propane).
Tare weight of the When using a scale to fill, note that the weight of the cylinder and
cylinder valves when empty is added to the weight of propane put into it.
Some cylinders have a "spit valve" for filling without a scale. The
spit valve is a small orifice threaded valve equipped with a dip tube
that extends down to the 80% level of the tank . When the spit valve
is manually opened during filling operations , it will start to spit liquid
propane when the liquid level reaches 80% at which time the filling
operation must be stopped.
Cylinders manufactured after January 1, 2008, with a capacity of
40 lb (18.2 kg) or less were required to have an overfill prevention
device (OPD) in compliance with UL 2227 , Standard for Overfilling
Prevention Devices. An OPD , as shown in Figure 4-2 , preven ts
filling beyond the 80% capacity.
Working pressure rating Usually given as 375 psig (2586 kPa) since the relief set point of
cylinder relief valves is 375 psig
October 2019 109

Figure 4-2
Overfill preventi ,on device (OPD)
Cylinders come in a variety of size s. Figure 4-3 s hows the common sizes as we ll as compon ents
of a typical propane cylinder .
Figure 4-3
Sizes of propane cylinders
Neck ring
Service valve
wi th integ ral
-J 1--...~.-.H,,.-.:--
pressure relief
device
Cylinder
Seam
lOOlbs
lOOlbs
Foot ring
Table 4-1 lists some of the co mmon propane cylinders, together with their applications and
characteristics.
110 October 2019

Table 4-1
Common propane cylinders - applications and characteristics
Type of Typical Propane capacity Water capacity Common DOT

service use and TC* Codes
lb (kg) US gal lb (liters) US gal
Stationary Homes, 420(191) 99 1000 119 48 , 48A , 48W
business (454)
Stationary Homes, 300 (136) 71 715 86 48 , 48A , 48W
business (324)
Stationary Homes, 200 (91) 47 477 57 48 , 48A , 48W
business (216)
Stationary Homes, 150 (68) 35 357 43 48
business (162)
Exchange Homes, 100 (45) 24 239 29 48 , 48A , 48W
business (108)
Exchange Homes, 60 (27) 14 144 (65) 17 48 , 48A, 48W
business
Motor fuel Tractor 100 (45) 24 239 29 48 , 48A , 48W
(108)
Motor fuel Tractor 60 (27) 14 144 (65) 17 48 , 48A , 48W
Motor fuel Forklift 43.5 (19.7) 10 104 (47) 12 48, 48A , 48W ,
4E
Motor fuel Forklift 33.5 (15.2) 8 80 (36) 9.6 48, 48A, 48W ,
4E
Motor fuel Forklift 20 (9) 4.7 48 (22) 5.7 48, 48A , 48W ,
4E
Motor fuel Forklift 14 (6.4) 3.3 34 (15.4) 4.1 48, 48A , 48W ,
4E
Portable Rec. 40 (18) 9.5 95 (43) 11 48, 48A , 48W ,
vehicles 4E
Portable Rec. 30 (13.6) 7.1 72 (32.7) 8.6 48, 48A , 48W ,
vehicles 4E
Portable Rec. 25(11.3) 5.9 59.5 (27) 7.1 48 , 48A, 48W
vehicles
Portable Rec. 20 (9) 4.7 48 (22) 5.7 48, 48A , 48W ,
vehicles 4E
Portable Rec. 10 (4.5) 2.4 23.8 2.8 48, 48A , 48W ,
vehicles (10.8) 4E
(Continued)
October 2019 111

Type of Typical Propane capacity Water capacity Common DOT

service use and TC* Codes
lb (kg) US gal lb (liters) US gal
Portable Indoors , 5 (2.3) 1.2 12 (5.4) 1.4 4B, 4BA , 4BW,
trailers 4E
Portable Torches , .93 (.42) 0.2 2 .2 (1) 0 .3 39 (disposable)
camping
4B240 (refillable)
* TC codes include M to designate metric specifications.
Tanks
When a larger installation is planned , propane storage tanks are often required to deliver a
sufficient flow of propane to meet the demand of connected appliances. Tanks may also be
preferred when the number of cylinders required is inconvenient to handle or when the delivery
schedule is not frequent enough to ensure a continuous supply.
As with propane cylinders, propane storage tanks have a label attached to them to identify their
characteristics . A typical ASME propane storage tank nameplate is shown in Figure 4-4.
Figure 4-4
Typical ASME propane storage tank nameplate
CERTIFIED BY ACME INDUSTRIES, INC.
■
ANYTOWN, ONTARIO, CANADA
MAWP PSI AT OF CAP.

--
MDMT OF AT PSI YEAR
--
I
SH. THK .
S/N
CRN
HD. THK.
SIZE
0.1.N.
ABOVEGROUND SERVICE. THIS CONTAINER SHALL NOT

D. RAD.
CONTAIN A PRODUCT HAVING A VAPOUR PRESSURE IN

EXCESSOF PSI
AT A TEMPERATURE OF •F. OUTSIDE AREA
MAWP • Gives the maximum allowable working pressure
• Minimum is 250 psig
CAP • Gives the tank capa city in US wat er gallons
CRN • The Canadian registration number
112 October 20 19
• Indicates compliance with the Code and the regulations
0 .1.N. (in Ontario) • In Ontario , the 0.1.N. indicates compliance with Ontario
regulations for pressure vessels.
Above ground or underground • The label will also state whether it is for above-ground
service or unde rground service.
The style of the nameplate varies among manufacturers and between the US and Canada.
All approved tanks will have a CRN on the label.
Table 4-2 lists the applications and characteristics of some common ASME propane storage
tanks.
Table 4-2
Common ASME propane storage tanks - types and characteristics
Type of Water capacity US gal Propane capacity gal* Propane

service (litres) (liters) capacity (lb)
Domesti c 100 (379) 80 (301) 338
Domestic 125 (473) 100 (379) 423
Domestic 150 (568) 120 (454) 508
Domesti c 250 (946) 200 (757) 848
Domesti c 325 (1230) 260 (984)
Domesti c 500 (1893) 400 (1514 )
Domesti c 1000 (3.8 m3) 800 (3 m3)
Industrial / 1000-5 000 800-4500
agricultural
(3.8-19 m3) (3-17 m3)
Service 1000-6 500 800 -58 50
stations
(3.8-24.6 m3) (3-22 m3)
Bulk plant or 12 000- 18 000 10 800-16 200
storage
(45.4-68 m3) (41-61 m3)
Bulk plant or 20 000-30 000 18 000-27 000
storage
(76-114 m3) (45.4-102 m3)
(Continued)
October 2019 113

Type of Water capacity US gal Propane capacity gal* Propane

service (litres) (liters) capacity (lb)
Bulk plant or 30 000-60 000 27 000-54 000
storage
(114-227 m3) ( 102-204 m3)
Bulk plant or 60 000-120 000 48 000-96 000
storage
(227-454 m3) (182-364 m3)
* Based on propane specific gravity of 0.508 at 60 °F (15.6 °C). Actual quantity depends on actual specific
gravity.
Valves and accessories

The design of valves, controls, and accessories found on propane tanks and cylinders vary
greatly with the design of the containers, manufacturers, and local code requirements . Stationary
cylinders or tanks (Figure 4-5) must contain a:
• service valve;
• filler valve ;
• safety pressure relief valve; and
• fixed liquid level gauge .
Figure 4-5
Stationary cylinder valves
Courtesy of Camosun College, Rodney Lidstone , licenced under CC BY
Service valve
Safety pressure relief valve
Filler valve
Portable cylinders have only one opening in the service end. A combination service valve is
usually installed in this opening .
114 October 2019

Service valve connections

An independent service valve controls the flow of gas out of the container. This type of valve is
found on both a propane cylinder and a propane tank. The outlet of the service valve is called a
service connection. There are two main types of vapour service connections on cylinders and
tanks :
• Prestolite (POL); and
• quick closing coupling (aCC).
POL valves are the oldest standard for propane tank connections. They have a left-hand thread
on the inside of the valve outlet (Figure 4-6) . The POL fitting is unique to vapour service and
cannot accidentally be connected to a liquid line.
Figure 4-6
POL thread for vapour service
Left-hand
thread
Hex nut Value out let
ace connection used for Acme valves (Figure 4-7) differs from POL valves in its size and use of
external threads. Easier to use ace connection ca n be tightened by hand . Acme propane valves
are also compatible with appliances that have POL connections, as they also have the internal
left-hand threads. A big advancement over the POL valve is the addition of a built-in safety device
that allows gas to flow only when the tank is attached to a device , preventing accidental leakage
while being stored.
October 2019 115

Figure 4-7
Acme service valve
Liquid service connections usually have a special thread (Figure 4-8) designed by the
Compressed Gas Association (CGA). This unique fitting prevents the valve from being
accidentally connected to a vapour service valve. Unlike the vapour withdrawal valve, the liquid
withdrawal valve has a right-hand thread.
Figure 4-8
CGA thread for liquid service
Nipple
Hex nut __/
Cylinders and tanks may also have changeover manifold assemblies attached to them (Figure 4-
9) . These devices are used in installations where ther e are two cylinders or tanks in use. It allows
the propane supply to be switched from the supply tank to a reserve tank when the propane
pressure in the supply tank drops below a certain point. This changeover is done without
disrupting the supply.
The main supply tank can then be refilled while the reserve tank continues to supply propane to
the attached systems. The manifold assembly has a method of indicating that it has switched the
supply from one tank to another.
116 October 2019

There are many different types of changeover manifold assemblies , but they all perform the same
operation. For information on specific manifold assemblies, consult the manufacturer 's
instructions.
Figure 4-9
Auto changeover valve
Connectors
A common type of connection on propane tanks and cylinders is a pigtail (Figure 4-10). This type
of copper tubing forms part of the vapour withdrawal system. It allows for flexibility in movement
of the rest of the piping in the system.
Figure 4-10
A pigtail
--
'
I
'
._ __ ---I
I' 1----"""" ""<1
----4 I t-----, ,.,____,,

'
I
'
October 2019 117

Filler valve
Stationary tanks and cylinders and tanks , rather than filling through the service valve, will have a
separate filler valve to prevent interruption of service. The double check valve design allows fuel
to enter the tank but prevents the propane from escaping when the fill hose is disconnected.
Figure 4-11
Double back-check filler valve
Protective cap
Upper check
closing spring
Uppe r
back-check
(soft seating)
Lower
back-check
Lower check (hard seating)
closing spring
Safety relief valve

The safety relief valve is one of the most important valves installed in an LP-gas container. Also
known as relief valves, pressure venting valves, and pop-off valves, their purpose is to
automat ically relieve excess pressure that can build up inside a cylinder or tank . For this reason ,
propane cylinders should always be stored outdoors in a well-ventilated area. The pressure relief
valve setting for cylinders is 375 psig , and tanks are either 312 psig or 250 psig .
Figure 4-12
External safety relief valve
Spring retainer
Spring
Valve body
Weep hole
eat disc
118 October 2019

Liquid level indicators

It is important to know the level of the propane liquid in the tank to ensure the tank is not overfilled
and to schedule refills when a stationary tank is running low.
Float type (face) gauge

A float is located inside the tank and as the liquid level changes, the movement of the float raises
or lowers indicating the liquid level in the tank or cylind er.
Figure 4-13
Float gauges
Courtesy of Rotarex SGR
Fixed tube gauge

The fixed liquid level gauge also called the bleeder valve, is the one and only gauging device that
accuratel y depicts the level of propane in the tank when it is being filled . The fixed tube gauge is
designed so that during the filling process , when the propane going into the tank reaches 80%,
liquid will come out of the opened valve. The face gauge is not to be used during the refuelling
process. During filling , the bleeder valve is opened, and the LP-gas vapour is allowed to vent out
the end of the tube . However, when LP-gas liquid reaches the bottom of the dip tube , a white fog
or mist vents out the gauge body. The white mist indicates that the maximum permitted filling
level has been reached and the filling operat ion must be immediately stopped
October 2019 119

Figure 4-14
Fixed liquid level gauge
Plug
Restricting
orifice
Body
Excess flow valve

Excess flow valves are in-line valves intended to close upon excessive discharge of vapour or
liquid resulting from a hose or piping break . If flow exceeds the valve setting, the valve will close,
reducing the flow to a trickle until the pressure across it equalizes. They are available in a large
variety of sizes and body configurations. For example, some propane service regulators will often
have an excess follow valve incorporated into the tank connection.
Figure 4-15
Excess flow valve
Combination service valves

These valves combine any number of the three basi c valves:
• service;
• filler ; and
• safety.
120 October 2019

The most common combination is the service and safety relief valve.
The service and safety relief combination valve comes in two distinct forms: one for vapour
service, the other for liquid service. Each combination valve is des igned to be used solely with
either vapour or liquid containers.
Vapour service
The combination valve shown in Figure 4-16 is designed for vapour service only. On portable
cylinders, the outlet connection will be used for both service and filling . This combination valve is
also equipped with a relief valve and a fixed liquid level gauge. The relief valve is only designed
to relief gas; therefore , it is important that portable tanks with this type of valve be installed and
transport in the upright position .
Figure 4-16
POL combination valve
Overfill protection device (OPD)

The OPD valve is a backup system to prevent the overfilling of gas cylinders . OPD valves use a
spec ial float that rises during refilling to block the valve when the cylinder is 80% full.
All small capac ity cylinders (4# to 40#) now come from the factory equipped with an OPD. A
cylinder that comes with an OPD can be recognized by the unique triangular-shaped hand wheel
(Figure 4-17) as well as by the letters OPD stamped on the valve and the valve handle.
October 2019 121

Figure 4-17
OPDvalve
OPD handle
Typical
old style handle
Liquid service
A combination valve used for liquid withdrawal is shown in Figure 4-18. It is designed for liquid
service since it comes with a CGA 555 connection.
122 October 2019

Figure 4-18
Combination valve for liquid service
Liquid service
outlet (CGA 555)
Vapour
(to relief
Excess-flow I valve only)
valve
I
I
I
I
Liquid withdrawal-(]
dip t ube I
I
The excess-flow valve protects the container against uncontrolled discharge of LP-gas in case
the gas line breaks. The excess-flow valve is installed in the liquid dip tube. The dip tube
completely isolates LP-gas liquid from the inlet to the relief valve. But vapour is free to flow
around the dip tube to the inlet of the safety relief valve.
Sizing and installing cylinders and tanks

When sizing a propane co ntainer , the most impo rtant consideration is the vapour or liquid
withdrawal capacity of the container. The container must always have a propane withdrawal
capacity that is high enough for the application. If the container's propane capacity is too low
(having an undersized tank or cylinder), the appliances may not operate properly.
You will briefly review the propane vapourization process before discussing the procedures for
sizing propane co ntainers. Knowing how propane reacts under temperature and pressure
changes will increase your understanding of the factors that influenc e container sizing .
October 2019 123

Propane vapourization
Propane is made up of hydrogen and carbon atoms . Under normal atmospheric pressure ,
propane is a vapour. To store propane, the vapour is pressurized and stored as a liquid . Although
it is stored as a liquid , when filled to capacity, only 80% of the container is filled with liquid , the
rest of the container is filled with vapourized gas . Overfilling the storage container reduces the
volume available for vapourization and may result in liquid withdrawal or a hydrostatic pressure
buildup.
The relationship between the propane liquid and vapour is constant unless the temperature of the
propane changes or the pressure inside the container changes .
When the temperature of propane liquid inside a pressurized container increases, the liquid boils
and vapourizes . This vapourization increases the pressure in the container. Since there is a
relationship between temperature and pressure , this boiling continues until the temperature and
pressure reach equilibrium at a new point (Figure 4-19).
Another way to make the liquid boil is to release some pressure. When the supply valve opens
and discharges vapour , a drop in pressure occurs . As a result , the liquid immediately boils off,
trying to re-establish the same pressure that was in the container before the valve was opened.
When the valve closes, the liquid continues to boil off until the cylinder is re-pressurized.
Figure 4-19
Propane vapourization point
200
180
160
..
QI
:::J
140
120
Saturated va~our in
propane cy inder
"'
"'
ai-
.. bl)
a.:;;; 100
.. 0.. Propane in
:::,- 80
0 liquid state
0..
nl 60
>
40
Propane in
20 vapour stat e
0
--44 - 30 - 20 - 10 0 10 20 30 40 so 60 70 80 90 100
boil ing
point
Temperature {°F)
Vapourization rate
The vapourization rate of a container is the volu me of propane that can be boiled off inside the
container during a period of time . The vapourization rate is expressed in cubic feet or cubic
meters of vapour per hour. When sizing a container for vapour service , always ensure that the
container 's vapourization rate is equal to , or greater than , the demand for propane . If it is smaller ,
the applian ces will not operate at their rated inputs due to low pressur e.
124 October 20 19
There are six basic factors that affect the vapourization rate of a propane container.
These factors either slow down the boiling rate or speed it up.
As a result , the vapourization rate either increases or decreases due to these factors .
Figure 4-20
Liquid propane boiling inside pressurized chamber
Cylinder
service valve High pressure
App liance burner
propane gas
Low pressure
propane gas
Propane vapo ur
Propane liquid
Propane cylinder
c::::)
Factor Description Effect on vapourization rate

Surface area of Heat is transferred through the In effect, the larger the wetted
tank walls of the container. surface area, the higher the
vapourization rate.
The specific area of the tank that
comes in contact with the propane
liquid is called the wetted surface
area.
Ambient Temperature directly affects the When the outside temperature is
temperature vapourization rate . high , the vapourization rate is high .
If the ambient temperature In winter, when the outside
(temperature around the wetted temperatures are lower , the vapour
surface area) is high , as in pressure is reduced . When the
summertime, more heat is vapour pressure is reduced, the
transferred to the liquid. vapourization rate is also reduced.
Temperature of gas The temperature of the liquid in the If the liquid temperature is low ,
co ntainer determines how much more heat is required from the
October 2019 125

Factor Description Effect on vapourization rate

extra heat is needed for a specific wetted surface area to bring the
vapourization rate. propane liquid to its boiling point.
Level of liquid As propane vapour is withdrawn, When the wetted surface area
the liquid level in the tank drops. decreases, heat transfer to the
This also means that the wetted liquid decreases, and the
surface area decreases. vapourization rate decreases.
Relative humidity As the demand for propane vapour The resulting "frost line" on the
increases, additional heat must be wetted surface (in high humidity)
transferred to the liquid. In acts as an insulator, drastically
transferring heat to the liquid , the reducing the vapourization rate of
air surrounding the wetted surface the container.
may cool.
If the air is very moist (high
humidity), the cool air may reach its
"dew point" temperature and
condense on the wetted surface of
the container. If a high demand for
vapour continues after the moisture
has condensed on the wetted
surface area, the dew or moisture
will continue to cool down rapidly.
When the temperature reaches 32
°F (0 °C), the moisture will freeze.
If the air is very dry (low humidity),
the temperature surrounding the
container can drop a great deal
before any moisture or dew
condenses.
Location Containers can be installed above The vapourization rate of an above-
or underground. Containers that ground tank or cylinder in the
are installed above-ground benefit winter drops because of the low
from high summer temperatures as outside temperatures.
well as direct sunlight.
Underground containers usually
have constant vapourization rates
all year round due to the relatively
constant temperatures
underground.
Sizing a container
When sizing containers, there are five important steps to ensure the factors that affect the
vapo urization rate are taken into account. Each of the following steps is extremely important in
properly sizing the tank or cylinder:
1) Determine the total demand of all present and future appliances.
2) Determine the total effective load on the container.
3) Determine the most severe weather conditions under which the container must operate.
126 October 2019

4) Determine the correct sizing table to use .

5) Select the proper size and number of propane containers for the application.
Step 1 - Determine total demand

1) Size the container so that it can handle the maximum possible load that will be placed on it.
2) Check the demand of all existing appliances .
3) Ask the customer if any appliances will be installed in the near future .
4) Locate the data or rating plate on each appliance in the system .
5) Record the input rating (Btu/h) of each appliance . Be sure to include the input ratings of
appliances that may be installed later.
6) If the data plate is missing , get this information by:
a) checking with the manufacturer or distributor of the appliance for the appliance's exact
rating in Btu/h ; or
b) measuring the size of the burner orifices and determining the rating from an orifice sizing
guide .
If you still cannot determine the input rating of the appliances , use Table 4-3 as a guide to various
input ratings. This table shows common domesti c , comm ercial, industrial , and agricultural
appliances and their respective input ratings . However , try to determine the exact rating before
referring to Table 4-3.
Table 4-3
Average appliance input ratings and load factors
Appliance Average input rating (Btu/h) Average load factor

Domestic
Range (with oven) 45 000 - 65 000 0.03
Dryer 20 000 - 25 000 0.15
Floor furnace 35 000 - 50 000 0 .60
Recessed wall furna ce 35 000 - 60 000 0.50
Central heating furna ce 70 000 - 125 000 0.50
Radiant heater 20 000 - 25 000 0.40
Water heater 35 000 - 50 000 0 .16
Commercial
Water heater 100 000 - 500 000 0 .50
Range (with oven) 45 000 - 65 000 0.30
Griddle 35 000 - 40 000 0.30
Oven 50 000 - 75 000 0.30
Fryer 100 000 - 150 000 0.50
(Continued)
October 2019 127

Appliance Average input rating (Btu/h) Average load factor

Clothes dryer 30 000-105 000 0.60
Industrial
Plumber 's pot 16 000-25 000 1.00
Tar kettle 500 000 - 2 000 000 1.00
Construction heater 6000-50 000 1.00
Agricultural
Grain/corn dryers 500 000 - 1 000 000 1.00
Peanut dryers 100 000 - 500 000 1.00
Tobacco curers 500 000 - 1 000 000 0.75
Poultry brooders 35 000 - 75 000 0.75
Livestock heaters 50 000-100 000 0.75
Step 2 - Determine total effective load

The appliance input ratings shown in Table 4-3 are based on continuous operation for one full
hour (Btu/h). However , in many cases, an appliance burner is controlled by a thermostat. As a
result, the burner does not operate for a full hour. Instead, it cycles on and off to satisfy the
temperature setting on the thermostat.
For example , an 80 000 Btu furnace requires 32 cu ft of propane every hour to operate
continuously . However , a properly sized furna ce that is installed in a well insulated home will
normally cyc le on and off five or six times each hour . As a result, the main burner operates for
approximately 30 minutes out of each hour.
This on and off cycling means that the supply withdrawn from the propane container is not
continuous.
In order to properly size a container , you need to know what gas supply is actually required for.
Formula to calculate effective load

To determine the effective (actual) load on a propane container, perform the follow ing calculation:
Inpu t rating x Load fac tor = Effective load
Where ...
Input rating Is that shown on the appliance rating plate
Load factor Is the actual amount of gas used , divided by the maximum amount of propane
that the appliance would use if it operated co ntinuously
128 October 2019

Where ...
The right-hand column of Table 4-3 contains the average load factors for
various appliances.
If the load factor for a particular application cannot be determined , use an
average load factor for the relevant type of appliance or equipment. The
following load factors are "safe" average load factors for individua l appliances :
• domestic 0.5
• commercial 0.5
• industrial 0.75
• agricultural 1.0
In the 80 000 Btu/h furnace example, the propane container only boils off half
(30 minutes) of the vapour that it requires to operate continuously . The load
factor is therefore 0.5.
Multiple appliances
Since the propane container may be supplying gas to many appliances , all loads must be added
together to find the effective load on the container. Use the following procedure :
1) Determine the input rating for each appliance or piece of equipment.
2) Multiply the input rating of each appliance by its proper load factor (Table 4-3) .
3) Add the effective loads of each of the appliances together to determine the total effective
load on the container .
For example , determine the total effective load of three domestic appliances , namely :
• domestic water heater (35 000 Btu/h);
• gas range (45 000 Btu/h); and
• central heating system (80 000 Btu/h) .
lnp11f raLi11gx f.oad J<,1c1or= Fjjti(:liFe load
35000 TJru/hx0 .lfi=5600 Rw/h

45 ()()() Btu/ II x 0.03 = 35(} Btu/ I,
8() ()()()Btu/Ii x 0. 50 = 40 l)f){ ) Btu/ h
= 46950 B11t/h
Step 3 - Determine weather conditions

As stated earlier , several factors affect the vapourization rate inside the propane container.
During vapour withdrawal, the two most important factors are :
• temperature ; and
• humidity .
To properly size a container for vapour withdrawal , always size the container so that it provides
propan e under the most difficult weath er conditions.
1) Determine the times when the container normally provides propane vapour to applian ces
(i.e ., morning only , summer only).
October 2019 129

2) Determine the lowest outside temperature that occurs during a normal operating period .
Step 4 - Determine sizing table

The tables for sizing containers are organized according to the type and size of container (ASME
tanks , stationary DOT/TC cylinders , portable DOT/TC cylinders , etc .). For this reason , first
determ ine the type of container to be used before selecting one of the tables.
There are three tables for sizing containers , all located in Appendix A:
Use ... For ...

Table 4A-1 ASME aboveground tanks
Table 4A-2 ASME underground tanks
Table 4A-3 DOT/TC portable cylinders , exchange cylinders , and stationary cylinders
Step 5 - Select propane gas containers

1) Now that the effective load, operating condit ions , and sizing table have been determined ,
select the proper size and number of container(s) from the tables.
- To make the tables easier to use, the vapour ization rates are not expressed in cubic feet
per hour ; instead , the ratings have been converted to Btu per hour (Btu/h).
- Additionally , the ratings indicate the vapourization rate when the container is ready to be
refilled . As a consequenc e, all ratings in the tables are based on a container that is a
quarter full (25% of the container 's water capacity) . As long as the container is at least
25% full , an adequate supply of gas is ensured.
Aboveground ASME tanks

To properly size an aboveground ASME tank , follow the steps using Table 4A-1 in App endix A .
1) Based on the relative humidity in the area , sele ct the applicable table :
Use .. . For ...

Table 4A-1a 50- 60% humidity
Table 4A-1b 60- 70% humidity
Table 4A-1c 70- 80% humidity
2) Based on the lowest temperature for the operating season of the tank , select the appropriate
temperature column in the table.
3) Read down the temperature column until you locate a Btu rating that is equal to, or greater
than , the effective load of the application .
4) Read across to the Tank capacity (gallons w.c .) column to locate the required tank size.
Underground ASME tanks

Table 4A-2 in Appendi x A lists the vapourization irate of various ASME tanks when they are
installed underground .
130 October 20 19
Note: The temperature column only lists 50 °F. Regardless of the time of year, the earth surrounding an
underground tank usually remains around 50 °F.
Note: The moisture content of the so il has been averaged out.
1) To select the proper size of an underground tank, read down the 50 °F column until you find
a rating that is equal to, or greater than , the effective load of the application .
2) Read across to the left to determine the proper size tank capacity (gallons w.c.) .
If the tank is undersized , a frost line could develop on the tank and the vapouri zation rate will drop
off to zero . If this occurs , the tank must be dug up and a larger tank set in, resulting in a waste of
time and money.
Note: Never unders ize an underg round tank.
Table 4A-3 in Appendix A lists the capacities of common DOT/TC cylinders .
This table is different from the others because each cylinder has four different vapourization
rates:
• two ratings for winter ; and
• two ratings for summer.
Further , the summer and winter ratings are divided into low and high humidity :
Average ... Is ...

High humidity 70%
Low humidity 30%
Because of the low capacities of cylinders , a 10% difference in humidity or temperature does not
greatly change the vapourization rate of the cylind er.
To select a DOT/TC cylinder for an application , use the following procedure :

1) Select the column in Table 4A-3 that represents the most severe weather conditions for the
area (winter and high humidity , summer and low humidity , etc.)
2) Determine the type of cylinder needed (portable , replaceable , or stationary).
3) Read down the column until you locate a Btu rating that is equal to, or greater than , the
effective load of the application .
4) Read straight across to the extreme left column , Cylinder Capacity, and select the cylinder
required.
Propane vapourizers can be used when equipment or applian ce demand exceeds the natural
vapouri zing capacity of the tank and placing a much larger tank , with higher vapourization
capacity would not be practical.
October 2019 131

Direct fired propane vapourizer shown in Figure 4-21 , uses a flame that directly heats the liquid
propane which turns it to gas for use in downstream , high vapour demand equipment. Liquid
propane is piped from the tank to the vapourizer where it is then heated and in turn , the propane
gas vapourization is accelerated. The vapourizer is essentially a boiler that does not build
pressure .
Figure 4-21
Propane direct fire vapourizer
Vapour line
Shut-off
valve Vapour
inlet
To service
line
Gas service line
Regulator
---.--..-7 ~
L1qu1dline
Thermostat
control Burner 10 to 40 ft _____..-
Ther mocouple
lead
Pilot Support and
protect pipes
-----
Container sizing for liquid withdrawal
Sizing LP-gas containers for vapourizers, liquid burner applications, and stationary engines is a
simple proced ure. Basically , the size of the container is based on two considerations:
• liquid withdrawal rate each day ; and
• minimizing th e number of gas deliveries to the customer.
In order to properly size containers for these applications , determine the daily withdrawal rate for
the application . Stationary engines are rated in the number of US gallons (litres) that they use in
one continuous hour of operation (gal/hr, I/hr). To size the container, determine the expected
number of hours that the engine must operate under normal conditions.
If there are additional loads in Btu/h co nvert:

• effective load Btu/h divided by 91,500 = gal/hr ; and
• effective load Btu/h divided by 24 ,174 = I/hr.
Installation clearances
Before planning the location of a propane container , check all code requirements fo r clearance
information . The diagrams and tables in App endix B serve only as a guide for approximate
clearance information. Refer to CSA B149 .2 , Propan e storage and handling code, for additional
information.
132 October 2019

The key thing to remember is that propane is flammable . Sparks from electric motors and
switches, for examp le, can transfer enough heat to cause co mbustion. Even the heat from a lit
ciga rette or a ve hicle exhaus t pipe can ignite a flammable mixture of propane and air.
Caution I Never smoke around propane installations!
Testing propane systems

For information on testing propane systems, refer to the Gas Trade Training Unit 8 Introduction to
piping and tubing systems> Code requirements for testing chapt er for additional information .
Appendix A: vapourization rates for tanks and

cylinders
Table 4A-1
Vapourization rate of aboveground ASME tanks (Btu/h)
Humidi- Tank Capacity so°F 40°F 30°F 20°F 10°F 0°F -10°F -20°F -30°F
ty
(Gallons W.C.)
120 46,326 39,651 35,745 31,970 29,951 27,920 27,920 25,570 23,470
150 57,424 49,145 44,299 39,629 37,123 24,616 34,089 31,688 29,431
250 76,937 65,842 59,358 53,096 49 ,729 46,376 45,699 42,460 39,440
a-60%
500 127,919 109,472 98,694 88,279 82,697 77,102 75,927 70,600 64,567
1,000 227,834 194,975 175,787 157,232 147,276 137,319 135,227 125,748 116,782
6,000 750,944 624,661 579,380 518,240 485,432 452 ,623 445,727 414,451 384,909
120 30,475 29,951 26,187 22,503 20,586 18,706 18,416 15,130 14,900
150 37,775 37,060 32,400 27,890 25,520 23,230 22,830 18,760 18,470
250 50,612 49,670 43,420 37,380 34,200 31,130 30,580 25,140 24,750
b - 70%
500 84,150 82,550 72,170 62,130 56,840 51,740 50,820 41,780 41,140
1,000 149,878 147,040 128,550 110,670 101,250 92,160 90,580 74,420 73,280
6,000 494 ,002 485,545 242,497 364,772 333 ,716 303,225 298,530 245,266 241,536
120 27, 199 25,536 16,433 12,923 12,706 12,507 9,235 9,123 7,476
150 33,714 33,000 20,360 16,020 15,760 15,510 11,460 11,290 9,270
250 45, 171 44,230 27,290 21,480 21,120 20,790 15,360 15,130 12,420
c-80%
500 75, 103 73,510 45360 35,700 35,100 34,550 25,530 25,150 20,640
1,000 133,764 130,940 80,790 63,580 62,530 61,540 45,480 44,800 36,770
6,000 440,822 431,369 266,379 209 ,554 226 ,005 202 ,779 149,785 147,970 121,197
October 2019 133

Table 4A-2
Vapourization rate (Btu/h) of underground ASME tanks
Underground Temperature 50°F (See Note 1)

Tank Capacity 50°F Outside Temperature
(Gallons w.c.)
120 35,391
150 43 ,879
250 58,777
500 97,727
1,000 174,061
6,000 573,723
Note:
1) All ratings based on tanks being 1/4 full.
For tanks 1/3 full, multiply Btus by 1.144
For tanks 1/2 full, multiply Btus by 1.41
Table 4A-3
vapourization rate of common DOT/TC cylinders (Btu/h)
vapourization rate (Btu/h} of common DOT/TC cylinders

Cylinder capacity (lbs. of Winter temperature =0 °F Summer temperature =70 °F
LP-gas}
Low High Low humidity High
humidity humidity 30% humidity
30% 70% 70%
5#- Portable 7000 4280 13 370 8182
20#- Portable 12 000 7650 23 870 14 600
40#- Portable 16 600 10 160 31 710 19 080
60# - Port/Exch. 20 700 12 660 39 540 24200
100# - Exchange 25000 15 300 47 750 29220
200#- Stationary 31 000 20 200 59 210 36240
300# - Stationary 39000 25090 74490 45 590
420# - Stationary 45000 29980 86 000 52 630
Note 1: Ratings based on cylinders being 1/4 full.
Note 2: The values for exchange (60 # and 100 #) cylinders are for the supply cylinders only.
When the supply cylinders are connected to an automatic changeover regulator or manifold,
one reverse cylinder should be added for each supply cylinder that is used (i.e., two supply
cylinders require two reserv e cylinders or a total of four cylinders for the installation) .
134 October 2019

Appendix B : Installation clearances for tanks and

cylinders
Figure 4B-1
Installation clearances for aboveground ASME tanks
For exceptions, see locat ion
of consumer tanks in t he
Propane Code Sources
of ignition
*Building openings
include windows,
doors, combustion
and fresh air intakes
~
~
----~
-- ----------
Over 10,000 USWG

at the discretion of the
authority having jurisdiction
~ -- ----
----
--
-- r Property line or adjacent concrete
or masonry building with no openings
or source of ignit ion within the clearances
specified in Table 10.10.2
October 2019 135

Figure 48-2
Installation clearances for underground ASME tanks
Min. 10 t
Min. SOft -J- (Note 1) Crawl
(Note 1) ',------,_~_
~-,r 1----.._ space
~~
t,_~-- ------_: ------ Min. 10 ft
-~--- (Note 1)
2,000 gal w .c.
I
, -- ---- ._-_.._,!
.J,_ ..
or less
' - - - - - .. Min. SOft
I '
'.. ' (Note 1)
-~,;;-
,~ ....... ,'
- ;~~~ --- '
2,000 gal w .c. to
30,000 gal w.c.
Note 1: Minimum distances for underground containers are

measuredfrom the relief valve and filli ng or liquid level gauge
vent connection at the container, except that no part of an
underground container can be less than 10 ft from a building
or line of adjoin ing property that may be built upon .
136 October 2019

Figure 48-3
Installation clearances for DOT/TC cylinders
Mi nimum 10 f t from
any air intake or
source of ignition For full requirements , see
(air condi tio ner) Installation of Cylinders,
Clause 11.3, in the B149.2
any bui lding opening
Propane Storage and
Firm, level, weatherproof below the level of the
Handling Code
base located on consolidated relief valve discharge
ground at grade level
Table 48-1
Minimum distance requirements of ASME tanks
Minimum distance requirements for stationary ASME tank installation
Distance to ... Minimum required distance Purpose and explanation

Nearest Varies with water capacity of Provides safe distance between buildings
important tank (see ILL , 2 & 3) (see and tank in the event of a building or LP-
building multiple tank installations) gas fore. Important buildings can be
storage shed , home garage , commercial
building , livestock bar, etc.
Nearest Varies with water capacity of Provides safe distance between tank and
property line tank (see ILL , 2 & 3) (See buildings on adjacent property in the event
which may be multiple tank installations) of a building fire or an LP-gas fire . On
built upon property bordered by public street, alley,
river , or stream , always measure distance
to the other side of the street , alley, etc.
Exterior 1O feet in any direction from fill Prevents LP-gas from igniting when tank is
sources of connection or outage gauge on filled . Exterior source of ignition can be gas
ignition tank light , gas grill, air conditioner, central A/C
compressor, heat pump , water pump , etc.
(Continued)
October 2019 137

Table 4B-1 (Continued)

Intakes of 1O feet in any direction from fill Prevents LP-gas from being drawn into a
appliance or connection or outage gauge on building or appliance when the tank is filled .
ventilation tank Always consider intakes to attic ventilators
systems or direct vented gas appliances. On mobile
homes , intakes may be underneath the
home .
Openings to 5 feet horizontally from relief Prevents LP-gas from settling in building in
homes that are valve outlet the event the relief valve "pops off ."
below the level Openings include crawl space entries ,
of the relief basement doors, storm shelter doors , and
valve the lower part of any door or window into
the building that may be lower than the
relief valve .
Stored trash , 1O feet in any direction from any Provides safe distance between tank and
hay, or other part of tank combustible material. Combustible
combustible materials include piles of firewood , hay
material (loose bales , bales of pine straw , constru ction
or piled) materials , or trash dumps .
Stored 20 feet in any direction from any Provides a safe distance between LP-gas
flammable part of tank and stored flammable liquid in the event of
liquids (other an LP-gas or flammable liquid fire . Always
than LP-gas) consider distance to diesel fuel tanks , fuel
oil tanks , mineral spirits tanks , or solvent
tanks. In some states , small LP-gas tanks
(less than 125 gals. w .c.) can be located
adjacent to flammable liquid tanks with a
liquid capa city of 600 gallons or less.
Creeks , rivers, Check state and local codes Prevents tank from being "washed away " in
streams or the event of flooding. Never place a tank in
drainage an area where high water levels could
problem cause the tank to tip over or wash away.
areas. Always consider drainage ditches or any
federal flood zone area. Check state/local
codes for distances and special installation
requirements (i.e. concrete base , tic
downs , etc.).
(Continued)
138 October 20 19
Table 4B-1 (Concluded)

Other LP-gas Varies with water capacity (see Provides a safe distance between tanks for
tanks ; multiple ILL. 4) access by fire fighting personnel in the
tank event of an emergency or LP-gas fire . Also
installations provides maintenance and working space
between tanks .
Cesspools , Varies with customer site Avoid installing LP-gas tanks directly above
septic tanks , any underground utility line that may have
water or to be serviced or repaired (i.e., septic tank ,
sewage lines , electric line). Also , never place tank in a
or any location where a bulk truck must drive over
underground a septic tank or cesspool to fill the tank .
utility line This applies to both aboveground and
underground tanks.
October 2019 139

Module 11 - Pressure Regulators, Overpressure Protection, Meters, and Fuel Containers2

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Use of this document

GAS TRADE TRAINING UNIT 11

Title: Pressure regulators , overpressure protection, meters , and fuel containers

To register for e-mail notification about any updates to this publication

If you require assistance , please e-mail techsupport@csagroup.org or call 416-7 4 7-2233 .

~A trademark of the Canadian Standards Association, operating as "CSAGroup"

Published in October 2019 by CSA Group

© 2019 Canadian Standards Association

Pressure regulators .................... ................................... ................................. ........................... 9

Overpressure protection ................ ................... ...................... ................................................ 76

Meters ................................ ............................................................................................. ........... 91

Figure 1-9 - Vent limiting orifice accessory ............................................................................. 23

Figure 3-2 - Curved bimetallic temperature correction device ................................................ 94

Contributors and members of the review panel

St. Clair College

David Kerr TS Technical Training

Technician School of Skilled Trades ,

St. Clair College

Joint Training and Apprenticeship Committee

Refrigeration Workers Local 787

Enbridge Gas Diistribution Inc.

Fleming College , McRae Campus

HVAC Training Academy

George Brown College

Gas trade training and Red Seal alignment

RodSNI \,.~ UM lraot Ullft 11 12 13 14 15 11 17 11 1S 20 21 22 23 24

Fimtubeam ht.ng lo,~ p,pirg

<I in,bilo ga....i.,..,., p,pu~ • rd ✓ ✓ ✓

rTret.17 Comm~ 9:1!fi-odsy,lcrns

tl 2019 Canadian Standards Association . All Rights Reserv ed.

The need for pressure regulators

First-stage regu lato r

Most pressure regulators are either pilot-operated or direct-operated . Pilot-operated regulators

Basic operation of a regulator

Here is how a regulator works:

Note: The closing force in a regulator is the downstream gas pressure.

The loading element

The following terms relate to flow and pressure regulation.

Flow and pressure Description

The measuring element

The restricting element

The dirt may also damage the soft valve seat.

The atmospheric vent

model Part number Colour code Outlet Approximate Approximate

Adjusting pressure on non-utility regulators

If... Then ...

12) Leak test the test points .

Vent limiting orifice

Leak limiting device

Leak limi ting

Internal safety relief

The internalrelief valve only opens if downstreampressureexceedsa set amount and

Overpressure shut-off (OPSO)

Main gas pressure regulator

Two-way stabilizer vent valve

Pressure inside buildings

General requirements for regulators

A pressur e regulator shall not be bypassed (Clause 5.2 .1.3).

Line pressure regulators

Additional requirements for propane regulators

Additional requirements for natural gas regulators