Regulator Seminar

Regulators Seminar
© 2008 Swagelok Company.- Confidential.
Content
1. Purpose/Introduction
– Functions
– Regulator Vs. Valve
– Regulator Basic
2. Basics Operations
– Pressure-Reducing
• Single-stage Regulator
• Two-stage Regulator
– Back-Pressure
– Auto-Changeover Regulator
– Vaporizer Regulator
3. Regulator Selection
– Options
– Criteria
4. Applications
5. Q&A
© 2008 Swagelok Company.- Confidential
Pressure regulator Lines
Analytical and Process

Instrumentation
3
1
1. Regulator Function
• Control Pressure (Downstream & Upstream)
• Gases and Liquid
• Self Adjust
Regulator vs Valve
Valves
vs.
Regulators
• Regulators control pressure

– Valves control flow
• Regulators do self-adjust to maintain pressure

– Valves do not self-adjust to maintain flow
Regulator Basic- Overview
2
Regulator Basic- Load Mechanisms
4 TYPES
Spring loaded Vs. Dome Loading
Gas in Gas out

Load/Sensing
Dome Chamber
Diaphragm
Control Element
Poppet
Inlet Outlet
Diaphragm vs. Piston Sensing
Diaphragm
•Greater sensitivity
•Better compatibility
Piston Sensing
•Higher outlet
pressure
•Less sensitive
3
Regulator Basic Control Element
Exp: Pressure Reducing (KPR)
Control Element
Seat retainer
Seat
Poppet
Poppet spring
Damper
2. Basic Operation
•Pressure-Reducing Regulators
– Spring Loaded: KPR, KCY, KLF, KHF,
KCP, KPP, KPF, KHP, KHR, RS, RS(H),
LRS(H), LPRS.
– Dome Loaded: RD, RD(H)-DP, LPRD
Regulator Basic Operation-Spring Loading
As compression of
spring increases,
the poppet is
pushed downwards
and the regulator
opens
The sensor
(diaphragm or
piston) balances the
spring force and
pressure forces
LOW
PRESSURE
HIGH
PRESSURE The poppet &
seat ‘bleed’ the
high pressure to
low pressure
side of the
regulator © 2008 Swagelok Company.- Confidential
4
Operating Principle
Balance of Forces
F1 = Spring Force
F2 = Inlet Spring Force
F3 = Outlet Pressure Force
F4 = Inlet Pressure Force
F1 = F2 + F3 + F4
Regulator Self-Adjustment
Note: This
animation
example is for 1. Handle is
KPR without self- completely
vent option backed out
3600 psig 0 psig
Note: This
animation
KPR without self- turned in
vent option
2. Sensor/poppet
react to allow flow
3. Downstream
pressure increases
3600 psig 10 psig
5
Note: This
animation
KPR without self- turned in further
vent option
2. Sensor/poppet
react to increase
flow
3. Downstream
pressure increases
3600 psig 20 psig
Note: This
animation
vent option
2. Sensor/poppet
react to increase
flow
3. Downstream
pressure increases
3600 psig 30 psig
Note: This
animation
vent option
2. Sensor/poppet
react to increase
flow
3. Downstream
pressure increases
3600 psig 40 psig
6
Note: This
animation
vent option
2. Sensor/poppet
react to increase
flow
3. Downstream
pressure increases
3600 psig 50 psig
Note: This
animation
example is for
KPR without self-
vent option
1. Downstream flow
is reduced causing
pressure to build
3600 psig 57 psig
Note: This
animation
example is for
KPR without self-
vent option
2. Sensor/poppet
react to decrease
flow
3600 psig 57 psig
7
Note: This
animation
example is for
KPR without self-
vent option
2. Sensor/poppet
react to decrease
flow
3600 psig 57 psig
Note: This
animation
example is for
KPR without self-
vent option
2. Sensor/poppet
react to stop flow
3600 psig 57 psig
Regulator Application
8
Regulator Basic Operation-Dome Loading
• Work exactly in the same way as a spring loaded controller
• Gas charge (usually is compressible gas or air)
• Standard dome loaded pressure regulators have a ratio of
1:1
• Useful with high flows, high volumes and high outlet
pressure
• Rubber diaphragm
Dome Loading
Pilot Pressure
Compressible gas
Pdome = Pset +
Dome
chamber
Valve opens
Dome Loading
Dome Chamber
Poutlet
Valve opens
°
Flow
Valve closes °
Poutlet
9
Dome Loading Methods
Note: Gas system
Dome Loading
Bleed to outlet
Pressure to pilot from inlet
External Pressure Source

Note: Liquid system
10
Regulator Characteristic
• Creep
• Lock up
• Droop
• Optimal flow range
• Choke flow range
• Cv
• Hysterisis
• SPE (Supply Pressure Effect)
Creep
• Outlet pressure increases over time
• If the poppet does not fully seat in the orifice, inlet pressure
may continue to bleed through the orifice.
– Over time this leakage can increase the outlet pressure until it
equals the inlet pressure
Creep
OUTLET PRESSURE
TIME
Creep
• Causes:
– Contamination of the seat (Upstream filtration critical – INSTALL
FILTERS)
– Damage to the poppet or seat
– Misalignment of the poppet to the seat
• KVV relief valve provides protection
• A regulator is not a shut-off device!
11
Lockup
• The difference in pressure between a flowing and non-
flowing condition.
• As outlet pressure builds, the balance of forces favor the
control element, which allows the poppet to seat itself and
close off inlet pressure.
• Therefore, P2 increases when V2 is shut-off
lockup
P1 P2
Off
F
Test Valve Flow
Regulator V2 Controller
Droop
• Droop is the reduction of outlet pressure experienced by
pressure-reducing regulators as the flow rate increases.
Droop
• Inlet pressure 500 psig / Set Static Outlet Pressure at 22 psig
• Flow increases to 2.5 scfm; outlet drops to 15 psig.
• What happens to outlet pressure if downstream demand
increases to 4.0 scfm? 6.0 scfm? 8.0 scfm?
What could
cause
downstream
demand to
increase?
12
Optimal Flow Range
• The portion of the flow curve in which a regulator should
operate for best performance
Optimal flow range
Lockup, Droop, and Optimal Flow Range
Lockup
Conventional
arrangement Droop
Kenmac
Monoflange
Optimal flow range
Choke Flow Range

• When a regulator is in the full open position it is no longer
regulating pressure.
– Acting as a restricting orifice
13
Cv – Flow Coefficient
• Expresses the flow capacity in imperial units - GPM (US
gallons per minute) of water that a valve will pass for a
pressure drop of 1 psi.
• For a regulator:
– Relative measure of the flow across the regulator seat
– Calculated from testing the regulator in the full open seat position.
Hysterisis
• The difference in outlet pressures at specific flow rates on
the flow curve when the downstream demand is increased
and the return curve when the downstream demand is
decreased. Contributor to lock-up
102
101 Hysterisis
100
Pout (psig)
99
98
97
96
95
0 10 20 30 40 50 60 70 80 90 100
Flow (scfm)
Operating Principle
Balance of Forces
F1 = Spring Force
F2 = Inlet Spring Force
F3 = Outlet Pressure Force
F4 = Inlet Pressure Force
F1 and F2 are constant.

As F4 decreases due to reducing inlet pressure (i.e.
depletion of a gas cylinder), the poppet is forced down
due to constant spring force, F1.
The poppet is forced downwards, the seat opens:
causing the outlet pressure to rise
14
SPE- Supply Pressure Effect
Change in outlet pressure
due to change in inlet
pressure
What would cause a

change in inlet pressure?
Answer: depletion of a gas cylinder
3600 psig 50 psig
Pinlet decreases from

3600 to 2600 = 1000 psig
1% of 1000 psig = 10 psig
Poutlet increases 10 psig
1. Upstream pressure
decreases as
cylinder is depleted
( 3600 psig) (50 psig)
2. Downstream
pressure increases
1% of the inlet
2600 psig 60 psig decrease
1%
Pinlet decreases from

3600 to 1600 = 2000 psig
1% of 2000 psig = 20 psig
Poutlet increases 20 psig
1. Upstream pressure
decreases as
cylinder is depleted
(50 psig)
(3600 psig) 2. Downstream
pressure increases
1% of the inlet
1600 psig 70 psig decrease
1%
15
500 psig 50 psig

3600 psig
1% 1%
Down Up 20 psig Down

2000 psig 0.2psig
(3600 psig) (50 psig)

(500 psig)
1600 psig 520 psig 49.8 psig
1% 1%
Regulator – Supply Pressure Effect

•KPR •KCY
– Single-stage “line” regulator – Two-stage regulator
– 1% SPE (supply pressure – .01% SPE (supply pressure
effect) effect)
– Commonly used with
cylinders
– Compensates for fluctuating
inlet pressures
– Diaphragm sensing element;
essentially two KPRs
16
KCY Function Details
Step 4 - Inlet pressures below 500 psig
are not effected by 1st stage Step 3 – Regulator outlet has an
(500-100 psig drop at inlet) x 1% = 4 psig additional 1% SPE from 2nd stage
INCREASE (20 psig rise) x 1% = 0.2 psig decrease
New outlet pressure
=50psig + 4psig New outlet pressure
= 54psig =50psig – 0.2psig
= 49.8psig
Typically, the 1st stage

Of KCY regulator
is preset at 500psig
Step 2 - Supply to 2nd stage has a Step 1 - Inlet supply from gas
1% SPE from 1st stage cylinder drops from 2500 psig to
(2500-500) x 1% = 20 psig increase 500 psig Outlet pressure
- its an inverse relationship - been set at 50psig
Back-Pressure
Regulators
Spring Loaded: KBP, KFB, KCB, KPB, KHB, BS,
LBS
Dome Loaded: BD
Pressure Reducing vs. Back Pressure
Inlet Outlet Inlet Outlet
Pressure-Reducing Back-Pressure © 2008 Swagelok Company.- Confidential
17
Back Pressure Regulator
Spring force sets pressure

Normally Closed
If inlet pressure is less than

set pressure, regulator
remains closed
If inlet pressure exceeds set
pressure, regulator allows
flow and excess pressure to
vent
Back Pressure Regulator:

Tank Over Pressure Control
• Back pressure regulators control upstream pressures by

venting to a lower pressure
Controls upstream
TANK pressure to prevent tank
from overpressure -
potentially caused by
increasing temperature

Analyzer System
• Back pressure regulators control upstream pressures when
downstream pressures vary (in a closed loop system)
Analyzer pressure Set at 40 psig (2.7 bar)

held at 40 psig
(2.7 bar) psig to
prevent 10 psig
FLARE
(0.7 bar) pressure
swing from
20 to
affecting analyzer 30
reading psig
(1.4 to
2.1
bar)
Back pressure
regulator controls
“back pressure” to Note: If the KBP was not there the
analyzer caused by 20-30 psig backpressure would
downstream pressure affect the analyzer reading.
variations in the flare
18
Analyzer System
Analyzer expecting 50 psig (3.4 bar) and will be damaged at 75 psig (5.2 bar)
KBP set to 60 psig (4.1 bar) to “protect” the analyzer
50 psig 50 psig
50 psig 60 psig
Flow » (3.4 bar) (4.1 bar)

Paint Spray Booth
Spray nozzles are

open allowing paint
to flow to the
application.
Spray nozzles close
building pressure in
line. 
KBP relieves
pressure (paint) back
to paint tank
Gas Cylinder
Changeover
KCM
19
Regulator – Changeover Manifold
• KCM  Changeover Manifold
 Ensures a continuous
flow of gases for critical
applications
 Automatically switches
gas feed from a
depleted gas source to
a secondary gas source
 Great for carrier gas
for gas
chromatographs (lab
and process) Valves and GI
 Essentially three KPRs transducers can be
added here!
 Accuracy is .01%
KCM – So how’s it really work??
Conventional
arrangement
Kenmac
DBB
Compliments of Tim Maruna,

Regulator Product Engineer - Highland © 2008 Swagelok Company.- Confidential
Conventional
arrangement
Kenmac
Monoflange

20
Conventional
arrangement

Conventional
arrangement

Conventional
arrangement

21
Conventional
arrangement

Regulator – Vaporising
KEV  Electrically Heated
Vaporizing
• Direct heating of process media
• Regulator is a KPR (One-piece body)
• Available in side or lower mounting
options
Typical Applications:
• Great for process GCs in refineries
• Vaporising liquid hydrocarbons. Ethylene, LPG,
Butane
• Natural gas sampling
• BTU sampling systems
• H2S and Mercaptan analysis
• Heating of gas samples to prevent condensable Heater cartridge
drop out
Regulator – Vaporising
KSV  Steam Heated
Vaporizing
• Direct heating of process media
• Regulator is a KPR
• One-piece body
• Steam tube runs completely through
body
Typical Applications
• Process gas chromatographs
• Pilot plant reactor gas
• Vaporizing medium weight
hydrocarbons
• H2S analyser systems
• Heating of gas samples to prevent
condensable drop out
22
Venting Regulators
• Self-vent regulator
– P2 will show both
increase and decrease
in pressure when
regulator is adjusted.
• Non Self-vent regulator
P1 P2 – P2 will show an
increase in pressure
OFF when regulator is
adjusted upward (open the
regulator- poppet away from seat).
– P2 will not show a
decrease in pressure
until V2 is opened. (close
Test Valve the regulator- poppet close to
seat).
Regulator V2
Venting Options
No Self-Vent Self-Vent No Self-Vent Self-Vent

No Captured No Captured Captured Vent Captured Vent
Vent Vent © 2008 Swagelok Company.- Confidential
Option: KVV Relief Valve

Purpose:
• Protect regulator, NOT
downstream equipment
• Required if isolation valve
is assembled to regulator
• Remember: Creep is the
outlet pressure increase
over time
23
Option
•Additional Color Handles
Black BK
Blue BL
Red RD
Orange OG
Yellow YW
Option: Accessories
Option: Panel
KCA Series
24
3. Selecting Criteria
1. Function of Regulator 4. Flow Requirements
– Pressure-reducing – Use flow curves
– Back-pressure • Curves are based on
– Changeover Nitrogen
– Vaporizer 5. System Compatibility
2. Inlet Pressure Range – Materials of construction (body)
– Matched to maximum supply – Seat material
pressure
– O-ring
– Helps determine model
3. Pressure Control Range 6. System Functionality
– Matched to maximum outlet – Helps in determining venting

pressure options and accessories
• Flow requirements may 7. End connections, porting,
dictate higher control range and mounting
– Determines diaphragm vs. piston
Quick Selection Guide
Important feature Look at Comments
Better Accuracy (Supply Pressure KCY, KHF (KPF),

Dual Stage or Balanced Poppet
Effect) LRS, RS(H)
High Flow KHF, KPF, RS(H) Cv =  1.0
Resists over pressure deformation or fatigue failure from pulse

High Outlet Pressure or Piston KPP, KCP, KPF,
/ pump effect, where a diaphragm may deform or crack
Sensor KHP, KHR, RS, RA
prematurely
KLF (KHF), Larger Diaphragm providing more sensitivity to outlet pressure
Sensitivity
LRS(H), RD change
Heating
KEV, KSV To vaporize liquids or to keep gas above its dew point
Compact size
KCP Dimensional or weight considerations
Low Control Pressure KLF, LoBar May require low inlet pressures also
4. Applications
25
Pressure-Reducing:
Aircraft Service Trolley
Vaporizing Regulator:
Sample System Ethylene Plant
Pressure Reducing and Vaporizing:

Chromatograph Application
26
Pressure Reducing:
Power Plant Grab Sample
Pressure Reducing:
Heavy crude analyzer
Process Sample Line
27
Cylinder Regulator
Regulator Application Sheet

• Market: Fire extinguisher
• Application: On board offshore

platform to keep vessels of water for
sprinkler at a high pressure
• Product: RD20

• Market: Air Force
• Customer: Royal Dutch Air Force
• Application: Test unit for EPU

(emergency power unit)
• Product: RSH2s in an integrated test

panel built by installation company
28

• Market: Semiconductor market
• Customer: Air Products
• Application: Bulk gas

distribution, reducing pressure
after evaporator

• Market: Beer industry
• Customer: Bavaria beer
• Application: Blanketing at 1.2 barg of

beer during transport from brewery to
end user (pub)
• Reduces CO2 cylinder pressure from

60 barg to 1.2 barg
29
• Market: Oil exploration
• Customer: Shell
• Application: Testing core samples by

controlling flow of water through
samples in Oman
• Product: Ratio backpressure valves
• Material of construction: SS316 /

duplex

• Market: Offshore oil industry
• Customer: Oil rig
• Application: Rack of nitrogen

cylinders, on each cylinder a pressure
regulator.
• Product: RS2

• Market: CNG mother-daughter
system
• Customer: Neogas
• Application: to reduce pressure

from tube trailer at customer to low
pressure for customer 250 – 8 bar
• Product: RDH10 – RDH25
• Material of construction: SS316
30
• Market: CNG dispenser
• Application: To control the maximum filling

pressure in CNG car at maximum of 220
barg
• Product: CRSN4 or CRSN6
• Material of construction: SS304
• Pressure inlet - outlet: 300 barg – 220

barg


31
• Market: CNG
compressor
• Customer: Aspro Delta
• Application: Relief
valves at each stage in 4
stage compressor

• Market: CNG control panel in
CNG filling station
• Customer: Sweden
• Application: Blue backpressure

to keep high pressure over gas
dryer

• Market: CNG Dispenser
32
• Market: CNG dispensers
• On dual hose dispensers - two hose

and two pressure regulators per
dispenser
• Customer: Meurs Netherlands

• Market: Pumps and injection
• Application pressure reducers on

mechanical seals
• Product RSHFA6
• Material of construction: SS316 and

painted by customer
• Note that painting is always by

customer

• Market: Beer brewery
• Customer: Dommelsch bier (Inbev)
• Application: Reducing pressure in

cleaning and barrel filling installation
• Product: LRS4 and LPRS8
Note: Thai Asia Pacific Brewery Bangkok
33
• Market: Navy
• Customer: Dutch Royal Navy
• Application: Reducing panels for high

pressure nitrogen and CO2
• Product: RSH4 and valves

• Market: Mechanical seals
• Customer: Man Turbo
• Application: Keep pressure on

gas seals
• Product: LPRS4

• Market: Hydrogen
reducing panel
• Customer: Linde
• Application: To
reduce high pressure
hydrogen to low
pressure
• 200 bar inlet
• Product: All types of

pressure regulators
34
• Market: Hydrogen reducing panel
• Customer: Linde

• Market: Semiconductor Industry
• Customer: Imec Belgium
• Application: Reducing panel for

Nitrogen backup system
• Product: RDS40 with orbital weld

ends

• Semiconductor industry at Imec
Belgium
35
• Market: R&D pilot plants
• One panel for Hydrogen, Nitrogen

and Oxygen
• This panel is in use to test start-up

engines on rockets

• Market: Gas supply
• Customer: Air Liquide
• Application: Reducing for Backup unit
• Product: RD15 with LRSN4 pilot
36
• Market: Gas supply
• Customer: Linde
• Application: Backup unit for

Nitrogen if compressor fails

• Market: Skid building
• Application: Two stage reducing

panel
• Product: RSH6 and LPRD10

• Market: Air balloon
• Customer: Sweden
• Application: Reduce gas from

cylinder to burner
• Product: RSH6
37
• Market: Air supply to fire fighting car
• Customer: Switzerland
• Application: Reduce high pressure air

to car engine when firefighting in
burning area with low oxygen because
of fire
• Product: RSH4 an LPRS10
5. Q & A
THANK YOU
38

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Regulator Seminar

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Regulators Seminar

© 2008 Swagelok Company.- Confidential.

© 2008 Swagelok Company.- Confidential

Pressure regulator Lines

Analytical and Process

© 2008 Swagelok Company.- Confidential

• Regulators control pressure

• Regulators do self-adjust to maintain pressure

© 2008 Swagelok Company.- Confidential

Regulator Basic- Overview

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential.

Spring loaded Vs. Dome Loading

Gas in Gas out

© 2008 Swagelok Company.- Confidential

Diaphragm vs. Piston Sensing

© 2008 Swagelok Company.- Confidential

Exp: Pressure Reducing (KPR)

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

Regulator Basic Operation-Spring Loading

© 2008 Swagelok Company.- Confidential

3600 psig 0 psig

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

3600 psig 57 psig

© 2008 Swagelok Company.- Confidential

3600 psig 57 psig

© 2008 Swagelok Company.- Confidential

3600 psig 57 psig

© 2008 Swagelok Company.- Confidential

3600 psig 57 psig

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential.

© 2008 Swagelok Company.- Confidential

External Pressure Source

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

Optimal flow range

© 2008 Swagelok Company.- Confidential

Lockup, Droop, and Optimal Flow Range

Optimal flow range

© 2008 Swagelok Company.- Confidential

Choke Flow Range

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

© 2008 Swagelok Company.- Confidential

F1 and F2 are constant.

© 2008 Swagelok Company.- Confidential

What would cause a

3600 psig 50 psig

© 2008 Swagelok Company.- Confidential

SPE- Supply Pressure Effect

Pinlet decreases from