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March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Basic Operation and Function of Industrial Regulators
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Regulators do not require an external power source,
resulting in less down time.
Regulators do not require an external packing gland
resulting in a lower chance of leakage.
Ease of maintenance.
Lower installation costs. Instantaneous reaction. Efficient and durable. Self-contained. (They do not require external piping.)
Regulator Advantages
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
FACTORS CONSIDERED BEST NEXT LAST
Line Size Cost – Thru 1-1/2” REG POR CRV
– 2” thru 3” POR REG CRV
– 4” and Up CRV POR REG
Cost/CV – Thru 1-1/2” POR REG CRV
– 2” and Up CRV POR REG
Capacity CRV POR REG
Outlet Pressure Level Capability CRV REG POR
Output Pressure Level Maintenance of Set Point CRV POR REG
Rangeability FTO REG CRV/POR FTC REG
Requirements for External Power – (Air or Electricity) REG/POR CRV
Stability CRV REG POR
Speed of Response REG POR CRV WOP CRV WP
Ability to Adapt to System Dynamics CRV POR REG
Fail-Safe Action CRV POR/REG
Adaptability (Add accessories, modify action) CRV REG PRO
Remote Set Point Capability CRV Regulator, Dome Loaded POR/REG
Maintenance Cost/Spare Parts REG POR CRV
KEY: CRV = Control Valve POR = Pilot Operated Regulator REG = Self-contained Regulator FTC REG = Flow-to-close Regulator FTO REG = Flow-to-open Regulator CRV WP = Control Valve w/positioner CRV WOP = Control Valve w/out positioner
Applying Regulators
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
PRESSURE REDUCING REGULATOR: A device that controls and responds to changes in its outlet pressure.
BACK PRESSURE REGULATOR: A device that controls and responds to changes in its inlet pressure.
DIFFERENTIAL PRESSURE REGULATOR: A device that maintains a constant differential pressure between a reference pressure and the pressure of the controlled fluid.
Fps
Frs
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
EXTERNAL PILOTED REGULATOR
A piston or diaphragm actuated regulator controlled by a separate external pilot mechanism.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
PRESSURE LOADED REGULATOR
A regulator using a fixed volume and pressure of compressible fluid as a spring and set point reference to accomplish pressure reduction or back pressure regulation. sometimes called a Dome Loaded Regulator.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
FTO–FLOW TO OPEN FTC–FLOW TO CLOSE
FTO vs. FTC
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Force-Balance Principle
REDUCING REGULATORS
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Inlet Pressure Tends to “Push” the Plug Open
FTO REDUCING REGULATOR
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
FTO REDUCING REGULATO with BALANCED TRIM
Inlet pressure tends to “PUSH” the plug open and closed at the same time,
causing a balanced effect.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
DIFFERENTIAL REDUCING REGULATOR
Loading Connection
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
FTO PRESSURE LOADED REDUCING REGULATOR with BALANCED TRIM
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
BACK PRESSURE / RELIEF REGULATOR
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
BP REGULATOR with UNBALANCED TRIM TOP/CAGE GUIDED
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
PRESSURE LOADED BP REGULATOR with UNBALANCED TRIM TOP/CAGE GUIDED
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
DIFFERENTIAL BACK PRESSURE
RELIEF REGULATOR
Loading Connection
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
PILOT-OPERATED REDUCING REGULATOR
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Droop
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
For a Reducing Regulator when flow demand increases the outlet pressure falls away or droops from set point.
For a back pressure regulator when the flow demand increases the inlet pressure
increases or builds above set point. Use a larger body size with higher Cv – Capacity. Use a composition diaphragm material. Use full port trim instead of reduced port trim. Use the lightest spring possible on pressure reducing and
heaviest on back pressure. Use dome loaded technology.
To Minimize Droop on Reducing Regulator and Build on Back Pressure Regulators
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Increasing Regulator Sensitivity
Use a composition diaphragm instead of metal
Use a lighter range springUse a balanced trim design
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
COMPOSITION More sensitive. Increased capacity Increased efficiency. Recommended when
compatible with fluids. Same price as metal.
METAL Less sensitive. Reduces capacity. Recommended for
high temperatures. Recommended
when composition is not compatible with fluid.
Composition vs. Metal Diaphragms
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
COMPOSITION
Tight Shut-off
No Seat Leakage
Extended Seat Life Recommended when
compatible with fluids.
METAL
Does not allow tight shut-off. Some seat leakage will
occur. Recommended for high
temperature applications. Recommended when
composition is not compatible.
Less expensive than composition seats.
Composition vs. Metal Seats
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Sizing a Regulator
Rule 1: Flow rate and set point are integral. Set point varies with flow.
The amount of variation set point with a given change in flow is called: Proportional Band Droop Offset Buildup
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Rule 2: The use of composition seats and diaphragms will provide:
Maximum Flow - Minimum Droop - Minimum Seat LeakageProportional Band Droop BuildOffset Accumulation
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Regulator Sizing Continued. . .
Rule 3: PRV and BPR DO NOT fail in the normal desired mode.
Rule 4: Regulators are best when used in systems where flow changes are minor.
Rule 5: DO NOT rely on a regulator as a shut off device.
Rule 6: Never hydro-statically test a regulator.
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
What is the service fluid?Inlet Pressure (P1)
Outlet Pressure (P2)
Flow Rate or Pipe SizeTemperature
Application and Selection Requirements
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Features Standard/General specifications. Principal of operation. Technical specifications
Design pressure/temperature Maximum allowable pressure drops. Trim combinations/Temp ranges.
Capacity Tables Dimensions & Weights
Technical Bulletins
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference