march 31st and april 1st, 2009mile high industrial and automation conference basic operation and...

March 31st and April 1st, 2009 Mile High Industrial and Automation Conference

Basic Operation and Function of Industrial Regulators


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


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


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


EXTERNAL PILOTED REGULATOR

A piston or diaphragm actuated regulator controlled by a separate external pilot mechanism.


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.


FTO–FLOW TO OPEN FTC–FLOW TO CLOSE

FTO vs. FTC


Force-Balance Principle

REDUCING REGULATORS


Inlet Pressure Tends to “Push” the Plug Open

FTO REDUCING REGULATOR


FTO REDUCING REGULATO with BALANCED TRIM

Inlet pressure tends to “PUSH” the plug open and closed at the same time,

causing a balanced effect.


DIFFERENTIAL REDUCING REGULATOR

Loading Connection


FTO PRESSURE LOADED REDUCING REGULATOR with BALANCED TRIM


BACK PRESSURE / RELIEF REGULATOR


BP REGULATOR with UNBALANCED TRIM TOP/CAGE GUIDED


PRESSURE LOADED BP REGULATOR with UNBALANCED TRIM TOP/CAGE GUIDED


DIFFERENTIAL BACK PRESSURE

RELIEF REGULATOR

Loading Connection


PILOT-OPERATED REDUCING REGULATOR


Droop


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


Increasing Regulator Sensitivity

Use a composition diaphragm instead of metal

Use a lighter range springUse a balanced trim design


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


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


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


Rule 2: The use of composition seats and diaphragms will provide:

Maximum Flow - Minimum Droop - Minimum Seat LeakageProportional Band Droop BuildOffset Accumulation


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.


What is the service fluid?Inlet Pressure (P1)

Outlet Pressure (P2)

Flow Rate or Pipe SizeTemperature

Application and Selection Requirements


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, 2009mile high industrial and automation conference basic operation and...

Documents

regulator slide

automation conference

mile high industrial

reference pressure

pressure reduction

pressure regulation

actuated regulator

regulator advantages