System Troubleshooting using Regulators

By John R. Anderson Fisher Controls Regional Manager Canada

Company Confidential Rev. 1/2006, Pg. 1 - JRA

System Troubleshooting with Regulators

Back to the Basics Regulator Failure Analysis System Problems Installation Problems Application Problems

Company Confidential Rev. 1/2006, Pg. 2 - JRA

Purpose of a Pressure Regulator

Pressure Reducing - To match a downstream flow demand while maintaining a constant outlet (P2) pressure. Pressure Relief/Backpressure To match an upstream flow demand while maintaining a constant inlet (P1) pressure.

Company Confidential Rev. 1/2006, Pg. 3 - JRA

Rules of Thumb for Regulator Selection

Always choose the lightest spring range for accuracy Always choose the smallest orifice to reduce inlet sensitivity Always choose the largest orifice to speed opening and closing

Company Confidential Rev. 1/2006, Pg. 4 - JRA

Basics of Regulator Failure Analysis

Understand regulator operation
Flow to close or flow to open Spring to close or spring to open Inlet Sensitivity Boosting Self operated, pilot operated (2 path or unloading) or relief valve

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Basics of Regulator Failure Analysis

Inlet Sensitivity - The changes in outlet pressure caused by a change in inlet pressures.
Flow tends to close
As inlet pressure increases, the setpoint will decrease

Flow tends to open

As inlet pressure increases, the setpoint will increase

Balanced
Changes in inlet pressure do not change outlet pressure
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Flow Paths In Self Operated Regulators

Unbalanced Valve Plugs
Inlet Sensitivity Flow to Close Flow to Open

P1 0 P2

A rise in P1 results in a decrease in P2

P1 0 P2

A rise in P1 results in a increase in P2

67CF Series Filter Regulators

ATMOSPHERIC PRESSURE INLET PRESSURE OUTLET PRESSURE

W7437

Flow tends to close

Company Confidential Rev. 1/2006, Pg. 7 - JRA

Flow tends to open

Self Operated Regulators - Balanced Valve Plugs

Inlet Sensitivity Balanced

P1 0 P2

A rise in P1 results in no change in P2

The surface area of the valve plug equals that of the balancing diaphragm surface area.

Balancing diaphragm

Inlet pressure closes Inlet pressure opens

Valve plug
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Boosting Methods in Self-Operated Regulators

Type 627 Farm Tap Type S201 Commercial Service

Turbo Booster Tube Pitot Tube

Set: P1= 50 psig P2= 6" w.c. Q=500 scfh 0.6 gas 10.0 20 psig 50 psig 9.0 99 psig

Farm Taps High pressure drops Small diaphragm area Minimal boosting Low to High Setpoints

Commercial Service Low pressure drops Large diaphragm area High boosting Low Setpoints
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8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0 500 1000 1500

Flow, scfh 0.6 SG Gas

2000

2500

3000

3500

4000

4500

Boosting

No Boosting With External Control Line Versions

Type 627M Farm Tap Type S201P Commercial Service

O-ring stem seal

External Control Line Tap

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Self Operated Regulator Failure Modes

Cantilever style commercial/residential service regulator
Diaphragm

Define Mechanical Failure Mode - Disc eroded

- Lever breaks - Diaphragm ruptures - Small leak
- Larger leak - Full rupture

Most problems occur at the orifice

Stem

Vent
Lever

- Stem seizes - Spring breaks - Vent plugs

P1
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P2

Self Operated Regulator Failure

Diaphragm

Cantilever style commercial/residential service regulator

ANSI B109.4 CSA 6.18

Defines worse case failure as lever disconnect for IRV sizing in residential services
Vent

Stem

Flow to open or close design?

Lever

Spring open or spring closed design?

P1
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P2

2 Path Pilot Operated Regulator Failure Modes

Control Line
INLET PRESSURE OUTLET PRESSURE LOADING PRESSURE ATMOSPHERIC PRESSURE

What happens when: P1 = P2 Control line break Pilot failed open Restrictor plugged Main spring broken Diaphragms broken No pilot P1 pressure Control line closed

Restrictor

PL P1
Spring open or spring closed design?
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P2
Flow to open or close design?

Flexible Element Pilot Operated Regulator Failure Modes

Variable Restrictor

Pilot

P1 = Inlet P2 = Outlet PL = Loading

What happens when: P1 = P2 Control line break Pilot failed open Restrictor Plugged Main spring broken Diaphragms broken No pilot P1 pressure Control line closed

Bleed/Sense Line

PL
Spring

Diaphragm/Plug

P1

P2
Spring open or spring closed design?

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Typical Flexible Element Regulator Failures

Debris in gas stream, damaged boot fails High cycling damaged boot, heat related Constant flow rate and boot takes a set Wide open flow condition High pressure drops Gas entrainment into the rubber Bubba uses to much grease in upstream plug valve(dirt collector) Aromatics
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Dirt/Poor Filtration
Dirty gas blew the inlet filter and destroys diaphragm and plugs cage

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Dirt Elastomer Erosion

Large particles in the gas stream destroy the rubber diaphragm and cage

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Cage erosion

Debris Damaged Diaphragm from Boot-Style Regulator

Wide open flow Debris in pipeline Fabric failure

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Boot Style Failure

Gas entrainment Boot took set

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System Problems With Relief Valves

Weeping relief valves
Thermal expansion of downstream gas Relief setpoint too close to regulator setpoint Failed regulator(orifice, disk)

Company Confidential Rev. 1/2006, Pg. 20 - JRA

Regulator and Relief Setpoint Considerations

Relief Valve
Start to discharge Buildup

P2
Lockup

Reseat

SYSTEM DEADBAND
Droop

Ensure system deadband between regulator and relief setpoints

Regulator
0

Q = FLOW

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Regulator and Relief Setpoint Considerations

Temperature Changes
Example:
Regulator set at 7 WC Relief set at 14 WC Gas temperature = 50 degrees F
Apply General Gas Laws
P1abs* V1 /T1R = P2abs* V2/T2R Pipe heats up to 150oF at no flow conditions

Downstream Gas Temp Increase = 100oF Downstream Pressure goes to 3.18 PSIG

GasTemp = 50oF
Company Confidential Rev. 1/2006, Pg. 22 - JRA

Bubbas BBQ
Joe Morris Proprietor

7 wc

Regulator System Troubleshooting

Freezing Meters Dirt/Poor filtration Aromatics Vent Piping Sour gas Noise

Company Confidential Rev. 1/2006, Pg. 23 - JRA

Regulator Freezing
Every 15 psi of pressure drop equals 1 degree F of cooling To avoid freezing the following can be done:
Heat the gas stream Heat the pilot supply Remove moisture from gas stream Inject antifreeze in pilot supply line
Company Confidential Rev. 1/2006, Pg. 24 - JRA

Bruest Pilot Heaters

Installation Problems
Regulator vent locations Control line placement Tubing incorrect Needle Valves Environment susceptible to corrosion

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Icing/Freeze Ups

Keep pilot vents free from ice build up

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Wrong Vent Orientation During Installation

Keep Vent Down

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Vent Locations and Restrictions

Vent pointed downwards to prevent rainwater Splashback avoid placement to close to the ground or meter Piping on vent can cause instability and significant loss of IRV capacity

Company Confidential Rev. 1/2006, Pg. 28 - JRA

Vent Piping
Restricted vent piping can cause the following:
Slow speed of response Instability Reduced IRV capacity

Vent Pipe Guidelines w/IRV Use same diameter pipe as vent Increase 1 pipe size for every 10 1 pipe elbow equals 3 of straight pipe Vent Pipe Guidelines wo/IRV Use same diameter pipe as vent Increase 1 pipe size for every 50 1 pipe elbow equals 3 of straight pipe

1 inch pipe

1 inch vent
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Relief Valve Failure Modes

Spring to close Valve plug sticking High Buildup
Always use OEM original replacement parts and not replicators

TYPE 1805

INLET PRESSURE OUTLET PRESSURE ATMOSPHERIC PRESSURE

A6671

Company Confidential Rev. 1/2006, Pg. 30 - JRA

Control Line Placement

Problem:
Improper control installation can cause a regulator to cycle, control the wrong pressure or respond slowly. Control lines are also called sense lines and static lines.

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Control Line Installation

Solution:
Plan the installation ahead of time using these guidelines:
Make the control line as short and straight as practical. Connect the control line 6 to 10 pipe diameters downstream of a turbulence generator (valve, tee, elbow, swage). Connect the control line to the point where the pressure is to be controlled.
Company Confidential Rev. 1/2006, Pg. 32 - JRA

Regulator In Swages

A B

RIGHT WRONG PRESSURE MAY BE LOWER IN THE SMALLER PIPING DUE TO HIGHER VELOCITY
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Regulator Supplying to Large Header

A B

RIGHT WRONG PRESSURE MAY BE LOWER IN THE CONNECTING PIPING DUE TO HIGHER VELOCITY
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Connect the control line at a location that is expected to be relatively free of turbulence.

A B

WRONG TOO CLOSE TO REGULATOR OUTLET CORRECT CONNECTION IS 6 TO 10 PIPE DIAMETERS DOWNSTREAM OF THE REGULATOR
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Connect the control line at a location that is expected to be relatively free of turbulence.

A B

WRONG PIPE SIZE CHANGE (SWAGE) CAUSES TURBULENCE CORRECT CONNECTION IS 6 TO 14 PIPE DIAMETERS DOWNSTREAM OF THE SWAGE
Company Confidential Rev. 1/2006, Pg. 36 - JRA

Improper Control Line Placement

Control Line Tap

Company Confidential Rev. 1/2006, Pg. 37 - JRA

CORRECT CONNECTION IS 6 TO 10 PIPE DIAMETERS DOWNSTREAM OF THE REGULATOR WRONG TOO MUCH TURBULENCE AT AN ELBOW CORRECT CONNECTION IS 6 TO 10 PIPE DIAMETERS DOWNSTREAM OF THE SECOND ELBOW. WITH THE CONNECTION AT THIS POINT, THE REGULATOR WILL COMPENSATE FOR PRESSURE LOSS THROUGH THE TWO ELBOWS.
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B C

Dampen Turbulence on Direct Operated Regulators

PROBLEM:
CONTROL LINE LOCATION APPEARS TO BE GOOD BUT REGULATOR CHATTERS.

SOLUTION:
THROTTLE THE NEEDLE VALVE SO THE REGULATOR IS NOT SUBJECTED TO TRANSIENT PRESSURE SPIKES. (DO NOT CLOSE THE VALVE)

Company Confidential Rev. 1/2006, Pg. 39 - JRA

Control Line Valve on Pilot Operated Regulators

THE FIRST CHOICE IS NOT TO INSTALL A VALVE IN THE CONTROL LINE THERE IS A SMALL FLOW (PILOT BLEED) DOWN THE CONTROL LINE. A RESTRICTION IN THE CONTROL LINE RESULTS IN A PRESSURE BUILD UP UPSTREAM OF THE RESTRICTION THIS RESULTS IN A FALSE PRESSURE SIGNAL TO THE PILOT AND ALSO CAN CAUSE CYCLING. IF A VALVE MUST BE INSTALLED, IT SHOULD HAVE A LARGE PORT AND BE IN THE FULL OPEN POSITION WHEN OPERATING.
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Control Line Tips

Control Line Diameter
The control line diameter should be selected to match the connection provided on the regulator. If the control line is long (over 10 feet), the size should be increased.

Control Line Length

Direct-Operated Regulators The control line can be any length. If the system is subject to quick load changes, friction in a long control line may delay the pressure wave and slow the regulator response time. Pilot-Operated Regulators The control line can be any length. If the control line is over 10 feet long, the diameter may be increased. A long, small diameter control line can restrict pilot bleed gas flow.
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Tubing Installation Not Correct

P1

P2

P1

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Tubing Installation Not Correct to Code

Wide Open Monitor
Worker and monitor with same control line connection Will NOT meet DOT 192 or Z662 codes for single failure mode If upstream pilot fails open it could affect monitor/worker.

Worker Control Line

Monitor Control Line

Company Confidential Rev. 1/2006, Pg. 43 - JRA

Needle Valve In Control/Sense Lines

Control lines inadequate or restriction in sensing downstream pressure

Needle valve installed providing 1/8 hole in sensing

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Bleed/Sense Lines Need to be Separate

Common Tap Point

If common tap point is used, increase tubing diameter at least 2 pipe sizes to prevent interaction between pilot sensing and bleed.

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Corrosive Environment

Ensure compatibility of regulator materials with ambient environment

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Two Path Pilot-Operated Regulators Reverse Pressure

Not all models can handle pressure when P2 > P1

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Casting Porosity

Sidewall porosity on body

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Self Operated System Instability Issues

Define the noise heard:
Buzz Surges Pants Vibrates Hammer Chugs Hunts Honks

Noise is common when: Cap removed Flapper valve broken High P1 with orifice to large for inlet

Flapper valve is important for proper operation

Company Confidential Rev. 1/2006, Pg. 49 - JRA

Eliminating Instability on Self-Operated Regulators

Go up one spring range Change to a smaller orifice size Change models Follow manufacturers guidelines on maximum operating pressures

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Common System Problems - Piping

Small volume piping
A short run of piping to the load can cause a regulator to go unstable

Restricted piping
Too many valves, orifices, small diameter piping before the load

Turbulent Piping
Swages, elbows, meters can interject backpressure

Noise 110-115 DbA max allowable

Source Treatment At valve orifice Path Treatment After valve outlet
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Load Dynamics
Fast changing loads burners, furnaces, etc. Low flows turndown requirements High flow excessive turbulence, some regulators will close at higher flows over what is published

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Boiler Loads
Use self operated whenever possible for maximum stability When using pilot operated, use a quick dump bleed pilot.
Quick dump bleed

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Conclusion
Basic troubleshooting of any regulator will require a working knowledge of how regulators operate and how to apply them effectively.

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