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How Does a Pilot-Operated Pressure

Regulator Work (Part 1)
Pilot-operated regulators vs Direct-operated regulators

As shown in How does a Direct-Operated Regulator Work?, direct-oper-

ated regulators are simple mechanical devices which automate pressure
control. Direct-operated regulators are well suited for many applications,
but not all. They are only moderately accurate and the size of the actuator
becomes prohibitive above many 2” line size applications especially at
higher pressure ratings. Pilot-operated regulators offer superior accuracy
and larger flow capability, which are both critical for applications such as
natural gas distribution, gas turbine feeds, and nitrogen blanketing large
tanks.

The below direct-op performance curve demonstrates that in order to

open further to supply an increasing flow demand, a direct-operated regu-
lator can’t maintain downstream pressure at setpoint. Instead, down-
stream pressure must droop below setpoint because the only way the in-
ternal parts of a regulator will travel open is if the diaphragm senses a de-
crease in that outlet pressure. The pilot-operated regulator must also
sense a decrease in downstream pressure to open but to a much smaller
extent as reflected on the chart.
All applications require some level of accuracy so even though both
products in this example reach the same maximum flow, the direct-oper-
ated regulator has much less useful flow capability. Accuracy constraints
for a potential application are plotted below showing that for the same
accuracy, the flow capability of the pilot-operated regulator is several
times more than the direct-operated regulator.
Components

Pilot-operated regulators have two major components: the pilot and the
main valve. The pilot is simply a self-operated regulator with external
registration. It is the brains of the regulator and it controls the opening
and closing of the main valve. The main valve is an actuator connected to
a valve through which essentially all of the flow passes.
The pilot and main valve both have an orifice, valve plug, and spring. The
pilot spring is adjusted to establish the pressure setting while the main
valve spring’s purpose is to provide shutoff force therefore it comes preset
from the factory with the correct compression. The restrictor is a small
hole that allows pressure to equalize after the pilot closes, closing the
main valve.

Two styles of pilot-operated regulators exist:

1. Loading (also known as two-path)
2. Unloading (also known as flexible element or boot-style)

Loading-Style

In this example application, 100 psig inlet pressure (red) is reduced to 10

psi outlet pressure (blue). When the pilot opens, it allows some of the high
inlet pressure to enter the loading pressure chamber, increasing the load-
ing pressure (green) which forces the main valve open. The restrictor con-
tinually bleeds loading pressure downstream so when the pilot closes, the
loading pressure escapes downstream through the restrictor allowing the
main valve to close.

All pilot-operated regulators follow the same sequence of events: 1) The

downstream pressure changes. 2) The pilot senses the pressure change
and moves in response.  3) The pilot movement alters the loading
pressure. 4) The change in loading pressure forces the main valve to
reposition.
The above animation demonstrates how a loading-style pilot-op reacts
when the downstream flow demand increases. The regulator must open
in order to supply the increased flow demand. First, the downstream pres-
sure decreases because the regulator is not meeting the increased flow
demand. The pilot then detects this decrease in pressure below its 10 psig
setpoint. The force from the decreased outlet pressure is now less than
from the spring, moving the diaphragm and valve plug downward. This
small movement by the pilot allows inlet pressure to flood into the load-
ing pressure chamber, increasing the loading pressure high enough that
its upward force on the main valve diaphragm is sufficient to exceed the
downward force from the downstream pressure and main spring. The
main valve opens, matching the increased flow demand while holding
outlet pressure slightly below setpoint.
The above animation demonstrates how a loading-style pilot-operated
regulator responds when downstream demand decreases to zero. The
regulator must close in order to meet the zero flow demand. First, the
downstream pressure increases because the regulator is still open, ex-
ceeding the flow demand. The pilot then senses this increase in pressure
above its 10 psig setpoint. The force from the increased outlet pressure is
now higher than the spring, moving the diaphragm and valve plug upward
and closed. The pilot closing stops inlet pressure from entering the load-
ing pressure chamber and the restrictor bleeds the loading pressure down
until it is the same pressure as outlet. The decrease in loading pressure
force upward on the main valve diaphragm is overpowered by the down-
ward force from the downstream pressure and main spring. The main
valve closes, matching the zero downstream demand while holding outlet
pressure just above setpoint.

Click here to continue to Part 2

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