243 Service Regulators

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1 Regulatr Installatin and Maintenance Instructins Service Regulatrs RM-06- Rev. Intrductin The is a large capacity general-purpse gas pressure regulatr. Its utstanding perfrmance and versatility make it an excellent chice fr use n industrial meter sets, cmbustin equipment, bilers, burners, unit heaters, furnaces, vens and ther applicatins. Use it fr natural gas, air, dry C, prpane, butane, L.P.G., nitrgen, and thers. Special materials are available fr certain crrsive gases. In additin t the standard mdels and internal relief mdels cvered in this bulletin, the is als available with lw pressure cut-ff, with built-in mnitr, and as a pilt perated regulatr (utlet pressures t psig), a back pressure valve, a relief valve, a vacuum regulatr and a vacuum breaker. Fr infrmatin, please cntact yur Sensus Sales ffice r authrized industrial distributr. The is manufactured in cnfrmance with Cde B.8. Nte: The term standard refers t Nn-IRV cnfiguratins. Mdel Specificatins -- and -- Maximum Inlet Pressure... psi utlet Pressures... w.c. t psi Pipe Sizes..., and Diaphragm... (nminal diameter) -8- and -8- Maximum Inlet Pressure... psi utlet Pressures... w.c. t psi Pipe Sizes..., and Diaphragm... 8 (nminal diameter) -8HP Maximum Inlet Pressure... psi utlet Pressures... t 0 psi Pipe Sizes..., and Diaphragm... 8 (nminal diameter) Maximum Inlet Pressures - psi psi* psi 0 psi* 0 psi 60 psit 00 psi psi psi RIFICE SIZE - VALVE * Applies nly t - with external cntrl line. t psi fr - with external cntrl line Temperature Limits -8 psi psi 0 psi 0 psi psi 00 psi psi psi The Mdel Service Regulatrs can be used fr flwing temperatures frm -0 F t 0 F. Buried Service The Mdel Service Regulatrs are nt recmmended fr buried service. Installatin and Start Up (See Illustratins n Page.). Make certain that regulatr and piping are free f dirt, misture, freign matter and ther debris.. Be sure all shipping screens r cvers are remved and regulatr is installed with flw in crrect directin.. Regulatr may be installed in any psitin; right-side-up, upside dwn, vertical pipe, hrizntal pipe, diagnal pipe, etc. By lsening unin blts (6), the diaphragm case assembly may be rtated t varius psitins in relatin t the bdy. Make certain (6) are re-tightened t hld diaphragm case assembly in new psitin and t reseal. CAUTIN The diaphragm case vent must be psitined t prtect against flding, drain water, ice frmatin, traffic, tampering, etc. The vent must be prtected against nest building animals, bees, insects, etc. t prevent vent blckage and minimize the chances fr freign material frm cllecting in the vent side f the regulatr diaphragm.. Make sure there are n leaks and all cnnectins are firm and tight. Tighten flange blts evenly and firmly. n screwed cnnectins apply pipe dpe t male threads nly.. n regulatrs arranged fr External Cntrl Line, run pipe r tubing frm NPT cnnectin in lwer case t the cntrl cnnectin in the utlet piping. This cntrl piping shuld nt be less than in size and shuld be adequately prtected against breakage (regulatrs g wide pen if the cntrl line is brken). In general, the cntrl cnnectin shuld be at least 8 pipe diameters frm the regulatr and in as straight a run f pipe as pssible. The cnnectin itself must be smth n the inside f the pipe. Pitch the cntrl line away frm the regulatr and avid misture pckets. Keep inside f cntrl line clean. Never install any type f autmatic shut-ff device, which clses cmpletely, between the regulatr utlet and the cntrl line cnnectin. CAUTIN It is the user s respnsibility t assure that all regulatr vents and/r vent lines exhaust t a nn-hazardus lcatin away frm any ptential surces f ignitin. Where vent line are used, it is the user s respnsibility t assure that each service regulatr is individually vented and that cmmn vent lines are nt used. 6. Adjust utlet pressure (set pint) by remving cap () r (e) and turning adjustment spring buttn (). n -8 HP remve cap (a), lsen lcknut and turn adjustment screw (b). Turn clckwise t increase and cunter-clckwise t decrease utlet pressure. nly adjust when gas is flwing thrugh regulatr. When adjustment is cmpleted, seal cap () r (e) must be securely screwed int place. The absence f this seal cap can result in unstable peratin.

2 Installatin and Start Up (Cntinued) 7. n regulatrs with Internal Relief Valve, there is n adjustment fr the internal relief. It is fixed, with relief beginning at apprximately 9 w.c. t 0 w.c., abve regulatr set pint, depending n relief spring (k) used. Internal Relief Valves must be carefully sized. Fr infrmatin, cntact yur Sensus Representative. 6. Regulatrs installed indrs must be vented utside. Run vent pipe frm regulatr vent cnnectin t safe place utside. Vent piping shuld be as shrt and direct as pssible. Vent piping fr regulatrs with internal relief valve (Mdels -- r -8-) must be large enugh t vent all relief valve discharge t atmsphere withut excessive back pressure and resulting excessive pressure in regulatr. Vent pipe utlet must be prtected against nest building animals, bees, insects, etc., and psitined t prtect against flding, drain water, ice frmatin, etc. but must allw free and unbstructed passage f air r gas. CAUTIN Turn gas n very slwly. If an utlet stp valve is used, it shuld be pened first. D nt verlad the diaphragm with a sudden surge f inlet pressure. Mnitr the utlet pressure during start-up t prevent an utlet pressure verlad. Servicing. Make sure the regulatr is entirely depressured befre disassembling.. Carefully nte lcatin and psitin f all disassembled parts t be certain reassembly is crrect. Inspect each part and replace thse that are wrn r damaged r therwise unsatisfactry.. Fr access t valve () and rifice () lsen unin blts (6) and remve diaphragm case assembly frm bdy. T remve valve (), first remve hair pin ctter (0b). rifice () unscrews frm bdy. Use -/8 hex scket thinwall type. When replacing rifice use mderate amunt f pipe dpe n rifice threads.. Befre reassembling and tightening unin blts (6), make certain Tetraseal (7) is in psitin.. T replace diaphragm; remve spring (), remve flange blts (8) and nuts (9), and disassemble diaphragm assembly. Remve ld diaphragm (a) frm diaphragm pan (b). Remve ld adhesive frm the diaphragm pan using a slvent such as methyl ethyl ketne (MEK). T reassemble, apply a thin, even layer f a rubber based adhesive such as M Industrial Adhesive #EC-87 t the cleaned, prepared side f the diaphragm pan. Attach the diaphragm t the adhesive side f the diaphragm pan, being careful t align the center hle f the diaphragm with the crrespnsing center hle in the diaphragm pan. Make certain all parts are reassembled in their crrect rder and blts (8) are tightened t a trque f 0 in-lbs. Blts must be tight enugh t prevent leakage but nt t tight that the diaphragm material is crushed r damaged. Diaphragm must nt be twisted r pinched. 6. Upn cmpletin f servicing, make certain that regulatr installatin is entirely free f leaks. CAUTIN Regulatrs are pressure cntrl devices with numerus mving parts subject t wear that is dependent upn particular perating cnditins. T assure cntinuus satisfactry peratin, a peridic inspectin schedule must be adhered t with the frequency f inspectin determined by the severity f service and applicable laws and regulatins. Cndensed Parts List The fllwing are the parts generally required in maintenance and servicing. Fr a listing f all parts refer t Parts List RP-06 ILL. Part N. Descriptin Number e d a a b d e f k k s b Cver Cap (IRV) Cver Cap (STD) Tetraseal x 8 -Ring #-0 -Ring #- Adjustment Spring Buttn Spring (See Table, st page) - Cver Assembly IRV (includes vent valve and spring) - Cver Assembly STD (includes vent valve and spring) -8 Cver Assembly (includes vent valve and spring) Flange Blt, 6 x Hex Hd Flange Nut, 6-8 Hex S.F. - Lwer Case - Lwer Case (tapped fr external cntrl line) -08 Lwer Case -08 Lwer Case (tapped fr external cntrl line) - Diaphragm -8 Diaphragm -8 HP Diaphragm - Diaphragm Pan -8 Diaphragm Pan -8 HP Diaphragm Pan Seal Washer Emery Clth Washer (faces against tp side f -8 HP diaphragm) Spring guide Spring guide (-8 HP) Internal Relief Valve Spring, fr -8- nly. (relief begins at apprx. 9 w.c. abve regulatr set pint) Internal Relief Valve Spring (relief begins at apprx. 9 w.c. fr --, and apprx. 0 w.c. fr -8- abve regulatr set pint) -8 HP Diaphragm Plate - Cupling-Lever- Stem Assembly -8 Cupling-Lever- Stem Assembly -8 (HP) Cupling-Lever- Stem Assembly Unin Blts, 6 x Hex Tetraseal (r -Ring) x -8 Thrat Blck with -Ring Seal - Thrat Blck with -Ring Seal Hair Pin Ctter Valve Assembly Buna N Valve Assembly Vitn Valve Assembly Buna N Valve Assembly Vitn rifice, Brass rifice, Brass rifice, Brass rifice, Brass 8 rifice, Brass rifice, Brass.07 rifice, Brass Travel Stp Stem Warning Tag-Travel Stp Warning Tag-Bdy Interchangeability Clamping Plate Dentes recmmended spare parts

3 Mdel Regulatr Illustratins Dia I.R.V. Regulatr - as shwn - Vent NPT k 9 (IRV CVER CAP) 0 (STD CVER CAP) -- Same as I.R.V. Regulatr except n Internal Relief Valve and Standard Cver Cap as shwn in inset. PIPE SIZES Flanged ANSI lb FF and Screwed -8 HP Remainder f regulatr same as -8- PIPE SIZES Flanged ANSI lb FF, and screwed e a STANDARD CAP 7 6 a d f STANDARD DIAPHRAGM ASSEMBLY Drilled and Tapped NPT n regulatrs arranged fr External Cntrl Line d d k a d 0 6 Dia. b a 6 0b Standard Regulatr THRAT BLCK - as shwn - WITH -RING SEAL (fr regulatrs arranged fr External Line Cntrl) INTERNAL RELIEF VALVE r 0 Same as Standard Regulatr except Internal Relief Valve as shwn in inset. PIPE SIZES Flanged ANSI lb FF, and screwed d 6 Vent NPT f 9 s a b a 6 0b b 8 e r d f Drilled and Tapped NPT n regulatrs arranged fr External Cntrl Line

4 Maximum Emergency Pressures The maximum pressure the regulatr inlet may be subjected t under abnrmal cnditins withut causing damage t the regulatr is the maximum inlet pressure (frm the table belw) plus 0 psi. The maximum pressure the diaphragm may be subjected t withut causing damage t the internal parts f the regulatr is: --...set-pint+ psi --, -8- and set-pint+ psi -8HP...set-pint+ psi Set pint is defined as the utlet pressure a regulatr is adjusted t deliver. If any f the abve pressure limits are exceeded, the regulatr must be taken ut f service and inspected. Damaged r therwise unsatisfactry parts must be repaired r replaced. The maximum pressure that can be safely cntained by the diaphragm case is: -- and psi -8- and psi -8HP... psi Safely cntained means n leakage as well as n bursting. Befre using any f the abve data, make sure this entire sectin is clearly understd. Nte:The use f an internal r external relief valve is rec mmended fr installatins subjected t n flw fr extended perids f time such as piltless ignitin systems. A travel stp stem is lcated in the -- and -- t prvide ver pres surizatin prtectin t internal cmpnents dur ing verpressurizatin. Spring Ranges CLR Red Red-Black Blue Blue-Black Green-Black Green range-black range Black Cadmium Cadmium Cadmium White t UTLET PRESSURE RANGE - -8 / t 6 / w.c. t 8 / w.c. 6 t w.c. 0 t 8 w.c. t 8 w.c. t psi / t psi / t psi } t White is nested inside Cadmium / t 6 / w.c. t 8 / w.c. 6 t w.c. t 8 w.c. t psi t / psi t psi t 6 / psi* 6 t 0 psi* PART NUMBER *-8 HP nly -8- (IRV) nly Full pen Capacity Use the fllwing frmulae fr the full pen capacity fr regulatrs.. Q = K P (P I - P )...(fr less than.89) KP. Q = I...(fr P greater than.89) Q = maximum capacity f the regulatr (in SCFH f 0.6 specific gravity natural gas.) K = the K factr, the regulatr cnstant (frm the table) P I = abslute inlet pressure (psia) P = abslute utlet pressure (psia) rifice Size-in. K ther Gases Regulatrs are mainly used n natural gas. Hwever, they perfrm equally well n LP gas, nitrgen, dry C air and thers. Fr capacities, multiply the table values n pages 8 thru 9 in Bulletin R-06 by the fllwing crrectin factrs: THER GASES CRRECTIN FACTR Air (Specific Gravity.0) 0.77 Prpane (Specific Gravity.) BTU Prpane-Air Mix (.0) 0.7 Nitrgen (Specific Gravity 0.97) 0.79 Dry Carbn Dixide (Specific Gravity.) 0.6 Fr ther nncrrsive gases: CRRECTIN FACTR 8 9 P I P 0.6 Specific Gravity f the Gas While used primarily fr natural gas services, Mdel regulatrs perfrm equally well n LPG vapr, air, dry C nitrgen and ther inert gas applicatins. Please cntact yur Sensus representative fr special cnstructin which may be available fr certain crrsive gases. Nte: The term standard refers t Nn-IRV cnfiguratins. P I Mnitring The Mdel Regulatrs make excellent mnitrs. They can act as standby regulatrs installed in series which assumes cntrl if a failure in the perating regulatr permits the utlet pressure t exceed the set-pint. It can be lcated in either the upstream r the dwnstream psitin. When a Mdel Regulatr is used t mnitr a regulatr with an identical inner valve (anther Regulatr), the ttal maximum capacity thrugh bth regulatrs can be figured at 70% f the capacity f ne regulatr alne. This applies with the mnitr lcated either up r dwnstream.

5 CNDENSED CAPACITY TABLE IN SCFH F NATURAL GAS (.6 Specific Gravity-.6 psia-60 F.) - INLET PRESSURE psi RIFICE SIZE and VALVE ANGLE w.c. RED ( w.c. 6,00,000,000 7 w.c. BLUE ( w.c.,000,000 UTLET PRESSURE SER PINT and w.c. GREEN ( w.c.,600 0,00,000,00,000 8 w.c. RANGE ( w.c.,00,00 6,00,000 psi BLACK (0. psi,0 6,600,000,00,000 psi CADMIUM (0.6 psi 8,00,00 6, ,000 6,00 9,00,0,700 9,00 0,00,000 0,000,00,00,00,000,600 0,000,00,00,000,0,00 0,000,00,000,000,00 and - with External Cntrl Line * * * 8,00 0,00,000,000 0,000 9,000 6,00 7,0 0,000,000 7,000,000,000 9,000 7,00 8,00,00 7,000,000 7,000 9,000,00 6,00,000,000 9,000,00 7,000 8,00 0,00,00,000 9,000 6,0 8,600 0,00,000,000,000,000 9,000 size nly. INLET PRESSURE psi RIFICE SIZE AND VALVE ANGLE 6 w.c. RED-BLACK ( w.c.,00 7,00,00 0,00,00,0,00,00,00,600 7 w.c. BLUE-BLACK ( w.c.,700 7,000,00 0,00,00,700,900,00,0, Refer t Bulletin R-06 fr detailed capacity tables and curves. UTLET PRESSURE SET PINT and 8 w.c. GREEN ( w.c.,00 6,600,00,900,90,00,00,,00 9,00,00,000 psi RANGE (0. psi,00 6,00,00,,700,0,00,60,000 7,000,00 7,00,00 psi BLACK (0.6 psi 7,00,00,000,00,600,000 6,00,00 6,0,00 7,600 7,00 psi* CADMIUM ( psi,00,00,0,00,000,00 0 psi* CADMIUM and WHITE ( psi 7,000 9,000 9,000,000,000 8,0,00,000 8,00 9,000 *-8HP nly.

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