Regulators are self-contained, control devices which use
energy from the controlled system to operate whereas
control valves require external power sources, transmitting
instruments, and control instruments.
Pressure Reducing Regulators
A pressure reducing regulator maintains a desired outlet
pressure while providing the required fluid flow to satisfy
a downstream demand. The pressure which the regulator
maintains is the outlet pressure setting (setpoint) of
the regulator.
Pressure Reducing Regulator Type
The two main types of regulators:
1. Direct-Operated
2. Pilot-Operated
SPRING
DIAPHRAGM
VALVE
INLET PRESSURE
OUTLET PRESSURE
ATMOSPHERIC PRESSURE
Figure 1. Direct-Operated Regulator
Direct-Operated Regulators
Direct-Operated regulators are the simplest style of the
regulators. At low set pressures, typically below 1 psig /
0.07 bar, they can have very accurate (±1%) control. At
high control pressures, up to 500 psig / 34.5 bar, 10% to
20% control is typical.
In operation, a direct-operated, pressure reducing
regulator senses the downstream pressure through either
internal pressure registration or external control line. This
downstream pressure opposes a spring which moves the
diaphragm and valve plug to change the size of the flow
path through the regulator.
Direct-operated regulators have many commercial and
residential uses. Typical applications include industrial,
commercial, and domestic gas service or instrument air.
Pilot-Operated regulators are preferred for high flow rates
or where precise pressure control is required. A popular
type of pilot-operated system uses two-path control.
In two-path control, the main valve diaphragm responds
quickly to downstream pressure changes, causing an
immediate correction in the main valve plug position.
At the same time, the pilot diaphragm diverts some of the
reduced inlet pressure to the other side of the main valve
diaphragm to control the final positioning of the main
valve plug. Two-path control results in fast response and
accurate control.
Pressure Reducing Regulator Selection
The majority of applications require a pressure reducing
regulator. Assuming the application calls for a pressure
reducing regulator. The following parameters must
be determined:
• Outlet pressure to be controlled
• Inlet pressure to the regulator
• Capacity required
• Shut-off capability required
• Process fluid
• Process fluid temperature
• Accuracy required
• Pipe size required
• End connection style
• Material requirements
• Control line needed
• Overpressure protection
4
Relief Valve / Backpressure Regulator
Relief Valve
Backpressure Regulator
Relief Valves and Backpressure Regulators
A pressure relief valve is a control device that opens to relieve
fluid to atmosphere during an overpressure occurrence. A
backpressure regulator is a control device that maintains a
constant upstream pressure throughout a given flow range.
Relief Valve Types
Relief valves are available in four general types: pop type,
direct-operated, pilot-operated, and internal relief valves.
Direct-Operated Relief Valves
System pressure is referenced under a diaphragm and
opposed by a spring. As system pressure increases past the
setpoint, the relief valve opens which allows fluid to escape
and protects the system. The increase in pressure above
the relief setpoint that is required to produce more flow
through the relief valve is referred to as pressure buildup.
SPRING
DIAPHRAGM
VALVE
CONTROL
LINE
PILOT
RESTRICTION
PILOT
EXHAUST
FLOW
INLET PRESSURELOADING PRESSURE
Figure 4. Pilot-Operated Relief Valve
EXHAUSTATMOSPHERIC PRESSURE
MAIN RELIEF
VALVE
MAIN REGULATOR
EXHAUST
Pilot-operated relief valves are used in applications
requiring high-capacity and low-pressure buildup.
Internal Relief
The regulator shown in Figure 5 includes an internal relief
valve. The relief valve has a measuring element (the main
regulator diaphragm), a loading element (a light spring),
and a restricting element (a valve seat and disk).
OPENED INTERNAL RELIEF
LARGE OPENING FOR RELIEF
VENT
FLOW
SYSTEM PRESSURELOWER-PRESSURE SYSTEM
Figure 3. Direct-Operated Relief Valve
(USUALLY ATMOSPHERE)
Direct-Operated relief valves are commonly used in industry
to protect industrial furnaces and other equipment.
Pilot-Operated Relief Valves
In normal operation, when system pressure is below
setpoint of the relief valve, the pilot remains closed.
This allows loading pressure to register on top of the
main relief valve diaphragm. Loading pressure on top
of the diaphragm is opposed by an equal pressure (inlet
pressure) on the bottom side of the diaphragm. With
little or no pressure differential across the diaphragm, the
spring keeps the valve seated. When the system pressure
increases past the setpoint, the pilot opens and exhausts
the loading pressure from the top of the relief valve main
diaphragm which allows the main valve to open.
The relief valve assembly is located in the center of
the regulator diaphragm. Internal relief is often used
in industrial applications where atmospheric exhaust is
acceptable, and low buildup is not required.
Backpressure Regulator Selection
Backpressure regulators control the inlet pressure rather
than the outlet pressure. The selection criteria for the
backpressure regulator is the same as for a pressure
reducing regulator.
5
Industrial Regulators Selection Table
Pressure Reducing Regulators
Liquid
Tank Blanketing
Process Gas
Fuel Gas
TYPE OR
SERIES
OPERATION
METHOD
BODY SIZE, NPS
INLET
PRESSURE,
psig / bar
67CSDirect1/4400 / 27.64350 / 117-71.1:67C
67DDirect1/2400 / 27.620,900 / 5601171.1:67D
1301Direct1/46000 / 4144500 / 1211171.1:1301
MR95Direct1/4 to 21000 / 68.9
SR5Direct1/2 to 3210 / 14.5
92BPilot1, 1-1/2, 2, 3, and 4300 / 20.7
92SPilot1 to 6 x 4300 / 20.7
92CPilot1/2, 3/4, and 1300 / 20.7
75ADirect1/2 to 2-1/2200 / 13.8
92WPilot1 to 4300 / 20.7
627Direct3/4, 1, and 22000 / 138 162,000 / 4342 1171.1:627