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BS(H)2 User Manual
Rev.date: 20-09-2010
BS(H)2
all types of connections
USER MANUAL
Read the complete manual before installing and using the regulator.
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BS(H)2 User Manual
Rev.date: 20-09-2010
WARNING
INCORRECT OR IMPROPER USE OF THIS PRODUCT CAN CAUSE SERIOUS PERSONAL
INJURY AND PROPERTY DAMAGE.
Due to the variety of operating conditions and applications for this product, the user is solely
responsible for making the final proper decisions concerning the correct assembly and functioning of
the product and assuring that all the performance, safety and warning requirements are met.
• Users must be trained and equipped for the handling, use and servicing of pressure products
and systems.
• Users must contact their gas or liquid supplier for specific safety precautions and instructions.
• Gaseous media should be free of excessive moisture to prevent icing at high flow.
• Always wear the appropriate protective clothing, including safety glasses, gloves etc. if required.
• Follow the applicable safety and maintenance procedures.
• Obey specific local regulations.
• Do not exceed the maximum inlet and outlet pressure of the product or its accessories.
• Operate within the temperature limits and other conditions specified for the product.
• Do not drop or damage the product in any other way. This may negatively effect the
performance of the product which can cause the product to malfunction.
• Venting fluids and gases can be dangerous. Vent to a safe environment away from people.
Ensure adequate ventilation.
• This product is not oxygen clean and therefore not suitable for oxygen service.
If there are questions or problems regarding the installation, operation and maintenance these should
be directed to the proper authority on site before continuing.
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BS(H)2 User Manual
Rev.date: 20-09-2010
CONTENTS
1
Introduction ..................................................................................................................................... 1
1.1 Detailed description ....................................................................................................................... 1
1.2 Special features and options ......................................................................................................... 1
1.3 Typical picture of the standard BS(H)2 and its components ......................................................... 2
2 Installation ....................................................................................................................................... 3
2.1 Points of attention before installation ............................................................................................ 3
2.2 Oxygen service ............................................................................................................................. 3
2.3 Installation instructions .................................................................................................................. 4
3 Operation ......................................................................................................................................... 5
3.1 Required tools for operation .......................................................................................................... 5
3.2 Points of attention before operation .............................................................................................. 5
3.3 Changing the set pressure ............................................................................................................ 6
4 Maintenance..................................................................................................................................... 7
4.1 Required tools for maintenance. ................................................................................................... 7
4.2 Points of attention before removal from the system and disassembly .......................................... 8
4.3 Removal from the system ............................................................................................................. 8
4.4 Disassembly .................................................................................................................................. 8
4.5 Inspection of disassembled parts .................................................................................................. 8
4.6 Points of attention before assembly .............................................................................................. 8
4.7 Assembly ....................................................................................................................................... 8
4.8 Recommended torques ................................................................................................................. 9
4.9 Testing ........................................................................................................................................... 9
4.9.1 Leakage across the seat ........................................................................................................... 9
4.9.2 Leakage across the piston o-ring .............................................................................................. 9
4.9.3 Required set pressure range ..................................................................................................... 9
5 Trouble shooting ........................................................................................................................... 11
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BS(H)2 User Manual
Rev.date: 20-09-2010
1 Introduction
1.1 Detailed description
The function of a backpressure regulator is to maintain a constant inlet pressure and to control the inlet
pressure with a variable flow.
This regulator is a piston sensing spring loaded backpressure regulator, designed for high inlet pressure.
Due to the “low torque-no wear” stem, the regulator is ideal for use in frequent readjustment type
applications. The regulator comprises a body and spring housing screwed together and has a removable
seat and valve.
The product is designed to be used between -20 °C and +80 °C, whether ambient temperature or media
temperature.
The regulator is soft seated for leak tight shut-off in zero flow conditions and is available in stainless steel.
The standard maximum in- and outlet pressure for the models are:
- Threaded models BS2 : Inlet 400 bar Outlet 400 bar
- Threaded models BSH2 : Inlet 700 bar Outlet 700 bar
Check the assembly drawing or regulator for the specific pressure limits of the supplied
regulator.
Standard features:
- ss 316L throughout
- piston sensing
- bubble tight shut-off
- 2.2mm valve
- 6 relief pressure ranges
- bottom mounting
1.2 Special features and options
The regulator is available with the following options:
- panel mounting
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BS(H)2 User Manual
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1.3 Typical picture of the standard BS(H)2 and its components
1 body 12 overtravel spring
2 spring housing 14 knob assembly
3 bodyplug 16 spring housing cover
4 seat retainer 17 retaining ring
5 piston plate 19 valve
6 piston 20 piston screw
7 seat 21 o-ring
9 bottom spring guide 22 o-ring
10 spring guide 23 o-ring
11 set spring 24 o-ring
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BS(H)2 User Manual
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2 Installation
2.1 Points of attention before installation
This regulator can be equipped with different options and connections.
Before installing the regulator you should fully understand the options and the suitability of your particular
regulator and its suitability for the application.
- The preferred mounting position of the regulator is horizontal with the adjustment knob facing
upwards.
It may be necessary to remove the regulator from the system during maintenance or service. Make
sure that this is possible, especially if mounted in a different position.
- The regulator is suitable for gases and liquids. Check if the materials on the assembly drawing,
which came with the regulator, are compatible with the used media.
- If this regulator is used with hazardous or toxic media, take the necessary safety precautions to
ensure a safe workspace and your personal safety.
Vent to a safe environment away from people and ensure adequate ventilation.
- Avoid sealing compounds which harden, be careful with anaerobic (loctite type) compounds.
Particles of these compounds can run into the regulator and lock moving parts.
- Frequent assembly and disassembly of the in- and outlet fittings can damage the in- and outlet
thread of the regulator. Damaged threads can cause serious injury.
- The product is designed to be used between -20 °C and +80 °C, whether ambient temperature or
media temperature. In all other cases consult SWAGELOK B.V..
- The regulator is standard not oxygen clean. Although all regulators are ultrasonically cleaned, this
does not make them suitable for oxygen use.
2.2 Oxygen service
- Specification of materials in regulators for oxygen service is the user’s responsibility. SWAGELOK
B.V. can perform cleaning for Oxygen service based on ASTM-G93LevelC/CGA4.1 at additional
cost.
WARNING
A BACKPRESSURE REGULATOR IS NOT A SAFETY VALVE AND SHOULD NOT BE USED AS SUCH.
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2.3 Installation instructions
- Verify that the regulator, the connections and its accessories are undamaged.
- Verify that the regulator and its accessories are suitable for the system operating pressure and
have the proper connections.
- Carefully clean all pipes and connections. Any swarf, lint, wire etc. may cause seat leakage.
- Verify the flow direction of the system and mount the regulator accordingly.
- The standard connection of the BS(H)2 is 1/4" NPT female.
To get a proper sealing across the thread, SWAGELOK B.V. recommends using teflon tape.
- Securely make the appropriate connections to the regulator in accordance with the procedures
recommended by the manufacturer of the connections.
- Verify that the regulator is mounted in the system without stress on the connections.
Stress on the connections can result in faulty connections and dangerous situations.
- Check if the in- and outlet fittings are fitted far enough into the regulator and check for leakage
across the fitting.
- Shut-off valves should be mounted in the system for service or maintenance.
- At the time of delivery, every unused gauge connection is plugged with blind fittings.
Remove these and connect gauges if desired.
- If earthing is required, connect an earth wire in a bottom-mounting hole.
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3 Operation
3.1 Required tools for operation
For changing the set pressure on a standard regulator, no tools are required.
3.2 Points of attention before operation
- The adjustment knob is provided with an anti-turnout locking ring, don't force it.
- The product can be hot or cold, depending on the environment temperature and the used media
temperature. Take the necessary precautions before operating or touching the product.
- If this regulator is used with hazardous or toxic media, take the necessary safety precautions to
ensure a safe workspace and your personal safety.
Vent to a safe environment away from people and ensure adequate ventilation.
- After flow, the inlet pressure will fall a little under the set pressure.
This is because of the closing force required for bubble-tight closing of the regulator.
This phenomenon is usually referred to as the “reseat pressure” and does not indicate a problem
with the regulator.
- An increase in the flow will result in a rise of the set pressure.
A decrease in the flow will result in a fall of the set pressure.
This is because of the force required for opening the valve of the regulator.
This phenomenon is usually referred to as the “accumulation pressure” and does not indicate a
problem with the regulator.
- An increase of the outlet pressure will result in a fall of the set pressure.
A decrease of the outlet pressure will result in a rise of the set pressure.
This phenomenon is usually referred to as the “dependency” and does not indicate a problem with
the regulator.
Each regulator type has its own dependency, which is related to the ratio between the effective seat area
and the sensing area. The approximate change can be calculated as shown below:
ΔP1 = ratio x ΔP2
A ratio of 1/X means that for every pressure change to P2 of X bar, the P1 pressure will change 1 bar:
BS(H)2, 0-10 bar: ratio = 1/224
BS(H)2, 0-25 bar: ratio = 1/224
BS(H)2, 0-100 bar: ratio = 1/74
BS(H)2, 0-175 bar: ratio = 1/34
BS(H)2, 0-350 bar: ratio = 1/17
BSH2, 0-700 bar: ratio = 1/7
Example:
Regulator with ratio 1/17
Start position: End position
P1 = 300 bar P1 = ?? bar
P2 = 0 bar P2 = 250 bar
ΔP1 = ratio x ΔP2
ΔP1 = 1/17 x (250-0)
ΔP1 = 14,7 bar
So, as a result of a pressure rise in the outlet pressure from 0 to 250 bar, the set pressure will fall from
300 bar to approximately 285,3 bar without adjusting the regulator.
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BS(H)2 User Manual
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3.3 Changing the set pressure
- Check the supply of medium at the inlet side.
- Make sure the inlet pressure is higher than the required set pressure and that the inlet pressure
does not exceed the maximum allowed inlet pressure. Open the shut-off valve at the outlet side.
- Open the shut-off valve at the inlet side slightly to allow a minimal flow.
- Turn the adjustment knob clockwise to increase the set pressure.
- Turn the adjustment knob counterclockwise to decrease the set pressure.
A shut-off valve on the outlet side must be opened to relief the pressure on the outlet side.
Final adjustment must be made while increasing the set pressure to obtain the most accurate set
point(s).
- Reduce the inlet pressure until there is no more flow.
- Open the shut-off valve at the inlet side fully to allow full flow during operation.
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4 Maintenance
4.1 Required tools for maintenance.
- a vice to fasten the regulator
- pincers to take out the o-rings
- a pair of tongs for a retaining ring 8mm
- a torque wrench
- a torque wrench socket 8
- a torque wrench socket 17
- a torque wrench “open end insert tool”, 36mm
- an open end wrench, 4mm
- media and temperature compatible lubricant for reassembling threaded parts
- media and temperature compatible lubricant for o-rings
- soapy water for leak-testing
WARNING
INCORRECT OR IMPROPER REPAIR OR SERVICING OF THIS PRODUCT CAN CAUSE SERIOUS
PERSONAL INJURY AND PROPERTY DAMAGE.
SWAGELOK B.V. recommends the product to be removed from the system and to be shipped to
SWAGELOK B.V. for service or maintenance as all regulators must pass rigid acceptance tests before
leaving the factory.
All repairs and servicing of this product must be performed by factory certified personnel and tested for
operation and leakage.
If this procedure is not followed for any reason, or if any customer changes are made to the product,
SWAGELOK B.V. cannot assume responsibility for the performance or safety of a customer repaired
product or for any damage resulting from failure of the product.
The product should be checked periodically for proper and safe operation.
It is the users sole responsibility to determine the frequency of maintenance based on the application.
L RECOMMENDATION
SWAGELOK B.V. RECOMMENDS TO HAVE SPARE-PART KITS READILY AVAILABLE ON SITE.
All regulators require maintenance at scheduled intervals. Annual maintenance is recommended under
normal use.
From experience SWAGELOK B.V. can tell that especially during the start-up of a system, the demand
for spare-part kits is high.
This is despite all the effort taken to assure a clean system, there is usually some debris left in the
system, which damages the regulator.
Having spare-part kits on site will save time and money, as the downtime of the system will be reduced
to a minimum, whether during start-up or normal operation.
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4.2 Points of attention before removal from the system and disassembly
- SWAGELOK B.V. recommends removing the regulator from the installation.
- Make sure that a spare-part kit is present.
- The adjustment knob is provided with an anti-turnout locking ring, don't force it.
- Check if the used media is hazardous or toxic.
If required take the necessary safety precautions to ensure a safe workspace and your personal
safety. Vent to a safe environment away from people and ensure adequate ventilation.
- Follow your system safety, maintenance or special local procedures when removing the regulator.
- The product can be hot or cold, depending on the environment temperature and the used media
temperature. Take the necessary precautions before operating or touching the product.
4.3 Removal from the system
- Isolate the regulator from all pressure sources by closing the appropriate valves in the system.
- Turn the adjustment knob counterclockwise to decrease the set pressure.
- Make sure that the inlet and outlet pressure are both reduced to zero and that the adjustment knob
is turned counterclockwise until it blocks, so that there is no more pressure in the regulator and no
more spring force on the spring housing.
A shut-off valve on the outlet side must be opened to relief the pressure on the outlet side.
4.4 Disassembly
- Loosen the spring housing and remove the spring housing, spring, both spring guides, piston plate
and the piston/valve assembly.
- Loosen the bodyplug to remove the bodyplug, seat o-ring and seat.
- Disassemble the piston/valve assembly.
4.5 Inspection of disassembled parts
- Check all parts for abnormal wear. Replace all parts in case of doubt.
4.6 Points of attention before assembly
- All parts must be clean and undamaged before starting assembly.
- SWAGELOK B.V. recommends replacing all o-rings before assembly.
- All threaded parts must be lubricated a little before assembly, this to avoid galling of threads.
- All o-rings need to be lubricated a little to improve the lifetime of the o-ring and the performance of
the regulator.
4.7 Assembly
Follow the points for disassembly in reverse order to assemble the regulator.
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4.8 Recommended torques
Only tighten the bolts or parts if the regulator is completely pressure less.
- Spring housing 30 Nm
- Piston screw 5 Nm
- Bodyplug 30 Nm
4.9 Testing
Check the regulator for leakage across the seat, with low- and high inlet pressure.
Check the regulator for leakage across the piston o-ring, with low- and high outlet pressure.
Check the required set pressure range.
4.9.1 Leakage across the seat
- Close all the valves and turn the adjustment knob counterclockwise until it blocks.
- Open the outlet valve completely.
- Slightly open the inlet pressure supply to the regulator and turn the adjustment knob clockwise until
you reach a set pressure of 10% of the regulators set pressure range. Close the inlet pressure
supply and check for leakage (bubbles) at the outlet by using a little soapy water.
It may be necessary to vent the inlet pressure a little for the valve to close bubble tight.
- Repeat the procedure with the highest set pressure suitable for the regulator.
4.9.2 Leakage across the piston o-ring
- Close all the valves and turn the adjustment knob counterclockwise until it blocks.
- Slightly open the inlet pressure supply to the regulator until you reach 1 bar inlet (and outlet)
pressure.
Close the inlet pressure supply and check the connection between body and spring housing for
leakage (bubbles) by using a little soapy water.
Don't forget the little reliefhole in the spring housing and the ⅛” NPT connection on the body.
- Repeat the procedure with the highest inlet (and outlet) pressure suitable for the regulator.
4.9.3 Required set pressure range
- Close all the valves and turn the adjustment knob counterclockwise until it blocks.
- Open the outlet valve completely.
- Slightly open the inlet pressure supply to the regulator and turn the adjustment knob clockwise and
check if it reaches the maximum set pressure suitable for the regulator.
A well performing BS(H)2 is 100% bubble tight.
If there is a leakage across the seat or the piston o-ring, the damaged parts must be replaced.
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5 Trouble shooting
Problem: Constant leakage from the outlet before the relief set pressure is reached.
Cause: A damaged valve and/or seat and/or seat o-ring.
Solution: Replace the valve and/or the seat and/or the o-ring.
Problem: The required set pressure can not be reached.
Cause: The inlet pressure is not high enough.
Solution: Make sure that the inlet pressure is sufficient.
Problem: Leakage between the body and the spring housing or through the relief hole at the side of the
spring housing or through the ⅛” NPT connection on the body
Cause: A damaged o-ring or insufficient torque on the spring housing.
Solution: Replace the o-ring or tighten the spring housing according to the torque specifications.
Problem: The inlet pressure rises too much when going from a static to a dynamic situation.
Cause: There is too much flow in the dynamic situation.
Solution: A larger regulator is required.
Check the specific application data with the flow curves in our documentation, if available.
Problem: The regulator will not relief at the set point.
Cause: The valve is sticking or the adjustment knob is accidentally adjusted.
Solution: Replace the valve or re-adjust the adjustment knob.
Problem: The set pressure has changed without adjusting the adjustment knob.
Cause: Changes to the outlet pressure will result in changes to the set pressure.
An increase of the outlet pressure will result in a fall of the set pressure.
A decrease of the outlet pressure will result in a rise of the set pressure.
Solution: Maintain a constant outlet pressure on the regulator. See section “operation” about
dependency.
Warranty Information
Swagelok products are backed by The Swagelok Limited Lifetime Warranty.
For a copy, visit swagelok.com or contact your authorized Swagelok repre se ntative.
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