WellMark 2001PR Installation, Operation & Maintenance Instructions

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Page 1

Installation, Operation & Maintenance Instructions

Note: This document is to be used in conjunction with WellMark Catalog Document, Section No.

5.2, “Series 2001PR Top Gun High Pressure Regulator”, pages 3 through 5.

WARNING!

Series

2001PR

for Series 2001PR “Top Gun” Regulator

Make sure that line pressure has been eliminated prior to the installation of any regulator. Prior to installation the line should be inspected to ensure that there is no debris that might damage the regulator. Install regulator with properly sized threaded connections and utilizing thread sealant.

The regulator should be installed with the flow arrow on the side of the body in the correct orientation to flow - i.e. higher pressure upstream, lower regulated pressure downstream.

most regulators, the Series 2001PR regulator has an outlet pressure ratingthat isless thanthe inletpressure rating. Overpressure protection must be provided to avoid over-pressure condition if the actual inlet pressure can exceed the outlet pressure rating. Refer to Table 1 and 2 for maximum inlet pressures, pressure drops andoutletpressure ranges.

The regulator maybeinstalled in anyorientationas long astheflow is in proper agreement with the flow arrow on the side of the body. However, the regulator should be positioned such that the screened Breather (24) will notcollectdebris or moisture.

As is true with

Over-pressure of this regulator or installation of the regulator in applications which may see pressure levels beyond those for which the regulator is designed may result in leakage and/or catastrophic failure. This failure could result in leaking gas, damage to surrounding equipment, personal injury or death. To prevent such damage/injury the regulator should be installed in a safe location and should be chosen based upon the user’s specific application.

It is highly recommended that suitable pressurerelieving devices, as recommended by appropriate codes or standards, be installed in your system to assure that maximum rated pressures are not exceeded.

Installation

The Series 2001PR Top Gun Regulator should be chosen based upon the maximum inlet pressures, pressure drops and outlet pressures as described inTable 1 and 2. Flow capacities are listed in Table 3. The operating temperature range is -20°F to 150°F. When choosing and installing a regulator one must ensure that the conditions do not exceed these parameters. Furthermore, large differentials in pressure across the regulator may result in the formation of ice in the orifice area. The resulting decrease in orifice area may affect the regulators ability to flow in sufficient volume for downstream demand. Therefore, large pressure drop applications may require the useofmore than one regulator.

VentLine Option

The Series 2001PR Top Gun Regulator includes a vent or Breather (24) in the Spring Housing (3). If there is concern about build-up of gas in a confined location, the Breather may be removed to allow installation of a remote vent line. With the Breather removed, a vent line may be installed into the1/4” NPT port. This vent line should be as large a diameter aspossible and shouldutilize minimal bends and elbows. Furthermore, the ventlineopening should be protectedfrom weather or debris andshouldbe checked regularly forblockage.

Table 1: Maximum Pressures and Pressure Drops

Port Diameter 1/8” 1/4” 3/8” 1/2”

Max. Allowable Inlet Pressure, psig 1500 1500 1000 750

Max. Allowable Pressure Drop, psid 1500 1000 500 250

The sum of the outlet pressure setting and the maximum allowable pressure drop

determines the maximum allowable inlet pressure for a given installation. For example, with a 3/8” seat ring orifice (maximum pressure drop of 500 psi) and a 275 psig outlet pressure setting,themaximum inlet pressure is 775psig (500 psi + 275psi+ 775 psi).

Table 2: Outlet Pressure Ranges

Outlet Pressure Range psig

Max. Outlet Pressure over

Pressure setting , psig

Max. Emergency Outlet (Casing) Pressure, psig

Internal parts of the regulator may be damaged if theoutlet pressure exceeds the pressure

setting beyondtheamounts shown.

This applies to outlet pressure settings below 350 psig only. For pressure settings above

350 psig, outlet pressure is limited to 550 psig, the maximum emergency outlet (casing) pressure.

27-50 46-95 90-150

200 200

150-200 200-275 275-500

550

The Company, L.L.C. Oklahoma City, Oklahoma Tel: (405) 672-6660 Fax: (405) 672-6661

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Page 2

Series

2001PR

Startup Operation

WARNING!

Release downstream pressure to prevent a potential over-pressure of the diaphragm. Failure to do so may result in property damage and/or personal injury. Always employ upstream and downstream pressure gauges to monitor startuppressures.

With the regulator isolated with shutoff valves on both the upstream and downstream sides, slowly open upstream valve followed by slowly opening the downstream valve. Check all connections for leaks and make necessary output adjustments by manipulating the Adjusting Screw (1) pertheadjustment procedures below.

Adjustment

The range of adjustment for a particular regulator is indicated on the nameplate. Different ranges can be achieved by substituting a different Spring (5).

IMPORTANT: If a newspring is installed the nameplate must be remarked to indicate thenewpressure range.

Refer to Tables 1 & 2 prior to adjustment for pressure and flow information, assuring that the chosen spring will facilitate the desired pressure regulation and that the maximum pressure output does not exceed the downstream systempressurelimits.

Loosen the Jam Nut(2).

ToINCREASEpressure:

TurnAdjustment Screw

ToDECREASEpressure:

TurnAdjustment Screw

Once thedesired pressure is achieved, holdAdjustment Screw while securing the Jam Nut.

clockwise

counter clockwise

Shutdown

WARNING!

Downstream pressure must be released to prevent an over-pressurization of the diaphragm. Failure to do so may result in property damage and/or personal injury.

Close the upstream block valve followed by closing the downstream block valve. Open the nearest vent valve between the regulator and the downstream block valve.

Operation

When the outlet pressure is lower than the set pressure, force generated by the Spring (5) upon the Spring Guide (7) and Diaphragm (11) causes the Lever Assembly (14) to hold the valve in an open condition. As the outlet pressure exceeds the set pressure, the Diaphragm, acting upon theLower Spring Guidecompresses the spring allowing the Lever Assembly to close the valve until the outlet pressure equalizes with thesetpressure.

Maintenance

Routine maintenance should be expected due to normal wear and tear, damage from external sources or debris. The regulator components - especially the moving and sealing parts - should be inspected periodically and replaced as necessary. Frequency of inspection/replacement depends upon severity of conditions, but may also be requiredbylocal/state/federal law or industrystandards.

Large pressure drops or large amounts of particulate in the flow will result in accelerated wear on the (21) and

(20).

Orifice

Replacing the Orifice, LeverAssembly andDiskAssembly

1) Disconnect piping from (18), removing Adapter and four (17).

2) Remove (20) and (19).

3) Remove vent piping ifitis installed.

4) Remove two (8), which secure the

Adapter Body Diaphragm Adapter

and (3)as a unit.

5) If the is to be replaced, drive out the (15) and slide the out of the . When replacing theLeverAssembly, make surethatthe slot engages the (12). Replace the pin.

6) Remove the (22) from the .

7) Use a 3/4-inch socket to remove and re-install the Valve Disk and holder.

8) Discard old and replace with new. Reinstall the into the .

9) R making sure that Carrier. Finally, tighten the two that secure the

Diaphragm Adapter/Spring Housing Body

IMPORTANT: away from the (18).

10) Re-install the to the , installing and tightening the four .

Cap Screws

Orifice Inlet Body Gasket

Cap Screws Diaphragm

(13) to the (23). Remove the

Spring Case

Lever Assembly Pin

Lever Assembly Diaphragm Adapter

Connector Head Assembly

ValveCarrier Body

Inlet Body Gaskets

ValveCarrier Body

e-install the unit,

Diaphragm Adapter/Spring Housing

the Lever Assembly properly engages the Valve

Spring Case InletAdapter

Inlet Adapter Body

Cap Screws

Valve Disk Assembly

Inlet Adapter

Cap Screws

unit to the

(3) must be oriented such that it points

The Company, L.L.C. Oklahoma City, Oklahoma Tel: (405) 672-6660 Fax: (405) 672-6661

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Page 3

Replacing the Diaphragm

1) Remove spring tension by loosening the (2) and turning the (1) counter-clockwise until all spring

Adjusting Screw

Jam Nut

compression is relieved.

2) Disconnect vent lineifinstalled.

3) Unscrew two (9) and four (10) with

Hex Nuts

(25).

4) Remove the (3).

5) Remove from the Lever Assembly, as a unit, the (11), (12), (7) and

Connector Head Assembly Lower Spring Guide

Cap Screw

Cap Screws Cap Screws

Spring Housing

Diaphragm

(6).

Series

6) Unscrew the (6) from the (12) and disassemble the (11).

7) Install a new , making sure that it is properly centered. Re-assemble and

Spring Guide Cap Screw

Cap Screw ConnectorHead

Diaphragm

Connector Head Assembly Lower

, securely tightened withthe .

2001PR

8) Engage Connector HeadinLeverAssembly.

9) Re-install the with and finger-tight only. Assure proper slack by slightly compressing the with the (tighten by turning clockwise). Finally, complete the tightening of all

Screws Nuts

and .

Spring Housing Cap Screws Nuts

Diaphragm

Spring Adjusting Screw

Cap

18 19 20

21 22

10 7 6

Parts List

Description DescriptionQty. Qty.Part No. Part No.Item Item

Adj. Screw, 27-50 Outlet Pressure 1 11014

1 Adj. Screw, 46-95 Outlet Pressure 1 11013

Adj. Screw, 90-500 Outlet Pressure 1 11097 2 Jam Nut 1 10098 3 Spring Housing 1 40440

Upper Spring Guide, up to 275 psi 1 11001 4

Upper Spring Guide, above 275 psi 1 11032

Spring, 27-50 Outlet Pressure 1 11027

Spring, Outlet Pressure

46-95 1 11028

Spring, 0 Outlet Pressure 5

6 Cap Screw 1 11012

8 Cap Screw 2 10090 9 Cap Screw 2 11011

10 Cap Screw 4 11010

11*

13 Diaphragm Adapter 1 40443 14 Lever Assembly 1 21023 15 Pin 1 11000 16 Gasket 1 11008

9 -150 1 11002

Spring, 50 Outlet Pressure

1 -200 1 11029

Spring, 2 - 5 Outlet Pressure

00 27 1 11030

Spring, 27 -50 Outlet Pressure

5 0 1 11031

Lower Spring Guide, up to 275 psi 1 40445

Lower Spring Guide, above 275 psi 1 40446

Diaphragm, Neoprene 1 11004

Diaphragm, Viton® 1 11033

Connector Head Assembly, Brass 1 21052

Connector Head Assembly, 316 SS 1 21053

24 Breather 1 05011-1640 25 Hex Nut 4 05000-1726 26 Name Plate 1 21039 27 Drive Screw 4 10075 28 Plug, 1/8” NPT (2” only) 1 06000-0494

Cap Screw, 1” 4 11009 Cap Screw, 2” 4 11050 Inlet Adapter, 1” Steel 1 40442 Inlet Adapter, 2” Steel 1 40589 Inlet Body Gasket, Copper 2 11005 Inlet Body Gasket, Composition (for NACE) 2 11015 Orifice, Brass 1/8” 1 21042 Orifice, Brass 3/16” 1 21112 Orifice, Brass 1/4” 1 21028 Orifice, Brass 3/8” 1 21040 Orifice, Brass 1/2” 1 21041 Orifice, Stainless Steel 1/8” 1 21043 Orifice, Stainless Steel 3/16” 1 21093 Orifice, Stainless Steel 1/4” 1 21044 Orifice, Stainless Steel 3/8” 1 21045 Orifice, Stainless Steel 1/2” 1 21046 Valve Disk Assembly, Brass/TFE 1 21026 Valve Disk Assembly, 316SS/TFE 1 21047 Valve Carrier, Brass 1 31005 Valve Carrier, 316SS 1 31011 Body, 1” Steel (WCB) 1 40444 Body, 2” Ductile Iron 1 40588

The Company, L.L.C. Oklahoma City, Oklahoma Tel: (405) 672-6660 Fax: (405) 672-6661

wellmarkco.com

Page 4

Series

2001PR

Table 3: High Pressure Regulator Flow Capacities (scfh of 0.6 Specific Gravity Gas; based on 20% Drop)

Outlet

Pressure

Range psig

27-50 300 50 5300 10,500 14,000 20,000 23,000

46-95 300 50 5200 8900 11,000 16,000 20,000

46-95

90-150

90-150 450 150 7700 17,000 24,000 36,000 —

150-200 450 150 7600 15,000 24,000 36,000 —

Inlet

Pressure

Outlet

Pressure

psig

60 900 2000 3100 5200 8100

75 1300 28500 3800 7200 10,000 100 1700 3500 5700 10,500 13,000 150 2600 5700 8700 13,000 17,000 200 3500 7800 11,000 16,000 19,000

400 6900 13,000 17,000 23,000 — 550 9600 16,000 20,000 26,000 — 600 9800 17,000 21,000 — —

1050 17,000 23,000 27,000 — — 1500 19,000 25,000 — — —

60 800 1500 2400 4300 6400

75 1200 2100 3100 5500 8000 100 1500 3100 4200 7500 10,000 150 2400 4500 6700 11,000 14,000 200 3400 6600 9400 14,000 17,000

400 6800 11,000 15,000 20,000 — 550 9500 13,000 17,000 23,000 — 600 9800 14,000 19,000 — —

1050 14,000 19,000 22,000 — — 1500 18,000 24,000 — — —

100 1700 3200 5000 8000 13,000 125 2200 4300 6700 10,000 15,000 200 3500 7300 10,000 16,000 22,000 250 4400 9400 13,000 19,000 24,000 325 75 5700 11,000 16,000 23,000 27,000 400 7100 14,000 19,000 27,000 — 575 9700 18,000 23,000 30,000 — 600 9900 19,000 25,000 — —

1075 18,000 27,000 32,000 — — 1500 23,000 32,000 — — —

125 2000 3600 5500 9200 13,000 150 2500 4600 6800 11,000 16,000 200 3600 6600 9400 13,000 22,000 250 4400 8500 11,000 18,000 26,000 300 100 5300 9800 14,000 21,000 30,000 350 6100 10,000 16,000 25,000 32,000 400 7000 13,000 18,000 27,000 — 600 9500 18,000 23,000 35,00 —

1100 19,500 28,000 35,000 — — 1500 25,000 35,000 — — —

150 2400 4600 6700 11,000 17,000 200 3500 6800 10,000 15,000 23,000 250 4300 8900 12,000 19,000 29,000 300 5200 10,000 15,000 25,000 34,000 375 125 6600 13,000 18,500 28,000 39,000 400 7300 14,500 19,000 29,000 — 500 7900 15,000 25,000 36,000 — 625 10,000 22,000 29,000 41,000 —

1125 18,000 33,000 42,000 — — 1500 26,000 43,000 — — —

200 2400 6800 10,000 16,000 26,000 250 4400 8800 13,000 20,000 32,000 300 5300 10,000 15,000 24,000 35,000 400 7100 14,000 22,000 34,000 42,000

650 9000 24,000 33,000 49,000 — 800 13,000 29,000 38,000 — —

1150 20,000 38,000 49,000 — — 1500 26,000 47,000 — — —

200 3400 6200 9300 16,000 24,000 250 4300 8800 12,000 20,000 27,000 300 5300 10,000 15,000 24,000 30,000 400 7100 14,000 21,000 32,000 38,000

650 9000 21,000 33,000 48,000 — 800 13,000 27,000 37,000 — —

1150 19,500 34,000 49,000 — — 1500 26,000 44,000 — — —

Seat Ring Orifice Diameter (Inches) Seat Ring Orifice Diameter (Inches)

1/4 1/41/2 1/23/8 3/83/16 3/161/8 1/8

Outlet

Pressure

Range psig

150-200 700 200 11,000 25,000 40,000 61,000 —

200-275 700 200 11,000 25,000 35,000 55,000 —

200-275

200-275 775 275 11,000 28,000 51,000 95,000 —

275-500 775 275 11,000 24,000 32,000 55,000 —

275-500

250-500 900 500 15,000 34,000 52,000 92,000 —

Inlet

Pressure

Outlet

Pressure

psig

250 4200 8300 12,000 20,000 30,000 300 5200 10,000 16,000 25,000 35,000 450 7800 16,000 26,000 43,000 50,000 600 9500 22,000 34,000 55,000 —

800 13,000 30,000 43,000 — — 1000 16,000 37,000 50,000 — — 1200 20,000 41,000 59,000 — — 1500 26,000 53,000 — — —

250 4200 8200 11,000 20,000 29,000

300 5200 10,000 14,500 25,000 35,000

450 7700 16,000 24,000 40,000 50,000

600 9500 22,000 31,000 51,000 —

800 13,000 29,000 42,000 — — 1000 16,000 36,000 50,000 — — 1200 19,000 41,000 55,000 — — 1500 26,000 51,000 — — —

300 4900 9000 15,000 28,000 42,000

400 7000 14,000 23,000 40,000 56,000

500 8500 18,000 29,000 51,000 65,000

600

750 12,500 28,000 44,000 69,000 — 1000 16,000 39,000 58,000 — — 1250 21,000 49,000 69,000 — — 1500 26,000 59,000 — — —

300 4700 9000 15,000 28,000 39,000

400 6900 14,000 25,000 40,000 54,000

525 8600 18,000 35,000 68,000 94,000

1000 16,000 39,000 67,000 — — 1275 21,000 50,000 87,000 — — 1500 26,000 60,000 — — —

300 4500 7500 10,000 20,000 31,000

400 6600 12,000 16,000 31,000 43,000

525 8600 16,000 21,000 39,000 56,000

1000 17,000 32,000 43,000 — — 1275 21,000 40,000 53,000 — — 1500 26,000 46,000 — — —

400 6600 11,000 16,000 31,000 42,000

550 9700 18,000 23,000 44,000 63,000

600 9900 19,000 26,000 48,000 —

700

800 13,000 26,000 35,000 61,000 —

900 15,000 29,000 39,000 — — 1300 22,000 43,000 58,000 — — 1500 26,000 49,000 — — —

500 8300 16,000 24,000 44,000 62,000

650 10,000 24,000 33,000 61,000 86,000

800 13,000 30,000 41,000 76,000 —

900 1000 17,000 38,000 54,000 — — 1200 20,000 46,000 63,000 — — 1400 24,000 55,000 76,000 — — 1500 26,000 60,000 — — —

550 8700 16,000 26,000 50,000 77,000

750 12,000 28,000 40,000 78,000 100,000

1000 17,000 39,000 60,000 100,000 — 1500 26,000 59,000 72,000 — —

9500 22,000 34,000 59,000 —

250

11,000 23,000 30,000 54,000 —

300

15,000 34,000 49,000 85,000 —

400

Table 4: Wide-Open Flow Coefficients

Orifice Size C

1/8 inch 13.9 0.49 28.4 3/16 inch 31.3 1.11 28.2 1/4 inch 55.1 2.03 27.2 3/8 inch 122.5 4.61 26.6 1/2 inch 216.0 8.18 26.4

The Company, L.L.C. Oklahoma City, Oklahoma Tel: (405) 672-6660 Fax: (405) 672-6661

wellmarkco.com