High Pressure Regulator Selection

Gases can be supplied in compressed gas high-pressure cylinders, liquid low-pressure cylinders or from low- pressure pipeline supply. The pressure from the supply source must be reduced to the desired working pressure for the application, to accomplish this a pressure reducing valve commonly referred to a regulator needs to be selected. Proper selection is critical for a safe and effective transfer of the gas from the gas supply to the instrument. Regulators are designed to control pressure. Regulators will not measure or control flow. An external device such as a flowmeter or metering valve specifically designed for flow control should be used for that purpose.

Selection of the correct regulator involves many variables. All items must be considered in making the proper regulator selection.

Materials Compatibility

Materials used to construct the pressure regulator need to be compatible with the intended gas service. All the wetted areas (parts of the regulator in contact with the gas) must be selected to avoid any reaction with the gas that can cause contamination in the gas stream or deterioration of the regulator components.

Inlet Pressure Rating

Inlet pressures can range from low pressure in pipeline usage to high pressure from compressed gas cylinders. Regulators used in a pipeline will normally have only one gauge to indicate delivery pressure while a cylinder regulator will have two gauges; one to show inlet pressure and the other to show delivery pressure. An exception to this would be the use of regulators for liquid gas cylinders. In this application, only the delivery pressure gauge would be required since the supply pressure is generally constant. When selecting the regulator it must be capable of handling the incoming inlet pressure. When the gas is supplied from a cylinder the CGA (Compressed Gas Association) inlet connection number will dictate the maximum supply pressure. This pressure can range from 100 PSI to over 6000 PSI.

Delivery Pressure Range

The desired working pressure for the operation may range from low pressure up to 15 PSIG to a much higher working pressure (7500-PSIG). The regulator selected must be able to supply the proper working pressure consistent with the requirements of the process.

Gas Purity

Maintaining the purity level of the gas is of primary importance in the selection of the regulator. The selected regulator must be resistant to any introduction of contaminants that can be detrimental to the process. In addition to the proper selection of materials for gas compatibility, the design, assembly and testing of the regulator are critical items to consider in the selection process. Clean room assembly and Helium leak testing are common procedures used to insure the integrity of the regulator.

Pressure Regulation,
Single-Stage or Two-Stage Design

All regulators are designed to reduce the inlet pressure to a desired working pressure. The regulator can reduce the pressure in either one step or two steps. A single-stage regulator reduces the pressure in one step and a two- stage regulator reduces the pressure in two steps, either may be suitable for the application based on the desired pressure control. Single-Stage regulators are best suited for applications where manual periodic adjustment of the delivery pressure settings is not a problem and the inlet pressure remains constant, such as the case in gas withdrawal from liquid cylinders. Two-stage regulators are two regulators built into a single regulator body. The first regulator (first stage) is preset at a non-adjustable pressure to reduce the incoming pressure to a lower pressure referred to as the intermediate stage. The second regulator (second stage) is adjustable within the desired delivery range. The two-stage regulator allows for steady delivery pressure without periodic adjustment, well suited for applications requiring constant pressure from full to nearly empty cylinder.

Operation of Pressure Regulators

Single-Stage Regulators

Gas enters the inlet (high-pressure) chamber and its pressure is indicated on the inlet pressure gauge. When the pressure adjusting knob is turned counterclockwise and completely backed out to the stop, a valve and seat assembly located between the inlet chamber and the delivery (low pressure) chamber prevents gas from moving any further. A filter located at the inlet to the valve and seat assembly, removes particulate matter from the gas stream to help protect the seat area.

Turning the pressure-adjusting knob clockwise causes the adjusting screw to push against a spring button that compresses the pressure adjusting spring. The force of the compressed spring, in turn, causes the diaphragm to flex and push against the valve. This opens the regulator allowing gas to flow from the inlet chamber to the delivery chamber of the regulator.

Gas entering the delivery pressure chamber begins to build pressure and creates a counter-force (counter to the pressure adjusting spring) on the diaphragm. This pressure is indicated on the delivery pressure gauge attached to the delivery chamber. When pressure builds sufficiently to counteract the spring tension, it pushes the diaphragm away from the poppet allowing the regulator valve to close. In this manner, pressure in the delivery chamber is controlled or regulated by the amount of spring tension placed on the diaphragm and is selectable by turning the pressure adjusting knob until desired pressure is indicated on the delivery pressure gauge.

When gas from the delivery pressure chamber is sent to the end process, the resulting decrease in gas volume in the delivery chamber causes a pressure reduction in the chamber. When this occurs, the spring tension again causes the diaphragm to push the valve open, allowing additional gas to enter the delivery chamber.

Two-Stage Regulators

These regulators incorporate all components of a single- stage regulator. In addition, however, they also contain a second pressure adjusting spring, diaphragm, and valve seat assembly. The first stage is not user adjustable with the pressure adjusting spring “pre-compressed” at the factory. This allows the first stage to feed pressure to the second (adjustable) stage. The normal maximum delivery pressure for two-stage regulators is 500 PSI.

The second stage then performs in a manner similar to that of a single-stage regulator, except that the inlet pressure to the second stage is relatively constant. The two-step pressure reduction produces a final delivery pressure showing little effect from changes in cylinder pressure.