Instruction Manual

ManualsBrandsCashco ManualsSensorsPGR-1

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-PGR-1

03-14

I. DESCRIPTION AND SCOPE

Model PGR-1 is a pressure reducing regulator used to control downstream (outlet or P2) pressure. Sizes are

1/2" (DN15), 3/4" (DN20), 1" (DN25), 1-1/2" (DN40), 2" (DN50), 3" (DN80) and 4" (DN100). This model is applied

primarily in gaseous service.

MODEL PGR-1

DIRECT-ACTING, PRESSURE LOADED

PRESSURE REDUCING REGULATOR

II. REFERENCES

Refer to Technical Bulletin PGR-1-TB for tech ni cal

speciﬁ cations for this reg u la tor.

ABBREVIATIONS

CW – Clockwise

CCW – Counter Clockwise

ITA – Inner Trim Assembly

III. INSTALLATION

SECTION III

SECTION II

SECTION I

1. Regulator may be rotated around pipe axis 360

degrees. For ease of maintenance, the rec om-

mend ed position is with the cover dome (2)

up wards.

2. Provide space below, above, and around reg u la-

tor for removal of parts during maintenance.

3. Install block valves and pressure gauges to pro-

vide means for adjustment, operation, bypass,

or removal of the regulator. A pipeline strainer

is recommended before inlet to remove typical

pipe line debris from entering valve and damaging

internal “soft goods”, primarily the dynamic seal.

CAUTION

Installation of adequate overpressure pro tec tion is recom-

mended to pro tect the reg u la tor from overpressure and

all down stream equip ment from damage in the event of

regulator failure.

Model PGR-1

Summary of content (16 pages)

PAGE 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-PGR-1 03-14 MODEL PGR-1 DIRECT-ACTING, PRESSURE LOADED PRESSURE REDUCING REGULATOR SECTION I I. DESCRIPTION AND SCOPE Model PGR-1 is a pressure reducing regulator used to control downstream (outlet or P2) pressure. Sizes are 1/2" (DN15), 3/4" (DN20), 1" (DN25), 1-1/2" (DN40), 2" (DN50), 3" (DN80) and 4" (DN100). This model is applied primarily in gaseous service. SECTION II II.
PAGE 2
SECTION IV CAUTION DO NOT HYDROSTATIC TEST THROUGH AN INSTALLED UNIT; ISOLATE REGULATOR FROM TEST. The "OUTLET RATING" as printed on the nameplate is the recommended “upper operating limit” for the sensing diaphragm. Higher pressures could cause internal damage. In addition, note on the nameplate that the Inlet and Outlet pressure and temperature ratings are at different levels. IV. PRINCIPLE OF OPERATION 1.
PAGE 3
SECTION VI VI. SHUTDOWN 4. Relieve any trapped upstream and downstream pressure and loading pressure from PGR-1. 1. Shutoff inlet block valve. 2. Allow sufficient time for the line pressure downstream of the inlet block valve to bleed down. 5. The regulator may now be removed from the pipeline or disassembled for inspection and preventative maintenance while in-line. 3. Shutoff the outlet block valve. SECTION VII VII. MAINTENANCE WARNING SYSTEM UNDER PRESSURE.
PAGE 4
7. Loosen the diaphragm flange bolts (23) and nuts (24) uniformly and remove. 8. Place matchmarks on body (1) and cover dome (2) flanges. Remove cover dome. 9. With wrench grasp and hold the milled “flats” on top of the valve plug (5) stationary. Rotate diaphragm nut (11) CCW and remove . 10. Remove upper diaphragm plate (7). 11. Remove diaphragm (6) and o-ring upper stem seal (13).
PAGE 5
3. QC Requirements: a. Valve plug (5); 1. 16 rms finish on its seating surface for tight shutoff. 2. No major defects on bottom guide spindle. b. Cage (4); 1. 16 rms finish on cylinder bore. No “ledges” formed due to wear from moving dynamic side seal (27) or wiper seal (16). c. Lower guide bushing (24) (non-replaceable): 1. 16 rms finish on bore. 2. Max 0.015 inch (0.38 mm) clearance between valve plug (20) spindle and lower guide bushing (24). d. Internal sensing drilled plug (32); 1.
PAGE 6
2. Place properly oriented seat (10) onto its shoulder at the lower end of cage (4). 3. Place new o-ring lower stem seal (13) into groove of valve plug (5). 4. Insert valve plug (5) upwards through lower end of cage (4) and through the center hole in guide bearing (9). Hold plug and cage together in the closed position. 5.
PAGE 7
1. Shut down system in accordance Section VI. 2. Disconnect the external sensing line, from the pilot valve sensing port. 3. Loosen all fitings and remove tubing that connect the inlet filter to the stablizer, the cover dome to the metering valve and the outlet of the metering valve to the outlet of the body. 4. Loosen and remove the two nuts (24) that secure the mounting bracket (3) and pilot to the cover dome (2). 5. Remove pilot assembly from main valve. 6.
PAGE 8
13. Place flange bolts through holes in spring chamber and body and engage nuts (51). Tighten nuts evenly in a star crossing pattern. Apply 15 - 18 ft-lbs. torque to finsih tightening. Ensure to secure the name plate (53) under one of the flange bolts (49) above the "inlet" of the pilot. 14. Rotate adjusting screw (47) CW into the spring chamber (32) to where the nut (48) comes in contact with the top of the spring chamber.
PAGE 9
1. Loosen adjusting screw nut (71) one revolution CCW. Relax range spring (75) forces by rotating adjusting screw (68) CCW until removed from spring chamber (62). 12. Reinstall adjusting screw (68) with nut (71) into the spring chamber (62). 13. Pressurize with air and spray liquid leak detector to test around body and spring chamber for leakage. Ensure that an outlet pressure is maintained during this leak test of at least mid-range spring level; i.e. 20-80 psig (1.4-5.5 Barg) range spring, 50 psig (3.
PAGE 10
9. Bench test unit for suitable operation. NOTE: Regulators are not tight shutoff devices. Even if pressure builds up beyond set point, a regulator may or may not develop bubble tight shutoff. In general, tighter shutoff can be expected with composition seat. pressure is maintained during this leak test of at least mid-range spring level; i.e. 20-80 psig (1.4-5.5 Barg) range spring, 50 psig (3.4 Barg) test pressure minimum. 10.
PAGE 11
SECTION VIII VIII. TROUBLE SHOOTING GUIDE When trouble shooting this regulator there are many possibilities as to what may be causing problems. Many times, the regulator itself is not defective, but one or more of the accessories may be. Sometimes the process may be causing difficulties. The key to efficient trouble shooting is information and communication.
PAGE 12
4. Diaphragm continually breaks (all regulators). Possible Causes A. Differential pressure across diaphragm may have exceeded limits. 5. Leakage at diaphragm flange. Remedies A1. Be aware of limits as well as where the various pressures are acting. Install pressure safety equipment as necessary. Possible Causes Remedies A. Body bolts not torqued properly. A. Torque to proper value (see Section VII, F-16). B. Pressures at diaphragm may be too high. B. Consult factory. 6.
PAGE 13
METERING VALVE Assembled View IOM-PGR-1 13
PAGE 14
Main Body Assembly with Dynamic O-ring Seal Item No. 1 2 4 5 6 7 8 9 10 11 12 13 14 14 Description Body Cover Dome Cage Plug Diaphragm Upper Diaphragm Plate Lower Diaphragm Plate Guide Bearing Seat Nut Guide Bushing Static Seal (Plug) Static Seal (Cage) * * * * Item No. 15 18 19 20 22 23 24 Description Dynamic Seal (Guide Bearing) Return Spring Internal Sensing Plug Pipe Plug (Dome) Cage Bolts Flange Bolts Flange Nuts * * Recommended Spare Parts. Items not shown 3 15.
PAGE 15
Vent to Atmosphere Sense Port Pilot Inlet Detail A Pilot Assembly Item No. 31 32 33 34 35 36 37 38 39 40 41 42 IOM-PGR-1 Description Body Spring Chamber Body Cap Range Spring Spring Button Pressure Plate Seat Stem Ball Holder Retainer Return Spring Pusher Post Item No.
PAGE 16
Vent Inlet Outlet Stabilizer Item No.