Beswick has over 40 years of experience in the design and manufacture of miniature pressure regulators.

Newer, patented, models incorporate low-friction diaphragms and an innovative spring design to achieve the smallest package size along with excellent performance.

Basics of Pressure Regulators

Pressure regulators maintain a constant outlet pressure despite variations in inlet pressure. Theyre essential for the safe operation of countless devices.
Pressure regulators are widely used in many common consumer and industrial applications. While they sometimes go unnoticed, they are often critical to safety, protecting equipment from damage and personnel from harm. For example, pressure regulators are used in gas grills to regulate propane pressure, in home furnaces to regulate natural gas, in medical/dental equipment to regulate oxygen and anesthesia gases, in pneumatic automation systems to regulate compressed air, in engines to regulate fuel pressure, and in fuel cells to regulate hydrogen. Although the applications vary considerably, all pressure regulators provide the same function. They reduce a supply pressure to a lower outlet pressure, and maintain this outlet pressure regardless of inlet pressure fluctuations. This reduction in pressure is the key characteristic of pressure regulators; outlet pressure is always below the inlet pressure. That said, a wide variety of pressure regulators are available to suit most any task. When choosing a pressure regulator, engineers should consider a number of factors to help select the best product for the job. Important considerations include: the type of regulator, materials of construction, inlet and outlet pressures, flow requirements, the fluid it will handle, temperature, and size constraints. Heres an overview of the fundamentals.

Contents Regulator basics 1 Design variations 2 Installation guidelines 3 Application considerations 3 Venting options 4

Regulator basics

In this single-stage regulator, pressurized fluid enters via the inlet port, flows through the valve, and then presses against the piston (or diaphragm). This pressure opposes the spring force and closes the valve once the outlet pressure reaches the setpoint. Turning the adjustment screw changes spring force and, thus, the regulated pressure.

A pressure regulator is comprised of three functional elements: 1. A pressure reducing or restrictive element (generally a poppet valve). 2. A sensing element (generally a diaphragm or piston). 3. And a reference force element (generally a spring). In operation, the spring generates a force which opens the valve. Pressurized fluid that enters the regulator via the inlet port flows through the valve and then presses against the sensing device (diaphragm or piston). The regulated pressure acts on the sensing element to produce a force which Beswick Engineering 1

Presented by

Regulator basics 1

Applications requiring long life and consistent performance will benet from Beswicks patented and award winning design.

Regulator accuracy is typically defined by charting outlet pressure versus flow rate. These performance curves show reduction in outlet pressure as the flow rate increases, a phenomenon known as droop/rise. Pressure regulator accuracy and capacity are defined by these charts showing the useful regulating capacity of a regulator.

Venting options 4

opposes the spring force and closes the valve. (The forces acting on the individual elements are shown in the Single-stage pressure regulator graphic on page one.) As mentioned previously, the most common sensing devices are pistons and diaphragms. Piston-style regulators are often used when higher outlet pressures are required or when outlet pressures are not held to a tight tolerance. Piston designs tend to be more sluggish because of friction between the piston This Beswick and the regulator body. These fricPRD3HP is tion forces, in turn, require greater a three-stage, changes in the downstream pressure non-relieving to overcome the additional forces diaphragm-style introduced by the moving piston. regulator. It can reduce inlet For higher accuracy, and in lowpressures of up to 3,000 psi down to the pressure applications, a diaphragm0 to 30-psig range. It measures only about style design is preferred. Diaphragm 1-in. diameter and weighs approximately regulators have an elastomeric 79 gm in brass. It is an excellent choice if element, instead of a piston, which inlet pressure will decay over time, such as eliminates friction forces. Also, with hydrogen storage tanks commonly used a diaphragm design yields better in fuel cell applications. Other uses include performance than the piston design medical and laboratory equipment, instrubecause the diaphragm can have a ments, ink-jet print engines, and semiconduclarger surface area than a piston. tor manufacturing equipment. Regulator accuracy is typically defined by charting outlet pressure Beswick Engineering 2

Installation guidelines 3

versus flow rate. The resulting graph shows changes in outlet pressure as flow rates change. This phenomenon is known as droop/rise. Droop is a term used when the outlet pressure drops below the set-point as flow increases. Rise is the increase in outlet pressure as flow decreases. As seen in the nearby curve, the effect is important to a user because it shows the useful regulating capacity of a regulator. Droop/rise is also caused by inlet pressure variations. As inlet pressures rise, outlet pressures fall; conversely, as inlet pressures fall, outlet pressures rise. Pressure regulator accuracy and capacity are defined by charting the amount of droop/rise for a given range of flows. When selecting a regulator, engineers should carefully examine pressure-versus-flow curves to ensure the regulator meets the necessary performance requirements. Another design factor not to be overlooked is orifice size. Increasing the valve port size can increase flow capacity. However, an oversized valve makes the regulator more sensitive to fluctuating inlet pressures, and may cause excessive droop/rise. Depending on the application requirements, engineers can choose from single- or multi-stage devices. Single-stage regulators are an excellent choice for relatively small reductions in pressure. For example, the air compressors used in most factories generate maximum pressures in the 100 to 150-psi range. This pressurized air is piped throughout the plant but is often reduced with a single-stage regulator to lower pressures (for example, to 80, 50, or 10 psi) to operate automated machinery, test stands, machine tools, leak-test equipment, linear actuators, and other devices. However, single-stage pressure regulators typically do not perform well with large swings in inlet pressure and/or flow rates. Dual-stage regulators may be a better choice in such instances. For example, in cases June 2013

Design variations 2

Design variations

Regulator basics 1

Miniature piston or diaphragm designs are available for your demanding application. Contact Beswicks degreed mechanical engineers for technical assistance.

Adjustment screw

Two-stage pressure regulator

INSTaLLaTiON GUidELiNES
Even after selecting the regulator that best suits your application, it must be properly installed to work as intended. A filter installed upstream of the regulator will ensure the valve seat is not contaminated or damaged by dirt and particulates. Gases should be free of excessive moisture to prevent icing of the regulator at high flow rates. Gases should also be free of any oils, greases, and other contaminants which could foul or damage the valve components. Do not connect regulators to a supply source with a maximum pressure greater than the rated inlet pressure of the regulator. Pressure regulators are not intended to be used as shutoff devices. When the regulator is not in use, the supply pressure should be turned off. To install a regulator: Begin by connecting the pressure source to the inlet port and the regulated pressure line to the outlet port. If ports are not marked, check with the manufacturer to avoid incorrect connections and possible damage to the internal components. Before turning on the supply pressure to the regulator, back off the adjustment control knob to restrict flow through the regulator. Gradually turn on the supply pressure so as not to shock the regulator with a sudden rush of pressurized fluid. Set the pressure regulator to the desired outlet pressure. If the regulator is non-relieving, it will be easier to adjust the outlet pressure if fluid is flowing and not dead-ended. If actual pressure exceeds the desired outlet pressure, vent the fluid from the downstream side of the regulator. Never vent fluids by loosening fittings, as injury may result. On a relieving-style regulator, counterclockwise rotation of the adjustment screw, knob, or cap will vent fluid from the downstream side of the regulator and lower the outlet pressure. Do not use relieving-style regulators with flammable or hazardous fluids. Be sure the excess fluid is vented safely and in accordance with all local, state, and federal regulations. To obtain the desired outlet pressure, make the final adjustments by slowly increasing the pressure from below the desired set point. If you overshoot the set point while setting the pressure regulator, back off the set pressure to a point below the set point and, again, gradually increase the pressure to the desired set point. Cycle the supply pressure on and off several times while monitoring the outlet pressure to confirm the regulator is reliably returning to the pressure set point. Outlet pressure should also be cycled on and off to ensure the pressure regulator is returning to the set point. In operation, take care not to turn in the adjustment screw so far that the reference spring reaches its solid height and thus eliminates any pressure regulation.

Design variations 2

1st-stage regulated pressure

Flow in

Flow out Pressure reducing valve

Supply pressure

In a two-stage regulator, the second stage is Adjustment screw isolated from large changes in inlet pressure by the first stage. This makes outlet pressure more stable, especially when the flow rate varies widely, or inlet pressure fluctuates or decays over time.

Installation guidelines 3

where the flow rate varies widely, or inlet pressures fluctuate or decay over time, a two-stage pressure regulator is ideal. With most single-stage regulators, a large drop in inlet pressure will cause a slight increase in outlet pressure. In a two-stage design, on the other hand, the second stage will not see these large changes in inlet pressure, only the slight fluctuations from the outlet of the first stage. This keeps the outlet pressure of the second stage much more stable. For this reason, a two-stage or three-stage regulator is recommended when equipment uses tanks of gases or storage cylinders, as is often the case in fuel-cell applications. A two-stage pressure regulator will compensate for the drop in inlet pressure as the gas is depleted without affecting the outlet pressures in the second stage. Dual-stage units are also used in gas-chromatography instrumentation and semiconductor applications.

Venting options 4

Application considerations

Beyond basic designs, engineers need to consider a number of other factors to ensure consistent performance and long life. These include: Beswick Engineering 3

June 2013

Regulator basics 1

Choosing the best regulator for your application is effortless using the online ordering system, www.beswick.com Contact Beswicks technical department for custom ideas.

Venting options 4

requires specialized knowledge for safe system design and oxygenMaterials. Pressure regulators come in a wide range of compatible lubricants must be specified. It is also important to materials including, but not limited to, corrosion-resistant determine if the fluid is flammable or hazardous, as this directly stainless steels, brass, aluminum, and plastics. Stainless steel affects venting, or relieving, requirements. provides long life and is ideal for clean rooms and corrosive fluids. When cost is a major concern, brass, aluminum, or Venting options plastic regulators may be better options. Aluminum is light Regulators come in relieving and non-relieving versions. weight while plastic is suitable for many medical applicaA relieving regulator (also known as self-relieving) tions involving bodily fluids. Plastic fluid-power products allows excess downstream pressure to be vented to are often ideal when economical, throw-away items are atmosphere. For example, if you set a relieving required. regulator to an output pressure of 30 psi and Operating pressures. The inlet and outlet then decide to reduce the output pressure pressures are important factors to consider to 10 psi, the relieving regulator will vent before choosing the best regulator. Key conthe excess downstream pressure (20 psi) siderations include the range of fluctuation and allow the outlet pressure to immediin the inlet pressure; the required outlet ately decrease to the desired 10 psi even pressure; and the allowable variation in if there is no flow (dead ended). outlet pressure. A relieving regulator is Flow requirements. The maximum This single-stage usually more convenient to flow rate that an application requires is an obvidiaphragm-type use in pneumatic systems ous design consideration. But also look at how regulator accepts inlet because you can easily much the flow rate varies. Porting requirements pressures to 500 psi and decrease the downstream are also an important issue, to ensure compatproduces output pressures pressure even if there is no ibility with mating equipment and to avoid restricting from 0 to 30 psi. Its especially flow. Note that the excess flow. suited to low flow/low pressure fluid should be vented safely Temperature. The pressure regulator must be able to regulation such as to 0.5 psi. and in accordance with all function properly at the expected operating temperatures. safety regulations. The primary concern is whether or not elastomeric seals and A non-relieving regulator will not vent excess downstream plastic components will operate as intended throughout pressure to the atmosphere. For example, if you set a nonthe expected temperature range. Additionally, the operating relieving regulator to 30 psi output, and then decide to reduce temperature may affect flow capacity and/or the spring rate in the output pressure to 10 psi, the non-relieving regulator will extreme applications. not immediately decrease to the desired 10 psi if there is no Size and weight. In many instances space is limited and flow (dead ended). As fluid flows through the regulator, output weight becomes a factor. Double check the port sizes, adjustpressure will decrease to the desired set point as the excess ment styles, and available mounting options. Some major downstream pressure is consumed. Non-relieving regulators are manufacturers also produce custom-engineered regulators to preferred for use with hazardous, explosive, or expensive gases meet non-standard size, porting, mounting, or performance because no gas is allowed to vent to atmosphere. requirements. Engineers must consider a number of Fluid compatibility. It is also important to consider the factors when applications demand that chemical properties of the fluid be it gas, liquid, fluid pressure be regulated. Fortunately, hazardous, or inert before determining the best pressure-regulator manufacturers offer materials for an application. Each fluid products across a wide range of types, sizes, has its own unique characterperformance levels, and price points in both istics, so care must be standard and custom versions to handle most any job. taken to select materials that The Beswick PR2 two-stage, piston-style regulator is designed for will withstand applications requiring either a large differential between input and output contact with the pressures, or precise pressure regulation. Both the high-pressure and lowprocess fluid. For pressure stages are adjustable. Maximum inlet supply pressure is 500 psig. example, if a pressure regulator will be used with oxygen, be aware that this fluid Beswick Engineering 4 June 2013

Installation guidelines 3

Design variations 2