عملکرد رگلاتور فشار – Pressure Regulator

Pressure Regulator

A pressure regulator is a control valve that reduces the inlet fluid pressure to a desired output level. Regulators are used for both gases and liquids and can be an all-in-one device with adjustable output pressure, or consist of a limiter and sensor in a single body, or a separate pressure sensor, controller, and flow valve.

Single-Stage Pressure Regulator

High-pressure gas enters the regulator from the source through the inlet valve. The gas then flows into the body, which is controlled by a valve. As the pressure rises, it pushes the diaphragm, causing the inlet valve to close and preventing any additional gas from entering the regulator. A pressure gauge is installed on the outlet side. Gas is drawn from the outlet, and the pressure inside the body is regulated accordingly.

The diaphragms are pressurized, causing the valve to open and allowing more gas into the source until a balance is achieved between the output pressure and the spring force. The output pressure can be adjusted using a handle or knob to compress the spring. The output and input pressures keep the diaphragm/poppet in a closed position against the spring force.

If the source pressure drops, the increased spring force allows more gas to flow into the regulator body, raising the output pressure until balance is achieved. Therefore, if the source pressure decreases, the output pressure will increase, providing an output pressure slightly below the falling supply pressure.

Two-Stage Pressure Regulator

A two-stage regulator consists of two single-stage regulators, designed to reduce pressure gradually in two steps instead of one. The first pre-set stage lowers the supply gas pressure to an intermediate level, and the gas then passes to the second stage. At this point, the gas reaches the working pressure, which is determined by the control knob connected to the diaphragm. The two-stage regulator also includes two safety valves to prevent overpressure and potential explosions. A major drawback of single-stage regulators is the need for frequent torque adjustments.

If the source pressure drops, the output pressure increases, requiring torque adjustment. In a two-stage regulator, automatic compensation handles any supply pressure drop. Single-stage regulators are typically used with pipelines and cylinders, while two-stage regulators are used with cylinders and manifolds.

Pressure Regulator Operation

The primary function of a pressure regulator is to match the gas flow through the regulator to the demand, while maintaining a constant output pressure.

If the load flow decreases, the regulator flow must also decrease. Conversely, if the load flow increases, the regulator must increase the flow to maintain pressure control, compensating for gas shortages in the system. A pressure regulator consists of a self-acting element, a loading element, and a measuring element.

• The loading element is a valve that can apply the necessary force to limit flow. For globe valve, butterfly valve, poppet valve و …

• The measuring element functions to determine when the input flow equals the output flow. The diaphragm is often used as the measuring element and can also serve as a combined element.

In the single-stage regulator illustration, a force balance on the diaphragm is used to control a valve and regulate pressure. With inlet pressure, the spring above the diaphragm pushes it down onto the valve to adjust the pressure. When the inlet pressure is applied, the poppet opens, allowing flow to reach the diaphragm and increase pressure in the chamber until the diaphragm moves upward against the spring.

 The applied pressure reduces the poppet flow, eventually stopping any further increase in pressure. By adjusting the top screw, the downward force on the diaphragm can be increased, requiring higher pressure in the upper chamber to maintain balance.

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