BD(H)20, 25(-DP)
Contents
1. diaphragm sensing 2 bubble tight shut off BD H 20 25mm seat BD H F25 32mm seat balanced valve pilot regulator 1 2 Special features and options The regulator is available with the following options dynamic regulation pilot regulator RHPS Series aoo OWAN N 1 3 Typical picture of the standard BD20 25 DP and its components gt EZ Uu en Z 72 Mam CHA w A qs AR n Tues Ju OO X9 oo OOOO A ben FLOW o o o o a Q oz g o g eo 9 o9 a go 9 El ays S o c o o o c c o N lalalo NLA A oO o e o o dD Qo D BS e 5r T D o oO wlceisrido ri T N gt o o E o o8 Es 3 Slo o gt LlLl o S o E o9 2 5 lojo c QB lola a lu oO s N OWAN al Manu Rev date 20 09 2010 BD H 20 25 User RHPS Series 1 4 Dome loading with differential pressure A differential pressure dome loaded regulator is a dome regulator with a set spring inside the dome The set spring is used to maintain a desired pressure difference between the dome pressure and the outlet pressure Usually the used dome pressure is a reference pressure taken elsewhere out of the system You set the desired differential pressure using the set spring and the remaining pressure is set using the dome pressure Qe OOGG 2 Installation2. Zi CWERNING INCORRECT OR IMPROPER REPAIR OR SERVICING OF THIS PRODUCT CAN CAUSE SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE SWAGELOK B V recommends the product to be removed from the system and to be shipped to SWAGELOK B V for service or maintenance as all products must pass rigid acceptance tests before leaving the factory All repairs and servicing of this product must be performed by factory certified personnel and tested for operation and leakage If this procedure is not followed for any reason or if any customer changes are made to the product SWAGELOK B V cannot assume responsibility for the performance or safety of a customer repaired product or for any damage resulting from failure of the product The product should be checked periodically for proper and safe operation It is the users sole responsibility to determine the frequency of maintenance based on the application RECOMMENDATION SWAGELOK B V RECOMMENDS TO HAVE SPARE PART KITS READILY AVAILABLE ON SITE All regulators require maintenance at scheduled intervals Annual maintenance is recommended under normal use From experience SWAGELOK B V can tell that especially during the start up of a system the demand for spare part kits is high This is despite all the effort taken to assure a clean system there is usually some debris left in the system which damages the regulator Having spare part kits on site will save time and money as the downtime of the system
3. excess pressure in the dome will leave the regulator through the relief connection Make sure that the inlet and outlet pressure are both reduced to zero A shut off valve on the outlet side must be opened to relief the pressure on the outlet side Disassembly instructions Loosen the hexagon socket head screws and remove the dome dome plate piston plate and valve assembly Loosen the body plug and remove the seat Inspection of disassembled parts Check all parts for abnormal wear Replace parts in case of doubt Points of attention before assembly All parts must be clean and undamaged before starting assembly SWAGELOK B V recommends replacing all o rings and the diaphragm before assembly All threaded parts must be lubricated a little before assembly this to avoid galling of threads All o rings need to be lubricated a little to improve the lifetime of the o ring and the performance of the regulator Assembly instructions Follow the points for disassembly in reverse order to assemble the regulator RHPS Series SR Riva OWAN 4 8 Recommended torques N Only tighten the bolts or parts if the regulator is completely pressure less Hexagon socket head screws M12 50 Nm Bodyplug 50 Nm Dome screw DP only 30 Nm 49 Testing Check the regulator for leakage across the seat with low and high inlet pressure Check the regulator for leakage across the diaphragm with low and high outlet pressure A well performin
4. will be reduced to a minimum whether during start up or normal operation 4 1 Required tools for maintenance a vice to fasten the regulator pincers to take out the o rings a torque wrench a torque wrench hexagon head key 10mm a torque wrench open end insert tool 38mm DP only amp 46mm an open end wrench 15mm DP only media and temperature compatible lubricant for reassembling threaded parts media and temperature compatible lubricant for o rings soapy water for leak testing RHPS Series SR Riva OWAN 4 2 4 7 Points of attention before removal from the system SWAGELOK B V recommends removing the regulator from the installation Make sure that a spare part kit is present Check if the used media is hazardous or toxic If required take the necessary safety precautions to ensure a safe workspace and your personal safety Vent to a safe environment away from people and ensure adequate ventilation Follow your system safety maintenance or special local procedures when removing the regulator The product can be hot or cold depending on the environment temperature and the used media temperature Take the necessary precautions before operating or touching the product Removal from the system Isolate the regulator from all pressure sources by closing the appropriate valves in the system Make sure there is no more pressure left in the dome If the pilot regulator is a self venting version the
5. BD H 20 25 DP USER MANUAL Read the complete manual before installing and using the regulator RHPS Series o OWAN N WARNING INCORRECT OR IMPROPER USE OF THIS PRODUCT CAN CAUSE SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE Due to the variety of operating conditions and applications for this product the user is solely responsible for making the final proper decisions concerning the correct assembly and functioning of the product and assuring that all the performance safety and warning requirements are met e Users must be trained and equipped for the handling use and servicing of pressure products and systems Users must contact their gas or liquid supplier for specific safety precautions and instructions Gaseous media should be free of excessive moisture to prevent icing at high flow Always wear the appropriate protective clothing including safety glasses gloves etc if required Follow the applicable safety and maintenance procedures Obey specific local regulations Do not exceed the maximum inlet and outlet pressure of the product or its accessories Operate within the temperature limits and other conditions specified for the product Do not drop or damage the product in any other way This may negatively effect the performance of the product which can cause the product to malfunction Venting fluids and gases can be dangerous Vent to a safe environment away from people Ensure adequate ventilation e This product is
6. RHPS Series 7 T p DL l rA Ny 2 dome 13 diaphragm plate 14 diaphragm 15 bottom springguide 20 o ring 21 o ring 24 socket head cap screw 25 ring 26 retaining ring 27 set spring 28 springguide 30 dome screw 31 setscrew BD H 20 25 User Manual Rev date 20 09 2010 WOKE N WARNING A PRESSURE REGULATOR IS NOT A SHUT OFF VALVE AND SHOULD NOT BE USED AS SUCH 2 1 Points of attention before installation This regulator can be equipped with different options and connections Before installing the regulator you should fully understand the options and the suitability of your particular regulator and its suitability for the application 2 1 2 2 The preferred mounting position of the regulator is horizontal with the dome facing upwards It may be necessary to remove the regulator from the system during maintenance or service Make sure that this is possible especially if mounted in a different position The regulator is suitable for gases and liquids Check if the materials on the assembly drawing which came with the regulator are compatible with the used media SWAGELOK B V recommends not to use a self venting version pilot regulator with hazardous or toxic media If required take the necessary safety precautions to ensure a safe workspace and your personal safety Vent to a safe environment away from people and ensure adequat
7. ation esses ener nnne nnn 6 39 8 Changing the set pressure essssssssssssseseseess eee enee enters sn trennt rennen ness nnns entrent 6 4 Maint ane cif ree n rt hSEREERRERRARKRRAEE AREE RERRRRRRRRREEREAKEPRARRRRR AS RR KRRRRRRRERRARRERERRRARARRRREAERKFEARSARKRRERERRRRRKRE AE 7 4 1 Required tools for maintenance sssssssssssssssseses enne enne en nnne nennt nennen 7 4 2 Points of attention before removal from the system sssssssssseeeeneerenes 8 4 3 Removal from the system c cccccceeeeeeeeeeeee cece eeesaeeeeeee scenes seaeeeeaaesecaeeesaaeedeaeeseneeesoaeeetaeeeeneeeeeess 8 4 4 Disassembly instructions cease naanin eei radai aeiaai aai aa aiia 8 4 5 Inspection of disassembled parts ssssssssssssssseseseeeeee ener nnne nene 8 4 6 Points of attention before assembly sse eene nennen nennen nnne 8 4 7 Assembly MST CEOS er oe ripe ane eie npa ea ne e ey ga tede Rete pan ore une Esas spa dee uu RR NER RSEN uas ate eee 8 4 8 Recommended torques ee Pg Rb e e E eee 9 49 TESNO scene eite eto bI ed atenta tmr T E ET UE 9 5 Trouble shootifig 5er pi ete ERR ert ERE et ERR eee eie LEER e Eres 11 RHPS Series SR Riva OWAN 1 Introduction 1 1 Detailed description The function of a backpressure regulator is to maintain a constant inlet pressure and to control the inlet pressure with a variable flow This regulator
8. e ventilation Avoid sealing compounds which harden be careful with anaerobic loctite type compounds Particles of these compounds can run into the regulator and lock moving parts Frequent assembly and disassembly of the in and outlet fittings can damage the in and outlet thread of the regulator Damaged threads can cause serious injury The product is designed to be used between 20 C and 80 C whether ambient temperature or media temperature In all other cases consult SWAGELOK B V The regulator is standard not oxygen clean Although all regulators are ultrasonically cleaned this does not make them suitable for oxygen use Oxygen service Specification of materials in regulators for oxygen service is the user s responsibility SWAGELOK B V can perform cleaning for Oxygen service based on ASTM G93LevelC CGA4 1 at additional cost Installation instructions Verify that the regulator the connections and its accessories are undamaged Verify that the regulator and its accessories are suitable for the system operating pressure and have the proper connections Carefully clean all pipes and connections Any swarf lint wire etc may cause seat leakage Verify the flow direction of the system and mount the regulator accordingly Securely make the appropriate connections to the regulator in accordance with the procedures recommended by the manufacturer of the connections Check if the in and outlet fittings are fitted far enough i
9. g BD H 20 BD H F25 is 100 bubble tight If there is a leakage across the seat or the diaphragm the damaged parts must be replaced RHPS Series ERR ura OWAN 10 RHPS Series o OWAN 11 5 Trouble shooting Problem The outlet pressure creeps up without increasing the dome pressure Cause A damaged valve and or seat Solution Replace the valve and or the seat Problem Leakage around the bodyplug Cause A damaged o ring or insufficient torque on the body plug Solution Replace the o ring or tighten the bodyplug according to the torque specifications Problem Leakage between the body and the dome Cause A damaged diaphragm or insufficient torque on the bolts Solution Replace the diaphragm or tighten the bolts according to the torque specifications Problem The required set pressure can not be reached Cause The inlet pressure is not high enough Solution Make sure that the inlet pressure is sufficient Problem The inlet pressure rises too much when going from a dynamic to a static situation Cause There is too much flow in the dynamic situation Solution A larger regulator is required Check the specific application data with the flow curves in our documentation if available Problem The outlet pressure does not drop if the pressure in the dome is lowered Cause The valve is sticking Solution Replace the valve assembly Problem The outlet pressure has changed without adjustin
10. g the dome pressure Cause Changes to the inlet pressure will result in changes to the outlet pressure A decrease of the inlet pressure will result in a rise of the outlet pressure An increase of the inlet pressure will result in a fall of the outlet pressure Solution Maintain a constant inlet pressure to the regulator See section operation about dependency Problem The regulator will not relief at the set point Cause The valve assembly is sticking or the dome pressure is accidentally adjusted Solution Replace the valve assembly or re adjust the dome pressure Warranty Information Swagelok products are backed by The Swagelok Limited Lifetime Warranty For a copy visit swagelok com or contact your authorized Swagelok representative RHPS Series oo OWAN
11. is a diaphragm sensing dome loaded backpressure regulator designed for high pressure high flow gases and liquids The regulator comprises a body and dome bolted together and has a removable seat and valve The product is designed to be used between 20 C and 80 C whether ambient temperature or media temperature The regulator is soft seated for leak tight shut off in zero flow conditions and is available in stainless steel or high tensile brass The regulator is a dome loaded type which means it must be connected to a controlled pressure source to operate The maximum in and outlet pressure for the models are limits for other connection types not included Threaded models BD20 01 DP Inlet 70 bar Outlet 70 bar Threaded models BDH20 01 DP Inlet 200 bar Outlet 200 bar Threaded models BD20 02 DP Inlet 70 bar Outlet 70 bar Threaded models BDH20 02 DP Inlet 200 bar Outlet 200 bar Flanged models BDF25 02 DP Inlet max 70 bar depending upon pressure rating of flange Outlet 70 bar Flanged models BDHF25 02 DP Inlet max 200 bar depending upon pressure rating of flange Outlet 200 Bar A Check the assembly drawing or regulator for the specific pressure limits of the supplied regulator N When using the BDH20 or BDHF25 with an inlet pressure higher than 200 bar a safety valve must be installed in the outlet line because the outlet pressure may not exceed 200 bar Standard features
12. ng the valve of the regulator This phenomenon is usually referred to as the accumulation pressure and does not indicate a problem with the regulator A decrease of the inlet pressure will result in a rise of the outlet pressure An increase of the inlet pressure will result in a fall of the outlet pressure This phenomenon is usually referred to as the dependency and does not indicate a problem with the regulator Each regulator type has its own dependency which is related to the ratio between the effective seat area and the sensing area Dependency Ratio BDH25 1 80 The approximate change can be calculated as shown below AP1 ratio x AP2 A ratio of 1 X means that for every pressure change to P1 of X bar the P2 pressure will change 1 bar 3 3 Changing the set pressure Check the supply of medium at the inlet side Make sure the inlet pressure is higher than the required set pressure and that the inlet pressure does not exceed the maximum allowed inlet pressure Open the shut off valve at the outlet side Open the shut off valve at the inlet side slightly to allow a minimal flow Controlled inlet pressure settings are obtained by adjusting the pressure in the dome Increasing the pressure in the dome raises the inlet pressure while decreasing the pressure in the dome lowers the inlet pressure Final adjustment must be made in flow condition to obtain the most accurate set point RHPS Series SR Riva OWAN 4 Maintenance
13. not oxygen clean and therefore not suitable for oxygen service If there are questions or problems regarding the installation operation and maintenance these should be directed to the proper authority on site before continuing RHPS Series ERR ura OWAN CONTENTS 1 loigenieilm 1 1 1 Detailed description 1 itera an died ie ore aes ume dd ab cede dd a Toa aae iea 1 1 2 Special features and options ssssssssssssssssssseeeeeee nennen nennen ness en nennt 1 1 3 Typical picture of the standard BD20 25 DP and its components sss 2 1 4 Dome loading with differential pressure sssssssssssssseeeen enne nennen 3 2 InstallatiORhi tree eer einen Bra RR ERR A ERRRREDRRDRRKRRARRREREURRTRRPRRRARRRRESRRRRR YRRARRRRRRRRRTRR RR RR 3 2 1 Points of attention before installation ssssssssssseseseeeeee eene nnne nennen nnne enne 4 2 1 OXygEN SENICE RR 4 2 2 Installation Instr ctions suis ete te eco tenete nte toe e aene Fort s ra a ern uaa Rene dua 4 2 3 PUN G TNS COMMS e 5 3 Operation nue ia RENS ERE AREEREMARIRERSRRRARRAR BAR ERKRARSRIRERESRKRRRRRARARSERARRRRKRRRRAREENRARR RKRRARRREERUARKRRRRRER NERARRAA 6 3 1 Required tools for Operatorin ennaa uer aen eeu eren ua e eps da eR ua dana d d 6 3 2 Points of attention before oper
14. nto the regulator and check for leakage across the fitting Check if the in and outlet flange is bolted in line with the systems counter flange at a correct preload and check for leakage across the flange facings Shut off valves should be mounted in the system for service or maintenance At the time of delivery every unused gauge connection is plugged with blind fittings Remove these and connect gauges if desired If earthing is required connect an earth wire under a dome bolt RHPS Series SR Riva OWAN 2 3 Filling the dome The dome can be filled in different ways 1 This can be done by taking the gas or liquid pressure from the system and feeding this through a needle valve or fixed orifice into the dome A spring loaded back pressure regulator controls the dome pressure The outlet pressure from the pilot regulator could be vented to the atmosphere or into the outlet line This is shown in sketch A The pressure in the dome can also be controlled with an external pressure source The gas pressure can be taken from a cylinder or shopair mains A spring loaded pressure regulator controls the dome pressure The regulator works best with a continuous bleed on the dome This is shown in sketch B It is not recommended to place a gauge on the dome to check the set pressure Because of forces in the regulator the dome pressure will always be lower than the inlet pressure Place a gauge in the inlet line to check the set press
15. ure NEEDLE VALVE FIXED ORIFICE L VENTING TO THE OUTLET LINE BACK PRESSURE PILOT REGULATOR PILOT REGULATOR VU CONTINUOUS BLEED BACK PRESSURE CYLINDER OR SHOPAIR MAINS DOME REGULATOR BACK PRESSURE DOME REGULATOR sketch A sketch B RHPS Series ERR ura OWAN 3 Operation 3 1 Required tools for operation For changing the set pressure on a standard regulator no tools are required 3 2 Points of attention before operation The product can be hot or cold depending on the environment temperature and the used media temperature Take the necessary precautions before operating or touching the product SWAGELOK B V recommends not to use a self venting version pilot regulator with hazardous or toxic media If required take the necessary safety precautions to ensure a safe workspace and your personal safety Vent to a safe environment away from people and ensure adequate ventilation If the shut off valve at the outlet side is closed after changing the set pressure the outlet pressure will rise a little because of the closing force required for bubble tight closing of the regulator This phenomenon is usually referred to as the lock up and does not indicate a problem with the regulator An increase in the flow will result in a rise of the set pressure A decrease in the flow will result in a fall of the set pressure This is because of the force required for openi
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