CRS4, 6 - Swagelok
Contents
1. An increase in the flow will result in a fall of the outlet pressure and is usually referred to as the droop This phenomenon 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 Changing the set pressure Check the supply of medium at the inlet side Make sure the inlet pressure is higher than the required outlet pressure and that the inlet pressure does not exceed the maximum allowed inlet pressure Open the shut off valve at the inlet side Open the shut off valve at the outlet side slightly to allow a minimal flow Controlled outlet pressure settings are obtained by turning the setscrew Turn the setscrew clockwise to increase and counter clockwise to decrease the set pressure A shut off valve on the outlet side must be opened to relief the pressure on the outlet side Open the shut off valve at the outlet side fully to allow full flow during operation Final adjustment must be made during operation to obtain the most accurate set point RHPS Series nc OWAN 4 Maintenance rete 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 s2. Remove the setscrew from the springhousing Loosen the springhousing by turning it counter clockwise and put it aside Take the setspring and spring guides out and put them aside Take out the piston plate together with the piston and push the piston out of the pistonplate Push the sliding bearing out of the pistonplate Take the body out of the vice Catch the bodyplate in your hand while you turn the body upside down Clamp the body in the vice with the bodyplug facing upwards Loosen the bodyplug by turning it counter clockwise and take it out of the body Remove the valve valvespring and valvering out of the bodyplug Remove the seat and all the o rings from the body bodyplug and pistonplate Inspection of disassembled parts Check the sealing edge of the seat and the sealing surface of the valve Check the piston for abnormal wear Check all other 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 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 RHPS Series nc M WOH 4 7 Assembly instructions Clamp the body in the vice with the bodyplug side upwards Place the correct o ring aro
3. Solution A shut off valve in the outlet line must be opened to reduce the outlet pressure Problem The outlet pressure has changed without turning the setscrew Cause Changes to the inlet pressure will result in changes to the outlet pressure Solution Maintain a constant inlet pressure to the regulator See section operation about dependency 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 nc M WOKE
4. Check the required outlet pressure range A well performing regulator is 10096 bubble tight If there is a leakage across the seat or the piston or leakage to the outside the damaged parts must be replaced RHPS Series nc M OWAN RHPS Series Pep Roa OWAN 5 Trouble shooting Problem The outlet pressure creeps up without turning the setscrew Cause A damaged valve and or seat Solution Replace the valve and or the seat Problem Leakage around the body plug Cause A damaged o ring or insufficient torque on the body plug Solution Replace the o ring ring or tighten the bodyplug according to the torque specifications Problem Leakage between the body and the spring housing or through the relief hole on top of the spring housing Cause A damaged piston o ring or insufficient torque on the springhousing Solution Replace the piston o ring or tighten the springhousing according to the torque specifications Problem The required outlet pressure can not be reached Cause The inlet pressure is not high enough Solution Make sure that the inlet pressure is sufficient Problem The outlet 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 Problem The outlet pressure does not drop if the setscrew is turned counterclockwise Cause The regulator is non venting
5. Removal from the system ssssssssssessssesss esent een nn nnn senten enn s snis ss nrt senten enne 6 4 4 Disassembly instructions sssssssssssseeseses eene enne nennen nennen nennen entr nr sette en nes 6 4 5 Inspection of disassembled parts cccccccceeceeeeeceeeeeceeeeecaeeeseeeeceeeessaeeeeaaeseeeeeseeeeesaeeseneessaees 6 4 6 Points of attention before assembly sssssssssessssseees ener nennen nennen 6 4 7 Assembly Instr ctlOnis ioci terrd uei edet Ra ddnde dati ba dare ecu d RR ad dE Raza quoe D nc ki Ra detained 7 4 8 Recommended torques sessssssssssssseeees esee enne nitens sinis sn nrte entes nsns nennen nenun ena 7 4 9 MEET 7 BIER 9 PED Declaration rien eaaa aaa Aaaa Fout Bladwijzer niet gedefinieerd RHPS Series CRS4 6 User Manual Rev date 20 09 2010 OWAN 1 Introduction 1 1 Detailed description This regulator is a piston sensing pressure regulator designed for high pressure gases and liquids The regulator comprises a body and spring housing screwed together and has a removable seat and valve The regulator is particular designed for use in dispensers for compressed natural gas but other applications could be possible 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 made of
6. CRS4 6 all types of connections USER MANUAL Read the complete manual before installing and using the regulator RHPS Series Se ue 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 ventilati
7. e wrench socket to fit the torque wrench 24mm 15 16 also fits socket wrench 13 mm to adjust the setscrew media and temperature compatible lubricant for reassembling threaded parts SWAGELOK B V uses Thurmo Past MA media and temperature compatible lubricant for o rings SWAGELOK B V uses Molykote M55 soapy water for leak testing RHPS Series nc M OWAN 4 2 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 Turn the setscrew counter clockwise to decrease the set pressure 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 Clamp the regulator in a vice
8. erstand the options and the suitability of your particular regulator and its suitability for the application It may be necessary to remove the regulator from the system during maintenance or service Make sure that this is possible 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 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 The regulators are ultrasonically cleaned but grease is used on the threads and o rings 2 2 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 The standard connec
9. hipped 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 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 and place the o rings a torqu
10. on e This product is 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 d eue OWAN CONTENTS 1 2 3 Intro dU Pme 9 1 1 1 Detailed d script N srin carinu naana aiana a nnn sn trt en tenis a aana 1 1 2 Special features and options sssssssssssssssseseseeenee ener entren enn sinere nenne 1 1 3 Typical picture of a CRSN4 and its components sse eene 2 Dcum 3 2 1 Points of attention before installation sseessssssseseeseneeeeen enne nnne neni 3 2 2 Installation INSTFUCTIONS coiere Foret aere nes Eee steer erede n eor ePi e dade Prag een ed abaa 3 Op ration mcs 4 3 1 Required tools for OperatlOniz co et eter tt ote te ertt pert da Rn gara ku bee aaa 4 3 2 Points of attention before operation ssssssssessssseeeen eene ennt tenentes 4 3 3 Changing the set DreSstre ce rit te ete eth eter b eie ave an nra ue cl dax eg Pax eds 4 cnim GG e 5 4 1 Required tools for maintenance sssssssssisseseseeeeeee ener enhn nnne intrent eines 5 4 2 Points of attention before removal from the system ssssssssssssseeeneenneenes 6 4 3
11. stainless steel The design pressures for in and outlet side are e inlet O 400 bar e outlet 0 400 bar N Check the assembly drawing or regulator for the specific pressure limits of the supplied regulator Standard features piston sensing bubble tight shut off 0 280 bar outlet pressure range 910 mm seat orifice balanced valve construction setscrew with nut to lock at the desired setpressure 1 2 Special features and options The regulator is available with the options anti tamper gauge port RHPS Series T OWAN 1 3 Typical picture of a CRSN4 and its components QQ N p Se N TS cy pm D PETS a TS OOGG Zz it D Sn az NET OOOO K NN HE OOS E Ue AX Koger y 4 FLOW 1 body 12 springguide 20 body o ring 2 springhousing 13 setspring 21 bodyplate 3 balance o ring 14 valvespring 22 sliding bearing 4 ring 15 pistonplate 24 piston o ring 7 bodyplug 16 piston 25 piston back up ring 9 valve 18 bodyplug o ring 28 nut 11 seat 19 seat o ring 29 setscrew hexagon head RHPS Series ae OWAN 2 Installation 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 und
12. tions of the CRSN4 are NPT threads according to ANSI B1 20 1 Use teflon tape to get a proper sealing across the NPT threads In case of BSPP parallel female SWAGELOK B V recommends using bonded seal rings to get a proper sealing across the thread Verify that the regulator is mounted in the system without stress on the connections Stress on the connections can result in faulty connections and dangerous situations Check if the in and outlet fittings are fitted far enough into the regulator and check for leakage across the fitting Shut off valves should be mounted in the system for service or maintenance If earthing is required wind an earth wire around the springhousing and use a clamp to fix it RHPS Series nc M WOKE 3 Operation 3 1 Required tools for operation To change the setpressure a socket wrench 13mm is required If the regulator is factory set the setpressure is noted on the regulator 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 If a shut off valve at the outlet side is closed without changing the set pressure the outlet pressure will rise a little This phenomenon is usually referred to as the lock up and does not indicate a problem with the regulator A decrease in the flow will result in a rise of the outlet pressure
13. und the seat and place the seat in the body Place the correct o ring the valvering the valvespring and the valve into the bodyplug Carefully place the bodyplug along with the correct o ring in the body do not damage the seat with the valvestem Tighten the bodyplug with the recommended torque Take the assembled bottom out of the vice turn it around and clamp it in the vice with the bodyplug facing downwards Place the bodyplate into the body Place the sliding bearing around the piston and push the sliding bearing into the pistonplate You could use the vice to press it into the pistonplate Check the mounted sliding bearing by moving the piston You should not feel friction when you move the piston Place the back up ring and then the piston o ring into the pistonplate Place the assembled pistonplate with the correct o ring into the body Place the springguides and the setspring on top of the piston and keep them on place with one hand Place the springhousing over the setspring and screw it into the body Tighten the springhousing with the recommended torque Screw the setscrew into the springhousing Recommended torques Make sure that the regulator is completely pressure less before you tighten the parts Bodyplug 50 Nm Springhousing 50 Nm Testing Check the regulator for leakage across the seat with low and high inlet pressure Check the regulator for leakage across the piston with low and high outlet pressure
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