RM-1306-1 Rev. 12 Regulator Installation and Maintenance Instructions 243 Service Regulators Introduction Installation and Start Up (See Illustrations on Page 3.) The 243 is a large capacity general-purpose gas pressure regulator. 1. Make certain that regulator and piping are free of dirt, moisture, foreign matter and other debris. Its outstanding performance and versatility make it an excellent choice for use on industrial meter sets, combustion equipment, 2. Be sure all shipping screens or covers are removed and boilers, burners, unit heaters, furnaces, ovens and other appli- regulator is installed with flow in correct direction. cations. 3. Regulator may be installed in any position; right-side-up, up- Use it for natural gas, air, dry CO , propane, butane, L.P.G., 2 side down, vertical pipe, horizontal pipe, diagonal pipe, etc. nitrogen, and others. Special materials are available for cer- tain corrosive gases. By loosening union bolts (16), the diaphragm case assembly In addition to the standard models and internal relief models may be rotated to various positions in relation to the body. covered in this bulletin, the 243 is also available with low pres- Make certain (16) are re-tightened to hold diaphragm case sure cut-off, with built-in monitor, and as a pilot operated regu- assembly in new position and to reseal. lator (outlet pressures to 35 psig), a back pressure valve, a relief valve, a vacuum regulator and a vacuum breaker. For CAUTION information, please contact your Sensus Sales Office or authorized industrial distributor. The 243 is manufactured in The diaphragm case vent must be positioned conformance with Code B31.8. to protect against flooding, drain water, ice formation, traffic, tampering, etc. The vent Note: The term standard refers to Non-IRV configurations. must be protected against nest building animals, bees, insects, etc. to prevent vent Model Specifications blockage and minimize the chances for foreign material from collecting in the vent 243-12-1 and 243-12-2 side of the regulator diaphragm. Maximum Inlet Pressure.........................................125 psi 1 Outlet Pressures......................................3 ⁄2” w.c. to 3 psi 4. Make sure there are no leaks and all connections are firm 1 1 Pipe Sizes................................................ 1 ⁄4”, 1 ⁄2” and 2” and tight. Tighten flange bolts evenly and firmly. On screwed Diaphragm..................................... 12” (nominal diameter) connections apply pipe dope to male threads only. 243-8-1 and 243-8-2 Maximum Inlet Pressure.........................................125 psi 5. On regulators arranged for External Control Line, run pipe 1 1 Outlet Pressures..................................3 ⁄2” w.c. to 4 ⁄4” psi 1 or tubing from ⁄2” NPT connection in lower case to the con- 1 1 Pipe Sizes................................................ 1 ⁄4”, 1 ⁄2” and 2” trol connection in the outlet piping. This control piping Diaphragm....................................... 8” (nominal diameter) 1 should not be less than ⁄2” in size and should be adequately 243-8HP protected against breakage (regulators go wide open if the Maximum Inlet Pressure.........................................125 psi control line is broken). In general, the control connection Outlet Pressures................................................3 to 10 psi should be at least 8 pipe diameters from the regulator and in 1 1 Pipe Sizes................................................ 1 ⁄4”, 1 ⁄2” and 2” as straight a run of pipe as possible. The connection itself Diaphragm....................................... 8” (nominal diameter) must be smooth on the inside of the pipe. Pitch the control line away from the regulator and avoid moisture pockets. Maximum Inlet Pressures Keep inside of control line clean. Never install any type of automatic shut-off device, which closes completely, between ORIFICE SIZE - VALVE 243-12 243-8 the regulator outlet and the control line connection. O 1 1 ⁄4” - 30 ••• 15 psi O 1 1 ⁄4” - 10 25 psi* ••• CAUTION O 1” - 30 25 psi 25 psi O 25 psi 1” - 10 40 psi* It is the user’s responsibility to assure that all O 3 40 psi ⁄4” - 30 40 psi regulator vents and/or vent lines exhaust to a O 3 40 psi ⁄4” - 10 60 psi non-hazardous location away from any potential t O 1 80 psi ⁄2” - 10 100 psi sources of ignition. Where vent line are O 3 100 psi ⁄8” - 10 125 psi used, it is the user’s responsibility to assure O 1 125 psi ⁄4” - 10 125 psi that each service regulator is individually vented O 125 psi .207” - 10 ••• and that common vent lines are not used. * Applies only to 243-12 with external control line. 80 psi for 243-12 with external control line t 6. Adjust outlet pressure (set point) by removing cap (1) or (1e) and turning adjustment spring button (3). On 243-8 HP Temperature Limits remove cap (1a), loosen locknut and turn adjustment screw The Model 243 Service Regulators can be used for flowing O O (1b). Turn clockwise to increase and counter-clockwise to temperatures from -20 F to 150 F. decrease outlet pressure. Only adjust when gas is flowing through regulator. When adjustment is completed, seal cap Buried Service (1) or (1e) must be securely screwed into place. The The Model 243 Service Regulators are not recommended for absence of this seal cap can result in unstable operation. buried service. Installation and Start Up (Continued) Condensed Parts List 7. On regulators with Internal Relief Valve, there is no The following are the parts generally required in mainte- adjustment for the internal relief. It is fixed, with relief begin- nance and servicing. For a listing of all parts refer to Parts ning at approximately 9” w.c. to 20” w.c., above regulator set List RP-1306 point, depending on relief spring (11k) used. ILL. Part No. Description Number Internal Relief Valves must be carefully sized. For informa- tion, contact your Sensus Representative. 1 143-16-005-00 Cover Cap (IRV) 1e 143-16-005-08 Cover Cap (STD) 6. Regulators installed indoors must be vented outside. Run 1 5 1d Tetraseal 1 ⁄2 x 1 ⁄8” 906534 vent pipe from regulator vent connection to safe place out- 2 951357 O-Ring #2-140 side. Vent piping should be as short and direct as possible. 2a 951376 O-Ring #2-142 3 143-16-009-00 Adjustment Spring Button Vent piping for regulators with internal relief valve (Models 4 Spring (See Table, 1st page) 243-12-2 or 243-8-2) must be large enough to vent all relief 5 243-12 Cover Assembly IRV (includes valve discharge to atmosphere without excessive back pres- 143-16-503-03 vent valve and spring) sure and resulting excessive pressure in regulator. 243-12 Cover Assembly STD (includes vent valve and spring) 143-16-503-19 Vent pipe outlet must be protected against nest building ani- 243-8 Cover Assembly (includes vent mals, bees, insects, etc., and positioned to protect against 143-82-503-04 valve and spring) flooding, drain water, ice formation, etc. but must allow free 5 8 910030 Flange Bolt, ⁄16 x 1” Hex Hd and unobstructed passage of air or gas. 5 9 Flange Nut, ⁄16 - 18 Hex S.F. 921002 10 143-16-002-00 243-12 Lower Case CAUTION 243-12 Lower Case (tapped for exter- Turn gas on very slowly. If an outlet stop valve is used, it should be opened first. 143-16-002-01 Do not overload the diaphragm with a sudden surge of inlet pressure. Monitor nal control line) the outlet pressure during start-up to prevent an outlet pressure overload. 243-08 Lower Case 143-82-002-00 243-08 Lower Case (tapped for exter- Servicing 143-82-002-01 nal control line) 11a 143-16-150-00 243-12 Diaphragm 1. Make sure the regulator is entirely depressured before 243-8 Diaphragm 143-82-150-00 disassembling. 121-10-150-50 243-8 HP Diaphragm 11b 143-16-017-00 243-12 Diaphragm Pan 2. Carefully note location and position of all disassembled 143-82-017-00 243-8 Diaphragm Pan parts to be certain reassembly is correct. Inspect each part 243-8 HP Diaphragm Pan 121-10-017-50 and replace those that are worn or damaged or otherwise 11d 143-16-115-00 unsatisfactory. Seal Washer 11e Emery Cloth Washer (faces against 143-82-178-00 top side of 243-8 HP diaphragm) 3. For access to valve (21) and orifice (24) loosen union 11f Spring guide 143-16-018-00 bolts (16) and remove diaphragm case assembly from body. 121-10-022-53 Spring guide (243-8 HP) 11k Internal Relief Valve Spring, To remove valve (21), first remove hair pin cotter (20b). 143-82-021-03 for 243-8-2 only. (relief begins at approx. 9” w.c. Orifice (24) unscrews from body. Use 1-5/8” hex socket “thinwall” type. When replacing orifice use moderate above regulator set point) 11k 143-16-021-02 Internal Relief Valve Spring amount of pipe dope on orifice threads. (relief begins at approx. 9”w.c. for 243-12-2, and approx. 4. Before reassembling and tightening union bolts (16), make certain Tetraseal (17) is in position. 20” w.c. for 243-8-2 above regulator set point) 11s 121-10-022-52 243-8 HP Diaphragm Plate 5. To replace diaphragm; remove spring (4), remove flange 13 243-12 Coupling-Lever- bolts (8) and nuts (9), and disassemble diaphragm assem- 143-16-530-00 bly. Remove old diaphragm (11a) from diaphragm pan Stem Assembly 243-8 Coupling-Lever- (11b). Remove old adhesive from the diaphragm pan using 143-82-530-00 Stem Assembly a solvent such as methyl ethyl ketone (MEK). 243-8 (HP) Coupling-Lever- 143-82-530-02 To reassemble, apply a thin, even layer of a rubber based Stem Assembly 3 1 16 910056 Union Bolts, ⁄16” x 1 ⁄4” Hex adhesive such as 3M Industrial Adhesive #EC-847 to the 1 1 17 904075 Tetraseal (or O-Ring) 2 ⁄4 x 2 ⁄2” cleaned, prepared side of the diaphragm pan. 18 243-8 Throat Block with O-Ring Seal 143-16-508-00 143-16-508-04 Attach the diaphragm to the adhesive side of the diaphragm 243-12 Throat Block with O-Ring Seal 20b 143-62-118-00 Hair Pin Cotter pan, being careful to align the center hole of the diaphragm o 21 143-16-511-09 Valve Assembly - 10 - Buna N with the corresponsing center hole in the diaphragm pan. o Valve Assembly - 10 - Viton 143-16-511-11 Make certain all parts are reassembled in their correct order o 143-16-511-10 and bolts (8) are tightened to a torque of 150 in-lbs. Bolts Valve Assembly - 30 - Buna N o 143-16-511-12 Valve Assembly - 30 - Viton must be tight enough to prevent leakage but not too tight 1 24 143-16-023-03 1 ⁄4” Orifice, Brass that the diaphragm material is crushed or damaged. 1” Orifice, Brass 143-16-023-02 Diaphragm must not be twisted or pinched. 3 143-16-023-01 ⁄4” Orifice, Brass 1 143-16-023-00 ⁄2” Orifice, Brass 6. Upon completion of servicing, make certain that regulator 3 143-16-023-04 ⁄8” Orifice, Brass installation is entirely free of leaks. 1 ⁄4” Orifice, Brass 143-16-023-10 CAUTION 143-16-023-11 .207” Orifice, Brass Regulators are pressure control devices with numerous moving parts subject to 25 143-16-060-02 Travel Stop Stem wear that is dependent upon particular operating conditions. To assure continuous 26 143-16-136-05 Warning Tag-Travel Stop satisfactory operation, a periodic inspection schedule must be adhered to with 27 Warning Tag-Body Interchangeability 143-16-136-06 the frequency of inspection determined by the severity of service and applicable 28 143-16-102-01 laws and regulations. Clamping Plate Denotes recommended spare parts 2 14” Dia. 13 10 ⁄32” Model 243 Regulator Illustrations 1 2 3 243-12-2 3 9 ⁄4” (IRV COVER CAP) 4 I.R.V. Regulator 10” (STD COVER CAP) Vent - as shown - 5 11 k 1” NPT 1 1b 1 1a 16 20b 21 24 243-12-1 5 ⁄8” Same as I.R.V. Regulator except no Internal Relief Valve and Standard Cover Cap as shown in inset. 8 7” or 10” PIPE SIZES 9 2” Flanged ANSI 125 lb FF 1 10 11 d 1 1f 13 1 ⁄2” and 2” Screwed 17 Drilled and Tapped 1e 28 1 ⁄2” NPT on regulators 27 arranged for External 25 26 Control Line 2a 18 19 STANDARD 11 d CAP 25 10 21 1 1a 243-8-1 243-8 HP Standard Regulator THROAT BLOCK - as shown - 13 11 d WITH O-RING SEAL Remainder of regulator (for regulators arranged same as 243-8-1 for External Line Control) STANDARD 243-8-2 PIPE SIZES 11 k DIAPHRAGM 5 2” Flanged ANSI 125 lb FF ASSEMBLY Same as Standard 1 1 11 a 1 ⁄4”, 1 ⁄2” and 2” screwed Regulator except Internal Relief Valve as 13 1 1d shown in inset. INTERNAL PIPE SIZES RELIEF VALVE 2” Flanged ANSI 125 lb FF 1 1 1 ⁄4”, 1 ⁄2” and 2” screwed 3 10 ⁄16” Dia. 1d 1 2 2 3 4 Vent 4 15 5 15 ⁄16” 1” NPT 5 3 9 ⁄4” 1 1f 11 b 16 21 1 1a 20b 24 1 1s 11 a 5 11 b ⁄8” 1 1e 8 7” or 10” 9 11 d 10 11 f 13 10 1 28 17 Drilled and Tapped ⁄2” NPT 13 on regulators arranged for External Control Line 19 8 ⁄32” 3 Maximum Emergency Pressures Full Open Capacity The maximum pressure the regulator inlet may be subjected Use the following formulae for the full open capacity for 243 to under abnormal conditions without causing damage to the regulators. regulator is the maximum inlet pressure (from the table P I below) plus 50 psi. 1. Q = K P (P - P )..............(for less than 1.894) o I o P o The maximum pressure the diaphragm may be subjected to P I KP without causing damage to the internal parts of the regula- I 2. Q = ....................(for greater than 1.894) P tor is: o 2 243-12-1..................................................set-point+3 psi 243-12-2, 243-8-1 and 243-8-2...............set-point+5 psi Q = maximum capacity of the regulator (in SCFH of 243-8HP...................................................set-point+5 psi 0.6 specific gravity natural gas.) Set point is defined as the outlet pressure a regulator is K = the “K” factor, the regulator constant adjusted to deliver. (from the table) P = absolute inlet pressure (psia) I If any of the above pressure limits are exceeded, the regulator P = absolute outlet pressure (psia) o must be taken out of service and inspected. Damaged or oth- erwise unsatisfactory parts must be repaired or replaced. 1 3 1 3 1 Orifice Size-in. .207” ⁄4” ⁄8” ⁄2” ⁄4” 1” 1 ⁄4” The maximum pressure that can be safely contained by the diaphragm case is: K 90 132 292 520 1100 1800 2480 243-12-1 and 243-12-2...............................................15 psi 243-8-1 and 243-8-2.................................................. 45 psi 243-8HP.......................................................................45 psi Other Gases Safely contained means no leakage as well as no bursting. 243 Regulators are mainly used on natural gas. However, they perform equally well on LP gas, nitrogen, dry CO air 2 Before using any of the above data, make sure this entire sec- and others. tion is clearly understood. For capacities, multiply the table values on pages 8 thru 19 Note:The use of an internal or external relief valve is rec in Bulletin R-1306 by the following correction factors: ommended for installations subjected to no flow for extended periods of time such as pilotless OTHER GASES CORRECTION FACTOR ignition systems. A travel stop stem is located in the 243-12-1 and 243-12-4 to provide over pres Air (Specific Gravity 1.0) 0.77 surization protection to internal components dur ing overpressurization. Propane (Specific Gravity 1.53) 0.63 1350 BTU Propane-Air Mix (1.20) 0.71 Spring Ranges Nitrogen (Specific Gravity 0.97) 0.79 SPRING OUTLET PRESSURE RANGE PART COLOR NUMBER 243-12 243-8 Dry Carbon Dioxide (Specific Gravity 1.52) 0.63 Red 143-16-021-03 3 1/2” to 6 1/2” w.c. ••• Red-Black 143-82-021-00 ••• 3 1/2” to 6 1/2” w.c. 0.6 Blue 143-16-021-04 5” to 8 1/2” w.c. ••• For other noncorrosive gases: Specific Gravity Blue-Black 143-82-021-01 ••• 5” to 8 1/2” w.c. CORRECTION FACTOR of the Gas Green-Black 143-82-021-02 ••• 6” to 14” w.c. Green 143-16-021-05 6” to 14” w.c. 12” to 28” w.c. Orange-Black 143-16-021-11 10” to 18” w.c. ••• Orange 143-16-021-06 While used primarily for natural gas services, Model 243 12” to 28” w.c. 1 to 2 psi Black 143-16-021-07 1 to 2 psi 2 to 4 1/4 psi regulators perform equally well on LPG vapor, air, dry CO 2 • Cadmium 143-16-021-08 1 1/2 to 3 psi 3 to 5 psi nitrogen and other inert gas applications. Please contact Cadmium 143-16-021-08 1 1/2 to 3 psi 3 to 6 1/2 psi* your Sensus representative for special construction which Cadmium 143-16-021-08 ••• may be available for certain corrosive gases. 6 to 10 psi* } White 143-16-021-13 ••• t Note: The term standard refers to Non-IRV configurations. White is nested inside Cadmium *243-8 HP only t • 243-8-2 (IRV) only Monitoring The Model 243 Regulators make excellent monitors. They can act as standby regulators installed in series which assumes control if a failure in the operating regulator permits the outlet pressure to exceed the set-point. It can be located in either the upstream or the downstream position. When a Model 243 Regulator is used to monitor a regulator with an identical inner valve (another 243 Regulator), the total maximum capacity through both regulators can be figured at 70% of the capacity of one regulator alone. This applies with the monitor located either up or downstream. 4 o CONDENSED CAPACITY TABLE IN SCFH OF NATURAL GAS (O.6 Specific Gravity-14.65 psia-60 F.) OUTLET PRESSURE SER POINT and SPRING ORIFICE INLET SIZE 6” w.c. 7” w.c. 11” w.c. 18” w.c. 1 psi 2 psi and RED BLUE GREEN ORANGE BLACK CADMIUM PRESSURE VALVE SPRING SPRING SPRING SPRING SPRING SPRING psi (1” w.c. (1” w.c. (2” w.c. (3” w.c. (0.2 psi (0.6 psi ANGLE droop) droop) droop) droop) droop) droop) O 1 2 1 ⁄4”-30 6,400 6,000 5,600 4,200 3,350 •••• O 1 5 1 ⁄4”-30 11,000 11,000 10,500 8,000 6,600 8,200 1 O 15 1 ⁄4”-30 14,000 14,000 14,000 13,500 13,000 15,500 O 25 1”-30 15,000 15,000 15,000 16,500 15,000 18,000 2” O 3 40 ⁄4”-30 20,000 20,000 20,000 20,000 20,000 20,000 243-12 O 3 60 ⁄4”-10 15,000 15,000 15,500 15,000 15,500 16,500 1 O 100 ⁄2”-10 13,000 13,000 14,000 14,000 14,000 16,000 3 O 125 ⁄8”-10 12,000 12,000 12,000 12,000 12,000 12,000 O 1 2 1 ⁄4”-30 4,000 3,800 4,000 3,000 2,800 •••• 1 O 5 1 ⁄4”-30 6,100 5,700 6,000 5,600 5,500 6,000 1 O 15 1 ⁄4”-30 9,300 9,300 10,000 10,000 10,000 13,000 1 1 ⁄2” O 25 1”-30 11,000 11,000 11,500 11,500 11,000 14,500 O 243-12 3 60 ⁄4”-10 12,000 10,500 12,500 12,500 12,500 15,000 1 O 100 ⁄2”-10 12,000 12,000 12,500 13,000 13,000 16,000 3 O 125 ⁄8”-10 11,000 11,000 11,000 11,000 11,000 12,000 O 5 1”-10 8,200 6,500 7,200 5,500 5,400 6,800 1 O * 5 1 ⁄4”-10 10,500 7,800 8,500 6,500 7,000 8,600 O 10 1”-10 12,000 10,000 11,000 8,000 8,500 10,500 1 1 ⁄2” and 2” 1 O * 10 1 ⁄4”-10 15,000 13,000 13,500 11,000 10,500 13,000 O 243-12 25 1”-10 20,000 17,000 17,000 15,000 14,500 20,000 1 O * 25 1 ⁄4”-10 22,000 20,000 20,000 18,000 18,000 25,000 with External O 40 1”-10 24,000 21,000 24,000 21,000 20,000 25,000 Control Line 3 O 80 ⁄4”-10 30,000 21,000 27,000 22,000 22,000 25,000 1 O 100 ⁄2”-10 19,000 19,000 19,000 19,000 19,000 19,000 O 3 125 ⁄8”-10 15,000 15,000 15,000 15,000 15,000 15,000 2” size only. OUTLET PRESSURE SET POINT and SPRING ORIFICE SIZE 6” w.c. 7” w.c. 18” w.c. 1 psi 3 psi 5 psi* 10 psi* INLET AND RED-BLACK BLUE-BLACK GREEN ORANGE BLACK CADMIUM CADMIUM and PRESSURE VALVE SPRING SPRING SPRING SPRING SPRING SPRING WHITE SPRING psi ANGLE (1” w.c. (1” w.c. (3” w.c. (0.2 psi (0.6 psi (1 psi (2 psi droop) droop) droop) droop) droop) droop) droop) O 2 1”-30 3,200 2,700 2,100 2,100 •••• •••• •••• O 10 1”-30 7,400 7,000 6,600 6,500 7,100 6,000 •••• O 1 25 1”-30 12,500 12,500 11,500 11,000 12,500 12,000 12,000 1 ⁄2” 3 O 40 ⁄4”-10 10,500 10,500 11,000 11,000 13,000 12,000 15,000 243-8 1 O 80 ⁄2”-10 11,500 11,500 12,000 11,500 13,500 11,000 17,000 O 3 100 ⁄8”-10 11,000 11,000 11,000 11,000 12,000 11,000 15,000 O 1 125 ⁄4”-10 8,000 8,000 8,000 8,000 8,000 8,000 9,000 3 O 2 ⁄4”-10 2,250 1,700 1,900 1,850 •••• •••• •••• O 3 10 ⁄4”-10 3,100 2,900 2,950 2,700 3,600 3,300 •••• 3 O 25 ⁄4”-10 4,200 4,200 4,400 4,150 5,000 4,400 9,000 1 1 ⁄4” 3 O 40 ⁄4”-10 4,200 4,800 5,300 5,300 6,300 5,800 12,000 243-8 1 O 80 ⁄2”-10 5,600 5,600 4,850 4,650 5,500 4,500 13,000 O 3 100 ⁄8”-10 6,000 6,000 6,000 6,000 6,550 6,000 13,000 1 O 125 ⁄4”-10 6,000 6,000 8,000 8,000 8,000 8,000 8,800 O 5 1”-30 5,500 4,000 4,400 •••• •••• O 10 1”-30 9,400 7,000 7,600 6,000 •••• O 25 1”-30 14,500 14,500 15,000 13,000 15,500 2” 3 O 40 ⁄4”-30 20,000 17,500 17,500 12,000 22,000 243-8 1 O 80 ⁄2”-10 14,000 13,500 15,000 11,500 18,500 O 3 100 ⁄8”-10 12,000 11,000 12,000 11,000 16,000 1 O 125 ⁄4”-10 8,000 8,000 8,000 8,000 9,000 Refer to Bulletin R-1306 for detailed capacity tables and curves. *243-8HP only. 4