Working in the HVAC, combustion, propane, and industrial markets requires tools and equipment that can handle the demands of process complexity in a safe and efficient manner. One area you should never skimp on is that of your gas regulators.
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These handy devices work hard to ensure the gas flowing through the lines into the equipment does so at the right pressure. Too much gas pressure can lead to a catastrophic explosion, harming others and destroying property. Conversely, not having enough pressure will render your equipment useless.
We understand that the world of regulators can be a little confusing. Each type serves a different purpose based on the application. Although you can rely on experts like us to help you out, understanding what a regulator is, how it works, the difference between pressure reduction and pressure regulation, and dual-stage vs. single-stage, will aid you in finding the best product for the job.
Here is a breakdown of what you need to know about gas regulators, whether it's a natural gas regulator or a propane gas regulator.
Designed in , the regulator's concept is easy, and its impact has been long-lasting. There are various types of regulators, but their function is the same: to use a valve system to control natural gas or propane pressure or other gas flow.
Common appliances that use regulators include gas stoves, propane grills, or oxy-fuel bottles for welding. Each type of regulator's components consists of a set spring attached to a rod that runs down from a set screw through a diaphragm into the valve.
There are three primary operating components working together to regulate the pressure within the valve. The loading mechanism determines the delivery pressure. Most often, it is a spring. The sensing element, or diaphragm, senses the force against the spring. Finally, the control element accomplishes the reduction of the inlet pressure through to the outlet pressure.
Gas enters the regulator's chamber, putting pressure on the diaphragm. The diaphragm then moves upward as controlled by the set spring. This allows a specific flow of fuel from the source to the appliance or device. Adjusting the control knob determines the rate of flow and the pressure. Turning clockwise will push the diaphragm down and allow more gas to come into the valve. Turn counter-clockwise to reduce the amount of fuel and pressure.
B38 Series Line and Service Regulator from Itron
The mechanics of the gas regulator work well together. However, there is another component that comes into play called the surrounding air. Atmospheric pressure, based on the elevation above sea level that the building sits, will affect gas pressure. The inner parts work by sensing the pressure both upstream and downstream. The air pressure affects the way the regulator senses downstream pressure.
The application between the two types is the main difference. A pressure reduction regulator is used to reduce the input pressure of the gas, so that it is at the ideal pressure on the outset. It is a normally open valve installed upstream of the pressure-sensitive equipment it needs to regulate, as it controls downstream pressure.
Pressure regulation is often called a back-pressure regulator or back-pressure valve. Its purpose is to maintain a set pressure at the inlet. It is a normally closed valve and is installed in parallel with or just after sensitive equipment to maintain upstream pressure.
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Dual-stage regulators utilize two regulators within the same housing, which operate to reduce pressure in two steps instead of only one step. At the first stage, the pressure of the supply (inlet) gas is reduced at an intermediate stage, generally about three times the maximum working pressure. The second stage further reduces the pressure to a reasonable working pressure. Sometimes, a dual-stage regulator may have two safety valves to lessen the possibility of an explosion.
Dual-Stage Regulator (Source: Wikipedia ' author: Mintrick.)
Single-stage regulators only have one regulator in which the gas supply enters, and the pressure is reduced. The delivery pressure is not as controllable as a dual-stage one is; thus, it should be used in operations where it can be monitored and easily adjusted as required, or the source pressure is nearly constant. An example of a single-stage regulator is a line regulator.
Single Stage Regulator (Source: Wikipedia ' author: Mintrick.)
Choosing which type to use should be based on the required consistency of gas flow needed for operating. Consider what kind of gas flow is required, and then make your choice.
The types of regulators are extensive and include appliance, line and service, pilot operated, direct acting, high pressure, back pressure, relief valves, and propane regulators. You can even find specialty items such as high-purity regulators for those unique jobs. At Norgas Controls, you can find the right type of regulator for your specific needs.
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Norgas' team of experts can help you find the right gas regulator for your application from our extensive inventory or design a custom solution to meet your specific needs. We have an extensive inventory of gas regulators ready to ship within 24-hours of your order.
Need to set up a quote for a client? Contact us. We will give you everything you need, from pricing to literature, to provide your customer with an accurate quote that will give you a leg up against the competition. We are your one-stop-shop for all your gas regulators, meters, valves, and accessories.
Call us at 514-697- or 888-GAS-REGS (427-) for all your gas regulators, gas flow meters, and gas valve needs.
How does a gas valve work?
In a nut shell: The gas valve's thermal well senses the temperature of the water inside the water heater. If the temperature of the water is below the desired temperature setting indicated by the dial on the gas control valve, the gas valve will open the gas supply line, feeding gas into the burner chamber via the burner tube (aka burner manifold tube) so that the burner will be lit/remain lit by the pilot assembly's ignitor. During this process, the pilot assembly and thermal well send electric signals to the gas valve to ensure that the unit is operating safely, and to tell the gas valve when to stop allowing gas into the burner assembly.
What should the light on a gas valve do?
If your gas valve has a status light, the light should normally be green or blue. Also, it should flash, typically once every four seconds, indicating that the water heater is idle; alternatively, the light may also alternate from bright to dim, indicating that the unit is heating water. If the light is off, there is no electrical power to the unit; if there is any other flash sequence or the light is red, there is likely an issue with your unit. For details regarding your specific unit, please refer to your installation manual, where you can typically find a diagnostic and troubleshooting chart; some gas valve models may also have a label with flash codes and explanations directly on their face plate.
How do I know if my water heater's gas valve needs to be replaced?
The most common indications that your gas valve needs to be replaced include:
- Gas valve related flash code (see Flash Code Section below)
- No hot water or inconsistent hot water (although this could be caused by many other issues)
- If you have changed the pilot assembly and still do not have a consistent flame, it is probably the gas valve
How much do replacement gas valves cost?/Are replacement gas valves expensive?
This depends on three major factors: the age of the unit, the size of the unit, and the availability of the gas valve.
The cost of a residential gas valve is typically anywhere from $110.00 to $250.00 (or more) each. Prior to contacting a service provider, be sure to check and see if your water heater is still covered under warranty; during your call to the manufacturer, they may be able to confirm the diagnosis of a faulty gas valve and send you a replacement part. If your unit is still under warranty, they typically send the part for free, with the option to add expedited delivery for a fee.
The average gas valve replacement requires a technician to be on site for 45 to 60 minutes. In the event that you are responsible for the labor costs, a simple way to save some money of your service call will be to drain your water heater prior to the technician's arrival; this way, they will be able to verify the faulty gas valve diagnosis, remove the old gas valve, install the new gas valve, re-fill your unit, check for gas leaks, and ensure that your unit is functioning properly without having to wait for the water to drain.
If you want to learn more, please visit our website Lpg Regulators.