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LP Gas Pressure Regulation

29 Apr.,2024

LP Gas Pressure Regulation

Propane Regulator - The Heart of the LP Gas System

The propane gas regulator is one of the most important parts of a propane gas system. The purpose of the regulator is to control the flow of gas and lower the pressure from the LP Gas tank to the appliance(s) in the gas system. The regulator not only acts as a control regarding the flow and distribution of propane but also as a safety barrier between the high pressure of the tank and the end use appliance(s). Most will rightfully argue that the LP Gas regulator is the heart of any propane gas system.

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Purpose of a Propane Regulator

Propane tank pressure can range from under 10 psig to over 200 psig. Residential applications will generally require 11 inches water column (amount of pressure required to push a column of water up 11 inches in a manometer, or about 6.3 ounces per square inch) and the regulator compensates for these pressure differences in the tank to supply a steady flow of required pressure to the household appliances. Not all applications are similar to that of residential use and will therefore utilize regulators for higher and lower pressures as required by the appliance(s). In summary, the purpose of a propane regulator is to "bottleneck" the propane down to a safe and usable pressure. An important point to note is that under normal operation, a propane regulator will make a "humming" noise. This is normal and should not be construed as a problem or regulator malfunction.

Types of Propane Tank Regulators

Although the purpose of a propane regulator is the same, different applications require different types of regulators. Regulator selection is determined solely by the propane application requirements. The demand downstream of the regulator is what determines what type of regulator is to be installed and where it's to be placed within the system. Some propane systems incorporate multiple regulators for efficiency while others such as a grill need only a low BTU grill regulator. Types of regulators include:

High Pressure Regulators
First Stage Regulators
Second Stage Regulators
Integral Two-Stage Regulators
Adjustable High Pressure Regulators
Automatic Changeover Regulators

"A regulator is a regulator" is a misleading statement that many consumers believe to be true. The fact is that installing the wrong kind of LP Gas pressure regulator will generally render a propane gas system inoperable. People don't realize that buying an LP Gas regulator from a friend or an internet site will more than likely result in wasted money. Regulators aren't all the same regardless of what one may think and an improper regulator or faulty LP Gas regulator installation means the entire installation is illegal and unable to be serviced until fixed. Keep in mind that replacing the regulator means interrupting the flow of gas and a leak check is required before the gas can be turned back on. Don't put yourself in danger by attempting to buy and install your own regulator. Call your propane company or a licensed LP Gas plumber. It will be safer and cheaper in the long run.

Protecting and Replacing LP Gas Regulators

Like any part of a propane system, the regulator needs to be protected. Protecting a regulator, for the most part means keeping it covered. Regulators are generally found under the tank dome or if installed outside the dome, they will have the vent pointed down. The vent is pointed down to prevent rain, ice and debris from entering the regulator. The vent should have a screen that keeps insects out of the regulator as some insects, such as the Mud Dauber (a.k.a. Dirt Dauber) will make a nest in a regulator that's missing its protective vent screen. Unprotected regulators that are exposed or not pointed with the vent facing down can easily be protected by cutting an empty plastic milk bottle to fit over the regulator until its placement and position can be corrected.

Regulators have internal moving parts that are subject to wear and tear and after some time, the regulator needs to be replaced. Propane companies can tell consumers when the regulator needs to be replaced due to age or malfunction and the consumer needs to take this advice seriously. The industry norm is 15 years before a regulator needs replacement while some regulator manufacturers recommend replacement every 25 years. If any regulator has ever been under water, such as on an underground propane tank, it needs to be replaced immediately. One very important fact to point out is that although propane regulators may be adjusted by licensed propane professionals, they are not repaired or subject to repair. They are replaced.

Propane Regulators: how they work

All regulators are made up of similar components and even though there are variations in features between manufactures, the basic components are the same in most propane regulators.

The basic parts that make up a regulator include:

Body: the main physical portion of the regulator and typically is the lower portion.

Cover: the upper part of the body and is typically color coded for its type of service. For example red could be for high pressure.

Inlet port: where the source gas vapor enters the regulator

Outlet

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port: where the source gas vapor exits the regulator.
Orifice: determines the amount of vapor that can pass into the regulator.
Lever: as the flow of vapor passes the orifice the lever pushes up on the diaphragm.
Diaphragm: senses pressure and starts and stops the flow of gas vapor through the regulator.
Main Spring: provides tension (force) on the diaphragm to regulate flow.
Relief: if excess pressure flow beyond the capacity of the regulator occurs, the relief mechanism (spring) allows the propane vapor to exit through the relief. This prevents excess pressure to build through the outlet or downstream of the regulator.
Vent: typically built into the cover and allows the regulator to breathe during normal operation; also it is typically where the relief mechanism discharges.
Vent Screen: keep debris from entering the regulator.
Dust Cap: allows you to visually see into the cover, retainer nut, and main spring.

Types of Propane Regulators

Although the purpose of propane regulators is the same, there are many different types of regulators, designed to fit many different applications or functions.

Sizing a regulator correctly for the load on the system is also very important. The typical types of regulators used in residential applications include:

First Stage (High Pressure)

– Typically placed at the container and decreases the container pressure to 10 psi (0,70 bar).
Second Stage (Low Pressure)

– Typically placed at the residence and decreases the pressure from the first stage regulator to inches of water column (11 typically).
Integral Two-Stage (Twin)

– Some smaller load systems can accomplish taking the container pressure down to inches of water column by utilizing a regulator that has both stages built into a single regulator, sometimes referred to as a twin stage or piggyback regulator.
Automatic Changeover

– Similar to an Integral Two-Stage regulator in regard to pressure regulation, but also has a mechanism which allows it to monitor vapor pressure switching from one tank to another in a multi-tank installation where 2 or more cylinders are being used for the source.
Two pound (2 lb.)

–Typically placed at the residence and decreases the pressure from first stage regulator to two pounds. Used in newer systems where the gas vapor demand is needed, and requires additional regulation before the appliance.
Line (appliance)

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–Typically placed before the appliance and decreases the pressure from two pounds to inches of water column (11 typically). There is no integral relief and typically uses a vent limiter.

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