A pressure regulator is a valve that controls the pressure of a fluid or gas to a desired value, using negative feedback from the controlled pressure. It helps to maintain control in pressure-related industrial applications which is important to the success of an operation in terms of both performance and safety.

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How does a Pressure Regulator Works?

A pressure regulator reduces a supply (or inlet) pressure to a lower outlet pressure and works to maintain this outlet pressure, despite fluctuations in the inlet pressure. The reduction of the inlet pressure to a lower outlet pressure is the fundamental characteristics of pressure regulators.

So, the main pressure regulator function is to match the flow of gas through the regulator to the demand for gas placed upon it, whilst maintaining a constant output pressure. If the load flow decreases, then the regulator flow must decrease also. If the load flow increases, then the regulator flow must increase in order to keep the controlled pressure from decreasing due to a shortage of gas in the pressure system.

Gas Cylinder Pressure Regulator Types

Most pressure regulators are either single-stage or two-stage devices selected based on applications.

At VIGO we offer a wide range of single-stage and two-stage (Also called double stage regulators) gas regulators for Inert, ultra high pure, flammable, Oxidizing, toxic and corrosive gas. Vigo regulators are meticulously designed to offer high leak integrity meeting your most demanding applications.

All our products compliance verification has been carried out against EN ISO 2503:2009 CLASS 2258 02 and ISO 13857:2019.

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This article is an overview on some key information on the single-stage regulator and two-stage regulators.

What is a Single Stage Gas Regulators?

Single-stage gas pressure regulators reduce cylinder pressure to delivery or outlet pressure in one step. A single-stage regulator is recommended where inlet pressure does not vary greatly or where periodic readjustment of delivery pressure does not present a problem.

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How does a Single stage Regulator work?

High-pressure gas from the supply enters into the regulator through the inlet valve. The gas then enters the body of the regulator, which is controlled by the needle valve. The pressure rises, which pushes the diaphragm, closing the inlet valve to which it is attached, and preventing any more gas from entering the regulator. The outlet side is fitted with a pressure gauge. As gas is drawn from the outlet side, the pressure inside the regulator body falls. The diaphragm is pushed back by the spring and the valve opens, letting more gas in from the supply until equilibrium is reached between the outlet pressure and the spring. The outlet pressure, therefore, depends on the spring force, which can be adjusted using an adjustment handle or knob.

The outlet pressure and the inlet pressure hold the diaphragm/valve assembly in the closed position against the force of the large spring. If the supply pressure falls, it is as if the large spring compression is increased allowing more gas and higher pressure to build in the outlet chamber until an equilibrium pressure is reached. Thus, if the supply pressure falls, the outlet pressure will increase, provided the outlet pressure remains below the falling supply pressure. This is the cause of the end-of-tank dump where the supply is provided by a pressurised gas tank. With a single-stage regulator, when the supply tank gets low, the lower inlet pressure causes the outlet pressure to climb. If the spring compression is not adjusted to compensate, the valves can remain open and allow the tank to rapidly dump its remaining contents. In other words, the lower the supply pressure, the lower the pressure differential the regulator can achieve for a given spring setting.

What is a Two-Stage or Double stage Regulators?

Two-stage regulators are designed to lower the high pressure in two stages. They require less readjustment and provide a more constant delivery pressure despite changes in inlet pressure. They are exceptionally well suited for high pressure cylinder applications.

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How does a Two stage or Double stage regulator work?

Two-stage regulators are two single-stage regulators in one that operates to reduce the pressure progressively in two stages. The first stage, which is present, reduces the pressure of the supply gas to an intermediate stage; gas at that pressure passes into the second stage. The gas now emerges at a pressure (working pressure) set by the pressure adjusting control knob attached to the diaphragm. Two-stage regulators have two safety valves for added protection. A major objection to the single-stage regulator is the need for frequent torque adjustment. If the supply pressure falls, the outlet pressure increases, necessitating torque adjustment. In the two-stage regulator, there is automatic compensation for any drop in the supply pressure. Single-stage regulators may be used with pipelines and cylinders. Two-stage regulators are used with cylinders and manifolds. Two-staged regulators are recommended for applications that require a constant outlet pressure for the life of a gas cylinder.

Single-Stage versus Two-Stage Regulators

But what’s the difference between single and two-stage regulators?

Single-stage gas pressure regulators reduce cylinder pressure to delivery or outlet pressure in one step. Two-stage gas pressure regulators reduce cylinder pressure in two steps. As gas cylinder pressure decreases, single-stage regulators produce minor fluctuations in delivery pressure, and delivery pressure also declines as the flow rate rises. In contrast, a two-stage regulator provides a more constant pressure level under a range of diverse operating conditions. This is due to the two-step process between cylinder pressure reduction and delivery pressure, which lowers the effect of delivery pressure fluctuations on regulator operations. The potential for lockup, which is the pressure increase beyond the delivery point that can cause flow to cease, is also higher for single-stage regulators than it is for their two-stage counterparts. Since mechanical characteristics influence the performance of each regulator, the choice depends on requirements.

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