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Maintenance and Inspection

Maintenance is an important factor in ensure the systems performance and service life of the regulator. Only trained persons can perform checks on gas regulators and other equipment supporting the gas delivery. It is recommended that the user purchases a new component, or if refurbishment is necessary, then the component is returned back to the manufacturer for refurbishment to take place.

The table below is a general guide for regulators which perform the function of the protective device. Other plant/equipment in the sytem may also require inspection and maintenance. Where a pressure relief valve is downstream of a regulator which is capable of discharging the regulator flow, then this becomes the proctective device. In these situations the regulator will not need to be changed but will still be subject to a functionality checks as detailed below. Always consult the equipment manufacturers information and instructions.

Regulators

Leak Check
Creep Test
Inert Purge
Maintenance
Replacement
Monthly Annual N/A N/A 5 years


Corrosive gases must use regulators declared as suitable for a corrosive gas. If a standard regulator is used it will not last 5 years and will result in failure.

Ensure the correct regulator is used for the type of gas, the volume and pressure required.

Leak Check

With regulator under pressure, check all connections with appropriate gas detector. Shut down gas source if leak is detected. Tighten or redo connection. If you are using toxic or corrosive gases, you must purge the connection first with an inert gas. Retest.

Creep Test

Regulator creep occurs when delivery pressure rises above the setpoint and occurs two ways:

  • Changes to the motion of the regulator springs when gas flow is stopped
  • Foreign material becomes lodged between the poppet and seat preventing tight shutoff

Inert Purge

In order to maintain cylinder integrity and obtain optimum performance, ALL regulators should be purged. For best results, utilise dilution purging – where alternating pressurising and depressurising the regulator with purge gas helps eliminate internal dead pockets that tend to hold contaminants.

Overhaul

Remove all regulators from service periodically and maintain in accordance with manufacturers guidance - this can only be carried out by trained persons. Alternatively arrange for the manufacturer to carry out the work.

Replacement

Once the life expectancy of a regulator has been exceeded, it should be replaced to protect against unexpected failure.

Other Plant/Equipment

Pressure relief valves

Examined every 6 years and valves replaced as necessary, refer to manufacturers information.

Flame Arrestors

Examined every 5 years and replace as necessary, refer to manufacturers information.