Sizing A Gas Regulator &#; An Overview

A gas regulator controls the overall amount of pressure in a combustible gas line. There are two basic types of gas regulators: one used with natural gas; the other with propane.

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Safe, efficient operation of all gas appliances requires low gas pressure. To obtain the right pressure it is critical to size the gas regulator correctly. If the gas regulator is too large, too much gas can flow into the appliance potentially causing an explosion. If too small, the appliance will not operate efficiently. At worst, it won&#;t operate at all.

What to Know and Do Before Buying a Gas Regulator

Think safety before sizing a gas regulator. Size the gas regulator according to the gas inlet pressure. For this information, contact your local gas company to find out where the inlet pressure is listed. Most of the time, it&#;s on the main gas meter for your home, but contact them directly to be sure.

Get the specifications included with operational instructions for the gas appliance. The specs should include British Thermal Unit (BTU) or the Standard Cubic Foot (SCF) for gas consumption. Read the outlet pressure required for the appliance and size the regulator, according to both the inlet and outlet gas pipe diameter. Most cases require that the inlet and outlet pipe diameters be the same. Designate which type of gas you are connecting to, natural gas or propane.

To summarize, before buying a gas regulator you need to know the following:

• Inlet pressure &#; can be given as inches water column, ounces, pounds.
• Outlet pressure &#; can be given as inches water column, ounces, pounds.
• Flow rate &#; maximum flow rate can be given as BTU/hour, Cubic Feet/hour.
• Pipe size &#; depends on the application and answers to the first 3 questions.
• Type of gas &#; normally natural gas, could be propane or another type of gas.
• Installation location &#; indoors or outdoors makes a difference in production selection.
• Generator application &#; if regulator is being installed for a generator it is sized to accommodate the initial surge of consumption during startup.
• Connected load, single appliance or multiple? Are any high efficiency?

Know and follow all local utility regulations when sizing a gas regulator as many local authorities require an inspection before the gas can be turned on for appliance operation.

Uses of Gas Regulators

Regulators are grouped in accordance with how fast they release gas to an appliance so there is a wide variation in size and shape of gas regulators. Though they have many different uses, there are two main types: high pressure and low pressure regulators.

High pressure regulators are designed to allow gas entering from a cylinder to do so at great force, then reduce the level and bring it to a level suitable for the appliance. They are often used with appliances that require powerful, concentrated heat output, including:

• commercial outdoor grills and barbecues
• gas torches for metal work
• roofing or road surface repairs
• blown-air heater for warehouse or barn use
• controlling gas furnaces
• controlling generators

Low pressure regulators are used with appliances that require a steady heat output. These include:

• portable indoor heaters
• camping stoves
• greenhouse or conservatory heaters
• patio heaters
• gas-fired barbecue
• gas-fired appliances in motor homes
• gas-fired appliance on boats

It is very important to know the application and any special expectations before buying and sizing a gas regulator. The materials used in a high pressure steam application will differ significantly when compared to a low pressure natural gas application. Are you locating the regulator indoors or outdoors? If indoors, will it be somewhere that noise may be an issue?

Be sure you have all the right information to properly size the regulator for the job it&#;s meant to do. For more advice or more information on sizing a gas regulator, get in touch with Hanover Supply Company today.

Propane regulator facts, propane facts, propane 101, high pressure and low pressure, types of propane regulators, and 

a word about propane tanks

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Should I buy the highest pressure propane regulator to insure enough gas delivery?

There is no advantage of having a propane regulator with a lot more btu/hr output than you actually need.  

Depending on the number of btu/hr that the gas appliance(s) requires, one chooses the adjustable propane gas regulator which delivers the required number of btu/hr. Choose the propane regulator that is the closest match.  

As you choose a higher and higher pressure high pressure propane regulator, the degree of control that the propane regulator valve has over the gas output decreases; i.e., turning the valve an 1/8" in a 0-60 psi adjustable propane regulator has a lot more effect than turning the valve an 1/8" in a 0-20 psi adjustable propane regulator. Choose the high pressure regulator which most closely matches your actual btu/hr need.

How long will my portable tank of propane last?

  

These figures are all theoretical. According to a major 20-pound propane tank producer, Blue Rhino, their 20-pound propane tank will only contain about 4.1 gallons of liquid propane which weighs just 17 pounds.  The empty propane tank weighs about 20 pounds so if you add the 17 pounds of gas you have a full propane tank weighing around 37 pounds.  

Folks also ask: "What is the pressure inside my portable tank?"   According to the publication NFPA58, a tank with 20 pounds of gas at 70°F has a pressure of 145 psi, at 90°F would have 180 psi, at 105°F would have 235 psi, and at 130°F would have 315 psi.

My propane tank and regulator ice up and the propane output is dropping.

 

Often the source of the problem is water within the small, portable propane tank.  Water is not supposed to be in the tank, but usually is. The propane inside the tank is in a liquid form.  Propane leaves the tank in a vaporized state. That change of state from liquid to gas requires a considerable amount of heat.The heat to vaporize can only come from the metal tank that contains the gas. If the demand for the propane is very high, the tank and regulator get noticeably colder and colder.  If the demand for gas is very high the vaporized propane delivered will decrease. If there happens to water along with the propane stored in the tank, the water vapor will freeze internally at the tank valve and can even freeze within the regulator and will further reduce or block the flow of propane to the supply hose.  This is noticed more profoundly when the demand for the propane is at a high level and/or the amount of liquid propane left in the tank is at a lower level.  Water does not mix with propane but both propane and water have vapor pressures within the tank.  Moving or shaking the tank is not helpful.

What can I do when the propane tank and regulator freezes?  

What can you do?   Buy the largest tank you can lug around.  As the internal surface area increases the heat sink increases because the metal cylinder has a larger heat reserve available. You could also complain to your retail gas supplier.  Ask them to purchase the gas from a gas wholesaler that adds some methyl alcohol into the propane. Methyl alcohol acts as antifreeze. Wholesale propane gas suppliers in colder climates often do this in the winter months. If that is not feasible then occasionally pour some hot water over the tank valve and propane regulator.  You can try to keep the propane tank and gas regulator in a warm place. The colder the propane tank and gas regulator gets, the more prone the tank and gas regulator will be to experience a freeze up during high propane demands. Lastly, keep a spare propane tank and be prepared to make a switch whenever you sense a decrease in the flow of the propane.

Caterers often like to use a manual tank changeover valve to quickly change to a warm, full tank by the simple turn of a valve. After you switchover to the new tank the other frozen tank can have time to warm back up or you can changeout the problem or empty tank.  A freeze up will be more pronounced with a less than half-full or a near-empty propane tank, and occurs more frequently in a smaller 5 gallon propane tanks than a larger propane tank. Experienced caterers commonly use as large of a propane tank as they can and keep a spare tank nearby. The use of a twin stage regulator will certainly help reduce these freeze-ups because the gas expansion process is drawing heat from two separate regulators rather than just one.  A twin stage regulator also delivers a more steady and even supply of gas.

 

What is a btu?

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A btu, or British Thermal Unit, is the amount of energy required to raise one pound of water one degree Fahrenheit.  

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A gallon of liquid propane contains 91,502 btu's.  

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If you want to learn more, please visit our website Propane Regulator Manufacturers.

A pound of liquid propane contains 21,591 btu's.

I have a low pressure regulator but it does not seem to supply enough gas for my appliance.

Unfortunately, many of the preset low pressure regulators available in the marketplace use 1/4"ID black hose and most are attached to a propane regulator with only a 1/4"ID NPT (National Pipe Thread Taper) outlet. There is a definite limit to the volume of gas that can be delivered through this small ID hose at a fixed low propane pressure of 6 ounces. 

What can I do if my preset low pressure regulator is not supplying enough gas?  Can I increase the pressure of the gas?

Why does my grill have little or no flame?

  

According to the Coleman company there are at least three possible reasons:

First is that the propane tank might have been improperly filled.  All tanks must be purged of air before being filled with gas. This purging requires filling with a small amount of gas and then emptying. Propane is heavier than air and will force the air out of the tank during the emptying. Filling with gas then can proceed.  If the tank is not purged then the air is the first gas to exit the tank and the grill will either have no flame or a very low flame for possibly over an hour until the air does fully exit the tank.
 
A second cause could be automatic activation of a surge protection device within the propane regulator. If you turn on the tank valve before you fully turn off each of the burner knobs on the grill, the surge protector could sense a leak and activate. The fuel flow will be reduced.  The remedy is to turn everything off, disconnect the tank, and reconnect everything before starting over.  

A third possible cause might be that the tank was overfilled.  All propane tanks are now fitted with Overfill Protection Devices (OPD) which is designed to be activated by a float valve.  The OPD feature prevents overfilling of the tank by shutting off the valve.  A 20% empty space is necessary to prevent the tank from venting large amounts of propane when the ambient temperature rises.  This OPD can also be inadvertently activated by tilting a very full tank during moving.
 

Interesting Facts

One gallon of water weighs 8.33 pounds.  It takes one btu to raise each pound of water 1 degree Fahrenheit or 8.33 btu's to raise one gallon of water one degree Fahrenheit. Knowing that, it is simple to calculate the number of btu's required to raise a known number of gallons of water to boiling...(assuming 100% thermal transfer of the heat from the flame and knowing the starting temperature of the water).  This is useful in determining approximately how long your tank of gas will last.

What is the better fuel, Propane or Natural Gas?

Volume to volume propane delivers more btu/hr than natural gas.

 For example, at 60 °F a flow of 1 cubic foot/hr of natural gas will deliver btu/hr but 1 cubic foot/hr of propane will deliver btu/hr...about 2.5 times more heat.  The reason for this is that methane (natural gas) has one carbon atom bound to four hydrogen atoms and propane has three carbon atoms bound to eight hydrogen atoms.The oxidation (burning) of a propane molecule releases 2.5 times more heat because the process is breaking many more chemical bonds within the molecule.  The end products of the complete oxidation (burning) of both a natural gas molecule or a propane gas molecule are the same, carbon dioxide and water. The difference is that you get a lot more carbon dioxide and water with the burning of the propane and, of course, a lot more heat.  

Natural gas is a reliable and cheap fuel. Many people opt for it if it is available. Propane is the more practical choice if your have a mobile cooking setup.  Our low pressure cast iron burners, pipe burners, and jet burners can be configured with different size orifices to give the same BTU/hr output regardless of which fuel you choose.

More propane 101

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A 20# LPG tank theoretically contains 4.72 gallons but in practice may only contain 4.1 gallons since gas cylinders are not supposed to be filled more than 80% full.    

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