Pressure Regulator

Alphard P/AP
< Accurate regulation Applications Description
< Easy maintenance It is designed for use in transmission and The Alphard P/AP is a pilot- operated regulator
distribution networks, as well as commercial available with or without an integrated safety
< Monitor application
and industrial supplies. shut-off device, type FTC (fail to close), or
< DVGW-approval FTO (fail to open). The pilot and feeder system
ensure constant outlet pressure when the
upstream pressure varies.

Technical Features
Inlet pressure range Pi: 0.5 – 101.2 bar
Outlet pressure range Po: 20 mbar – 60.0 bar
Minimal different pressure Dp: 0.5 to 1.5 bar, dependent on application
Flow rate up to 300.000 Sm3/h Natural gas
Accuracy class AC 1/SG 5 to AC 10/SG 30
Accuracy class SSV AG 1 to AG 30
Operating temperature -20°C to +60°C
Acceptable gases Natural gas, propane, butane, air, nitrogen, and all non-corrosive gases.
Safety devices Optional built-in SSV
OPSO/UPSO: Over- and under-pressure shut-off
Options adapter electronic Internal Silencer, Monitor version,
Conical for outlet side (2 x DN), Pneumatic and remote control devices

Sizes & Connections

Sizes DN 25, 50, 80, 100, 150, 200, 250, 30
Body lengths See table
Flanges PN16, 25, 40, 63
ANSI 150, 300, 400, 600

Materials
Body GS-C 25N / GS C 45
Actuator regulator Forged steel (C 45 N)
Actuator SSV Steel (zinc coated), Al Mg Si F 28
Pilot/Feeder Steel, zinc coated/Stainless steel
Sliding tube Steel, zinc coated
Internal parts Steel, zinc coated/Stainless steel
Seals NBR rubber/Viton
Diaphragm NBR rubber/NBR rubber, reinforced fabric
<Alphard P/AP
 Operating principle
< The equilibrium position of the diaphragm, The diaphragm-system (3.1) of the regulator
and consequently the opening grade of the (3) measures the outlet pressure on the
valve is determined by the closing spring of outlet side, the desired value of the outlet
the valve and the pressure difference between pressure is set by adjusting the spring of the
the downstream pressure and the actuating regulator (3). By turning the setting screw
pressure. (3.3) clockwise the outlet pressure is
< This pressure is supplied by the pilot unit, increased, anti-clockwise the outlet pressure
connected by a special feeding device to the is decreased.
upstream pressure. When the outlet pressure, Po, falls below
the desired value, that is, when the flow rate
< In this way, the pressure in the upper increases, the orifice (3.2) of the regulator
chamber is compensated automatically and (3) is opened and the actuating pressure ps
consequently the downstream pressure is under the working diaphragm (4.1) is
regulated. increased. The sliding tube (4.2) of the valve
(4) is opened more and the outlet pressure
The actuating pressure Ps is produced in the po increases.
system which consists of the fine strainer (1), In case of decreased flow rate, the orifice
pre stage (2) and regulator (3). The pre (3.2) of the regulator (3) is closed, the
stage and regulator are spring-loaded actuating pressure ps under the working
systems. diaphragm (4.1) is decreased by a small flow
In order to increase the regulation accuracy, through a by-pass-bleed (3.4) on the outlet
the pre stage (2) generates a constant side.
intermediate pressure Pz before the regulator. If the flow is 0, the regulator (3) is closed,
This intermediate pressure is set at the fixed the actuating pressure and the outlet
spring of the pre stage and is dependent on pressure become the same value, and the
the outlet pressure po. Consequently, in closing spring (4.3) of the valve closes the
order to secure an accurate regulation, the main valve (4).
system must have a minimum pressure
difference (Pi–Po) of 0.5 bar up to 20 bar and
1.5 bar up to 100 bar inlet pressure.

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Pressure range
Feeder- / Regulator-type Inlet pressure (bar) Outlet pressure (bar)
AL 30 / CU 120 0.5 – 19.5 0.02 – 0.15
AL 30 / CU 120 0.5 – 40.0 0.05 – 0.6
AL 30 / CU 80 MP 1.0 – 50.6 0.5 – 20.0
AL 20 / CU 80 MP DM 7.0 – 101.2 6.0 – 22.0
AL 20 / CU 80 AP 21.0 – 101.2 20.0 – 60.0

Accuracy class and closing group

Outlet pressure range (bar) Accuracy class AC Closing group SG
0.02 – 0.05 AC 10 SG 30
>0.05 – 0.1 AC 5 SG 20
>0.1 – 0.5 AC 5 SG 10
>0.5 – 4.5 AC 2.5 SG 10
4.0 – 11.0 AC 2.5 SG 5
6.0 – 60.0 AC 1 SG 5

KG-factor and orifice diameter

DN Orifice diameter (mm) Kg-factor (m3/h/bar) Natural gas
25 25 566
50 51 2322
80 76 4644
100 102 8772
150 152 17441
200 203 29928
250 254 48504
300 305 69144

Closing group AG of SSV

Type Who (bar) AG Whu (bar) AG
CA 77 0.013 – 0.13 10 0.008 – 0.06 15
>0.13 – 0.35 5 0.06 – 0.14 10
0.27 – 1.2 5 0.15 – 0.45 10
>0.45 – 1.05 5
CA 40 0.3 – 0.5 10 0.2 – 1.4 10
0.5 – 10.2 5 >1.4 – 3.9 5
CA 30 * 1.3 – 3.9 5 1.3 – 2.5 10
>3.9 – 18.2 2.5 / 1 >2.5 – 7.0 5
CA 15 * 2.9 – 9.0 5 2.9 – 10.0 10
9.0 – 72.8 2.5 / 1 >10.0 – 27.9 5
* piston type

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 Spring range of regulator
Type Spring
CU 120 Spring Order Colour Wire
Spring range Wh (mbar) number number ø (mm)
20 – 30 140 5 ML14015 1.5
20 – 100 78 5 ML07815 mint green 1.7
50 – 200 10 5 ML01015 signal yellow 2.0
100 – 400 77 5 ML07715 light blue 2.5
300 - 600 18 5 ML01815 signal blue 4.0

Type Type Type Spring

CU 80 MP CU 80 MP DM CU 80 MP Spring Order Colour Wire
Spring range Spring range Spring range number number ø (mm)
Wh (bar) Wh (bar) Wh (bar)
0.5 – 4.0 65 5 ML06515 Mint green 5.0
>4.0 – 11.0 59 5 ML05915 Light blue 7.0
6.0 – 15.0 6.0 – 15.0 60 5 ML06015 Signal blue 7.0
11.0 – 20.0 11.0 – 20.0 61 5 ML06115 Signal red 8.0
16.0 – 27.0 62 5 ML06215 Clay brown 8.5
M 20.0 – 32.0 20.0 – 32.0 63 5 ML06315 Black 9.0
K >32.0 – 48.0 64 5 ML06415 White 10.0
>48.0 – 60.0 296 5 ML29615 Aluminium 11.0

G Dimensions and Weights of the regulator

Dimensions L (mm) / Weights W (kg)
PN PN 16 / ANSI 150 PN 25 / PN 40 ANSI 300 ANSI 600
H
DN L W L W L W L W
25 184 53 197 54 197 55 210 60
50 254 85 267 86 267 88 286 95
80 298 139 317 141 317 143 337 150
C E F 100 352 225 368 228 368 235 394 250
150 451 465 473 472 473 480 508 500
200 543 1025 568 1033 568 1050 610 1090
250 673 1770 708 1787 708 1810 752 1875
300 737 2575 775 2596 775 2640 819 2785

Dimensions (mm) - PN 16 to ANSI 600

DN A B C D E F G H J K M

J
25 160 150 168 206 102 55 395 330 560 215 260
50 160 156 190 262 128 55 415 370 600 265 310
80 160 167 210 332 154 55 440 420 650 305 350
100 160 173 245 400 172 55 280 460 510 355 400
150 160 205 290 530 220 55 355 570 620 415 460
B
200 160 230 340 650 285 55 400 700 750 455 500
250 160 243 395 780 334 55 490 880 930 525 570
A
L
300 160 260 425 910 370 55 575 1050 1100 605 650

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Built in shut-off valve, Alphard CA
Operating principle

The safety shut-off valve Alphard CA is The sliding tube (21) closes the orifice (23)
made up of the control device (10) using the force of the closing spring (32).
and body with an integrated closing system The gas flow stops. To reset the closed SSV,
(20). pressure compensation is necessary first by
The controlled pressure Po is connected (5) operating the self-closing bypass valve (24).
by a sensing line to the diaphragm (4) Afterwards, the outlet pressure closes the
of the control device (3). control device (3).
The springs for higher and lower pressure The reset lever (1) is operated by turning a
shut-off are fixed to either side of the dia- square socket key clockwise (square diameter
phragm. 10mm)
Excessive or insufficient outlet pressure caused After resetting the valve, the key should be
by failure of the regulation system will lift or removed.
droop the diaphragm.
A small lever opens the catch between
switch lever (2) and reset lever (1).

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 Spring range for higher and lower shut-off

a) High shut-off

Type Spring
CA 77 CA 40 CA 30 CA 15
Spring range Spring range Spring range Spring range Spring Order Colour Wire
Who (mbar) Who (bar) Who (bar) Who (bar) number number ø (mm)
13 – 50 265 5ML26515 signal yellow 1.7
40 – 130 0.3 – 0.5 266 5ML26615 mint green 2.2
100 – 350 0.4 – 1.3 1.3 – 2.3 2.9 – 9.0 267 5ML26715 light blue 2.8
270 – 720 1.0 – 2.7 1.8 – 4.75 7.1 – 19.1 268 5ML26815 signal blue 3.5
590 – 1200 2.15 – 5.5 3.9 – 9.8 15.5 – 39.1 269 5ML26915 signal red 4.5
4.5 – 10.2 18.2 – 32.0 32.0 – 72.8 270 5ML27015 clay brown 5.5

b) Lower shut-off

Type Spring
CA 77 CA 40 CA 30 CA 15
Spring range Spring range Spring range Spring range Spring Order Colour Wire
Who (mbar) Who (bar) Who (bar) Who (bar) number number ø (mm)
8 – 25 258 5ML25815 signal yellow 0.9
20 – 60 259 5ML25915 mint green 1.2
50 – 140 0.2 – 0.5 260 5ML26015 light blue 1.6
110 – 260 0.4 – 1.0 1.3 – 1.7 2.9 – 6.9 261 5ML26115 signal blue 2.0
215 – 450 0.8 – 1.7 1.4 – 3.0 5.7 – 11.9 262 5ML26215 signal red 2.4
380 – 660 1.4 – 2.5 2.5 – 4.4 10.0 – 17.5 263 5ML26315 clay brown 2.8
580 – 1050 2.1 – 3.9 3.8 – 7.0 15.3 – 27.9 264 5ML26415 black 3.2

Note :
It is only possible to select the spring range for over- and under-pressure within for one type
of control device. For example CA 40, with an over-pressure range of 0.3 to 10.2 bar and
under-pressure range of 0.2 to 3.9 bar.

Example for ordering :

Gas pressure regulator Alphard P/AP DN 50, ANSI 600 with integrated shut-off, type CA 40
Who = 10.2 bar, Whu = 0.2 bar.

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Device design

For the determination of the device size, the characteristic value KG at the lowest inlet
pressure Pi (bar) and the highest flow rate in standard state Qn (m3/h) is calculated.

The following formula is valid for The following formula is valid for
supercritical relief: subcritical relief:

Po + 1 2 x Qn Po + 1 Qn
≤ 0.54 c KG = ≥ 0.54 c KG =
Pi + 1 (Pi + 1) Pi + 1 v(Po + 1) (Pi - Po)

Example 1 natural gas: Example 2 nitrogen gas:

Pi min. = 32 bar Qn max. 25.000 m3/h Pi min. = 12 bar Qn max. 2.000 m3/h
Po max. = 8 bar Natural Gas (d = 0.6) Po max. = 8 bar Nitrogen Gas (f = 1.25)

8 +1 8 +1
= 0.27 c KG supercritical = 0.69 c KG subcritical
32 + 1 32 + 1
2 x 25.000 2.000
KG required = = 1515 c DN 50 KG required = x 1.25 = 416 cDN25
(32 + 1) v(8+1) (12-8)

For other gases except natural gas, the calculated KG value is to be multiplied
with the following factor ƒ (see Example 2).

Gas Density relation factor ƒ

air (d = 1.0) 1.29
nitrogen (d = 0.97) 1.25
propane (d = 1.75) 1.61
butane (d = 2.09) 1.87
city gas (d = 0.43) 0.85
natural gas (d = 0.6) 1.0

ƒ= d
0.6

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For more information, www.actaris.com
D-76185 Karlsruhe - Germany
Hardeckstrasse 2
Actaris Gaszählerbau GmbH

tel + 49-721 5981 0

fax + 49-721 5981 189
GA-0048.0-GB-04/04- © Copyright 2004, Actaris, All Rights Reserved. - Actaris reserves the right to change these specifications without prior notice.