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Wide-open vs Working Monitors

Working Monitor Pressure Regulators in Fuel Gas Pressure Control

Working Monitor Pressure Regulators in Fuel Gas Pressure Control

Is that Regulator Working?

How Does a Pilot-Operated Pressure Regulator Work (Part 2)

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Working Monitors
Working monitors are an underutilized form of overpressure
protection in large gas distribution applications such as city
gate stations, district stations, and large industrial meter sets.

 Working monitors, like an upstream wide-open monitor setup,

are composed of two regulators in series where both
regulators sense downstream pressure and have a pilot on
the upstream regulator set above the downstream regulator
pressure setting; however, an additional pilot is added to the
upstream regulator to control the pressure between the two
regulators. The two pilots on the upstream regulator are
installed in series with the working pilot controlling
intermediate pressure and the monitor pilot open and on
standby in case the downstream regulator malfunctions.

The upstream regulator must be a pilot-operated regulator,

but the downstream regulator can be pilot-operated or direct-
operated and can even have internal registration. 

Upstream Regulator Failure

If the upstream regulator malfunctions, the intermediate

pressure will increase to equal inlet pressure and the
downstream regulator will continue controlling outlet
pressure. 

 Normal conditions:
 

Conditions upon upstream regulator failure:

 Downstream Regulator Failure

If the downstream regulator malfunctions causing outlet

pressure to rise, the monitor pilot on the upstream regulator
will take over control of the upstream regulator. The
intermediate pressure will decrease below the worker pilot’s
setting causing the worker pilot to go open.

Normal conditions:
  

Conditions upon downstream regulator failure:

 Overpressure protection
 working monitor
 Pressure-reducing Regulators
 pressure control

Nathan Wilhelm

 6 Nov 2019 2:36 PM

 2

2 Replies
Mooney Regulators in Pressure
Reducing Service with a Working Monitor
Sistema de regulación Monitor-Trabajador: 1.
Introducción
El sistema de regulación Monitor - Trabajador,
consta de dos reguladores en serie, de los cuales
uno trabaja “trabajador” mientras el otro
monitorea “monitor” permaneciendo este
totalmente abierto, entrando en forma automática
cuando el regulador trabajador falla, esto debido a
que la presión del regulador monitor esta 5 psi;
por encima del set del regulador trabajador .
En este arreglo los 2 reguladores tienen las líneas
de sensoras, conectadas aguas abajo de del
regulador trabajador. 2. Detalles del sistema de
regulación
Los reguladores de presión son equipos
diseñados para mantener una presión constante
aguas abajo de los mismos, independientemente
de las variaciones …ver más…

La fuerza ejercida por el resorte, se expresa con

la siguiente ecuación, conocida como
“Ley de Hooke”.
F = −K ⋅ X
(EQ.4)
donde;
F= Fuerza (Lbf) o (N)
K= Constante de elasticidad del resorte (Lbf/in) o
(Nw/m)
X= Deformación del resorte, (in) o (m)
A medida que el vástago de la válvula reguladora
se desplaza, el resorte se deforma cambiando de
esa manera la fuerza ejercida por el resorte. Los
cambios en la fuerza suministrada por el resorte
significan cambios en la presión de entrega.

Elementos que componen un Regulador

En esencia, un regulador está compuesto por tres
elementos:
1. Elemento restrictor: orificio de la válvula y
tapón.
2. Elemento de medida o sensor: diafragma y
conductos o tubing.
3. Elemento de Carga: Resorte, gas comprimido o
gas regulado suministrado por un piloto.
Un regulador típico, es una válvula de globo en la
cual, el vástago se mueve por la interacción de un
diafragma. El vástago es solidario al diafragma y
su cambio de posición es transferido al vástago,
modificando el área de la sección transversal que
atraviesa la corriente de flujo. El movimiento del
diafragma está “limitado” o “controlado" por un
resorte que actúa del lado opuesto al área que
sensa la presión de entrega o presión a controlar.
La presión de entrada actúa sobre el área
proyectada de tapon
'Working Monitor' Regulator Solves Pressure
Problems
Michael Calaway and Ryan Baker discuss two
redundant regulator configuration options and an
application example at Dow Freeport

By Dave Perkon, technical editor, Control Design

Oct 14, 2015

About the author

Dave Perkon is technical editor for Control Design. He has worked with a wide variety of

fortune 500 companies in the medical,

semiconductor, automotive, defense and
solar industries.
Fuel gas provides the heat essential to many
process manufacturing operations.
Accurately controlling  its pressure is
important for optimum combustion and
energy efficiency, and regulator reliability is
critical to ensuring continuous operations.
During a presentation entitled "Gas Pressure
Control: Why a Working Monitor Regulator
System?" at the Emerson Global User
Exchange this week, Michael Calaway,
business development manager at Emerson
Process Management, together with Ryan
Baker,  Fisher Valve and Regulator account
manager from local business partner Puffer-
Sweiven, discussed two redundant regulator
configuration options as well as an
application example at Dow Freeport.
Fuel gas pressure control
A typical fuel gas pressure control application
is a fuel gas header that might sit on the
fence line of the facility or on the main line
entering a large processing unit. The fuel gas
header pressure regulator is typically pilot
operated, providing more accurate pressure
control than a standard regulator. It also
provides quick response to demand
changes, attenuates noise and provides a
high degree of reliability.

"Varying gas demands caused high

fluctuations in the pressure. It was a mess."
Puffer-Sweiven's Ryan Baker discussed how
a redundant, working monitor regulator
configuration that has helped improve fuel
gas pressure control at Dow Freeport.
To help ensure a longer life and improved
reliability in this typically single regulator
application, a dual regulator, "monitor"
system can be used. "The monitor set-up is
two regulators in series with just a slight
difference in regulator pressure setpoint. If
one fails open, the other picks up and
continues to operate."
Further, monitoring systems come in two
configurations called "open" and "working."
The open monitor set-up is so-named
because the first of the regulators in series
remains wide open until it's called upon to
act upon the failure of the second. Both
regulators sense the same downstream
pressure. If the downstream regulator is set
to 10 psi and the upstream one to 15 psi, the
upstream monitor regulator remains wide
open during normal operation and the
downstream regulator does all the heavy
lifting.
One disadvantage of this configuration is that
since the monitor regulator remains open,
"we don't know if the first regulator is
prepared to respond," Calaway said. "The
working monitor set-up addresses this
disadvantage by adding a second pilot and
controlling to an intermediate pressure
between the two regulators. During normal
operations, then, the two regulators share
the load. If either regulator fails, pressure
control is maintained; only the intermediate
pressure changes, alerting operators to the
malfunction. "The smaller pressure step
across each regulator can also help with
reliability and noise reduction," Calaway
added. "These advantages were very
important to the situation at Dow."
Dow chose a working monitor regulator set-
up as the new best practice to replace
existing split-range control valves. "Dow had
a split-range control valve with two fuel
pressure regulators in series that had slow
loop response time, high flow instability and
a low degree of maintainability," explained
Puffer-Sweiven's Baker. "Varying gas
demands caused high fluctuations in the
pressure. It was a mess."
"The new working monitor design allowed the
elimination of relief valves and added desired
redundancy," said Baker. Further, the
solution resulted in a compact final
installation using common 3-in. valves.
"Response to a flare event was almost
instantaneous, with little to no pressure
droop, overshoot or cycling." There have
been no issues since installation about a
year ago. With these advantages and low
maintenance, Dow is looking into other
applications for this working monitor
regulating system, Baker said

https://www.researchgate.net/figure/Mooney-
Regulators-in-Pressure-Reducing-Service-with-a-
Working-Monitor_fig4

https://www.emerson.com/documents/automation/
manuals-guides-complete-technical-section-fisher-en-
140704.