Filter Regulator Installation & Maintenance

 Filter Regulator Installation & Maintenance 

1.  Warnings 

• Beware of all dangers associated with equipment under pressure and any potential hazards.
• Use suitable personal protective and safety equipment.
• Conduct all maintenance without pressure in the system.

2.  Product Description and Functionality 

Filter-regulators are designed to reduce a higher upstream pressure to a lower downstream pressure, which is adjustable by the user within the setting range of the model. This downstream pressure can be set to the desired value by rotating the knob on the top of the filter regulator and looking at the pressure gauge to see the set pressure.

After the pressure is set by the user, the filter regulator is self-adjusting and maintains a constant downstream pressure. However, variable flow rates or large variations to the inlet pressure may affect the actual downstream pressure.

In addition, filter regulators help to remove condensate and impurities from the air running through it. This is done by spinning the air and running it through a filter. Any condensate collected will be discharged through the automatic drain once it reaches its discharge level.

3. Installation & Commissioning 

Filter Regulators are a reliable and relatively simple piece of instrumentation as long as they are installed and commissioned correctly. The below points should be observed when installing.

• Make sure all areas and surfaces are as clean as possible
• Ensure the line is vented of pressure if installing on a live system
• Ensure that the upstream airline is as clean as possible and no foreign debris is present
• Check the direction of flow marked on the regulator to establish the correct inlet and outlet. The unit will not work if the direction of flow is reversed.
• Ensure the pressure gauge is installed on the regulator
• Thread tape or thread paste will need to be used to ensure a bubble tight seal
• Ensure the drain is facing down
• If using the mounting bracket ensure it has a sufficient installation surface to attach too
• Once the installation has occurred and the fittings are tightened gradually bring pressure back to the line
• The adjustment knob on top of the regulator can now be adjusted to set the desired pressure
• Check for any leaks at the inlet, outlet and pressure gauge

4. Maintenance 

Filter Regulators should be inspected for proper function as part of routine maintenance. Here they can be visually checked for any leakage, corrosion and too much residue build up in the filter bowl. If necessary the line may need to be isolated and vented of pressure (both upstream and downstream) so the bowl and filter of the filter regulator can be removed and cleaned. Try to ensure no debris is caught in the filter regulator as this can cause premature failure of the unit. The maintenance intervals will depend upon the quality of the air used by the system. A visual inspection every 6 months would be a good start and may need to be shortened or lengthened depending on the findings.

5. Troubleshooting 

The following troubleshooting table helps the identification of the probable cause of malfunctions and how to solve them.

Problem	Cause	Remedy
External Leakage	Fittings are not tight enough or a thread sealant has no been used	Tighten threads or use a thread sealant
Leakage from the bonnet	Diaphragm is damaged or large debris stuck	Check diaphragm and test for result
Outlet Pressure Is too Low	Upstream pressure has dropped	Increase Upstream Pressure
Air leaking out drain	Pressure differential not present to seat the drain	Needs a 2 Bar pressure differential to sea properly
Drain will not close	Foreign debris caught in drain float	Remove bowl and clean
Low Flow Rate	The filter is clogged	Remove the bowl and clean the filter