IOM 3000.0 REV. A 12541

ISO 9001 Groth Corporation 1993

IOM 3000.0JULY 1993

Installation, Operation and Maintenance Manual for

Blanket Gas Regulator

Series 3000

IOM 3000.0 REV. A 12541

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE NO.

A MAIN SECTION INTRODUCTION GENERAL INFORMATION SAFETY INSTALLATION OPERATION & MAINTENANCE DRAWINGS & BILL OF MATERIAL

Regulator Design, Function & Operation Regulator Function - Flowing/Shut-off Condition General Instructions Inspection & Installation Operation: Pressure Setting Operation: Flow Capacity Setting Blanketing the Tank Recommended Spare Parts Troubleshooting Guide Preventive Maintenance & Disassembly Assembly Recommended Testing & Setting Procedure Exploded View - Drawing Bill of Material Cross-Sectional - Drawing Model Identification & Product Limited Warranty

1

2 3

4

5

6 7 8 8 9

10 - 11 12 - 13

14

15 16 17 18

B LIST OF FIGURES* No. 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15

DESCRIPTION Tank Installation - Safety Equipment Regulator Function - Flowing Condition Regulator Function - Shut-off Condition Blanketing Regulator Installation Orifice Sleeve Orientation Spring Bonnet Assembly Piston/Body Assembly Piston Assembly - "Exploded" Orifice Sleeve Orientation Orifice Sleeve Orientation Piston Assembly - "Exploded" Piston/Body/ Diaphragm Assembly Spring Bonnet Assembly Blanketing Regulator - "Exploded" Assembly Blanketing Regulator - Cross-Sectional Assembly

1 3 3 5 7

10 10 11 11 12 12 13 13 15 17

C LIST OF TABLES No. 1 2 3 4 5 6 7 8 9

DESCRIPTION 3000 Series Regulator Specifications Flow Capacity Model 3000 Spring Table Model 3010 Spring Table Model 3020 Spring Table Orifice Selection Recommended Spare Parts Recommended Bolt Torque Bill of Material - 3000 Series Regulator

2 2 6 6 6 7 8

13 16

IOM 3000.0 REV. A 12541

*Note: Some Figures are duplicated for the convenience of the reader INTRODUCTION The gas blanketing regulator is one of the principal components typically installed on a storage tank to protect the tank and its contents. It is a precision regulator that is capable of maintaining a very low gas pressure (1/2" WC minimum) in the tank by controlling the flow of a high pressure (200 PSI maximum) blanketing gas. It maintains a positive tank pressure when fluid is pumped out or as fluid temperature decreases. Typically nitrogen or another compatible gas is used to displace the tank product vapors. This reduces product evaporation and prevents atmospheric contaminants, including moisture, from entering the tank, minimizing internal tank corrosion and product contamination. The use of inert blanketing gas minimizes air pollution due to leakage or emergency venting.

In addition to the blanketing regulator, a tank must be protected from structural damage by pressure and vacuum relief valves. A typical tank installation is shown in Figure 1 which includes the regulator, a pressure vacuum relief valve and an emergency pressure relief valve. Groth Corporation manufacturers all of these devices. The regulator must be carefully maintained by a knowledgeable valve technician. It should only be assembled under clean conditions, preferably in a shop environment. Carefully read and understand this manual before attempting to adjust set pressure or flow capacity, or repair the regulator. Groth Corporation offers repair services for all products manufactured by the Tank Protection Division.

Figure 1: Tank Installation - Safety Equipment

GAUGE

EMERGENCY RELIEF VALVEGROTH MODEL 2400

PRESSURE/VACUUMRELIEF VALVE

GROTH MODEL 1420

GAS BLANKET REGULATORGROTH MODEL 3000

BLANKETGASSUPPLY

SENSE LINE

1

REGULATOR DESIGN, FUNCTION & OPERATION The Groth Model 3000 Regulator is a high capacity spring operated, diaphragm type, balanced piston regulator design for tank blanketing applications. The regulator controls the flow of blanketing gas to the vapor space in the storage tank. When the internal pressure of the tank is at or above set pressure, the diaphragm force exceeds the spring force and the regulator is shut off bubble tight. When the tank pressure falls below the set point, the spring force opens the regulator and blanket gas flows into the tank (See Figures 2 and 3). The regulator must be sized to provide sufficient blanket gas to prevent the loss of tank pressure due to liquid discharge or decreased ambient temperature. Table 2 lists the maximum flow capacity of the regulator for various blanketing gases. Actual system flow will depend on supply system piping, tank connection piping and position of the internal orifice sleeve. Set pressure is the pressure at which the regulator begins flowing when tank pressure is decreasing and stops flowing when tank pressure is increasing. This manual is intended to provide recommended procedures and practices for installation, operation, and maintenance of the Groth Series 3000 Regulator. Any standard procedures and practices developed in a specific plant or process should supersede this manual. Although this manual cannot cover all possible contingencies, following these guidelines should provide safe regulator performance.

Note that throughout this manual, the item numbering is listed in [ ] after the part description. Refer to the exploded assembly drawing on page 15 and the parts list on page 16.

TABLE 1

REGULATOR SPECIFICATIONS

3000 3010 3020 Flow Coefficient (CV)

12.5 12.5 12.5

Inlet/Outlet 1" NPT (F) or 1"150# RF Flange

1" NPT (F) or 1" 150# RF Flange

1" NPT (F) or 1" 150# RF Flange

Supply Pressure 200 PSI

200 PSI

200 PSI

Tank Pressure

2" WC to 2.0 PSI

1/2" WC to 2" WC

1 PSI to 10 PSI

Max. Tank MAWP

25 PSI 10 " WC 150 PSI

TABLE 2

FLOW CAPACITY * 3000 SERIES REGULATOR SCFH

Supply

Pressure PSI

Nitrogen Natural Gas

0.6 G

Air

5 10 15 20 30 40 50 60 80

100 120 140 160 180 200

5700 8700

11300 13800 18600 23200 27700 32100 40700 49300 57900 66500 75100 83700 92300

5800 8800

11500 14000 18900 23600 28200 32600 41300 50100 58800 67500 76300 85000 93700

7400 11300 14600 17900 24000 30000 35800 41500 52600 63700 74800 85900 97000

108100 119200

*Internal orifice sleeve installed in 100% flow capacity position.

For information not contained in this manual, please contact:

Groth Corporation

Groth Products Group P. O. Box 15293

Houston, TX. 77220 713-675-6151 (phone)

713-675-6739 (fax)

2

Figure 2: Regulator Function - Flowing Condition

OUTLET

INLET

HIGH PRESSUREBLANKETING GAS

HIGH PRESSUREBLANKETING GAS

LOW PRESSUREPROCESS VAPOR

VENT

VENT

SENSE PORT

Figure 3: Regulator Function - Shut-off Condition

OUTLET

INLET

HIGH PRESSUREBLANKETING GAS

LOW PRESSUREPROCESS VAPOR

LOW PRESSUREPROCESS VAPOR

VENT

SENSE PORT

3

SAFETY GENERAL INSTRUCTIONS This section is intended as an overview of safety guidelines that should be followed during the installation, operation and maintenance of Groth Series 3000 Gas Blanketing Regulator. To understand the context of these warnings and instructions, read and understand this complete manual. The gas blanketing regulator is one of the principal protection devices typically installed on a product storage tank. It is a precision regulator that is designed to maintain a positive pressure on the tank. This will prevent product loss or contamination from atmospheric air when pumping liquid out or when the stored fluid cools.

WARNING

1. In the event of an actuator or body diaphragm

failure, the regulator will fail in the OPEN position. Gas flow will NOT be shut off. Operating and emergency pressure relief valves must be sized to flow regulator capacity in addition to normal and emergency venting requirements.

2. Gas Blanket Regulator flow capacity is based on

tests conducted with five feet of 1" SCH. 40 discharge piping. Consult factory for capacity data if regulator is to be installed with longer pipe or numerous fittings or valves between the regulator and the tank it is blanketing.

3. The regulator is normally factory set at the desired set pressure and orifice restriction. These settings and spring range are stamped on the nameplate. DO NOT attempt to readjust the set pressure beyond the limits specified in Tables 3, 4 and 5.

4. The regulator is to be connected to the tank or

vessel with a minimum 0.300" ID tubing sense line. This line must be kept open and unobstructed to ensure that the regulator "senses" the actual tank pressure. For some applications, a nitrogen purge may be required to ensure that this line remains open. Consult factory for recommendations.

5. DO NOT attempt to remove the regulator from

the line or perform field repairs in line without first isolating the regulator from both the tank and the supply gas line. Bleed all pressure before removing the spring bonnet or the flow orifice locking screw, or opening up the actuator cases.

6. Note the orifice sleeve position when

disassembling the regulator. It was factory set according to the flow requirements listed on the order and must be re-installed in the same position to ensure the correct flow.

7. The regulator body and actuator case are

exposed to process vapors. Observe all safety precaution as specified on the Material Safety Data Sheet for the products that are in the tank.

8. The vents on the spring bonnet and upper case

must both be clean and open to the atmosphere and should be inspected periodically.

4

INSPECTION AND INSTALLATION The regulator is packaged and supported to prevent damage or contamination in shipping. It should be similarly protected during subsequent handling and storage. Always keep all ports plugged to prevent intrusion of foreign materials. Before installation, inspect the unit visually. If there are indications of physical damage or internal contamination, the regulator must be disassembled, cleaned and inspected before installation. If factory set, the spring adjustment cap and the orifice selector locking screw must be secure. Report any shipping damage to your carrier. The regulator inlet and outlet connections are 1" NPT (F) or 1" 150# RF ANSI flange. The regulator must be installed level, the direction of the flow is marked on the body. It is to be installed in accordance with accepted piping practices. Full bore block valves should be installed upstream and downstream of the regulator and in the sense line to allow it to be removed from the system for maintenance.

The regulator discharge line must be as short as possible to obtain the rated gas flow rate. It is not recommended to exceed a 5' length of 1" SCH 40 pipe. Consult with the factory for piping recommendations if it is necessary to install the regulator a greater distance from the tank. The supply line must be capable of providing the rated flow at the minimum supply pressure. The sense line should be minimum 300" ID tubing and is to be connected to the tank at least 12" from the regulator discharge line (See. Figure 4).

WARNING Regulator flow capacity listed in Table 2 is based on tests with 5' of 1" SCH. 40 discharge pipe and a 2" supply hose reduced to 1" pipe at regulator supply port. Depending on discharge line size, length and number of fittings, regulator flow capacity may be less than published curves. Supply and discharge piping should be designed to minimize losses at desired flow condition. Consult factory for non-standard installation regarding flow capacity.

Figure 4: Blanketing Regulator Installation

TANKPRESSUREGAUGE

BLANKETGASSUPPLY

DISCHARGEPIPING5' MAXLENGTH

12" MIN

BLOCK VALVE-1" MIN FULL BORE

(2)

(3)

(1)

SENSE LINE

BLOCK VALVE-1/2" MIN FULL BORE

TANK ROOF

5

OPERATION PRESSURE SETTING The regulator may be set at the factory or on the tank or vessel when initially introducing blanketing gas. A pressure gauge (or manometer) is required to show the tank pressure. Set pressure is adjusted by removing the valve cap [1] and rotating the adjusting screw [2]. Back off the jam nut [3] and turn the screw clockwise (tighten) to increase set pressure. The Model 3000 Regulator covers a range of set pressures from 2" WC to 2.0 PSI, using (7) different springs.

The model 3010 is required for set pressures from 1/2" WC to 2" WC, and model 3020 from 2.0 PSI to 10.0 PSI. In some cases, different actuator components are also required, either to reduce the weight for low settings or to withstand the forces due to higher pressure. (See. Tables 3, 4 and 5). The set pressure range with the original spring is stamped on the valve nameplate. The regulator will not function properly if the setting is not within this range. If higher or lower settings are required, the necessary components can be obtained from Groth Corporation. They must be installed according to instruction in the maintenance section of this manual. Tables 3, 4 and 5 show standard set pressure ranges.

TABLE 3

SPRING TABLE MODEL 3000

TANK BLANKETING REGULATOR MEDIUM PRESSURE RANGE

SET PRESSURE RANGE: 2" WC - 2.0 PSIG

Spring Range

Min. Setting

Max. Setting

Spring P/N

Support Plate

Back-up Plate

Tank MAWP

1 2.0" WC

3.4" WC

84209001 (Yellow)

83602015 83601005

4 PSI

2 3.4" WC

6.3" WC

84209002 (Green)

83602015 83601005

4 PSI

3 6.3" WC

10.9" WC

84209003 (Pink)

83602015

83601005 4

PSI

4 11.0" WC

18.5" WC

84209004 (Blue)

83602025 83601025

25 PSI

5 18.6" WC

27.7" WC

84209005 (White)

83602025

83601025

25 PSI

6 1.00 PSI

1.37 PSI

84209006 (Gray)

83602025

83601025

25 PSI

7 1.38 PSI

2.0 PSI

84209007 (Black)

83602025 83601035 25 PSI

TABLE 4 SPRING TABLE

MODEL 3010 TANK BLANKETING REGULATOR

LOW PRESSURE RANGE

SET PRESSURE RANGE: 0.5" WC - 2.0" WC Spring Range

Min. Settin

g

Max. Setting

Spring P/N

Support Plate

Back-up Plate

Tank MAWP

1

0.5" WC

0.6" WC

84209008 (Red)

83602035 83601005 10" WC

2

0.7" WC

1.0" WC

84209001 (Yellow)

83602035 83601005 10" WC

3

1.1" WC

2.0" WC

84209002 (Green)

83602005 83601015 10" WC

TABLE 5 SPRING TABLE

MODEL 3020 TANK BLANKETING REGULATOR

HIGH PRESSURE RANGE

SET PRESSURE RANGE: 1.0 - 10.0 PSIG Spring Range

Min. Setting

Max. Setting

Spring P/N

Support Plate

Back-up Plate

Tank MAWP

1

1.0 PSI

1.80 PSI

84209002 (Green)

84829005 N/A 150 PSI

2

1.81 PSI

3.07 PSI

84209003 (Pink)

84829005 N/A 150 PSI

3

3.08 PSI

5.21 PSI

84209004 (Blue)

84829005 N/A 150 PSI

4

5.22 PSI

10.0 PSI 84209005 (White)

84829005 N/A 150 PSI

WARNING

The recommended set pressure range of the regulator spring is stamped on the nameplate. Never adjust a spring for a set pressure above its upper design limit as specified in Tables 3, 4 and 5. Exceeding the spring rang may compress the spring to its solid height. If this happens the regulator may not close and the tank could be over-pressured if the relief valve capacity is less than supply gas flow rate.

6

FLOW CAPACITY SETTING Unless otherwise specified, the orifice selector sleeve [34] is factory set at the 100% full open position. If reduced capacity is specified on an order, the sleeve is set at the appropriate restriction. Actual capacity at any other position can be calculated by multiplying the capacity value from Table 2 for a specific pressure by the decimal fraction from Table 6. Flow capacity can be adjusted by rotating the orifice sleeve (See Warning). It has a series of indexing holes, four of which are marked with the numbers 1-2-3-4 (See Figure 5). Two unmarked holes are used to assist when rotating the sleeve. Adjustment can be made by loosening and backing the lockdown screw completely out of the body. The sleeve position can then be viewed and the sleeve rotated by inserting a small diameter wire into the holes.

Figure 5: Orifice Sleeve Orientation

2

3 2

34

36 35

When replacing the locking screw, grease the O-Ring [35] and slip it over the screw threads. Thread the screw [36] into the body, finger tight, until the point enters the sleeve and the head seats onto the O-Ring. Then wrench tighten the head firmly against the body, compressing the O-Ring. Sleeve position and valve capacity are shown in Tables 2 and 6. These tables are based on the supply pressure at the regulator inlet and piping as recommended in the installation section.

TABLE 6 ORIFICE CAPACITY

Orifice Sleeve

Position Flow

Multiplier

1

1.0

2

0.75

3

0.50

4

0.25

WARNING

The adjustable orifice is located in a pressure containing chamber. Close the supply valve and release all pressure before making adjustments.

WARNING

The regulator orifice sleeve is factory set at the specified flow capacity. When repairing a regulator, note the position of the indexing holes at disassembly. The sleeve must be re-assembled in the same position to ensure the proper flow capacity. NEVER adjust the orifice sleeve position without written instructions from your plant operations group.

7

BLANKETING THE TANK Before installing a new or replacement regulator, the tank pressure must be below the desired set pressure so the regulator setting can be verified. Sequentially open the block valves in the following order: (1) Sense Line, (2) Regulator Discharge Line and (3) Regulator Supply (See Figure. 4). If the regulator was set at the factory, blanket gas will begin to flow immediately. The tank pressure must be monitored closely to verify that the gas flow shuts off within the specified limit above set pressure. If the regulator was not set at the factory, make sure that the adjusting screw [2] is backed out as far as possible (no spring compression). When the blanket gas supply valve is turned on, there will be no flow, unless the tank pressure is very low. Now slowly turn the adjusting screw to increase tank pressure and the gas will begin to flow. The tank pressure can be increased as gradually as desired until the correct pressure setting is attained. When tank pressure is reached, back out adjusting screw, if necessary, until gas flow stops.

WARNING When adjusting the regulator on the tank, always be sure that the sense line is open and unobstructed. Monitor the tank pressure accurately.

WARNING In the event of actuator diaphragm [14] or piston diaphragm [21] failure, the regulator will fail in the OPEN position. Under this condition gas flow will NOT be shut off by the regulator. The tank pressure relief valve(s) must be sized to relieve the condition of full regulator capacity, pump in rate; and thermal expansion due to temperature rise. In the event of blanket supply gas failure, the regulator will NOT protect the tank from collapse due to a vacuum condition. The operating relief valve should include a vacuum breaker set according to the tank's design vacuum capacity.

RECOMMENDED SPARE PARTS When ordering spare parts, include model and serial number of regulator, pressure setting, and required material for soft goods.

TABLE 7

RECOMMENDED SPARE PARTS

ITEM DESCRIPTION QUANTITY 14 Diaphragm, Actuator 2 21 Diaphragm, Piston 4 25 O-Ring, Piston 2 22 O-Ring, Guide Ring 2 35 O-Ring, Locking Screw 2 6 Spring 1

11 Vent, Case 1 7 Vent, Bonnet 1

39 Gasket, Actuator 2

8

TROUBLESHOOTING GUIDE

PROBLEM

INSPECTION

SUGGESTED CORRECTIVE ACTION

Gas flowing at tank pressure above specified set point.

Flow indicator in blanket gas line.

Damaged seat, O-Ring or diaphragm or pressure setting too high. If original pressure setting has not been disturbed, remove regulator and repair.

Gas not flowing at tank pressure below specified set point.

Flow indicator in blanket gas line.

Damaged spring or pressure setting too low. If original pressure setting has not been disturbed, remove regulator and repair.

Gas leaking from upper vent or bonnet flange.

Soap bubble test and joining surface or emission indication near vent.

Damaged upper piston diaphragm. Remove regulator from tank and replace diaphragm. Diaphragm installed incorrectly. Reinforcement fabric must be opposite to pressure (see page 13).

Gas leaking from lower body seal or case vent.

Soap bubble test at joining surface or emission indication near vent.

Damaged lower piston diaphragm. Remove regulator from tank and replace diaphragm. Diaphragm installed incorrectly. Reinforcement fabric must be opposite to pressure (see page 13).

Process vapor leaks from case flange or vent.

Soap bubble test at joining surface or emission indication near vent.

Damaged actuator diaphragm or loose case bolts. Tighten bolts or remove regulator from tank and replace diaphragm.

Tank pressure above or below specified operating range during pump out or pump in.

Observe tank pressure indicator during pumping operations.

Excess or insufficient blanket gas flow. Check flow orifice orientation. Refer to Tables 2 & 6 for flow capacity data. Check gas supply pressure. Remove and repair regulator if other conditions are correct.

Tank pressure or vacuum exceeds vent settings during pump out or pump in.

Observe tank pressure indicator during pumping operations.

Pressure/vacuum relief vent not functioning properly. Inspect and repair or replace as necessary.

9

PREVENTIVE MAINTENANCE Periodically, while in service, examine the regulator for leakage at bolted connection, adjusting screws, etc. Test for blanket gas or process vapor emissions from vent caps. DISASSEMBLY

All service on the regulator may be performed with the following common tools:

7/16" thru 1" box end wrenches 3/8" open end wrench* 3/16" Allen key *Wrench must be 16" long for flanged units. Thread a 1/2" pipe nipple into the sense port on the lower diaphragm case [15]. Use a vise and clamp onto the pipe nipple. This makes a good holding

fixture and provides some degree of rotation while working on the regulator.

Remove the adjustment screw cap [1] and loosen the jam nut [3]. Turn the adjustment screw [2] counterclockwise to completely relax the spring [6]. Remove the cap screws [28] and the lock washers [29]. Remove the spring bonnet [4]. Remove the spring upper button [5], the spring [6], the lower spring button [5] and then the bonnet adapter ring [10]. Use a 3/8" open end wrench and insert it through the inlet port to hold onto the piston [24] at the wrench flats. Remove the upper piston pin [8] while holding onto the piston. Be careful not to let the piston rotate during removal of the upper piston pin. The piston diaphragms [21] can easily be torn if care is not taken.

Figure 7: Piston/Body Assembly

9

8

21

24

WRENCHFLATS

20

Remove the upper diaphragm retainer [9] and the upper piston diaphragm [21].

WARNING Before removing the regulator from the tank for service, block supply pressure and vent all trapped pressure. Never attempt to remove the regulator from the line if it is pressurized.

Figure 6: Spring Bonnet Assembly

1

2

3

5

4

6

28

7

29

WARNING

Do NOT attempt to remove the spring chamber [4], flow orifice locking screw [36], or any pipe connections from the body [20], while the regulator is pressurized.

WARNING

Diaphragm actuator case and regulator body are exposed to the process vapor(s). Observe all standard safety precautions as specified on Material Safety Data Sheets for the product(s) that are in the tank. These precautions apply both during removal of the regulator from the tank and while repairing it.

10

Remove the hex nuts, lockwashers, and hex bolts (items 18, 17, & 16 respectively). Remove the upper diaphragm case assembly [12] straight up. Loosen the vise and remove the lower diaphragm case with the pipe nipple still intact. Turn the upper diaphragm case assembly upside down and use a vise to hold on to the body [20]. Insert the 3/8" open end wrench through the inlet port and hold on to the piston at the wrench flats while loosening the countersunk screw [37] (See Figure 12).

Figure 8: Piston Assembly - "Exploded"

24

25

31

32

33

Remove the washer [38], the diaphragm [14], the diaphragm support plate [13] and then the back-up plate [19]. Use a 3/16" Allen hex key and remove the countersunk screws [30]. Remove the upper diaphragm case [12]. Lift the piston sub-assembly [24] straight up and remove from the body for disassembly. Lay the piston subassembly horizontally on a clean flat surface. Hold the piston at the wrench flats and remove the lower pin [26], the diaphragm retainer [9], the diaphragm [21], the O-Ring [22] and then the guide ring [23]. Remove the piston sub-assembly from the body.

Remove the lift stop ring [33] from the groove by expanding the ring slightly; and slide it over the piston with care. Do not overexpand the ring. Remove the retaining ring [32] with retaining ring pliers. Expand retaining ring just enough to slide over the piston. Be careful not to scratch the piston surface. Remove the O-Ring retainer [31] and the o-ring [25].

Figure 9: Orifice Sleeve Orientation

2

3 2

34

36 35

Refer to "FLOW CAPACITY SETTING" and warnings before disassembling lockdown screw [36] from body. Loosen and screw the lock down screw [36] completely out of the Body. Before removing the orifice selector sleeve [34], make note of its position by looking through the 1/2" lock down screw port. There will be a number stenciled on the sleeve indicating the position of the sleeve. Note this number for re-assembly. Refer to Tables 2 & 6 to determine flow capacity of the regulator at a specific open position. All components should be examined for damage or wear. Replace all seals and diaphragms. Prior to reassembly, make sure all components are clean and free of contamination.

11

ASSEMBLY Before assembly note the following material and tool requirements: 1. Diaphragms, O-Rings, gasket, vents and

spring as listed in Table 7: Recommended Spare Parts on page 8.

2. Lubricants & Thread Sealants A. Silicone Grease Dow Corning No. 33 B. Anti-Galling Lubricant Dow Corning G-N Metal Assembly Spray C. Thread Sealant Loctite Threadlocker No. 222 D. Fluoropolymer tape 3. Assembly Tools A. 7/16" - 1" box end wrenches B. 3/8" open end wrench* C. 3/16" Allen key * Wrench must be 16" long for flanged units. All screw threads and static O-Ring should be lightly greased with silicone grease. Lubricate the piston OD at both ends and the spring adjusting screw with an anti-galling spray. If the greases listed above are not compatible with the tank vapors, use equivalent lubricants for that media. All pipe threads are to be wrapped with Fluoropolymer tape or suitable pipe thread sealant applied sparingly. Before installing the orifice selector sleeve, read the section entitled "FLOW CAPACITY SETTING" and related warnings on page 7. Install the orifice selector sleeve [34] into the regulator body. Observe the sleeve position locking hole by looking in the locking screw hole in the body. The hole in the sleeve should be exactly centered in the screw hole. If the holes do not line up exactly, invert the sleeve and reinstall. The position indicating numbers will also be seen through the screw hole. These numbers indicate % open and flow capacity according to Tables 2 and 6. Make sure that the sleeve position is on the same number as when disassembled, or on the number that provides the specified flow requirements.

Figure 10: Orifice Sleeve Orientation

2

3 2

34

36 35

Grease the locking screw O-ring [35] and slip it over the screw threads. Thread the locking screw [36] into the body, finger tight, until the point enters the sleeve and the head seats onto the O-ring. Then wrench tighten the head firmly against the body, compressing the O-ring. Note: Damage to the sleeve will occur if force is applied with the point of the locking screw.

Figure 11: Piston Assembly - "Exploded"

24

25

31

32

33

Assemble the piston sub-assembly according to Figure 11. Install the O-Ring [25] from the top end of the piston. Do not rotate the o-ring, but stretch it just enough to clear the piston diameter. When installing the retaining ring [31], snap ring [32] and lift stop ring [33] expand the rings just enough to

12

clear the piston without scratching the piston or permanently deforming the rings. Secure the body in a vise with the bottom surface facing upward and the inlet port accessible (See Figure 12). Spray the piston sub-assembly with an anti-galling lubricant and insert it and the guide ring [23], into the body. Install the body O-Ring [22]. Set the piston diaphragm into the upper actuator housing with reinforcing fabric away from the piston (opposite to the supply pressure). Refer to Figure 12. Attach the upper diaphragm case [12] to the body, being sure that the piston wrench flats are accessible through the inlet port before tightening the countersunk screws [30].

Figure 12: Piston/Body/Diaphragm

21

31

32

33

34

26

13

38 3719

21

23

24

25

22

WRENCHFLATS

Attach the sense diaphragm [14], support plate [13], back-up plate [19] and washer [38] (See Figure 15). Clean thread surfaces thoroughly and apply Loctite Threadlocker No. 222 to countersunk screw [37]. Align diaphragm and case holes and hold piston with a 3/8" wrench through inlet port while tightening the countersunk screw [37]. Attach the gasket [39] and lower diaphragm case [15] with hex bolts, lockwashers and nuts [16, 17, & 18].

Clean all surfaces before assembly and tighten bolts uniformly; refer to Table 8 for recommended torque. Reposition the assembly in the vise. Install the upper piston diaphragm [21], retainer [9] and pin [8]. Hold piston with 3/8" wrench through inlet port while tightening pin. Install the bonnet adapter ring [10], spring [6], spring buttons [5] and spring bonnet [4]. Attach bonnet to body with hex bolts [28] and lockwashers [29]. Tighten bolts uniformly; refer to Table 8 for recommended torque.

Figure 13: Spring Bonnet Assembly 1

2

3

5

4

6

28

7

29

Thread set pressure adjusting screw [2] into bonnet until it engages the upper spring button. Tighten lock nut [3] and replace cap [1]. Note: See Recommended Testing and Setting Procedure.

TABLE 8 RECOMMENDED BOLT TORQUE

[FT. - LB.]

Screw Size

1/4"

5/16"

3/8"

7/16"

1/2"

Torque

6

11

20

32

44

WARNING Replace bonnet vent [7] or case vent [11] if damaged or restricted. A plugged case vent could prevent the regulator from closing. This could cause an over-pressure condition in the tank. A plugged bonnet vent would prevent the release of supply pressure from the bonnet. This could cause personal injury when disassembling.

13

RECOMMENDED TESTING AND SETTING PROCEDURE 1.0) Equipment 1.1) A high pressure air (or inert gas) supply

system capable of maintaining supply pressure at 0-200 PSI. Flow may be controlled by a reducing regulator or valve.

1.2) A low pressure air (gas) supply system capable of maintaining sense pressure at 1/2" WC to 10 PSI. Pressure may be controlled by a regulator or needle valve and a small accumulator. If a needle valve is used, it will require frequent adjustment because the regulator consumes a significant volume of air when operating.

1.3) A means of indicating or measuring air flow with a capacity of approximately 30 SCFH.

1.4) A means of soap bubble shell testing the assembly.

2.0) Test procedure and Acceptance Criteria. 2.1) Connect the high pressure air supply to the

regulator inlet port. 2.2) Connect the low pressure air supply to the

regulator sense port. 2.3) Connect a reduced size manual shut-off valve

to the outlet port. 2.4) Connect a small diameter hose or plastic tube

to the inlet of the flow indicator or flow meter. Use a hand held port cover to attach the flow meter to the regulator outlet port. Never connect the flow meter rigidly to the regulator unless the flow meter is rated for full air supply pressure.

2.5) Connect a small diameter hose or plastic tube to the outlet of the flow indicating device so the end may be immersed in a container of water.

2.6) Close the outlet valve and set the supply air pressure to the maximum available, but not greater than 300 PSI. Soap bubble test the entire assembly at this pressure. Open the

outlet valve and reduce the supply until a minimum audible flow is observed.

2.7) Adjust the sense pressure to the specified

regulator set pressure. Adjust the regulator screw to shut off (no audible flow). Now increase the sense pressure to 2 times the specified set pressure or 1.5 times the specified tank MAWP, whichever is greater. Soap bubble test the actuator housing.

2.8) Increase the supply pressure to the specified system pressure (100 PSI if not specified).

2.9) Slowly decrease the sense pressure and adjust the regulator screw until the air flow is 5-20 SCFH at the specified setting. Lock the adjusting screw at this setting.

2.10) While immersing the outlet tube in water, increase the sense pressure until the regulator is bubble tight. If this pressure exceeds 15% or 2" WC greater than the set pressure, examine the seat and O-Ring. Do not adjust the regulator screw to improve bubble tightness.

2.11) Remove the bonnet vent. Shut off the supply pressure. Slowly decrease the sense pressure to zero, while observing the stroke of the piston thru the bonnet vent port. The stroke must be 0.18" minimum. Replace the bonnet vent.

3.0) Test report data. 3.1) The following data should be recorded for

future reference: Model, Tag & Serial numbers Test media Body & Actuator shell test pressure Supply pressure Set pressure Bubble tight pressure

14

Figure 14: Blanketing Regulator - "Exploded" Assembly

8

9

21

21

9

26

16

11

12

19

30

13

14

38

37

39

15

17

24

25

31

32

33

PISTONSUB-ASSY

ACTUATOR & PISTON ASSY

BODY & SPRINGBONNET ASSY

34

36

35

20

10

5

6

5

7

29

28

4

2

3

1

23

22

18

15

TABLE 9 BILL OF MATERIAL

3000 SERIES BLANKET GAS REGULATOR

MATERIALS OF CONSTRUCTION ITEM QTY DESCRIPTION CARBON

STEEL STAINLESS

STEEL 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

1 1 1 1 2 1 1 1 2 1 1 1 1 1 1

36 36 36 1 1 2 1 1 1 1 1 1 4 4 4 1 1 1 1 1 1 1 1 1

Cap, Adjustment Screw Screw, Pressure Adjustment Nut, Hex Bonnet, Spring Button , Spring Spring Vent, Bonnet Pin, Upper Piston Retainer, Diaphragm Adapter, Bonnet Vent, Case Case, Upper Actuator Plate, Diaphragm Support Diaphragm, Actuator Case, Lower Actuator Bolt, Hex Washer, Lock Nut, Hex Plate, Back-Up Body Diaphragm, Piston O-Ring, Guide Ring Ring, Guide - Piston Piston O-Ring, Piston Seat Pin, Lower Piston Nameplate Bolt, Hex Washer, Lock Screw, Flathead Retainer, O-Ring Piston Seat Retaining Ring Stop, Lift Sleeve, Orifice Selector O-Ring, Lockdown Screw Screw, Locking - Flow Orifice Screw, Flathead Washer, Countersunk Gasket, Actuator

CS SS SS CS CS

316 SS PVC or Alum

316 SS 316 SS

CS PVC or Alum

CS 316 SS

Fluoropolymer CS SS SS SS

316 SS 316 SS

BUNA-N BUNA-N

316 SS 316 SS

BUNA-N 316 SS 316 SS

SS SS SS

316 SS SS SS

316 SS BUNA-N

316 SS 316 SS

SS Non-Asbestos

SS SS SS

316 SS 316 SS 316 SS

PVC or Alum 316 SS 316 SS 316 SS

PVC or Alum 316 SS 316 SS

Fluoropolymer 316 SS

SS SS SS

316 SS 316 SS FKM FKM

316 SS 316 SS FKM

316 SS 316 SS

SS SS SS

316 SS SS SS

316 SS FKM

316 SS 316 SS

SS Non-Asbestos

16

Figure 15: Blanketing Regulator - Cross-Sectional Assembly

1

2

3

4

5

6

7

8

9

10

11

1213

14

30

15

19

22

23

24

25

21

21

26

18 17 16

28 29

REF

20

31

33

34

32

35

36

38

27

39

37

PISTON DETAIL

TOP VIEW

SHOWS TRUEORIENTATION

INLET

OUTLET

SENSEPORT

17

The nameplate on the Groth Series 3000 Tank Blanketing Regulator contains the model number, serial number, set pressure & range and supply pressure. The model number contains additional information about material of construction, capacity and options. The following chart will assist in relating the model number to the specifications of your regulator:

3000 N 5 V 1 O

Connections

Material

Soft Goods

Orifice

Options

N F Z

1" NPT (F) 1"150# RF Special

3 5 Z

Carbon Stl 316 SS Special

B V E Z

Buna-N FKM EPDM Special

1 2 3 4

100% 75% 50% 25%

0 Z

None Special

Model 3000 2" WC to 2 PSI Pressure Range Model 3010 1/2" WC to 2" WC Pressure Range Model 3020 1 PSI to 10 PSI Pressure Range

A "Z" in the model number indicates a non-standard material or feature. Review your purchase specifications or consult Groth Corporation for more details.

EXAMPLE 3000 N 5 V 1 0 Indicates a 3000 Series Regulator with Set Pressure Range from 2" WC - 2 PSI, 1"

NPT Body Connections, 316 SS Construction, FKM Elastomers, Full Capacity Orifice and No Special Requirements.

PRODUCT LIMITED WARRANTY A. Seller warrants that products which are manufactured

by Seller, are manufactured in accordance with published specifications and free from defects in materials and/or workmanship for a period of (12) twelve months. Seller, at its option, will repair or replace any products returned intact to the factory, transportation charges prepaid, which Seller, upon inspection, shall determine to be defective in material and/or workmanship. The foregoing shall constitute the sole remedy for any breach of Seller's warranty.

B. THERE ARE NO UNDERSTANDINGS,

AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE REGARDING PRODUCTS) UNLESS SPECIFIED IN THE SALES CONTRACT. THIS CONTRACT STATES THE ENTIRE OBLIGATION OF SELLER.

Seller makes no warranties, either express or implied,

except as provided herein, including without limitation thereof, warranties as to marketability,

merchantability, for a particular purpose or use, or

against infringement of any patent of products. In no event shall Seller be liable for any direct, incidental or consequential damages of any nature, or losses or expenses resulting from any defective new product or the use of any such product, including any damages for loss of time, inconvenience, or loss of use of any such product.

C. The original Manufacturer shall be solely responsible

for the design, development, supply, production, and performance of its products hereunder, and the protection of its trade name or names, if any. It assumes no responsibility, for products modified or changed in any way by its agent or customer. Any such modifications or changes to products sold by Seller hereunder shall make the product limited warranty null and void.

D. The Manufacturer shall be under no obligation to

manufacture, sell, or supply, or to continue to manufacture, sell or supply any of the Products.

ADDENDUM A Groth Corporation continually reviews and revises designs and specifications to improve quality and performance of its manufactured products. The specifications and procedures in this addendum supersede the applicable sections of the

manual for all Groth blanket gas regulators manufactured after 7/1/1994.

PRESSURE SETTING

All springs and spring ranges are the same, however, balance springs have been added in some spring ranges. Refer to tables 3, 4 and 5 below.

FLOW CAPACITY SETTING

The setting procedure is the same, but additional flow restrictions are available, down to 5% of full flow. Refer to table 6 below.

DISASSEMBLY

Some regulators utilize a balance spring inside the body (refer to Tables 3 & 4 and Figure 12 on the reverse side of this page).

Hex bolts [28] are used in place of the countersunk screws [30] to mount the body to the actuator housing. As the bolts are removed, the internal spring [30] will force the guide ring [23] out of the body. The force is not great enough to present a hazard, but caution should be used to prevent damage to the ring. The spring can then be removed as part of the piston sub-assembly. Proceed with disassembly according to the manual.

ASSEMBLY

Prepare the body, piston sub-assembly and upper actuator housing according to the manual. Attach the piston diaphragm [21], diaphragm retainer [9] and lower piston pin [26] to the piston sub-assembly. Note: The reinforced (rough) surface of the piston diaphragm [21] must be facing away from the piston, ie: high pressure on the smooth side. This is critical for the top (inlet) piston diaphragm. Proceed with assembly according to the manual, except where a balance spring is utilized, then proceed as follows:

Slide the small end of the balance spring [30] over the piston sub-assembly until it seats on the retaining ring [32]. Insert this piston/spring sub-assembly into the body. Fit the large end of the balance spring into the groove in the guide ring [23] and compress the spring as you insert the guide ring and O-Ring [22] into the body. Hold the guide ring as you position the actuator housing [12] onto the body. The weight of the housing will maintain compression of the spring. Install hex bolts [28] and lockwashers [29] and tighten uniformly. Proceed with assembly according to the manual.

See piston/body/diaphragm sub-assembly drawing (Figure 12) and bill of materials on the next page.

TABLE 3 Spring Table Model 3000

Set Pressure Range: 2" WC to 2.0 PSI Tank MAWP: 25 PSI

Spring Range

Min. Setting

Max. Setting

Spring P/N

Balance Spr P/N

1

2.0 In WC

3.4 InWC

84209001 Yellow

85493001 Yellow

2

3.5 In WC

6.3 InWC

84209002 Green

Not Required

3

6.4 In WC

10.9 InWC

84209003 Pink

Not Required

4

11.0 In WC

18.5 InWC

84209004 Blue

Not Required

5

18.6 In WC

27.6 InWC

84209005 White

Not Required

6

1.0 PSI

1.37 PSI

84209006 Gray

Not Required

7

1.38 PSI

2.0 PSI

84209007 Black

Not Required

TABLE 4 Spring Table Model 3010

Set Pressure Range: 0.5" WC to 2.0" WC Tank MAWP: 10 In WC

Spring Range

Min. Setting

Max. Setting

Spring P/N

Balance Spr P/N

8

0.5 In WC

0.6 In WC

84209008 Red

85493001 Yellow

1

0.7 In WC

1.0 In WC

84209001 Yellow

85493001 Yellow

2

1.1 In WC

2.0 In WC

84209002 Green

Not Required

TABLE 5 Spring Table Model 3020

Set Pressure Range: 2.0 PSI to 10.0 PSI Tank MAWP: 25 PSI Standard 150 PSI Optional

Spring Range

Min. Setting

Max. Setting

Spring P/N

Balance Spr P/N

4 2.0 PSI 3.3 PSI 84209004

Blue Not

Required

5 3.4 PSI 5.1 PSI 84209005

White Not

Required

6 5.2 PSI 7.3 PSI 84209006

Gray Not

Required

7 7.4 PSI 10.0 PSI 84209002

Green Not

Required

29 28 38 37 26 13

30

34

810 9 21

22

19

23

33

36

35

32

31

25

24

Figure 12

ITEM QTY DESCRIPTION

8 9

10 13 19 21 22 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38

1 2 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1

Pin, Upper Piston Retainer, Diaphragm Adapter, Bonnet Plate, Diaphragm Support Plate, Back-Up Diaphragm, Piston O-Ring, Guide Ring Ring, Guide - Piston Piston O-Ring, Piston Seat Pin, Lower Piston Bolt, Hex Washer, Lock Spring, Balance Retainer, O-Ring Piston Seat Retaining Ring Stop, Lift Sleeve, Orifice Selector O-ring, Lockdown Screw Screw, Locking - Flow Orifice Screw, Flathead Washer, Countersunk