High Volume Oxygen Regulators
OXYGEN REGULATORS
SELECTING A REGULATOR FOR BURNING BARS AND SURE CUT RODS
The first step in selecting an Oxygen regulator is the Oxygen Supply. There are two types of Oxygen supplies, High Pressure (up to 3500 psi) and Low Pressure (600 psi max). The second step is the applications required Set Pressure and Volume.
For Oxylance applications, regulators must be capable of flowing high volumes of Oxygen, (up to 100 cfm) at pressures up to 150 psi. In all cases, the volume and pressure an oxygen regulator can flow depends on the supply or inlet pressure and volume (P1) and the required outlet pressure and volume (P2).
Inlet VOLUME (P1) is critical for Oxylance applications. For example, a single liquid oxygen cylinder with internal vaporizer will only produce 6 cubic feet of gaseous oxygen per minute and our exothermic cutting rods require from 10 to 100 cubic feet per minute. Over drawing a liquid oxygen cylinder will result in regulator freeze up and damage to downstream equipment. (See our section on external vaporizer systems). Regulators for liquid oxygen must be rated for Cryogenic service.
Regulators must be selected according to the following criteria:
- Gas Supply (High Pressure cylinders or Liquid Oxygen)
- Supply Pressure (P1)
- Supply Volume
- Hose Inside Diameter
- Required Set Pressure (P2)
- Required Volume
Standard High-Pressure Regulators have a ¼” npt Inlet port and ¼” npt Outlet port. These regulators are fine for applications using ¼” or 3/8” id oxygen hoses. For all applications using larger diameter hoses the regulator needs outlet ports closely matching the hose id.
Different types of regulators and their applications
- Two Stage high pressure regulators. Work well with high pressure cylinders and hose diameters up to 3/8” id. They do not work for Cryogenic applications.
- Single Stage high pressure regulators. ¼” npt Inlet Port with ½” Outlet Port can be used with high pressure cylinders and hoses with inside diameter up to ¾”.
- Cryogenic application regulators for vaporizer systems. Manifold Regulators
- Distribution Regulators. These are designed to be used on manifolds and pipeline systems where the inlet pressure is lower, and the outlet volume requirement is high. These are available with inlet / outlet ports from ½” up to 2”.
A two-stage regulator for high pressure cylinders is two regulators built into one body. Typical two stage regulators have the first stage (first regulator) preset to 500 psi. This is preset at the factory and not adjustable. The second stage then regulates the pressure down to the design pressure of the torch being used. Normally this is between 40 and 150 psi. These regulators perform best with small cutting torches and the Oxylance Sure Cut system. They will not provide the volume and pressure required to run Lance Pipe or Burning Bars.
Single Stage regulators can be manufactured for higher flow rates (Cv) and the external port can be larger. The Oxylance REG-5-250 is a single stage regulator designed with a ½” npt outlet port (P2) that will flow 10,000 cubic feet per hour at 150 psi from high pressure cylinder systems.
(Single Stage High Pressure regulator with ½” outlet port (P2)
MANIFOLD REGULATORS FOR VAPORIZER SYSTEMS
(1/2” Inlet (P1) and ½” Outlet (P2) regulator for Cryogenic applications on external vaporizers)
These regulators are designed for high Cv with inlet pressures as low as 200 psi.
OXYGEN REGULATORS FOR STEEL MILLS AND FOUNDRIES
(Sliding Gate ¾” regulator with Inline Filter in an Oxylance designed regulator enclosure)
Low Pressure Distribution regulators (also referred to as Manifold Regulators) have inlet and outlet ports that are ½” npt and larger. Matching a regulator for these applications is critical. With a line pressure of 200 to 275 psi the lance stations require a regulator that has enough flow capacity (Cv) to keep up with the flow demand, while maintaining the desired outlet pressure (P2). All the criteria for regulators must be considered when selecting a regulator for lancing operations.
- Supply Pressure (P1)
- Supply Volume
- Hose Inside Diameter
- Required Set Pressure (P2)
- Required Volume
The most dependable Distribution Regulator we have found is a design called Sliding Gate Regulators. Sliding Gate regulators are designed to operate in situations where plant oxygen is supplied from liquid oxygen bulk tanks or an Air Separation Plant. The operating pressure of these systems range from 200 to 275 psi. The liquid is fed into a vaporizer system that heats the oxygen to ambient temperature and sends the gaseous oxygen to the plant via a pipeline.
All distribution and manifold regulators require an inline filter to prevent internal damage from contaminates in the piping system.
HELPFUL TERMS
DROOP – A decrease in outlet pressure caused by an increase in flow rate through a pressure reducing regulator
P1 – Inlet Supply pressure and volume
P2 – Desired Outlet / Set Pressure
Delta P – Differential Pressure
Flow – Required Quantity of Gas passed by the regulator
Cv – Flow Capability of the regulator. This is determined by a set of flow standards.
