Swagelok PRS15 User manual

PRS15 Pressure-Reducing Regulator
User Manual
Read the complete manual before installing and using the regulator.

2
Safe Product Selection
When selecting a product, the total system design must be considered to ensure safe, trouble-free
performance. Function, material compatibility, adequate ratings, proper installation, operation, and
maintenance are the responsibilities of the system designer and user.
WARNING
•Users must be trained and equipped for the handling, use, and servicing of pressure
products and systems.
•Users must contact their gas or liquid supplier for specific safety precautions and
instructions.
•Gaseous media should be free of excessive moisture to prevent icing at high flow.
•Always wear the appropriate protective clothing, including safety glasses, gloves, etc., if
required.
•Follow the applicable safety and maintenance procedures.
•Obey specific local regulations.
•Do not exceed the maximum inlet and outlet pressure rating of the product or its
accessories.
•Operate within the temperature limits and any other conditions specified for the product.
•Do not drop or damage the product in any other way. This may negatively affect the
performance of the product which can cause the product to malfunction.
•Venting fluids and gases can be dangerous. Vent to a safe environment away from people.
Ensure adequate ventilation.

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Contents
Introduction........................................................................................................................................................ 4
Overview.......................................................................................................................................................... 4
Standard Features........................................................................................................................................... 4
Additional Options ........................................................................................................................................ 4
Oxygen Service............................................................................................................................................... 4
Installation.......................................................................................................................................................... 5
Points of Attention Before Installation ............................................................................................................. 5
Installation ....................................................................................................................................................... 5
Operation............................................................................................................................................................ 6
Required Tools for Operation.......................................................................................................................... 6
Points of Attention Before Operation............................................................................................................... 6
Adjusting the Set Pressure.............................................................................................................................. 6
Maintenance....................................................................................................................................................... 7
Required Tools for Maintenance..................................................................................................................... 7
Points of Attention Before Removal from the System..................................................................................... 8
Removal from the System............................................................................................................................... 8
Assembly Reference Data............................................................................................................................... 9
Points of Attention Before Reassembly......................................................................................................... 12
Reassembly................................................................................................................................................... 13
Testing.............................................................................................................................................................. 14
Seat Leak Test .............................................................................................................................................. 14
Shell Leak Test.............................................................................................................................................. 14
Troubleshooting .............................................................................................................................................. 15

4
Introduction
Overview
- The PRS15 series are spring-loaded pressure-reducing regulators designed for high-sensitivity regulation
of gases and liquids.
- For pressure and temperature rating information refer to the Sanitary Pressure Regulators, RHPS Series
catalog, MS-02-436.
WARNING
Check that system pressures and temperatures do not exceed those stated on the regulator as
this could result in product failure.
Standard Features
- Threaded construction
- Stainless steel as standard
- Fully serviceable
- Diaphragm sensing
Additional Options
The regulator is available with the following options:
Anti-tamper
Oxygen Service
- For more information about hazards and risks of oxygen enriched systems see the Swagelok Oxygen
System Safety technical report (MS-06-13).
- Cleaning and packaging to ensure compliance with product cleanliness requirements stated in ASTM G93
Level C is provided as standard. Refer to the Sanitary Pressure Regulators, RHPS Series catalog, MS-
02-436, for additional information.

5
Installation
CAUTION
Do not use the regulator as a shutoff device. A level of leakage across the regulator seat can
occur during normal operation.
Points of Attention Before Installation
Before installing the regulator you should fully understand the suitability of your particular regulator for the
intended application.
- The preferred mounting position of the regulator is horizontal with the spring housing facing upwards per
Fig 2. Alternative mounting positions may increase the risk of component wear.
- It may be necessary to remove the regulator from the system during maintenance or service. Ensure that
this is possible.
- The regulator is suitable for gases or liquids. Ensure compatibility between the regulator’s materials of
construction and the system media.
Installation
- Verify that the regulator, its connections, and any accessories are undamaged.
- Verify that the regulator and any accessories are suitable for the system operating pressure and
temperature and have suitable connections.
- At the time of delivery any gauge ports may be plugged with blind fittings. Remove these and connect
gauges if desired.
CAUTION
Ensure all upstream tubing/pipework is clean and free from debris. Any swarf, lint, wire, etc. may
damage the regulator, resulting in a seat leak.
- Verify the flow direction of the system and mount the regulator accordingly.
- Securely make the appropriate connections to the regulator in accordance with the procedures
recommended by the connection manufacturer.
- Ensure that the tubing/pipework and the regulator are adequately supported and that there is no stress on
the connections.
- Upstream and downstream shutoff valves should be installed in the system to facilitate servicing,
maintenance, and troubleshooting of the regulator.

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Operation
Required Tools for Operation
- No tools are required for changing the set pressure on a standard regulator.
- A 12 mm open-ended wrench and a 4 mm hex drive are required for anti-tamper regulators.
Points of Attention Before Operation
CAUTION
The product can be hot or cold, depending on the environmental temperature and the process
media temperature. Take the necessary precautions before operating or touching the product.
- Stopping flow through the regulator by closing a downstream shutoff valve may result in a rise in outlet
pressure above the set pressure. This is usually referred to as “lock-up”. This phenomenon does not
indicate a problem with the regulator.
- A decrease of the flow rate may result in a rise of the outlet pressure. An increase of the flow rate may
result in a fall of the outlet pressure. This is usually referred to as “droop”. This phenomenon does not
indicate a problem with the regulator.
- A decrease of the inlet pressure may result in a rise of the outlet pressure. An increase of the inlet
pressure may result in a fall of the outlet pressure. This is usually referred to as “inlet dependency” or
“Supply Pressure Effect (SPE)”. This phenomenon does not indicate a problem with the regulator.
Adjusting the Set Pressure
- The set pressure is the desired outlet pressure of the regulator.
- To set the regulator, ensure that the supply pressure is greater than the required set pressure but does
not exceed the maximum rating of the regulator.
- The regulator must be able to flow in order for it to reduce the outlet pressure.
1. Partially open any downstream valve. This will allow minimal flow through the regulator when adjusting the
set pressure, reducing media consumption during this process.
2. Fully unwind the adjustment knob counterclockwise.
3. Steadily open the supply valve to allow inlet pressure to the regulator.
4. To operate the regulator, turn the adjustment knob clockwise to increase the set pressure. Turn the knob
counterclockwise to reduce the set pressure.
5. To obtain the most accurate set pressure, final adjustment must be made while increasing the set
pressure. If the desired outlet pressure is exceeded, reduce the pressure below this value then increase
up to it.
6. Fully open the downstream valve to allow full flow during operation.
7. Once under flow conditions make any final set pressure adjustments per steps 3 and 4 if required.

7
Maintenance
WARNING
Incorrect or improper repair or servicing of this product can cause serious personal injury and
property damage.
- All repairs, servicing, and testing of this product must be performed by competent personnel.
- Following any maintenance of the regulator, it is recommended that the product be tested for operation
and leakage.
- The product should be checked periodically for proper and safe operation. It is the user’s sole
responsibility to determine the frequency of maintenance based on the application.
- To reduce maintenance related system downtime to a minimum, either during commissioning or normal
operation, Swagelok recommends having maintenance kits readily available on site. The need for
maintenance kits is particularly important during the commissioning phase of a system installation due to
residual assembly debris remaining in the system. Such debris can cause a seat leak in the regulator,
resulting in components needing to be replaced.
Required Tools for Maintenance
Smooth-jawed vise
Calibrated torque wrench up
to 37 lbf·ft (50 N·m)
13 mm socket
Lubricant (included in kit):
Krytox® 240 AC
36 mm socket
24 mm open-ended
wrench
Liquid leak detector
50 mm crows foot
Table 1

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Points of Attention Before Removal from the System
- Swagelok recommends removing the regulator from the system for servicing and maintenance.
- Follow all local system safety and maintenance procedures when removing the regulator.
WARNING
Before removing a regulator from the system, to avoid personal injury, you must:
•Depressurize the system.
•Purge the system to remove any residual system media left in the regulator.
•Always vent to a safe environment away from people and ensure there is adequate
ventilation.
CAUTION
Check if the process media is hazardous or toxic. If required, take the necessary safety
precautions to ensure a safe workspace and your personal safety.
CAUTION
The product can be hot or cold, depending on the environmental temperature and the process
media temperature. Take the necessary precautions before operating or touching the product.
Removal from the System
1. Isolate the regulator from all pressure sources by closing all appropriate upstream valves in the system.
2. With the regulator set, open all appropriate downstream valves to allow pressure to vent from the
regulator.
WARNING
Ensure all pressure on the inlet and outlet has been fully vented. The accidental release of
residual trapped pressure can cause serious personal injury.
3. Disconnect and remove the regulator from the system.

9
Assembly Reference Data
Item
Component Name
Kit Type(s)
Torque
lbf·ft (N·m)
Recommended Lubrication
(included in kit per Table 1)
1
Body plug
C1, C2
37 (50)
Lubricate threads
2
Body plug O-ring
B1, B2, C1, C2
3
Poppet spring
C1, C5
4
Poppet O-ring
A1, A2, B1, B2, C1
Lubricate
5
Poppet
A1, A2, B1, C1
6
Seat
A1, B1, C1
7
Seat O-ring
A1, B1, B2, C1
8
Body
N/A
9
Diaphragm screw
C1
Lubricate threads
10
Diaphragm
B1, B2, C1, C3
11
Bottom spring guide
C1
12
Washer
C1
13
Hex nut
C1
11 (15)
14
Clamp ring
C1
15
Set spring
C1, C4
16
Spring guide
C1
Lubricate central recess
17
Ball
C1
Lubricate
18
Spring housing
N/A
37 (50)
Lubricate threads
19
Knob assembly
D1
Lubricate threads
20
Anti-tamper set screw
D1
Lubricate threads
21
Anti-tamper cover O-ring
B1, B2, C1, D1
22
Anti-tamper cover
D1
Lubricate threads
Table 2
For more information on RHPS series maintenance kits, refer to the Sanitary Pressure Regulators, RHPS
Series catalog, MS-02-436.

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PRS15 Series, Exploded View
Fig 1