Gas pressure regulators are essential components in city gas distribution systems, designed to reduce and stabilize the gas pressure for safe and efficient use by end consumers. These devices typically consist of several key modules, including a pressure regulator for adjusting pressure, a filter for removing impurities, a heat exchanger to prevent ice blockage caused by rapid gas expansion, and a flow meter for measuring gas consumption. These components are usually assembled using welding and flange connections to form a complete and functional system.
When designing and manufacturing gas pressure regulators, it is crucial to understand their classification under the special equipment regulations. Unlike pressure vessels or pipelines, these devices are categorized as "component combination devices" in the special equipment catalog. As such, manufacturers must obtain proper licensing from the AQSIQ (General Administration of Quality Supervision, Inspection and Quarantine) before production. Additionally, any associated pressure vessels, such as filters, heat exchangers, or buffer tanks, must be manufactured by certified entities with appropriate pressure vessel licenses.
Design and manufacturing standards vary depending on the operating pressure levels. Different pressure sections may require different materials, such as flanges, valves, and pipes, to ensure safety and cost-effectiveness. Non-destructive testing of welds should also be tailored to the specific pressure conditions. Pressure tests can be conducted separately for each section, while an airtightness test should be performed after assembly to ensure no leaks occur.
Safety is a top priority in the design of gas pressure regulators. Key safety measures include the installation of emergency shut-off valves and safety relief valves. The emergency shut-off valve is typically placed upstream of the pressure regulator and activates when pressure exceeds the set limit, protecting downstream equipment. A safety relief valve is installed downstream of each stage to release excess pressure and prevent damage to the system. The settings of these valves must be carefully coordinated to avoid unnecessary shutdowns and ensure continuous gas supply.
Static electricity buildup is another critical concern. Due to the presence of non-metallic gaskets and thread sealants, static charges can accumulate and cause sparks. To mitigate this risk, conductive copper wires or plates should be installed across flanges or threaded joints if the resistance between them exceeds 0.03 ohms. These conductive elements must be rust-free, tightly connected, and not painted. Proper grounding of the entire system is also necessary, especially if the ground resistance exceeds 100 ohms.
Odorization is another important feature. Natural gas is odorless, making leaks difficult to detect. To address this, an odorant such as tetrahydrothiophene (THT) or ethanethiol is added to the gas to make leaks easily noticeable. This helps prevent accidents and ensures early detection of potential issues.
Pressure and temperature monitoring instruments should be installed after each stage of regulation to provide real-time data on system performance. Remote monitoring capabilities can further enhance operational efficiency and safety.
In conclusion, as natural gas and other clean energy sources become more widely used, the importance of reliable and safe gas pressure regulators continues to grow. However, without clear and consistent design and manufacturing standards, there is a risk of defects that could lead to serious safety issues. Therefore, regulatory authorities must strengthen oversight of the entire lifecycle of these devices—from design and production to installation and operation—to ensure quality and safety.
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