Grove Regulator Engineering Handbook Sections 1-8

GROVE VALVE AND
REGULATOR COMPANY
REGULATOR ENGINEERING
DATA BOOK
RELEASE 1.0
JANUARY 1994
TABLE OF CONTENTS
.1 _0 INTRODUCTION
2 _0 FLEXFLO REGULATORS
3 _0 PILOT REGULATORS
4- _0 FLEXFLO SYSTEMS
5_0 SIZING
6_0 SURGE RELIEF
7 _0 SPECIALITY REGULATORS
a _0 ENGINEERING DATA
SECTION 1 INTRODUCTION
1.1 WHAT ARE PRESSURE REGULTORS?
1.2 BASIC REGULATOR CONCEPT
1.3 PIPELINE PRESSURE CLASS
1.4 REGULATOR CAPACITY
1
SECTION 1 INTRODUCTION
The Regulator Engineering Data Book is a central source of

technical information pertaining to the Grove Pressure Regulator
product line. This book does not duplicate the information in
the catalogs except as needed for clarity. The purpose of this
data book is to simply convey technical information to all users
of Grove pressure regulators. If required technical information
can not be found in this text, please inform engineering so that
it can be added in a later revision.
1.1 WHAT ARE PRESSURE REGULATORS?
Grove pressure regulators control inlet or outlet pipeline fluid

(liquid or gas) pressure. During normal operation the pipeline
fluid pressure is always higher on the inlet side of the
regulator and lower on the outlet side. Because the fluids
travel from high pressure to low pressure, the high pressure
piping connected to the regulator is referred to as upstream and
the low pressure piping is referred to as downstream. The basic
variables in a regulator are inlet pressure outlet pressure and
flow rate. The regulator is manually adjusted to maintain the
inlet or outlet pressure at a specific level, this is known as
the "Set Pressure". The regulator is a variable valve that
automatically adjusts to maintain its set pressure.
1.2 BASIC REGULATOR CONCEPT
The most common application is downstream pressure control, this

is known as "Reducing" service. A perfect reducing regulator
will control outlet set pressure regardless of inlet pressure or
flow rate. During normal operation fluid is flowing through the
pipeline and reducing regulator. If the outlet pressure rises
above the set pressure the regulator closes, reducing flow and
downstream pressure. If the outlet pressure drops lower than the
set pressure the regulator opens increasing flow and downstream
pressure. The regulator is constantly adjusting its regulated
flow so that the downstream set pressure is maintained.
Upstream pressure control in known as "Back Pressure" service. A

perfect backpressure regulator will control the inlet pressure
regardless of outlet pressure or flowrate. During normal
operation fluid is flowing through the pipeline and backpressure
regulator. If the inlet pressure drops lower than the set
pressure the regulator closes reducing flow and increasing inlet
pressure. If the inlet pressure rises higher than the set
pressure the regulator opens increasing flow and decreasing the
inlet pressure.
Different designs are used for variables such as: cost, pipe
size, flowrate, fluid, pressure, and temperature. Flexflo
regulators are generally used for high flowrate (up to
10,000,000+ SCFH gas) and low pressure (less than 1,440 psi) in
n::o+-".,..",,1
- ... - - - - - -
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1 - 1
low flowrate (less than 10,000 SCFM gas) and higher pressure
ranges (up to 6,000 psi). Large capacity regulators do not work
well in low flow service and high pressure regulators are more
expensive than low pressure regulators.
1.3 PIPELINE PRESSURE CLASSES
All pipelines and pressure regulators can fail or burst if

overpressurized. The rating of the pipe determines the maximum
allowable operating pressure (MAOP). Most Grove regulators are
designed around standard pressure classes: 150, 300, and 600. The
maximum operating pressure for these pressure classes' are 285
psi, 740 psi, and 1480 psi, respectively at temperatures
between -20 and 100 degrees F for carbon steel regulators such as
the Model 80 and Model 900TE. For regulators with 316 stainless
steel pressure containing parts (i.e., Model 83) the MAOP is 275
psi, 720 psi, and 1440 psi for class 150, 300, and 600,
respectively. The MAOP decreases for temperatures higher than
100 F (fig 1-1). At low temperatures (less than -20 F) some high
strength/yield carbon steels and rubber materials become brittle
and can fail. Always be sure that the application temperature is
within the temperature rating of the regulator. Because the
maximum temperature rating of most Grove regulators is less than
200 degrees F, the reduction in pressure rating due to high
temperature is minimal (less than 200 psi). A regulator must
have a pressure rating at least as high as the normal pipeline
operating pressure.
1.4 REGULATOR CAPACITY
The most difficult part of selecting a regulator for an

application is the capacity sizing. All regulators have a
maximum valve coefficient, Cv. The Cv of a regulator is defined
by the Instrument Society of America equations. There are
different equations for critical and non-critical flow of
incompressible fluids (liquids) and compressible fluids (gases).
The flow capacity of a regulator is proportional to the pressure
difference between the inlet (P1) and outlet (P2). In non-
critical flow, the differential pressure increases as the
regulator flow capacity increases. At a specific differential
pressure the flow capacity reaches a maximum and can not
increase, this maximum capacity condition is called critical
flow. The type of flow can be determined by the following
formulas 1 :
For liquid service:
non-critical flow P2 < FL2 (P1 - Pv)
critical flow P2 > FL2 (P1 - Pv)
_
,,_ .. .... "'"
1 V._'.I.'_
1 - 2
For gas service:
non-critical flow P2 < Pl/2
critical flow P2 > Pl/2
Grove uses the following formulas to solve the flow capacity of

all regulators. Refer to section 8 for specific fluid
parameters.
Liquids
non-critical flow
Liquids
critical flow
Gases
non-critical flow
Gases
critical flow
Q-907CVP1
1 - 3
Variable Definitions
P, Inlet Pressure (PSIA)

Pz Outlet Pressure (PSIA)
Pv Vapor pressure of liquid at flowing temperature (PSIA)
OP Pressured Differential, P,-P z (PSI)
Q Flow Rate (SCFH for gas, GPM for liquid)
G Specific Gravity (Air = 1.0 for gas, Water = 1.0 for
liquid)
T Inlet Gas Temperature (OR)
Z Supercompressibility factor*
Y, Expansion Coefficient, Y, = 1 - (X/3F KXr )
FL Pressure Recovery Factor
FK Specific Heat Ratio Factor
Cv Valve Capacity Factor(dimensionless)
X OP
P,
Xr Pressure drop ratio Xr = 0.84 FLZ
Note: See sect 10n 8 for spec Hi c f1 u1 d and va lYe parameters.
By placing the application characteristics and regulator CV into

the appropriate equation the maximum capacity of the regulator
can be solved. The maximum capacity of the regulator must be
greater than the required flow of the application for proper
pressure control. Grove uses these formulas for the Specialty
regulator line and a modified version of these formulas for the
Flexflo regulator line.
There are several variations of the formulas that can be
important when comparing regulators manufactured by other
regulator companies. Grove uses Cv to quantify the relative
capacity of a regulator; other companies use Cg for gas
calculations. The relationship between CV and Cg is:
Cg = CV * 40 * FL
The capacity formulas can be time consuming if calculated by
hand. Grove has developed computer programs to simplify the
sizing process. More details of sizing are in Section 5.
In some cases it is desirable to have a Cv greater than the

largest available CV of a single regulator. By placing multiple
regulators in parallel the combined Cv can be increased. The
increased CV is additive, for example three 12.4 Cv regulators
piped in parallel have a total Cv of 37.2.
1 - 4
6000
~ 21
5800 I ~
~
or } STAINLESS STEELS
5600 EXCEPT 304
5400
~
5200
5000
1\ or
} CARBON MOLY AND
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4800
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4600
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4400 ALL STEELS BELOW
4200
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600°F EXCEPT 304
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-200 200 400 600 800 1000 1200 1400 1600 1800
TEMPERATURE. ° F
FIG. 1-1
1 - 5
SECTION 2 FLEXFLO REGULATORS
2.1 FLEXFLO OPERATING PRINCIPLE
2.2 MODEL DESCRIPTIONS

2.3 VALVE COEFFICIENT CV
2.4 FLEXFLO COMPONENT MATERIAL LISTING
2.5 WEIGHTS AND DIMENSIONS

2.6 END CONNECTIONS
2.7 CORE SLOTS AND REDUCED CAPACITY
2.8 FLUID COMPATIBILITY

2.9 JACKET VOLUMES
2.10 MODEL 80/887 BODY AND CORE CONFIGURATIONS
2.11 FLEX FLO FAILURE MODES

2.12 INSPECTION OF FLEXFLO SYSTEMS
2.13 900TE TOP ENTRY REGULATOR
2.14 FLEX FLO TUBE REMOVAL AND INSTALLATION FOR

MODELS 80, 81 AND 887
2
SECTION 2 FLEXFLO REGULATORS
Flexflos are used in both gas and liquid service. They are
available in sizes 1" to 12" and pressure classes 150 to 600.
Although Flexflos are called regulators they do not control
pressure by themselves and must be used with some type of pilot
regulator. The flexflo/pilot can be used to control inlet
pressure or outlet pressure. Flexflos are also known as
"expansible tube" regulators.
2.1 FLEXFLO OPERATING PRINCIPLE
The working components of the Flexflo regulators are the tube,

core and body:
TUBE The tube expands or contracts radially controlling the flow
through the unit. When the tube is against the core there is no
flow. When the center section of the tube is fully expanded
against the body and away from the core the unit is fully open.
CORE The core is cylindrically shaped with a hemispherical

barrier in the center that prevents fluid from passing straight
through the center. Slots are cut in the cylinder on either side
of the barrier. Fluid passes from the inlet of the core through
the inlet side slots, around the outside of the barrier, back
through the outlet side slots and through to the outlet of the
flexflo.
BODY The body seals the jacket volume and provides a surface
which the tube can expand against. Because the tube is sealed
against the body at the ends the space between the tube and body
acts as a pressure containing volume. This space is known as the
"jacket" volume. The jackets of all Flexflos are pressurized
through a 1/2" NPT fitting at the outside center of the body.
The Flexflo regulator is simply a large variable capacity valve.

The capacity of the Flexflo is controlled by the jacket pressure.
When the jacket pressure is equal to inlet pressure the regulator
is closed (Fig. 2-1) and when it is equal to outlet pressure the
regulator is considered open (Fig. 2-2), normally at its maximum
rated Cv. The Flexflo normally operates at a jacket pressure
that is between the inlet and outlet pressures, controlling the
amount of fluid passing through the unit when throttling. The
optimum operating Cv is 5 to 80% of the maximum Cv.
The rubber tube is elastic and is designed to fit tightly around

the core. This design helps to insure positive shutoff but
hinders the opening of the regulator when operating at low
differential pressures (Pinlet - Poutlet). If the differential
pressure is insufficient, the tube will not expand due to tube
tension and the Flexflo will not fully open even though the pilot
has vented the jacket pressure to downstream in the fully open
position.
2 - 1
FLEXFLO
CLOSED POSITION
---+-+-+-~-BODY
TUBE
~~;;~~r1~==~--~-CORE
JACKET PRESSURE =INLET PRESSURE
FIG 2-1
2 - 2
FlEXFlO
OPEN POSITION
DY
TUBE
CORE
JACKET PRESSURE < INLET PRESSURE
FIG 2-2
2 - 3
If the differential pressure is sufficient to partially expand
the tube, the regulator is functional but not able to operate at
its full capacity, rated cv. The Grove flow formulas and sizing
programs account for the reduction in flow when solving the flow
capacity of a specific regulator in an application. Because of
this problem there are a number of tubes with different
elasticities to match their normal differential pressures. A
class 600 tube uses stiff material that is difficult to stretch
because a tough material that will not extrude through the core
slots is required for the high pressure service and the unit will
not be working at low differential pressures. The class 150 tube
is made of more a flexible and elastic material that allows the
tube to expand with less differential pressure. Because the
normal operating pressures are much lower the tube will not be
damaged even though the rubber is less durable. In model 80s the
tube thickness varies with pressure class. Higher pressure units
have thicker tubes.
2.2 MODEL DESCRIPTIONS

The Models 80, 81, 82, 83 and 900TE are the only Flexflo
regulators that have been produced by Grove.
2.2.1 MODEL 80
The Model 80 is the original Flexflo regulator. The core is a

straight cylinder. The model 80 is available in sizes 1" to 12".
Different cores and tubes are used for each pressure class of the
regulator. The end connections are screwed ends for the 1" and 1
1/2" unit. The body styles for sizes 4" through 12" are line
removable, meaning that the line flange plates can be separated
and the body, core and tube assembly can be removed for
maintenance without removing the end connection bolting. The
construction is cast iron cores with steel body and flanges; one
exception is the class 600 core which is fabricated. Because the
core is a straight cylinder the tube must be pressed onto the
core, a press can also be used to remove the tube. Because tubes
are generally only removed when they have failed they are
commonly cut along their length to remove them from the core.
The inner surface of the tube can be inspected while on the core.
In general tube wear normally occurs over the downstream slots at
the barrier. By looking at the tube through the downstream slots
the condition of the tube can be evaluated.
2.2.2 MODEL 81
The Model 81 is a lower cost version of the Model 80. The

internal core and body profile are identical to the Model 80 but
the Model 81 is a "wafer" design, that is it fits between raised
face flanges and is held in place be long studs and nuts. The
Model 81 is available in 1 1/2", 2" and 3" sizes in pressure
classes 150 and 300.
2 - 4
2.2.3 MODEL 82
The Model 82 is a light weight, "wafer" design, less expensive

version of the Model 80. Except for the 8-inch size, this model
has been discontinued. Special orders are required for
replacement tube and cores on all sizes. The face to face
dimensions are the same as the Model 83.
2.2.4 MODEL 83
The Model 83 is a 316 stainless steel Flexflo regulator. The

core is a tapered design, which allows the tube to be installed
and removed without a press. The Model 83 is known as a "wafer"
design. The regulator fits between two raised face flanges and
is held in place by line flange nuts and bolts. The same body is
used for class 150, 300 and 600. The same tube geometry is used
for all pressure classes. The tube is available in stronger
materials for high pressure service and more flexible materials
for low pressure service. Two versions of the Model 83 tube are
available, a ribbed and non-ribbed design. The ribbed version
was developed to put a greater rubber wall thickness over the
barrier of the core. This additional material helps the tube
contract tightly around the core when the flow needs to be
stopped. The drawback of using the ribbed tube is a reduction in
flow capacity of between 7 to 15%. If tight shut off is not
required the non-ribbed tube will work well and provide maximum
flow capacity. The Model 83 had a shut off problem when it was
first introduced. SinceJthe tube materials have been improved
and the ribbed tube has been introduced, lock up failures have
been reduced.
2.2.5 MODEL 900TE
The 900TE is a "top entry" regulator whereby the expansible tube

can be accessed by removing the closure and then the core while
the regulator body and pilot remain in the pipeline; no special
tools are required for this operation. The core used is a
tapered design similar to the Model 83. The regulator has raised
face flange end connections. In contrast the Model 80, 81, 82
and 83 bodies must be removed from the pipeline and the pilot and
associated tubing must also be removed. The regulator must then
be disassembled in order to access the tube. Most regulators
must be inspected periodically. By having an easy access
regulator the inspection process is greatly simplified, saving
the pipeline company money in maintenance costs. The tubes used
by the Model 83 and 900TE are the same. Stronger tubes are used
with for higher service pressure regulators and lower elastic
tubes are used for low pressure service.
2 - 5
2.2.6 MODEL 887
The Model 887 is a surge reliever. Its purpose is to protect

pipelines from pressure surges and overpressurization. The 887
is normally teed into a liquid pipeline. When the pipeline
pressure exceeds the set pressure of the surge reliever, the unit
opens and liquid passes through the 887. See Section 6 for more
information regarding surge relievers.
2.3 VALVE COEFFICIENT cv
The Cv's for all standard Flexflo regulators are listed on table
2-1. These include the following variables: 50% capacity cores,
N-body, W-body (liquid service only), ribbed tubes. The Cv's
listed are for the full open condition. In some applications the
full open cv is unattainable, normally due to insufficient
differential pressure to fully expand the tube. Always check the
sizing of an application before selecting a regulator. If the
differential pressure is insufficient to fully expand the tube
the maximum Cv will be unattainable. The Cv's listed are used
with the flow formulas in sections 1 and 5 to compute the flow
capacity.
Some regulator manufacturers use a Cg instead of a Cv to quantify

the rated capacity of their regulators. Table 2-2 gives the Cg
conversions for the 900TE regulators.
2 - 6
FLEXFLOCv
MODEL 80
PRESSURE SIZE Cv100% CORE Cv5O% CORE
CLASS (INCHES) NBODY WBODY NBODY WBODY
150 1 9.5 9.5 63 63
11/2 30 31 20 20.7
2 613 64 40.9 42.7
3 124 130 827 86.7
4 230 283 153.3 188.7
6 528 564 352 376
8 910 1000 fJXJ.7 «»'7
10 1145 1385 7633 9233
12 1610 2020 1073.3 1346.7
300 lIn 333 333 22.2 22.2
2 64.7 64.7 43.1 43.1
3 130 130 86.7 86.7
4 245 283 1633 188.7
6 528 $64 352 376
8 910 toOO &.16.7 fH>.7
10 1145 1385 7633 9233
12 1610 2020 1073.3 1346.7
600 1 10 10 6.7 6.7
11/2 15.5 15.5 10.3 10.3
2 20.7 26.3 13.8 17.5
3 50.4 63.8 33.6 42.5
4 95 121 633 SO.7
6 207 262 138 174.7
8 642 742 428 494.7
10 742 990 494.7 660
12 1072 1437 714.7 958
TABLE 2-1
2 - 7
MODEL 81
PRESSURE SIZE Cvl00% CORE Cv50% CORE
CLASS (lNa-JES) NBODY WBODY NBODY WBODY
150 11/2 30 31 20 20.7
2 61.3 64 40.9 427
3 124 130 827 86.7
300 11/2 33.3 33.3 222 222
2 64.7 64.7 43.1 43.1
3 130 130 86.7 86.7
MODEL 82
PRESSURE SIZE Cvl00%
CLASS (lNa-JES) CORE
150/300 11/2 46
2 73
3 134
4 230
6 379
8 599
MODEL 83
CLASS (lNa-JES'I RIBBEDTlJBE NON-RIBBED TUBE RIBBED TlJBE NON-RIBBED TUBE
150/300/600 1 9.5 12 4.75 6
11/2 41 47 2(15 23.5
2 61 77 30.5 38.5
3 118 155 59 77.5
4 211 234 110.5 117
6 275 390 137.5 195
MODEL900TE
CLASS (lNa-JES) RIBBEDTlJBE NON-RIBBED TUBE RlBBEDTUBE NON-RIBBED TUBE
150/300/600 2 50 58 25 29
3 91 94 45.5 47
4 120 128.5 60 64.25
TABLE 2-1
2 - 8
TOPENTRYP~UREREGUlATORCgCOMPAR~ON
UNIT MOONEY FISHER GROVE GROVE

SIZE FLOWGRID EASY JOE 900fE 900fE
RIBBED NON-RIBBED
r 460
2" 1960 2040 1680 1717
3" 3672 3820 1Z76 2895
4" 6700 6400 3696 3752
()' 12000
Cg = 40xFLxCv
TABLE 2-2
2.4 FLEXFLO COMPONENT MATERIAL LISTING
The materials used for all of the major Flexflo components are
listed on table 2-3. All assembly components are exposed to the
pipeline fluid in pressure reducing and backpressure service.
For Flexflos that are controlled by the Model 888 pilots such as
Model 887 units, only the jacket volumes are exposed to nitrogen
or air.
If there is a fluid/material compatibility problem there are
methods of isolating materials from the pipeline fluid. The cast
iron core of the Model 80 can be nickel plated or phenolic
coated. The wetted parts of the closures, body and core can also
be phenolic coated. The phenolic coating is a plastic that is
will not react with most corrosive fluids like salt water.
FLEXFLO COMPONENT MATERIAL LISTING

MODEL PRESSURE CORE BODY CLOSURE OR 11JBE
a..ASS COVER PLATES STANDARD
80 150{300 CASfIRON CARBON S1EEL CARBON STEEL NITRILE
80 600 CARBON STEEL CARBON STEEL CARBON STEEL NITRIIE
81 150/300 CASTIRON· CARBON SIEEL CARBON SIEEL NITRRE
82 150/300 ALUMlNUM CARBON STEEL CARBON STEEL HYDRIN
83 All STAINLESS STL STAINlESS STL STAlNLESS STL HYDRIN
900IE AIL SfA1NLESS SIL CARBON STEEL CARBON STEEL HYDRIN
STANDARD FLEXFLO TUBE MATERIAlS ARE LISIED HOWEVER ALL UNITS

CAN BE ORDERED wrrn AL1ERNATE lUBE MA1ERIALS
TABLE 2-3
2 - 9
2.5 WEIGHTS AND DIMENSIONS
The outline dimensions and weights of all Flexflo regulators are
listed on table 2-4. All Flexflos are designed to be used with
raised face flange piping connections (some special end
connections are available on special order). The face to face
dimensions are listed as well as the outer diameter. Most
Flexflos are cylindrical in shape, the outer diameter refers to
the widest circular section not including pressure tap bosses.
Because the 900TE is not cylindrical in shape an outer diameter
is not listed; see 900TE bulletin for dimensions. The Model
900TE is designed with the same face to face dimensions as the
Fisher 399 and Mooney Flowgrid regulators. All of these
regulators are interchangeable.
2.6 END CONNECTIONS
The following diagrams show the different types of standard

Flexflo raised face end connections that are available and how
the body, core and tube can be removed from a pipeline.
Fig. 2-3 Line Removable

Fig. 2-4 Wafer Type
Fig. 2-5 Raised Face Flange Ends
Fig. 2-6 Top Entry
An exploded view of the 900TE shows how the tube and core are
removed from the regulator. The body of the 900TE does not have
to be removed from the pipeline in order to repair or replace the
working internal components.
2 - 10
FLEXFLO WEIGHTS AND DIMENSIONS
MODEL 80
PRESSURE SIZE FACE TO FACE OurER DIAMETER WElGrIT END
CLASS (INCHES) (INCHES) (INCHES) (LBS) CONNECI1ONS
150 1 67/8 4!¥'8 12 SCREWED
11/2 71/14 51!¥!6 19 SCREWED
2 10 611/16 34 RAISED FACE FLANGE
3 11 3{14 8!¥'8 57 RAISED FACE FLANGE
-
4 123{8 133{4 154 LINE PiANoEREMOVABLE
6 16 !¥'8 17 !¥'8 292 LINE FLANGE REMOVABLE
8 213{8 a:l 3{4 6a:l LINE FLANGE REMOVABLE
10 261/2 227/8 1110 LINE FLANGE REMOVABLE
12 29 263{8 1310 LINE FLANGE REMOVABLE
300 2 101/2 7!¥'8 43 RAISED PACE FLANGE
3 121/2 97/8 94 RAISED PACE FLANGE
4 131/8 141/8 a:ll LINE FLANGE REMOVABLE
6 167/8' 177/8 310 LINE FLANGB REMOVABLE
8 223{8 a:l3{14 700 LINE FLANGE REMOVABLE
12 301/2 281/8 1800 LINE FLANGB REMOVABLE
600 1 67/8 511/16 21 SCREWED
11/2 81/14 73{8 35 SCREWED
2 111/14 83{16 64 RAISED FACE FLANGE
3 15 10.3{4 130 RAISED FACE FLANGE
.. 151/2 161/8 340 LINE FLANGE REMOVABLE
6 a:l 19!¥'8 600 LINE FLANGE REMOVABLE
8 24 23 1160 LINE FLANGE REMOVABLE
10 29!¥'8 27 2080 LINE FLANGE REMOVABLE
12 321/4 293{4 2860 LINE FLANGE REMOVABLE
MODEL 81
PRESSURE SrzE FACE TO FACE OlJI'ER DIAMETER WEIGrIT END
CLASS (INC~) (INCHES) (INCHES) (Las) OONNECTIONS
150 11/2 5 31/4 8 WAFER TYPE RAISED FACE FLANGE
2 6 4 13 WAFER TYPE RAISED FACE FLANGE
3 73{4 53{8 30 WAFER TYPE RAISED FACE FLANGE
300 11/2 53{16 3!¥'8 9 WAFER TYPE RAISED FACE PLANGE
2 61/8 43{8 16 WAFER TYPE RAISED PACE FLANGE
3 71/8 51!¥!6 32 WAFER TYPE RAISED FACE FLANGE
MODEL 82
PRESSURE SIZE FACE TO FACE OUTER DIAMETER WEIGrIT END
CLASS (INCHES) (INCHES) (INCHES) (Las) OONNECI'IONS
15CV300 J
11/2 311116 33/8 11 WAFER TYPE RAISED FACE FLA~q~
2 43{16 41/8 17.16 WAFER TYPE RAISED FACE FLANGE
3 415116 53/8 26.4 WAFER TYPE RAISED FACE FLANGE
4 513/16 67/8 55 WAFER TYPE RAISED FACE FLANGE
6 7 8314 112.2 WAFER TYPE RAISED FACE FLANGE
8 81/2 11 189.2 WAFER TYPE RAISED FACE FLANGE
TABLE 2-4
2 - 11
MODEL 83
PRE!SSURE stZE FACE TO PACE OurER DlAMETBR WEIGH!' END
CLASS (INCI-f&) (INCHES)
~, ~ .... (LBS) CONNBCI'IONS
151l'3OCV600 1 41/16 23t'4 5.5 SCREWED
11/2 311/16 3a'32 8 WAFER TYPE RAISED PACE FLANGE
2 43(16 43{8 12 WAFER TYPE RAISED PACE FLANGE
3 415116 571!32 24 WAFER TYPE RAISED PACE FLANGE
. 511116 73/32 35 WAFER TYPE RAISED FACE fIlANGE
6 7 91/4 58 WAFER TYPE RAISED PACE FLANGE
MODEL9OOTE
PRESSURE SIZE FACETOpACE WEIGH!' END
CLASS (~~.~
(INCHES) (LBS) CONNECl'lONS
150 2 10 40 RAISED PACE PLANOE
3 11 3t'4 96 RAISED PACE PLANGB
4 137/8 124 RAISED PACE FLANGE
300 2 101/2 45 RAISED PACE PLANOE
3 121/2 103 RAISED PACE PLANOE
4 141/2 1« RAISED PACE FLANGE
600 2 111/4- 49 RAISED PACE PLANGB
3 131/4 119 RAISED FACE PLANOE
4 151/2 164 RAISED PACE PLANOE
MODEL 887
PRESSURE SIZE FACETOpACE 0urER DIAMETER WEIGH!' END
(Jt........ rn .....
CLASS ~ (INGHES) (LBS) CONNECrtONS
150 4 147/8 183{8 500 LINE FLANGE REMOVABLE
8 211/2 71718 1440 LINE FLANGE REMOVABLE
10 243{4 311/2 1950 LINE FLANGE REMOVABLE
12 283{8 36 3370 LINE FLANGE REMOVABLE
300 4 15 19 600 LINE FLANGE REMOVABLE
6 191/8 25 1150 LINE FLANGE REMOVABLE
12 313{8 38518 42C(J LINE FLANGE REMOVABLE
600 4 1615{16 201/8 750 LINE FLANGE REMOVABLE
10 29518 347/8 4150 LINE FLANGE REMOVABLE
TABLE 2-4
2 - 12
RAISED FACE FLANGE
LINE REMOVABLE
TO REMOVE THE FLEXFLO CORE AND TUBE:

1. SEPARATE LINE FLANGES WITH JACKING NUTS
2. REMOVE UPPER THROUGH BOLTING
3. PULL OUT THE BODY, TUBE AND CORE ASSEMBLY
FIG. 2-3
2 - 13
...,........ .- ...
RAISED FACE FLANGE

1. SEPARATE LINE FLANGES
2. REMOVE UPPER THROUGH BOLTING
3. PULL OUT THE BODY, TUBE AND CORE ASSEMBLY
FIG. 2-4
2 -14
RAISED FACE FLANGE ENDS

1. REMOVE LINE FLANGE BOLTING
2. REMOVE REGULATOR FROM PIPELINE
J L I
I
---- I I I
, ,
,
~,C : ,
I I I I
I I
FIG. 2-5
2 - 15
~HEX BOLTS
O-RINL;
CORE
N
I
~
HOUSING
RT CONN.
N P~ 2 PLCS.
I NLETp RT PLCS.
OUTLETp~02 CONN.
1/4" 1/-4'" N
JACKETpPTO~ TPLCS
CONN
1/2" N
ILSOOTE_EXPL
2.7 CORE SLOTS AND REDUCED CAPACITY
The relationship between the Cv of the regulator and the number

of open downstream slots is shown in Figure 2-7a and Figure 2-7b.
The Model 80 and Model 81 with 50% of the outlet slots filled
have full-open Cv's approximately 70% of the 100% capacity cores.
These 70% capacity cores are often referred to as "half-capacity"
cores. True half-capacity cores for the Model 83 and 900TE have
only 25%-33% of the downstream slots open, and as such, have Cv's
at 50% of the 100% capacity cores. Table 2-5 lists the number of
upstream and downstream slots for full and half-capacity cores.
A regulator will not work well when it is oversized for a

particular application. In such cases, it is desirable to reduce
the maximum capacity of the regulator. Generally, a regulator CV
should not be 20 times greater than the minimum required Cv. By
using the chart a regulator core can be produced that has the
ideal CV for a specific application.
To determine the number of downstream slots to fill given the

desired Cv, first solve the desired Cv as a percentage of the
maximum Cv. From this point on the "% of maximum Cv" scale draw
a horizontal line that intersects the curve. From the
intersection point draw a vertical line intersecting "% of
Downstream Slots Open" scale. Multiply the "% of Downstream
Slots Open" by the number of downstream slots in the existing
Flexflo core to solve the number of open slots. Fill the
required number of downstream slots symmetrically around the core
diameter. We normally weld the slots closed for custom capacity
Flexflo cores.
2 - 17
ReI.1-25-94~Appr. ry/ SK-6-753
FLEXFLO CORE SLOTS Sht.1/2
ANSI 100% 100%CAP 70%CAP 50%CAP

IMODEL SIZE PRESSURE PART(4) INLET OUTLET OUTLET OUTLET
CLASS(5) NUMBER SLOTS SLOTS SLOTS SLOTS
80 1" NPT-275 200-01049 3
80 1" NPT-1500 200-01049 3
80 1 112" NPT-275 200-01482 18 <> :/.18 .•.•......• ·.· · .·. 9 6
80 1 1/2" NPT -1500 200-01484 1414 · '· 7 4
80 2" 150 200-02084 8
80 2" 300 200-02085 8
80 2" 600 200-02093 6
80 3" 150 200-03072 12
80 3" 300 200-03073 12
80 3" 600 200-03082 9
80 4" 150 200-04446 12
80 4" 300 200-04447 12
80 4" 600 200-04031 8
80 6" 150 200-06444 13
80 6" 300 200-06443 13
80 6" 600 200-06036 9
80 8" 150 200-08446 52 " (···· .• ·. 52 · .• · ·.26 17
80 8" 300 200-08445 17
80 8" 600 300-0803C 116 · •.•.\C: . Jt~ .· ... . . . §$ 37
80 10" 150 200-10047 16
80 10" 300 200-1004€ 16
80 10" 600 200-10058 112 . 112 5.
6 36
80 12" 150 200-12052 48 .. A9 24 15
80 12" 300 200-12053 48 .48 24 15
80 12" 600 200-12062 42
81 1 1/2" 150/300 200-01483 18 ~? · . 18 9 6

·cc
81 2" 150/300 200-02085 24 . 'T
. . . '24
... . . . 12 8
81 3" 150/300 200-03073 36 I·· .'. 36 19 12
03 1" 150/300/600 356-0100:: 21 21 11 7

83 1 1/2" 150/300/600 356-01001 45 45 23 15 ~ CJ-';
83 2" 150/300/600 356-02001 48 49 24 16 .....
- ' "''-
-.~
',"> I
83 3" 150/300/600 356-03001 51 51 26 17 () c,
('7 1
83 4" 150/300/600 356-04001 54 54 27 18 -..J
~ III
83 6" 150/300/600 356-06001 60 60 30 20 '.
o
~
900TE 2" 150/300/600 364-02001 48 49 24 16 N

900TE 3" 150/300/600 364-03001 51 51 26 17
900TE 4" 150/300/600 364-04001 54 54 27 18
TABLE 2-5
2-18
SK-6-753
FLEXFLO CORE SLOTS Sht.212
ANSI
MODEL SIZE PRESSURE PART INLET OUTLET
CLASS NUMBER SLOTS SLOTS
887 4" 150 2(}()..;.()4449 36 18
887 4" 300 2()();:;'O4035 36 18
887 4" 600 ~OO-()4036 24 12
887 6" 150 200-06445 40 20
887 6" 300 20~644:2 40 20
887 6" 600 2()()~()03S 28 14
887 8 1r 150 2®.i-Q~444 52 26
887 8" 300 ?Q07Q~441 52 26
887 8" 600 3.QQSi)Q()31 116 58
887 10" 150 ~ejQQ~g 48 24
887 10" 300 2()Q2100~ 48 24
887 10" 600 2C)Q..j6060 112 56
887 12" 150
. ... J9
20()~J2()4 48 24
887 12" 300 ?OO·12649 48 24
887 12" 600 266~12065 128 64
NOTES:
1. Shading Indicates cores most commonly stocked
2. Ref. SK-4-169 for Model 80/81 slot curves.
3. Ref. SK-4-207 for Model 83/900TE slot curves.
4. Model 80 part numbers are for 'K' cores.
5. NPT Cold Working Pressure given.
TABLE 2-5
---
>-'
([;
.........,
/
I
'
iT' c'
( I
2-19
'" Reoulator jjataboo;': Dist1~i:~ULio:;

FIGURE 2-7a
2-20
% of Cv vs % of Open Slots
MODEL 83 AND 900TE
100~--~----~--.~!::.----~--~--~----~--~.----~~!--~
! !----l
.
I I I I I
o 10 20 30 40 50 60 70
.., 80 90 100
% of Downstream Slots Open
Cv ACCURACY: +/- 10%
FIG. 2-7 b
2 - 21
Fluid compatibility is a question that must be raised during the

sizing process. In the Flexflo bulletins is a listing of
available tube material codes and a basic fluid compatibility
chart. This section will not go into great detail of what
rubbers are compatible with what fluids, however, it does discuss
specific reactions that can occur when there is a compatibility
problem and what Grove checks for when we suspect a chemical
reaction problem.
The most common type of fluid incompatibility causes swelling and

softening of the rubber. MTBE and aromatic fluids have a
tendency to cause certain rubber materials to swell. The fluid
is absorbed by the rubber and the volume of the rubber increases.
Eventually the swelling will stop however it is possible for the
rubber volume to increase by 30+%. When swelling occurs, the
jacket cavity volume is reduced which can reduce the flow
capacity of the regulator.
Rubber hardening is another rubber failure due to fluid

incompatibility. Some fluids like sulfur act as curing agents
with rubber. Curing agents in contact with some rubber materials
will harden the rubber which is then more susceptible to
cracking.
Blistering is a common problem with high pressure gas service.

The blistering is usually caused by a combination of high
pressure gas and high fluid temperature. Under these conditions
gas is absorbed into the rubber. When the tube is depressurized
the trapped gas expands within the rubber causing blisters. To
avoid blistering be sure that the service temperature is within
the rated operating range of the regulator.
Plasticizer leaching causes the rubber to loose volume and

flexibility. Some hydrocarbon condensates react with rubber to
dissolve the plasticizers within the compound. The rubber looses
weight and flexibility when the plasticizers are removed.
If a Flexflo tube is returned for an engineering evaluation,

Grove may measure rubber hardness (durometer), and tensile
strength. If these characteristics are within the rubber
specifications the failure is most likely to be a mechanical
problem. Rubber samples that do not have normal physical
properties may be incompatible with some element of the pipeline
fluid.
The Grove Rubber Department has compiled a summary of fluid

compatibilities for various tube materials in SK-4-155 which is
included in this section.
2 - 22
Supersedes 10/27/S0 SK-4-155
~el.l0/31/90 ~J Appr . Sheet 1 of 7
.ev.05/0S/91;f.S. Appr .rr
HODEL 80,81,83,887 , 900TB TUBB MATERIALS
MAT'L
CODE DESCRIPTION
1
725 Epichlorohydrin Hydrin C-115 30 durometer
Soft, very low modulus material
Temperature range: -40°F to 120°F (-40°C to 49°C)
Uses:
1. Liquid and gaseous hydrocarbon service

2. Product service to 25% aromatics
3. Sour service to 5% H2S, Sulfur or mercaptans by weight.
Not recommended:
1. Aromatics above 25%

2. Water
3. Phosphate esters
4. Ketones and ethers
5. Sour gasoline - peroxides
6. Amines
7. Methyl and ethyl alcohol and blends with hydrocarbons.
S. Above 60 psi pressure
2
732 Fluoroelastomer Fluore1 75 durometer (was X-1122)
Medium modulus material
Temperature range:
(j)(f)
::r~
Uses: ID I
1D.to.
rt-l
f-'
1. Broad range of hot fluid resistance f-' Ul
2. Automotive fuels and oil Ul
o
3. Hydraulic fluids H;
4. Aircraft fuels and oils

5. Aromatic solvents
Trademark of Zeon Chemical Co.
2 Trademark of 3M Co.
2 - 23
..
10/31/90 SK-4-1SS
Rev.05/08/91 Sheet 2 of 7
MAT'L
~ DESCRIPTION
732 (continued)
HQt recommended:
1. Strong caustic, ammonia
2. Steam
3. Ethers and ketones
4. Methyl and ethyl alcohol
733 Epichlorohydrin Hydrin ~ 75 durometer
High pressure, high temperature, tear resistant material
Temperature range: OaF to 175°F
Uses:
- Same as 878 -
4
740 Hydrogenated Nitrile Tornac 85 dUrometer (was X-1191)
High pressure material
Temperature range: 10°F to 212°F (-12°C to 100°C)
Uses:
1. Fuel oils and gasoline up to 40% aromatics

2. Methanol and water (fj(fj
::r~
3. Crude oil with up to 5% sulfur by weight CD I
4. MTBE/Gasoline blends CD~
rtl
5. Natural gas, propane and butane with up to 5% CO2 f-I
N lJ1
lJ1
Not recommended: o
H1
Service where DMOS (di-methyl di-sulfide) is used with

crude or natural gas
3 Trademark of Zeon chemical Co.
4
Trademark of Polysar Co.
2 - 24
10/31/90 SK-4-155
v.05/08/91 Sheet 3 of 7
MAT'L
~ DESCRIPTION
5
744 Hydrogenated Nitrile Tornac 75 durometer
Standard tube material for medium pressure service, class 300
Temperature range: 10 0 F to 212°F (-12°C to 100 0 C)
Uses:
- Same as 740 -
745 Hydrogenated Nitrile Tornac, 65 durometer
Standard tube material for low pressure service, class 150
Temperature range: 10 0 F to 212°F (-12°C to 100 0 C)
Uses:
- Same as 740 -
Nitrile, Chemigum6 Nominal 75 durometer
Temperature range: 10 0 F to 150 0 F (-12°C to 66°C)
Uses:
1. Liquid and gasoline hydrocarbon service

2. Water, hydrocarbon mixes (f)(f)
::r'?;:
3. Product service to 20% aromatics (D I
4. Maximum H2S, sulfur mercaptans: 0.5% by weight (D04
rtl
I-'
WUl
Ul
o
t-h
5 Trademark of Polysar Co.
6 Trademark of Good Year Chemical Co.
2 - 25
10/31/90 SK-4-155
ev.05/08/91 Sheet 4 of 7
MAT'L
~ DESCRIPTION
814 (continued)
Not recommended:

2. Phosphate esters
3. Ketones and esters
4. Amines
5. Sour gasoline (peroxides)
6. methyl nor ethyl alcohols, nor blended with hydrocarbons
846 Nitrile, Chemigum6 Nominal 75 durometer
Temperature range: 10°F to 150°F (-12°C to 66°C)
Uses:
- Same as 814 -
~ recommended:
1. Aromatic above 15%

2. - Same as 814 -
(Formula revised 6-80)

6
878 Epichlorohydrin, Hydrin 200-130 Nominal 65 durometer {f){f)
Standard modulus material

::r?::
(]) ,
(])r t*'"'
f-'
Temperature range: -20°F to 150°F (-29°C to 66°C) *'" lJl
lJl
o
Uses: I-h
1. Liquid and gasoline hydrocarbon service

2. Product service to 30% aromatics
3. Sour service to 5% HzS, sulfur or mecaptans by weight
2 - 26
10/31/90 SK-4-155
'!v.05/08/91 Sheet 5 of 7
MET'L
~ DESCRIPTION
878 (continued)
Not recommended:

2. water
3. Phosphate esters
4. Ketones and ethers
5. Sour gasoline (Peroxides)
6. Amines
7. Methyl nor ethyl alcohols, nor blended with hydrocarbons
880 Polyisoprene, natural rubber nominal 65 durometer (was X-653)
Temperature range: OaF to 150°F (-18°C to 66°C)
Uses:
1. Potable drinking water

2. Salt water and brackish water
3. Mill scale and water containing particulate matter
Not recommended:
1. Any hydrocarbon service

2. Exposure to air; long term or above 120°F
3. Sulfur or H2S above 0.5% by weight
7
888 Ethylene Propylene Diene Monomer, Nordel (E.P.D.M.) (was X-603)
Nominal 70 durometer (J)(J)
::r:;.;:
(]) I
Medium modulus material (])~
rtf
f-'
Temperature range: -20°F to 175°F (-29°C to 80°C) Ul Ul
Ul
o
H1
7
Trademark of E.I. DuPont.
2 - 27
10/31/90 SK-4-155
v.05/08/91 Sheet 6 of 7
MAT'L
~ DESCRIPTION
888 (continued)
Uses:
1. Water and hot water

2. Anhydrous ammonia
3. Hydrogen sulfide
4. Carbon dioxide
5. Phosphate esters
6. Ketone and amines
7. Urea
li2.:t recommended:
1. Hydrocarbon service
2. Potable water service
8
893 Epichlorohydrin Terpolymer Hydrin 400 Nominal 50 durometer
(was X-1003)
Low modulus material

Uses:
- Same as 878 -
Not recommended:
- Above class 150 pressure -
o
Hl
8 Trademark of Zeon Chemical Co.
2 - 28
10/31/90 SIt-4-155
Rev.05/08/91 Sheet 7 of 7
9
894 Phosphonitrilic Fluoroelastomer, Fluorocarbon (?N.F.)
Nominal 65 durometer (was 887)
Uses:
1. Aromatics to 100%
2. Very sour hydrocarbon service to 10% H2S by weight
3. Product service
a. Diesel fuels and oils
b. Jet fuels
c. Arctic diesel and blended with isopropyl alcohol
d. Gasolines
e. Anhydrous ammonia
4. Liquid propane and butane
Not recommended:
1. Hot water and blends with Glycols above 125°F

2. Steam
3. Methyl alcohol nor its blends with any hydrocarbon
4. Acetone or ketones
5. Class 600 pressures
9
Trademark of Ethyl Corp.
2 - 29
2.9 JACKET VOLUMES
Table 2-6 lists the volume between the Flexflo tube in the closed
position and the regulator body. The model 887 surge reliever
has a slightly different assembly configuration. The jacket
volume is the space between the tube and an internal liner. The
annular volume is the space between the internal liner and the
outer body.
This information can be important when trying to predict the

response time of a regulator. For example a 2" regulator wi~l be
able to open much faster than a 12" regulator using an 829S
pilot. When the tube expands the displaced gas must pass through
the 829S regulator. The displaced gas volume required to fully
expand the tube is over 100 times greater for the 12" unit than
for the 2" unit.
The 887s have an annular space in addition to the jacket volume.

This annular space is shown in a cut-away sketch of the 887 Fig.
2-8.
2 - 30
JACKET VOLUMES IN CUBIC INCHES
CLASS 150 CLASS 300 ClASS 600
MODEL SIZE NBODY WBODY NBODY WBODY NBODY WBODY
80 1"
11/2" 1.7 1.86 1.93 2.1 ' 2.0 2.22
2" 3.5 3.8 4.0 4.4 4.2 4.56
3" 10.5 11.4 10.5 11.4 12.1 13.2
4" 32.5 35.4 35.8 39 31.9 34.8
6' 93.5 102 110 120 93.5 102
8" 187 204 204 222 204 222
10" 319 348 363 396 363 396
12" 517 564 583 638 583 638
MODEL SIZE CLASS 150 CLASS 300

81 1112" 1.7 1.93
'1' 3.5 4.0
3" 10.5 10.5
MODEL SIZE CLASS 150 CLASS 300

-
82 1112" 1.71 1.71
2" 2.87 2.87
3" 5.55 5.55
4" 7.08 7.08
6" 24.4 24.4
8" 70.77 70.77
MODEL SIZE CLASS 150 CLASS 300 CLASS 600

83 1" 0.94 0.94 0.94
11/2" 3.12 3.12 3.12
2" 5.63 5.63 5.63
3" 11.47 11.47 11.47 I
4" 24.02 24.02 24.02
II .'
6" 48.37 48.37 I 48.37 I
TABLE 2-6
2 - 31
MODEL SIZE a.ASS150 aASS300 a.ASS600
900IE 2" 5.63 5.63 5.63
3" 11.47 11.47 11.47
4" 24.02 24.02 24.02
MODEL SIZE VOLUME CLASS 150 CLASSJOO CLASS 600

8117 (j' JACKEf 103 109 94
ANNULAR 946 984 858
IDTAL 1049 1049 952
~ JACKET 226 231 232
ANNULAR 1994 2123 2094
IDTAL 2220 2354 2326
10" JACKET 360 382 386
ANNULAR 3262 3482 3471
TOTAL 3622 2864 3857
12" JACKET 615 654 642
ANNULAR 5606 6000 5753
TOTAL 6221 - 6654 6395
TABLE 2-6
2 - 32
MODEL 887
ANNU, VOLUME
\
\
d"~""'i 0",: ~ ~; """', . ~
I
~_ 1lJ ~ ' _ >!,!
-. .
/(
I
\,
....
JACKET VOLUME
/
FIG. 2-8
2 - 33
2.10 MODEL 80, 81 AND 887 BODY AND CORE CONFIGURATIONS
The Model 80/81 body and core designs vary depending upon the
type of service that the unit is going into; gas, liquid or
liquid relief. For most gas applications the N body and K core
are used together. This is the most common configuration. For
most liquid applications the W body and H core are recommended,
although it is not uncommon to use a NK combination in liquid
service. The N body does not allow the tube to expand as far
away from the core as the W body thus the Cv for the liquid
regulators is higher than for the gas regulators. The K and H
cores also differ in design. The H core has holes drilled close
to the barrier for slower shutoff. In liquid service if flow
through the regulator is immediately stopped a pressure spike
will result. It is important to shut off flow slowly. By having
holes drilled through the barrier of the core the regulator does
not slam shut as the tube contracts and flow is shut off. If the
K is used in liquid service the core should be drilled with holes
like the H core. Because gases are compressible and less
difficult to control pressure, no holes are drilled in the K
core. The core variations are shown on Fig. 2-9 and the body
variations are shown on Fig. 2-10.
Surge relievers have another variation of core and tube design.

The most obvious difference is the R core which has half as many
downstream slots as upstream slots. The reduced downstream slots
were found to actually increase flow for a given surge relief
condition. The R core is otherwise identical to the H core.
More details of surge relief mechanics are given in section 6.
The reliever body allows the tube to expand farther over the
outlet side of the core than the W body.
For surge relief applications the R core is used with a relief

body. The R core is a half capacity H core. The 887 has a
higher flow capacity with half of the outlet slots closed due to
its operating mechanics.
2 - 34
MODEL 80 CORE VARIATIONS
"K" Core -standa~d for gas x x:

x:;
and liquid service,for pilot
operation ..
1
UK" Core with half of the- T
downstream slots filled.70%

I
of standard capacity.
(Special Order)
I I I
"H" Core for liquid service x:

t r x:
(Special Order)
I
't
, , '
fiR" Core standard for 80-888 .,,---====-c

and 887 surge reliever. •
- - - -+--
't
-TIT - 4E======:=E3-- --
r ,
2 - 35
FIG. 2-9
'~,..-.!,.. ••
T
oR.
/I N " 750Dy' I
Standard for
--~ Caa Service
".,-
II
W- ::J?o.DY
"
Standard for
Liquid Servic~
Obsolete Gas Body Design

, .
FIG. 2-10
? - ~k
2.11 FLEXFLO FAILURE MODES
The most common types of regulator failures are listed below.
The failures are grouped by tube, core, and body.
2.11.1 FLEXFLO TUBES

Erosion Rupture (Abrasive Media)
Abrasive particles such as iron oxide, sand, etc., in a gas
stream can erode the Flexflo tube. This damage most often occurs
just downstream of the core barrier.
Fluid Incompatibility
Fluids that are incompatible with Flexflo tube materials are
absorbed by the rubber. This absorption can cause swelling and
weakening the tube.
Exceeded Rated Pressure

If the Flexflo is used beyond its normal pressure rating the tube
can burst or be extruded through the downstream core slots.
Exceeded Tube Life

Regulators that have been in service for over 15 years can have
strength problems due to excessive use. Tubes should be replaced
after 5 years of service.
Liquid Cavitation
Liquid cavitation can damage the Flexflo tube this is a result of
a high pressure drop. We have seen 887's fail in the closed
position. We believe that this type of failure is due to
cavitation (very rare) .
Lock Up Failure
The Flexflo tube has been in the expanded position for a great
deal of time and cannot close tightly against the core. This is
generally seen in Model 83's with non-ribbed tubes. A ribbed
tube normally solves the problem.
Molding Defect
If the tubes are improperly molded the rubber does not "knit"
well. The rubber is easily pulled apart at these sections. The
result is usually a rupture during normal service. If the torn
surfaces of a tube appear to be smooth, it is possible that the
cause of the failure was due to a molding defect.
Blisters
When the tube is used in high pressure service and the Flexflo is
exposed to temperatures above the rated limits, gas can be
absorbed into the rubber material. When depressurized for
inspection the gas expansion forces within the tube can exceed
the rubber bonding strength and blisters appear. In service the
ambient pressure compresses the blisters.
2 - 37
2.11.2 CORES
Vibrational Crack
If the regulator is vibrating normally due to turbulent service
(poor piping arrangement) it is possible in some cases for the
inlet ribs to crack and the core completely separates from its
end flange. This type of failure is most common in unusual
piping arrangements, for example, when large diameter pipe necks
down and up at the inlet and outlet of the Flexflo.
Outlet Slot Erosion (Abrasive Media)

If abrasive media is in the gas flow stream, the core can be
eroded as high velocity particles impact with the core.
Vibrational Outlet Slot Damage

If the Flexflo is severely undersized the tube opens and closes
very rapidly. As the tube vibrates against the core, the impact
of both pieces creates enough heat to damage the core. This
failure resembles erosion.
2.11.3 BODIES
porosity Leakage
Due to early casting problems we have had body casting leakage
through the 2" 900TE body.
2.12 900TE TOP ENTRY REGULATOR ADVANTAGE
The top entry regulator was developed to simplify the inspection

and maintenance procedures of pressure regulators. In general
the Flexflo regulators fail due to some type of problem with the
tube. with normal Flexflo regulators the main assemblies must be
completely removed in order to access the tube (see section 2.6).
with the 900TE, the body remains in the pipeline and none of the
flange bolting or the pilot piping have to be removed. The
closure is the only piece that is removed to access the core and
tube.
The 900TE regulator (Fig. 2-11) competes directly with the Fisher
399 (Fig. 2-12) and the Mooney Flowgrid (Fig. 2-12). There are a
number of advantages that the 900TE has over the Fisher and
Mooney regulators:
2.12.1 FEWER INTERNAL COMPONENTS
The Grove 900TE has fewer internal components that could

potentially fail than the Fisher 399 or Mooney Flowgrid. The
only moving part of the Grove 900TE is the Flexflo Tube. Because
the tube is the only part to wear out the potential causes of
failure are minimal. The simple internal design also minimizes
the possibility of loosing small components during disassembly.
Both Fisher and Mooney use a significantly larger number of

internal components than the Grove 900TE. Both use an internal
2 - 38
mechanical spring and a diaphragm. The Fisher 399 is further
complicated by a sliding diaphragm support piston and position
indicator. with more moving parts there is an increased
possibility of component failure. Also because all of the
internal parts come loose during disassembly there is a higher
possibility of loosing parts during maintenance.
2.12.2 PILOT MOUNTING OPTIONS
The Grove 900TE has more pilot mounting options than the Fisher
399 or Mooney Flowgrid. Grove has two jacket connection ports so
the pilot can be mounted on either side of the regulator in the
upright position.
Both the Fisher and Mooney only have a single control pressure
port of the top of their regulators (except for the Fisher 6"
399). The pilot of the Fisher 399 can be mounted on either side
of the regulator however the top closure must be rotated in order
to change the position of the control pressure port, this
involves unscrewing a number of studs and nuts from the body. The
Mooney control pressure port location requires the user to mount
the pilot on its side making control pressure adjustments
awkward.
2.12.3 1/2" PIPE CONNECTION FOR PILOT MOUNTING
The Grove 900TE pilot connection is more stable than the Fisher
399 or Mooney Flowgrid. Grove uses a 1/2" pipe between the
regulator and pilot. This acts as a structural connection the two
units. Wrench adjustments can be made to the pilot without
worrying about bending pipe or loosening threaded connections.
Fisher and Mooney both use only a 1/4" pipe connection between
the regulator and pilot. The smaller pipe is a weaker link than
the 1/2" Grove piping. The long 1/4" piping used on the Fisher
399 can create a stability problem when the pilot is adjusted.
2.12.4 EASIEST REGULATOR TO MAINTAIN
The Grove 900TE is easier to disassemble than the Fisher 399 or

the Mooney Flowgrid because none of the pilot tubing needs to be
removed with the 900TE when inspecting or maintaining the
regulator. The internal Flexflo tube is accessed by simply
unscrewing the closure bolts and removing the core. The simple
design makes the 900TE nearly impossible to incorrectly
disassemble or reassemble. Because the pilot is not involved with
the disassembly there is no possibility of changing any of the
pilot settings during inspection or maintenance. Once the pilot
tubing is installed it will never have to be disassembled.
Both the Fisher 399 and Mooney Flowgrid require the pilot inlet,
outlet and sense connections to be broken prior to disassembly.
The disassembly and assembly of tubing connections during
inspection or maintenance increases the possibility of damage to
2 - 39
the fittings. The Fisher 399 and Mooney Flowgrid are considerably
more complicated designs than the 900TE and as such, the
probability of incorrect assembly is also increased.
2.13 FLEX FLO TUBE REMOVAL AND INSTALLATION

FOR MODELS 80, 81 AND 887
In general, when Model 80, 81 and 887 Flexflo tubes are removed
from their cores, the tube is simply cut down the length and
discarded. This method is the quickest and easiest way to remove
a tube from a core. It also makes inspection easy because the
inner surface of the tube can be easily viewed.
There are other methods of removing the tube without destroying

it. To remove a Model 80, 81 or 887 tube intact, disassemble the
flange or closure components of the Flexflo. The tube and core
are placed over a cylinder that has an inner diameter slightly
larger than the outer diameter of the core and longer than the
length of the tube. The edge of the cylinder rests against the
tube and a downward force is applied to the center of the barrier
of the core. The driving force is usually a hydraulic press,
which is required for thick tubes. It is possible to use hammers
to separate light weight tubes and cores. The core will slide
into the center of the cylinder while the tube stays stationary.
The core will eventually fall away from the tube (Fig. 2-14).
To install a tube onto a core of a Model 80 or 887, the core is

placed on a solid surface with the inlet side facing up. The
inner surface of the tube is lubricated with glycerine or grease
and placed on top the core with the flange end down. To get the
leading edge of the tube over the core, tilt the tube so that
most of the circumference is around the outer diameter. Press
down on the top section of the tube that is not over the core
yet. Once the beginning portion of the tube is completely over
the core press straight down of the tube until the tube is
completely over the core. The tube is normally pressed over the
core with a hydraulic press. If the tube is thin as in a class
150 design it may be possible to install the tube over the core
with mallets knocking against the inlet edge of the tube.
2 - 40
FLEX FLO
SLOTTED
BODY CORE
NO FLOW
CLOSED POSITION
IF THE JACKET PRESSURE IS GREATER THAN OR EQUAL
TO THE INLET PRESSURE THE FLEXFLO IS CLOSED
FLOI . .
OPEN POSITION
IF THE JACKET PRESSURE IS LESS THAN OR EQUAL TO
THE OUT-LET PRESSURE THE FLEXFLO IS FULLY OPEN
FIG. 2-11 2 - 41
• • 1 ___ _
'I :,:':. '
I'
. .! f'
TYPE 161
PILOT CONTROL SPRINO
TYPE 161 PILOT

VALVE PLUG
TYPE 161
PilOT VALVE
PLUG SPRINO
TYPE 399
DIAPHRAGM
SUPPORT
TYPE 399
_ _ INLET PR~S SU n ~ DIAPHRAGM
~ LOADING PRESSURE
c:=.:J DOWNSTREAM PRE SSU RE
Fisller 399
2 42
FIG. 2-12
::'"1f.tr;'}' .·.It
,
..:,.
. :: .~
~}
restriction pilot regulator
control pressure
throttling ! .
--"--1>--- e Ie m e nf
Inlei outlet
Mooney Flowgrid
FIG. 2-13
2 - 43
PRESS
t
TUBE REMQVAL REVERSE CORE AND TUBE ASSEMBLY.
PRESS CORE INTO BODY TO REMOVE
TUBE
PRESS
t
TUBE REPLACEMENT LUBRICATE
INSTALL TUBE,CENTER ~
PRESS IN CORE
TUBE REMOVAL & REPLACEMENT

FIG. 2-14 2 - 44
SECTION 3 PILOT REGULATORS
3.1 PILOT OPERATING PRINCIPLE
3.2 829S REDUCING PILOT
3.3 829S BACKPRESSURE PILOT
3.4 829S DROOP FOR REDUCING SERVICE
3.5 BACKPRESSURE 829S RISE ABOVE SET
3.6 829S VARIABLE ORIFICE AND INTERNAL VALVE Cv

3.7 820 AND 830 PILOTS
3.8 REMOTE PILOT CONTROLLERS
3.9 PILOT DESCRIPTIONS
3.10 FILTERS AND STRAINERS
3
SECTION 3 PILOT REGULATORS
Pilot regulators are mechanisms that control the Flexflo or other

pilot controlled regulators. Pilots and main regulators made by
different manufacturers are generally interchangeable. The most
common pilots are pressure reducing and back pressure. Pilots
can only control Flexflo regulators through the jacket port. As
discussed in the Flexflo section increased jacket pressure tends
to close the regulator while decreased jacket pressure opens the
regulator.
3.1 PILOT OPERATING PRINCIPLE
The following paragraphs are brief explanations of the operating

principles of pressure reducing, back pressure and differential
pilots.
In pressure reducing service the pilot maintains a constant

outlet pressure from the Flexflo. If the outlet pressure is
above the set pressure the pilot increases the jacket pressure
and reduces the flow through the Flexflo. As flow to the
downstream piping is reduced the fluid pressure is also reduced.
If the outlet pressure is below the set pressure the pilot
decreases the jacket pressure and increases the flow through the
Flexflo. Conversely as flow to the downstream piping is
increased the fluid pressure is also increased. During normal
operation the jacket pressure is constantly adjusted so the
outlet pressure is constant.
Back pressure pilots monitor the inlet pressure. Its operation

is opposite of the pressure reducing pilot. If the inlet
pressure is higher than the set pressure the jacket pressure is
decreased allowing fluid to flow through the Flexflo reducing the
inlet pressure. If the inlet pressure is lower than the set
pressure the jacket pressure is increased preventing fluid from
flowing through the Flexflo increasing inlet pressure.
Differential pressure pilots monitor the differential pressure

between two pressure points, typically the inlet and outlet of a
flow restriction in series with the Flexflo. If the differential
pressure is lower than the set pressure the flow is increased
causing more fluid to pass through the restriction and increasing
the differential pressure. If the differential pressure is
higher than the set pressure the flow is decreased causing less
fluid to pass through the restriction and decreasing the
differential pressure. When an orifice plate is used as the flow
restricting device the system is a constant flow regulator.
3.2 829S REDUCING PILOT
The 829S pilot contains an internal valve, an adjusting spring, a

variable orifice and diaphragms. The position of the diaphragms
determines whether the internal valve is open or closed. The
spring compression controls the set pressure by pushing down on
3 - 1
the diaphragms, the sense (downstream) pressure pushes up on the
diaphragms. If the sense pressure is greater than the set
pressure, the sense pressure overcomes the spring force and the
diaphragms move up closing the internal valve. Fluid travels
from the inlet past the closed internal valve through to the
jacket connection. Thus when the internal valve is closed the
inlet and jacket connections have equal pressure and the Flexflo
is closed (Fig. 3-1).
If the sense pressure is lower than the set pressure the spring
force is greater than the sense pressure force, the diaphragms
are pushed down opening the valve. Fluid now passes through the
pilot from the inlet through to the outlet. The internal valve
is larger than the variable orifice. As fluid flows through the
pilot a large pressure drop is taken at the variable orifice and
a low pressure drop is taken at the internal valve. Ideally the
pressure drops from inlet pressure to the outlet pressure across
the variable orifice and no pressure is lost across the internal
valve. This allows the jacket pressure to drop to the outlet
pressure and the Flexflo to go wide open (Fig. 3-2).
3.3 829S BACK PRESSURE PILOT
The back pressure 829S uses the same components as the pressure
reducing pilot however the internal valve is facing the spring
barrel. If the sense pressure is lower than the set pressure the
spring holds the internal valve closed. Fluid travels from the
inlet through the variable orifice, past the internal valve to
the jacket port. Because the jacket port is a static connection
the inlet and jacket pressures equalize and the Flexflo closes
(Fig. 3-3).
If the sense pressure is greater than the set pressure the spring
force is exceeded, the diaphragms move up and the internal valve
opens. Fluid passes through the inlet to the outlet. The
internal valve is larger than the variable orifice, so as fluid
flows through the pilot the variable orifice restriction causes a
pressure drop. The jacket pressure can be reduced to nearly the
outlet pressure, causing the Flexflo to go wide open (Fig. 3-4).
3 - 2
REDUCING PRESSURE 829S PILOT
CLOSED POSmON
INTERNAL OUTLET
VALVE
VARIABLE
ORIFICE .........~
INLET
DIAPHRAGMS
SENSE
FIG. 3-1
3 - 3
.l<.hUULlNU PKh~~UKE M29S PlLOrr
OPEN POSI'rION
INTERNAL
VALVE OUTLET
VARIABLE
ORIFICE
INLET
DIAPHRAGMS
SENSE
FIG. 3-2
3 - 4
BACK PRESSURE 829S PILOT
CLOSED POSmON
INTERNAL
VALVE
OUTLET
VARIABLE
ORIFICE
DIAPHRAGMS
SENSE
FIG. 3-3
3 - 5
BACK PRESSURE 829S PILOT
OPENPOSmON
INTERNAL
VALVE
OUTLET
DIAPHRAGMS
SENSE
FIG. 3-4
3 - 6
3.4 829S DROOP FOR REDUCING SERVICE
As the flow through a regulator increases the outlet pressure
decreases through pressure reducing systems. The droop of a
regulator is related to the spring stiffness, the diaphragm area,
the variable orifice setting and the internal valve size. The
following graphs are for the 829S with M1 rotor, 5/64" diameter
internal valve. Note what variable orifice setting is being
used.
To solve the droop of an application first determine the maximum
flow capacity of the regulator for the specific application inlet
and outlet pressures (the Flexsize program is the easiest
method). Then determine the maximum required application flow
capacity. Divide the required flow by the maximum regulator flow
capacity and convert this number into a percentage. Go to the
appropriate 829S graph and draw a vertical line through the
percentage of regulator flow capacity scale. The line will
intersect three variable orifice setting curves. Draw a
horizontal line through the curve intersection corresponding to
the correct variable orifice setting. The droop or "pressure
drop below shut-off pressure" is found on the vertical axis.
The droop between a minimum and maximum flow rate can be solved
by finding the droop at a maximum flow and subtracting the
minimum flow droop.
Note that the droop for the "0" setting variable orifice is lower
than the droop for higher settings. This lower droop makes the
outlet pressure control more accurate.
EXAMPLE
The ramp or droop for a specific application can be found by
using the graphs with regulator capacity information.
The inlet pressure is 90 psi and the outlet pressure is 60 psi.

The maximum application flow rate is 110,000 SCFH. How much
droop will the system have between lock up and the maximum
application flow rate?
1. Determine the pilot to be used.

We are using an 829S pilot with a 20 - 75 psi control range,
the variable orifice is set at "3".
2. Solve the maximum capacity of the regulator being used.

Find the maximum regulator capacity from the sizing program
(Fig. 3-5). In this case a 2" model 900TE with an inlet
pressure of 90 psig and an outlet pressure of 60 psig has a
maximum flow capacity is 180,000 SCFH.
3. Solve the application flowrate as a percentage of the

maximum regulator capacity.
The application flowrate is 61% (61.1% = 110,000
SCFH/180,OOO SCFH) of the maximum capacity.
3 - 7
t*************************************************·*************************-
SP.GR. NATURAL GAS CAPACITY OF QTY 1: 2-INCH CL 150 893 RIB TUBE
MOD 900TE FLEXFLO REGULATOR
180 X1000 SCFH AT 60 DEG F
AT 90 PSIG UPSTREAM AND 60 PSIG DOWNSTREAM PRESSURES
******************************************************************************.
****************************************************************************** •
• 6 SP.GR. NATURAL GAS FAILED-OPEN CAPACITY OF QTY 1: 2-INCH
CL 150 893 RIB TUBE MOD 900TE FLEXFLO REGULATOR
180 X1000 SCFH AT 60 DEG F
AT 90 PSIG UPSTREAM AND 60 PSIG DOWNSTREAM PRESSURES
*******************************************************************************
Press SHIFT-PRTSC for printout
DO YOU WISH TO DO ANOTHER GROVE MODEL 900TE REGULATOR PROBLEM (YIN)?
FIG. 3-5
-2 :~ - -~ ~ :
<::;
t:)
3t-
t-
W
<?
W
U
0 i:
C2
a
w
3 -'
'"«
4 ;:;:
«
>
w
'"
«
o 10 20 30 40 50 60 70 80 gO 100
% OF REGULATOR FLOW CAPACI~(
FIG. 3-6
3 - 8
4. Solve the droop by referring to the specific the pilot graph
(Fig. 3-6).
On the reducing pressure 829S 20 - 75 psi control range
graph draw a line from the horizontal axis at 61% straight
up to the number 3 curve. At the intersection draw a
horizontal line to the vertical axis. In this case the
intersection is at -4.25. This is the total droop from shut
off to maximum application flow. If the unit is locked up
at 60 psi the outlet pressure will droop to 55.75 (60 -
4.25) when the unit is passing the maximum application flow.
The droop charts for all control ranges of the 829s are shown in
Fig. 3-7.
3 - 9
o
,....
~
Do....
V;-2 ~
-1'-./ 06
3~
Ww .
~O:::: 4~
=> -4
0....
0(.1)
0::::(.1)
~
~w ~
0:::: ~
wo.... lX
~
0:::: L- -6 >
=>L- ~
(.1)0 ~
(.1)1 ....
wI-- . ell
0:::::::> (')
0.... I -8 d
(.I) 3 - 10 PSI RANGE 'V
829/829S REDUCING PILOT
-10
o 10 20 30 40 50 60 70 80 90 100
% OF REGULATOR FLOV CAPACITY
FIG. 3-7
3 - 10
o
-2
.t3 - 25 PSI RANGE

829/829S REDUCING PILOT
-
c3
v
-10
o 10 20 30 40 50 60 70 80 90 100
% OF REGULATOR FLO~ CAPACITY
FIG. 3-7
3 - 11
o
/"\.
I-i
V>
-2 ,...
(.1
~o... l!J
o'J .
..J w ~ .. ~
I-
au
w~ (.1
t:Q::::J -4 0
au
.....
0... V> 0 ~
oV> ~
~w
~~ au
0... 3 ..J ~
4 ....<a:
<
W
~L....
-6
::::JL.... >
v>O au
a:
V>I ". 20 - "75 'PSI RANGE <
WI-
~::::J 829/829S REDUCING PILOT
...
o...:r -8 crII
M
V>
d
'"
-10
o 10 20 30 40 50 60 70 80 90 100
I. OF REGULATOR FLO~ CAPACITY
FIG. 3-7
3 - 12
o
r"\.
~(;) -2 '"...CJZ"
Do...
..J'-/
l-
I-
. W
Ww '"W
I=Q~
0...::J -4
...l!.
0
0::
0(1) C
~(I)
~w ~
~
wo...
...
p:j
<t
0::
<t
~u... -6 >
::Ju... .... W
(1)0 0 0::
<r
(1)1 .- ....
wI- ,60 _:- 15.0 PSI RANGE· ell
~::J 829/829S REDUCING PILOT M
0... I -8 dv
(I)
3
4
-10
o 10 20 30 40 50 60 70 80 90 100
I. OF REGULATOR FLOV CAPACITY
FIG. 3-7
3 - 13
o
-2
---. -4
-
VI
CI
Z
3:~
0
....J
Wo::
ro::>
.........
w -6
-8
...
- 125 - 350 PSI RANGE
829 /829S REDuONG PILOT ~
tj
Ii:
~
a..(f)
O(f)
o::W -10
00::
" ~
m
0... <
W 0::
0:: LL
LL -12 ~
::>0
0 W
(f) I 0:::
<
~ ~ -14 . "If'
0::::>
~
0... ~ -16 ,..,
3
ci
'-'
-18 4
-20
o 10 20 30 40 50 60 70 80 90 100
% OF REGULA TOR FLOW CAPACITY
FIG. 3-7
3 - 14
0
-4
-8 300 - 600 PSI RANGE
REDUCING PILOT
,....
-12 " I'
829/829S
:3(;;) -16
Do....
--1'\../ '"
Ww -20
,::Q~
a..:::J "
0(.1) -24
~(.I)
~w
~ -28
wo....
~LL
:::J
LL
-32
(.1)0
(.1)1
o .IS
wI- -36 M
~:::J r.-..; fi;; d

'V
a.. I
(.I) -40
-44 3
-48
4
-52
o 10 20 30 40 50 60 70 80 90 100
FIG. 3-7
3 - 15
3.5 BACK PRESSURE 829S RISE ABOVE SET
The rise above set pressure for back pressure 829S regulators is
determined in the same manner as the droop for reducing service
829S. The difference is that as flow increases the inlet
pressure to the regulator increases (Fig 3-8). When a back
pressure regulator is being used in relief service it is
important to know what the rise above set pressure will be.
3 - 16
10
w 8
~
::::>
(/)
(/)
w
~
0.. 6
r-
w
(/) ~
~
w ~
> 4
0 4~
CD 3<
...
« 0 ..
w
(/)
(')
~
2 3 - 10 PSI RANGE
cf
V'
829/829S BACK PRESSURE PILOT
a
o 10 20 30 40 50 60 70 80 90 100
FIG. 3-8
3 - 17
10
w 8
a:::
:J
(f) "c:I
(f) '"j:
Z
w
a::: I-
~
a.. 6
f-
w
(f)
-
4~
Ij
"-
1&.1
w 3~
> 4 <
0
CD O~
« >
, 1&.1
w ~
(f) . -8 - 25. PSI RANGE -or
2 829/829S BACK PRESSURE PILOT
a::: «J
M
d
v
,I
o
o 10 20 30 40 50 60 70 80 90 100
/. OF REGULATOR FLo~ CAPACITY
FIG. 3-8
3 - 18
10
w
0::: 8
:::>
(f)
'"....'"'
l:J
Z
~
(f) ~
W w
0:::
u
'"w
Q.. 6 4 ~....
r 3 ~
0
w W
(f) ...J
III
w 0 ....ac:
~
>
0
4 >
~
III w
ac:
<{ ~
2l)75 PSI RANGE ..,.

W .II
(f) 829/82'9S BACK PRESSURE PILOT
0:::
2 M
:l 0
'"
o
o 10 20 30 40 50 60 70 80 90 100
FIG. 3-8
3 - 19
10
4
3 "
w
0.::: 8 ~'"
:::> 5
(f)
(f) '"
W 0 tf
0.:::
a.. 6 S
C
t.I
I- ..J
w ~
....
(f)
~
w >
> 4 t.I
0 ~
m
<l:: "'"
, 60 - 150 PSI RANGE
.
•
M
w 829/829S BACK PRESSURE PILOT d
(f) v
2
0.:::
o
o 10 20 30 40 50 60 70 80 90 100
FIG. 3-8
3 - 20
20
18 4
,...,
w 3 en
0
a::: 16 z
" ~
:::::>
en .
en 14
lj
w
a::: 0
£L:
£l. 12 ~
t-
w ~
en 10 Ql
<
w a::
> 8 ~
0 w
CD ~
« 6 125 - 350·P~ RANGE
<
..,.
~
w 829/829S BACK PRESSURE PILOT ~
en 4
-
a::: Ii"'"
I')
0
'-'
2
o
o 10 20 30 40 50 60 70 80 90 100
% OF REGULA TOR FLOW CAPACITY
FIG. 3-8
3 - 21
52
4
48
44 3
40
w
0:::
~
l-
36 I-
:::> o~
(f)
l..t
(f) (.)
w 32 ~
0::: 2i
CL
28 l..t
..J
t- ~
w ....
~
Q!
(f)
24 ~
>
w
> ~
~
0 20 ;-
CD oil
<{
16 M
w
(f) 1/
0::: 12 300 - 600 PSI RANGE
829/829S BACK PRESSURE PILOT
8
o
o 10 20 30 40 50 60 70 80 90 100
% OF REGULATOR FLO~ CAPACITY
FIG. 3-8
3 - 22
3.6 829S VARIABLE ORIFICE AND INTERNAL VALVE cv
In most pilot systems the jacket pressure is controlled by an

internal valve and a variable orifice. The variable orifice
restriction is held constant while the internal valve is
constantly adjusted to control the jacket pressure. The
relationship between the variable orifice and the internal valve
effects the total CV of the pilot. The CV of the pilot from
inlet to outlet is the sum of the variable orifice Cv and the
internal valve cv.
The Cv also affects the rate at which the regulator opens and
closes. When closing the inlet gas runs directly to the jacket
thus the closing time is only affected by the variable orifice
cv. Higher orifice settings close the regulator faster.
When the regulator opens gas is passing through the variable

orifice as well as the internal valve. The opening response time
is also affected by the variable orifice. Low orifice settings
open the regulator faster.
The response time of the regulator is improved as the variable

orifice is opened, the accuracy however is decreased due to
higher droop. with lower orifice settings the regulator accuracy
is increased but the stability of the regulation is decreased due
to the slower response time.
When setting the pilot we try to adjust the pilot so that the
minimum stable orifice setting is used. start the system with a
high orifice setting and adjust the setting lower until the
control becomes unstable.
The variable orifice CV graphs (Fig. 3.9) show the Cv's at

different settings of all variable orifice rotors that Grove
makes. The M1 rotor is standard for most 829S pilots. The 829L
has the same rotor and internal valve arrangement. The internal
valve maximum cv's are:
Orifice Diameter Cv service

5/64" 0.168 gas
1/8" 0.400 liquid
3 - 23
Rei. 8-21-92 Appr.
SK-4-2Q2
Sheet 1 of 2
VARIABLE ORIFICE Cv
Cv vs ORIFICE SETfING
0.6 ,,
,
0.5
I.
0.4
3 0.3
0.2
0.1
00 1 2 3 4 5 6 7 8
ORIFICE SETIING
ROTOR
---L1
FIG. 3-9 (j)(j)

::07:
(1) I
(1) ,j:o.
r-tl
tv
f-' 0
LJ
o
Hl
3 - 24
SK-4-202
Sheet 2 of 2
VARIABLE ORIFICE Cv
Cv vs ORIFICE SETTING
0.16
0.14
0.12
0.1
() 0.08
0.06
0.04
0.02
0
0 1 2 345 6 7 8
ORIFICE SETTING
ROTORTYPE
I --- S -+- S1 ---*- M1 -B- M
(j)(j)
:Y7::
FIG. 3-9 (1)
(1)~
I
rtl
tv
~v 0
tv
o
rn
3 - 25
3.7 820 AND 830 PILOTS
The 820 and 830 pilots are the high pressure units used for all
control pressures that exceed 600 psi. Both units use a three
way valve to control the jacket pressure. To open the Flexflo
the inlet port is closed by the valve and the jacket and outlet
ports are connected. When Pjacket = Poutlet the Flexflo is fully
open. To close the Flexflo the internal valve closes off the
outlet port and the jacket and inlet ports are connected. When
Pinlet = Pjacket the Flexflo is closed. Normally the valve is
positioned so that the jacket port is partially opened to both
the inlet and outlet ports. The units can be used for gas or
liquids and their maximum control pressure is 1,200 psi.
The 820 pilot is used for reducing service (Fig. 3-10). The
"high differential pressure sense" port is connected downstream
of the Flexflo. If the sense pressure is higher than the set
pressure, the internal valve is pushed to close the outlet port,
connecting the inlet and jacket ports, closing the Flexflo. If
the sense pressure is lower than the set pressure, the spring
force pushes the internal valve to close the inlet port, opening
the Flexflo.
The 830 pilot is used for back pressure service (Fig. 3-11). The
"high differential pressure sense" port is connected upstream of
the Flexflo. If the sense pressure is higher than the set
pressure the internal valve is moved towards the open position.
With the sense pressure lower than the set pressure the unit is
closed.
Both units have a sensitivity adjustment screw which moves the

position of the inlet port seal. By narrowing the distance
between the outlet seal and inlet seal the pilot becomes more
sensitive. When the distance between the outlet and inlet seals
is increased the pilot becomes less sensitive. The position can
be determined by looking at the adjustment screw. With the arrow
pointing towards the outlet port the pilot is most sensitive,
with the arrow pointing towards the spring barrel the pilot is
least sensitive. The seat is cam driven so the only indication
of the seat position is where the arrow is positioned front to
back. The variable orifice setting on the jacket connection only
affects the opening and closing response times and not the droop.
Both units have two sense ports for differential pressure

applications. It is possible to control the pressure across a
flow restriction by connecting a high differential pressure sense
port upstream of the restriction and the low differential
pressure sense port downstream of the restriction. If the
differential pressure is lower than the set point the Flexflo
opens. If the differential pressure is higher than the set
pressure the Flexflo closes. This set up is often used with
orifice plates for constant flow control.
3 - 26
820 PILOT
LOW INLET JACKET OUILET

HlG
DIFFERENTIAL DIFfERENTIAL
PRESSURE PRESSURE
SENSE SENSE
FIG. 3-10
830 PILOT
JACKEr OlfTLET
LOW HIGH
nI}--~ERENTr A1" D [FFERENTI AL
PRESSUHE PRESS1JRE
SENSI:: ::-lENSE
FIG. 3-11
3 - 27
3.8 REMOTE PILOT CONTROLLERS
There are a number of different ways to remotely adjust the set

pressure of a Flexflo regulator.
DIAPHRAGM MOTOR VALVE (DMV)

The diaphragm motor valve Model 826 uses a pneumatic low pressure
signal to adjust the Flexflo from shut off to full open. This is
not a pressure regulating system by itself. A separate control
system supplied by the customer senses the inlet and outlet
pressure and sends the appropriate control signal to the
diaphragm motor valve (Fig. 3-12).
829S TELEMETERING
The 829S control pressure can be varied by telemetering. Gas
pressure applied to the vent port in the spring barrel of the
829s will increase the set pressure of the pilot. The set
pressure of the pilot will increase by the exact pressure applied
to the vent port. For example if the pilot is set at 250 psi
outlet and 25 psi is applied to the vent port the new set
pressure is 275 psi (Fig. 3-13).
REMOTE MOTOR DRIVE SYSTEM

Engineering Gas Products makes an electrically driven remote set
pressure adjuster. The unit mounts on top of the 829s. A 120
volt AC electrical signal turns on a motor that adjusts the set
pressure of the pilot. A variable resistor indicates the
position of the adjustment screw (Fig. 3-14).
829S USED AS A DMV

It is possible to use the 829S in the same operation as the 826
diaphragm motor valve. The 829S can be arranged as a normally
open (reducing) or normally closed (back pressure) pilot. The
normal control pressure range is 3 - 15 psi or 6 - 30 psi. We
have found that 60 - 150 spring range gives the best sensitivity
across the 3 - 15 psi control pressure range. The sense port is
used as the control pressure port and is not connected to any
section of the pipeline (Fig. 3-15).
3 - 28
FIELD PROVEN
APPLICATIONS
GROVE MODELS 80-826 AND 8O-826A

DIAPHRAGM MOTOR VALVE OPERATION OF FLEXFLO (MODELS 80-826 & 8O-826A)
This application shows the Flexflo operated by a pres·
sure or flow controller.
A small diaphragm motor valve is used to control the
pressure on top of the tUbe.
The controller may be set by telemetering or may be
manually set.
106·00519-Cv = .03 to .18
DMV - Research Controls
Cv= .2
ITEM PART NAME MATERIAL

DIMENSIONS
1 FLEXFlO VALVE STEEL
2 iOIAPHRAGM MOTOR VALVE STEEL A I B I c I 0
3 IJACKET CONNECTOR STEEL 1I\6\\a\6\

.. SINGLE VARIABLE ORIFICE STEEL
5 ELBOW VI NPT STEEL
6 CLOSE NIPPLE VI NPT STEEL
7 ELBOW \ NPT x \ TUBE STEEL
~ iADAPTER VI NPT X \ TUBE STEEL
9 ADAPTER \ NPT x \ TUBE STEEL
11
12
TUBING [\W)
CONTROLLER ..
VZ C.Re.S .
13 PRESSURE REGULATOR
E3 e
14 NAMEPLATE C.Re.S .
0 STRAINER ADAPTER ('to NPT) C.Re .S. -- - , = - 0
NOTE:
'SUPl'tIED BY CUSTOMER FIG. 3-12 fl¢=~_~==.~=====
i i. i~
. - ~~
- ~-
u
r-
PRESSURE BOOSTING BY TElEMETERING r-----~METAMETER
Shown here is a way of using the Flexflo on a telemet·

rically controlled system. 20 psi
(2) RECEIVER
CONTROLLER
(0-20 psi)
The Metameter receiver controller is remotely set. When f----="::"""'::"=-----lO
GAS SUPPLY
0 ~------''---...:....-;
RELAY
the set point is raised, it puts out an increased pneu· l...-____..J
matic signal. This is piped into the spring case of the 1 TO 2
pilot regulator. OR
AUX . GAS 1 TO 3
If 20 psi is the maximum desired boost then the relay
is not required . SUPPLY
If a boost higher than 20 psi above base setting is reo
quired then a relay (1·2 or 1·3) may be used.
FIG. 3-13
3 - 29 Bulletin No. 532·AP·1

ENGINEERED GAS PRODUCTS, INC.
REMOTE SET-POINT PILOT
• FOR GROVE MODELS

829 AND 829S PILOTS
• SURFACE OR EXISTING
REGULATOR MOUNTED
• EASE OF CONVERSION
FOR EXISTING
REGULATOR STATIONS
• QUICK RELEASE FOR

MANUAL OPERATION
• STANDARD HEATER
TO PREVENT
CONDENSATION AND
FREEZE-UP
FIELD INSTALLATION
(SURFACE MOUNTED)
- -..
• 1/2 RPM MOTOR SPEED
STANDARD, WITH OTHER
SPEEDS OPTIONAL.
• 10-TURN ADJUSTABLE
LIMIT SWITCHES, HIGH
AND LOW SET
• NE A 4 A D 7
EXPLOSIO -PROOF
HOUSI G
• POWER 120 VAC,

60 HZ, SI GLE PHASE
ASSEMBLY
ASSEMBLY (COVER REMOVED)
FIG. 3-14
3 - 30
MECHANICAL ELECTRICAL
I
.... ".'1
--.-.,.~#
, . , I'NIU' N"""'~
.l-1_ _ _ I-_ _ _-----'-_ _ _ ~ u.::..-;i~,.
.r,,, .0..-.-9
" . .-'tuEJ
l'AlC""",J,/~
I
;"~"I
-"="'- - - - -
11 f - -_ _
STAT
GROVE
MODEL 829 OR 829S
PILOT
REPRESENTED BY:
ENGINEERED
GAS PRODUCTS, INC.
P.o. BOX 294
9/85
EAST BRUNSWICK, N.J. 08816
201/257-9117 • TELEX 135054
FIG. 3-14
3 - 31
NORMALLY CLOSED DMV
CONTROL FLEXFLO
OPEN POSITION
P outlet
INTERNAL
VAL
OPEN
JACKET
P inlet & sense
FIG. 3-15
3 -32
3.9 PILOT DESCRIPTIONS
Below is a listing of most pilots that Grove has used in the

past. Most of these designs are now obsolete however by being
able to identify what type of pilot a customer has, a suitable
replacement can be found. Some pilots are manufactured by
outside vendors. The manufacturing company if other than Grove
is listed next to the model number.
MODEL 41F
TYPE: A.C. Solenoid Operator
OBSOLETE remote on/off pilot.
normally closed.
MAX. CONTROL PRESSURE 1,500 psi
CONTROL VOLTAGE 24V, 120V, 220V, and 440V
MODEL 41M
TYPE: A.C. Solenoid Operator
remote on/off pilot.
normally open or closed.
MAX. CONTROL PRESSURE 1,500 psi
OBSOLETE
MODEL 42M
TYPE: Dome pressure/Diaphragm design
OBSOLETE
MODEL 42F
TYPE: Dome pressure/Diaphragm design
OBSOLETE
MODEL 43F
TYPE: Hand lever actuator
Manually operated on/off controller
OBSOLETE
MODEL 820
TYPE: Pressure reducing or differential
pressure pilot, spring/diaphragm
design
MAX. CONTROL PRESSURE 1,200 psig
3 - 33
MODEL 821
TYPE: Pressure reducing/back pressure
Dome pilot.
MAX. CONTROL PRESSURE 1,500 psig
OBSOLETE
MODEL 824
TYPE: Proportional operator
OBSOLETE
MODEL 825
TYPE: Reducing pilot
OBSOLETE
MODEL 826
MANUFACTURER: Research Control
TYPE: Diaphragm Motor Valve
Normally open or normally closed
MAX. CONTROL PRESSURE: 1,500 psig
CONTROL SIGNAL: 3-15 psi or 6-30 psi.
MODEL 826A
TYPE: Diaphragm Motor Valve
MANUFACTURER: Skinner
OBSOLETE
MODEL 827
TYPE: Pressure reducing
Spring/diaphragm pilot
MAX. CONTROL PRESSURE: 1,000 psi
OBSOLETE
MODEL 829
TYPE: Reducing/back pressure pilot
Brass construction
MAX. CONTROL PRESSURE: 600 psi
OBSOLETE
MODEL 829S
TYPE: Reducing/back pressure pilot
316 Stainless Steel construction
MODEL 830
TYPE: Back pressure or differential
pressure pilot
3 - 34
MODEL 833
TYPE: Back pressure pilot
Spring/diaphragm design
OBSOLETE
MODEL 834
MANUFACTURER: Reliance
OBSOLETE
MODEL 835
MODEL 888
TYPE: Nitrogen bottle hook-up
Back pressure/relief pilot
Regulator capacity proportional to
rise above set pressure
MODEL 889
TYPE: Back pressure/relief pilot
Piston/spring design
MODEL 896
MANUFACTURER: MECO
TYPE: Pressure reducing pilot
OBSOLETE
MODEL 896A
MANUFACTURER: Bastian-Blessing
MODEL 896C
MANUFACTURER: Reliance
3 - 35
MODEL 896E
MANUFACTURER: Fisher
MAX. CONTROL PRESSURE: 10" water column
MODEL 896G
MANUFACTURER: Rockwell
MODEL 900
TYPE: Liquid level pilot
Used with liquid storage tanks
OBSOLETE
3 - 36
3.10 FILTERS AND STRAINERS
In most applications it is important to properly protect the

pilot from damage caused by particulate in the gas stream. The
internal valve and variable orifice can be plugged and the valve
seat can be damaged by large particles passing through the pilot
tubing. The strainers have 40 mesh screen material to remove
particles from the gas stream. The strainer flow resistance is
so minimal that its Cv normally does not have to be accounted for
when calculating the pressure loss through the pilot tubing (Fig.
3-16).
The filter has a 35 micron filtration rating. It is important to

connect the FT-35 in the upright position with the inlet and
outlet above the vent port. Instal~ a small valve on the vent
port. It is common to install a valve on the vent port.
Condensation can accumulate in the bottom of the filter and
should be drained periodically by opening the valve (Fig. 3-17).
The Cv of the filter is 0.21.
3 - 37
STRAINER ADAPTER UNITS
\
4 N.P·T
SOFT SOLOeR AROUND AOA.PTeR,
CAP AND ALONe:. SEAM.
Construction: Stainless Steel Body and perforated screen - 3/64 dia. holes
Standard for all Model 80 and 81'Flexflos

1/4 NPT Part No. 104-00036
Standard for all Model 80 rpoduced before 1972
3/8 NPT Part No. 104-00018
MODEL 82 ONLY
DlAS'T1SOt.. R:\..lG
PLASTISOL
(WlT>~ \Is CIA. "'tN. T·HN HOLE:) RING
(wm-{ Yeo CiA.. Mlt..i. ThR0 ~OLr::)
40M£.51-1
~\. S'T\... SCQ..€.£..N
(t:WU.~D ""0 SEAM WE.DEO)
Part No. 104-00037

Size 1 1/2" - 6"
Part No. 104-00038

Size 8"
Strainers are inserted into the Flexflo inlet boss to prevent fouling of
the pilot system.
FIG. 3-16 Bulletin No. 532-FA-2

GROVE FLEXFLO
FLEXFLO I ACCESSORIES
.T- TYPE FILTER MODEL FT-35
I• BODY
2. FILTER ELEMENT
3. STUD
" 4. O-RING
"
,.:
" :, 5. CLOSURE (TOP)
.
"
:'
.II ~ ....
I
" 6. CLOSURE (BOTTOM)

"
2
"
~
"
Contruction: Steel - Zinc Plated
Plastic Porous
Connections: 1/4" NPT

.L"NPT
4 Maximum Pressure: 1500 PSI
DRAIN
The Grove T-Type filter can be used ahead of the Model 829 or other pilots to prevent
fouli~g of the Pilot System
The cartridge filter element is made of high density polyethylene providing a large surface
area and filtration to 35 microns,
The element can be readily replaced without tools by removing the bottom closure, replacing
:he filter and reassembling (hand tight) while still in the line.
FIG. 3-17 Bulletin No. 532-FA-1

SECTION 4 FLEX FLO SYSTEMS
4.1 FLEXFLO AND 829s CONNECTIONS
4.2 PRESSURE REDUCING SYSTEM
4.3 BACKPRESSURE SYSTEM
4.4 OTHER PILOT INSTALLATION
4.5 MONITOR SYSTEMS
4.6 TWO STAGE WITH MONITOR OVERRIDE
4.7 START UP INSTRUCTIONS

4.8 FAILURE MODES
4.9 BACKPRESSURE REGULATOR RELIEF CAPACITY CHARTS
4
SECTION 4 SYSTEMS
This section addresses the hookup of Flexflos and pilot

regulators. Normally the inlet, jacket and outlet connections
are made directly between the Flexflo and pilot. In pressure
reducing service the sense line is connected at least 6 pipe
diameters downstream. For example the sense line of a 3"
regulator in a 3" pipeline should be connected 18" downstream of
the regulator. Because there can be a significant amount of
turbulence directly downstream of the regulator, the sense line
is moved to a section of pipe that has smooth gas flow. In back
pressure service the sense line is normally teed directly into
the inlet tubing. Because fluid flow into the regulator is
generally not turbulent there is no need to move the sense line
farther upstream. This simplifies the tubing connections.
Because the pilot can be affected by particles in the gas stream

it is common to install a filter or screen before the inlet of
the pilot.
4.1 FLEXFLO AND 829S CONNECTIONS
The Flexflo and 829S port fittings, port threads and recommended
tUbing connections are listed below:
FLEX FLO 829S PORT THREAD PRESSURE CONNECTION
INLET INLET 1/4" NPT 1/4" SS TUBING

OUTLET OUTLET 1/4" NPT 3/8" SS TUBING
JACKET JACKET 1/2" NPT 1/2" PIPE
SENSE 1/4" NPT 1/4" OR 3/8" SS TUBING
The outlet tubing is larger in diameter than the inlet tubing to

minimize the piping friction losses as gas flows from the jacket
to the outlet. If the gas cannot flow easily through the outlet
tubing the jacket will not be able to vent down to outlet
pressure thus restricting flow through the regulator. Small flow
restrictions are not a problem with the inlet tubing only.
Restrictions like filters and small diameter tubing will not
hinder normal operation.
4.2 PRESSURE REDUCING SYSTEM
When properly assembled a pressure reducing system should

resemble the arrangement of Fig. 4-1. In this example the outlet
pressure is higher than the set pressure. The force of the
pipeline fluid pushing up on the diaphragms is greater than the
spring force pushing downs on the diaphragms. The internal valve
is closed and gas passes directly from the inlet to the jacket.
With the inlet and jacket pressures equal the Flexflo is closed.
The regulator is trying to reduce the outlet pressure by stopping
fluid from passing through to the downstream piping.
4 - 1
PRESSURE REDUCING FLEXFLO
CLOSED PosmON
Poutlet > Pset
P outlet
INTERNAL OU11.ET
V
~""'~_IIIII ·JACKET
P inlet
SENSE
P jack~t
FIG. 4-1
4 - 2
In Fig. 4-2 the pressure reducing system is shown in the wide
open position. The outlet pressure is lower than the pilot set
pressure. The force of the fluid pushing up on the diaphragms is
lower than the spring force pushing down on the diaphragms. The
internal valve is open and the jacket pressure is vented to
outlet pressure. With the jacket pressure less than inlet
pressure the regulator is open. The regulator is trying to
increase the downstream pressure by allowing higher pressure
fluid to pass through to the outlet piping.
4 - 3
PRESSURE REDUCING REGULATOR
OPENPosmON
P outlet < P .......
P outlet
P sense
iiiil:l
r......-.....,.... JACKET
P inlet
FIG. 4-2
4 - 4
4.3 BACK PRESSURE SYSTEM
In Fig. 4-3 a back pressure/relief system is shown. The outlet

of the Flexflo is connected to low pressure outlet piping. The
inlet pressure is lower than the pilot set pressure and the
internal valve is closed. The spring force pushing down on the
diaphragms is greater than the fluid pressure force pushing up on
the diaphragms. Gas passed directly from the inlet to the
jacket. The Flexflo is closed when the inlet and jacket
pressures are equal. The regulator is trying to build back
pressure by preventing fluid from flowing out of the upstream
piping.
In Fig. 4-4 the back pressure system is open. The inlet pressure
has exceeded the pilot set pressure. The fluid force pushing the
diaphragms up is greater than the downward force of the spring.
The internal valve is open and the jacket pressure is vented to
outlet pressure. In this example as fluid flows through the
outlet piping the pressure builds to 300 psi. The regulator is
trying to decrease the inlet pressure by venting upstream fluid
to the outlet.
The sizing of an 829S pilot configured for back pressure service

is significantly different from the sizing of a Flexflo with an
888 hook up. The relief valve described utilize the full
capacity of the regulator as soon as the internal valve of the
pilot is wide open. The 888 pilot opens in proportion to the
inlet rise over set pressure. See section 6 for the proper
sizing of 888 pilot operated regulators.
4 - 5
BACK PRESSURE FLEXFLO
CLOSED POSITION
Pinlet < Pset
P outlet
JACKET
P inlet & sense
FIG. 4-3
4 - 6
BACK PRESSURE FLEXFLO
OPEN POSITION
Pin let > Pset
P outlet
INTERNAL
VAL
OPEN
INLET
....... JACKET
rllft)~g:::~
P inlet & sense
FIG. 4-4
4 - 7
4.4 OTHER PILOT INSTALLATION
It is possible to use other manufacturer's pilots or a reducing

regulator as the pilot of a Flexflo regulator. It is sometimes
convenient to use a Grove specialty regulator for high pressure
applications. Fig. 4-5 shows how to use a generic regulator as a
Flexflo pilot. A variable orifice is mounted between the inlet
and jacket ports of the Flexflo. The variable orifice should
have a significantly smaller Cv than the regulator being used, 10
to 50% of the rated pilot cv. The regulator is connected between
the jacket and outlet ports. If the regulator has an external
sense port this should be connected six pipe diameters downstream
of the Flexflo.
It is possible to use a back pressure regulator as the pilot for

the Flexflo however an external sensing port must be used. The
unit is installed like the reducing regulator except that the
sense port is connected to the inlet piping. If the back
pressure regulator has only internal sensing the system will not
have normal control. The regulator will hold the jacket pressure
constant like an 888 configuration. with this type of set up the
flow capacity increases in proportion to the percent rise above
the relief pressure.
4 - 8
EXTERNAL SENSING REQUIRED EXTERNAL SENSING OPTIONAL
FOR BACK fRESSURE SERVICE FOR REDUCING SERVICE
•• •••••••••••••••••••••••• ••••••••••••••••••••••
• •
• • •
• •
• •
• VARIABLE •
• ORIFICE •
• •
• •
• •
• .. •
• '
•
• plLOT •
• •
• •
•
FLEXFLO
FIG. 4-5
4 - 9
4.5 MONITOR SYSTEMS
WORKER\MONITOR SYSTEM
Monitor systems are used to protect pipelines from regulator

failures. If a single regulator fails the unit can go to its
full open capacity and the outlet pressure can rise well above
the normally controlled pressure. with a monitor system the
pipeline is protected from a single regulator failure by a second
back up or monitor regulator. The working regulator normally
controls the outlet pressure. The monitor regulator controls the
outlet pressure only if the working regulator fails open,
protecting the pipeline in the event of a failure. The normal
Flexflo monitor system consists of two regulators in series. The
regulators are hooked up with the sense tubing connections of
both pilots tied to the outlet piping. The pilots are set to
slightly different outlet pressures, typically a 5 psi difference
between the two. The pilot with the lower set pressure is the
working regulator and the higher set pressure pilot is the
monitor. The common configuration is for the upstream regulator
to be the worker based on the following (Fig 4-6):
1. The core of the upstream regulator acts as a strainer for

the downstream regulator
2. Abrasive media that is in the gas stream will damage the

upstream regulator before the downstream regulator.
3. with the monitor upstream the tube tends to be overexpanded

and will have difficulties shutting off when the working
regulator fails. In this set up the monitor internal
pressure is high while the jacket pressure is low. This
causes the tube to be expanded against the regulator body.
with the monitor in the downstream position the jacket
pressure is never lower than the pipeline pressure. The
inlet pressure will be higher than the jacket pressure but
the outlet and jacket pressures will be equal. This
arrangement prevents the tube from being over expanded
during normal operation.
Although it is more popular to have the working regulator

upstream of the monitor it is not uncommon to have a system where
the monitor is upstream of the working regulator (Fig. 4-7).
Notice in this set up that the intermediate pressure is close to
inlet pressure indicating that the upstream regulator is wide
open. Typically the regulator with the lower differential
pressure is the monitor unit while the regulator with the high
differential pressure is the working regulator.
In normal operation the working regulator is controlling the

outlet pressure while the monitor is fully open. The outlet
pressure is at the set point of the working regulator. The
monitor is normally wide open. Because the outlet pressure is
slightly lower than its set pressure the pilot is fully open
4 - 10
trying to raise the outlet pressure. In the example the inlet
pressure is 500 psi and the outlet pressure is 250 psi. The set
pressure of the working pilot is 250 psi. The working regulators
pilot only senses the outlet pressure thus the pressure just
downstream of the working regulator is higher than its set
pressure, 280 psi.
Flexflo regulators normally fail open in gas service. When the

upstream regulator fails it will go to full open capacity. The
outlet pressure will increase to the set pressure of the second
pilot. By monitoring the outlet pressure the pipeline workers
can determine if there has been a failure by watching the outlet
pressure. If the outlet pressure is at the working regulators
set pressure the system is operating normally. If the outlet
pressure is at the monitor regulators set pressure the working
regulator has failed.
In Fig. 4-6 if the working regulator fails the intermediate

pressure will rise to nearly 500 psi and the outlet pressure will
be slightly higher than 250 psi. In Fig. 4-7 if the working
regulator fails the intermediate pressure will drop to less than
300 psi and the outlet pressure will be slightly higher than 250
psi.
4 - 11
INTERNAL
VALVE
RFGln..l\ lTNG
f ,• .
P inlet P intemlediate P outlet
WORKING REGULATOR MONITOR REGULATOR
FIG. 4...:6
4 -12
INTERNAL
YA LYI3
W1DEOI'EN
P intemlediate
P outlet
MONITOR REGULATOR WORKING REGULATOR
FIG. 4-7
4 - 13
4.6 TWO STAGE WITH MONITOR OVERRIDE
The two stage monitor override system is similar to the normal

working\monitor system (4-8). If the second stage downstream
regulator fails the monitor will protect the downstream piping
from over pressurization. In a simple monitor system normally
both regulators are controlling the outlet pressure of the
system. with a two stage monitor system, the upstream regulator
has a pilot that normally controls the intermediate pressure
between the regulators. The downstream regulator's pilot
controls the outlet pressure. The upstream regulator also has a
pilot that monitors the system outlet pressure. This system can
be useful if it is desirable to take two pressure cuts. The
advantages are:
1. It is easier for regulators to control lower differential

pressures.
2. Less noise is generated if the required pressure drop is

distributed between the two regulators instead of at one
regulator.
If the upstream regulator fails the downstream regulator will

continue to control the outlet pressure even though its inlet
pressure increases. If the downstream regulator fails the
upstream regulator monitor pilot will sense that the outlet
pressure has exceeded its normal outlet pressure and take over
control of the upstream regulator. The monitor pilot controls
the outlet pressure to the monitor set pressure which is slightly
higher than the normal outlet pressure. It is important to watch
the intermediate pressure of this type of system. If the
intermediate pressure rises this is an indication that the
upstream regulator has failed, the outlet pressure may not be
significantly affected by an upstream failure.
4 - 14
INTERNAL
VALVE
REGULATING
P intennediate P outlet
FIG. 4-8
4 - 15
4.7 START UP INSTRUCTIONS
Once the regulator(s) is installed in the pipeline the following

procedures should be followed to start the system. It is nearly
impossible to damage the Flexflo or pilot however the outlet
pressure can easily exceed the downstream pressure rating if the
pilot is incorrectly adjusted. It is important to have a basic
understanding of the Flexflo/pilot operation before starting the
system up.
4.7.1 Pressure Reducing System (Any Flexflo with 829S pilot)

See Figs. 4-1 and 4-2
After the reducing regulator has been installed in the pipeline,

open the downstream block valve, set the variable orifice of the
pilot to "8" and unscrew the adjusting screw of the pilot so that
there is no internal spring compression. Slowly open the
upstream isolation valve and allow inlet fluid pressure to the
regulator. The fluid should shut off at the regulator. Turn in
the adjusting screw and watch a gage reading the outlet pressure.
Slowly bring the outlet pressure up to the desired outlet
pressure. Once the regulator is properly controlling the correct
outlet pressure adjust the variable orifice to a lower setting,
this will reduce the droop of the regulator and reduce the outlet
pressure fluctuations. It is cornmon for the outlet pressure to
become unstable as the variable orifice setting is reduced, if
this happens leave the rotor just above the unstable setting.
After all of the pilot settings have been made tighten down the
lock nut of the adjusting screw.
4.7.2 Back Pressure System (Any Flexflo with 829S pilot)

with the back pressure regulator installed in the pipeline, open

the downstream block valve, set the variable orifice of the 829s
to "0" and turn in the adjusting screw so that the unit does not
open as soon as inlet pressure exposed to the regulator. Do not
screw the adjustment screw all the way in, this will make the
internal spring go solid and damage the valve seat. Slowly
increase the inlet pressure to the desired set pressure of the
regulator. Once the correct set pressure is applied to the
inlet, turn the adjusting screw out of the pilot until the
internal valve opens. The sound of the fluid passing through the
pilot should be audible when the valve opens. After all of the
pilot settings have been made tighten down the lock nut of the
adjusting screw.
If it is impossible to bring the inlet pressure to the set

pressure, disconnect the sense tubing from the inlet port. Apply
the available inlet pressure to the regulator. Apply the desired
set pressure directly to the sense port. Once the correct set
pressure is applied to the inlet, turn the adjusting screw out of
the pilot until the internal valve opens. Tighten down the lock
4 - 16
nut once all the pilot settings have been made and reconnect the
sense tubing to the inlet port.
4.7.3 Single Stage Pressure Reducing Monitor System

with the reducing regulators installed in the pipeline, open the

downstream block valve, set the variable orifices of the pilots
to "4" and unscrew the adjusting screws of the pilots so that
there is no internal spring compression. It is convenient to
have a gage between the two regulators. Apply full inlet
pressure to the regulators. There should not be any flow through
the regulators at this point. Turn in the adjusting screw of the
upstream regulator until the screw is almost all the way into the
spring barrel, the intermediate pressure should rise close to the
inlet pressure. Turn in the adjusting screw of the downstream
regulator until the outlet pressure reaches the desired monitor
setting, usually about 5 to 10 psi higher than the normal
regulating pressure. Turn out the upstream pilot adjustment
screw until the outlet pressure drops to the desired outlet
pressure. Turn down the variable orifice settings as low as
possible with steady flow and screw down the adjustment screw
lock nuts. This set up is for the working regulator being
upstream and the monitor downstream.
For monitor upstream and working regulator downstream, turn in

the adjusting screw of the downstream regulator until the screw
is almost all the way into the spring barrel. There should not
be any intermediate pressure yet. Turn in the adjusting screw of
the upstream regulator until the outlet pressure reaches the
desired monitor setting. Turn in the adjusting screw of the
downstream regulator until the outlet pressure reaches the
desired outlet set pressure.
4.7.4 Two Stage with Monitor Override

See Fig. 4-8
This procedure is the only way to properly adjust this type of

system. There are three pilots used with this system. Refer to
Fig. 4-6 for a system drawing.
Location Identification
left side of drawing upstream pilot

center of drawing monitor pilot
right side of drawing downstream pilot
with the reducing regulators installed in the pipeline, open the

downstream block valve, set the variable orifices of the pilots
to "4" and unscrew the adjusting screws of the pilots so that
there is no internal spring compression. A gage between the two
regulators is required. Apply full inlet pressure to the
regulators. There should not be any flow through the regulators
at this point. Turn in the adjusting screw of the monitor
4 - 17
override pilot until the screw in almost all the way into the
spring barrel. Turn the upstream regulator adjusting screw in
until the desired intermediate pressure is reached, tighten the
lock nut on this regulator. Turn the downstream regulator
adjusting screw in until the outlet pressure is slightly higher
than the desired monitor pressure. Turn out the monitor pilot
adjustment screw until the outlet pressure begins to drop. At
this point the upstream regulator is controlling outlet pressure.
stop adjusting the monitor pilot when the desired monitor set
pressure is reached. Tighten the adjusting screw lock nut on the
monitor pilot. Turn out the adjusting screw of the downstream
regulator until the desired outlet pressure is reached, then
tighten its adjusting screw lock nut.
4.8 INSPECTION OF FLEXFLO SYSTEMS
It is cornmon to periodically conduct a functional check of the

Flexflo system. The inspection usually consists of a functional
bubble tight shutoff test and a visual inspection of the tube
which requires that the Flexflo be disassembled.
The shutoff or "lock up" test requires that the inlet and jacket
pressures be equalized. This is normally done through the pilot.
For pressure reducing systems a valve downstream of the regulator
is closed and the pressure between the Flexflo and the valve is
monitored. The sense line of the pilot must be between the
regulator outlet and the valve for this test. The downstream
pressure must rise to the set pressure of the pilot and stop flow
if the unit is working properly. If the outlet pressure
continues to rise above the set pressure the system is not
shutting off properly. The failure is either in the pilot (the
internal valve does not shut off) or the tube (rupture on
downstream side of tube or tube will not close tightly around the
core).
By placing a gage in the jacket port it is easier to diagnose the

problem. If the inlet and jacket pressures are equal and there
is no shut off the tube will not close tightly around the core.
If the jacket pressure is slightly lower than the inlet pressure,
5 to 10 psi, even though the outlet pressure is above the set
pressure, the internal valve seat of the pilot is probably
damaged and can not shut off completely. If the jacket pressure
is significantly lower than the inlet pressure, 20+ psi, the
flexflo tube is probably punctured on the downstream side. If
the regulator completely shuts off regardless of downstream
pressure, the tube has been punctured on the upstream side.
If the Flexflo is in back pressure service, check the lock up of

the regulator by adjusting the pilot set pressure higher than the
normal inlet pressure. The fluid flow must stop as the pilot set
pressure exceeds the inlet pressure. Adjust the set pressure
lower than inlet pressure to check the correct operation of the
unit.
4 - 18
The surge relief 887 or Flexflo-888 units can be inspected by
placing a gage on the jacket port of the unit. If the jacket
pressure has dropped below the original set pressure and the unit
is fully open there is a good possibility that the tube has
failed due to a puncture on the outlet side. If the jacket
pressure is equal to the inlet pressure regardless of
fluctuations there is a possibility that the tube has punctured
on the inlet side, causing a closed failure.
4.9 FAILURE MODES
There are a number of common failures that can occur to Flexflo

systems. Below is a listing of the various failure modes:
I. FLEXFLOS
A. TUBES
1. EROSION RUPTURE (ABRASIVE MEDIA)
Abrasive particles in a gas stream can erode the
flexflo tube causing heavy wear. The erosion
normally occurs over the outlet section of the
tube.
2. FLUID INCOMPATIBILITY
Fluids that are incompatible with flexflo tube
materials are absorbed by the rubber causing
swelling and weakening the tube. The weakened
tube material may not be able to withstand the
rated operating pressures.
3. EXCEEDED RATED PRESSURE

If the flexflo is used beyond its normal pressure
rating the tube can burst or be extruded through
the core slots.
4. EXCEEDED TUBE LIFE

Regulators that have been in service for over 15
years can have strength problems due to excessive
use. Tubes should be replaced after a maximum of
5 years of service.
5. LIQUID CAVITATION
Cavitation can damage the flexflo tube, this is a
result of a high pressure drop in liquid service.
We have seen closed failures that we believe are
due to cavitation (very rare). The tube is
punctured over the upstream section of the Flexflo
and the jacket and inlet pressures are equalized.
6. LOCK UP FAILURE
The flexflo tube has been in the expanded position
for a great deal of time and cannot close tightly
against the core. This is generally a problem
4 - 19
with Model 83's with non-ribbed tubes. A ribbed
tube normally solves the problem.
7. MOLDING DEFECT
If the tubes are improperly molded the rubber does
not "knit" well. The rubber separates from itself
in these sections. The result is usually a
rupture during normal service.
8. BLISTERS
When the tube is used in high temperature and
pressure service, gas can be absorbed into the
material. When depressurized for inspection the
gas expansion forces that are generated when the
tube is brought down to ambient pressure can
exceed the rubber bonding strength and blisters
will appear. In operating service pressure the
blisters are compressed and the unit is
functional. This type of failure is common to
systems that have been used in excessive
temperatures, beyond the rubber rating.
9. VIBRATIONAL FAILURE
When the regulator is severely oversized for an
application the tube tends to open and close
rapidly close to the barrier section. The
vibration causes enough heat to damage the rubber
by exceeding the rated material temperature. The
result is that the tube appears to be eroded and
the damaged material has a hard, burn texture.
10. FREEZING
When the regulator is used below its rated
temperature range the rubber can become very stiff
and fail to shut off quickly. Ice can also form
on the barrier of the core. When the tube
contracts around the core the ice prevents the
proper shutoff.
B. CORES
1. VIBRATIONAL CRACK
If the regulator is vibrating due to turbulent
service (poor piping arrangement) it is possible
in some cases for the inlet ribs to crack and the
core completely separates from its end flange.
2. OUTLET SLOT EROSION (ABRASIVE MEDIA)

If abrasive media is in the gas flow stream the
core can be eroded as high velocity particles
impact with the core.
3. VIBRATIONAL OUTLET SLOT DAMAGE

If the flexflo is severely undersized the tube
opens and closes very rapidly. As the tube
4 - 20
vibrates against the core and eventually both
pieces heat and are damaged. The failure
resembles erosion and the outlet slots will have a
cut that runs in line with the fluid flow stream.
C. BODIES
1. POROSITY LEAKAGE
Casting problems can result in leakage through
some of the sand cast regulator bodies.
D. PILOTS
1. DIAPHRAGM RUPTURE
If the sense or outlet ports are over pressurized
the 829s pilot diaphragms can burst. If the
serrations on the diaphragms sealing surfaces have
sharp burrs the diaphragms can be torn in normal
service.
2. POPPET FAILURE
If the spring of a back pressure 829S is over
tightened the poppet can be driven into the valve
seat, damaging the pilot. If the sense pressure
port of a pressure reducing 829S is over
pressurized the poppet can be excessively
compressed against the internal valve thereby
cutting the poppet. Swelling can result if the
poppet is exposed to an incompatible fluid. The
swelling causes the internal valve to close even
though the unit should be in the full open
position.
3. ORIFICE PLUGGED
If a strainer is not used on the inlet of the
pilot it is possible for a large particle to
become lodged in the variable orifice or the
internal valve. This is more common in crude oil
service.
4. DIAPHRAGM BLISTERING
The diaphragms of the 829s can blister easily if
exposed to temperatures above 165 F. This heat
damages the rubber bond and allows gas to permeate
the rubber. Blisters can form when the diaphragms
are removed from the pressurized service. The
load bearing component of the diaphragms is the
nylon fabric insert. The strength of the fabric
is not affected by blisters in the rubber.
5. FREEZING
If liquids freeze within the regulator, usually
sealing off the internal orifice, the result can
be a closed failure of the pilot. The larger
internal orifice is less prone to this freezing
failure.
4 - 21
4.10 BACK PRESSURE REGULATOR RELIEF CAPACITY CHARTS
Pressure reducing and monitor system capacity charts are

available for all Grove Flexflo regulators in reducing pressure.
The back pressure relief capacities have not been published.
Table 4-1 lists the capacities of the Flexflo in relief service
for natural gas. The capacity varies with the size of the
Flexflo, type of Flexflo, set pressure, type of backpressure
pilot used, and tube material used. The "Buildup Over Set
Pressure" is the amount of over pressure required to get the
pilot to fully open with the variable orifice set at o.
For example a 4" model 82 with a set pressure 60 psi and a 20-75
psi control range back pressure 829s is used as a relief valve in
a pipeline. The pipeline pressure will have to build up 6.5 psi
above set pressure (66.5 psi) in order to get full capacity,
614,000 SCFH, from the relief valve. If the pipeline pressure
does not reach 66.5 psi the capacity of the relief valve will be
less than 614,000 SCFH.
4 - 22
FLEXFLO WITH 829S BACK PRESSURE REGULATOR CAPACITY CHARTS
MODEL 80
SPRING DATA BUILDUP REGULATOR
COLOR CONTROL SET OVER SET PRESSURE CAPACITY IN lCOO SCFH
CODE RANGE PRESSURE PRESSURE RATING I" 11/2" 'Z' 3" 4" 6"
GREY 3-10 3 3_0 VLDTUBE 0- 3.4 15 70 133 335
6 Pmax< 60 0- 14 40 86 162 391
10 0- 29 49 100 1!Xl 457
WHITE 8-25 15 3.5 0- 35 58 120 m 543
20 1.4 - 40 67 138 262 631
25 3.5- 46 76 156 296 713
BROWN 20-75 30 4.5 LDTUBE 13 52 86 178 337 813
45 Pmax< 275 25 68 113 233 «1 1060
60 31 84 139 2ff7 5« 1310
75 36 100 166 342 648 1560
NICKEL 60 -ISO 75 6.5 37 102 170 349 662 1m
100 47 129 214 441 835 2010
125 57 156 259 533 1010 2430
ISO 67 183 303 625 1180 28SO
YELLOW 125-350 ISO 12 srDTUBE 71-- 220 386 652 1320 2940
200 Pmax< 720 92'"- 283 497 839 1700 3790
250 11~- 346 609 1020 2080 4640
300 133-- 409 721 1220 2460 5490
3SO 153-- 473 833 1410 2840 63SO
ORANGE 300-600 400 34 183-- 566 996 1680 3400 7m
BLACK 4SO , 204-- 630 1110 1880 3790 8460
500
- 225-- 694 1220 2070 4180 9330
5SO 2W- 1':f.} 1340 2260 4570 10200
j 600 267*- 824 14SO 2460 4970 11100
- I" MODEL 80 IS Nor AVAILABLE IN VLDTUBE, FLOW CAPACITIES ARE FOR LDTUBE
-- I" MODEL 80 IS Nor AVAILABLE IN srDTUBE, FLOW CAPACITIES ARE FOR HPTUBE
TABLE 4-1
4 - 23
MODEL 82
SPRING DATA BUILDUP
COLOR CONTROL SET OVER SET REGUlATOR CAPACITY IN 1(0) SCFH
CODE RANGE PRESSURE PRESSURE RATING 11/2" 2" 3" 4" 6"
GREY 3-10 3 3.0 LDTUBB 6 13 16 24 39
6 P _ < 275 11 18 32 51 63
10 18 27 51 83 137
WHITE 8-25 15 3.5 43 66 110 164 271
20 50 77 129 192 317
25 61 96 174 278 458
BROWN 20·75 30 4.5 76 121 223 375 618
45 99 158 290 498 821
60 122 195 357 614 1012
75 1.045 230 423 77Jj 1197
NICKEL 60 -150 75 6.5 14S 23S 432 742 1223
100 187 'l!J7 545 936 1543
125 226 359 658 1129 1863
150 265 421 m 1322 2183
YBLLOW 125 -350 150 12 srDTUBE 2.048 393 1Z2. 1240 20«
200 Pmax< 720 324 515 945 1623 2675
250 431 683 1257 2156 3548
300 510 809 1487 2546 4198
350 589 935 1717 2946 4858
BLACK 300-600 400 34 6n 1082 1981 3548 5603
ORANGE 450 761 1213 2215 3967 6266
500 , 846 1342 2451 4389 6931
550 920 1472 '26(f1 4813 7600
600 1007 1598 2925 5239 8273
MODEL 83 --- .--

-SPiuNO---DATA-- --c--
BUILDUP
COLOR CONTROL SBT OVERSBT REGULATOR CAPACITY IN 1(0) SCFH
CODE RANGE PRESSURB PRESSURE RATING I" 11/2" 2" 3" 4" 6"
GREY 3-10 3 3 VLDTUBE 1.8 25 40 60 105 137
6 Pmaz< 60 6.2 42 66 107 192 232
10 11 51 79 145 229 370
WHITE 8-25 15 3.5 13 62 94 174 269 432
20 15 72 110 :nJ 313 508
25 17 81 124 227 357 577
BROWN 20-75 30 4.5 LDTUBE 19 92 142 230 407 569
45 Pmax< 275 25 121 185 337 531 858
60 31 149 228 417 656 1060
75 38 177 Tl2 496 780 1260
NICKEL 60 ·150 75 6.5 37 181 277 507 797 1290
100 47 228 350 639 1010 1630
125 57 Il5 423 772 1210 1960
150 67 323 495 905 1420 2300
YELLOW 125·350 150 12 srDTUBE 69 333 512 935 1471j 2380
200 Pmax< 720 89 429 658 1200 1890 3060
250 .- 109 524 805 1470 2310 3740
____ 3()) __ ~ 129 620 953 1740 2740 4430
--51ii'~
350 149 716 1100 2020 3170
ORANGE 300·600 400 '-34- 178 850 1320 2410 3790 6130--
BLACK 450 199 953 1470 2680 4220 6820
500 219 1050 1620 2960 1650 7520
550 , 240 1150 1770 3240 5080 8230__
I I 600 200 1250 1920 3510 SS20 8930 I
TABLE 4-1
4 - 24
SECTION 5 SIZING
5.1 COMPUTER SIZING PROGRAMS
5.2 FLEXSIZE HAND CALCULATIONS

5.3 VISCOSITY CORRECTION FACTORS
5.4 RULES OF THUMB
5.6 TEMPERATURE
5.7 REDUCING PILOT SIZING
5.8 BACKPRESSURE PILOT SIZING
5.9 COMMON CONVERSION FACTORS

5.10 HIGH PRESSURE REGULATORS
5
SECTION 5 SIZING
To obtain the correct pressure control, it is critical to select

a regulator that is the right size for the application. The flow
capacities of regulators are compared to each other by their
maximum Cv's. For a given application, the maximum required Cv
can be solved knowing the following flow conditions: minimum
inlet pressure, maximum outlet pressure, maximum flow rate, and
maximum fluid temperature. A properly sized regulator will
always have a maximum rated Cv that is higher than the maximum
required Cv of the application.
There are several ways to solve the required Cv of an

application: Computer program, mathematical calculation and the
Grove sizing slide rule. These sizing methods cover the flow
capacity of a regulator but a number of other factors need to be
considered when selecting a regulator including: operating
temperature, fluid compatibility, fluid viscosity, required
controlled pressure accuracy.
5.1 COMPUTER SIZING PROGRAMS
The computer sizing programs Flexsize, for Flexflo regulators or

Powersize for specialty regulators run on IBM compatible personal
computers. By inputing the required flow conditions a suitable
regulator will be selected by the program. The flow capacity of
a specific regulator can be solved with the program also. The
sizing programs are adequate for sizing almost all applications.
5.1.1 RUNNING THE SIZING PROGRAM FROM THE DISK
1. Insert the diskette into the disk drive.
2. Set the prompt to the floppy drive being used. A:

(enter) or B: (enter)
3. To run Flexsize type: GWBASIC FLEXSIZE (enter)
4. To run Powrsize type: POWRSIZE (enter)
5. The program will give further instructions once it is

running.
5.1. 2 INSTALLING THE SIZING PROGRAMS ONTO A HARD DRIVE
1. Insert the diskette into the disk drive.
2. Set the prompt to the drive being used. A: (enter) or

B: (enter)
3. To run the installation program type: GINSTALL (enter)
4. The program will notify you upon successful

installation
5 - 1
5.1.3 RUNNING THE PROGRAMS FROM A HARD DRIVE
1. Set the prompt the hard drive. C:\ (enter)
2. Set the default directory. CHDIR C:\GROVE (enter)
3. To run Flexsize. GWBASIC FLEXSIZE (enter)
4. To run Powrsize. POWRSIZE (enter)
5.1.4 FLEXSIZE REGULATOR SIZING EXAMPLE
The Flexsize program is used to find an appropriate regulator for

any liquid or gas application. Please note that the program can
be used for back presurejrelief or reducing sizings. For relief
service the inlet pressure should be entered as the set pressure
of the unit and the outlet pressure is normally 0 psi.
In the example a Model 80 is sized for a natural gas application

that has an inlet pressure of 500 to 650 psi, an outlet pressure
of 120 psi and a flowrate of 1,200,000 SCFH.
5 - 2
GROVE FLEXFLO MODEL MENU
1 80 .
2 83
3 900TE
4 EXIT
TYPE NUMBER AND PRESS ENTER KEY? 1
I SERVICE MEDIA OPTIONS MENU
1 GAS
2 GAS MONITOR
3 LIQUID
» YOU HAVE SELECTED A HODEL 80 STANDARD TUBE GAS APPLICATION «
CONTINUE (YIN) ? Y
5 - 3
I GAS SELECTION MENU I
SELECT FROM THESE OPTIONS:
1 AIR
2 NATURAL GAS (.6 SP.GR)
3 OTHER GAS
1 PROBLEM TYPE SELECTION MENU I
1 FIND FLOW CAPACITY 9F A MODEL 80 FLEXFLO REGULATOR

2 SIZE A MO~EL 80 FLEXFLO REGULATOR
I FLEXFLO PRESSURE CLASS MENU I
1 CL 150 60 PSIG MAX CWP

4 CL 600 1440 PSIG MAX CWP (1200 MAX dP)
5 - 4
-------------------------
I FLOW CONDITIONS INPUT I
ENTER VALUE AFTER EACH ? SIGN
MINIMUM UPSTREAM PRESSURE(PSIG)? 500

MAXIMUM DOWNSTREAM PRESSURE(PSIG}? 120
MAXIMUM REQUIRED FLOW RATE (UNITS OF 1000 SCFH)? 1200
*******************************************************************************
QTY 1: 3-INCH 720 PSIG CWP MOD 80 FLEXFLO REGULATOR IS
REQUIRED TO FLOW 1200 X1000 SCFH OF
.6 SP.GR. NATURAL GAS AT 60 DEG F AND 500 PSIG UPSTREAM AND
120 PSIG DOWNSTREAM PRESSURES
CALCULATED FLOW CAPACITY OF THIS VALVE
WITH THIS GAS AT THESE PRESSURES AND TEMPERATURE IS 1940 X1000 SCFH
*******************************************************************************
*******************************************************************************
.6 SP.GR. NATURAL GAS FAILED-OPEN CAPACITY OF QTY 1 : 3-INCH 720 PSIG CWP
MOD 80 FLEXFLO REGULATOR IS
1940 X1000 SCFH AT 60 DEG ~
~~ 500 PSIG UPSTREAM AND 120 PSIG DOWNSTREAM PRESSURES
~****************************************************************************
Press SHIFT-PRTSC for Printout
DO YOU WISH TO DO ANOTHER GROVE MODEL 80 REGULATOR PROBLEM (YIN)?
5 - 5
5.1.5 POWRSIZE SIZING EXAMPLE
The Powrsize program is used to find an appropriate regulator for

a nitrogen gas application that has an inlet pressure of 4,500 to
5,500 psi, an outlet pressure of 3,000 psi and a flowrate of
2,500 SCFM
5 - 6
GROVE VALVE & REGULATOR Co.
6529 HOLLIS ST.
OAKLAND. CA. 94608
********************
POWREACTOR SIZING PROGRAM
1. SIZE AN APPLICATION
2. CALCULATE VALVE PERFORMANCE
3. END THIS SESSION
ENTER SELECTION: 1
*APPLICATION?
1. Commercial <default>
2. NAVY
ENTER SELECTION; 1
*ENTER CUSTOMER NAME/JOB DESC <49 char. max>

> <
POWRSIZE SIZING EXAMPLE
*SERVICE?
1. Reducing
2. Back Pressure
ENTER SELECTION: 1
*PRESSURE?
MINIMUM INLET psig
[Enter? for other units]: 4500
MAXIMUM OUTLET psig: 3000

*SPECIFIC GRAVITY
1. Acetylene .9000
2. Air [default] 1.0000
3. Butane 2.0000
4. Ethane 1.0300
5. Helium .1380
6. Hydrogen .0690
7. Hethane .5500
8. Natural Gas .6000
9. Nitrogen .9700
10. Oxygen 1.1000
II. Propane 1.5200
12. Other - INPUT Value .0000
ENTER SELECTION: 9
*FLOW UNITS
ENTER MAX FLOW RATE scfm

[Enter? for other units]: 2500
5 - 7
******************************************************************
• ••• APPLICATION SIZING CRITERIA ••• •
• •
• CUSTOMER POWRSIZE SIZING EXAMPLE •
• SERVICE Reducing INLET PRESSURE 4500.00 •
* FLOW MEDIA Nitrogen OUTLET PRESSURE 3000.00 •
• SP GRAVITY .97 APPLICATION Cv .9519 •
• FLOW REQD 2500.00 SCFM RECOMMENDED Cv 1.2374 •
******************************************************************
» For hardcopy hit Shift-PrtSc «
Hit return for more
******************************************************************
• •• VALVES MEETING CRITERIA •• •
• •
• MODEL DESCRIPTION FIGURE ORIFICE Cv •
... •
• 1. 202B POWREACTOR 11127 .250 1. 40 •
• 2. 202B POWREACTOR 11127 .375 2.30 •
• 3. 301B POWREACTOR 11167 .375 2.40 •
• 4. 212B PQWREACTOR 11128 .500 4.00 •
... 5. 301B POWREACTOR 11167 .500 5.00 •
• 6. 301B POWREACTOR 11167 .750 10.70 •
• 7. 311B POWREACTOR 11170 1.000 12.40 •
• 8. 311B POWREACTOR 11245 1.500 26.00 NOTE •
• •
• NOTE: THIS VALVE WILL BE OPERATING AT LESS THAN 5% RATED CAP •
**********************~~.*******~********************* ************
» For hardcopy hit Shift-Pr~Sc «
Calculate Valve Performance? YIN: Y
Enter Menu No: 1
******************************************************************
• POWREACTOR •
• •
• MODEL FIGURE INLET OUTLET ORIFICE CV •
• 202B 11127 6000. 6000. .250 1. 40 •
******************************************************************
• » FLOW CONDITIONS « •
• •
• MEDIA: Nitrogen INLET PRESSURE 4500.00 •
• SP' GR: .97 OUTLET PRESSURE: 3000.00 •
******************************************************************
• » VALVE PERFORMANCE « •
******************************************************************
• FLOW RATE: 3676.96 SCFM VALVE CAP: 67.991 % •
* *
******************************************************************
» For Hardcopy Hit Shift PrtSc «
Select Another? YIN: Y

5 - 8
5.2 FLEX FLO HAND CALCULATIONS
The following examples show the step by step processes when Model
80, 81, 82, 83 and 900TE Flexflo regulators are selected.
The Model 80 sizing method is used for Model 81's. For gas
applications use the NK body and core combination. For liquids
use the WH body and core combination. The liquid and gas
configurations have different C and FL values in the sizing
tables.
5.3 VISCOSITY CORRECTION FACTORS
The flow capacity of Flexflos can be affected by fluid viscosity.

If the fluid viscosity is lower than 100 SSU the capacity
reduction is negligible. If the fluid viscosity is greater than
100 SSU refer to the viscosity correction nomograph (Fig. 5-1).
5 - 9
. v 5115/75~ APpr.J~
?'tev. 7-1-75c?G:j Appr. ~
, Rev .11- 25 -75<il:. lAppr.
SK-4-149 '.
!;Rev. 9-16-7~ ;Appr.f-9 Sheet 1 of 6

Rev. 2-18-7lfTC- Appr·t~
GROVE MODEL 80 FLEXFLO
Flow Rate Prediction Method

For Pilot Operated Reducing or Back Pressure Regulators
PART I
GAS FLOW
The ~odel 80 Flexilo General Gas Flow RB;te Equations are:-
A. Subcritical Flow (When AP/Pl <Fk x.: II<
Q =59.6 C YI PI jpl'G~ (SCFH) (1)
(SCFH) (2)
I'
where
0 ' -' - - when - - - 6P~. 8E

C, = C {6P-. 8E\ ~ - - - - - . 8E<6P<2E
{ P\'
1. 2E I
Cp - - - - - - - 6P~2E
1 " ------ AP/P(, .02
YI = I -.333 6P- ) - - - - - - .02< AP/Pl< X t Fk
{ X t PI ~
.667 - - - - - - - - - - AP/PI ~Xt Fk
Definitions
Q : Max. Gas Flow Rat e at 60 0 F (SCFH) en (/

~
(l) /'
Qc = Critical Gaa Flow Rate at 60 0 F (SCFH)
....
(l)
I
..... ..t:o
PI • Inlet Pressure (PSIA) 0 I
.....
P2 • Outlet Pressure (PSIA) 0')
~
<..{
6P -- PI - P 2 Pressure Differential (PSID)
C = Partially open Capacity Factor
(continued)
I
5 - 10
, ./ 5/15/75
'Rev 7/1/75
SK-4-1~9
'Rev. 2-18-76 Sheet 2 of 6
Definitions (continued)
Cpo., = Valve Wide Open Capacity Coefficient (See Table 1)
CI = Critical Flow Factor (See Table 1)
Pk = Specific Heat RatIo Factor (See Table 2)
G = Gas Specific Gravity (Air = 1. 0) (See Table 2)
E = Tube Expansion Factor (See Table 1)
Tl = Inlet Gas Temperature (oR)
Xt = Critical Pressure Drop Ratio (See Table I)
Y1 = Expansio!1 Coefficient
Z = Compressibility Factor for Natural Gas
For other gases refer to literature
(See Fig. 1)
pI • P2 or PI (I-Xt) whichever is higher •
Q is maximum gas flow rate and occurs when the pressure in the
Flexflo jacket and the pressure in the downstream line are equal.
Tempera ture Adjustment

For gas flow inlet temperatures other than standard conditions (60° F),
multiply the flow rate at standard conditions by, J 520/T C~ R).
Q (FO) = Q (60° F,), x . j 5iO
Where en
:T C.0
-
en
ro
t-.)
0
.....
7'
~
I
0')
~
cD
-Ref. !SA 539.3
5 - 11
2-18-76 SK-4-149
Sheet 3 of 6
TABLE 1
--------~
GROVE FLEX FLO CONSTANts FOR GAS REGULATORS
WORKIl'O
PRESSURE SIZE C
(psIG) (Inch) (NBody) Cl E ~
60 1-1/2 30 28.19 6.0 .503

2 61. 3 22.83 4.6 .330
3 124 23:25. 3. 1 .342
4 230 23.75 3.1 .357
6 528 24.92 2.9 .393
8 910 24.67 2.2 .385
10 1145 25.14 2.3 .400
12 1610 25.14 2.3 .400
200 " 275 1. 9.6 32.05 21.4 .650

1-1/2- 30 28.19 12.0 .503
2 61. 3 22.83 9.1 .330
3 124 23.25 6.1 .342
4 230 23.75 6.1 .357
6 528 24.92 5.7 .393
8 910 24.67 4.4 .385
10 1145 25.14 4.6 .400
12 1610 25.14 4.6 .400
,
400 & 720 1-1/2 33.3 29.59 ·27.8 .554
2 64.7
- 26.73 21. 5 .452
3 130 22.38 14.7 .317
4 245 24.02 14.7 .365
6 528 ! 24.92 13.7 .393
8 910 24.67 10.6 .385,
10 1145 25.14 11. 2 .400
12 1610 25.14 11. 2 .400
1440 & 1 10 32.05 58.2 .650
1-1/2 20 32.05 41.8 .650
1200 Maximum 2 .25 32.05 32.7 .650
Differential 3 87 27.88 22.8 .492
4 168 20.81 25.4 .274
6 327 24.34 22.8 .375 I
8 750 24.08 10.6 .395 - I
10 925 24.98 11. 2 .395 I ~ {fI
12 1340 25.14 11. 2 .400 I~ A
I I
t"'T
1440 &. 1-1/2 15.5 32.05 41. 8 .650 I .t::..

(,.0.>
2 20.7 32.05 32.7 .650 I g, ,

1200 Maximum 3 50.4 26.07 22.8 .430
Differential I -
-
4 95 23.85 25.4 .360 I 0> ~
6 207 23.85 22.8 .360 1<..0
8 642 24.'82 10.6 .390 I
10 742 24.98 11. 2 .395 I
12 1072 25.14 11. 2 .400 I
I
\ 5 - 12
. Rey 7/1/75
I •
s:<Sheet
- 44- of149
6
I Rev. 2-18-76
GAS G
Acetylene .90 0.90
Air 1.00 1.00
Butane .79 2.00.
Ethane .B4 1.03
Helium 1.19 Cl14

i
Hydrogen 1. 01 0.07
Methane .94 0.55

,
Natural Gas .94 0.60
Nitrogen 1.00 0.97
Oxygen 1.00 1.10

..
Propane .Bl 1.52
GAS PROPER TY COEFFICIENTS
TABLE 2
........
(j)
til
~
ct>
~
ct>
.-? •
.t:'-
.t-
o
......
en J':-,.
t.D
FIG. 1
5 - 13
v OJ/I:J!"I:J
SK-4-149
.f:V. 7-1-75-
-';'I. 2-18-76 Sheet 5 of 6
GROVE MODEL 80 FLEXFLO

For Pilot Operated Reducing or Back Pressure Regulators
PART II
LIQUID FLOW
The Model 80 Flexilo General Liquid Flow Rate Equation is:-
Q = c· . JAP/G • (GPM)
where o -- -'----
c = <;. (AP -. BE.' - -when - - • BE<AP<2E
1.2E )
Cv - - AP~2E
Definitions
Q • Max. Liquid Flow Rate (GPM)
PI • Inlet Pressure (PSIA)
P2 :: Outlet Pressure (PSIA)
6P • PI -P Pressure Differential (PSID)

2
Cv :: Capacity Factor - . for Flexflo (See Table 3)
, -. .'. C
,,'
= Partially Open Capacity -Factor (Dimensionles s)
G • Liquid Specific Gravity (Water :I: 1. 0)
E Cl "Tube Expansion Factor (See Tab~e 3)
til
NOTES; :::r- (f)
CD
CD
r+- 7\:
1. *Ref. ISA - S39. 1 (}l I
0 .~
..... I
2. Q is maximum liquid flow rate and occurs when the pressure in the en
Flexflo jacket and the pressure in the downstream line are equal.
..t::::..
3. Forv1BcoBity correction of Q, refer to SK-4-130A. U)
5 - 14
'" J 5/15/75
SI<-4- \49
Sheet 6 of 6
l',evl1- 25 - 75
~,ev.Y9-16-75
Rey. 2-3-16 TABLE 3
GROVE FLEXFLO CONSTANTS

FOR LIQUID RECiTTl.A TORS
WORKING PRESSURE SIZE C, E

(PSIG) (Inch) \N HodYJJ(W1foay)
60 1-1/2 30 31 6. 0
2 61.3 64 4.6
3 124 130 3.1
4 230 283 3. 1
6 528 564 2. 9
8 910 1000 2.2
10 1115 1385 2.3
~________~--------+---'~1~2---+_1_6_10--~2_0~2~0--~~~2.3
1 9.5 9.5 21.4
200 & 275 1-1/2 30 31 12. 0
2 61.3 64 - 9.1
3 124 130 6. 1
4 230 283 6. 1
6 528' 564 5. 7
8 910 1000 4.4
10 1145 13GS 4.6
12 ,1610 2020 4.6
400 & 720 1-1/2 33.3 33.3 27.8

2 64. 7 64. 7 21. 5
3 130 130 14.7
4 245 283 14.7
6 528: 564 13. 7
8 910 1000 , 10.6
10 1145 1385 11.2
~ __________________ ________
~
12 1610 2020
~----4-------~---
11. 2 ---
1 210 10 58.2
1440 & 1-1/2 0 26 41.8
1200 Maximum 2 25 41.5 32.7
Differential 3 87 90
4 168 190 25.4
6 327 414 22.8 'en
,::;- C: '
8 750 860 10. 6 ~
II......
.~ /t.
,\
10 925 1065 11. 2
12 1340 1540 11.2 ,C!'l
10
J:.
:..... L
1440 & 1-1/2 15.5 15. 5 41. 8 jC!'l
1440 Maximum 2 20.7 26.3 32.7 I

I
Differential 3 50.4 63.8 22.8

4 95 121 25.4
6 207 262 22.8
8 642 742 'fbi 10. 6
10 742 990 ficb 11. 2
12 1072 1437 1v'f 11. 2
5 - 15
HODEL 80 EXAMPLE PROBLEM
PI (inlet pressure) = 500 psia

P2 (outlet pressure) = 120 psia
Flowrate = 1,200,000 scfh
Fluid = natural gas
Specific gravity = 0.6
Find a suitable regulator for this application.
Basic equation for critical flow
Q-C1CP1~ Fk
GZ
Find: Cl C
C1C-...Q.~
Pl
GZ
Fk
Fk = .94 from table 2

Xt = 0.4 assumption
pI = P2 or Pl(I-Xt) the higher of the two

P2<Pl(I-Xt)
pI = 500(1-0.4) = 300
Z = .94 from fig.l
Cl C- 1, 2 000 , 000 I (. 6) ( . 9 4 )
500 ~ .94
Cl C = 1,859
because OP > 2E C=Cp
Find a class 300 regulator that has a Cp Cl>I,859
in the 400 & 700 working pressure section of table 1 the 3"
un~t Cp = 130 and Cl = 22.38, Cp Cl = 2,909
Recheck the results of using the 3" model 80 to solve the

maximum capacity of the regulator.
Solve Q
Q-C1CP1~ Fk
GZ
5 - 16
Q_ (22.38) (130) (500) I ~ 94
~ (.6) (.94)
Q = 1,878,009 scfh (capacity)
Which is greater than the required flow 1,200,000 scfh.
5 - 17
uIJ·"%/lu
Rev ~ 3/1 7/7 fW ;f. Appr. 1,1

SK-4-147
Sheet 1 of 10
Rev. 1-26-77~ it' App;~
Rev. 9-22-78 RSB/~App~
GROVE MODEL 82 FLEXFLO II

For Reducing or Back Pressure Regulators
Working Pressure to 720 psi
(Used in Combination With Grove Pilots)
PART I
GAS FLOW
*The Flexflo II General Gas Flow Rate Equations are:
Subcritical Flow (when6P / PI < . 45 Fk)

Q = 59.6 C Yl PI ~ (SCFH)
JdZ-PT.
Critical Flow (when6P/P l ~ .45 Fk)
Qc = 26.6. C PI fFk
Jaz- (SCFH)**
Where:
Q = Max. Gas Flow Rate at 60 0 F (SCFH)

0
Qc = Critical Gas Flow Rate at 60 F (SCFH)
PI = Inlet Pressure (PSIA)
P2 -- Outlet Pres sure (PSIA)
6P Pressure Differential, PI- P 2 (PSI)

=
Cp = Wide Open Capacity Coefficient (See Fig. 1) (/)
tf.l
:::r
-- Specific Heat Ratio Factor (See Fig. 3) ro A
Fk ro I
<+
I-' ...b..
(continued) 0
....., I
*Ref. ISA S39. 3 (similar equation development). I-'
0 ~
Q is the maximum gas flow rate and occurs when the pressure in the
Flexflo II jacket and the pressure in the downstream line are equal. --..J
**y 1, the expansion coefficient, is accounted for in the Critical Flow

equation.
5 - 18
vll't/ UJ
Rev. 3/17/76 SK-4-1'47 . '
Sheet 2 of 10
Where: (continued)
G = Gas Specific Gravity (See Fig. 3)
Y1 = Expansion Coefficient (See Fig. 5)
Z = Compressibility Factor. For Natural Gas see Fig. 4.

For other gases refer to suitable literature.
Fc = Valve Opening Fact or (See Fig. 2)
C = F c C p = Partially Open Capacity Factor
Gas Flow Rate of .6 Natural Gas at 600 F
Subcritical Flow (When P/Pl <.42)
Q = 76.9 C Yl PI ~
. JZPl-
Critical Flow (When P/P 1 ~. 42)
Qc = 33.3 C PI ji.
Wide Open Capacity Coefficient For Class 125, 150, and 300
Flexflo II
FIG. 1
Size 1-1/2 2 3 4 6 8 10 12
46 73 1 34 230 379 599 889 1293

.- til
p- en
C1l
C1l
<+
A
,
~ ~
0
1-4)
.......
0 ..t::,.
-J
5 - 19
~-~'!I"'/~
Rev.r9-22-75
Rev. 3/17/76
Rev. 1-26-77
Rev. 9/22/78 SK-4-141
Sheet 3 of 10
.' .'*~
1./
H-+H i-W-J-J I I I . i- ' -H+t- L ;r- :_++ ' I '
+t-ri- ± t1 ~~h"J . "! ! : L . ' l ' _;tl-tl - i _L u+ttU_~r-; rt~
T ! ' -
I :. -
I H
H+H- -p--++ r~T4-l +r~. I
~ t
-TJ;
~i ' , t i t
-rrY-
I "
t
-p=,t= l-:-r
'I' J. '
, I LJ. .-
If'
n~1
I
8- -HJl- - -r;:t+ H++-=-H-i±s-H-~ , i i " I i ,_ -1 -ctti
-~- -~- -i.. H-+'
-t1rt -H r-:-ttt
±ttJ
,-.!- i..l-' -~ H+.LL
:- +.J.-1 i -
I--H= - ~ IIJ-
t ' ~"I" ~-l-~ -:-l--i-l ,-1- l-r ..1-l-j"l=1- L +t--r~- -f-+# -,.."ct=t,- P.=t
J_L IT
+1-- 1
" r- [ - I '_I I
+Ti'Tt+..+_
~- ~ r ~ t =1T,.-+-4-lI I I t t . t, I',' I ., I' t I I ' \ _ _ \. J •
19
f
~~ ..
~
;
o
N
IJJ
: ,-!> 1- i ' J
. ·-t J -,-: I-~
iTiT ~-r-!-i
. . . r 1 •
",71_:.
., '
I
I
_ rt
I t
; i-
:!
l-!-'l: !
-I -I ,I
r'>
. ./5/14/75 SK-4-147' M b
Rev .t'9-16-7S Sheet 4 of 10
Rev. 3/1 7 / 76
GAS G
Acetylene '.90. 0.90
Air 1.00 1. 00
Butane .79 2.00
Ethane .84 1. 03
Helium 1. 19 0.14
Hydrogen 1.01 0.07
Methane .94 0.55
Natural Gas .94' 0.60
Nitrogen 1.00 0.97
Oxygen 1.00· 1. 10
Propane . 81 1. 52
GAS PROPER TY COEFFICIENTS

At 60 0 F and 30 In H g •
FIG. 3
Supercompressibility of Average NaturcU

Gas of O. 6 Specific Gravity
At 600 F.
N 1.00: ~·++-~1~'--··J--~-
I ' .. : '.1.. I1-- .. _. ·f...;.4.L
" .'1.·---+-l......,..4.0·
. I: ::1: . ;;: :.. , .:';
-r·-· . .
'::'1 . ";:J;~': ~···!·_·I·_·L_:II'·~MMji:.~1
.. I'" r'" .. ,. ,~·:~.:.·I~:·
,. " .). ~l: '" ..~!.;~L.0
t'I··'· ~ (j)
hf
o 95 "'f".... ........
"t;'
,
f":· : . ': ,I. t I 'It; :.ij ::rj ;;:1 ,:t
' .~~-!-t'::,;;~ ':: /::t, :
t :::, .:
7':
...
Cll
.....,. : _, ,:_, __ ~~.~~ :T;-t;-'-:r ~:- .. _ .. :~.
' .".,"'1'
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t ..
.1 ::::
u I " . , ., . • • , . . . . . . , " •.. 1 . . . . . . ",.1,.1 I

ro
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11'
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.. J.:·: ::.j±:
t ::1',,:, :::~.;., ,::: .:',:::' ':;:,:';:
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. :.~. ~ :... "'.' '~'I"'"

i' .I
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-
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'M 85" "I: I: • '. j: ; '.:
;.:; • . "--r-- +..-rl;-·-r'.:.·-f....... -:~.- --:I-~' I"""I-;";'~- .....:+:.:- -..J
aJ
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; ",
i':
t , ; , • , j ~ ,',' f. ' ,: :
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o. 80' ~T~:·lL:·::!':: 1·:·I·I·;:·,,:.T~·I·'::I~~:~!·::;;':" -;" :;:~ '.J~.~

S . , ,.:, .. :~-:~ ~~ :"';":'I···:"""--i-~-r~· ·-;..;f:- "_ .... ':'-~'j'
8 :. : .. i :::,i;' ··Iii.: "j; . i . ·Ii:;· :":1::: ::,'.. . j'::: I
h I:·· i I ttt/"~j':": :.
, "j "I t .:,,/-.:: . . :f~···'
:1 ·! :.. 1" :r···, :...1:":1..:': J';'.
I'
•75
t t tj ,t ,
'lJ t t l "1'" ,I, ,: It.. "I"
0... ~ ,." ! t t' , j :" ': t, i!' .I , ' .' I,
~ U 200 400 600 800 1000 '1200 . '1400' 1600

P (psig) ,
(Pz OR .58 Ff WHICHE Vt=R, IS GREATER)
FIG. 4
5 - 21
5/14/75 SK.; 4 -147'~B
R.ev • .,9-22-75 Sheet 5 or 10
Rev. 3/17/76
:1 : :,::';;L i;::'ll -!.-~-, ' __ 1 :.:i_;):_:J~,: ._~J ~:; : ;; .. -

\ 1 '\; I'"i i Ii' I
I
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' j...; 'l'j':' I;:' I','
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I' 'I'• ','IIj I:,,; .": I:::··
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"I' 'II' ., II 'I" " ,.,., 'I 'I" I" ,\ot 1,1. .. ,. j'l ,'.
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: :! .: ~' I',.,
, .. .
roo'
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.; ::'1' I,,: ,i" !.:I ,II: J'ii~ '1' : '1 1. 1 '.:: ,';: .,': .... ;:., I, .. il·
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. , : :"
, .....
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'ft-'" rt·+ r'" -, ... _-\ -.
;! '"1 I:':
'I . ..:', !. , ,'I' ,11'1:. I I: II ;; j: ;:':
I " I I • ,.
I' .:; "', :
. . . . . . . ' "1 ' .
-'II .
'';'':''I':'''~ ~....:..,--:..! - ",!"'." ,.. '';.;...:'" '.'~..:...."" ., -:- •• ! •.
:..... ~'0":Ill:
:··;r:,I. ::"'1 :: ...····1.··. ::;;\:11 1 I';~; :ili,::'::...
AR : ;;:1 I',:" ';
'I'
.,
'w: ;..:-r'" -;::'::":-1"--'

t •• ••• 1 , •• ' •• "'" t"
".- ::.': :·1.': :~:' .-:
",t.
: !-!~t 1:-> ,:.
:: :' ;:::
I:;';
;:;' .~ :: ':': r::: I..:....
, .. I "., .... ..
...: .:: ::, .. :I: ::!f: ::: ::!: ii:,':::'
.• ./-:" -I I, .. ~ .• " •..• ,.,
m;r::::l':;: ;'i'I:;;'7 :;.:~r-:-I~~-:r~-;·:· ,. -...... ,:::: :::!I':':ITt!r-
; I. I:'! j:.: :;': :: I j ,I.·..; ..
!: :." il:: ::: 1 . !. ' . . . . . ::.
_I" .. l+ 1-" .. I. ,'-' -- !.-- .. - '''1' I " I. . - ~ ... --r"
:':: ~':! 0 6'~: ATURAL' GAS" ", I . ,:::: '1 1 :1::'
· ;!i~Ji;t :}'·G. ;~:: ::: ".-.-t,t ~) ..~~t:~I~:-I:~ I:,: : .~-
"jl-.-.... ,' ......
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.10 . 20 ~P;lPf .30 .40 .! 0
>-0)
h
i.
....
0
j
_ I . ,--1..
h
FIG. 5 -...2
./
5 - 22
vS/14/75 ~1<-4-147
Rev. 19-22-75 Sheet 6 of 10
Rev. 3/17/76
Subcritieal Flow Example:
For a 4-inch Flexflo II Regulator, natural gas service
Where:
PI = 614.7 PSIA = (600 PSIG + 14. 7)

P2 - 600.7 PSIA = (586 PSIG + 14.7)
~P = 600. -586 = 14 PSI

Cp = 230 (From Fig. I)
Fe = .65 (From Fig. -2)
G = .6
£::"P/Pl =' 14/614.7 = .023
Y1 = .98 (From Fig. 4)
Z .90= (From Fig. 5)

C ~ Fc C p = .65 (230) = 149.5
Thus from the su~critical flpw equation of Sheet 2:
Q = 76. 9x 149. 5 x . 98 x 614. 7 j: g~ 3

:
Q = 1. 11 MM SCFH
Critical Flow Example:
For a 2-inch Flexflo II Regulator, natural gas service
- ' ..... Where:
Pt = 36 PSIA = (21. 3 PSIG + 14. 7)

tr.l (I'
::r
'P2 = 18 PSIA _(3.3 PSIG + 14.7) (t)
(t)
7':
r+ I
.6 P = (3 6 -18) PSI = 18 PSI 0'> h
,
, j, 0
.....,
.6P/P 1 = .50 ~
0 h
•.. ~-~.-
C p -- 73 '." -...].
r
"\
Fc -- .98
G = .6
Z = 1.00
C = Fe C p - . 98 (73) = 71. 5
5 - 23
vtS/14/75
Rev. 19-22-75
SK-4-147
Sheet 7 of 10
Re v. 3/1 7 /76
Thus from the Critical Flow Equations of Sheet 2:
Qc = 33. 3t x 71. 5 x 36 j L00

Qc = 85 .. 7 M SCFH
Temperature Adjustment
For gas flow inlet temperatures other than standard conditions (60 0 F),
multiply the flow rate at standard conditions by, ./520/ T (OR).
Q (Non-Standard)
Temperature
= Q (SCFH, 60 0 F) x /5 20
T
Where
tf.I (j)
::r
m A
m
c+
,
-l
0
.....
~
,
,.....
0 ~
--..J
5 - 24
/5/14/75 ~K-4-147
Re v . 3/17 / 76 Sheet 8 of 10
FLEXFLO II

For Reducing or Back Pressure Regulators
(Used in Combination With Grove 829 or 827 Pilots)
PART II
LIQUID FLOW '..
The Flexflo II General Liquid Flow Rate Equation is:
Q = C J PIG
* (GPM)
Where:
Q = Maximum Liquid Flow Rate (GPM)
PI = Inlet Pressure (PSlA)
P2 = Outlet Pressure (PSlA)
6P P1 -P2, Pressure Differential (PSI)

=
Cy = Capacity Coefficient (See Fig. 6)
G = Liquid Specific Gravity (Water = 1. 0)
Fc = Valve Opening Factor (See Fig. 7)

C = Fc C y = Partially Open Capacity Factor
FIG. 6
tf.l (/1
Size 1-1/2 2 3 4 6 8 10 12 ::r
(D
(D
A
<+ I
Cv 41 70 122 202 327 512 756 1095 Q;) J':::,..
....,
0
I-"
0
~
--.J
*Ref. ISA - S39. 1 5 - 25

V5/14/75
He v. 3 / 1 7 / 7 6 SK-4-147
Sheet 9 of 10
Liquid Flow Example:
For 4-inch Flexflo II in water service
Where:
(PSIA)
(PSIA)
~p = 13 (PSI)
Fc = .58 (From Fig. 7 )

Cv = 202 (From Fig. 6)
C . 58 x 202 = 117.2
=
G -- 1. 00
Q - 117.2 J 13/1. 00
- 422 GPM
CIl (jl
::r'
CD A
CD I
......
co ~
0
.....,
.......
0 ~
-.J
5 - 26
I
Model 82 Example Problem
P1 (inlet pressure)=500 psia

P2 (outlet pressure)=120 psia
Flow Rate=1,200,000 scfh
Fluid=Natural Gas
Specific Gravity=0.6
step 1 (jp = 380 psi

P1 = 500 psia
Fie = 0.94
0.45 F Ie=.45.(.94) = 0.423
AP>0.45Fk critical Flow

P
step 2 Solve the required to pass the specified flow
or
C Qc ~
(required) - 26. 6P1 ~ Ii;
Z=.947 at P=0.58
C 1,200,000 I
0.6(.947) -70.15
(required)- 26.6 (500) ~ 0.94
step 3 Select a regulator that has a "C" valve greater than

C requi red
C=FcC p
Fc=1.0
Cp=73 for a 2" CL 300
step 4 Calculate the maximum regulator flow capacity
Qc=33.3CP1~ 1
2
=33.3(73)500 ~=1/249/000
~ ~
A 2" Cl 300 is the correct size unit for this

application.
5 - 28
SIZING THE GROVE MODEL83
FLEXFLO®
'. \ . . . ..,' :"i~ :. ·";.";;;~y·,,-:· . . ~... "(~: .. ~ ~.:: ~.. '. ' . : .! " '::".-?,' '.,: '.~ :
. - . , '" ... .
COMPRESSIBLE FLUIDS SUBCRITICAL FLOW

STEP 1. Determine if application is subcritical or critical STEP. 1. Solve: Trial Cv = 0MAX
----:.:~-==-
flow.
59.6P1V~P
~P/P, ~ 0.5 = Critical;~P/P, < 0.5 = Subcritical
GZP,
where: P, = (Inlet Pressure PSIA) and
~P = Difference between P, and P2 (Out· where : 0MAX = SCFH (Maximum for Ap-
let Pressure PSIA) plication-Compensated for
Temperature from Step 3
STEP 2. Determine Supercompressibility Factor (Z). This
above)
may be taken from Figure 1 for Natural Gas. Z
~P = Difference between P, and
curves !of other gases may be found in Engineer·
P2 as defined in Step 2
Ing Handbooks or the International Critical Ta-
above .
bles. If appropriate Z curves are not easily
G = Specific Gravity (Air = 1.0)
available, this factor may be omitted with little
Z = Supercompressibility Factor
effect on low outlet pressure . (i.e . Below 200
PSIA). Determine the higher number between P 2
P, = Inlet Pressure PSIA
(Outlet Pressure PSIA) and P,/2 (Inlet Pressure STEP 2. Compare trial C v with full open Cv as shown in
PSIA Divided by 2) intersect curve with higher Table 1.
number to find Z.
Size (Inches) 1112 2 3 4 6
SUP£IICOIAPIIESSIlIlUTY Of AVEIIAGE NATURAl C v Full Open 47 77 155 234 390
GAS Of 0.' SPECIFIC GIIAVITY AT eo' F
1.00 XI (Gas) .64 .56 .46 .50 .47

.74 .75
i
FL (Liquid) .87 .82 .77
.95
'Max °
(GPM)Wa!er 400 750 1500 2250 3800
TABLE 1
I .90
.85
t
'For liquid other than water 0MAX (Other liquid) = 0MAX
Water/vG (Other liquid)
I .80
.75
0 200
II
I,
L j II
400 600 800
JI
1000 1200 1400
j
1800
STEP 3. Pick valve size that has full open Cv larger than
trial C v .
STEP 4. Determine valve opening factor (A) by entering
~P at bottom of Figure 2 and intersecting line
pI
FIGURE I
TEMPERATURE COMPENSATION
STEP 3. Solve : OtvlAX = SCFH 520
T
where : T(OR) = 460 + OF
'. p r>,
Cont,nued on Page 3
5 - 29
2"LD 1%" & 2" STD
6" VLD 1%" LD
4"LD
~~~
3 3"LD 3" STD
/i6"LD /
4"
1%" & 2"V
1.0
IInll
11111•
~
4"STD
\
.90
I •
1. 111
IlIJ
I~ I
•
.80
.70 '11m ~. . mlim
c(
I
a: .60 , III: ~~ lf~ ! ! ~
illl ll4Rl ~I',,"m ml
fIl
II! ~mlml
I ,
UI
~
0
~ ,
: IVI .M
, , ,
.. ;;: "
" I
"
CJ : : "i' i : I:::, ,ii :
z .50
"
[ i 'li !i: "

z
w .. iJ I
I
, Ii
: :
,'i,,n 1: :ii' ..
Q. , .. ,
~
0 I: !:",!I I i ! i in
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,, i , , ,
:!I :
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iii
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, ii; "
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.30 .. , j i:i! 'I' Wi , ii! i: ,
: : "
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, , I!,!' ;,:1 ' "ii : II;,
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!li ii'!!:: ! '!Ili:: I 'I In

fflt+f. I.
hi'!!l! : "I~;: 1+::

, ::;: ';i '.,
;' :1 ; V ; : i
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'i;:: K '
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: :
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'" '~i ; I:! jj i:: :~ ', !!i'
~! '!"iHf,] :j ,!H~;i-' ·i.i' : 'j:;i W
!1f lH: ' 1\::.,[;,',', 1 Ji :Ilii:j ii::lH'
!::!j' iii! Ii! " ,Ii'
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' 11 ' , ; Ii
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: " ; ,;!j" '" :h;. !H',
I,' .j !: .. ,
IlL ,
o
10 20 30 40 50 60 70 80 90 100
FIGURE 2
* For 2",3" and 4" Ribbed Tube Valve Opening Factor, See Grove
Model 900 TE Brochure.
5 - 30 2
STEP 5. II ~P(Allow) was used, solve: ~P(Allow) = Fl2 GAS SIZING BY SOUND
(PI-FFPV) where Fl is found in Table 1 for valve PRESSURE LEVEL (SPL)
size selected in Step 4 above. If P I -P 2 is lower
The curves below display the quantity of gas, on each size
" there is no cavitation or choked flow and PI-P 2 is
to be used for ~P in Step 6.
Grove Model 83 Flexflo which can pass at given inlet pre-
sures at 85 dBA or less. These curves are based on critical
STEP. 6. Solve Cv = _~ flow, so any ~P less than critical flow will be quieter. The line
A~ above the intersection of PI and 0 is the valve size that will
G not exceed 85 dBA for that application. Grove Engineering
will compute the SPl for any gas application within ± 5
Compare this number to full open C v in Table 1. If
dBA. If the application requires 90 dBA and/or the ~P is
this causes a larger valve to be selected than in
below critical, a smaller valve may be used.
Step 3, recompute Step 4, Step 5, and Step 6 and
compare to full open C v in Table 1.
!
DEFINITIONS &
PI Inlel Pressure (PSIA)
P2 Outlet Pressure (PSIA)
6P Pressured Differential, PI -P2 (PSI)
a Flow Rate (SCFH for gas-GPM for liquid)
OMax Gas Flow Rate Corrected For Temperature
G Specific Gravity (Air = 1.0 for gas-water = 1.0
for liquid)
T Inlet Gas Temperature (OR)
Z Supercompressibility factor (see figure 1 for nat-
" A
ural gas)
Valve Opening Factor (see figure 2)
YI Expansion Coefficient (see figure 3 for natural Grove has available a "Flex flo Regulator/Monitor
gas) System Sizing Program". The sizing program is
XT Critical Pressure Drop Radio (see table 1) . available in diskette form and is for use on IBM® Per-
FK Specific Heat Ratio Factor (see table 2) sonal Computers PC/XTIAT or Compatibles. Please
Cv Valve Capacity Factor (dimensionless) contact your local representative or Grove direct for
(Wide open C v shown in lable 1 for each size) your free copy.
FF Critical Pressure Ratio (from figure 4)
Fl liquid Pressure Recovery Factor (see table 1)
Pv Vapor Pressure at Flowing Temperature (PSIA)
Pc Critical Pressure (PSIA)
P, Higher of P"2 or P2
NOTE:
Single Regulator capacities shown on chart are theoretical maximums for the given conditions . Grove recommends
that the size selected have a maximum capacity of at least 20° over the maximum expected in the application to assure
good control.
TABLE 2-Monitor capacities are based on two Model 83 Flexflos® of the same size in series. The inlet pressure (P 1)
is upstream of the monitor set. The outlet pressure (P 2) is downstream of the set. The capacities are calculated where
the intermediate pressure (PM) allows the same capacity through both Flexf'os~.
4
5 - 31
STEP 5. Determine expansion coefficient (Yl) by entering LlaUID FLOW
~P/PI at bottom of Figure 3 and intersecting valve
STEP 1. Solve for FF (Critical Pressure Ratio Factor) by
size selected in Step 3 above. entering bottom of Figure 4 with Pv (Vapor Pres-
STEP 6. Multiply A by Yl' sure-PSIA) divided by It (Critical Pressure PSIA)
STEP 7, Divide trial C v by product of A Y1• It = 3206.2 PSIA for water. Pv may be found in
steam tables for water. Pc and Pv may be found
STEP 8. The number obtained in Step 7 is the Cv required in handbooks for other liquids. If these variables
in this application. Grove recommends that the are not known, the proper Cv required will not be
valve size selected should have a full open Cv at known if there is cavitation or choked flow in this
least 20% higher than the Cv required. application. As a rule of the thumb, cavitation or
choked flow is unlikely where the outlet pressure
(P2 ) is substantially higher than the vapor pres-
sure of the liquid at its flowing temperature. With a
CRITICAL FLOW very small ~p. it is even less likely. In the event
STEP. 1. Solve: Trial Cv = QMAX that cavitation andlor choked flow is known not to
39.8Pl~ exist. Steps 1 and 2 may be skipped.
GZ STEP 2. Solve Trial ~P(Allow) = .62 (Pl- FFPV)"
where: Fk is the specific heat catio factor. This
factor may be found in Table 2 for some STEP. 3. Solve Trial Cv = _L
common gases.
QMAX, PI' G, and Z are as in subcritical
0! G
flow above. where: ~P is the lower number of Trial ~P(Allow)
and P1-P2 . G = Specific Gravity of liquid
(water at 60°F = 1.0) and Q = GPM.
GAS _ _ _ _F~ _____ ._._Q_ .. _ Compare Trial C v with full open C v as
Acetylene .90 0.90 shown in Table 1: however, if Q is larger
Air
Butane
Ethane
1.00
.79
.84
1.00
2.00
1.03
than Max Q in Table 1, use next larger
size valve .
o
Helium 1.19 0.14
Hydrogen 1.01 0.07 STEP 4. Determine value opening factor (A) by entering
Methane .94 0.55 ~P at bottom of Figure 2 and intersecting line
Natural Gas .94 0.60
representing valve size selected in Step 3 above.
Nitrogen 1.00 0.97
Oxygen 1.00 1.10
Propane .81 1.52
TABLE 2
STEP 2. Compare trial Cv with full open Cv as shown in

Table 1.
STEP 3. Pick valve size that has full open Cv larger than
trial C v.
STEP 4. Determine valve opening factor (A) by entering
~P at bottom of Figure 2 and intersecting line
10 20 30 40 so 60 7() 80 90 100
repres~nting valve size selected in Step 3 above.
VAPOR PRESSURE-PSI'"
STEP 5. Solve: Cv = QMAX CRITICAL pnEssunE- PS!A
----"-'---- nGURE <4
39.8AP1~
GZ
where A comes from Step 4 above and Xt comes
from Table 1.
STEP 6. The number obtained in Step 5 is the Cv required
in this application. Grove recommends that the
valve size selected should have a 'full open Cv at
least 20% higher than the Cv required.
5 32 Conl!nU'2d on Page 4
KODEL 83 EXAMPLE PROBLEM
P1 (inlet pressure) = 500 psia = 34.5 bar

P2 (outlet pressure) = 120 psia = 8.28 bar
Fluid = natural gas
specific gravity = 0.6
STEP 1
OP = P1 - P2 = 500 - 120 = 380 PSI
OP/P1 = 380/500 = 0.76 > 0.5 critical flow
STEP 2
P1/2 = 250. P2 =120 P1/2>P2
p1 = 250 from fig. 1 Z = 0.95
Note that p1 does not equal P1
CRITICAL FLOW
STEP 1
Solve Trial Cv
Cvtrial- Qmax
39.8Pl I.5Fk
~GZ
Fk = .94 for natural gas table 2

CVtrial _______l~,2_0_0~0=,=0=0=0======
39.8(500) .5{.94)
(.6) (.95)
Cv trial = 66.4
STEP 2 & 3
THE FULL OPEN Cv OF A 2" VALVE IS 77 AND IS LARGER THAN THE
TRIAL cv 66.4 TABLE 1
STEP 4
DETERMINE VALVE OPENING FACTOR (A) BY ENTERING Qp AT BOTTOM OF
FIGURE 2 AND INTERSECTING LINE REPRESENTING VALVE SIZE
SELECTED IN STEP 3
Qp = 380 PSI BECAUSE 380 IS OFF THE BOTTOM SCALE A = 1.0
5 - 33
STEP 5
SOLVECv- 1,200,000
39.8API~ xtFk
GZ
Fk=.94 from table 2
xt = .56 from table 1
G = .6 from table 2
CV_______~1~,~2~0~0~,=0=0=0=======
(.56)(.94)
39.6(1.0)500
(.6)(.95)
CV = 63.1
STEP 6
Grove recommends' that the cv of the valve selected be 20%
higher than the application Cv.
Cv valve = 77 CV = 63.1
1.2 x 63.1 < 77 a 2" model 83 is the proper regulator for the
application.
5 - 34
SIZING THE GROVE MODEL 900 TE
TOP ENTRY FLEXFLO®
COMPRESSIBLE FLUIDS
Ribbed
.·_1.Cv
Xl
}~&( 21::; '~m~Y8 \~~ t ~~<"'k .~ t,
50
Q.6O
91
0.54
120
0.51
!AlYE SIZING Tube FI 0.-84 0.79 o.n
STEP 1. Detec-.ine if awl ication is Slb:ritical or o max 300 660 .1175
critiClil flOil Tv 58 94 128.5
Standard Xt 0.46 0.50 0-.16
~/Pl <
~/Pl >=
.5
.5 ..= SWcritical
Critical
.
Tube Ft 0.74 o.n 0.73
o max 300 660 1175
STEP 2. Deteraine ~ COIIpI"essibil ity Factor Z
For Natural Gas enter pz at bottaca of Fig.l and
intersect curve to find Z. (Z curves for other *MaxQ based on velocity of 30 ft/sec for optimal tt.be
gases may be fOU'ld in Gas Engineering life. To adjest MaxQ for other liquids divide by G
Hanc:booIcs. Omitting Z in applications where P2
is less than 200 psia will produce a slightly
conservative sizing_> SUPERCOMPRESSIBIUTY FACTOR Z
.6 S.,..etfic Gravity Natura« 0 .. at 60 F
STEP 3. Calculate Trial tv Z
$(j)critical: Trial Cv =_Q_ _ YG*Z*Pl(46{}+T) '~ . . . ...

~ .
1359*Pl . . dP , o.r.; •
~
Critical: Trial Cv = Q .y G*Z(460+T)
- 0 ."
1
~ .
'"
STEP 4. Select Trial valve Size

907*P1 _5*Fk 0 .&5
0.8
i
I
----- ~
i----- :--. ---:. .
-
C~re trial Cv with full open Cv as shown in
1
Table 1. Pick valve size with Cv > Trial Cv_ 0.75
0 200 600 800 1,000 1,200 1,- 1,600
pz
F9ft'e 1
STEP 5. Detel1line Valve Opening Factor A
Enter dP at the bot tom of the set of curves in
Fig. 2 representing the valve size selected in
Expansion Coefficient
.6 SpGt Natura' Ga.
STEP 4 _If dP does not intersect curve then A=1. y
STEP 6. Detel1line Expansion Coefficient Y '~

0 .95
-:..:
Skip to STEP 7_ for critical applications.
0.9
~
..,
Enter dP/Pl at bottom of appropriate graph in
Fig. 3 representing the valve size selected in 0.85
'~.~ .
~.
. " ~.~::--
STEP 4. . ": .,,:,. t----...
0 .8
! ... :,:~;:-I---...
STEP 7. Calculate Appl ication tv 0 .15
.. . ~
i
I I i ....~... .
0 .7
$(j)cr i tical: Application Cv = Trial Cv i 1 ! · ·l~· ,-~ .667
A* Y 0 .65
0 0' 02 0.3 0 .' 0 .5 06 07
dP/p 1
Critical·: Applicati on Cv = Trial cv~ 2' J'
,. 900TE Ribbed Tube
A Xt - - - -- --
y
1.2 * Appli cation Cv
,
NOTE: Gr o ve r ecommends Valve Cv ,
>
0 .95
~ . ;
- !
~ ; : I
· ·~ L .
0 .9
VALVE CAPACITY i
0 .85
; ~. '
, i
$(j)cri tical: Qmax = 1359*Cv*A*Y*P1 -V G*Z*P1dP(460+T) 0 .8
~
;
: .
075 ~
,
0.1
Critical : Qmax = 907*Cv*A*P1 './ Xt*Fk 065 f-- - - .667
G*Z*(460+T) : i
06 1
0 o· 02 0 3 C' 05 06 07
dP/P1
:r ~ " 900TE Non-Ribbe d Tube
- - -----
I= I 'J'-Jr (~ :
5 - 35
INCOMPRESSIBLE FLUIDS VAlVE CAPACITY
~l Flow: dP < Fl*(P1 - Ff*Pv)
VAlVE SIZING
STEP 1. Detenline Ff
Qmax .. Cv*A JdP/G
If It is known that operating conditions will Choked Flow: dP > Fl*(P1'Ff*Pv)
not cause cavitation or choked flow skip to
STEP 3. For water at 60 F, if P2>.47*P1 skip Qmax" Cv*A J(Fl2.(P1-Ff*pv»/G '
to STEP 3.
Find Ff by entering Pv divided by Pc at the CRrnCAl PRESSURE RATIO FACTOR Ff

bottom of Fig. 4. For water at 60 F Pc=3206.2 Ff
and Pv=.256 (see Steam Tables for Pv of water
at other t~ratures). See handbooks for Pv
& Pc of other liquids . If these variables are
not known, the proper Cv requi red wi II not be
known if there is cavitation or choked flow.
As a rule of thumb, cavitation or choked flow
is I..I\l ikely where outlet pressure P2 is
substantially higher than the Pv of the liquid
at its flowing temperature. With a very small
dP, it is even less likely. 0.1 oL..-o..l .$--0:':.•::-~0'::"
.,_..:....J0.2_'--OL.3-.....:..I.O.•--'-01.;. .7'---0:':.•:--'-'---:0.':"g-~
STEP 2. calculate Trial d>(allowable) (Pv/Pe)
Figure •
Tri.l dP(allow) =.53(P1·Ff*Pv)
STEP 3. calculate Trial tv

GAS FIe G
Trial Cv = Q ,,~ Acetylene 0.90 0.90
Air 1.00 1.00 LIQUID G
Butane 0.79 2.00 Crude (typ) 0.86
where dP is lower of Trial dP(allow) and P1-P2
Ethane 0.84 1.04 Gasoline (typ) 0.75
STEP 4. Select Trial Valve Size Helium 1.19 0 .14 Water 1.00
Compare Trial Cv with full open Cv's as shown Hydrogen 1.01 0.07
in Table 1. Pick a valve size with Cv > Trial Methane 0.94 0.55
Cv. Table 3
Natural Gas 0.94 0.60
STEP 5. Deterwine Viscosity Correction Factor Kq Nitrogen 1.00 0 .97
For fluids with very low viscosities such as Oxygen 1.00 1.10
gasol ine or water no viscosity correction is Propane 0.81 1.52
required, let Qc = Q and go to STEP 6 . If
viscosity exceeds 35 SSU, determine the
viscosity correction factor for the va l ve size Table 2
selected from Fig.5, and solve Qc = Q/Kq .
DEFINITIONS
STEP 6. Check Valve Flow capacity A Valve Opening Factor (Fig.3)
If Qc > HaxQ, select next larger size valve. Cv Valve Capacity Factor (dimensionless)
If viscosity correction was used, recalculate (Wide open Cv shown in Table 1 for each size)
Qc as in STEP 5. dP Pressure Differential, P1'P2 (PSI)
Ff Critical Pressure Ratio (Fig . 4)
STEP 7. Oeterwine Valve Opening Factor A Fk Specific Heat Ratio Factor (Table 2)
Enter dP at the bottom of the set of curves in Fl Liquid Pressure Recovery Factor (Table 1)
Fig.2 representing the valve size selected. G Specific Gravity(Tbl.2 for gas-Tbl.3 for liquid)
P1 Inlet Pressure (PSIA) (psia = psig+14.7)
STEP 8. Recalc dP(allowable) P2 Outlet Pressure (PSIA)
If Trial dP(allow) from STEP 2 was us ed, find Pc Critical Pressure (PSIA)
Fl for the val ve size selected from Table 1 and Pv Vapor Pressure at Flowing Temp (PSIA)
calculate pz Higher of (P1/2) or P2 (Fig . 1)
Q Flow Ra te (SCFH for gas - GPM for liquid)
dP(allow) - Fl 2 ( P1-Ff*Pv) T Inlet Gas Temperature (F a renheit)(Std=60 F)
Y Expansion Coefficient (Fig.2 for nat.gas)
I f dP < dP(allow), there is no cav ita ti on or Xt Critical Pressure Dr op Ra tio (T able 1)
choked flow . In cas es of cav it at ion Grove Z supercompress ibility Factor(Fig.1 for nat . gas)
recommends cons idering multi p le st age
regulati on wi thin dP(allow).
STEP 9 . Cal culate Application Cv For special appl icati ons or s i zing conf i rma t ion cont act
App l ication Cv =.2£-V G GROVE VALVE & REGULATOR Co_

A dP 6529 Holl is Street
Oakl and, CA 94608- 1070
Telephone : (510)655 -7700
I f val ve Cv < Appl ic at ion Cv, selec t ne xt Ou t s ide CA:( 800)847-1 099
l arger s ize val ve and go to STE P 5. FAX: ( 510)420-2 150
5 - 36
VALVE OPENING FACTOR A
2" Ribbed Tube 2" Non-Ribbed Tube

A A
::.,. . ..• - , y - .. -+' • • • ~"l'~--+-,-, ".-<- ...... -++4'<+.
V. .,-.
:; ::i:::::: :~::£:: ~::::::: ::;:.;::~ ::i:,::;;: E:::::
r-.:" . :-:
~'.
0.9 1--+_-
..-':'-:f-..-..-.. -,,+:-.:_ot ~"'_- ,:-::f-:-:-;.,",":,:,"";--'i:-::"'~~~~:~-j1':-:::-::-:-;-1. 0.9 I----+---,~--+--_r_'-~--:-'--_+_-__I
I---r--;.-+----+-f---I,---+---+--'-rl---l 1
I----+-++---+-:-~+_-_r'_f--_+_-__I
. ;:;: I ;:.:;: ::~:~:::: ::~:/: ;::::~~~:

0.8 0.8
. :1
I . ,.~ ....
0.7 f--IF-~+-,-"--+.:c....---1c.:-,:,:,-:,,r:;";"+-L-+-'-"--'1
... :::::.:::.: '::r:' 0.7 1:---+-/+.--+--.r---++...:.-+----1~~:...j
0.6 f--j+--'-+--:'t--:----1I-..-..-::+:-::-~:-:-':.-1:....~,-':,...:::-:-,.+.-
..-...-..-1. 0.6 /----:-. +IJ+-:-:-:-:-.+-/-..=-+--.. +---j--+--:...j 7-.
: :::1::::: 0.5 1----t1f---+7--+-:-'--+_-~--_+_-__I

0.5 ./.+----+---+-.::-::.-,,1+-:.-.-,.-
I---H--+--+.--.--"-- ...+.---1
0.4 1--++...--+--'--+---1'---+-:-,/+:,-:.-1:--+-.-.-_-I 0.4 r-:----#i:
/.-:-.. --:-:'i,
. I
-:--:t---j--:--+--t---1
....
0.3 I-+-~--+-:.-.:-
J
.. -+---1'-----1'--+:..- ..-.::--+-.-...-1
: , . . : : - : :::,,:1. ... , .... -I ,',..
0.3 /---++--i-+--t--+--+-...::....-l--.:.+-~
,; ... ~ ;
02
.. /' ';.;, :
'." :;,>'''':::'' :::::::-
0.2/---:-i
J'-_+-/!-:-.-:+.-..~--+--+-:-::-"-:+----1~~:...j
0.1 /---t-+r-+-~--+--+---';'-f"';";";";-+--'::';'':..;~:..;':..:j
O.l!..f' ...'
o
, .' . -J' ,::::.
,.~. : -:~.~
"! •• - .' O~~~·--"~·-+·~~·-~---~'_-~·_-J-__~~~~
o 10 20 30 60 70 80 o 5 10 15 20 25 30 35
(P1-P2) (P1-P2)
3" Ribbed Tube 3" Non-Ribbed Tube

A A
I ,,.,.,
, :-. :/. ~
' - ..- :-,_:
~
'--- -,• ....:.'
. • . -.,.
.",".
- '-'.+
0.9 . 0.9 t---.-j-+C+----+i---+-:-_-i:-.~~.,.:.,-+-r-.-.~-l
0.8 I , 0.8 t-----l'-j--.,----f,+----+---,"-"-'.-+~-__l
t- ... :-
0.7 I .,
,,
0.7
:r-
<
/----/+-+---'---+----+'----+-:--'-"--"-1
' /:::
0.6 I .
-J
I
0.6
i.
1:-+-:--:1,'-:---+---:--:':-+-:~-:--j----f
/----f-:
~. "
,
0.5
0.5 t--.-I+-.--+-:~'--+-.-.-'--+---~---_-~_l
I
0_4 /----l++--:-'.,--+--?-+--/-f--J:f--~~--l
.i 0.4 f---If----+-j---+-,:----+-~-+~~~
,,
0.3 L+-'---+--;..-+/-+---I---+---l
f----+ 0.3 /----t--i:'---+-----+---:--+~--l
0.2 / '
0.2 t--+--7t----,:-+----+-----I-----l
./
, . ..
0.1/, .. ,' "" 0.1 /--+-r+-~:-+--'----+--.:....--'-+--=.~~
o ~~I _ • .,;.:..•• ,....,.- ,;
OL-~-i_L_~·_~ __ ~ __ ~~_~~
o 10 20 30 40 50 60 o 5 10 15 20
(P1 ~P2) (P1-P2)
4" Ribbed Tube 4' Non-Rlbbed Tube
A A
,
0.9 I ,
,, "
V
.'
,
- , .~ . ..
;..'+-'--'-'-'-~-'-"--'--+------f
f--'-"--+f--'-"--'-',.
, -'
0.8
I ,,
,
.... -
,,
07 0.7
,
06~---~-~-f___-~~---,_+_----4
, .:1
I
0.6 / ,
,
0.5 r-----lY---i'c..'
,,
-+--~_+_-T-I-+__-__j I I ,
,
I :'
r
0.5
I ,
/
I
0.4 I II
II 0.4
,
I
03
I j V L 'I
r .: ~
I.
03
I 1 ,, '
' I
I1
I
i
02
I I 'I" , I
r'
/
02
1, I
i ,, I
01
j,;' 01
0
0 -.0
.-:-
20 30 40 50
o
o
L 1
! !
10
I
15 20
VLD CI 150 CI 300 C1600 (P1·P2)

725 TUBE 893 ~uBE 878 TuBE 740 TUBE
5 - 37
VISCOSITY CORRECTION NOMOGRAPH
MODEL 900TE
VISCOSITY FACTOR FOR FLOW KQ
~!lI\!lU S [! ~ .; un ~ § 8§ §
FLOW TURNING
RATE AXIS
BARRELS PER DAY GAllONS PER
(BPD) MINUTE
(GPM) SA YBOl T SECONDS CENTISTROKES
UNIVERSAL (SSU) (CS)
NL CLASSES
VALVE
SIZE -
INCHES
FLEXFlO SELECTION ' 00

JOO
'00
' 00
""
60
'0
)0
20
'0
.•
6
5 - 38
HODEL 900TE EXAMPLE PROBLEM
P1 (inlet pressure) = 500 psia

P2 (outlet pressure) = 120 psia
OP = P1 - P2 = 380 psia
Fluid = natural gas
Specific gravity = 0.6
STEP 1
OP/P1 = 380/500 = .76 >.5 critical flow
STEP 2 Determine Z factor
pz = P1/2 or P2, whichever is higher
pz = 500/2 = 250
Z = .95
STEP 3 Calculate trial Cv
T = 60 degrees F
trialCv- Q GZPl (460+T)

907Pl .5Fk
trialCV- 1,200,000 (.6) (.95) (460+60)

(907) (500) (.5).94
trial Cv = 66.4
Step 4 select a valve with a higher Cv than the trial Cv the

3" 900TE has a Cv of 91 with ribbed tube
Step 5 Determine valve opening factor

A = 1 because dp is 380 psi and off the graph scale fig 3
Step 6 Determine expansion coefficient Y
dP/P1 = 380/500 = .76
Y = .667 from fig 2.
Step 7 Calculate application Cv

xt = .54
applicationCv- trialCv ~ .5
A xt
5 - 39
applicationCv- 66. 4
1
~ .5
.54
application Cv = 63.9
because the application Cv is lower than the 3" 900TE Cv the
unit is correct for the application
VALVE CAPACITY
Qmax-907 CVAPl
XtFk
GZ(460+T)
0.54(.94)
Qmax-907 (91) (1) (500)
.6 (.95) (460+60)
Qmax = 1,707,813 scfh
5 - 40
5.4 RULES OF THUMB
The following are guidelines that can be used where experience

does not dictate otherwise. All systems are different and these
guidelines can not be interpreted as absolute.
5.4.1 PRESSURE CUT RATIO
The "pressure cut ratio" is equal to Pinlet (PSIA)/Poutlet

(PSIA). It is desirable to operate at a pressure ratio less than
20. For example if the inlet pressure to a regulator is 3,000 psi
the outlet pressure should not be lower than 150 psi (150 =
3,000/20). If the pressure cut is high this tends to produce a
great deal of noise and vibration. The required maintenance will
also be higher due to higher wear. There is also a chilling
effect as gas expands from high to low pressure that can cause
pipeline freezing.
Under low flow or low outlet pressure conditions with a hand

loader the pressure ratio should not be a problem and can be
disregarded. A hand loader reducing pressure from 2,000 psi to 3
psi at 10 SCFM will not have control problems.
To avoid a high pressure cut ratio two stage pressure regulation

can be used. By placing two or more regulators in series it is
possible to increase the maximum recommended pressure cut ratios
up to 400. For example an application with an inlet pressure of
6,000 psi can be reduced to 300 psi then reduced to 15 psi.
To improve high pressure cut performance, external sensing can be

used on some Powreactor regulators. Normally all specialty
reducing regulators monitor the outlet pressure within the
regulator body. Turbulent flow is often generated at the outlet
of a high pressure cut regulator and normally specialty
regulators sense the outlet pressure in this potentially
turbulent area. Because the regulator is sensing turbulent flow
the outlet pressure control is inaccurate. By sensing the outlet
pressure at a smoother flow section with external sensing the
regulator can more accurately control the outlet pressure and
handle a higher pressure cut ratio.
5.4.2 MINIMUM REQUIRED Cv
Often times regulator applications are sized only by their

maximum Cv without considering the minimum cv. Grove recommends
caution when using regulators at less than 5% of their rated
capacity. It is common for regulators to be damaged by low flow
operation. In Flexflos the tube must operate very close to the
core. As soon as the regulator opens the outlet pressure exceeds
the set pressure. The regulator closes until the outlet pressure
drops below set pressure then repeats the opening cycle. This
causes poor outlet pressure control. In some low flow cases the
tube will open and close very quickly. The tube will vibrate
against the core and enough heat can be generated to damage the
5 - 41
tube and core. Typically very rough indentations in the tube
will appear just downstream of where the barrier contacts the
tube. The core can appear to be worn by erosion with grooves cut
into the downstream slots next to the barrier.
To solve the minimum required CV use the sizing programs or

mathematical formulas and input the maximum inlet pressure, the
minimum outlet pressure and the minimum flowrate. As discussed
the minimum Cv should be no less than 5% of the rated cv.
Check to see if the fluid is compatible with the regulator soft

goods. If the application fluid is suspected of not being
compatible with the rubber goods consult with Grove. Some common
fluid incompatibilities are listed below:
FLUID COMPATIBLE RUBBER INCOMPATIBLE RUBBER

Water EPDM, Nitrile Hydrin
Sour Gas Hydrin Nitrile
MTBE Nitrile, Tornac Hydrin
When a rubber is compatible with a fluid there is no reaction

between them, the rubber is inert to the fluid. If there is a
compatibility problem there are a number of different reactions
that can occur.
5.5.1 Swelling
The fluid can be absorbed by the rubber causing swelling, which
weakens the rubber. In a Flexflo a swollen tube can expand to
fill the jacket cavity preventing the regulator from attaining
full capacity.
5.5.2 Leaching
The fluid can react with and dissolve specific materials in the
rubber. For example we have found that some hydrocarbon
condensates dissolve the plasticizers in nitrile rubber. The
plasticizers give the rubber a softer texture and hardness
(durometer). with the plasticizers removed the rubber is harder
and has a lower density.
5.5.3 Chemical By-product

Some fluids react with the rubber to produce harmful byproducts.
Water when in contact with Hydrin produces hydrochloric acid.
This acid reacts with steels and promotes corrosion.
5.6 TEMPERATURE
The temperature can affect the flow capacity of the regulator.

The program sizes the application assuming that the gas is at 60
F. Generally for ambient temperature applications the thermal
affects on capacity can be neglected. At -65 F the flowrate will
5 - 42
increase by 14.7% and at 165 F the flowrate will decrease by
8.8%. For more accurate flow rates use the following formula:
520
(460 + T)
Extremely high and low temperatures adversely affect rubber

goods. At higher than rated temperatures the rubber is more
prone to blistering. Under high temperature conditions gas can
be absorbed into the rubber at high pressure. When the rubber
component is removed from a high pressure atmosphere, the
absorbed gas cannot escape quickly and expands in the rubber
creating blisters. The rubber bonds are broken at the blister
location and should not be reused. While in use the rubber is
not blistered because it is surrounded by high pressure gas, thus
the rubber strength is not compromised until it is removed from
the high pressure atmosphere. When heaters are used on 829S
pilots this is a common cause of diaphragm blisters and
punctures.
At low temperatures rubber becomes very stiff and brittle. The

diaphragms can crack if flexed while they are below their rated
temperatures. Flexflo tubes also become much more difficult to
expand at low temperatures. The lower temperature ratings of
tubes are based on the temperature at which a Flexflo tube is no
longer flexible and can no longer regulate pressure.
5.7 REDUCING PILOT SIZING
For any reducing system select a pilot that has a control range
just above the maximum application outlet pressure, this will
produce the most accurate pressure control. Higher outlet
pressure control range pilots have higher droop and require more
of a rise above set pressure to shutoff.
MODEL OUTLET PRESSURE CONTROL RANGE

829L .145 to 6.5 psi
829S 3 to 600 psi
820 15 to 1,200 psi
5.8 BACK PRESSURE AND RELIEF PILOTS SIZING
Regulator sizings for backpressure or relief applications are

nearly identical to the sizing of reducing regulators. Run the
Flexsize program using the set pressure as Pin, downstream
pressure as Pout (usually 0 for atmospheric relief) anq the
maximum required flow rate. The program will select the correct
Flexflo regulator. A backpressure pilot can then be selected
based on the desired upstream pressure to be controlled.
5 - 43
BACKPRESSURE PILOTS
MODEL OUTLET PRESSURE CONTROL RANGE

829S 3 to 600 psi
830 15 to 1,200 psi
5 - 44
SECTION 6 SURGE RELIEF
6.1 888 PILOT CONTROL
6.2 PRESSURE SURGE DESCRIPTION
6.3 887 SIZING
6.4 RESPONSE OF THE MODEL 887
6.S CAVITATION DAMAGE
6.6 FLUID VELOCITY Vs POTENTIAL SURGE PRESSURE
6.7 SURGE RELIEVER PLACEMENT
6.8 SPEED OF RESPONSE
6.9 SAMPLE 887 SIZING PROBLEM
6
All 887s are line removable designs. The cores are "half
capacity", half the number of downstream slots as upstream slots.
The 887 is available in sizes 4" to 12" with ANSI raised face
flange end connections, class 150, 300 and 600.
6.1 888 PILOT CONTROL
The 80-888 has the same flow capacity characteristics as the 887.
Use the 887 sizing formulas for sizing model 80-888s. The
difference between the two units is the speed of response to rise
over set pressure. The 80-888 cannot respond as fast as the 887.
The pressurized nitrogen that controls the set pressure must vent
from the jacket volume to a nitrogen bottle. Typically the 80-
888 can fully open in 2-4 seconds, larger sized units require
more opening time due to more gas displacement.
We are still developing the flow formulas for other Model 83 and
900TE Flexflos used with the 888 pilot.
6.2 Pressure Surge Description
Surge protection in liquid pipelines is a requirement in any type

of system that is normally operating at pressures close to the
pipeline pressure rating. Under these conditions any change in
fluid velocity can cause the internal pressure to exceed the pipe
pressure rating, potentially damaging the pipeline.
The following is a description of a simple pressure surge. The

components are a reservoir, a pipeline and a valve.
V=+10 FT /SEC
P=250 PSI -r--
-
~ SOURCE ~ ~ ~
~V ~
.~
-
6 - 2
A valve downstream of a reservoir closes. The velocity of the
liquid at the valve stops. The liquid pressure throughout the
pipeline does not change instantaneously. A pressure wave moves
up the pipeline at the sonic velocity of the liquid. The liquid
in front of the pressure wave is moving towards the valve at the
normal rate, the pressure behind the wave is static at the normal
pressure plus the surge pressure.
IN FRONT OF WAVE BEHIND WAVE

V=+10 FT/SEC v=o
P=250 PSI P=735 PSI
<: •
- -
SOURCE > > •
• I I ~V
•• I I I
• V'"
Once the pressure wave has reached the source all of the liquid
in the pipeline has stopped. All of the liquid in the pipeline
is at the surge pressure, higher.than the normal working
pressure.
V=O
-
P-735 PSI
-
SOURCE I I I I I I I I I I ~/
I I I I
V""
Liquid begins to flow out of the pipeline in order to relieve the
excess pressure. Another pressure wave moves towards the valve.
Pressure behind the wave is moving and is at the normal operating
pressure. The liquid in front of the wave is at the surge
pressure and is static.
BEHIND WAVE IN FRONT OF WAVE

V= -10 FT/SEC > V= 0
..-----, p- 250 PSI • P-735
-
I I I ~V
: I
~SOURCE~<____<____:~_I___I___I ___I~V~~___
Ii
6 - 3
Once the pressure wave reaches the valve again all of the liquid
is moving towards the reservoir.
V=-10FT/SEC
P- 250 PSI -,-
-
SOURCE ~ ~ V
-E
"'"
V"'"
The liquid momentum causes a negative pressure wave. From the

valve a pressure wave moves towards the source. Liquid in front
of the wave is moving away from the valve at normal pressure.
Liquid behind the wave is static and at a lower than normal
pressure. The pipeline pressure cannot drop below 0 psia.
IN FRONT OF WAVE BEHIND WAVE

V=-10 FT/SEC v=o
P=250 PSI < • P= -14.7 P
SOURC < < I I

. I
When the wave has reached the source all of the liquid is static
and at a lower than normal pressure.
v=o
P--147PSI
- SOURCE I I I I I I I I I I I I I I I~V
~ ____________ ~V~~_
6 - 4
Liquid begins to flow into the pipeline again to fill the vacuum.
BEHIND WAVE IN FRONT OF WAVE

V 10 FT/SEC
= V=Q
P = 250 PSI P-= -14.7
>
•
DURCE -...,..> -->~ .•• I
•
•
When the wave hits the valve the cycle will be complete and start
over again.
V = 10 FT/SEC
P - 250 PSI
-
~<
-
SOURCE > > :;..
All of the energy is either in pressure or velocity. In a

frictionless pipeline, the cycle described would go on
indefinitely.
6 - 5
6.3 887 SIZING
The general flow formula for 887s is attached (Fig. 6-1). This
formula predicts the liquid flow through the 887 given the set
pressure, the specific gravity, the percent rise above set
pressure, the size of the 887 and the pressure class of the 887.
First use the percent rise over set pressure to solve the F-
factor. The low and medium pressure chart is used for class 150
and 300 units (Fig. 6-2), the high pressure chart is used for the
class 600 units (Fig. 6-3). Draw a vertical line that intersects
the specified % rise over set pressure. The vertical line will
intersect the sloping curves that correspond to each of the
different 887 sizes. Draw a horizonal line through the
intersection and solve the F-factor. With the F-factor solve the
general flow formula for flow. Please note that the F-factor
curves have changed from the old catalog F-factor curves. Only
use F-factor graphs published after 1992. Also, the F-factor
curves represent the average F-factors at any given overpressure.
as derived from a multitude of data points. Good sizing practice
is to select a reliever that can pass at least 15% more than the
minimun required capacity for the application.
There are several other factors that may influence the flowrate
through the 887 (Fig. 6-1), specifically, back pressure,
cavitation, and viscosity. These factors generally do not affect
the fluid flow rate through the 887 although they should be
checked when in doubt.
6.3.1 The Maximum Flow for Optimum Tube Life
This flow formula is based loosely on the maximum allowable fluid

velocity. By using the fluid flow formulas to convert the flow
rate into a velocity, the maximum recommended velocity can be
found. For class 150 and 300 the maximum velocity is 63 to 71
ft/sec. For class 600 the maximum velocity is 49 to 58 ft/sec.
The maximum allowable fluid velocity of the lower pressure
classes is about 35% higher than the high pressure class maximum
velocity. In general it is unsafe to operate liquids at rates
higher than the maximum velocities listed and it is highly
unusual for an application to have a velocity near these rates.
Normally liquid velocities should be held to less than 50 ft/sec.
6.3.2 The Effects of Back Pressure

The flow formula is based on the maximum Cv of the 887 and the
normal liquid flow formula. The C values listed are the maximum
Cv's for each unit.
C = Cv
P differential.
So the formula is equal to:
Q = Cv (Pdifferential. ) /G
6 - 6
SIZING PROCEDURE-FLEXFLO® SURGE RELIEVER
SectIoI11. The o.n...I Flow Fonnul. Section 4. Cevttatlon
U. !he loCIoMng equation lor caleulliling liquid now tIw Model 887 Surge Aallevers. First calcutlile ~P allow. to delennine if cavitation will be pr.-n4.
~
I:l. P allow. - .8 (PlASS' TC Pv) psid.
0- F : (GPM) Where: P allow. - Max I:l. P across val ... wi1hout cavitation psid.
P1ASS- tnlelPress.psia(Ps + PO.P + 14.7)
a - Flow Rat. In U.S. Gallons pet MIn.
Ps - Set Pressure, psIg rc - Critical pressure rlilio lor .....erTc - 0.94 lor other tiquids. See
G - Spedflc o.avity of Uquid appropriate handbook.
F - Flow Factor. See SK·3-465 and SK·3-~
P v _ Vapor pr_e of !towing liquid psi •. See eppropriale handbook.
A
II I:l. P allow. is smaller than the actual I:l. PI P - Ps + pO.P.• P ) lhen cavitation
wi. occur. Cavitation wilt CatJM ina88S4d ~ 11M!! and may or may no4 affect capacity.
s.ctIon 2. Malmum Flow lor OptImum Tube U. Calrutate 0eav. to deler...ne maximum now possible considering the effects 01 cavitation.
a should no4 exceed Ormx lor cases where c1Jty is continuous.

0eav _ C ~ _ _I:l._P_:_Iow_._ _ (GN)
0MA)( _
°L (GPM)
G
Compare Q Cay with °
The actuat IIow witt be the tesser of the two.
VALUES OF 0L
Nominal Size 0L Low & Med Press 0L High Pr855

(Thru 0 300) (0600)
3,100 2,300 Section 5. The EHect. of VlecoeIty.
"6 6,300 5,000
8 11,200 9,000
10 15,500 12,000 Kinematic Viscosity
12 22,500 17,500 Reduce the nowrate (the now at
a given overpressure or the
SSU cs maximum flow rate) by the
(Sa)1xJtt Seconds) (Cent'slokes) 100Iowing percentage
100 21 4%
Section 3. The EHect. of a.ck P.-. __
150 32 6%
200 43 8%
a-.,se of the effects 01 back pressure, flow wilt noI exceed 0e
250 54 10%
(GPM) Use the above table tor approximate corrections for ..;sicosities between 100 and 250 SSU
For V1sicos.ties greater than 250 SSU or tor more precise data at any ";scosity use the
viSCOSIty correction nomograph
Where: Max.mum /tow rate possible where bock pressure .5 Itmrt.ng
U.S. gallons per mtn
P op ~ The overpressure. ie the amounl by wt.ich the actual
pressure upstream of the valve exceeds the set pressure
psid
Ps =. Back Pressure. PS'9
VALUES OF C FOR MClOEl 887
SIZE lOW MEDIUM HIGH

PRESSURE PRESSURE PRESSURE
4 240 240 t61

6 479 479 352
8 850 850 731
10 1177 1177 905
12 1720 t720 1309
FIG. 6-1
6 7
GROVE MODEL 887
SURGE RELIEVER HIGH PRESSURE
F - factor
3~ .---------------------------------------------------------~
"., ".
.. "
".,-
300 - ...................................................................................................................................................................................; ..::;;;-••..................................
-' - . ..",.
_..-.. -- -- --
250 - ., ••• ' • • • • • • < •• > • • • • • • • • - • • • • • • • • • • • • • • • • • • • • • • , •••••••••••••••••••••••••••••• , •••••••••••••••••••• , •••••••••••••••••• , •••••••••••••••••••••••• , •••••••••••••••••• , •••~ '\~.~~
... •••••••• , ••••••••• , ••• , ••• , •••••• , . . . . . . . . . • •• , •••• " ••••••• ,
" .. .". . ".
200 _ .... ... ,........ "." .... "..... "........................ "......................... "..... , .. "' ... .."...
·7-~~··:· .. ·,,······ .. ·· .. ····.. ····· .. ·· .... .... .",.,.,. .",."
..,,-.. ~ ................................., 0"
f .... " " · · ___ --- •• '
150 r- ........................................................... >;...-.,<.-.. ~ ....... ~ . :;;.: . --..~...~ . :::~;: ... >, ....,.,::.~ .... ~ .... : ...
.. ,.,..
-- --
.. '"
",... .. -
:;;..; .... ,,<:.~ .... ;;. .. ;;;....- ...~ ~:.;.:,., .. ,..... :.:.:.:.: ..........................................................................................................~.. ~.. :.:. .~.
100 r- .0- ___ _
"",...
".........
__ --
--..",.,.
.0-
....
__ - - - - - - -
---------
£:{'\ .""".. ~ -- .... ' .. .' or"!. ':":' ~ -. ::.::~.::_: ••-:-: ... •••• • ••••• ..........
........ ~.~ .~.. :-:::.. . . . . . . . . ~~H~~.~~~~
u _ ._._ ~
;JV - ___ • .::. _ _ _ _ _ _
o ~:~:~~:-:~.~.~------------ I I I
I
o 5 10 15 20 25 30
Percent Overpressure
12"
FIG. 6-2
6 - 8
GROVE MODEL 887
, SURGE RELIEVER LOW & MEDIUM PRESSURE
FLOW FACTOR
~ ~----------------------------------------~~~
..........
.'
.. '
.. " .....
. . . . . . . . . . . . . . . . . ........... ...... ......... ..................
",...",../ ~:.< . . ...........................
, 600 -
,..,'
.'
-- - -- - =;,;;.~
.,.,
--
-- - -
,
.". .. ",.' ......
................................................................................./;.~.........................................................._....................................... ..... .. :....... ,.: . .....
400 I----
,., .. ...... .
.,.,
--- .. .. '
- .. ' '
,. .. .. ,
'
- ---- .. .. .. ..
'
'
'." .. '
.. ' .. '
'
- --
- .. '
...... ' ---
-- --
~.. ~.,., ... , .. , ........... , ....... , ..
200 - . ttf'!':0· . ....... " ........ 7 . ...... " ...... " ..... , . . . . ... ~. •••• ."
---
.................................. ,.. ,._ ':" ___ - - fII': _
.... ..... .. , ......... ------

,.,
". ."" --------
.........
..... ....... .
---------
-
o,.:~<i;:i~-c:c~~~~:·- ---------- I
1 I
o 10 20 30 40 50
PERCENT RISE OVER SET PRESSURE
10"
__________ ............... _ _ _ _ _ 00_00_00-
FIG. 6-3
6 - 9
6.3.3 cavitation
This formula is similar to the back pressure formula but limits

the maximum differential pressure across the 887 to the
cavitation differential pressure. The formula assumes that when
the differential pressure is great enough to cause cavitation in
the fluid, the flow will not increase even if the differential
pressure is increased. Although it is desirable to prevent
cavitation it has not been proven that cavitation reduces flow as
described by this formula. Because this formula limits the
maximum flow through the 887, there is no harm in using it. The
more damaging affect of cavitation is cavitation erosion which is
described in section 6.5.
6.3.4 The Effects of Viscosity
The viscosity correction nomograph (Fig. 6-4) is used to account

for reduced flow capacity in Flexflos passing high viscosity
liquids. High viscosity fluids like heavy oils do not flow
through the Flexflo core slots as easily as light fluids like
water. This type of flow restriction is not accounted for in the
normal flow formula. The viscosity correction factor is solved
using the Flexflo size, pressure class, flowrate and fluid
viscosity.
The viscosity correction nomograph should also be used for all

other Flexflos in viscous liquid applications.
6 - 10
Viscosity correction nomograph
HOW TO USE A NOMOGRAPH
IF You KNOW AND WAN T TO
FIND FOR
THE N TO THESE STEPS:
--
en
N
VISCOUS FLOW STEP 1 STEP 2 STEP 3 Z
""o
r ~lever
si ze and tl"\e maximum rellel lind reilEll rale Q as II fluid had negllQlble lind K Irom 'IISCOUS nomograpn. 1oCaI"'9 compu\8
maximum allowable capacity o,.,s VISC05'ry. from formula reiONel' 9Ze on a>aS 1. Q (no( (}..oj on a>os 2. 0... KQ Q
% pressure rise
atx)Ve set pressure
Ps
Q - F..('Ps'I G VlS05iry at operallng COI'IdtIonS at the
relOEN8f on aJ<is 3. and USlI'VJ curve on god.
4
VISCOSITY FACTOR FOR FLOW Ka
S! I! S I! 8 & S S ~ 0 n. §§ ~ 8 § 8 :II
FLEXFLO SELECTION n
EX.TRA HIGH m
PRESSURE
HIGH c
PRESSURE
MEDIUM AND
FLOW
RATE
TURNING c
LOW PRESSURE AXIS :II
I I BARRELS PER OA GALLONS PER m
NOMINAL
VALVE
(BPO) ;;::
21XlOOOO
MINUTE
(GPM) SA YBOL T SECONDS CENTisTROKES
I
SIZE· 'i1
UNIVERSAL (SSU) (CS)
INCHES r
: ~ +II; m
8..:::c 8
I
100000
X
6_ 1 6
eoooo
I!OOOO 'i1
I
40000
30000 r
'3 -+-,
-
I
.1
20000
10000
!!OOO
o®
6000
2-,-I 2
<000
JOOO
(J)
""'"
,.,.,
1000 C
600
"'300" :D
200 G)
100
80 m
110
'0 ,.
)0
:D
m
20 )2
10
•, r
-
m
<
m
:D
FIG. 6-4 4
6 - 11
6.4 Response of the Model 887
The response of a Model 887 is described here for a set pressure

of 150 psi whereby a surge is induced by the rapid closure of a
valve. At the instant the valve is closed, the pipeline pressure
begins to build rapidly. The pipeline pressure briefly exceeds
150 psi and the 887 begins to pass fluid. As the tube expands
the jacket pressure rises slightly and the pipeline pressure
drops to the set pressure of the reliever once the surge relief
flow has passed. As the line pressure is decreases, the jacket
pressure reduces to its original value.
Surge tests on the Model 887's (reference Model 887 ETR-3, 1978)
revealed that the tube begins to open in .030 seconds with the
tube fully open between .100 and .200 seconds.
6.5 CAVITATION DAMAGE
Cavitation damage can occur when liquid is depressurized to the

point that the liquid vaporizes. Normally the liquid pressure
drop and cavitation occur just downstream of the surge reliever.
The liquid vaporizes and quickly becomes liquid again, however
the problem is that when the vapor bubbles form there is a small
explosion which can be very erosive to objects that they corne in
contact with. This is known as cavitation erosion. Any liquid
that is depressurized beyond an allowable differential pressure
will cavitate. The formula for cavitation is:
allowable differential pressure = .8 (P~~ - rcPv)
P1 = absolute inlet pressure

rc = critical pressure ratio
Pv = vapor pressure of liquid
(Note: Consult engineering handbooks for values of rc)
If the actual differential pressure of an system is greater than

the allowable differential pressure there will be cavitation.
In the case of the 887, the outlet flow is directed to the center
of the pipe and the cavitation bubbles form in the center of the
pipe. Because the outlet flow is not directed at any piping or
valve components there is usually no damage to the 887 or piping
even when minor cavitation exists.
There are varying degrees of cavitation. In minor cases

cavitation sounds like gravel is flowing in the piping. In
extreme cases there will be extreme pipe vibration and noise.
There have been 887 cores heavily eroded by cavitation at the
outlet slots and tubes punctured over the inlet section of the
core resulting in a closed failure.
To prevent cavitation in the 887, the differential pressure

across the unit should be reduced. This can be accomplished by
adding back pressure to the reliever during surge relief. A flow
6 - 12
restriction can be installed just downstream of the 887. Size
the restriction so that with the flowrate of a normal surge the
backpressure produced by the restriction will prevent the
allowable differential pressure across the 887 from being
exceeded.
6.6 FLUID VELOCITY VS POTENTIAL SURGE PRESSURE
The potential pressure rise is directly related to fluid

velocity. The table below shows the change in pipeline fluid
velocity and the resulting maximum possible potential surge
pressure. If a crude oil pipeline passing fluid at a velocity of
10 ft/sec was suddenly stopped, the pipeline pressure could
increase by 484.6 psi over the normal operating pressure.
Crude oil
Change in Increase in pressure
velocity (ft/sec) (psi)
3 145.4
5 242.3
7 339.2
10 484.6
15 726.9
20 969.2
25 1,211.6
30 1,453.9
Water
Change in Increase in pressure
velocity (ft/sec) (psi)
3 194.1
5 323.6
7 453.0
10 647.1
15 970.7
20 1,294.3
25 1,617.9
30 1,941.5
Because of the potential pressure rise due to velocity change it

is important to have low pipeline liquid velocity. From a
pipeline design point of view it is much safer to use larger
diameter pipe and have fluid flow at reasonable velocity rather
than use small diameter pipe with high velocity. The kinetic
energy of the fluid in large diameter pipe will be much lower
than the kinetic energy of the fluid in small diameter pipe for
the same flow rate. A 6" pipe must flow at 2.25 times the
velocity of a 12" pipe to pass the same flowrate of liquid.
Conversely it is more economical to build pipelines with high
flowrates and small diameter pipes.
6 - 13
6.7 SURGE RELIEVER PLACEMENT
It is important to place the surge reliever as close as possible

to the source of the surge. The surge source can be any
mechanism that affects the flowrate. If the flow has been
reduced or stopped a pressure wave moves up the pipeline from the
flow restriction. Flow does not have to be completely stopped to
generate a pressure surge. If the surge source and surge
reliever are too far apart the pipe between the surge source and
surge reliever can still be damaged.
As long as the surge reliever is close to and upstream of the

pressure surge source the pipeline will be protected. Most
valves cannot stop flow instantaneously thus the pressure rise is
also not instantaneous. The slower the pipeline fluid velocity
changes, the longer the surge reliever has to react before the
MAOP is exceeded.
The speed of response of the 887 is related to the distance that

the 887 is placed from the surge source (Fig. 6-5). If the surge
reliever is located 100 ft away from the surge source, there is a
time delay between the time that the pressure at the source
exceeds set pressure and the time that the pressure at the surge
reliever exceeds the set pressure. The pressure surge travels up
the pipeline at the sonic velocity of the fluid. For example if
the 887 is installed 100 ft upstream of the surge source, the
pressure wave will take 0.023 second (0.023 = (100 ft)/(4335
ft/sec» to reach the surge reliever, with the pressure wave
traveling at 4335 ft/sec. The 887 will respond to the surge
within .100 second. The total speed of response is 0.123. This
is the time from the start of the surge to the time that the
piping pressure is relieved.
Pressure surges are not generated instantaneously, generally the

source of the surge is a pipeline increasing in pressure at a
specific rate. This can typicallY be anywhere from 50 to 300
psi/sec. In the previous example, if the rate of pressure
increase at the surge source is 200 psi/sec the pressure at the
surge source can rise up to 24.6 psi (29.2 psi = (0.123 sec)(200
psi/sec» higher than the set pressure of the surge reliever
before the 887 responds.
6 - 14
-
~ SOURCE ~ ~ ~ ~ v ~
V~
SPEED OF SOUND IN
CRUDE OIL = 4,335 FTISEC
< .
- ~.
~l(
•
SOURCE ~ ~
: I
I I
•
I I
•
,..----t
TIME DELAY = .123 SEC H
OURCE ~
H TIME DELAY = 2.3 SEC
OURCE I I I I I I I I I I I I
I
1<, 10,000 Ff ~I
FIG. 6-&
6 - 15
6.8 SPEED OF RESPONSE
The speed of response in a surge reliever can be critical to the

prevention of surge damage. Surges can reach their maximum
potential pressure quickly. The above examples have assumed
instantaneous pressure rise, in actuality the pipe pressure
increases at a given rate. A typical surge can increase pipe
pressure at a rate of 200 psi/sec. It is always better to have a
faster acting surge reliever.
For example a surge reliever that responds within .1 sec will be

able to respond to a 200 psi/sec surge when the pressure has
risen 20 psi above the set pressure while a surge reliever that
has a 1 second response time will allow the pipe pressure to
exceed the set pressure by 200 psi before responding. The faster
response time can make the difference between pipe protection and
damage.
If the surge pressure 'rate of rise can be controlled and reduced,

a fast rate of response surge reliever is not required. The rate
of rise of the surge source affects the required response time
but does not affect the maximum potential surge pressure. The
same maximum surge pressure is reached when flow is completely
stopped regardless of shutoff sp~ed.
6.9 SAMPLE 887 SIZING PROBLEM
The following is a surge relief slzlng to prevent the pipeline

pressure from exceeding the maximum allowable pressure. The
sizing procedure does the following:
1) Determines the potential pressure rise.

2) Determines the required flowrate to keep the pipeline
pressure below the MAOP.
3) Selects a suitable surge reliever for the application.
Problem specifications:
fluid Oil
specific gravity 0.86
bulk modulus 31,320,000 lb/ft 2
maximum flow rate 6,000 GPM
pipe line 10 10 inches
relief set pressure 500 psi

maximum allowable pressure 575 psi
maximum normal pipe pressure 450 psi
6 - 16
Physical Characteristics of Liquids at 60°F
LIQUID SPECIFIC BULK MODULUS SONIC
GRAVITY ELASTICITY VELOCITY
(lb/ft2) (ft/sec)
Benzene 0.88 21,924,000 3,586
Glycerin 1. 26 92,498,400 6,155
Kerosine 0.804 27,561,600 4,206
Mercury 13.57 547,056,000 4,561
Oil 0.86 31,320,000 4,335
Water Fresh 1.0 45,727,200 4,858
Water Sea 1.025 47,397,600 4,885
1) Sonic Velocity of Liquid
a = 1 = (g) (k)
(w/g) (l/k) w
w = sg x 62.4 (lb/ft3 )
0.86 x 62.4
53.66 lb/ ft 3
9 = 32.2 ft/s2
k = 31,320,000 lb/ft 2
a = (32.2) (31,320,000)
(53.66)
a = 4,335 ft/sec
2) Fluid Velocity
v = .002228 x Q(gpm)
A (ft2)
Q = 6,000 gpm
A = Pi/4 (10)2
10 = 10 in = 10/12 ft = .8333 ft
A = (3.1416/4) (0.8333)2 = .5454 ft2

v = (.002228) (6,000)
.5454
v = 24.51 ft/sec
6 - 17
3) Maximum Potential Surge Pressure
H = a v
g
H = (4,335) (24.51)
32.2
H = 3,300 ft = (3,300 ft) (.4335 psi/ft) (.86)
H = 1,230.2 psi
4) Maximum Potential Pipeline Pressure
Pmax = Pinlet max + H
Pmax = 450 + 1,230.2
Pmax = 1,680.2 psi
5) Potential Rise Above the Maximum Allowable Pressure
P above maximum allowable = Pmax - Pmaop

= 1,680.2 - 550
= 1,1;30 psi
This is the potential pressure that can be generated if flow
is stopped instantaneously without a surge protection
device.
6) Surge Relief Flow Rate Required to Keep Pipeline Pressure

Below the MAOP
If enough fluid is removed from the pipeline at the surge

source the maximum operating pressure will not be exceeded.
The required amount of fluid is determined by:
Q = (A) (V) / • 002228
A = 0.5454 ft2
P = (1,130 psi)/«.4335 psi/ft) (.86»
3,031 ft
V = (P) (g) /a
(3,031) (32.2)/4,335
22.51 ft/sec
Q = (0.5454) (22.51)/.002228
5,511 GPM
6 - 18
7) Surge Relief Sizing
Size a relief valve based on set pressure, maximum allowable pressure

and required fluid to be removed to prevent MAOP from being exceeded.
Q (F) (Pset)/sg
F (Q)(sg)/Pset
(5,511 gpm)(.86)/(500 psi)
229
The allowable % rise over set pressure = 575/500 - 1 = 15%
On the F-factor graph (Fig. 6-2) intersect an F = 229 horizontal line

with a 15% rise over set pressure vertical line. Select a surge
reliever that has a flow curve higher than the intersection point of the
drawn lines. In this case a 12" 887 class 300 will have the required
capacity to prevent any possible pressure surge.
6 - 19
SECTION 7 SPECIALTY REGULATORS
7.1 PRESSURE REDUCING HANDLOADER REGULATORS
7.2 MODEL 15
7.3 MODEL 16
7.4 BACKPRESSURE HAND LOADER REGULATORS
7.5 PRESSURE REDUCING DOME REGULATORS

7.6 BACKPRESSURE DOME REGULATORS
7.7 DOME LOADING METHODS
7.8 VALVE PERFORMANCE
7.9 APPLICATION Cv
7.10 SIZING METHODS
7
SECTION 7 SPECIALTY REGULATORS
This section describes the operation of Grove specialty

regulators. The specialty regulators include: Handloaders, Mity
Mites, and Powreactors. These units tend to be used for high
pressure, low flow applications. Because the units are generally
designed to withstand class 1500 and 2500 pressures they are
extremely durable. Unlike the Flexflos, all specialty regulators
are made for high pressure service but will work equally well in
low pressure applications.
7.1 PRESSURE REDUCING HANDLOADER REGULATORS
Grove pressure reducing handloader regulators are low capacity

high pressure regulators that adjust outlet pressure through a
handwheel. By turning the handwheel clockwise the outlet
pressure is increased, by turning the handwheel counterclock-wise
the outlet pressure is decreased. The handwheel mechanically
compresses or decompresses the internal spring of the regulator.
The spring compression applies force to the top of the diaphragm.
The position of the diaphragm determines if the internal valves
are open or closed. The spring force pushes down on the
diaphragm opening the valve between the inlet and outlet of the
regulator. The bottom side of the diaphragm is exposed to the
outlet pressure. The outlet pressure pushes up on the diaphragm
allowing the internal valve to close.
Normally when a loader is first installed the handwheel is turned

fully counter clock wise and the internal valve is closed, no
fluid is passing through the unit. Inlet pressure is applied and
the handwheel is turned clockwise compressing the spring and
opening the internal valve. Fluid passes through the regulator
(Fig. 7-1). As fluid fills the outlet piping of the regulator
the outlet pressure builds. When the outlet pressure exerts
enough force against the bottom of the diaphragm the spring force
is overcome and the diaphragm moves up closing the internal valve
(Fig. 7-2). If the handwheel is further turned clockwise the
cycle is repeated.
7.1.1 Outlet Pressure Range

A number of different outlet pressure ranges are available. Each
of the different ranges uses a different spring. Light springs
(i.e., those with low spring rates) are used for lower control
ranges than heavier springs with high spring rates. The lighter
spring will control the outlet pressure more accurately. It is
best to use a hand loader regulator with a control range just
above the maximum required outlet pressure.
7.1.2 Valve and Diaphragm Sizes

There are two different diaphragm sizes and valve sizes
available. Low pressure units use a larger diaphragm (2"
diameter) and high pressure units use smaller diaphragms (1 1/4"
diameter). Larger diaphragms are more accurate than the smaller
diaphragms. The valves are 3/64" and 3/32" in diameter. Smaller
7 - 1
REDUCING VALVE OPEN
RELIEF VALVE CLOSED
HANDWHEEL - -
SPRING---i-~
RELIEF VALVE --t--:::jl:+--':~
~~~~ OUTLET
REDUCING VALV
FIG. 7-1
7 - 2
REDUCING VALVE CLOSED
p"G.UEF VALVE CLOSED
. ..................
...........................
............................ ..........................
.......................... . ................. . .
.........................................................
.......................................................
............................
.............................
............................. ..........................
..........................
.......................... .........................................................
........................................................
............................................................ .. ,-
.............................
............................. ..........................
.......................... ............................................................
.........................................................
~~ ~ ~ ~~ ~;~ ~ ~ ~; ~;~~; ~~~~~~ ~ ~~ ~ ~ ~ ~~ ~~;; ~~ ~;~ ~;~ ~ ~ ~ ;~~ ~ ~~~; ~ ~~~ ~~~; ~ ~; ~ ~ ~ ~~~ ~ ~ ~ ~~~~ ~~ ~ ~ ;~~~ ~~ ~ ~~~ ~ ~;~ ~ ~ ~~~ ~~~~~~ ~ ~ ~ ~ ~~
::::::::::::::::::::::::::::: :::::::::::::::::::::::::: :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
HANDWHEEL --~~
:::::::::: ..
SPIUNG ___----t---t\
RELIEF VAL VE/-~~_,i

DIAJlIIRAGM
OUTLET
REDUCING VALVB
FIG. 7-2
7 - 3
valves are more accurate but have a smaller flow capacity. The
small valve is designated with an "X" at the end of the model
number, for example 15LHX.
7.2 MODEL 15
The Model 15 is a pressure reducing and relieving regulator. If

the outlet pressure is above the set pressure the internal relief
valve opens allowing fluid from the outlet side of the regulator
to pass through to atmosphere through the spring barrel (Fig. 7-
3). By venting outlet fluid the outlet pressure will decrease.
The model 15 is ideally suited for controlling the pressure
within a fixed or static volume (dome of a Powreactor regulator,
the jacket port of a Grove Model 887 Surge Reliever, etc). The
Model 15 can be used for both gasses and liquids however the
relief valve vents pipeline fluid directly into the spring barrel
area. Liquids can fill the spring barrel and eventually leak out
of the unit.
It is not always desirable for the gas vented by the relief valve
to be exposed to the atmosphere. The Model 15 has a pipe away
relief option. The spring barrel is completely sealed and the
relief gas can be passed to a remote location by connecting
tubing to a 1/4" NPT fitting in the side of the spring barrel.
7.3 MODEL 16
The Model 16 is a pressure reducing regulator only. The

difference between the Model 15 and Model 16 is that the Model 16
does not have a relief system. The absence of the internal
relief makes the Model 16 less suitable for static applications
(i.e., loading the dome of regulator) than the Model 15. In a
static pressure application with the Model 16, turning the
handwheel counterclockwise causes the internal valve to shut
thereby trapping the pressure in the outlet leg. In order for
the outlet leg pressure to be reduced, there must be a vent path
installed in the outlet leg to vent trapped pressure. Pressure
can then be increased again by turning the handwheel clockwise.
(See paragraph 7.7.3 for further comparison with the Model 15.)
The Model 16 is best suited for applications where the fluid

media is flowing. Turning the handwheel counterclockwise in a
flowing application will reduce outlet pressure without having to
install a special vent path.
7.4 BACK PRESSURE HANDLOADER REGULATORS
The back pressure handloader regulators, Models 153 and 155,

control upstream pressure by allowing fluid to pass through the
unit when the inlet pressure exceeds the set pressure of the
unit. When the inlet pressure is below the set pressure the
regulator is closed. The internal mechanics of a back pressure
regulator are different than a pressure reducing regulator.
7 - 4
REDUCING VALVE CLOSED
RELIEF VALVE OPEN
HANDWHEEL -----..I~
SPRING ---t---.c-
RELIEF VALVE --+---l.

~r?J"~U-~~~
REDUCING VAL
FIG. 7-3
7 - 5
BACKPRESSURE VALVE OPEN
PRESSURE COMPRESSES
SPRING. VALVE OPENS
FIG. 7-4
7 - 6
. . JNl.ET<PSeT
BACKPRESSURE VALVE CLOSED
PRESSURE DOES NOT EXCEED

SPRING FORCE. VALVE IS
CLOSED.
FIG. 7-5
7 - 7
Inlet pressure is exposed to the bottom of the diaphragm and
exerts an upward force. The hand wheel adjusted spring force
pushes down on the diaphragm. For back pressure regulators when
the spring force is greater than the force exerted by inlet gas
pressure, the diaphragm is pushed down and the internal valve is
closed (Fig. 7-4). When the inlet pressure exceeds the spring
force the diaphragm is pushed up and the internal valve opens
venting fluid through to the outlet side (Fig 7-5).
The Model 153 has a maximum Cv of 0.17 and the Model 155 has a
maximum Cv of 0.04.
7.5 PRESSURE REDUCING DOME REGULATORS
Dome regulators use gas pressure instead of spring force to push

down on the diaphragm establishing an outlet set pressure. If
the outlet pressure is below the dome pressure the diaphragm is
pushed down opening the internal valve (Fig. 7-6). If the outlet
pressure is above the set pressure the diaphragm is pushed up
allowing the internal valve to close (Fig. 7-7). The dome plate
is a barrier between the dome volume and the diaphragm. It acts
as a stop for the diaphragm and prevents it from being
excessively stretched when the outlet pressure is greater than
the dome pressure. At the center of the dome plate is a small
hole that restricts gas as it passes from the volume above the
diaphragm to the dome volume. This orifice acts as a dampening
device, preventing the diaphragm from moving too quickly damaging
the moving components.
7.5.1 Unbalanced Valves (Fig. 7-8)

Unbalanced valves are used on all Grove Handloaders, Mity Mites
and Powreactor regulators that have a "0" as the second digit in
their model number, for example "202G". The unbalanced valve has
inlet pressure under the valve and outlet pressure over the
valve. Because the inlet pressure is always greater than the
outlet pressure the valve is always trying to be closed by the
forces within the regulator. The higher the inlet pressure the
greater the force required to open the valve. The outlet
pressure is affected by the inlet pressure. without changing the
set pressure, if the inlet pressure increases, the outlet
pressure will decrease. Conversely if the inlet pressure
decreases, the outlet pressure will increase. The larger the
orifice size and the smaller the diaphragm size the greater the
affect of inlet pressure. See Unbalanced Effect in the valve
performance section.
7.5.2 Balanced Valves (Fig. 7-9)

The balanced valve is used on Powreactor regulators that have a
"1" as the second digit in their model number for example "311B".
The balanced valve is designed such that outlet pressure exists
above and below the internal valve. The force required to open a
balanced valve is less affected by the inlet pressure. Thus the
outlet pressure is not affected by changes in inlet pressure.
7 - 8
TYPICAL POWREACTOR REGULATOlt
IN OPEN AND CLOSED MODES
DIAPHRAGM
DOWN POSITIO
PDOMB > p OUlLET

VALVEOPEN
INLET
V'ALVE
DOWN/OPEN
FIG.; 7-6
DIAPHRAGM
UP POSITION
PDOME < POUlLET

VALVE CLOSED
VALVE
UP/CLOSED
FIG. 7-7
7 - 9
UNBALANCED VALVE
THE "UNBAlANCED" DESIGN

HAS OUfLET PRESSURE ON
THE TOP OF THE VALVE AND
UPSTREAM PRESSURE ON
THE BOlTOM OF THE VALVE.
FIG. 7-8
BALANCED VALVE
THE "BALANCED" DESIGN

HAS DOWNSTREAM
~~~ PRESSURE ON EITHER SIDE
OF THE VALVE.
FIG. 7-9
EXTERNAL SENSE
CONNECT TO DOWNSTREAM
PIPING WHERE FLOW IS NOT
TURBULENT
INLET
INTERNAL SENSE
PORT IS PLUGGED
FIG. 7-10
7 - 10
7.5.3 External Sense (Fig. 7-10)
The pressure of the gas volume under the diaphragm is called the
sense pressure. Because the sense pressure is connected to the
outlet pressure within the regulator the unit is "internal
sensing". There are some applications that require the sense
pressure to be external to the regulator. If there is a high
pressure drop across the regulator there can be turbulence at the
outlet port of the regulator causing inaccurate sensing of the
true outlet pressure. The 202B, 212B, 301B, 311B, 402F, 412F and
411B Powreactors can be changed to external sense by plugging the
internal sense passage and connecting tUbing between the sense
volume and downstream piping. The advantage is that the flow
downstream of the regulator can be less turbulent allowing more
accurate control of outlet pressure.
7.5.4 Helium and Hydrogen Service

Because helium and hydrogen have a very low viscosity/density
they are not dampened sufficiently with the standard dome
orifice. A special extra small dome orifice should be considered
when using a Powreactor regulator in either helium or hydrogen
gas service.
7.5.5 Old Pressure Reducing Dome Regulators

occasionally a customer will find an old Grove dome regulator and
want to know information about the unit. The old design is very
similar to the existing Powreactors. Table 7-1 lists all of the
old units and specifies the pressure ratings, end connection
sizes, orifice size and maximum cv. There are a few variations
in the model number lettering that can change the description of
the regulator. If the letter "W" is located in place of the "G",
like WBX-204-KI5 then the regulator is externally loaded only and
does not have dome loading needle valves. If the letter "R" is
located in place of the "G", RB-206-K3 then the regulator has two
sets of dome loading needle valves. Because these units are
obsolete it can be difficult to get spare or replacement parts.
7.6 BACK PRESSURE DOME REGULATORS
Grove back pressure dome regulators are upstream pressure

controlling mechanisms. The diaphragm also acts as the valve
seal and is the only moving part. The dome pressure force pushes
down on the diaphragm trying to close the valve. The inlet fluid
pressure is exposed to the bottom of the diaphragm working to
open the valve. If the inlet pressure is greater than the dome
pressure the diaphragm moves up opening the internal valve (Fig.
7-11). If the dome pressure is greater than the inlet pressure
the diaphragm is pushed down sealing the internal valve (Fig. 7-
12).
7.7 DOME LOADING METHODS
There are several methods of accurately controlling the set

pressures of Grove dome regulators: internal loading needle
7 - 11
OLD POWREACTOR REGULATORS
MAXIMUM CONNECTION ORIFICE
UNIT INLET/OUTLET PIPE SIZE SIZE MAX Cv
08204 K2 1,000/1,000 11"'
1"-1" 1/4" 1.0 I
08204 K3 1,000/1,000 1/2" 3/8" 2.0
08204 K4 1,000/1,000 1/2" 1/2" 3.3
08205 K2 1,000/1,000 3/4" 1/4" 1.0
08205 K3 1,000/1,000 3/4" 3/8" 20
08205 K4 1,000/1,000 3/4" 1/2" 3.3
OB206 K2 1,000/1,000 1" 1/4" 1.0
08206 K3 1,000/1,000 1" 3/8" 20
08206 K4 1,000/1,000 1" 1/2" 3.3
08305 [(2j 1,000/1,000 3/4" 5/16" 1.8
08305 K3 1,000/1,000 3/4" 3/8" 26
08305 K4 1,000/1,000 3/4" 1/2" 4.4
08305 K5 1,000/1,000 3/4" 3/4" 8.6
08306 K25 1,000/1,000 1" 5/16" 1.8
OB306 K3 1,000/1,(0) 1" 3/8" 2.6
08306 K4 1,000/1,000 1" 1/2" 4.4
08306 K5 1,000/1,000 1" 3/4" 8.6
OB306 K6 1,000/1,000 - 1" 1" 11.0
08307 K25 1,000/1,000 1 1/4" 5/16" 1.8
GB307 K3 "1,OOOil ,()()() 11/4~ 3/Pl 2.6
08307 K4 1,000/1,000 11/4" 1/2" 4.4
08307 K5 1,000/1,000 1 1/4" 3/4" 8.6
08307 K6 1,000/1,000 1 1/4" 1" 11.0
08308 K25 1,000/1,000 1 1/2" 5/16" 1.8
08308 K3 1,000/1,000 11/2" 3/8" 2.6
08308 K4 1,000/1,000 1 1/2" 1/2" 4.4
08308 K5 1,00011,000 11/2" 3/4" 8.6
08308 K6 1,000/1,000 1 1/2" 1" 1!~
TABLE 7-1
7 - 12
MAXlMUM CONNECfI0N ORIFICE
UNIT INLET/OUTLET PIPE SIZE SIZE MAXCv
GI3X 204 K15 3,500/1,500 1/2" 3/16" 0.7
GBX204 K2 3,500/1,500 1/2" 1/4" 1.2
GBX204 K25 3,500/1,500 1/2" 5/16"
- ..- - _.-_.-_. --- 1 - - " ' - - - - - - . - - -..- - .. ---.---- - ..--- ----- - .. _------- 1.5
, .. '--'---
GBX204 K3 3,500/1,500 1/2" 3/8" 24
GBX205 K15 3.500/1,500 3/4" 3/16" 0.7
GI3X 205 K2 3,500/1,500 3/4" 1/4" 1.2
GBX205 K25 3,500/1 ,500 3/4" 5/16" 1.5
GBX205 K3 3,500/1,500 3/4~ 3/&~ 2.4 ---
1----
GBX206 K15 3,500/1,500 1" 3/16" 0.7
GBX206 K2 3.500/1,500 1N 1/4" 1.2
GI3X206 K25 3,500/1,500 1" 5/16" 1.5
GBX206 K3 3,500/1 ,500 1" 3/8" 24
GBX305 K2 - 3,500/1,500 3/4" 1/4" 1.2
GBX305 K25 3,500/1 ,500 3/4" 5/16" 21
GBX305 K3 3,500/1,500 3/4" 3/8" 29
GBX305 K4 3,500/1,500 3/4" 1/2" 4.4
GBX306 K2 3,500/1,500 1" 1/4" 1.2
GBX306 K25
1---.
3,500/l,500 1" 5/16" 21
GBX306 K3 3,500/1,500 1" 3/8" 29
GBX306 K4 3.500/1.500 1" 1/2" 4.4
GBX307 K2 3.500/1 ,500 - 11/4" 1/4" 1.2
GBX307 K25 3,500/1,500 11/4" 5/16" 21
GBX307 K3 3,500/1,500 . - -_.----_. 11/4" __. 3/8" .- 29
r---
GBX 307 K4 3,500/1,500 11/4" 1/2" 4.4
GBX308 K2 3,500/1,500 11/2" 1/4" 1.2
GBX308 K25 3,500/1,500 1 1/2" 5/16" 2.1
GBX308 K3 3,500/1,500 11/2" 3/8" 2.9
GBX308 K4 3,500/1,500 11/2" 1/2" 4.4 - -
TABLE 7-1
7 - 13
MAXIMUM CONNECTION ORlFICE
UNIT INLET/OUTLET PIPE SIZE SIZE MAX Cv
OS 408 K3 1,000/1,000 1 1/2" 3/8" 2.6
OS 408 K4 1,000/1,000 1 1/2" 1/2" 4.0
OS 408 K5
'---- ----------- _.-
1,000/1,000 1 1/2" 3/4"
----_..- ---'---"- - ---- --------- ------- .--------- 10.0
------~-----
OS 408 K6 1,000/1,000 11/2" 1" 12.0

GS410 K3 1,000/1,000 2" 3/8" 2.6
OS 410 K4 1,000/1,000 2" 1/2" 4.0
OS 410 K5 1,(0)/1,000 2" 3/4" 10.0
OS 410 K6 1,000/1,000 2'" 1" 120
OS 410 K8 1,000/1,000 2" 11/2" 20.0
OS 428 K3 1,500/1 ,500 1 1/2" 3/8" 26
OS 428 K4 1,500/1,500 1 1/2" 1/2" 4.0
OS 428 K5 1,500/1 ,500 11/2" 3/4" 10.0
OS 428 K6 1,50011,500 11/2" 1'" 120
OS 430 K3 1,500/1,500 2" 3/8" 26
OS 430 K4 1,500/1 ,500 2" 1/2" 4.0
OS 430 K5 1,500/1 ,500 2" 3/4" 10.0
GS430 K6 1,500/1,500 2" 1" 12.0
OS 430 K8 1,500/1,500 2" 11/2" 20.0
OS 448 K3 3,500/1,500 1 1/2" 3/8" 2.6
GS448 K4 3;500/1.500 1 1/2" 1/2" 4.0
-
OS 448 K5 3,500/1,500 1 1/2" 3/4" 10.0
OS 448 K6 3,500/1~500 1 1/2" 1" 12.0
OS 450 K3
r-----
3,500/1,500 2" 3/8" 2.6
-'-
OS 450 K4 3,500/1,500 2" 1/2" 4.0
OS 450 K5 3.500/1.500 2" 3/4" 10.0
OS 450 K6 3,500/1,500 2" 1" 12.0
OS 450 K8 3,50011 ,500 2" 1 1/2" 20.0
OH408 K3 6,000/3,000 1 1/2" 3/8" 26
OH408 K4 6,000/3,000 1 1/2" 1/2" 4.0
OH408 K5 6,000/3,000 11/2" 3/4" 10.0
OH 408 K6 6,000/3,000 1 1/2" 1" 12.0
TABLE 7-1
7 - 14
·. BACK_PRESS.URE
MITY MITE REGULATORS
PnOME > PINlET

VALVE CLOSED
INLET
OUTLET
FIG. 7-11
PDOME < P1NLET

VALVE OPEN
INLET ~
OUTLET
FIG. 7-12 7 _ 1 t:;

INTERNAL LOADING
NEEDLE VALVES
r-
DOME
OPEN mp AND BOITOM NEEDLE ,....
VAI..VES TO ALLOW GAS FROM nm
INLET m 1HE DOME, INCREASING
Ir I
1HE SET PRESSURE
L....
~~
~
~
§~
CWSE BOTTOM NEEDLE VAI..VE

AND OPEN TOP NEEDLE V AI..VB "'--
DOME
TO VENT 1HE DOME PRESSlJRE, .... "'"
REDUCING 1HE SET PRESSURE
~
II ~
.....
~
.....
If
tf~
t:::
~
~
~
CLOSE Born NEEDLE VALVES TO
LOCK IN THE SET PRESSURE
FIG. 7-13
7 - 16
valves, loadinq manifold, handloader and electronic control
mechanisms. -
7.7.1 Internal Loadinq Needle Valves (Fiq. 7-13)

The internal loading mechanism is an integrai part of the
following Grove regulators model 94, 112B, 112BR, 202G, 212B,
302G, 402E and 412E. Two needle valves control the dome pressure
using the inlet gas. with both valves open gas passes from the
inlet to the dome increasing the set pressure. with the lower
valve closed and the upper valve open, gas passes from the dome
to atmosphere decreasing the set pressure. Once the desired set
pressure is reached both valves are closed and the dome pressure
is locked in.
7.7.2 Loading Manifold (Fig. 7-14)

Loading Manifolds consist of a loading and venting valve
connected between a high pressure source and the dome of the
regulator. The set pressure is controlled by slowly opening the
load valve until the desired outlet pressure is attained then
sealing this pressure in the dome. If the dome pressure is too
high the pressure can be reduced by opening the vent valve. By
slowly pressurizing and depressurizing the dome, the correct
outlet pressure can be attained.
7.7.3 Handloader (Fig. 7-15)

A Model 15 can be connected directly between a high pressure gas
source and the dome of the regulator. By turning the handwheel
clockwise the dome pressure is increased and by turning the
handwheel counterclockwise the dome pressure is decreased. This
method also compensates for variations in dome gas temperature.
As gas is heated it expands increasing dome pressure. The Model
15 vents gas out of the dome if the set pressure is exceeded and
adds gas to the dome if the gas cools and contracts. This
mechanism is more accurate than the manifold loading method.
7 - 17
LOADING MANIFOLD
VENT
VALVE
CYllNDER SUPPLY
VALVE VALVE
DOME
TO HlOH PRESSURE
OASSUPPLY
OPERATION
OPEN SUPPLY AND CYllNDER VALVES,
CLOSE VENT VALVE TO INCREASE DOME
PRESSURE
OPEN VENT AND SUPPLY VALVEs, CLOSE
CYUNDER VALVE TO DECREASE DOME
PRESSURE
CLOSE All VALVES TO LOCK IN DOME
PRESSURE
FIG. -7-14
HANDLOADER
DOME
MODEL 15
TO HIOH PRES SUR E

OASSUPPLY
OPERATION
TIJRN HANDWHEEL CLOCKWISE TO
INCREASE DOME PRESSURE
TIJRN HANDWHEEL COUNTER CLOCKWISE
TO DECREASE DOME PRESSURE
FIG. 7-15
7 - 18
AVAILABLE PRESSURE REDUCING
HANDLOADER REGULATORS
OUTLET
MAXIMUM PRESSURE OUTLET RISE AVERAGE
INLET CONTROL RELIEF MAXIMUM PER 1,000 PSI LOCKUP
MODEL PRESSURE RANGE SYSTEM Cv INLET DROP PSI
15L 6,000 0-25 YES 0.06 3.0 1.7
16L 6,000 0-25 NO 0.06 3.0 1.7
15LX 6,000 0-25 YES 0.018 1.0 1.7
16LX 6,000 0-25 NO 0.018 1.0 1.7
15L 6,000 0-60 YES 0.06 3.0 1.7
16L 6,000 0-60 NO 0.06 3.0 1.7
15LX 6,000 0-60 YES 0.018 1.0 1.7
16LX 6,000 0-60 NO 0.018 1.0 1.7
~----
0-150
---- -----
15L 6,000 YES 0.06 3.0 1.7
16L 6,000 0-150 NO 0.06 3.0 1.7
15lX 6,000 0-160 YES 0.018 1.0 1.7
16LX 6,000 0-160 NO 0.018 1.0 1.7
16L 6,000 0-300 YES 0.06 6.4 3.0
16L 6,000 0-300 NO 0.06 5.4 3.0
15LX 6,000 0-300 YES 0.018 1.8 3.0
16LX 6,000 0-300 NO 0.018 1.8 3.0
15L 6,000 0-760 YES 0.06 11.0 6.0
16L 6,000 0-750 NO; 0.06 11.0 6.0
6,000 0-750 YEa 0.018 3.7 6.0
- 15LX
- 0-750
- -
3.7 6.0
16LX 6,000 NO 0.018
15LH 6,000 0-1,000 YES 0.06 16.0 9.0
---- --
16LH 6,000 0-1,000 NO 0.06 16.0 9.0
~~LHX 6,000 0-1,000 YES 0.018 6.5 9.0
16LHX 6,000 0-1,000 NO 0.018 6.5 9.0
15LH 6,000 0-2,000 YES 0.06 33.0 19.0
16LH 6,000 0-2,000 NO 0.06 33.0 19.0
16LHX 6,000 0-2,000 YES 0.018 11.0 19.0
16LHX 6,000 0-2,000 NO 0.018 11.0 19.0·
15LH 6,000 0-3,100 YES 0.06 33.0 19.0
16LH 6,000 0-3,100 NO 0.06 33.0 19.0
-
15LHX 6,000 0-3,100 YES 0.018 11.0 19.0
6,000
16LHX
1--.--- -0-3,100
- - - - -NO----
0.018 11.0 19.0
--
15KX 6,000 0-2,000 YES 0.018 6.9 12.0
1610(. 6,000 0-2,000 NO 0.018 6.9 12.0
15KX 10,000 0-2,000 YES 0.018 6.9 12.0
1610< 10,000 0-2,000 NO 0.018 6.9 12.0
15KX 6,000 0-3,500 YES 0.018 6.9 12_0
161<X 6,000 0-3,500 NO 0_018 6.9 12.0
>-----
1510< 10,000 0-3,500 YES 0.018 6.9 12.0
161(X 10,000 0-3,500 NO 0.018 6.9 12.0
151(X
1----.
6,000 0-6,000 YES 0.018 6.9 12.0
1610< 6,000 0-6,000 NO 0.018 6.9 12.0
15KX
--.---
10,000 0-6,000 YES 0.018 6.9 12.0
------ ------- . _ - - - - - - - -
1610< 10,000 0-6,000 NO 0.018 6.9 12.0
TABLE 7-2
GROVE PRESSURE REDUCIN( ,")OME REGULATORS
MAXIMUM MAXIMUM OUTLET RISE AVERAGE INTERNAL EXTERNAL

DIAPHRAGM INLET OUTLET ORIFICE MAXIMUM PER 100 PSI LOCKUP LOADING SENSING VALVE
MODEL SIZE PRESSURE PRESSURE SIZE Cv INLET DROP PSI OPTION OPTION TYPE
94 2" 5,000 3,000 3/32" 0.14 0.41 1.0 YES NO UNBALANCED
94 2" 5,000 3,000 3/16" 0.65 2.3 6.1 YES NO UNBALANCED
112B 2'" 6,000 6,000 3/16" 0.50 0.3 7.1 YES NO BALANCED
112BR 2" 6,000 6,000 3/16" 0.50 0.18 7.1 YES NO BALANCED
202B 3" 6,000 6,000 3/16" 0.70 0.94 2.6 YES YES UNBALANCED
202B 3" 6,000 6.000 1/4" 1.40 1.5 3.3 YES YES UNBALANCED
202B 3" 6,000 6,000 5/16" 1. 50 2.2 4.0 YES YES UNBALANCED
202B 3" 6,000 6,000 3/8" 2.30 2.6 4.4 YES YES UNBALANCED
212B 3" 6,000 6.000 1/2" 4.0 0.92 6.7 YES YES BALANCED
202G I 3" 3.500 3.000 3/16" 0.7 0.94- 2.6 YES NO UNBALANCED
202G 3· 3,500 3,000 1/4" 1.2 1.5 3.3 YES NO UNBALANCED
202G 3" 3,500 3,000 5/16" 1.5 2.2 4.0 YES NO UNBALANCED
202G 3" 3,500 3.000 3/8" 2.4 2.6 4.4 YES NO UNBALANCED
,
202G 3· 3,500 3,000 I 1/2" 3.4 '5,0 6.0 YES NO UNBALANCED
301 B 5" 6.000 6.000 3/8" 2.4 0.99 1.5 .NO YES UNBALANCED
301 B 5" 6,000 6,000 1/2" 5.0 1.6 1.9 NO YES UNBALANCED
301 B 5" 6,000 6,000 3/4'" 10.7 3.5 2.9 NO YES UNBALANCED
311 B 5,0 6,000 6,000 1" 12.4 0.75 3.7 NO YES BALANCED
311 B 5" 6.000 6,000 1 1/2" 26.0 1.0 8.0 NO YES BALANCED
302G 5,0 3,500 2,000 3/8" 2.4 0.99 1.5 YES NO UNBALANCED
302G 5,0 3,500 2,000 1/2" 4.4 1.6 1.9 YES NO UNBALANCED
302G 5" . 3,500 2,000 3/4" 8.6 3.5 2.9 YES NO UNBALANCED
302G 5" 3,500 2,000 1" 11.0 5.9 3.7 YES NO UNBALANCED
402E 73/4" 6,000 3,000 1/2" 4.0 0.62 0.8 YES NO UNBALANCED
402E 73/4" 6,000 3,000 3/4" 10.0 1.4 1.1 YES NO UNBALANCED
402E 73/4" 6,000 3.000 1" 12.0 2.3 1.5 YES NO UNBALANCED
412E 73/4" 3,600 3.000 1 1/2" 20.0 0.55 2.2 YES YES BALAN(;ED
402F 73/4" 6,000 3,000 1/2" 4.0 0.62 0.8 YES YES UNBALANCED
402F 73/4" 6.000 3,000 3/4'" 10.0 1.4 1.1 YES YES UNBALANCED
402F 73/4" 6,000 3,000 1'" 12.0 2.3 1.5 YES YES UNBALANCED
412F 73/4" 3,600 3,000 1 1/2'" 20.0 0.55 2.2 YES YES BALANCED
411 B 73/4· 6.000 6,000 2 1/2" 69.0 0.65 5.1 NO YES BALANCED
TABLE 7-3
7 - 20
7.7.4 Electronic Control Mechanism
Electronic control mechanisms can be used to precisely control

the dome and outlet pressure of a Powreactor regulator. Two
solenoid valves increase or decrease the dome pressure. The two
valves are the load and vent solenoids. The load solenoid
connects a high pressure gas source to the dome. The vent
solenoid connects the dome to atmosphere. The mechanism also
allows remote control of the set pressure via an electronic
signal. The dome pressure is monitored by a pressure transducer.
When the unit is operating the reference set pressure signal is
compared to the pressure transducer signal. If the dome pressure
is above the set pressure (the outlet pressure is also above set
pressure) the vent solenoid valve opens and decreases the dome
pressure. If the dome pressure is lower than the set pressure
the load solenoid valve opens and increases the dome pressure.
By continuously loading and venting the dome pressure is held
constant, regardless of the diaphragm position. This type of
mechanism is the most accurate means of controlling the regulator
set pressure. Note that use of an electronic controller requires
special consideration for both controller selection and hook-up.
7.8 VALVE PERFORMANCE
The following performance characteristics will affect the outlet

pressure. The accuracy of a regulator in a specific application
can be found by calculating the following effects.
7.8.1 Unbalanced Effect (Tables 7-2 & 7-3)

The outlet pressure is affected by changes in inlet pressure.
The change in outlet pressure can be predicted by using the
"outlet rise per inlet pressure drop" data from tables 1 and 2.
As the inlet pressure decreases the outlet pressure will rise.
If the inlet pressure increases the outlet pressure will
decrease. For example a Model 202B with a 1/4" orifice has a
normal inlet pressure of 2,000 psi and an outlet pressure of 50
psi. If the inlet pressure drops 500 psi to 1,500 psi the outlet
pressure will rise. The "outlet rise per 100 psi inlet drop" is
1.5 psi. The inlet pressure drop is 500 psi so the rise in
outlet pressure is 500/100 x 1.5 psi = 7.5 psi. Therefore the
outlet pressure increases to 57.5 psi. If the inlet pressure
increases the outlet pressure decreases by the same ratio.
7.8.2 Lockup (Tables 7-2 & 7-3)

The average lockup is the normal pressure rise above set pressure
required to shut off flow through the regulator. If a 202B with
a 1/4" orifice is normally set at 50 psi outlet pressure, at low
flow the outlet pressure will have to exceed this set pressure in
order to get the regulator to close or lockup. This average
lockup pressure is 53.3 psi for this specific unit. A lower
lockup pressure is generally desirable. Regulators with larger
diaphragms and smaller valves have lower lock up pressures. The
lockup values listed on tables 1 and 2 are average values. There
can be fluctuation between identical regulators.
7 - 21
7.8.3 Droop (Table 7-4)
Pressure reducing regulators are designed to maintain the outlet
pressure at the set pressure. As the flow increases through the
regulator the outlet pressure decreases in all Grove regulators.
This outlet pressure characteristic is called droop. Regulators
that have very little droop are more accurate than regulators
with high droop. Regulators with larger diaphragms and smaller
orifices have lower droop. In dome type regulators droop is also
proportional to the dome pressure. A regulator with a higher set
pressure will have more droop than a regulator with a lower set
pressure. The droop of a Grove dome regulator can be solved by
knowing the application CV and the dome pressure using the
formulas listed.
For handloaders the droop can be solved using the nomograph chart
125-K-5.
7.9 APPLICATION CV
The maximum rated CV of a regulator is listed on Grove specialty

regulator catalog information sheets and table 2. The Cv is used
to determine the maximum flow capacity of a regulator for a
specific inlet pressure, outlet pressure and fluid conditions.
Always use a regulator that has a higher maximum rated Cv than
maximum application cv. There are often times when the pressure
and flowrate conditions are not constant for an application. To
calculate the maximum application Cv use: the type of fluid, the
minimum inlet pressure, the maximum outlet pressure and the
maximum flowrate. To calculate the minimum application Cv: use
the maximum inlet pressure, the minimum outlet pressure and the
minimum flowrate. The application CV can be calculated using the
Grove computer sizing program Powrsize, the Grove sizing slide
rule, Grove regulator nomographs or mathematical Cv formulas.
For best performance the minimum and maximum application cvs
should be between 5 to 80% of the maximum rated CV of a
regulator.
7.10 SIZING METHODS
There are several different ways to size a regulator for an

application the most common methods are listed below. The least
time consuming methods are the sizing program and the sizing
slideruler.
7.10.1 Powrsize Regulator Sizing Program

The sizing program is used to help find the best regulator for a
specific application. By imputing the minimum inlet pressure,
maximum outlet pressure, maximum flowrate and fluid into the
program, the maximum application Cv, a recommended regulator CV
and a listing of suitable regulators will be produced by the
program. The program can also be used to solve the minimum
application CV by imputing the maximum inlet pressure, minimum
outlet pressure and minimum flow rate.
7 - 22
/
DROOP FORMULA FOR SPECIALTV REGULATORS
DROOP IS THE CHANGE IN OUTLET PRESSURE AS THE

REQUIRED FLOW INCREASES FROM lOW TO MAXIMUM
DROOP ... D-FACTOR x Cv (required) x Pdome (Psig)
D-FACTORS ARE LISTED BELOW

Cv (required) - THE APPlICATION Cv
Pdome - Poutlet+(Pin-Pout)l1oo x UNBALANCED EFFECT
REGULATOR ORIFICE DFACTOR

SIZE DIAMETER
400 1 112 0.003636
400 1 0.00476
400 314- 0.007163
400 112- 0.00983
400 318 0.01566
300 1 0.00704
300 314 0.009417
300 112 0.01833
300 318 0.02125
300 5116 0.03
300 114 0.0333
200 112 0.0394
200 318 0.04375
200 5116 0.0695
200 114 0.06208
200 3116 0.06762
100 3116 0.1524
100 3/32 0.27432
TABLE 7-4
7 - 23
7.10.2 Sizing Nomographs
Self explanatory sizing nomographs for handloaders, Mity-Mites
and Powreactors are included in the Specialty Regulator catalog.
7.10.3 Sizing Sliderule

The Grove "Pressure Regulator Selector" is a slide rule that can
solve the flow capacity of Specialty Regulators given the inlet
pressure, differential pressure, and specific gravity. It is
available upon request.
7.10.4 Sizing Formulas (Section 1)

Standard ISA Cv formulas can be used to calculate the application
Cv. These formulas are included on table. These formulas are
used in the sizing program and are the most accurate means of
solving the application Cv.
7 - 24
SECTION 8 ENGINEERING DATA
8.1 GAS PROPERTIES
8.2 FLUID PROPERTIES
8.3 CONVERSIONS
8.4 MISCELLANEOUS RELATIONS
8.5 PRESSURE RECOVERY FACTORS (F L )
8
ENGINEERING DATA
8.1 GAS PROPERTIES
SPECIFIC BEAT RATIO SPECIFIC GRAVITY

GAS (Fit) (G)
Acetylene 0.90 0.90

Air 1.00 1.00
Butane 0.79 2.00
Ethane 0.84 1.03
Helium 1.19 0.14
Hydrogen 1.01 0.07
Methane 0.94 0.55
Natural Gas 0.94 0.60
Nitrogen 1.00 0.97
Oxygen 1.00 1.10
Propane 0.81 1.52
8.2 FLUID PROPERTIES

A. Vapor Pressure (Pv)
Note: Properties are at 60·F
(Water/Steam) Pv = .2563 psia

(Ammonia) P v = 107.6 psia
(Propane) Pv = 110.0 psia
B. Specific Gravity (G)
Fluid
Fresh Water 1.00

Ethylene Glycol 1.12
Crude oil .84-.908
Gasoline .66-.8
Salt Water 1.03
1 Values shown are nominal values at 68·F. Consult handbooks

for more precise values.
8 - 1
8.3 CONVERSIONS
To Convert Multiply By To Obtain
8.3.1 Flow
ft 3 /sec 448.831 (US) gpm
(US) gpm 2.228x10-3 cfs
(oil) Barrels/hr .700 (US) gpm
(US) gpm 1.4286 (oil) Barrels/hr
CU meter/hr 4.402 gpm
gpm 2. 2715x10-~ Cu meter/hr
1 liter/min .2642 gpm
gpm 3.7850 liters/min
8.3.2 Pressure
PSI 6.8966x10-2 BAR
BAR 14.500 PSI
k.,/CM2 14.220
PSI 7.0323x10-2
PSI 144.00 PSF
PSF 6.9444x10- 3 PSI
k.,jM2 1. 422x10- 3 PSI
PSI 7.0323x10 2 k.,/M2
IN of water(4·C) 3.613x10-2 PSI
PSI 27.678 IN of water ( 4°C)
PSI 2.307 ft of water
ft of water .43346 PSI
PSI 6.895 kPA
kP. .14503 PSI
1 NIM2 1.00 Pascal (P.)
1 Pascal 1.00 N/W
8.3.3 Viscosity
(Dynamic)
Ibm/ft-sec 1487 centipose
centipose 6.7249xlO-· Ibm/ft-s
Ibf-s/ft2 47900.00 Centipoise
Centipoise 2.0877xl0-5 Ibf-s/ft2
(Kinematic)
centistokes 1.076x10- 5 ft2/S
ft2/S 92900 centistokes
8 - 2
8.3.4 Temperature
( °c to of) TOC = (5/9)X(ToF -32)
( of to oR) TOR = TOF + 459.67
where TOC = Temperature in °c

TOF = Temperature in of
TOR = Temperature in oR
8.4 MISCELLANEOUS RELATIONS

8.4.1 SCFH to Mass Flow Rate
W = .0764 Qb G
where W = mass flow rate of gas in lb.Jhr
~ = gas flow rate in SCFH

G = gas specific gravity
8.4.2 Gas Flow to SCFM

Use the following relation to convert gas flow at a given
pressure, flow, and temperature to the equivalent flow in SCFM:
Q. = 35.374 (P~ + 14.7) Q~/(Z~ + (T~+460»
where Q. = gas flow in SCFM
P~ = pressure in psig
Q~ = flow in cu. ft. per min at T~ and P~
T~ = temperature in OF
Z~ = super compressibility factor. Use graph in

Fig 8-1 for natural gas. Consult engineering handbooks or Grove
Engineering for other gases.
8.4.3 Absolute Pressure (psia)
Psia = 14.7 + psig
where
psig = gage pressure
8 - 3
8.5 PRESSURE RECOVERY FACTORS (F L )
Siz.e Ex Model 83 E( Model 900TE

1 1/2 .87 -----
2 .82 .74
3 .74 .77
4 .77 .73
6 .75 -----
MODEL 80:
Sin Ex Cl 150 1\ Cl 300 E( Cl 600
1 .88 .88 .88
1 1/2 .77 .81 .88
2 .63 .73 .88
3 .64 .61 .77
4 .65 .66 .57
6 .68 .68 .67
8 .68 .68 .69
10 .69 .69 .69
12 .69 .69 .69
8 - 4
Supercompressibility of Average Natural
Gas of 0.6 Specific Gravity
At 6()0 F.
1.00
.95
.90
.85
.80
.75
o 200 400 600 800 1000 1200 ) .tOO 1600
PI
FIG. 8-1
8 - 5

Grove Regulator Engineering Handbook Sections 1-8

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Grove Regulator Engineering Handbook Sections 1-8

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GROVE VALVE AND

1.3 PIPELINE PRESSURE CLASS

1.4 REGULATOR CAPACITY

The Regulator Engineering Data Book is a central source of

1.1 WHAT ARE PRESSURE REGULATORS?

Grove pressure regulators control inlet or outlet pipeline fluid

1.2 BASIC REGULATOR CONCEPT

The most common application is downstream pressure control, this

Upstream pressure control in known as "Back Pressure" service. A

1.3 PIPELINE PRESSURE CLASSES

All pipelines and pressure regulators can fail or burst if

1.4 REGULATOR CAPACITY

The most difficult part of selecting a regulator for an

For liquid service:

non-critical flow P2 < FL2 (P1 - Pv)

critical flow P2 > FL2 (P1 - Pv)

non-critical flow P2 < Pl/2

critical flow P2 > Pl/2

Grove uses the following formulas to solve the flow capacity of

P, Inlet Pressure (PSIA)

Note: See sect 10n 8 for spec Hi c f1 u1 d and va lYe parameters.

By placing the application characteristics and regulator CV into

In some cases it is desirable to have a Cv greater than the

2.2 MODEL DESCRIPTIONS

2.5 WEIGHTS AND DIMENSIONS

2.8 FLUID COMPATIBILITY

2.11 FLEX FLO FAILURE MODES

2.14 FLEX FLO TUBE REMOVAL AND INSTALLATION FOR

2.1 FLEXFLO OPERATING PRINCIPLE

The working components of the Flexflo regulators are the tube,

CORE The core is cylindrically shaped with a hemispherical

The Flexflo regulator is simply a large variable capacity valve.

The rubber tube is elastic and is designed to fit tightly around

JACKET PRESSURE =INLET PRESSURE

JACKET PRESSURE < INLET PRESSURE

2.2 MODEL DESCRIPTIONS

The Model 80 is the original Flexflo regulator. The core is a

The Model 81 is a lower cost version of the Model 80. The

The Model 82 is a light weight, "wafer" design, less expensive

The Model 83 is a 316 stainless steel Flexflo regulator. The

2.2.5 MODEL 900TE

The 900TE is a "top entry" regulator whereby the expansible tube

The Model 887 is a surge reliever. Its purpose is to protect

2.3 VALVE COEFFICIENT cv

Some regulator manufacturers use a Cg instead of a Cv to quantify

UNIT MOONEY FISHER GROVE GROVE

2.4 FLEXFLO COMPONENT MATERIAL LISTING

FLEXFLO COMPONENT MATERIAL LISTING

STANDARD FLEXFLO TUBE MATERIAlS ARE LISIED HOWEVER ALL UNITS

2.6 END CONNECTIONS

The following diagrams show the different types of standard

Fig. 2-3 Line Removable

TO REMOVE THE FLEXFLO CORE AND TUBE:

TO REMOVE THE FLEXFLO CORE AND TUBE:

TO REMOVE THE FLEXFLO CORE AND TUBE:

The relationship between the Cv of the regulator and the number

A regulator will not work well when it is oversized for a

To determine the number of downstream slots to fill given the

ANSI 100% 100%CAP 70%CAP 50%CAP

81 1 1/2" 150/300 200-01483 18 ~? · . 18 9 6

03 1" 150/300/600 356-0100:: 21 21 11 7

900TE 2" 150/300/600 364-02001 48 49 24 16 N

'" Reoulator jjataboo;': Dist1~i:~ULio:;

Cv ACCURACY: +/- 10%