Do you need a propane regulator

The propane gas regulator is one of the most important parts of a propane gas system. The purpose of the regulator is to control the flow of gas and lower the pressure from the LP Gas tank to the appliance(s) in the gas system. The regulator not only acts as a control regarding the flow and distribution of propane but also as a safety barrier between the high pressure of the tank and the end use appliance(s). Most will rightfully argue that the LP Gas regulator is the heart of any propane gas system.

Purpose of a Propane Regulator

Propane tank pressure can range from under 10 psig to over 200 psig. Residential applications will generally require 11 inches water column (amount of pressure required to push a column of water up 11 inches in a manometer, or about 6.3 ounces per square inch) and the regulator compensates for these pressure differences in the tank to supply a steady flow of required pressure to the household appliances. Not all applications are similar to that of residential use and will therefore utilize regulators for higher and lower pressures as required by the appliance(s). In summary, the purpose of a propane regulator is to "bottleneck" the propane down to a safe and usable pressure. An important point to note is that under normal operation, a propane regulator will make a "humming" noise. This is normal and should not be construed as a problem or regulator malfunction.

Types of Propane Tank Regulators

Although the purpose of a propane regulator is the same, different applications require different types of regulators. Regulator selection is determined solely by the propane application requirements. The demand downstream of the regulator is what determines what type of regulator is to be installed and where it's to be placed within the system. Some propane systems incorporate multiple regulators for efficiency while others such as a grill need only a low BTU grill regulator. Types of regulators include:

"A regulator is a regulator" is a misleading statement that many consumers believe to be true. The fact is that installing the wrong kind of LP Gas pressure regulator will generally render a propane gas system inoperable. People don't realize that buying an LP Gas regulator from a friend or an internet site will more than likely result in wasted money. Regulators aren't all the same regardless of what one may think and an improper regulator or faulty LP Gas regulator installation means the entire installation is illegal and unable to be serviced until fixed. Keep in mind that replacing the regulator means interrupting the flow of gas and a leak check is required before the gas can be turned back on. Don't put yourself in danger by attempting to buy and install your own regulator. Call your propane company or a licensed LP Gas plumber. It will be safer and cheaper in the long run.

Protecting and Replacing LP Gas Regulators

Like any part of a propane system, the regulator needs to be protected. Protecting a regulator, for the most part means keeping it covered. Regulators are generally found under the tank dome or if installed outside the dome, they will have the vent pointed down. The vent is pointed down to prevent rain, ice and debris from entering the regulator. The vent should have a screen that keeps insects out of the regulator as some insects, such as the Mud Dauber (a.k.a. Dirt Dauber) will make a nest in a regulator that's missing its protective vent screen. Unprotected regulators that are exposed or not pointed with the vent facing down can easily be protected by cutting an empty plastic milk bottle to fit over the regulator until its placement and position can be corrected.

Regulators have internal moving parts that are subject to wear and tear and after some time, the regulator needs to be replaced. Propane companies can tell consumers when the regulator needs to be replaced due to age or malfunction and the consumer needs to take this advice seriously. The industry norm is 15 years before a regulator needs replacement while some regulator manufacturers recommend replacement every 25 years. If any regulator has ever been under water, such as on an underground propane tank, it needs to be replaced immediately. One very important fact to point out is that although propane regulators may be adjusted by licensed propane professionals, they are not repaired or subject to repair. They are replaced.

A gas regulator reduces high pressure from the gas bottle to a consistent regulated pressure as required by the application. Gas regulators are used for compressed gases liquefied under pressure, such as LPG gas regulators for SWAP‘n‘GO LPG bottles and larger household gas cylinders delivered by Elgas.

Gas Regulator function

The primary function of an LPG gas regulator is to reduce the LPG gas bottle pressure from 400-1200kPa down to the required 2.75kPa operating pressure for gas appliances. Gas bottle pressure varies with temperature but the LPG gas regulator must consistently maintain 2.75kPa.

Gas regulator types include LPG gas regulator, acetylene gas bottle regulator and oxygen gas bottle regulator. The gas regulator setup can include bayonet fittings, pol gas fittings and other gas regulator fittings suitable for a variety of gas appliances and equipment such as MIG welders. Elgas LPG cylinders are regularly checked to ensure the gas regulator and other gas fittings are connected properly and functioning optimally.

How does a gas regulator work?

LPG enters the regulator through the inlet port and the pressure is controlled by a factory pre-set spring loaded diaphragm. The diaphragm moves with pressure changes and adjust the inlet valve accordingly. Gas regulators are an essential component of your LPG system for reducing gas pressure and making it safe to use for your home, business, BBQ, caravan or motorhome.

The pressure within an LPG gas bottle can be 400-1200 kPa vs the 2.75 kPa LPG gas regulator gas pressure typically required by LPG gas appliances. LPG gas regulator gas pressure is pre-set to achieve standard operating pressure. It’s worth noting that a propane gas regulator is the same as an LPG regulator. LPG is the same as propane.

This short video (8:29) explains all of the basics of LPG, LPG gas regulators, gas fittings and more…

Removing a gas regulator from a gas bottle

(Gas Bottles with POL Fittings)

If your BBQ bottle or propane tank is empty and the gas regulator is faulty, the regulator may need replacing. If you are an Elgas customer, we have it covered and will replace your old gas cylinder with a new one. Here are a few simple steps involved in removing and replacing your old gas regulator.

1. Make sure the gas valve hand wheel is turned off.
2. To remove the gas regulator, turn the gas regulator hand wheel clockwise.
3. Unscrew and remove the regulator and replace it with a new one.

A small amount of gas remaining in the system may be released when you remove the gas regulator.

Regulator gas pressure

Low, medium and high pressure can all be accommodated by a gas regulator. Gas pressure regulators are adjustable using balanced diaphragms. Adjustable regulator gas pressure versions include 150 kPa acetylene gas regulators, 800 kPa oxygen gas regulators, 150 kPa argon gas regulators, 50 psi nitrogen gas regulators and 150 psi helium gas regulators.

Regulator gas pressure can be factory pre-set, as is the case with an LPG gas regulator at 2.75 kPa. Other gases have a factory pre-set maximum but are adjustable downward to reduce the working pressure. Adjustable gas regulators have two circular pressure gauges and an adjusting knob.

One gauge indicates the pressure in the cylinder (incoming pressure) and the other gauge indicates the regulator gas pressure of the gas coming out (outlet pressure). This outlet pressure is the working pressure that is set by the user for the particular application.

These gas regulators come in single stage and dual stage models. Dual stage regulators are better at maintaining a constant high pressure or low pressure but they are also more expensive to purchase.

How does a gas regulator work?

A gas regulator works to automatically reduce high pressure gas in the gas cylinder to the required lower pressure for the appliances or equipment. A gas regulator does this with a diaphragm and springs that make automatic gas regulator adjustment to modulate the pressure.

Gas regulator operation works in conjunction with the gas pressure vent which allows the gas regulator diaphragm to work freely. If the gas regulator vent is obstructed, gas flow will be impaired. The gas regulator vent should remain free of dirt and debris to ensure proper gas regulator operation.

Elgas takes a safety-first approach to LPG cylinder use. We service all out cylinders regularly and use only the best regulators, adaptors, connectors, jacks and other gas fittings so you can enjoy energy-efficient and economical heating, cooking and hot water for your home or business.

Gas regulator problems

Gas is the go-to energy source for indoor use, plus BBQ and outdoor cooking Australia-wide. But what if your grill isn’t working properly or the flame is too low and ineffective? You might be having regulator problems. Here are some gas regulator problems that are occasionally experienced by grillers, along with some simple solutions.

Low temperature or low flame: If your regulator tends to get sticky, it will limit the amount of vapour feeding your burners and won’t provide the desired grilling temperature.

Grill isn’t receiving gas: If your tank is full and you’re grill isn’t receiving any gas, you might have a gas leak. If there is a leak, it’s time to replace the regulator.

The gas regulator is frozen: Vapour inside the regulator is very cold, so it’s normal for condensation to build up. Freezing inside the regulator is common, but there are things to look out for.

• The gas cylinder isn’t upright
• The gas cylinder is overfilled

Both of these can cause a gas regulator to freeze up and not work properly.

Orange or yellow flame: Check the valves and hoses for obstruction. Regulator components may need replacing.

With Elgas on your side, regulator problems are a thing of the past. If economical clean-burning gas is on your wishlist, we‘ve got you sorted. For gas sales, service, replacement regulator kits and top quality spare parts, choose Elgas.

Gas bottle fittings

Gas bottle fittings include the gas regulator, gas piping, BSP connectors, gas valves and POL  gas bottle fittings required to build a complete LPG gas system that connects the gas bottle to the appliance. Gas bottle fittings called pigtails or copper pigtails are flexible gas tube POL gas bottle fittings that connect the gas bottle to the changeover valve or directly to the gas regulator.

The gas regulator gas flow comes from the changeover valve, which determines which gas bottle is being used. Licensed gas fitters are required for all gas related work involving gas regulators, gas pressure, gas bottle fittings and brazing with filler for gas appliances.

BBQ gas bottle with POL fittings

BBQ gas bottle fittings (POL  gas bottle fittings) involve less components than home installations. Typical BBQ gas bottle fittings include a POL LPG gas regulator with POL  gas bottle fittings, gas hose and connector. The POL LPG gas regulator, gas hose and connector usually come as an assembly but hoses are also sold separately.

Camper valve adapters may also be required for POL fittings or BBQ gas bottle fittings if you have a camper valve gas bottle or appliance. Some outdoor appliances also require Piezo electric ignitors, replacement valves, various BBQ gas bottle fitting adapters and gas fitting kits for natural gas BBQ conversions. For information about SWAP’n’GO gas bottles and other Elgas services, contact us online, over the phone, or in person at your nearest Elgas service centre.

Make sure you know the type of thread your fittings use. Thread types include BSPP, BSPT, and NPT threads.

LPG is stored under pressure

LPG is stored under pressure as a liquid in a gas bottle that is usually made from welded steel, stainless steel, galvanised steel or composite materials. LPG (Propane) turns back into a gas when you release some of the pressure in the gas bottle by turning on your appliance. The pressure within a gas bottle can be 800-900kPa. This varies based on the ambient temperature, exposure to the radiant heat of the sun and the amount of gas remaining in the gas bottle.

Gas regulator pressure for appliances

The appliance inlet pressure for Australian LPG gas appliances typically requires 2.75kPa gas regulator gas pressure. Gas regulator gas pressure flow is reduced and ensure a consistent 2.75kPa gas pressure safely delivered from the gas bottle to your appliances via the gas bottle fittings. Gas regulators for LPG bottles are an essential part of an LPG system. Without LPG gas regulators reducing the gas regulator gas pressure, the LPG would be unsafe to use.

LPG gas regulators must reduce the high pressures as shown in the LPG Pressure chart above to the required 2.75kPa gas regulator gas pressure. The LPG gas regulator shown (right or above) includes an automatic changeover valve.

Gas bottle regulator types & sizes

Gas bottle gas regulator types & sizes vary depending on the gas load. Although the purpose of LPG gas regulators is the same, different gas load applications may require different gas bottle regulator types and sizes.

The gas demand of the appliance determines what gas bottle gas regulator type, gas bottle fittings and size of LPG gas regulator is installed. For example, if the combined megajoule (MJ) rating of your home’s appliances is quite high, an LPG gas bottle regulator with a higher MJ rating size would be required.

Commercial sized LPG gas regulators are completely different and frequently comprised of two separate gas regulator units and gas bottle fittings. Also, please note that under no circumstances should a BBQ gas regulator ever be used on a home installation.

Gas bottle regulator adjustment controls

There are various gas regulators and fittings used depending on the gas. Some gas regulators are pre-set to work at a specific gas pressure, such as LPG and natural gas regulators. Other regulator types include adjustment controls and gauges for monitoring and adjusting the gas pressure.

Gas regulator types are rated according to flow rate, with different size gas regulators operating with specific gas loads. For example, you wouldn’t use a BBQ gas bottle gas regulator for a whole house. There are also two-stage gas regulators, with two separate gas regulators. This system is used when there is a long run of gas bottle fittings between the gas bottles and the application.

Some gases, like acetylene, are reactive with certain types of metal. This means that the gas regulator and gas bottle fittings must be manufactured from specific materials. See accompanying image of acetylene gas regulator.

Gas pigtails POL fittings

The gas bottles are connected by ’pigtails’ to a changeover valve. The changeover valve is connected to the gas regulator with POL  gas bottle fittings. Pigtails can be made of solid copper, rubber or braided metal over a rubber interior. Copper is generally considered the best choice for gas bottle fittings, as rubber and braided pigtails have a limited life span.

Pigtails can catch or trap debris over time so they should be replaced when the gas regulator is replaced. Pigtails are relatively flexible gas bottle fittings that can absorb the shock of sudden movement or jarring if the installation is accidentally bumped. Without flexible gas bottle fittings, the rigid hose would be more susceptible to leaks.

Propane (LPG) piping

A gas line runs from the gas regulator to your appliances. This gas line is the service piping. Propane pipe (LPG pipe) generally consists of copper or plastic polyethylene tubing. The propane piping needs to be installed correctly and legally by a qualified professional gas fitter for the entire installation to be safe and serviceable.

Gas bayonet connections – If you have a portable gas heater, it will be connected to your home LPG supplied using a bayonet connection that can be floor or wall mounted. The male connector, on the end of the heater hose, plugs into the female connector which is, in turn, connected to the LPG service piping. Please see:

How to Connect & Disconnect Gas Bayonet Fittings

Manual gas changeover valves

With manual changeover valves, you need to manually reset the valve when the first bottle is empty. The changeover valve has a lever which must be set to the gas bottle in use. To use a manual changeover valve, follow these three steps:

1. Turn the empty gas bottle valve clockwise to CLOSE the valve.
2. Adjust the changeover valve lever to point towards the second gas bottle, which will be filled and ready to go, courtesy of Elgas.
3. OPEN the valve on the full gas bottle by turning it anti-clockwise.

If you need a new full gas bottle from Elgas for your home or business, give us a call for delivery to your home or business. Order a replacement gas bottle when you switch over between bottles and you will never run out of gas.

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