T/SP/PRS/28

SPECIFICATION

FOR SINGLE-STAGE LEVER TYPE METER

REGULATORS FOR GAS FLOW RATES NOT
EXCEEDING 6 m³/h AND INLET PRESSURES IN THE
RANGE 75 mbar TO 2 bar

AUGUST 2004
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CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iv

SECTION 1. PRODUCT REQUIREMENTS

INTRODUCTION 1

1. SCOPE 1

2. REFERENCES 2

3. DEFINITIONS 2

4. MATERIALS 3

5. FINISH 4

6. TORSION AND BENDING 4

7. DESIGN AND DIMENSIONS 4

8. PERFORMANCE 6

9. TYPE TEST APPROVAL 10

10. REGULATOR SETTING AND SEALING 10

11. PROTECTIVE DEVICE SETTING 10

12. MARKING AND LABELLING 11

13 PROTECTION AND PACKAGING 11

SECTION 2. QUALITY ASSURANCE REQUIREMENTS

14. SCOPE 13

15. QUALITY MANAGEMENT SYSTEM 13

16. QUALITY PLAN 13

17. ACCESS FOR TRANSCO DESIGNATED QUALITY ASSURANCE PERSONNEL 15

18. VALIDATION OF INITIAL PRODUCTION 16

19. CONCESSION AND PRODUCTION PERMIT PROCEDURE 16

TABLES

1a Performance criteria for outlet pressure tests at 2 bar inlet pressure 7

1b Performance criteria for outlet pressure tests at 350 mbar inlet pressure 8

2 Performance criteria for lock-up tests 9

3 Performance criteria for speed of response tests 10

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Page

APPENDICES

A LIST OF REFERENCES 17

B TYPE TEST ON PROTECTIVE COATINGS 19

C TORSION AND BENDING MOMENT TESTS 20

D SIZE ENVELOPES FOR REGULATOR INSTALLATIONS 22

E REQUIREMENTS FOR OVERPRESSURE PROTECTION SYSTEM 24

F TYPE TESTS ON REGULATORS 26

G MECHANICAL LIFE TEST 30

H SUMMARY OF TYPE APPROVAL TESTS 31

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FOREWORD

This Specification was approved by Measurement and Process Policy Manager, as document number
EPSG/A02/10067 on 14th. May 2003 for use throughout Transco.

Comments and queries regarding the Technical content of this engineering document should be directed
to;

Safety and Engineering

Transco
Brick Kiln Street
Off Coventry Road
Hinckley
Leicestershire
LE10 0NA

Further copies of this engineering document can be obtained from Dataform Print Management using the
print requisition form G004 quoting the Form Number of this Transco engineering document (not the
designation) and your cost code.

Transco documents are revised, when necessary, by the issue of new editions. Users should ensure that
they are in possession of the latest edition by referring to the Transco Register of Engineering
Documents available on TransNet.

Compliance with this engineering document does not confer immunity from prosecution for breach of
statutory or other legal obligations.

Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.

DISCLAIMER
This engineering document is provided for use by Transco and such of its contractors as are obliged by
the terms of their contracts to comply with this engineering document. Where this engineering document
is used by any other party, it is the responsibility of that party to ensure that the engineering document is
correctly applied.

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BRIEF HISTORY

First published as T/SP/PRS 28 May 2002

Editorial Update to comply with GRM August 2004

© Transco

This Transco engineering document is copyright and must not be reproduced in whole or in part by any
means without the approval in writing of Transco plc.

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SPECIFICATION FOR
SINGLE-STAGE LEVER TYPE METER REGULATORS FOR
GAS FLOW RATES NOT EXCEEDING 6 m³/h AND INLET
PRESSURES IN THE RANGE 75 mbar TO 2 bar

SECTION 1. PRODUCT REQUIREMENTS

INTRODUCTION
T/SP/PRS/28: defines the requirements for single-stage lever type meter regulators for gas flow rates not
exceeding 6 m3/h and inlet pressures in the range 75 mbar to 2 bar. Regulators complying with
T/SP/PRS/28 will satisfy the recommendations in IGE/TD/15, which was published in 2002.

Alternative designs/materials to those currently being used will be considered against this specification
provided the performance and dimensional requirements of T/SP/PRS28 are met.

Quality assurance requirements for regulators covered by this specification are given in Section 2 of the
specification.

Details on the installation of domestic sized gas meters, regulators and associated components on
medium pressure (MP) services are given in BS 6400, IGE/TD/15 and T/PR/TMP11.

Attention is drawn to the need to take appropriate precautions to ensure safety when carrying out the
methods of test required by this specification.

NOTES

1. Demonstration of compliance with T/SP/PRS28: Issue 1 is required before the commencement

of supply against this specification. Production testing, as applicable, is required during the
manufacturing process at the frequency specified in the manufacturer's quality plan.
2. Changes in contractual requirements or relevant documents may necessitate revision of
T/SP/PRS28: Issue 1.

1. SCOPE
This section of T/SP/PRS28 defines the requirements for single-stage medium pressure meter regulators
purchased under contract by Transco for use with 2nd family gas at flow rates not exceeding 6 m3/h, and
with inlet pressures in the range exceeding 75 mbar to not exceeding 2 bar.

NOTES

1. Requirements for low pressure meter regulators for gas flow rates not exceeding 6 m3/h and
with inlet pressures not exceeding 75 mbar are given in T/SP/PRS3: Issue 3.
2. Requirements for two-stage medium pressure meter regulators for gas flow rates not exceeding 6
m3/h and with inlet pressures in the range 350 mbar to 2 bar are given in T/SP/PRS29.

Regulators to T/SP/PRS28 shall:

a) Have a nominal outlet pressure of 22 mbar.

b) Be capable of passing 6 m³/h gas at a minimum outlet pressure of 19 mbar:
■ at 75 mbar inlet pressure, when initially adjusted for 350 mbar inlet pressure;
■ at 350 mbar inlet pressure, when initially adjusted for 2 bar inlet pressure.

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c) Be suitable for an inlet maximum operating pressure up to 2 bar, and a maximum

incidental pressure up to 2.7 bar without change in performance when the inlet pressure
returns to normal.
d) Be suitable for domestic meter installations housed in either a surface mounted meter
box, a semi-concealed meter box, or a semi-concealed meter box with box extension -
see Appendix D for typical space restrictions.
e) Be suitable for installation in environments with ambient temperatures in the range -
20°C to +60°C.
f) Under a reasonably foreseeable single fault condition, have an outlet pressure not
exceeding 50 mbar.

This specification applies to regulators with inlet and outlet connections:

i) at right-angles to each other;

ii) in-line with each other;
iii) forming a “U” shape.

See Figure C.1 of Appendix C for illustrations of the different regulator configurations.

Section 2 deals with the quality assurance obligations placed on the manufacturer.

NOTE - All pressures quoted in this specification are gauge pressures.

2. REFERENCES
This specification makes references to the documents listed in Appendix A. Unless otherwise stated the
latest editions of the documents apply, including all amendments and revisions.

3. DEFINITIONS
3.1 General
For the purposes of this specification, the definitions given in 3.2 and 3.3 apply.

3.2 Miscellaneous
maximum incidental pressure (MIP): the maximum pressure which a system is permitted to
experience under fault conditions, limited by safety devices.

maximum operating pressure (MOP): the maximum pressure at which a system can be operated
continuously under normal operating conditions.

“perpendicular” orientation: a regulator so oriented that its diaphragm is in the vertical plane.

reasonably foreseeable fault: a fault that could reasonably be anticipated and which the protective
system is designed to successfully deal with such that an unsafe situation does not occur.

single-stage lever type regulator: a regulator which breaks down inlet pressure to outlet pressure in a
single stage and which includes a lever mechanism to multiply the diaphragm force in order to give good
control of outlet pressure and to give good lock-up.

“upright” orientation: a regulator so oriented that its diaphragm is in the horizontal plane with the
loading spring above the diaphragm.

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3.3 Mandatory and non-mandatory requirements

To establish compliance with a Transco Product Specification, it is necessary to be able to identify those
provisions that are to be satisfied and those that give freedom of choice. Product Specifications express
these in the following manner:

can: indicates a physical possibility.

may: indicates an option which is not mandatory.

shall: indicates a mandatory requirement.

should: indicates a strong preference, but allows deviations exceptionally.

will: indicates an intention by Transco to do something.

4. MATERIALS
4.1 General requirements
4.1.1 The regulator shall be constructed of materials conforming to appropriate European,
International or British Standards.

NOTE - The contractor may propose equivalent materials to alternative specifications for
consideration by Transco.

4.1.2 The quality of materials, the dimensions used and the method of assembling the various parts
shall be such that construction and performance characteristics are safe. Moreover, the performance
characteristics shall not alter significantly during a reasonable life (i.e. at least twenty years) when the
regulator is installed and used according to the manufacturer's instructions, T/PR/TMP11, IGE/TD/15
and BS 6400. Under these circumstances, all components shall withstand any mechanical, chemical and
thermal conditions to which they may be subjected during service.

4.2 Casing components

4.2.1 The main body shall be:

a) cast in iron to BS EN 1561, BS EN 1563 or BS EN 10213;

b) cast in aluminium alloy EN AC-46500 to BS EN 1706 in accordance with
BS EN 1559-1 and BS EN 1559-4; or
c) cast in zinc alloy ZP0400 to BS EN 12844 in accordance with BS EN 1559-1 and
BS EN 1559-6.

4.2.2 The diaphragm case/spring housing(s) shall be:

a) made from one of the materials listed in 4.2.1;

b) pressed or deep drawn from aluminium alloy EN AW-1050A to BS EN 485-2 with a
minimum wall thickness of 1 mm; or
c) pressed or deep drawn from steel with a minimum wall thickness (after forming) of
0.8 mm and complying with 6.3 of BS EN 1359.

4.3 Resistance to corrosion

Any parts, including springs, in contact with the gas or the surrounding atmosphere, shall be
manufactured from corrosion-resistant materials or shall be suitably protected. The corrosion protection
for springs and other moving parts shall not be impaired by movement.

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4.4 Polymeric components

4.4.1 General
Components made from polymers (e.g. seals, diaphragms, valve pads, valve seats, valve spindles) shall
be homogeneous and free from inclusions, grit, blisters and surface imperfections visible to the naked
eye. Such components shall contain no level of porosity that would significantly affect the strength of
the component.

4.4.2 Elastomeric components

Components made from elastomers (e.g. seals, diaphragms, valve pads, valve seats) shall be class A2,
ozone resistant, to BS EN 549.

The regulator diaphragm shall be fabric-reinforced.

4.4.3 Stress resistance of plastics

Attention shall be given to the use of appropriate materials and design including the avoidance of stress
raisers. Where plastic materials are used within the regulator the design shall be such that manufacturing
and operating stresses do not result in excess stresses that may cause premature failure of the
components, and that under any such failure any split of diaphragm material is avoided or arrested.
Assembly methods shall be such as to minimise stress levels, particularly residual stresses following
assembly.

NOTE - An example of a suitable method is a ‘snap-fit’ assembly.

5. FINISH
All parts, including those with protected surfaces (e.g. plated or coated with paint), shall withstand the
humidity test of Appendix B without signs of corrosion, lifting, or blistering that are visible to the naked
eye.

6. TORSION AND BENDING

6.1 General
Regulators shall be constructed such that they have adequate strength to withstand likely mechanical
stress to which they may be subjected during installation and service.

6.2 Torsion
The regulator shall be subjected to a torque of 85 Nm in accordance with C.1.1 of Appendix C. After
testing, there shall be no permanent deformation, and any leakage shall not exceed that specified in
8.2.2.

6.3 Bending moment

The regulator shall be subjected to a bending moment of 225 Nm in accordance with C.1.2 of Appendix
C. After testing, there shall be no permanent deformation, and any leakage shall not exceed that
specified in 8.2.2.

7. DESIGN AND DIMENSIONS

7.1 General requirements
7.1.1 The regulator configuration shall be one of the types specified in the Scope (i.e. right-angle,
in-line, or “U” shaped); these are illustrated in Figure C.1 of Appendix C.

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The regulator, along with any necessary fittings, shall be capable of being readily installed in a standard
surface mounted meter box, a standard semi-concealed meter box, or a semi-concealed meter box with
box extension. Size envelopes are given in Appendix D for guidance on suitable dimensions.

NOTE - At the time of publication, the built-in meter box fitted with a regulator to T/SP/PRS28 is
an option Transco will not use due to the requirement for additional safeguards. Allowable
configurations may be determined by reference to the latest editions of T/PR/TMP11 and
T/SP/PRS40.

7.1.2 Screws provided in the regulator for servicing purposes shall conform to appropriate British,
European or International standards.

7.1.3 Screws provided in the regulator for servicing purposes shall not be of the thread cutting type.

7.1.4 Holes for screws, pins etc., which are used for the assembly of parts, shall not penetrate gas
ways. The wall thickness between gas ways and holes for screws, pins, etc., shall be at least 1 mm.

NOTE - This thickness requirement limits the minimum thickness of the remaining material at the
base of blind (fixing) holes in castings, forgings, etc.

Regulators shall be factory-set at the required outlet pressure at the stated inlet pressure (see 10.1).

Regulators may be provided with an adjustable spring loading device to facilitate adjustment of the
outlet pressure (at the manufacturer’s discretion). When provided, the adjustment facility shall be
accessible only by the use of tools, and facilities for sealing the adjustment shall be provided to prevent
unauthorised interference. It shall not be possible for the adjusting device to be set in such a position as
to keep the valve permanently open. Adequate steps shall be taken to ensure that the setting of the outlet
pressure adjuster cannot be disturbed by vibration.

Sealing tie holes for regulator adjustment seals and protective device adjustment seals shall be 2.5 mm
diameter (minimum).

7.2 Connections
7.2.1 Inlet connection
The inlet connection shall be threaded ¾ inch internal taper to BS 21 (RC¾).

7.2.2 Outlet connection

The outlet connection shall be either:

a) threaded ¾ inch internal taper to BS 21 (RC ¾); or

b) threaded 1 inch internal taper to BS 21 (RC 1),

as specified by Transco.

7.3 Overpressure protection

Overpressure protection shall be provided by a slamshut and creep relief valve, and shall conform to the
requirements of Appendix E.

Regulators shall be designed such that any reasonably foreseeable failure of any one component within
the regulator shall not cause the outlet pressure to rise above 50 mbar.

Alternative methods of providing overpressure protection may be proposed by the contractor for
consideration by Transco.

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All overpressure protection components shall operate effectively across the temperature range for which
the regulator is designed to operate (i.e. -20°C to +60°C).

7.4 Vents and breathers

Regulators shall be designed such that any gas leaking from a failed diaphragm or from a relief valve is
routed to a common point on the regulator to facilitate venting through a single line to discharge outside
of the meter box. The regulator design and materials of construction shall ensure that the maximum flow
through the external vent shall not exceed 1.75 m³/h under any fault condition.

NOTE - This may require a restrictor to be fitted in the vent line.

The relief vent pipe shall have a minimum internal diameter of 6 mm, and means shall be provided to
firmly attach the vent pipe to the regulator body such that it will not become detached during service.
The regulator vent outlet shall incorporate effective means to prevent entry of dirt and foreign materials.

7.5 Failure mode effect analysis

The manufacturer shall submit a fault/failure mode effect analysis for the regulator which identifies the
fault or failure modes that the designer has considered, and how the design of the regulator limits any
consequential overpressure condition at the outlet of the regulator to the requirements of this
specification.

The manufacturer shall state the basis for the sizing of the relief valve and vent.

8. PERFORMANCE
8.1 Test conditions
Unless otherwise specified, tests shall be carried out with air at 20 ± 5 °C and at an ambient temperature
of 20 ± 5 °C. All measured values shall be converted to standard conditions, i.e. 15 °C, 1013.25 mbar,
dry.

Gas flow rates may be converted to an equivalent air flow rate by the following equation:

Q air = 0.6 &Q gas

Where: Qair is air flow rate to be used in the test

Qgas is the equivalent natural gas flow rate through the regulator.

8.2 Strength and gas tightness

8.2.1 When the regulator is strength tested in accordance with F.1 of Appendix F, there shall be no
cracking or permanent deformation.

8.2.2 When the regulator is tightness tested in accordance with F.1 of Appendix F, any leakage of
air shall not exceed 30 cm³/h (or bubble tight for a period of 5 seconds).

NOTE - The strength test and gas tightness test may be combined where appropriate.

8.3 Outlet pressures

The regulator shall be initially set in accordance with F.2.1 of Appendix F depending on the inlet test
pressure.

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NOTE – It is recognised that single- stage MP meter regulators cannot comply with the performance
requirements over the full inlet pressure range of 75 mbar to 2 bar without their set point
being adjusted.

When the regulator is tested with air, in accordance with F.2.2, it shall satisfy the performance criteria in
Tables 1a and 1b (without chatter or hunt) with the regulator in its “upright” orientation and also with
the regulator in its “perpendicular” orientation.

TABLE 1a - Performance criteria for outlet pressure tests at 2 bar inlet pressure
Regulator set Test inlet
Test air
Test for inlet pressure Outlet pressure range
flowrate
pressure of:
i) Outlet pressure at 2 bar 2 bar 4.65 ±
high flow rate. ± 2% 0.08 m³/h Not less than 19 mbar nor
2 bar 350 mbar 4.65 ± greater than 23 mbar.
± 2% 0.08 m³/h
ii) Outlet pressure at 2 bar 2 bar 0.23 ±
low flow rate. ± 2% 0.03 m³/h Not less than 19 mbar nor
2 bar 350 mbar 0.23± greater than 23 mbar.
± 2% 0.03 m³/h
iii) Maximum outlet 2 bar 2 bar 2.70 ± Notwithstanding the
pressure setting ± 2% 0.05 m³/h requirements in i) and ii),
(adjustable the outlet pressure shall not
regulators only). rise above 30 mbar when
the pressure adjustment
device is set at the position
giving the maximum outlet
pressure.
NOTES
1. 4.65 m3/h air is equivalent to a gas flow rate of 6 m3/h (Q max)
2. 0.23 m3/h air is equivalent to a gas flow rate of 0.3 m3/h (5% Q max)
3. 2.70 m3/h air is equivalent to a gas flow rate of 3.5 m3/h

The regulator shall first be adjusted to suit a 2 bar inlet pressure, then tested over a range of flowrates up
to at least 9 m3/h (including the high and low flowrates defined in Table 1a) to develop an outlet
pressure/flow characteristic. Without adjusting the set point of the regulator, an outlet pressure/flow
characteristic shall also be developed for a 350 mbar inlet pressure.

The inlet pressure corresponding to an outlet pressure of 16.9 mbar at 6 m3/h gas flow rate shall be
determined.

The regulator shall then be adjusted to suit a 350 mbar inlet pressure, then tested over a range of
flowrates up to at least 9 m3/h (including the high and low flowrates defined in Table 1b) to develop an
outlet pressure/flow characteristic. Without adjusting the set point of the regulator, an outlet
pressure/flow characteristic shall also be developed for a 75 mbar inlet pressure.

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TABLE 1b - Performance criteria for outlet pressure tests at 350 mbar inlet pressure
Regulator set Test inlet
Test air
Test for inlet pressure Outlet pressure range
flowrate
pressure of:
i) Outlet pressure at 350 mbar 350 mbar 4.65 ±
high flow rate. ± 2% 0.08 m³/h Not less than 19.0 mbar nor
350 mbar 75 mbar 4.65 ± greater than 23 mbar.
± 2% 0.08 m³/h
ii) Outlet pressure at 350 mbar 350 mbar 0.23 ±
low flow rate. ± 2% 0.03 m³/h Not less than 19.0 mbar nor
350 mbar 75 mbar 0.23 ± greater than 23 mbar.
± 2% 0.03 m³/h
iii) Maximum outlet 350 mbar 350 mbar 2.70 ± Notwithstanding the
pressure setting ± 2% 0.05 m³/h requirements in i) and ii),
(adjustable the outlet pressure shall not
regulators only). rise above 30 mbar when
the pressure adjustment
device is set at the position
giving the maximum outlet
pressure.
NOTES
1. 4.65 m3/h air is equivalent to a gas flow rate of 6 m3/h (Q max)
2. 0.23 m3/h air is equivalent to a gas flow rate of 0.3 m3/h (5% Q max)
3. 2.70 m3/h air is equivalent to a gas flow rate of 3.5 m3/h

The inlet pressure corresponding to an outlet pressure of 16.9 mbar at 6 m3/h gas flow rate shall be
determined.

8.4 Lock-up
The regulator shall be initially set in accordance with F.2.1 of Appendix F depending on the inlet test
pressure.

NOTE – It is recognised that single-stage MP meter regulators cannot comply with the performance
requirements over the full inlet pressure range of 75 mbar to 2 bar without their set point
being adjusted.

When the regulator is tested at an ambient temperature of 20 ± 5 °C and with air at 20 ± 5 °C in

accordance with F.2.3, it shall meet the performance requirements of Table 2 with the regulator in its
“upright” orientation and also with the regulator in its “perpendicular” orientation.

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TABLE 2 - Performance criteria for lock-up tests

Maximum lock-up pressure at
Regulator set for ambient temperature of:
Test inlet pressure
inlet pressure of:
20 °C -20 °C
3 bar ± 2% 30.0 mbar (Note 1) -
2 bar 2 bar ± 2% 27.5 mbar (Note 2) 32 mbar (Note 1)
350 mbar ± 2% 27.5 mbar (Note 2) -
350 mbar ± 2% 27.5 mbar (Note 2) -
350 mbar
75 mbar ± 2% 27.5 mbar (Note 2) -
NOTES:
1. Total leakage of air across the valve shall not exceed 60 cm3/h
2. Total leakage of air across the valve shall not exceed 28 cm3/h

When the regulator is tested at an ambient temperature of -20 ± 2 °C and with air at between 0 °C and 5
°C flowed through the regulator at 1 m3/h for one minute immediately prior to the test, in accordance
with F.2.3, it shall meet the performance requirements of Table 2 with the regulator in its “upright”
orientation.

8.5 Speed of response

The regulator shall be initially set in accordance with F.2.1 of Appendix F depending on the inlet test
pressure.

NOTE – It is recognised that single-stage MP meter regulators cannot comply with the performance
requirements over the full inlet pressure range of 75 mbar to 2 bar without their set point
being adjusted.

When the regulator is tested with air, in accordance with F.2.4, it shall satisfy the performance criteria in
Table 3 with the regulator in its “upright” orientation and also with the regulator in its “perpendicular”
orientation.

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TABLE 3 - Performance criteria for speed of response tests

Regulator set for Test inlet Outlet pressure/time
Test volume
inlet pressure of: pressure characteristic
A vessel having an internal 2 bar 2 bar The outlet pressure shall not
volume of 630 ml ± 10 ml ± 2% exceed 33 mbar, measured not
(e.g. an E6 meter having an less than 0.5 s after the valve
internal volume within this has closed.
range).
2 bar 350 mbar The outlet pressure shall not
± 2% remain below 14 mbar for a
period longer than 0.5 s, when
the valve is opened.
A vessel having an internal 350 mbar 350 mbar The outlet pressure shall not
volume of 630 ml ± 10 ml ± 2% exceed 33 mbar, measured not
(e.g. an E6 meter having an less than 0.5 s after the valve
internal volume within this has closed.
range). 350 mbar 75 mbar The outlet pressure shall not
± 2% remain below 14 mbar for a
period longer than 0.5 s, when
the valve is opened.

8.6 Mechanical life

After the regulator is tested in accordance with Appendix G, it shall satisfy the requirements of 8.2 to 8.4
inclusive. Diaphragms shall show no sign of perforation, cracking, deformation or delamination.

9. TYPE TEST APPROVAL

A summary of the type approval tests to be satisfied is given in Appendix H.

10. REGULATOR SETTING AND SEALING

10.1 Unless otherwise specified in writing by Transco, regulators shall be factory set in the
“upright” orientation to give a pressure at the outlet of the regulator of 23 mbar +0, - 0.5 mbar at an air
flow rate of 0.23 ! 0.03 m³/h (equivalent to a gas flow rate of 0.3 m³/h) and at an inlet pressure of 2 bar ±
100 mbar.

NOTE - The regulator outlet pressure is pre-set at the above value to take account of the pressure
absorption of the meter and achieve a pressure at the outlet of the meter consistent with BS
6400 (nominally 21 mbar).

10.2 Where an adjustment facility is provided, it shall be adequately sealed so as to prevent its
setting from being interfered with without breaking of the seal. The seal shall incorporate the
manufacturer’s specific mark, e.g. trademark or initial letter(s) of company name, in a distinctive font.

11. PROTECTIVE DEVICE SETTING

11.1 Unless otherwise specified in writing by Transco, the slamshut valve shall be factory set to
47.5 mbar (to give an operating pressure in the range 45 to 50 mbar). The regulator shall be supplied
with the slamshut in the open (armed, or latched) position.

11.2 Unless otherwise specified in writing by Transco, the relief valve shall be factory set to 35
mbar (to give an operating pressure in the range 31.5 to 38.5 mbar).

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11.3 Where an adjustment facility is provided, it shall be adequately sealed so as to prevent its
setting from being interfered with without breaking of the seal. The seal shall incorporate the
manufacturer’s specific mark, e.g. trademark or initial letter(s) of company name in a distinctive font.

12. MARKING AND LABELLING

12.1 Marking
Each regulator shall be clearly marked with an arrow, cast or embossed in the casing, indicating the
direction of gas flow.

NOTE – These regulators do not require to be CE marked, but shall be accompanied by adequate
instructions for use and shall bear markings to permit identification of the manufacturer
within the European Community.

12.2 Labelling
12.2.1 Unless otherwise specified in writing by Transco, each regulator shall be marked with the
following:

a) Manufacturer’s name, abbreviated or in full;

b) The text “PRS28 Iss. 1”;
c) The text “Medium Pressure” or “MP”;
d) The minimum inlet operating pressure, i.e. “Pi min = 75 mbar”;
e) The maximum inlet operating pressure, i.e. “Pi max = 2 bar”;
f) The outlet pressure, i.e. “Po = 22 mbar nominal”;
g) Maximum flow rate, i.e. “Qmax = 6 m³/h”;
h) The text “2ND FAMILY GAS”;
i) The year and week number (e.g. 0252), or a sequential number, traceable to the
manufacturer's production records.

12.2.2 Markings shall be made directly onto the casing (see 12.2.2.1) or on a label (see 12.2.2.2).
Upper case lettering shall have a character height of not less than 3 mm and a stroke width of not less
than 0.2 mm. Lower case lettering etc. shall be in proportion.

12.2.2.1 Direct markings shall be printed (e.g. ink-jet), cast or stamped onto the casing with the
markings complying with the legibility and durability requirements of Appendix A of BS EN 60730-1.

12.2.2.2 Labels shall be type 1 to BS 4781 or comply with the legibility and durability requirements of
Appendix A of BS EN 60730-1.

12.2.3 Markings and labels shall be able to withstand the humidity test in Appendix B and withstand
60 ± 5 °C for 28 days (see Appendix F) without signs of lifting or blistering of the label visible to the
naked eye and without loss of legibility of the markings.

13. PROTECTION AND PACKAGING

The regulator shall be adequately packed for protection against damage and deterioration during all
stages of processing, storage and delivery.

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SECTION 2. QUALITY ASSURANCE REQUIREMENTS

14. SCOPE
This section specifies the minimum quality assurance requirements for products covered in Section 1 of
this specification.

15. QUALITY MANAGEMENT SYSTEM

15.1 A formalised quality management system is required.

15.2 Either the supplier shall provide evidence of certification by an accredited independent third
party certification body or where a supplier does not hold the aforementioned certification, the supplier's
quality management system shall be subject to evaluation by quality assurance personnel designated by
Transco. The requirements of BS EN ISO 9001 shall be used for this purpose. A copy of the supplier's
quality manual, relevant quality plans and other related documents shall be provided on request.

16. QUALITY PLAN

16.1 General
16.1.1 The supplier shall provide a quality plan which demonstrates, to the quality assurance
personnel designated by Transco, that the items supplied conform to the requirements of this
specification.

16.1.2 Any changes to the quality plan shall be agreed between Transco and the supplier before
introduction.

NOTES
1. Much of the generic documentation required will normally be contained in the supplier's
existing quality manual and supporting procedures. The plan will provide a mechanism to tie
existing generic quality system procedures to the specific requirements of this Specification.

2. The format of and the level of detail in the plan should suit the supplier's method of operation
and the complexity of the activities to be performed. The plan should be as brief as possible
and may be in the form of flow diagrams, a textual presentation or a mixture of both.

3. The plan should indicate, either directly or by reference to appropriate procedures or other
documents, how the required activities are to be carried out.

16.1.3 Where applicable, the quality plan shall include, but is not limited to, the following elements:

- purpose;
- nominated contacts;
- design control;
- control of bought-in material;
- control of parts manufacture;
- control of subassembly;
- control of product assembly and test;
- inspection, measuring and test equipment;
- product audit;
- nonconforming product;
- statistical techniques;

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- control of packaging and delivery;

- product identification and traceability;
- quality records.

NOTE - Requirements and guidance on the content of these elements follows below.

16.2 Purpose
The purpose of the quality plan shall define the Product Specification (and issue) to which it is to be
applied.

16.3 Nominated contacts

Contact details of the supplier's personnel with responsibility for the following aspects shall be provided:

a) Production quality. This concerns those matters which arise during manufacture of the
product and its associated component parts.
b) Technical quality. This relates to those matters arising from the design and
performance of the product and its associated component parts.
c) Service quality. This relates to those matters that arise in the field or on any products
and their associated parts returned from the field.

16.4 Design control

The quality plan shall indicate when, how and by whom validation and verification of design output
conformity to design inputs is to be carried out, controlled and documented. Where applicable, the plan
shall indicate the extent to which Transco is to be involved in design activities, such as participation in
design reviews and design verification tests. The plan shall reference applicable codes, standards and
specifications.

16.5 Control of bought-in material

Details shall be provided of the actions to be taken to control the quality of bought-in material including
raw materials. This shall also include manufactured parts or components that are sent out to
subcontractors for further processing.

16.6 Control of parts manufacture

16.6.1 This shall describe the controls applied to all parts of the product that are manufactured in
house. This shall include bought-in items which are subject to further manufacturing operations.

16.6.2 Where parts are subjected to subsequent processing, details shall be provided to show the
controls applied to ensure conformity of process and product.

16.7 Control of subassembly

This shall detail any control operations carried out on subassemblies prior to their assembly into the
product, but excluding any detailed previously.

16.8 Control of product assembly and test

16.8.1 The test and inspection procedures applied during and/or following product assembly shall be
detailed. This shall include reference to all tests applied during routine examinations together with any
additional checks carried out during first-off examinations.

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16.8.2 Any additional tests, type tests or inspections carried out on an occasional but predetermined
basis to check particular attributes of the product, or to prevent performance drift, shall be included.

16.9 Inspection, measuring and test equipment

The quality plan shall indicate the control system to be used for inspection, measuring and test
equipment specifically intended for use for the product, including calibration and calibration status.

16.10 Product audit

Details shall be given of product audits carried out to determine whether production remains in control
(see Note 1).

NOTES
1. These details should indicate the extent of any tests and inspections performed
detailing such aspects as responsibility, sample source, whether the product is
complete and packaged, relevant acceptable quality levels (AQLs), audit sampling
frequency etc. (see also Notes 2, 3 and 4).
2. There is no AQL for critical non-conformances. A critical non-conformance is
defined as one that will cause the product to be hazardous to the installer, user or
environment.
3. Where any doubt arises in the use of sampling plans and/or the definitions of class A
and B characteristics, reference should be made to BS 6001-1.
4. The AQL for class A is 1.5% and the AQL for class C is 2.5% (General Inspection
Level 1 and single sampling plan for normal inspection).

16.11 Non-conforming product

The quality plan shall indicate the procedures to be followed when a non-conforming product is found.
This shall cover aspects such as the identification and segregation of affected products, sub-assemblies
or other components and the implementation of corrective action.

16.12 Statistical techniques

Where specific statistical techniques are relevant they shall be indicated in the quality plan.

16.13 Control of packaging and delivery

The quality plan shall indicate the control actions to be taken to ascertain the suitability of the packaging
and delivery to ensure that the product will be delivered to the specified site in a manner that will ensure
that the required characteristics are not degraded.

16.14 Product identification and traceability

Where traceability is a requirement, the quality plan shall define its scope and extent, including how
affected products are to be identified.

16.15 Quality records

The quality plan shall indicate how key records specific to the product are to be controlled, including
how long they shall be retained and in which language.

17. ACCESS FOR TRANSCO DESIGNATED QUALITY ASSURANCE PERSONNEL

17.1 The supplier shall afford access and facilities to Transco designated quality assurance
personnel to visit production lines, quality audit areas, warehouses and other appropriate premises to

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T/SP/PRS/28

check that the products or component parts conform to this specification and that the quality plan is
being effectively operated.

NOTE - The quality assurance personnel will be called upon to attend the factory regularly, on
a daily basis if necessary, to carry out quality audits on finished products and spare parts, to
investigate reported defects and to confirm that the supplier's quality control ensures that the
agreed requirements are consistently achieved.

17.2 The supplier shall make available, on request, the appropriate quality records, drawings and
other control documents.

18. VALIDATION OF INITIAL PRODUCTION

At the start of each contract, no delivery of product to Transco shall be made until a satisfactory
examination of initial production has been completed by the Transco designated quality assurance
personnel and the supplier has demonstrated the effectiveness of the quality plan.

19. CONCESSION AND PRODUCTION PERMIT PROCEDURE

Application for a concession/production permit (see Note 2) shall be made to the relevant Transco
designated quality assurance engineer.

NOTES
1. All applications shall be confirmed in writing, signed by the supplier's nominated
representative. Items may be released only upon communication from the Transco
designated quality assurance engineer that the request has been accepted.
2. For the purposes of this section of the specification, the following apply:
- Concession is permission to use or release a limited quantity of material, components or
stores already manufactured that do not conform to specified requirements (N.B.
“already manufactured” is to include items partially manufactured.).
- Production permit is permission in advance of, or during, manufacture to use materials
or make components that differ from the specified requirements. This permission may
operate for a limited quantity or period, and on no account may it be allowed to extend
to another contract without further application being made from the supplier.

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APPENDIX A
LIST OF REFERENCES
This specification refers to the documents listed below (see clause 2)

British standards
BS 21 Specification for pipe threads for tubes and fittings where pressure-tight joints are
made on the threads.
BS 4781 Specification for pressure-sensitive adhesive plastics labels for permanent use.
BS 6001-1 Sampling procedures for inspection by attributes. Sampling schemes indexed by
acceptable quality level (AQL) for lot-by-lot inspection.
BS 6400 Specification for installation of domestic-sized gas meters of maximum rated
capacity not exceeding 6 m3/h.
BS EN 485-2 Aluminium and aluminium alloys - sheet strip and plate.
Part 2: Mechanical properties.
BS EN 549 Specification for rubber materials for seals and diaphragms for gas appliances and
gas equipment.
BS EN 1057 Copper and copper alloys. Seamless, round copper tubes for water and gas in
sanitary and heating applications.
BS EN 1359 Gas Meters. Diaphragm gas meters.
BS EN 1559-1 Founding. Technical conditions of delivery. General.
BS EN 1559-4 Founding. Technical conditions of delivery. Additional requirements for
aluminium alloy castings.
BS EN 1559-6 Founding. Technical conditions of delivery. Additional requirements for zinc alloy
castings.
BS EN 1561 Founding. Grey cast iron.
BS EN 1563 Founding. Spheroidal graphite cast iron
BS EN 1706 Aluminium and aluminium alloys. Castings. Chemical composition and mechanical
properties.
BS EN 10213 Technical delivery conditions for steel castings for pressure purposes.
BS EN 12844 Zinc and zinc alloys. Castings. Specifications.
BS EN 60730-1 Automatic electrical controls for household and similar use.
Part 1: General requirements.
BS EN ISO 9001 Quality management systems. Requirements.

Institution of Gas Engineers publications

IGE/TD/15 Services and metering installations for a gas flow not exceeding 6 m3h-1 at supply
MOP exceeding 75 mbar but not exceeding 2 bar.

Transco Engineering documents

T/PR/TMP11 Procedures for installation of MP metering installations for flows not exceeding
6m3/h using an approved single-stage regulator (to PRS28) with inlet pressures
between 75 mbar and 2 bar.

J644 ( Rev 08/04 ) - 17 -

T/SP/PRS/28

T/SP/PRS3 Product specification for meter regulators for gas flow rates not exceeding 6 m3/h
and inlet pressures less than 75 mbar.

T/SP/PRS29 Product specification for two-stage meter regulators for gas flow rates not exceeding
6 m3/h and inlet pressures in the range 350 mbar to 2 bar.

T/SP/PRS40 Product specification for medium pressure meter installation kits for flow rates not
exceeding 6 m3/h.

V9 Technical specification for the performance requirements for slamshut valves for
governor installations with inlet pressures in the range greater than 75 mbar to not
greater than 7 bar.
Part 1: Spring operated diaphragm type slamshut valves.

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 T/SP/PRS/28

APPENDIX B
TYPE TEST ON PROTECTIVE COATINGS (See Clause 5)
Resistance to humidity test
Apparatus
The apparatus shall consist of a closed cabinet, in which the relative humidity is maintained at not less
than 95% by cycling the temperature of a water bath continuously over a range from 42 °C to 48 °C,
thereby ensuring that copious condensation occurs on the samples under test.

Method
Place the regulator, with its label attached, in a chamber at a temperature cycling between 42 °C and 48
°C and with a relative humidity exceeding 95% for 48 h. At the end of this period, remove the regulator
from the chamber and examine with the naked eye for signs of corrosion, lifting or blistering of the
surface. Leave the regulator for 24 h at an ambient temperature of 20 ± 5 °C and then examine again.

Performance
The finish or surface shall conform to the requirements in clause 5. The label shall show no signs of
lifting or blistering visible to the naked eye, and there shall be no loss of legibility of the markings.

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APPENDIX C
TORSION AND BENDING MOMENT TESTS (SEE 6.2, 6.3)
C.1 MECHANICAL STRENGTH TESTS
C.1.1 Torsion test
Method
The regulator shall first be tested for leakage in accordance with F.1 of Appendix F.

Connect pipes, at least 300 mm in length, to the inlet and outlet of the regulator (threaded connections
shall be hand tight, union connections shall be tightened to a torque of 40 Nm). Clamp the inlet pipe at a
distance not less than 40 mm from the regulator. Apply a torque (of 85 Nm) to the outlet pipe for
approximately 10 s. The method of applying the torque for each regulator type is illustrated in Figure
C.1.

After application of the torque, re-test the regulator for gas tightness in accordance with F.1 of Appendix
F.

Performance
After testing, there shall be no permanent deformation, and any leakage shall not exceed that specified in
8.2.2.
Applied
³ 40 mm torque.
Regulator Force applied in
³ 40 mm one direction,
Inlet Outlet then the other
(in the plane of
Clamp the page).
Inlet
Clamp 300 mm
Regulator
(B) In-line regulator
Outlet
300 mm

Regulator

Applied
torque. Inlet Outlet
³ 40 mm

Force applied in one

direction, then the other (in
300 mm

the plane of the page).

Applied
(A) Right-angle regulator Clamp
torque.

Force applied in one

direction, then the other (in
the plane of the page).
Drawing not to scale.
(C) "U" regulator

FIGURE C.1 - Illustration of applied force and torque for mechanical strength tests
C.1.2 Bending moment test
Method
Following completion of the torsion test, clamp the inlet pipe at a distance not less than 40 mm from the
regulator and apply a force of 750 N to the outlet pipe, at a distance from the regulator of 300 mm as
illustrated in Figure C.1, for approximately 10 s in each of two opposite directions. The method of

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applying the force for each regulator type is illustrated in Figure C.1 (the in-line regulator shall be tested
in its “upright” orientation).

After application of the bending moment, re-test the regulator for gas tightness in accordance with F.1 of
Appendix F.

Performance
After testing, there shall be no permanent deformation, and any leakage shall not exceed that specified in
8.2.2.

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APPENDIX D
SIZE ENVELOPES FOR REGULATOR INSTALLATIONS

FIGURE D.1 – Surface mounted meter box

FIGURE D.2 – Semi-concealed meter box with E6 bracket

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FIGURE D.3 – Semi-concealed meter box with top view index diaphragm meter

FIGURE D.4 – Semi-concealed meter box with ETM extension and ETM or U6 meter

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T/SP/PRS/28

APPENDIX E
REQUIREMENTS FOR OVERPRESSURE PROTECTION SYSTEM
E.1 Slamshut requirements
The slamshut shall comply with the requirements of V9: Part 1, except that:

a) The maintenance free life shall be 10 years (not 5 years as specified in V9: Part 1).
b) The operating ambient temperature range shall be -20 °C to +60 °C (not -20 °C to +50 °C
as specified in V9: Part 1).

E.2 Performance of protective system

E.2.1 Regulator diaphragm failure test
E.2.1.1 Method
a) Install the regulator in a typical meter installation with a suitable demand valve on the
outlet to simulate consumer demand.
b) Record outlet pressure (to the consumer) and flow rate from the diaphragm vent at a
consumer flow rate of zero and 1.15 m³/h of air (equivalent to 1.5 m³/h of gas) with the
regulator diaphragm in the following condition:
- new (undamaged);
- 3 mm long circumferential split on crest of convoluted part of diaphragm, adjacent to
the atmospheric vent;
- 3 mm split extended to 5 mm;
- 5 mm split extended to 7 mm;
- continue to extend the split in 2 mm increments, noting the outlet pressure and vent
flow and consumer flow at each increment, until the outlet pressure increases to the
relief valve set point and/or the slamshut valve operates.

NOTE - The consumer demand shall be set at 1.15 m³/h of air (equivalent to 1.5 m³/h
gas) with the diaphragm undamaged. The demand valve will then not be
further adjusted as the split length is increased. The consumer’s flow will
increase as the split causes the back pressure on the diaphragm to rise.
The above test shall be carried out at inlet pressures of 350 mbar and 2 bar (the regulator set point
having been correctly adjusted for each inlet pressure). The outlet pressure shall be 22 mbar (nominal).

E.2.1.2 Results
To be presented in tabular and graphical form showing the variation of outlet pressure, consumer flow
rate, and relief valve/atmospheric vent flow rate with change in length of diaphragm split.

E.2.1.3 Performance
The outlet pressure (to the consumer) shall not exceed 50 mbar, and the vent flow rate shall not exceed
1.35 m³/hr of air (equivalent to 1.75 m³/hr gas), at any split length or inlet pressure.

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E.2.2 Blocked-open valve test

E.2.2.1 Method
a) Block open the valve orifice by placing a small piece of hard narrow wire diametrically
across the knife-edge in such a way that it will prevent the soft seat from sealing at the no
load condition.
b) Record the outlet pressure and the relief valve/atmospheric vent flow rate with a consumer
demand of zero, and at suitable increments of flow up to 6 m3/h.

The above test shall be carried out at wire diameters over the range 0.2 mm to 0.8 mm, and at inlet
pressures of 350 mbar and 2 bar (the regulator set point having been correctly adjusted for each inlet
pressure). The outlet pressure shall be 22 mbar (nominal).

E.2.2.2 Results
To be presented in tabular and graphical form showing the variation of outlet pressure and relief
valve/atmospheric vent flow rate with change in consumer flow rate at the various wire diameters.

E.2.2.3 Performance
The outlet pressure (to the consumer) shall not exceed 50 mbar with either a 0.2 mm diameter wire or a
0.8 mm diameter wire, at any consumer flow rate. The vent flow rate shall not exceed 1.35 m³/h of air
(equivalent to 1.75 m³/h gas) with either wire at either inlet pressure.

E.2.3 Relief valve performance test

E.2.3.1 Method
a) Install the regulator so that the relief valve set point can be checked by an external
pressure source.
b) Apply pressure to the outlet pipework of the regulator at a rate of 15 mbar/minute from
80% of relief valve set point (crack-open) until the relief opens, i.e. flow rate of 0.1 m³/h.
Reduce applied pressure to determine the relief valve reseat pressure. Check the set point
and reseat pressure a further 4 times.
c) Repeat the above test with the regulator at -20 ± 2 °C and at 60 ± 2 °C.
d) With the regulator at 20 ! 5 °C apply pressure to the outlet pipework to determine the flow
rate versus pressure characteristic of the relief valve at suitable increments up to an
applied pressure of 150 mbar.

E.2.3.2 Results
To be presented in tabular and graphical form.

E.2.3.3 Performance
a) The accuracy of the set point of the relief valve shall be within ± 3.5 mbar of the nominal
set point (set at 35 mbar by the manufacturer).
b) The reseat pressure shall be within ± 15% of the set point.
c) The average value of the set point of the relief at 60 °C and –20 °C shall not vary by
greater than ± 15% from the average value determined at 20 ºC.
d) The flow rate versus pressure characteristic shall be within the manufacturer’s stated
performance limits.

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APPENDIX F
TYPE TESTS ON REGULATORS (See 8.2 to 8.5)
F.1 STRENGTH TEST AND EXTERNAL GAS TIGHTNESS TEST
Method
Blank the regulator’s inlet connection, and seal the relief vent. Apply an air pressure of 150 mbar (when
carrying out the strength test) or 75 mbar (when carrying out the tightness test) to the regulator’s outlet
connection, and measure any external leakage from the regulator.

NOTE - This will cause the slamshut to fire.

Remove the blank from the regulator’s inlet connection, un-seal the relief vent, and blank the regulator’s
outlet connection. Reset the slamshut, and apply an air pressure of 3 bar (when carrying out the strength
test) or 2 bar (when carrying out the tightness test) to the inlet connection of the regulator. Measure any
external leakage from the regulator. After the strength test, examine the regulator for signs of any
cracking or permanent deformation.

The accuracy of measurement of pressure and flow shall be ± 2%.

NOTE - The strength test and tightness test may be combined where appropriate.

Performance
The leakage rate in the tightness test shall not exceed that specified in 8.2.2.
There shall be no cracking or permanent deformation after the strength test.

F.2 PERFORMANCE TESTS

F.2.1 Test setting conditions
Before carrying out the tests in F.2.2, F.2.3 and F.2.4, the regulator (in its “upright” orientation) shall be
set to an outlet pressure of 23 mbar at an air flow rate of 0.23 ! 0.03 m³/h and at an inlet pressure of
either:

a) 2 bar ± 0.1 bar, or

b) 350 mbar ± 10 mbar

depending on the particular inlet test pressure.

F.2.2 Outlet pressures test

Method
Supply air to the apparatus shown in Figure F.1. Straight lengths of smooth bore pipe are used for
connections to the regulator under test.

Test the regulator over a range of flow rates to develop an outlet pressure/flow characteristic.

The accuracy of measurement of pressure and flow shall be ± 2 %.

Performance
The performance of the regulator shall conform to 8.3.

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 T/SP/PRS/28

d = 20 +0.5
-0

1. Adjustable regulator for inlet pressure

2. Flow meter
3. Inlet pressure gauge
4. Differential pressure gauge
5. Outlet pressure gauge
6. Regulator under test
7. Manual control valve
Detail A

All dimensions in mm

FIGURE F.1 - Performance characteristics test apparatus

F.2.3 Lock-up test
Method
Supply air to the apparatus shown in Figure F.2. For this test, item (8) shall be a vessel of 630 ml ±10 ml
(e.g. an E6 meter having an internal volume within this range). The solenoid valve (12) is kept fully open
during the test.

With the shut-off valve (5) open and the flow meter isolating valve (3) closed, slowly close the rate
setting valve (13) in not less than 5 s and hold the regulator under these conditions at constant
temperature.

NOTE - If the test is specified to be carried out at low ambient temperature, air at a
temperature of between 0 °C and 5 °C shall be flowed through the regulator at
1 m3/h for 1 minute before closing the rate setting valve.

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T/SP/PRS/28

Lock-up conditions shall be established within 10 minutes. At this time open the flow meter isolating
valve (3) and close the shut-off valve (5), and measure the leakage at the flow meter (4).

The accuracy of measurement shall be ± 2%.

Performance
The lock-up characteristics of the regulator shall conform to 8.4.

NOTE - The flow meter (14) may be mounted upstream of the regulator under test.

1. Adjustable regulator for inlet pressure

2. Bleed point (to prevent lock-up of adjustable regulator)
3. Flow meter isolating valve
4. Sensitive flow meter, for lock-up test
5. Shut-off valve
6. Inlet pressure gauge
7. Regulator under test
8. Gas meter or vessel (see F.2.3)
9. 2 metre length of Ø 28 mm copper pipe to BS EN 1057
10. Fast response pressure transducer with recording equipment
11. 150 mm length of Ø 28 mm copper pipe to BS EN 1057
12. Quick acting solenoid valve, for speed of response test
13. Rate setting valve
14. Flow meter, for speed of response test

Figure F.2 - Lock-up and speed of response test rig

F.2.4 Speed of response test
Method
Supply air to the apparatus shown in Figure F.2. For this test, item (8) shall be a vessel of 630 ml ± 10
ml (e.g. an E6 meter having a internal volume within this range). The flow meter isolating valve (3) is
kept closed during the test.

Adjust the rate setting valve (13) to pass 2.7 m³/h ± 0.05 m³/h of air.

Record the outlet pressure of the regulator as the solenoid valve is opened, and as the solenoid valve is
closed.

The accuracy of measurement shall be ± 2%.

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Performance
The speed of response shall conform to 8.5.

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T/SP/PRS/28

APPENDIX G
MECHANICAL LIFE TEST (SEE 8.6)
Method
Place the regulator, with label attached, in an ambient temperature of 60 ± 5 °C, with inlet and outlet
connections open to the atmosphere, for 28 days. At the end of this period, subject the regulator to an
accelerated mechanical life test at room temperature. The accelerated mechanical life test shall be so
arranged that the diaphragm and valve pad operate in the normal mode and over the full stroke 5000
times at a rate of not less than 120 cycles/h, with the regulator in the “upright” orientation, and for a
further 5000 times at the same rate with the regulator in the “perpendicular” orientation.

Performance
After the test, the regulator shall satisfy the requirements of 8.2, 8.3 and 8.4, and the diaphragm shall
show no signs of perforation, cracking, permanent deformation or delamination.

The label shall show no signs of lifting or blistering visible to the naked eye, and there shall be no loss of
legibility of the markings.

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 Description of test Test Method Regulator Orientation Regulator inlet test pressure Require- Comments
diaphragm ments

350
Appendix Horizontal Vertical 75 mbar 2 bar 3 bar Clause
mbar
Resistance to humidity B - - - - - - 5.1

J644 ( Rev 08/04 )

APPENDIX H

Strength test F.1 - - - - - - 8.2.1 - Zero inlet pressure, outlet

pressurised to 150 mbar.
F.1 - - - - - Yes 8.2.1 - Inlet 1.5 maximum operating
pressure, outlet blanked.

Tightness test F.1 - - - - - - 8.2.2 - Zero inlet pressure, outlet

pressurised to 75 mbar.
F.1 - - - - Yes - 8.2.2 - Inlet at maximum operating
pressure, outlet blanked.
SUMMARY OF TYPE APPROVAL TESTS

Outlet pressure at high flow rate F.2.1, F.2.2 Yes - Yes Yes Yes - 8.3 - Inlet 75 and 350 mbar (set at
F.2.1, F.2.2 - Yes Yes Yes Yes - 8.3 350 mbar) and 350 mbar and
2 bar (set at 2 bar).

Outlet pressure at low flow rate F.2.1, F.2.2 Yes - Yes Yes Yes - 8.3 - Inlet 75 and 350 mbar (set at
F.2.1, F.2.2 - Yes Yes Yes Yes - 8.3 350 mbar) and 350 mbar and
2 bar (set at 2 bar).

Maximum pressure setting F.2.1, F.2.2 Yes - - Yes Yes - 8.3 - 3.5 m³/h gas flow, maximum
(adjustable regulators only) F.2.1, F.2.2 - Yes - Yes Yes - 8.3 outlet pressure setting.

Lock-up at ambient temperature F.2.1, F.2.3 Yes - - Yes Yes Yes 8.4
of 20 ºC F.2.1, F.2.3 - Yes - Yes Yes Yes 8.4

Lock-up at ambient temperature F.2.1, F.2.3 Yes - - - Yes - 8.4 - Regulator at -20°C, test gas
of -20 ºC (air) between 0°C and 5°C.

Speed of response F.2.1, F.2.4 Yes - Yes Yes Yes - 8.5 - Inlet 75 and 350 mbar (set at
F.2.1, F.2.4 - Yes Yes Yes Yes - 8.5 350 mbar) and 350 mbar and
2 bar (set at 2 bar).

Mechanical strength:
i) Torsion C.1.1, F.1 Yes - - - - - 6.2, 8.2.2 - Tightness test to F.1 before
and after torsion test.
Ii) Bending moment C.1.2, F.1 Yes - - - - - 6.3, 8.2.2 - Tightness test to F.1 before
and after bending test.

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T/SP/PRS/28

TABLE H.1 – Performance before accelerated mechanical life test

 Description of test Test Method Regulator Orientation Regulator inlet test pressure Require- Comments

- 32 -
diaphragm ments

75 350
Appendix Horizontal Vertical 2 bar 3 bar Clause
mbar mbar
T/SP/PRS/28

Strength test G, F.1 - - - - - - 8.6, 8.2.1 - Zero inlet pressure, outlet

pressurised to 150 mbar.
G, F.1 - - - - - Yes 8.6, 8.2.1 - Inlet 1.5 maximum operating
pressure, outlet blanked.

Tightness test G, F.1 - - - - - - 8.6, 8.2.2 - Zero inlet pressure, outlet

pressurised to 75 mbar.
G, F.1 - - - - Yes - 8.6, 8.2.2 - Inlet at maximum operating
pressure, outlet blanked.

Outlet pressure at high flow rate F.2.1, G, F.2.2 Yes - Yes Yes Yes - 8.6, 8.3 - Inlet 75 and 350 mbar (set at
F.2.1, G, F.2.2 - Yes Yes Yes Yes - 8.6, 8.3 350 mbar) and 350 mbar and
2 bar (set at 2 bar).

Outlet pressure at low flow rate F.2.1, G, F.2.2 Yes - Yes Yes Yes - 8.6, 8.3 - Inlet 75 and 350 mbar (set at
F.2.1, G, F.2.2 - Yes Yes Yes Yes - 8.6, 8.3 350 mbar) and 350 mbar and
2 bar (set at 2 bar).

Maximum pressure setting F.2.1, G, F.2.2 Yes - - Yes Yes - 8.6, 8.3 - 3.5 m³/h gas flow, maximum
(adjustable regulators only) F.2.1, G, F.2.2 - Yes - Yes Yes - 8.6, 8.3 outlet pressure setting.

Lock-up at ambient temperature F.2.1, G, F.2.3 Yes - - Yes Yes Yes 8.6, 8.4
of 20 ºC F.2.1, G, F.2.3 - Yes - Yes Yes Yes 8.6, 8.4

Lock-up at ambient temperature F.2.1, G, F.2.3 Yes - - - Yes - 8.6, 8.4 - Regulator at -20°C, test gas
of -20 ºC (air) between 0°C and 5°C.

Resistance of label to high G Yes - - - - - 12.2.3

temperature

TABLE H.2 – Performance after accelerated mechanical life test

J644 ( Rev 08/04 )

 Description of test Test Regulator Orientation Regulator inlet test pressure Require- Comments
Method diaphragm ments

Appendix Horizontal Vertical 75 mbar 350 mbar 2 bar 3 bar Clause

J644 ( Rev 08/04 )

Tests in accordance with V9: E.1 - - - - E.1 - Upper test temperature 60 °C
Part 1 (not 50 °C).

TABLE H.3 – Requirements for over-pressure slamshuts

- 33 -
T/SP/PRS/28
 Description of test Test Method Regulator Orientation Regulator inlet test pressure Require- Comments

- 34 -
diaphragm ments

75 350
Appendix Horizontal Vertical 2 bar 3 bar Clause
mbar mbar
T/SP/PRS/28

Diaphragm failure:
- At consumer flow rate = Zero E.2.1 Yes - - Yes Yes - E.2.1.3 - Inlet 350 mbar (set at 350
mbar) and 2 bar (set at 2 bar).
Diaphragm split to be extended
in 2 mm increments until relief
- At consumer flow rate = 1.5 m3/h E.2.1 Yes - - Yes Yes - E.2.1.3 valve and/or slamshut
operates.

Blocked-open 2nd stage valve:

- At consumer flow rate = Zero to E.2.2 Yes - - Yes Yes - E.2.2.3 - Inlet 350 mbar (set at 350
6 m3/h mbar) and 2 bar (set at 2 bar).
Flow to be increased in
increments from zero to 6 m3/h

Relief valve performance:

- Accuracy of set point and reseat E.2.3 Yes - - - - - E.2.3.3 - Five checks of set point and
pressure at ambient temperatures of reseat pressure
20°C, 60°C and -20°C

- Flow rate/pressure characteristic E.2.3 Yes - - - - E.2.3.3

TABLE H.4 - Requirements for over-pressure protection system

J644 ( Rev 08/04 )