CUSTOMER WORK INSTRUCTIONS FOR THE GM & GL G-STICK Regulator REBUILD

Document #: CWI-GM/GL G-Stick

Rev.: 0

Rev. Date: 08/10/06

Page 1 of 4

 

 

Purpose: To define disassembly and re-assembly of G-STICK Regulator

 

G-STICK Regulator Disassembly

1.    The assembly drawing of G-STICK regulator

1 LP Gauge: 2 Body: 3 Control Knob: 4 Housing Cap: 5 Control Knob Cover:

6 Nut: 7 Lock washer: 8 Adjusting Screw: 9 Spring Button: 10 Spring: 11 Gasket: 12 Diaphragm: 13 Diaphragm Button: 14 Spring: 15 Gland: 16 Valve Stem:

17 Seat: 18 Nozzle: 19 O-ring

 

2.    Put on clean latex or vinyl gloves. *Change gloves when visible dirt, oil or debris is present.

 

3.    Remove the control knob cover, loosen the nut (6), remove the nut, the lock washer (7), then unscrew the control knob (3) from the regulator body.

 

4.    Loosen the housing cap (4) with a wrench, insure the G-Stick is securely clamped, then screw off the housing cap, and turn the adjusting screw (8) counterclockwise until it bottoms out in the housing cap.

 

5.    Remove the spring button (9), spring (10), diaphragm button (13), gasket (11) Diaphragm (12) and the O-ring (19).

 

6.    Loosen the nozzle (18) with a tee type socket wrench, then slowly remove the seat assembly including nozzle (18), seat (17), valve stem (16), spring (14) and gland (15).

(Note: Debris, like metal shavings could fall from the Teflon seat when being removed)

 

G-Stick Regulator Inspection

1.   Put on clean latex or vinyl gloves. *Change gloves when visible dirt, oil or debris is present.

2.     Perform a visual inspection of the G-STICK regulator components, ensuring that the diaphragm is not damaged or deformed and the seating areas are free of debris or foreign materials.

3.    Replace components with a G-Stick regulator rebuild kit.

If non-repairable defects are found return regulator to Evans  Components for disposition.

G-STICK Regulator Reassembly 

1.    Using new rebuild kit parts (SS-GM/GL-100), consisting of the following parts diaphragm (12), gasket (11), nozzle (18) and seat (17) install using the following steps.

2.    Seat assembly: install the seat (17) into the nozzle (18), install the friction washer into the gland (15). Then in order, place the spring (14) and the gland (15) onto the valve stem (16).

3.    Place the seat assembly into the body (2), by continually tightening the nozzle in slow increments, using a T-style socket and torque wrench, torque to 12.5 – 14.5 ft/lbs.

4.    Use your latex gloved index finger, lubricate with only a small amount of approved lube onto the thread of the adjusting screw (8). Place the O-ring (19) on the body, then cover the O-ring (19) with the diaphragm (12) Lubricate with O2 compatible lube on the rim of the body where the diaphragm seals.

5.    In the following order place the diaphragm button (13), gasket (11), spring (10), spring button (Note: the concave of the spring button is placed up and lubricated with a small amount approved lube) on the diaphragm, then cover them with the housing cap assembly. And continue to tighten the housing cap in increments, using a crows foot torque wrench, to a torque setting of 44~48 ft/lbs.

The ball valve leakage test:

6.    Close the ball valve and cap the outlet of the G-Stick. Set the inlet pressure to a maximum of 500 PSI (the rated inlet pressure), turn the adjusting screw (8) clockwise to open the regulator valve, the indicator on LP gauge shouldn’t move.

The regulator leakage test:

7.    The internal leakage test:  open the ball valve and close the outlet of the regulator. Then set the inlet pressure to a maximum of 500 PSIG, the indicator on LP gauge shouldn’t move if the regulator valve isn’t opened.

8.    The external leakage test:  open the ball valve and close the outlet of the regulator. Then set the inlet pressure at to a maximum of 500 PSIG (the rated inlet pressure), adjust the regulator to pressurize the outlet pressure to a maximum 150 PSIG (the rated outlet pressure).  Verify all the connections by pressure decay test.

9.    Then decrease the outlet pressure from a maximum of 150 PSIG to 50 PSIG, and keep this pressure for 15 min, the variation of the outlet pressure should be within ±2 PSIG.

Flow test:

10.  Open the ball valve and the outlet of the regulator, set the inlet pressure to a maximum of 500 PSIG, then adjust the regulator to increase the outlet pressure from 0 PSIG to a maximum of 150 PSIG. During the pressure increase, the indicator on the LP gauge should move steadily higher and the regulator should not whistle.

11.  Open the ball valve and close the outlet of the regulator.  Adjust the adjusting screw (8) of the regulator to increase the outlet pressure from 0 PSI to a maximum 150 PSI, then install the control knob (3), the nut (6), the lock washer (7) on the adjusting screw, and continue to tighten the nut in increments, using a torque wrench, with a torque setting of 14~16.5 ft/lbs.

12.  Install the control knob cover (5).

13.  Helium leak test or Pressure snoop test Regulator.

 

 

 

Reviewed and approved

Revision History

Rev

Description of Changes

Author & date

0

Original issue -

GBP 08/14/06