[et_pb_section fb_built=”1″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” custom_padding=”2em||0px||false|false” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_heading title=”Pressure Vessel Regulation in Gas and Oil Infrastructure” _builder_version=”4.27.4″ _module_preset=”default” custom_css_free_form=”selector h1 {|| text-wrap: pretty;||}” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_image src=”https:\/\/www.alicat.com\/wp-content\/uploads\/2025\/07\/Pressure_vessel_hero.webp” alt=”pressure vessel” align=”center” force_fullwidth=”on” _builder_version=”4.27.5″ _module_preset=”default” custom_margin=”1.5rem||||false|false” hover_enabled=”0″ custom_css_free_form=”selector img {|| object-fit: cover;||}” global_colors_info=”{}” theme_builder_area=”post_content” module_id=”article-hero-image” sticky_enabled=”0″][\/et_pb_image][et_pb_divider color=”#2A3B47″ divider_weight=”2.5px” _builder_version=”4.27.4″ _module_preset=”default” height=”0px” custom_margin=”3rem||3rem||true|false” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_divider][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” custom_padding=”0px||0px||true|false” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]Pressure vessels are central to the oil and gas industry. Whether storing hydrocarbons, facilitating chemical reactions, or separating process streams, these vessels operate under extreme pressure and temperature conditions.<\/p>\n
Inconsistent or imprecise pressure control can lead to safety risks, process inefficiencies, equipment damage, and regulatory non‑compliance. Over‑pressurization risks vessel failure or activation of safety relief systems, while under-pressurization can disrupt downstream processes or cause phase separation issues. The pressure control system must therefore be considered a critical part of the vessel\u2019s design.[\/et_pb_text][et_pb_heading title=”Limitations in traditional pneumatic control systems” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n
Many plants still rely on pneumatic control systems built around mechanical regulators and binary solenoid valves. While functional, these setups are inherently limited. They cannot dynamically adjust to fluctuations in supply pressure, ambient temperature, or source gas composition.<\/p>\n
As a result, when pressure drifts, valve behavior becomes unpredictable, introducing errors and instability downstream. Systems without proportional valves that rely on basic pneumatic controls also create operational delays when switching between feed gases or process lines, increasing the risk of pressure surges, flow interruptions, and contamination during transitions. These shortcomings can negatively impact the performance of compressors, separators, and downstream instrumentation tied to the vessel.<\/p>\n
[\/et_pb_text][et_pb_heading title=”The role of intrinsically safe solutions” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n
In systems with proportional and electronic control, a regulatory obstacle arises: electronics have the potential to produce sparks and must be rerouted or enclosed in bulky protective housings. This drives up cost, increases maintenance complexity, and consumes valuable space in already crowded plant environments.<\/p>\n
The challenge for the process engineer then, is to design a system that balances responsive, precise pressure control with compliance to safety standards, particularly in highly regulated hazardous zones. This balance must account not only for the pressure vessel itself, but also for the critical systems that rely on it.<\/p>\n
[\/et_pb_text][et_pb_heading title=”Case study: integrating a dual-valve pressure controller” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_image src=”https:\/\/www.alicat.com\/wp-content\/uploads\/2025\/07\/IS-Pressure-Info-01.webp” title_text=”IS-Pressure-Info-01″ _builder_version=”4.27.4″ _module_preset=”default” max_width=”50%” max_width_tablet=”100%” max_width_phone=”100%” max_width_last_edited=”on|phone” custom_padding=”||2rem|2rem|false|false” custom_padding_tablet=”|||0rem|false|false” custom_padding_phone=”|||0rem|false|false” custom_padding_last_edited=”on|tablet” module_alignment_tablet=”center” module_alignment_phone=”center” module_alignment_last_edited=”on|tablet” custom_css_main_element=”float: right;” global_colors_info=”{}” custom_css_main_element_last_edited=”on|phone” custom_css_main_element_phone=”float: none;” custom_css_main_element_tablet=”float: right;” theme_builder_area=”post_content”][\/et_pb_image][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]<\/p>\n
When a North American gas company set out to design a new pressure control system, they integrated an\u00a0intrinsically safe IS-PRO\u2122 dual-valve pressure controller (PCD)<\/a> to maintain vessel pressure within a Class I, Division 1 explosive location.<\/p>\n In this configuration, the IS-PRO\u2122 PCD supplied pilot pressure to a dome\u2011loaded pressure regulator (DLPR) \u2014 a type of regulator that uses a pilot signal, rather than a mechanical spring, to control back pressure. This setup offers faster response times, greater accuracy, and better stability across varying flow rates, making it ideal for high\u2011performance and high\u2011risk environments like oil and gas facilities.<\/p>\n By adjusting the pilot pressure proportionally, the ISPCD enabled high\u2011resolution, closed\u2011loop control of the DLPR. This allowed for automated pressure regulation without introducing spark risks in a Class I, Division 1 hazardous location. The system was configured to maintain vessel pressure between 0 and 100 PSIG (0 to ~6.9 bar), with inlet pressures ranging from 120 to 150 PSIG (8.3 to 10.3 bar). Exhaust was vented to atmosphere, and the ambient temperature ranged from 20 to 115 \u00b0F (\u22126.7 to 46.1 \u00b0C).<\/p>\n The ISPCD\u2019s precise control capabilities and compatibility with digital setpoints made it particularly well\u2011suited for use with DLPRs, enabling reliable pressure management while ensuring compliance with intrinsically safe requirements.<\/p>\n [\/et_pb_text][et_pb_heading title=”System integration and measurable benefits ” _builder_version=”4.27.4″ _module_preset=”default” title_level=”h3″ global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_heading][et_pb_text _builder_version=”4.27.4″ _module_preset=”default” custom_margin=”||2rem||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]The IS‑PRO’s ability to measure absolute, gauge, or differential pressure — and communicate data via digital or analog signals — allowed seamless integration into the facility’s existing SCADA infrastructure. This enabled proportional control and accurate pressure measurement, improving both vessel safety and overall system efficiency.<\/p>\n In critical oil and gas operations, where pressure vessels must perform reliably under volatile conditions, precise pressure control is non‑negotiable. By integrating the IS‑PRO™ dual‑valve pressure controller, the engineer replaced manual, static control with automated, closed‑loop control. This ensured consistent pressure regulation and resulted in a more efficient process aligned with the demands of modern oil and gas infrastructure.[\/et_pb_text][et_pb_text module_class=”cta-link” _builder_version=”4.27.5″ _module_preset=”default” text_font=”|700|||||||” text_font_size=”16px” text_line_height=”1.8em” custom_margin=”||2rem||false|false” locked=”off” global_colors_info=”{}” theme_builder_area=”post_content”]Learn more about IS-Series intrinsically safe instruments for the gas and oil industry