Pressure loaded regulator with dual diaphragm and redundant seal

A method of reducing leaks in a regulator, the method comprising:

• providing a fluid regulator having a regulator body including a fluid inlet and a fluid outlet connected by a fluid flow path, the regulator further having an orifice disposed in the fluid flow path, and a seat disposed in the orifice, a control element disposed within the fluid flow path, the control element being shiftable between an open position spaced away from the seat and a closed position seated against the seat, the control element being arranged to respond to fluid pressure changes to control flow of a process fluid through the orifice, and the regulator further having an actuator attached to the regulator body;
• providing a first metal diaphragm;
• coupling a radially inward portion of the diaphragm to the control element;
• providing a second resilient diaphragm;
• providing a third metal diaphragm;
• providing a radially outer upper gasket between the first metal diaphragm and an actuator housing of the actuator;
• providing a radially inner upper gasket between the first metal diaphragm and a diaphragm plate coupled to the first metal diaphragm;
• providing a radially outer lower gasket between the third metal diaphragm and the regulator body;
• providing a radially inner lower gasket between the third metal diaphragm and a diaphragm cap coupled to the third metal diaphragm;
• and
• coupling a radially inward portion of the third diaphragm to the control element,
• wherein the second diaphragm comprises a resilient material and the second diaphragm is located between the first diaphragm and the third diaphragm.

A method of reducing leaks in a regulator, the method comprising:

• providing a fluid regulator having a regulator body including a fluid inlet and a fluid outlet connected by a fluid flow path, the regulator further having an orifice disposed in the fluid flow path, and a seat disposed in the orifice, a control element disposed within the fluid flow path, the control element being shiftable between an open position spaced away from the seat and a closed position seated against the seat, the control element being arranged to respond to fluid pressure changes to control flow of a process fluid through the orifice, and the regulator further having an actuator attached to the regulator body;
• providing a first metal diaphragm;
• coupling a radially inward portion of the diaphragm to the control element;
• providing a second resilient diaphragm;
• providing a third metal diaphragm;
• coupling a radially inward portion of the third diaphragm to the control element;
• providing each of the first diaphragm, the second diaphragm, and the third diaphragm with a substantially planar center portion and an annular planar skirt portion that are connected by a middle portion angled relative to the substantially planar center portion and the annular planar skirt portion;
• and providing an outer gasket and an inner gasket, the outer gasket being located proximate the annular planar skirt portion and the inner gasket being located proximate the substantially planar center portion, wherein the second diaphragm comprises a resilient material and the second diaphragm is located between the first diaphragm and the third diaphragm;
• wherein the outer gasket comprises a radially outer upper gasket located proximate the annular planar skirt portion of the first diaphragm, and wherein the inner gasket comprises a radially inner upper gasket located proximate the substantially planar center portion of the first diaphragm, further comprising a radially outer lower gasket located proximate the annular planar skirt portion of the third diaphragm, and a radially inner lower gasket located proximate the substantially planar center portion of the third diaphragm.