Repair Manual 12 PL PILOT

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1 Repair Manual 12 PL PILOT

2 12 PL PILOT REPAIR MANUAL INDEX Introduction... 1 Elastomer Materials... 2 Disassembly... 3 Assembly... 7 Testing NOTE: We reserve the right to modify or change, without prior notice, any statement or information contained herein. If exact dimensions or specifications are required by the customer certified prints will be furnished for a minimum charge upon request to KIMRAY, Inc. Copyright 2006, KIMRAY, Inc.

3 INTRODUCTION SCOPE This instruction manual contains repair information for the Kimray 12 PL Floatless Liquid Level Controller with additional information in regarding calibration. DESCRIPTION The 12 PL Floatless Liquid Level Controller uses change in vessel liquid level to control the pilot assembly acting against the adjustable spring load. Change in liquid level repositions a small three way valve (pilot plug and seat) which controls diaphragm Pressure in the vessel dump valve. OPERATION The Kimray 12 PL maintains a constant liquid level in a vessel by providing a indirect pneumatic signal to operate a pressure closing dump valve. This signal can be set for either semi snap or throttle acting. MAINTENANCE Maintenance should be performed on a regular basis. An initial inspection interval of 12 months is recommended. Depending on the service conditions and the condition of the level controller, the inspection interval may be decreased or increased. WARNING Before performing any service, be sure that the vessel pressure has been relieved and liquid has been drained. Be sure that any operating or instrument gas lines have been disconnected. GENERAL SPECIFICATIONS: Working pressure* 125 psi -- Hydrostatic Test: ANSI B16.37 Pilot Spring Range 4 inches to 4 feet H2O Optional Springs 8 feet and 30 feet H2O Bonnet Max. Pressure 125 psi Material Option Gray Iron ASTM A48-94a Class 20 Ductile Iron ASTM A395 Class Steel ASTM A 216 WCB Body Max. Pressure 125 psi Material Options Gray Iron ASTM A48-94a Class 20 Ductile Iron ASTM A395 Class Steel ASTM A 216 WCB Connections: Separator Gas 1/4 inch NPT Separator Liquid 1 inch NPT To Valve Actuator 1/4 inch NPT Interior Parts Gray Iron, Steel Gauge Brass Base and Bourdon Tube Diaphragms Nitrile *Design is hydrostatically tested to at least 4 times the stated working pressure. (ANSI Standards require at least 1 1/2 times the stated working pressure.) To get the long service you have come to expect from Kimray products, always use GENUINE KIMRAY PARTS when doing repairs. Remember, parts made to less than Kimray specifications don t save you money!!! ENG Rev. 4 Issued Page 1

4 ELASTOMER MATERIALS TEMPERATURE: -25 to +500 F -30 to +260 C APPLICATION: Crude Oil & Gas Production (High heat), Steam Flood Production Chemicals (corrosion inhibitors) Amine Sweetener Systems, Gasoline, Diesel, Fuel Oil Systems FLUID / GAS: Crude Oil & Gas Production, H2S, Steam, Petroleum fluids, Sea Water HSN (Highly Saturated Nitrile) TEMPERATURE: -15 to +300 F -26 to +149 C APPLICATION: Crude Oil & Gas Production w/ H2S C02 FLUID / GAS: Crude Oil & Gas H2S, C02, Sea Water TEMPERATURE: Buna-N: -40 to +220 F -40 to +105 C Low-Temp: -85 to +120 F -65 to +49 C APPLICATION: Crude Oil & Gas Production Glycol Dehydrators, Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal, Methanol Injection Pumps, Water pump seals, Hydraulic pump seals FLUID / GAS: Crude Oil & Gas, Good to Poor in Sour Production (See HSN), Water, Glycols, Hydraulic Oils, Resistance to crude oil in the presence of hydrogen sulfide and amines, Diesel fuel, fuel oils DO NOT USE WITH: Aromatic hydrocarbons, chlorinated hydrocarbons, phosphate esters (hydraulic fluids) TEMPERATURE: -350 to +500 F AFLAS is a trade mark of Asahi Glass Co NITRILE GYLON APPLICATION: High heat, high chemical resistance, highly resistance to gas permeation TEMPERATURE: -10 to +350 F -23 to +177 C APPLICATION: Crude Oil & Gas Production, Glycol Dehydrators, Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal, Methanol Injection Pumps. (Also Vacuum Service) (Gas permeability is very low) FLUID / GAS: Crude Oil & Gas, Sour Gas (C02), Propane, Gasoline, Diesel, Fuel Oil Systems DO NOT USE WITH: Hot Water, Not preferred for wet H2S, Methyl Alcohol, Amines, Sodium hydroxide solutions TEMPERATURE: -65 to +300 F -54 to +148 C APPLICATION: Steam Flood FLUID / GAS: Steam, Water, Alcohol DO NOT USE WITH: Crude Oil & Gas, Diester Lubricants (Lube Oils) TEMPERATURE: -40 to +220 F -40 to +104 C APPLICATION: High abrasion resistance Seats, Diaphragms FLUID / GAS: Crude Oil gas and Water, Sour Gas (C02), propane, butane, fuel, mineral oil and grease TEMPERATURE: ±0 to +300 F -17 to +149 C APPLICATION: Production Heaters, Thermostats FLUID / GAS: Crude Oil & Gas at High Temperature DO NOT USE WITH: Alcohol, Glycols VITON is a trade mark of Dupont ETHYLENE PROPYLENE POLYURETHANE POLYACRYLATE Page 2

5 DISASSEMBLY STEP 1 SECURE PL PILOT Use 1" NPT jig (Fig 1.1) to Secure pilot in vise if available (Fig. 1.2). STEP 2 REMOVE ADJUSTING SCREW Loosen lock nut and remove adjustment screw and nut from top of pilot (Fig 2.1 & 2.2). Figure 1.1 Figure 1.2 STEP 3 REMOVE LOWER STABILIZING HOUSING Figure 2.1 Figure 2.2 Remove tubing and set aside. (Fig 3.1). Remove seat from lower stabilizing housing (Fig 3.2) make sure set screw is tight on ring (Fig 3.3). Figure 3.1 Remove 4 bolts to stabilizing housing and remove housing (Fig 3.4). Figure 3.2 Figure 3.3 Stabilizing Housing Bolts Housing Figure Page 3

6 DISASSEMBLY STEP 4 REMOVE BONNET Flip controller over and remove 4 bolts from upper bonnet (Fig 4.1). Pry off bonnet gently with flat blade screwdriver If stuck (Fig 4.2). Remove spring and spring plate also (Fig 4.3). Watch for ball # 254 to fall out under spring plate. Figure 4.1 STEP 5 REMOVE DIAPHRAGM Remove 10 bolts and nuts (Fig 5.1) and pry apart housings (Fig 5.2). Figure 4.2 Figure 4.3 Loosen upper diaphragm #250 (Fig 5.3) and pull through upper housing (Fig 5.4). Figure 5.1 Figure 5.2 Figure 5.3 Figure 5.4 Page 4

7 DISASSEMBLY STEP 6 DIAPHRAGM ASSEMBLY Place diaphragm assembly in vise and remove #111 seat with a 9/16 socket (Fig 6.1). Seat #111 Flip diaphragm assembly over in vise and Remove pivot stem with 5/8 wrench (Fig 6.2). Pivot Stem Figure 6.1 Remove pivot stem from cap (Fig 6.3) and discard old diaphragm. Figure 6.2 Now remove diaphragm plate and diaphragm from pilot housing (Fig 6.4) and discard old diaphragm. Figure 6.3 Finally remove spacer from pilot housing (Fig 6.5) and discard old diaphragm. Figure 6.4 Figure Page 5

8 NOTES Page 6

9 ASSEMBLY STEP 1 CHECK PARTS Clean all parts and replace if worn or damaged. You will need re-build kit #RCL it is helpful to place everything on a clean table and double check to make sure all parts are there (Fig 1.1). STEP 2 MOUNT LOWER HOUSING Secure lower housing back on to jig (Fig 2.1). Figure 1.1 STEP 3 ASSEMBLE DIAPHRAGMS Roll O-Ring onto pivot stem (Fig 3.2) and insert through cap #255 (Fig 3.3). Figure 2.1 Insert #250 diaphragm over stem and housing (Fig 3.3, 3.4). Figure 3.1 Figure 3.2 Make sure #250 Diaphragm is rolled evenly around the O.D. Place gasket on new #111 seat (Fig 3.5). Figure 3.3 Figure 3.4 Figure Page 7

10 ASSEMBLY Insert spacer over pilot housing, (Fig 3.6) then place diaphragm #259 over spacer (Fig 3.7). Now place diaphragm plate #246 over diaphragm (Fig 3.8). Figure 3.6 Figure 3.7 Insert pivot stem and start threads on to pilot housing (Fig 3.9), then tighten snug without folding diaphragm gasket (Fig 3.10). Figure 3.8 Figure 3.9 Figure 3.10 Flip over diaphragm assembly and insert seat #111 and pilot plug into pilot housing (Fig 3.11), and tighten snug without making gasket #250 fold or tear (Fig 3.12). Pilot Plug big ball STEP 4 ASSEMBLE HOUSING With lower housing in vise upside down insert diaphragm assembly from under side. Make sure seat #111 and small ball of pilot plug are facing you (Fig 4.1). Pull diaphragm up through housing careful not to tear it (Fig 4.2). Figure 3.11 Figure 3.12 Figure 4.1 Figure 4.2 Page 8

11 ASSEMBLY Hold diaphragm assembly with one hand making sure gasket #250 is lying smooth and even. Then place lower stabilizing housing on to lower housing with vent line facing away from 1" NPT connection (Fig 4.3). Tighten housing with 4 bolts (Fig 4.4). Turn housing over and place upper housing on with 1/4" NPT connection 90 deg clockwise from 1" NPT connection (Fig 4.5). Figure 4.3 Figure 4.4 Pull #250 diaphragm up through hole being careful not to tear (Fig 4.6). Bolt housings together making sure to put the 2 longer #1942 bolts around 1" NPT connection. (Fig 4.7) then use the #191 bolts for the remaining 8 holes. Figure 4.5 Figure 4.6 #1942 long bolts STEP 5 INSTALL BONNET Apply grease to top of pivot stem (Fig 5.1). Then place #245 ball on top of pivot stem ( Fig 5.2). Figure 4.7 Figure 5.1 Figure 5.2 Place spring plate on top of ball using grease to hold it (Fig 5.3). Align spring on top of spring plate and place upper spring plate on at this time ( Fig 5.4). Figure 5.3 Figure Page 9

12 ASSEMBLY Place bonnet over spring with 1/4" NPT facing 180 deg from 1" NPT (Fig 5.5). Tighten bonnet with 4 bolts, do not over tighten (Fig 5.6). Figure 5.5 Figure 5.6 Insert adjustment screw and lock nut with washer and packing seal (Fig 5.7) Pack Seal STEP 6 INSTALL TUBING Install tubing by starting threads on stabilizing housing and rotating bonnet connection into tubing (Fig 6.1). Figure 5.7 Rotate STEP 7 INSTALL SEAT Tighten ring around seat #266 by placing adjustment knob on stem and hold flush with end of stem, (it will be adjusted later). Lubricate O-Ring and install, then screw into housing (Fig 7.1). Figure 6.1 Ring #267 Figure 7.1 Page 10

13 TESTING STEP 1 BASIC SETUP PROCEDURE Secure in vise (Fig 1.1) Using a regulator split into 2 connections and attach to 12 PL, this is so you can apply pressure to both sides of diaphragm at same time. Bring up to 30 psi pressure (Fig 1.2) Figure 1.1 STEP 2 SETTING FOR THROTTLE Position upper adjustment screw 6 turns from bottom (Fig 2.1). Figure 1.2 Start with seat ring adjusted out. (Fig 2.2) Seat Ring #267 STEP 3 SET SEAT While holding your thumb on the output line (Fig 3.1) adjust lower seat in until you start to hear or feel pressure. Loosen adjustment ring without changing position of lower seat. Position ring against lower housing and tighten set screw (Fig 3.2) This adjustment has set throttle mode and is required before doing snap. This is approximate only further adjustment is required when installed. Figure 2.1 Figure 2.2 Figure 3.1 Figure 3.2 Make sure ring is all the way against housing and output pressure has just started before locking down. Test by rotating adjustment in and out a few times to make sure set point stays the same. Page 11

14 TESTING STEP 4 SETUP FOR SNAP Turn upper adjustment screw out 3 turns from bottom. Back lower seat out 1 turn (Fig 4.1) Turns out Inches of span / / /4 23 Figure 4.1 These are approximate only will have to be re-adjusted once installed. Page 12

15 12 PL PILOT REPAIR MANUAL NOTES

16

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