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12 PL PILOT REPAIR MANUAL INDEX
Introduction
1
Elastomer Materials
2
Disassembly
3
Assembly
7
Testing
11
NOTE: We reserve the right to modify or change, wAhout 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.
6 Copyright 2006. KIMRAY. Inc.
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12 PL PILOT REPAIR MANUAL INTRODUCTION SCOPE This instruction manual contains repair information for the Kimray 12 PL Float less Liquid Level Controller with additional information in regarding calibration. DESCRIPTION The 12 PL Float less 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' Pilot Spring Range Optional Springs Bonnet Max. Pressure Material Option
Body Max. Pressure Material Options
Connections: Separator Gas Separator Liquid To Valve Actuator Interior Parts Gauge Diaphragms
125 psi Hydrostatic Test: ANSI B16.37 4 inches to 4 feet H2O 8 feel and 30 feet H2O 125 psi
Gray Iron ASTM A48-94a Class 20 Ductile Iron ASTM A395 Class 65-45-12 Steel ASTM A 216 WCB 125 psi
Gray Iron ASTM A48-94a Class 20 Ductile Iron ASTM A395 Class 65-45-12 Steel ASTM A 216 WCB 1/4 inch NPT 1 inch N PT
1/4 inch NPT Gray Iron, Steel Brass Base and Bourdon Tube 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!!!
ENO-002.1 Rev. 3
Issued 1-17-2007
worn. lat n ray.com
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12 PL PILOT REPAIR MANUAL ELASTOMER MATERIALS AFLAS1 Is a trade mark d Asahl Olass Co
VITON 45 Is a traLle mark or Dupont
TEMPERATURE: -25° to +500° F -30° to +260° C
TEMPERATURE: -10° to +350° F -23° to +177° C
APPLICATION: Crude Oil & Gas Production (High heat), Steam Flood Production Chemicals (corrosion inhibitors) Amine Sweetener Systems, Gasoline, Diesel, Fuel ON Systems
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 ON & Gas Production, H2S, Steam. Petroleum fluids, Sea Water
HSN (Highly Saturated Nitrile)
FLUID / GAS: Crude ON & Gas, Sour Gas (CO2), Propane, Gasoline, Diesel, Fuel Oil Systems DO NOT USE WITH: Hot Water, Not preferred for wet H2S. Methyl Alcohol, Amines, Sodium hydroxide solutions
TEMPERATURE: -15° to +300° F -26° to +149° C
ETHYLENE PROPYLENE APPLICATION: Crude ON & Gas Production w/ H2S CO2
FLUID / GAS: Crude ON & Gas H2S, CO2, Sea Water N IT R ILE
TEMPERATURE: Buna-N: -40° to +220° F -40° to +105° C Low-Temp: -85° to +120° F -65° to +49° C
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 (Lute Oils)
POLYJR:THANE
APPLICATION:
Crude Oil & Gas Production Glycol Dehydrators,
TEMPERATURE: -40° to +220° F -4 0° to +1 04° C
Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal,
Methanol Injection Pumps, Water pump seals, Hydraukc pump seals FLUID / GAS: Crude ON & 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
APPLICATION: High abrasion resistance Seats, Diaphragms
FLUID / GAS: Crude ON gas and Water, Sour Gas (CO2), propane, butane, fuel, mineral oil and grease
POLYACRYLATE DO NOT USE WITH:
Aromatic hydrocarbons, chlorinated hydrocarbons, phosphate esters (hydraulic fluids)
GYLON
TEMPERATURE: tO° to +300° F -17° to +149° C
TEMPERATURE: -350° to +500° F
APPLICATION: Production Heaters, Thermostats
APPLICATION: High heat, high chemical resistance, highly resistance to gas permeation
FLUID / GAS: Crude Oil & Gas at High Temperature DO NOT USE WITH: Alcohol, Glycols, Hydrocarbons
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12 PL PILOT REPAIR MANUAL DISASSEMBLY
STEP 1
SECURE PL PILOT Use 1" NPT jig (Fig 1.1) to Secure pilot in vise if available (Fig. 1.2).
Figure 1.1
7i..:_jurc: 1.2
7igure 2.1
7igure 2.2
STEP 2 REMOVE ADJUSTING SCREW Loosen lock nut and remove adjustment
screw and nut from top of pilot (Fig 2.1 & 2.2).
STEP 3
REMOVE LOWER STABILIZING HOUSING
Remove tubing and set aside. (Fig 3.1)
Figure 3.1
Remove seat from lower stabilizing housing (Fig 3.2) make sure set screw is tight on ring (Fig 3.3)
Figure 3.2
Figure
Remove 4 bolts to stabilizing housing and remove housing (Fig 3.4)
Stabilizing Housing Bolts
Housing
Figure 3.4
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12 PL PILOT REPAIR MANUAL 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 4.2
Figure 4
STEP 5 REMOVE DIAPHRAGM Remove 10 bolts and nuts (Fig 5.1) and pry apart housings (Fig 5.2).
Figure 5.1
.1
lip
r
7i)
:2
Loosen upper diaphragm #250 (Fig 5.3) and pull through upper housing (Fig 5.4).
Eigurc 5.3
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Figure 5.4
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12 PL PILOT REPAIR MANUAL DISASSEMBLY
STEP 6 DIAPHRAGM ASSEMBLY
Place diaphragm assembly in vise and remove #111 seal 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).
Figure 6.2
Remove pivot stem from cap (Fig 6.3) and discard old diaphragm
Figure 6.3
Now remove diaphragm plate and diaphragm from pilot housing (Fig 6.4) and discard old diaphragm
Figure 6.4
Finally remove spacer from pilot housing (Fig 6.5) and discard old diaphragm
Figure 6.5
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12 PL PILOT REPAIR MANUAL NOTES
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12 PL PILOT REPAIR MANUAL 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 dean table and double check to make sure all parts are there (Fig 1.1).
Figure 1.1
STEP 2 MOUNT LOWER HOUSING Secure lower housing back on to jig (Fig 2.1).
Figure 2.1
STEP 3
ASSEMBLE DIAPHRAGMS Roll 0-Ring onto pivot stem (Fig 3.2) and insert through cap #255 (Fig 3.3). 0
Figure 3.2
Figure 3.1
Insert #250 diaphragm over stem and housing (Fig 3.3, 3.4).
Immwill Fa k e sure
m is rolled evenly around the 0.D.
em
Figure 3.3
Figure 3.4
Place gasket on new #111 seat (Fig 3.5).
Figure 3.5
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12 PL PILOT REPAIR MANUAL ASSEMBLY
Insert spacer over pilot housing, (Fig 3.6) Then place diaphragm #259 over spacer (Fig 3.7).
igure 3.1
Figure 3.6
Now place diaphragm plate #246 over diaphragm (Fig 3.8).
7igure 3.3
Insert pivot stern and start threads on to pilot housing (Fig 3.9), then tighten snug without folding diaphragm gasket (Fig 3.10).
7igure 3.E1
igure 3.10
Figure 3.11
7igurc 3.12
Figure 4.1
Figure 4.2
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).
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12 PL PILOT REPAIR MANUAL 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). Figure 4.3
Figure 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). Pull #250 diaphragm up through hole being careful not to tear (Fig 4.6).
m째 4.5
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. #1942 long bolts
Figure 4.7
STEP 5 INSTALL BONNET Apply grease to top of pivot stem (Fig 5.1). Then place #245 ball on top of pivot stern ( Fig 5.2).
Figure 5.1
Figure 5.2
Figure 5.3
Figure 5,1
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).
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12 PL PILOT REPAIR MANUAL 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).
4=11
Figure 5.6
Insert adjustment screw and lock nut with washer and packing seal (Fig 5.7)
a:',1( Seal
Figure 5.7
STEP 6 INSTALL TUBING Install tubing by starling threads on stabilizing housing and rotating bonnet connection into tubing (Fig 6.1). Rotate
Figure 6.1
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 0-Ring and install, then screw into housing (Fig 7.1).
Figure 7.1
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12 PL PILOT REPAIR MANUAL TESTING
STEP 1
BASIC SETUP PROCEDURE Secure in vise (Fig 1.1)
Figure 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 1.2
STEP 2 SETTING FOR THROTTLE
Position upper adjustment screw 6 turns from bottom (Fig 2.1). Start with seat ring adjusted out. (Fig 2.2)
Figure 2.1
7igure 2.2
Figure 3.1
Figure 3.2
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.
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.
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12 PL PILOT REPAIR MANUAL 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 1
11/4 1 1/2 1 3/4
Inches of span 12 14 17
Figure 4.1
23
These are approximate only will have to be re-adjusted once installed.
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12 PL PILOT REPAIR MANUAL NOTES
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KIAMAY
12 PL PILOT
Repair Manua/ www.kimray.com
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