No-Bleed Pilot Valve
Being Environmentally Responsible Has Just Become Very Profitable With WellMarkÕs MIZER No-Bleed Pilot Valve For CEMCO Controllers ¨ ¨
If You’re A Gas Producer Using Pneumatic Continuous-Bleed Controllers for Wells or Separators, You’re Losing Thousands of Dollars Every Year In Lost Emissions QUICK FACT: Figuring the average price of gas at $7/m your continuous bleed controllers are costing you over $1000.00 per year, per controller in lost profits.
THE 10 MINUTE SOLUTION: Install WellMark’s Patented MIZER® Pilot Valve in your controllers and never lose another penny. Plus, improve the air quality for generations to come.
Other MIZER® Models Are Available
Pilot Valve
Being Environmentally Responsible Is Now Easier Than Ever Before With WellMark’s MIZER®® Pilot Valve. Guaranteed To Improve Air Quality And Your Bottom Line, for Generations To Come. A Green Idea From The WellMark Company
wellmarkco.com
No-Bleed Method of Operation EQUILIBRIUM
US Patent No. 5,158,111
DEPRESSED
POSITION
RELEASED
Equilibrium Position (Non-Venting Closed):
Level Controller Sensing Rod Seat Actuation Poppet
Exhaust From Actuator Operation And Actuator Line Only
Exhaust Seal “C” Dynamic Seal
Actuator Outlet Supply
Seal “B” ( CLOSED )
When the MIZER® Pilot Valve is in “Steady State”, both Seal “A” and Seal “B” are closed and the Control Flapper is in neutral position. (See Fig. 1)
Depressed Position: (Non-Venting Actuating) Seal “B” ( REMAINS CLOSED )
Seal “A” ( CLOSED )
Controller Body
Pilot Valve
Seal “A” ( OPENS )
Seal “B” ( OPENS ) Seal “A” ( CLOSES )
Operating Supply
When the Control Flapper depresses the Actuation Poppet, Seal “A” is opened, supplying gas to the process valve. Seal “B” is closed, preventing gas from bleeding or venting through the vent port. The MIZER® Pilot Valve is designed so that the gas flow is related to the position of the controller flapper. (See Fig. 2)
Released Position: (Non-Continuous Venting) Position Lock Nut
(Fig. 1) Non-Venting Closed
(Fig. 2) Non-Venting Actuating
(Fig. 3) Non-Continuous Venting
When the Control Flapper is released it closes Seal “A” and opens Seal “B” allowing gas to vent.Venting occurs ONLY when the control valve calls for it, and then, ONLY the gas in the process line and actuator is released. ( See Fig. 3)
Simple 10 Minute Installation
Shut off supply and bleed pressure off controller. Remove controller adjustment screw and blow out supply line to remove debris. Lubricate MIZER® o-rings and then insert MIZER® Pilot Valve and screw into controller clockwise until tip reaches sensing rod seat.Turn on supply.Turn MIZER® clockwise to set desired output pressure. NOTE:Turn MIZER® clockwise to lower level or counter clockwise to raise level. Once set, lock the MIZER® Pilot Valve in position with supplied lock nut.
How To Order Use the MIZER¨ Model Number below for CEMCO controllers. Other retrofit MIZER¨ models are available for other controllers upon request. ®
MIZER MODEL Number: M1110 -111 Contact your WellMark representative today for more information. ©2006 The WellMark Company • MIZER ® is a registered trademark of The WellMark Company US Patent No. 5,158,111 • WCM-MIZER-4CEMCO-1006 • Litho USA
The Company, L.L.C. 1903 S.E. 29th Street Oklahoma City, OK 73129 P.O. Box 95459 Oklahoma City, OK 73143 Tel: (405) 672-6660 Fax: (405) 672-6661 Email: twc@wellmarkco.com
wellmarkco.com
Section No. 3.9
Series
MIZER
®
MIZER® No-Bleed Pilot Valve Application The MIZER® No-Bleed Pilot Valve is the most cost-effective solution for converting high-bleed pneumatic controls to low-bleed operation. This device effectively stops continuous bleed operation between dump cycles, thereby reducing environmentally-concerning methane emissions, while allowing previously wasted gas to be sent to the sale line. Conservatively, user can anticipate 90% savings from recaptured gas based upon estimated cycle rates of the controls. 95-98% values may be achieved in some applications.
Features • Kits Available For: • Cemco Cantilever Level Controls • FMC Invalco Flexlever Level Controls • Emerson/Fisher 2500 Level Controls • Emerson/Fisher 4100Z "Wizard" Pressure Controllers • Emerson/Fisher 4150/4160 Pressure Controllers • Cemco and FMC Invalco kits are field-installable in minutes – unit does not have to be shut down for installation. Installation of pressure controller kits, although more in-depth, are still the most painless and cost-effective solution for converting highbleed to low-bleed. • Uses existing tubing and connections – no new plumbing required. • MIZER® works in either snap acting or throttling application. • MIZER® solution allows field personnel to continue using control devices that are familiar. • Conversion from high-bleed to low-bleed may qualify user for Carbon Credits.
Specifications Max. Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . 64 psig Operating Temperature . . . . . . . . . . . . . . -20°F to + 200°F Materials: . . . . Stainless Steel with Nitrile and Delrin® seals Average Bleed Rate . . . . . . . . . . . . . Approx. 6.6 scf per day
Bleed Gas vs. Vent Gas "Bleed" gas is defined as gas that bleeds to atmosphere between dump cycles. "Vent" gas is that gas which, after energizing the dump or control valve must be released to atmosphere, and is usually a small fraction by comparison to the bleed gas volume. It is because of the high bleed between dump cycles that the EPA discourages the use of high-bleed pneumatic devices to control liquid level and gas pressure. The MIZER® device actually stops the continuous flow of gas from these controllers, only allowing gas to flow to the con-
The
trolled device (dump valve or control valve) when necessary. Therefore, the amount of potential gas savings is dependent upon (among other things) the initial bleed rate and the frequency of operation of the controller and valve. In other words, a separator unit that fills slowly and dumps infrequently is bleeding substantial amounts of unutilized gas pressure to atmosphere most of the time. All of this gas that is vented to atmosphere between dump cycles would be saved when using a MIZER® retrofitted controller. Likewise, if the controller is very active, dumping fluid frequently, the savings would be less, as more gas is being used to activate the valve. It should be noted that neither the MIZER® nor any other lowbleed device is capable of saving gas that has been used to energize the valve. This gas will always be lost after the valve cycles and the diaphragm and connection lines vent. If the lines are not allowed to vent the valve will not return to the original (usually closed) position.
Ease of Installation The Cemco and FMC Invalco level control versions of the MIZER® pilot valve installation is a simple and painless operation. In fact, unlike installing traditional no-bleed level controllers, which require breaking the process connection, the MIZER® pilot valve is installed by simply removing the operating gas pressure from the controller, installing the MIZER®, blowing out the supply line to keep it clean, reattaching the supply line and adjusting. Different controllers require different kits–some containing more parts than others. Retrofit kits for pressure controllers such as the Emerson/Fisher 4150 or 4160 are more complex and therefore the procedure is also more complex, possibly requiring shut down. But, no welding of new fittings, no new tubing, no new cabinet refits are required. The MIZER® installs in minutes – not hours or days as is the case with installation of any complete new controller. Last, but not least, the operator continues using the controller they already know and trust – no need to learn the operating quirks of a completely new control.
Company, L.L.C. • Oklahoma City, Oklahoma • Tel: (405) 672-6660 • Fax: (405) 672-6661 • wellmarkco.com
©2009 The WellMark Company, L.L.C. • Litho USA • WCM-Mizer-5/09 • US Patent No. 5,158,111 • All registered trademarks are the property of their respective owners. 23
Section No. 3.9
Series
MIZER
®
MIZER® No-Bleed Pilot Valve Liquid Level Controls & Pressure Controllers • Potential Savings per Control (3 to 15 psig controllers*) Based upon typical onshore facility* supply pressure of 20 psig and $6.00 gas Type Control
Supply Pressure Bleed Rate Air Bleed Rate Gas Daily Bleed Rate Yearly Bleed Rate Annual Dollars LOST psig SCFH SCFH SCFD SCFY to Emissions CEMCO 6900 20 19.7 26 614 224,119 $1,344.72 EMERSON/FISHER 2500 20 27 35 842 307,169 $1,843.01 EMERSON/FISHER 2502 20 27 35 842 307,169 $1,843.01 EMERSON/FISHER 2506 20 27 35 842 307,169 $1,843.01 LIQUID FISHER 3570 20 13 17 405 147,896 $887.38 LEVEL FISHER 3582 20 13 17 405 147,896 $887.38 FISHER 3660 20 5.2 7 162 59,158 $354.95 FMC INVALCO 415 20 23 30 717 261,662 $1,569.97 FMC INVALCO 215 20 23 30 717 261,662 $1,569.97 FMC INVALCO 402 20 23 30 717 261,662 $1,569.97 EMERSON/FISHER 4100Z 20 33 43 1029 375,429 $2,252.57 PRESSURE EMERSON/FISHER 4150 20 27 35 842 307,169 $1,843.01 EMERSON/FISHER 4160 20 27 35 842 307,169 $1,843.01 * Offshore facilities commonly use 6 to 30 psig controllers with average supply pressure of 35 psig. Bleed rates and dollars lost due to emissions would conservatively be 1.5 times those listed above. Manufacturer
Model
Method of Operation EQUILIBRIUM
DEPRESSED
POSITION
RELEASED
Level Controller Sensing Rod Seat
Exhaust From Actuator Operation And Actuator Line Only
Exhaust
Actuation Poppet
Seal “C” Dynamic Seal Actuator Outlet Supply
Seal “B” ( CLOSED )
Seal “B” ( REMAINS CLOSED )
Seal “A” ( OPENS )
Seal “A” ( CLOSED )
Controller Body
Seal “B” ( OPENS ) Seal “A” ( CLOSES )
Operating Supply
Position Lock Nut
(Fig. 1) Non-Venting Closed
(Fig. 2) Non-Venting Actuating
(Fig. 3) Non-Continuous Venting
Equilibrium Position: (Non-Venting Closed) When the MIZER® Pilot Valve is in “Steady State”, both Seal “A” and Seal “B” are closed and the Control Flapper is in neutral position. (See Fig. 1) Depressed Position: (Non-Venting Actuating) When the Control Flapper depresses the Actuation Poppet, Seal “A” is opened, supplying gas to the process valve. Seal “B” is closed, preventing gas from bleeding or venting through the vent port. The MIZER® Pilot Valve is designed so that the gas flow is related to the position of the controller flapper. (See Fig. 2) Released Position: (Non-Continuous Venting) When the Control Flapper is released it closes Seal “A” and opens Seal “B” allowing gas to vent. Venting occurs ONLY when the control valve calls for it, and then, ONLY the gas in the process line and actuator is released. (See Fig. 3)
Conversion Kit Assembly Part Numbers Type Control LIQUID LEVEL
Conversion Kit Model Number 1110-111 4010-111 7010-111
Part Number 06500-6905 31066 06500-7018
5010-111
06500-7093
8010-111
06500-7019
PRESSURE
The
Converts CEMCO CANTILEVER CONTROL FMC INVALCO FLEXLEVER CONTROL EMERSON/FISHER 2500 CONTROL EMERSON/FISHER 4100Z "WIZARD" CONTROLLER EMERSON/FISHER 4150/4160 CONTROLLER
Company, L.L.C. • Oklahoma City, Oklahoma • Tel: (405) 672-6660 • Fax: (405) 672-6661 • wellmarkco.com
24 ©2009 The WellMark Company, L.L.C. • Litho USA • WCM-Mizer-5/09 • US Patent No. 5,158,111 • All registered trademarks are the property of their respective owners.
Installation and Calibration Instructions for Model 1110 WARNING
Retrofit Kit
for Cemco Cantilever Level Control Nozzle Seat
User must isolate the control from signal pressure prior to disassembly and installation of this product. Failure to do so may result in free flow of gas during installation, property damage and/or personal injury. Always employ upstream and downstream pressure gauges to monitor startup pressures.
Application The Model 1110 Retrofit Kit is designed to convert an existing continous-bleed Cemco Model 6900 Level Control to a non-continousbleed configuration. This reconfiguration results in significant gas savings, as well as providing a much cleaner and safer environment. The MIZER® Pilot Valve will operate in both Snap-Acting and Throttling applications. User must realize that liquid level control performance is a function of the efficiency of both the control AND the valve, as some valves flow more efficiently than others. This device can be installed without shutting down or draining the unit, thereby eliminating concerns about spills or lost production. However, since the control will be inactive during the retrofit, and to avert any possibility of overfill during this procedure, it is recommended that installation take place while the vessel is in a low liquid condition.
Installation and Calibration Shut off supply pressure and process pressure to the controller. Remove the controller adjustment screw and blow out the supply line to remove any debris. Lubricate the MIZER® O-rings with a multi-purpose grease and insert the MIZER® Pilot Valve, screwing it clockwise until the tip reaches the nozzle seat. ®
Turn on supply pressure to the controller. Adjust the MIZER® Pilot Valve in and out until the desired pressure is achieved
How the MIZER Pilot Valve Operates
NOTE: Clockwise adjustment will LOWER the fluid level. Counter-clockwise adjustment will RAISE the fluid level. Once set, lock the MIZER® Pilot Valve in place by tightening the supplied jam nut
The
Company, L.L.C.
Oklahoma City, Oklahoma
Equilibrium Position (Non-Venting Closed) ® When the MIZER Pilot Valve is in “Steady State”, both Seal “A” and Seal “B” are closed and the control’s Nozzle Seat is in a neutral position (See Fig. 1). Depressed Position (Non-VentingActuating) When the Nozzle Seat depresses the Actuation Poppet, Seal “A” is opened, supplying gas to the process valve. Seal “B” is closed, preventing gas from bleeding or venting through the vent port. The MIZER® Pilot Valve is designed so that the gas flow is related to the position of the Nozzle Seat (See Fig. 2). Released Position (Non-Continuous Venting) When the Nozzle Seat is released it closes Seal “A” and opens Seal “B”, allowing gas to vent. Venting occurs ONLY when the control valve calls for it, and then, ONLY the gas in the process line and actuator is released (See Fig. 3).
Tel: (405) 672-6660
Fax: (405) 672-6661
© The WellMark Company • Litho USA • All registered trademarks are the property of their respective owners. • IOM-1110 071120
wellmarkco.com 1
Installation and Calibration Instructions WARNING
Model 8010
User must isolate the control from signal AND process pressure prior to disassembly and installation of this product. Failure to do so may result in free flow of gas during installation, property damage and/or personal injury. Always employ upstream and downstream pressure gauges to monitor startup pressures.
Retrofit Kit
for Fisher Model 4150 & 4160 Control (12) and base plate assembly (11) from the controller. Loosen the bellows screws (15) and remove the bourdon tube assembly screws. Gently swivel the beam (14) and bourdon tube outward as an assebmly and remove the Flapper and Screw (4) from the beam and discard.
Application
Remove the Calibration Adjuster (7) and the Reversing Block (6), setting aside the screws to be reused during the Mizer® installation.
The Model 8010 Retrofit Kit is designed to convert an existing highbleed Fisher Model 4150 or 4160 Pressure Controller to a low-bleed configuration. This reconfiguration results in significant gas savings, as well as providing a much cleaner and safer environment.
Remove the Proportional Band Valve (2) Remove Relay Plug (3) from relay.
Dismantling of Existing Components ®
Note: Before proceeding be sure that the stock controller is properly calibrated to zero.
Installation of the Mizer Components
Shut off supply pressure and process pressure to the controller. Remove the Relay TubingAssembly (5) and the Reset Valve Tubing (1).
Install Relay Plug (B) in relay, tightening until the o-ring makes up, with tubing port facing left or right of the relay.
Remove the Compensator Tubing (8) from the bellows manifold (10). Remove the control tubing assembly. Remove the base plate screws
Install 5” Reset/Bellows Tubing (F2) from left port of Span Valve to the Reset Valve port (4150: connect from span valve to bellows manifold).
Install Span Valve (D) using a general purpose thread sealant.
3
4
Flapper & Screw
5
Relay Tubing Assembly
5
7
Calibration Adjuster
8
Compensator Tubing (2 Sets)
9
Control Tubing Assembly
5
25
25
30
0 psi
8
30
0
2 Sets
psi
MAX PRESS
P
R ER
EPEAT
8
5 10000 PSIG
6 5 4 3
7
2
9
MIN
Reversing Block
9
15 10OUTPUT20
.025
6
15 10SUPPLY20
.5
Relay Plug
1
2
2
3
ET
Proportional Band Valve
.01 5
RES .01
74
2
5 .0
Reset Valve Tubing
.1
1
1
D SE CLO
10
0
PROPORTIONAL BAND
13
10
6 11
10 Bellows Manifold
100
4
12 Baseplate Screws (4 ea.)
14
13 Bourdon Tube
7
200
PSIG
50
11 Baseplate Assembly
150
0
250 300
PRESSURE SETTING
14 Beam 15 Bellows Screws
The
Company, L.L.C.
NOTE: Illustration shows direct acting configuration.
Oklahoma City, Oklahoma
2 each
Tel: (405) 672-6660
15
12
4 each
Fax: (405) 672-6661
© The WellMark Company • Litho USA • All registered trademarks are the property of their respective owners. • IOM-8010 070626
wellmarkco.com 1
Mount Mizer® Valve Assembly (A) on Manifold (E) utilizing the Reversing Block Screws, installing them from the back side of the manifold.
Connect the 4” Output Tubing (F3) to the relay. Connect the 9” Supply Tubing (F1) from the Relay Plug (B) to the port on the Mizer® Valve (A).
Install Manifold Plug (H) in the open port on the back side of the manifold.
Connect the 12” Span Valve Tubing (F4) from the Span Filter (G) to the right port of the Span Valve (D). IMPORTANT: It is critical that no tubing lines interfere with any moving parts within the controller.
Install the Span Filter Assembly (G) in the front port of the manifold. Install 4” Output Tubing (F3) in the top port of the manifold.
Calibration Procedure
Install manifold to base plate using existing screws, positioning the manifold to the center step of the slot.
Note: This procedure assumes that the stock controller was properly calibrated to zero.
Install the Adjustable Housing Assembly (C) onto the beam and secure by pushing the spring retainer up through the beam slot and rotating it 90 degrees.
1)
Turn on instrument supply pressure to controller.
2)
Turn the Span Valve to “0” and the Reset to “CLOSED”.
Gently swivel the beam back into level position and secure the bourdon tube, reconnect the control tubing assembly and retighten the bellows screws (VERY important!).
3)
Adjust Pressure Setting to “0”.
4) Turn the Flapper Thumb wheel counter clockwise until it makes contact with the Mizer® poppet and gives a 3-6 psi output.
Align the adjustable Housing Assembly to the center of the Mizer® Valve poppet and secure it by tightening the two outer screws on the housing. Re-install the base assembly into the controller and reconnect the tubing lines to the bellows manifold.
5)
Turn Pressure Setting dial to desired pressure.
6)
Turn on process pressure energizing bourdon tube.
7) Put controller in service, making adjustments to span valve and reset valve as necessary to control oscillations.
Back Side of Manifold E
H
C
Adjustable Housing Assembly
D
Span Valve Assembly
E
Manifold
F1
F1 Supply Tubing
F3
15 10SUPPLY20 5
15 10OUTPUT20 5
25 30
0
25 psi
EPEAT
6 54
987
MIN
2
ET 74
10
.01
D SE CLO
D
21
.025
.01 5
RES
3
R ER
.5
MAX PRESS
10000 PSIG
30
0
psi
P
Relay Plug Assembly
0
B
5 .0
Mizer ® Valve Assembly
F2
.1
A
B
F4
F2 Reset Tubing/Bellows Tubing A
F3 Output Tubing I
F4 Span Valve Tubing
100
C
G
Span Filter Assembly
H
Manifold Plug
E
I
Flapper Thumbwheel
G
The 2
50
Company, L.L.C.
Oklahoma City, Oklahoma
150
200
PSIG
0
250 300
PRESSURE SETTING
Tel: (405) 672-6660
Fax: (405) 672-6661
wellmarkco.com
© The WellMark Company • Litho USA • All registered trademarks are the property of their respective owners. • IOM-8010 070626
IOM-4010
Installation, Operation and Maintenance Instructions Mizer® 4010 Retrofit Kit For FMC Invalco General Purpose Enclosure CT Flex Tube Controls
. WARNING . User must isolate the control from signal pressure prior to disassembly and installation of this product. Failure to do so may result in free flow of gas during installation, property damage and/or personal injury. Always employ upstream and downstream pressure gauges to monitor startup pressures.
STOP! During disassembly DO NOT discard the original tubing fittings and mounting screws, as they will be used to install the retrofit. 1)
Shut off supply pressure to controller. Disconnect supply and output tubing lines. Remove tubing fittings from pressure block.
2)
Unscrew the four screws holding pressure block to level control case and remove block from case. Reverse the flapper assembly by moving the angle bracket and adjusting screw to the opposite position (see Photos 1 and 2 below).
Standard Invalco control (bracket up)
Invalco control with Mizer (bracket down)
3)
Mount and secure pressure block provided in kit. Install supply and output tubing fittings. NOTE: Purge supply line before making connection to assure evacuation of any particulate.
4)
Connect supply and output tubing lines.
5)
Lightly coat the Mizer valve O-rings with a general purpose lubricant. Install the Mizer valve from the bottom, up through the pressure block by screwing it in a clockwise fashion. Thread the Mizer into the control case until the O-ring makes up tightly.
6)
Turn on supply pressure to 25 psig. With the fluid below the displacer, move the flapper adjusting screw downward until it makes contact with the poppet and achieves a 1 to 3 psig output signal. Back the flapper adjustment screw off until the output falls to 0 psig.
7)
Adjust level as needed.
FMC Invalco is a trademark or registered trademark of FMC Technologies.
070308
1903 SE 29th Street • Oklahoma City, OK 73129 • Tel 405.672.6660 • Fax 405.672.6661 • www.wellmarkco.com • Certified to ISO9001:2000