In this guide we’ll walk you through everything there is to know about pressure regulators.
From the basics of how it works to step-by-step repairs and troubleshooting, you’ll gain a solid foundation of knowledge on how to operate and maintain Kimray’s pressure regulators.
Use the table of contents to skip to different sections of the learning path.
Kimray’s Back Pressure Regulator is a staple in oil and gas production. Numerous oilfield applications, including on separators, flow treaters, free water knockouts, compressor stations, and gas gathering systems use it.
Considered an “integrated valve,” the regulator’s pilot—the key to opening and closing the it—is connected to the valve body and comes out as one piece. By adjusting the bolt at the top of the regulator, the spring is pushed down to a set point. The spring presses down on the diaphragm assembly.
This positions the three-way valve. The three-way valve then allows gas from upstream to push down on the diaphragm.
If the set point is exceeded, the upstream pressure pushes up on the diaphragm assembly, therefore closing off the three-way valve and allowing gas to be vented from the top of the diaphragm and allowing the upstream pressure to be vented.
The Back Pressure Regulator allows you to hold pressure on production vessels by adjusting the set point to the desired maximum upstream pressure. The valve senses this and releases when this designated set point is reached.
Over time, the internals of the regulator experience wear and tear that can affect production processes, so it’s necessary to disassemble and replace key internal parts with a Kimray Repair Kit. In this repair series learn how to disassemble, examine, and reassemble the Kimray Back Pressure Regulator.
If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
A Pressure Reducing Regulator is used to maintain a downstream pressure set point. Pressure Reducing Regulators are often used as suction controllers on compressors.
In this video, we'll show you how to repair a 2" Pressure Reducing Regulator.
Before you begin disassembly, use a marker to make a mark on each layer of the valve. This way when you reassemble the valve, you'll be able to line up each piece correctly.
Next, we’ll disassemble the lower housing.
If you've done everything correctly, you should feel the resistance of the spring as you push down on the pilot plug.
If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
Kimray's Spring Loaded Back Pressure Regulator is a dependable, easy-to-operate, zero-emission solution for holding back pressure on an oil and gas vessel.
The primary reason a producer would want to use the spring-loaded back pressure regulator over a pilot-operated regulator is that it requires no instrument gas. This means the valve releases no emissions.
Another advantage is you can flow liquid or gas or both simultaneously. For example, in a two-phase free water knockout, it can regulate the oil and gas together, allowing the vessel to separate the water from these elements.
In this video and article, we'll show you how to repair a Spring Loaded Back Pressure Regulator
Stainless steel internals can be used when this valve is subject to corrosive applications. These internals include the stem, ratio plug, diaphragm plate, removable seat and the seat disc.
If you are repairing a non-lube model, the lower housing will look a little different and there will be a few other pieces in the repair kit.
The non-lube option is offered for many regulators and low pressure control valves. It is commonly used in applications where the orientation of the piping is vertical making it difficult for the oil to communicate with the stem. It could also be used in cases where the process media does not allow for potential contaminants, such as oil lubricant.
If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
A Back Pressure Regulator is a specific type of control valve that holds pressure on production vessels such as separators, treaters, and free water knockouts and releases upstream pressure when a designated set point is reached.
When a back pressure regulator is operating correctly, it vents pressure off the diaphragm as it adjusts. However, some producers need to convert the regulator from venting to non-venting. You may need to do this if you are using the regulator inside a building, facing increased emissions regulations, or for safety concerns.
To make this process as simple as possible, we offer all-in-one non-vent conversion kits that include the tubing, connector, tee and elbow. To order one of these kits or speak with an expert about this process, reach out to your local Kimray store or authorized distributor.
These are the parts you will need for this process:
We’re in a controlled environment for the video, but if you are doing this in-line, you will need to isolate and depressurize the valve first.
If you’re using a vice, mount it slightly off center so that when it comes times to install the new elbow, you’ll be able to attach it without adjusting the valve.
Now your back pressure regulator is non-venting. If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
We have other solutions available to help you meet your company’s ESG goals, including electric actuators and pilots, non-vent control valves and more. For more information, check out our emissions solutions guide.
Looking for practical steps to take to achieve your ESG commitments? One source of natural gas emissions may be your back pressure regulator.
We’ll show you a simple change you can make to prevent your back pressure regulators from venting natural gas.
The 330 SGT BPOS was installed on our separator and commissioned 7/15/22. There were no issues to report during startup, and once in service, the valve functioned correctly.”
-Engineer, E&P in the Delaware Basin
Options for Zero-Emission Regulators
To eliminate emissions from your regulator, you have two options:
Either option can be purchased new, or you can easily convert an existing regulator to either operation with only a few extra parts.
* The outside supply regulator will fail open when you lose supply gas.
Why choose one or the other? If your pressure differential—or the pressure drop across the valve (𝚫P)—is 10 PSI or less, we recommend converting to an outside source of supply air.
The back pressure regulator with outside supply (BPOS) can be used to eliminate emissions when you incorporate an air compressor into your operation for instrument supply.
Note that you can also use the BPOS to hold back pressure in wet gas applications to reduce the likelihood of malfunction due to heavy condensate. This was the primary use of this product’s predecessor, the liquid back pressure regulator.
When you’re doing a conversion, we recommend also installing a repair kit. We’ll be showing both processes in this video. For a 2" Back Pressure Regulator conversion and repair, you will need the following tools and components:
We’re in a controlled environment, but if you are doing this in-line, you will need to isolate and depressurize the valve first. Before beginning, consult your company’s safety guidelines and use the appropriate personal protective equipment (PPE).
2" BP to BPOS Conversion | ||
|---|---|---|
| QTY. | DESCRIPTION | PART |
| 1 | 2” MASTER REPAIR KIT | RYG |
| 1 | 2”-6” BPOS CONVERSION KIT | ROA |
| 1 | TUBE 3/8 SS6 3 BPOS | 72SS6 |
| 2 | ELL 3/8 x 1/4 NPT STEEL | 877 |
3" BP to BPOS Conversion | ||
|---|---|---|
| QTY. | DESCRIPTION | PART |
| 1 | 3” MASTER REPAIR KIT | RYK |
| 1 | 2”-6” BPOS CONVERSION KIT | ROA |
| 1 | TUBE 3/8 OD SS | 73SS |
| 2 | ELL 3/8 x 1/4 NPT STEEL | 877 |
| 1 | CONN 3/8 X 1/4 NPT STEEL | 876 |
4" BP to BPOS Conversion | ||
|---|---|---|
| QTY. | DESCRIPTION | PART |
| 1 | 4” MASTER REPAIR KIT | RYO |
| 1 | 2”-6” BPOS CONVERSION KIT | ROA |
| 1 | TUBE 3/8 OD SS | 73SS |
| 2 | ELL 3/8 x 1/4 NPT STEEL | 877 |
| 1 | CONN 3/8 X 1/4 NPT STEEL | 876 |
6" BP to BPOS Conversion | ||
|---|---|---|
| QTY. | DESCRIPTION | PART |
| 1 | 6” MASTER REPAIR KIT | RYR |
| 1 | 2”-6” BPOS CONVERSION KIT | ROA |
| 1 | TUBE 3/8 304SS 6 BPOS | 74SS |
| 2 | ELL 3/8 x 1/4 NPT STEEL | 877 |
With the valve fully disassembled, now is a good time to organize your workspace and open your Kimray Repair Kit to prepare for assembly.
Because this repair kit can be used for other products, there will be two remaining pieces that will not be used:
Your back pressure regulator is now ready to use with an outside supply source. If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
We have other solutions available to help you meet your company’s ESG goals, including electric actuators and pilots, non-vent control valves and more. For more information, check out our emissions solutions guide.
ESG requirements are a growing topic among oil and gas producers. One step you can take to support these goals is to eliminate natural gas emission from your pressure reducing regulators.
You can achieve non-vent operation by purchasing our non-vent pressure reducing regulators or by converting your existing regulators with a few simple parts. You may also want to do this if you are using the regulator inside a building or for other safety concerns.
In this video, Will show how to quickly and easily convert a pressure reducing regulator to non-vent.
We’re in a controlled environment, but if you are doing this in-line, you will need to isolate and depressurize the valve first. Before performing any service, consult your company's safety guidelines and requirements. Follow all regulations and wear all necessary PPE.
While doing this conversion, we also recommend using a repair kit for basic maintenance and improved operation.
Now your pressure reducing regulator is non-venting. If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
We have other solutions available to help you meet your company’s ESG goals, including electric actuators and pilots, non-vent control valves and more. For more information, check out our emissions solutions guide.
A Pressure Reducing Balanced Regulator (PRB) controls pressure downstream of the valve. The balanced feature greatly reduces the effect of varying upstream pressure. These regulators are commonly used as suction control valves on compressors where a higher degree of set point accuracy is needed. The primary difference between Kimray’s Pressure Reducing Regulator and the Balanced version is the set point drift ratio.
The standard version of this valve is classified as non-bleed intermittent vent and meets many producer's emissions standards. However, if your goal is to eliminate emissions or you need to install your regulator inside of a building, we recommend using the non-vent PRB.
You can achieve non-vent operation by purchasing a new non-vent version or by converting your existing PRB with a few simple parts.
We’re in a controlled environment in the video, but if you are doing this in-line, you will need to isolate and depressurize the valve first. While doing this conversion, we also recommend using a repair kit for basic maintenance and improved operation.
Now your pressure reducing balanced regulator is non-venting. If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
We have other solutions available to help you meet your company’s ESG goals, including electric actuators and pilots, non-vent control valves and more. For more information, check out our emissions solutions guide.
Looking for practical steps to take to achieve your ESG commitments? One source of natural gas emissions may be your pressure reducing regulator.
In this video, we'll show how a simple change can prevent your Pressure Reducing Regulators from venting natural gas.
To eliminate emissions from your regulator, you can either choose a non-vent or an outside supply regulator operated with compressed air. Either option can be purchased new, or easily converted with only a few extra parts.
If your pressure differential — or the pressure drop across the valve (𝚫P) — is 10 PSI or less, we recommend converting to the outside supply regulator.
If your regulator has been in service, we recommend also installing a repair kit.
We’re in a controlled environment, but if you are doing this in-line, you will need to isolate and depressurize the valve first. Before beginning, consult your company’s safety guidelines and use the appropriate personal protective equipment (PPE).
If you have any questions about any part of this repair process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
We have other solutions available to help you meet your company’s ESG goals, including electric actuators and pilots, non-vent control valves and more. For more information, check out our emissions solutions guide.
Pressure Regulators Learning Path
Tips & Troubleshooting
