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.
One of the ways energy producers are reducing their emissions footprint is by converting their gas regulators to non-vent.
In this video, we show you an animation of what’s actually going on inside both the non-venting back pressure and non-venting pressure reducing regulators.
Upstream pressure flows into the valve inlet and travels through the valve body, exiting through the downstream side.
With the adjusting screw unthreaded, there is no tension on the pilot assembly to move the valve to a closed position.
Upstream pressure also travels through the tubing, flowing into a filter housing where debris and trash are caught to prevent malfunction before entering the pilot and underneath the sensing diaphragm.
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The pilot plug upper seat is closed, blocking upstream pressure.
The pilot plug lower seat, which is the pressure vent, is open, allowing the valve seat to be in the open position.
When the adjusting screw is tightened and the spring tension is greater than the upstream pressure, it forces the pilot assembly to move down.
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This positions the pilot plug to open the upper seat and allows full upstream pressure to now push down on the motor valve diaphragm.
The pilot plug movement adjusts the amount of pressure on the diaphragm, repositioning the stem and seat assembly.
The flow through this regulator is from underneath the valve seat.
The upstream flow pushes up on the valve seat as the gas is pushing down on the motor valve diaphragm. Because the motor valve diaphragm area is twice that of the seat, the regulator can be held in a closed position with equal pressure on both surfaces.
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If upstream pressure exceeds the spring tension, which is your set point, it pushes against the pilot assembly, closing off the supply side of the pilot plug and unseating the lower seat, which is the pressure vent.
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Gas holding the valve closed then vents from the top of the motor valve diaphragm to the lower housing and downstream side of the valve, allowing the valve to open and the upstream pressure regulated.
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The regulator will begin controlling upstream pressure as it increases or decreases, maintaining a constant back pressure set point.
With the upstream pressure neither above nor below the set point, the pilot assembly assumes a position in which both seats of the pilot plug are closed.
The Kimray Non-Vent Pressure Reducing Regulator monitors and controls downstream pressure.
With the adjusting screw unthreaded, there is no tension on the pilot assembly to move the valve to an open position.
Upstream pressure flows into the inlet and is blocked by the closed seat in the valve body.
Upstream pressure also travels through the tubing into a filter housing where debris and trash are caught to prevent malfunction.
The flow continues underneath the pilot plug and fills the cavity of the motor valve diaphragm. This pushes down on the diaphragm, diaphragm plate, stem, and seat, keeping the valve in the closed position.
Because the motor valve diaphragm area is twice that of the seat, the regulator can be held in a closed position with equal pressure on both surfaces.
The pilot plug lower seat is closed, blocking upstream pressure.
The pilot plug upper seat, which is the pressure vent, is open, allowing diaphragm pressure to vent from underneath the motor valve diaphragm and the valve seat to be in the closed position.
When the adjusting screw is tightened and the pilot spring tension is greater than the downstream pressure, it forces the pilot assembly to move down.
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This positions the pilot plug to open the lower seat and allows full upstream pressure to now flow into the cavity of the motor valve diaphragm.
Now the pressures are equalized on both sides of the diaphragm and the upstream pressure can push open the valve seat.
The pilot plug movement adjusts the amount of pressure in this cavity, repositioning the stem and seat assembly to control the downstream setpoint.
If downstream pressure exceeds the spring tension, which is your set point, it pushes against the pilot assembly, closing off the lower seat and unseating the upper seat, which is the pressure vent.
Gas holding the valve open is vented from underneath the motor valve diaphragm to the downstream side of the valve, allowing the valve to close and the downstream pressure to be regulated.
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With the downstream pressure neither above nor below the set point, the pilot assembly assumes a position in which both seats of the pilot plug are closed.
The regulator will maintain and control a constant downstream pressure set point.
One of the ways energy producers are creating emissions-free operation is by using compressed air as the source of outside supply for control devices.
The back pressure regulator with outside supply, or BPOS, and the pressure reducing regulator with outside supply, PROS, can be purchased new or converted from a standard regulator. For a step-by-step guide, check out our conversion videos.
In this video, we’ll help you better understand these valves by walking through an animation of what’s happening when using compressed air as a source of outside supply.
Producers use a Back Pressure Regulator to monitor and control upstream pressure. Here's how the Back Pressure Regulator with Outside Supply (or BPOS) works:
Upstream pressure enters the valve, travels under the seat and exits through the downstream side of the body.
Upstream pressure also travels through the sense line into the pilot housing and underneath the diaphragm of the pilot assembly.
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With the adjusting screw unthreaded, there is very little tension on the pilot assembly, about 10 PSI.
In this position, the pilot plug is pushing against the upper seat, closing off the lower seat.
The outside source of supply pressure, commonly compressed air, travels through a filter where debris is caught before entering the upper housing and under the pilot plug. This flow is blocked by the closed lower seat.
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The supply pressure to the regulator needs to be at least 60% of upstream pressure. For example, if you’re trying to hold 100 PSI, you need at least 60 PSI of supplied air. If you have the ability, just match the supply air pressure with your set point.
When the adjusting screw is tightened and the spring tension is greater than the upstream pressure, it forces the pilot assembly to move down.
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This positions the pilot plug to open the lower seat and allows outside supply pressure to enter the upper housing cavity and push down on the diaphragm, moving the valve to a closed position.
The upstream flow pushes up on the valve seat as the supply pressure is pushing down on the diaphragm. Because the area of the diaphragm is twice the area of the seat, the regulator can be held in a closed position with equal pressure on both surfaces.
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If upstream pressure exceeds the spring tension, which is your set point, it pushes the pilot assembly up, closing the lower seat and cutting off the supply pressure from entering the housing.
The outside supply pressure holding the valve closed then vents through the breather plug on the bonnet, allowing the valve to open and the upstream pressure regulated.
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The regulator will control upstream pressure as it increases or decreases, maintaining a constant back pressure set point.
Producers use a Pressure Reducing Regulator to monitors and control downstream pressure.
Upstream pressure enters the valve, travels under the seat and exits through the downstream side of the body.
This downstream pressure also travels through the sense line into the pilot housing and underneath the diaphragm of the pilot assembly.
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An outside source of supply pressure travels through a filter where debris is caught before entering the upper housing, beneath the lower seat. This pressure fills the upper housing cavity and pushes down on the diaphragm, closing the valve seat.
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Because the motor valve diaphragm area is twice that of the seat, the regulator can be held in a closed position with equal pressure on both surfaces.
The pilot plug lower seat is closed, blocking upstream pressure.
The pilot plug upper seat, which is the pressure vent, is open, allowing diaphragm pressure to vent from underneath the motor valve diaphragm and the valve seat to be in the closed position.
With the adjusting screw unthreaded, there is very little tension on the pilot assembly, about 10 PSI.
When the adjusting screw is tightened and the pilot spring tension is greater than the downstream pressure, it forces the pilot assembly to move down.
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This pushes down on the pilot plug and opens the lower seat, allowing supply pressure to flow into the cavity of the lower housing, below the diaphragm.
Now the pressures are equalized on both sides of the diaphragm and the upstream pressure can push open the valve seat.
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The booster spring helps the regulator to open by pushing up on the diaphragm plate, raising the valve seat.
When downstream pressure exceeds the spring tension, which is your set point, it pushes against the pilot assembly, closing off the lower seat and the outside supply pressure from the lower housing.
The pressure that was in the lower housing is then vented through the breather plug in the bonnet.
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With the downstream pressure at the set point, the pilot assembly assumes a position in which both seats of the pilot plug are closed.
Now the regulator will maintain and control a constant downstream pressure set point.
The Kimray Spring Loaded Back Pressure Regulator is a dependable, easy-to-operate, zero-emission solution for holding back pressure on an oil and gas vessel.
In this video, Mike explains how it works.
The primary reason you 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 FWKO, it can regulate the oil and gas together, allowing the vessel to separate the water from these elements.
Other applications include heater treaters, central tank batteries, flash separators, and flares.
Process fluid enters the valve on the upstream side. It’s communicated up to the actuator chamber either internally through the stem or through an external tube depending on the model.
The upstream pressure creates a force on the diaphragm and diaphragm plate. When it overcomes the force of the spring, the valve opens.
This allows the upstream pressure to release downstream of the valve.
As the upstream pressure starts to fall below the spring set point, the valve closes.
The set point is controlled using the adjusting screw. To increase the set point, turn it clockwise; to decrease the set point, turn it counter-clockwise.
Pressure Regulators Learning Path
Installation, Repairs & Conversions
