Kimray PDC User manual

All Pictures shown are for illustration purpose only. Actual product may vary due to product enhancement.
‡ Configuration of High Pressure Control Pilot is a trademark of Kimray, Inc.
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PRESSURE DIFFERENTIAL CONTROLLER
QUICK START GUIDE
CAUTION
When ordered, the pilot conguration and construction materials were
selected to meet specic pressure, temperature, pressure drop and
uid conditions. Since some body/trim material combinations are
limited in their pressure drop and temperature ranges, do not subject
the high pressure pilot to any other conditions without rst contacting
the Kimray Inc. sales ofce or a sales / applications representative.
CAUTION
Prior to installing, the instructions provided herein should be completely
reviewed and understood before operating or repairing this equipment.
All CAUTION and WARNING notes must be strictly observed to
prevent personal injury or equipment damage.
Description
The Kimray pressure differential controller (PDC) connects across
the orice plate of a meter run to maintain a constant stable pressure
differential across the meter run. This relates to a constant ow rate
when the upstream pressure is constant. This pilot adjusts the ow rate
to maintain the pressure differential by positioning a pressure opening
control valve that has characterized equal percentage valve trim for
precise ow control.
A typical PDC pilot installation is mounted so that the pressure
differential across an orice plate is applied across the diaphragm.
The output signal from the PDC pilot operates a diaphragm control
valve to maintain the desired pressure differential across the orice
plate.
Figure 1
Installation
Before installing the PDC level controller, inspect it for shipment
damage and for foreign material that may have collected during
shipment. Inspect the openings in the controller and clean the
pipe lines to remove scale, chips and debris.
Verify all pressure connections are tight before pressurizing the
system.
1. Locate the motor valve conveniently upstream or downstream of the
meter run.
2. Size and install the proper orifice plate for flow conditions. Determine
the pressure differential set point desired and install the proper
spring for the maximum pressure differential to be controlled. (See
Fig. 3)
3. A metering valve or adjustable orifice can be installed to take part of
the pressure drop to provide better control conditions for the valve.
4. Mount the controller so that it is accessible and level. Connect the 1”
connector upstream of the orifice plate and the 1/4” NPT connector
downstream. Install isolation valve manifold if desired.
5. Connect a dry instrument gas source (20-30 psig) to the pilot supply
and connect the control tubing to the valve. A needle valve on this
line is sometimes helpful in stabilizing the motor valve / controller
system. (See Fig.1)
2" HPCV
w/ Equal Percentage
Seat Meter Run
2" Metering Valve
(Optional)
Pressure Differential Controller
Mounting
Bracket
2990
Neddle
Valve
Optional
Isolation
Valves
2nd Stage
Instrument Regulator
1st Stage
Regulator
FD-200
Filter
Drip pot
Flow
Start-up procedure:
1. Open the isolation valves and close the equalizing valve (if used)
prior to applying pressure to the meter run to prevent an excessive
pressure drop across the diaphragm. Excessive pressure drops
across diaphragm will cause the diaphragm to rupture.
2. Turn the control knob fully counterclockwise.
3. Open the gas stream to the meter run.
4. Adjust the control knob until the motor valve begins to open.
5. Continue to adjust the control knob until the desired pressure
differential is obtained. If the valve is fully open and the pressure
differential is not obtained, recheck flow conditions, pressure, valve
sizing and orifice sizing.
6. If the valve hunts (moves open and closed excessively), close the
needle valve in the motor valve supply gas line until the positioning
becomes stable or replace the motor valve trim with a smaller inner
valve.
7. The Controller can now be set for the maximum limit or adjusted to
control the desired pressure differential.

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PRESSURE DIFFERENTIAL CONTROLLER
QUICK START GUIDE
For questions or comments, contact your local Kimray authorized distributor, or visit www.kimray.com.
Kimray Inc.
52 NW 42nd Street
Oklahoma City, OK 73118
Customer Service: 405.525.6601 | [e-mail] Product/Tech Support: 405.525.4264 | [e-mail]
WARNING
A leaking pilot is an indication that
service is required. Failure to take pilot
out of service immediately may cause a
hazardous condition.
WARNING
Before any service, be certain that the
pilot is fully isolated and that all pressure
upstream and downstream has been
relieved. Use bypass pilots or fully shut
off the process.
Be sure that any operating or instrument
gas lines have been disconnected.
Never assume that a check pilot is fully
blocking the downstream line.
NOTE
Never stand directly in front of or over
a pilot when the system is pressurized.
The pilot could suddenly open, blowing
debris into the person’s face and eyes.
NOTE
If conditions indicate the possibility of
backward ow you may wish to install
check pilots
WARNING
Before beginning installation:
• Read and follow instructions.
• Make sure the pilot cannot operate
during installation.
Do not exceed the maximum supply
pressure specied on the pilot name-
plate.
Never tighten any tting or the main
connections to the pilot while there is
pressure on the line.
Only use genuine Kimray replacement parts.
Repair kits and detailed repair instructions
are available for each pilot.
Visit www.kimray.com or
contact your Kimray authorized distributor
for more information.
SG:P003 Issued 10/20
Troubleshooting
Problem Possible Cause(s) Possible Solution
Leaks between upper and lower anges. Check for any damage to ange o-ring. Clean the lower ange groove so it is free of debris.
Inspection Schedule
Body
Under normal conditions, the body will last for years.
Severe conditions will require inspection more frequently. The body should be inspected every time valve trim is in-
spected.
*Under severe operating conditions, the maintenance schedule described will not be adequate and a shorter maintenance interval may be required.
Start-up and Test
With the installation completed and
appropriate relief and check pilots installed
and set, slowly open the upstream and
downstream shutoff pilots. In order to test
the functionality of the pilot, allow only a
small amount of upstream pressure through
the upstream shutoff pilot. Check for proper
pilot operation by cycling the source of
instrument gas several times.
Maintenance
Maintenance should be performed on a
regular basis. An initial inspection interval of
12 months is recommended. Depending on
the service conditions of the pressure pilot,
the inspection interval may be decreased or
increased.
The pressure pilot can be repaired without
being removed from the piping.
Repair Tips
• If pilot bleeds gas continuously, the pilot
plug seat may be dirty.
• Evenly tighten the screws which hold the
bonnet on.
• Diaphragms will harden with age.