Eng-002.3 Rev.3 High Pressure

Repair Manual

High Pressure Motor Valves

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL INDEX

Introduction ..................................... ....................................................... ..................................... ...................................... .......................... ....... 1 Elastomers ..................................... ........................................................ ...................................... ...................................... .......................... ....... 2 Materials ......................................... ........................................................... ..................................... ...................................... .......................... ....... 3 Pressure Open to Pressure Close Conversion .................................. .............................................. ............ 5 HPMV Disassembly ................. ................................... ..................................... ...................................... ................................. .............. 9 HMPV Inspection of Parts ....................... .......................................... ...................................... .................................. ............... 17 HPMV Assembly ................... ..................................... ..................................... ...................................... .................................. ............... 19 HPMV Testing ................ ................................... ...................................... ...................................... ...................................... ..................... .. 25 Piston Balanced Disassembly ................. ................................... ..................................... .................................. ............... 27 Piston Balanced Inspection of Parts ................... ...................................... ..................................... ...................... .... 35 Piston Balanced Assembly ................ ................................... ..................................... .................................... ..................... ... 37 NOTE: We reserve the right to modify or change, without prior notice, any statement statement or information contained herein. 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. ® Copyright 2006, KIMRAY, KIMRAY, Inc.

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL INDEX

Introduction ..................................... ....................................................... ..................................... ...................................... .......................... ....... 1 Elastomers ..................................... ........................................................ ...................................... ...................................... .......................... ....... 2 Materials ......................................... ........................................................... ..................................... ...................................... .......................... ....... 3 Pressure Open to Pressure Close Conversion .................................. .............................................. ............ 5 HPMV Disassembly ................. ................................... ..................................... ...................................... ................................. .............. 9 HMPV Inspection of Parts ....................... .......................................... ...................................... .................................. ............... 17 HPMV Assembly ................... ..................................... ..................................... ...................................... .................................. ............... 19 HPMV Testing ................ ................................... ...................................... ...................................... ...................................... ..................... .. 25 Piston Balanced Disassembly ................. ................................... ..................................... .................................. ............... 27 Piston Balanced Inspection of Parts ................... ...................................... ..................................... ...................... .... 35 Piston Balanced Assembly ................ ................................... ..................................... .................................... ..................... ... 37 NOTE: We reserve the right to modify or change, without prior notice, any statement statement or information contained herein. 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. ® Copyright 2006, KIMRAY, KIMRAY, Inc.

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HIGH PRESSURE MOTOR VALVE REPAIR MANUAL INTRODUCTION

SCOPE This instruction manual contains repair information for the standard 1" and 2" Kimray High Pressure Motor Valve and the 2” through 6” Piston Balanced High Pressure Motor Valve. DESCRIPTION The High Pressure Motor Valves are all actuated with a pneumatic actuator which features an open yoke and travel indicator. indicator. The actuators are reversible reversible between pressure opening and pressure pressure closing configurations. The standard High Pressure Motor Valve employs a ball and cone seat configuration. The Piston Balanced High Pressure Motor Valve shuts off with a resilient seat. OPERATION The Kimray High Pressure Motor Valves Valves require no more than 30 psig to operate. The pneumatic pressure drives a diaphragm against a return return spring. When pneumatic pressure is relieved, the valve shuts. 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 valve, the inspection interval may be decreased or increased. The valve can be repaired without being removed from the piping. WARNING Before performing any service be sure that the valve is fully isolated and that all pressure upstream and down has been relieved. • Use bypass valves or fully shut off the process • Be sure that any operating or instrument gas lines have been disconnected. • Never assume that a check valve is fully blocking the downstream line. • Never tighten any fitting or the main connections to the regulator while there is pressure on the line. To get the long service you have come to expect from Kimray products, always use GENUINE KIMRAY repairs. s. Remem Remember ber,, parts parts made made to less than than Kimray Kimray specifi specification cations s don’t don’t save you PARTS when doing repair money!!!

ENG-002.3 REV. 3 Issued 1-17-200 1-17-2007 7

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL ELASTOMERS

AFLAS

VITON

® is a trade mark of Asahi Glass Co

® is a trade mark of Dupont

TEMPERATURE: -25° -2 5° to +5 +500 00°° F -30° -3 0° to +2 +260 60°° C


APPLICATION: Crude Oil & Gas Production (High heat), Steam Flood Production Chemicals (corrosion inhibitors) Amine Sweetener Systems, Gasoline, Diesel, Fuel Oil 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 Oil & Gas Production, H2S, Steam, Petroleum fluids, Sea Water

HSN (Highly Saturated Nitrile)

FLUID / GAS: Crude Oil & Gas, Sour Gas (C02), Propane, Gasoline, Diesel, Fuel Oil Systems DO NOT USE WITH: WITH: Hot Water, Not preferred for wet H2S, Methyl Alcohol, Amines, Sodium hydroxide solutions


ETHYLENE PROPYLENE APPLICATION: Crude Oil & Gas Production w/ H2S C02 FLUID / GAS: Crude Oil & Gas H2S, C02, Sea Water

NITRILE TEMPERATURE: Buna-N: -40° -4 0° to +2 +220 20°° F -40° -4 0° to +1 +105 05°° C Low-Temp: -85° -8 5° to +1 +120 20°° F -65° -6 5° to +4 +49° 9° C

TEMPERATURE: -65° -6 5° to +3 +300 00°° F -54° -5 4° to +1 +148 48°° C APPLICATION: Steam Flood FLUID / GAS: Steam, Water, Alcohol DO NOT USE WITH: WITH: Crude Oil & Gas, Diester Lubricants (Lube Oils)

POLYURETHANE

APPLICATION: Crude Oil & Gas Production Glycol Dehydrators, Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal, Methanol Injection Pumps, Water pump seals, hydraulic pump seals FLUID / GAS: Crude Oil & Gas, Good to Poor in Sour Production (See HSN), Water, Water, Glycols, Hydraulic Oils, Resistance to crude oil in the presence of hydrogen sulfide and amines, Diesel fuel, fuel oils

TEMPERATURE: -40° -4 0° to +2 +220 20°° F -40° -4 0° to +1 +104 04°° C APPLICATION: High abrasion resistance Seats, Diaphragms FLUID / GAS: Crude Oil gas and Water, Sour Gas (C02), propane, butane, fuel, mineral oil and grease

POLYACRYLATE DO NOT USE WITH: WITH: Aromatic hydrocarbons, chlorinated hydrocarbons, phosphate esters (hydraulic fluids)

GYLON

TEMPERATURE: ±0°° to +3 ±0 +300 00°° F -17° -1 7° to +1 +149 49°° C

TEMPERATURE: -350 -3 50°° to +50 +500° 0° 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: WITH: Alcohol, Glycols, Hydrocarbons

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL MATERIALS

Standard materials in the standard Kimray High Pressure Motor Valve include: Exterior Parts: Bonnet Body

Ductile Iron ASTM - A395 Cast Steel ASTM - A216 WCB

Interior Parts: Stem Cage Stuffing Box Seat Plug

303 Stainless Steel Free Machining Steel AISI 12L14 Free Machining Steel AISI 12L14 Tool Steel AISI D2 Carbide/303 Stainless

Elastomers: Packing O-Rings Diaphragm

Nitrile/Teflon Nitrile Nitrile

Standard materials in the Kimray Piston Balanced High Pressure Motor Valve include Exterior Parts: Bonnet: Body

Ductile Iron ASTM - A395 Cast Steel ASTM - A216 WCB

Interior Parts: Upper Housing Stem Cage Stuffing Box Seat Piston

Steel AISI C1018 316 Stainless Steel 316 Stainless Steel Free Machining Steel AISI 12L14 Tool Steel AISI D2 Tool Steel AISI D2

Elastomers: Packing O-Rings Diaphragm

Nitrile/Teflon Nitrile Nitrile

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!!!

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL NOTES

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL PRESSURE OPEN TO PRESSURE CLOSE CONVERSION

STEP 1 BLOCK DISSASEMBLY Start from disassembling the Travel Indicator Block (Fig. 1.1)

Figure 1.1

STEP 2 BREATHER PLUG Remove the breather plug from the Bonnet (Fig. 2.1)

Figure 2.1

STEP 3 ADJUSTING SCREW Remove the Adjusting Screw from top of Bonnet (Fig. 3.1)

Figure 3.1

STEP 4 PIVOT Remove Pivot from Adjusting Screw (Fig. 4.1)

Figure 4.1

STEP 5 BONNET Remove the Bonnet by loosing the bolts (Fig. 5.1 and 5.2)

Figure 5.1

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Figure 5.2

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STEP 6 SPRING Remove the Spring from the Diaphragm Plate (Fig. 6.1)

Figure 6.1

STEP 7 DIAPHRAGM PLATE Use an adjustable wrench to hold the Upper Stem (Fig. 7.1) while loosening the Diaphragm Plate (Fig. 7.2)

Figure 7.1

Figure 7.2

Remove the Diaphragm Plate from the Yoke (Fig. 7.3)

Figure 7.3

STEP 8 RETRIEVING O-RING NOTE: THIS STEP SHOULD BE FOLLOWED IF YOU DO NOT HAVE AN EXTRA O-RING. Remove the bolts from the Yoke (Fig. 8.1) Flip the Yoke upside down and loosen the Lower Adjusting Screw (Fig. 8.2) Figure 8.1

Figure 8.2

Use a pick remove the O-Ring from the Adjusting Screw (Fig. 8.3) After the O-Ring has been removed, tighten Adjusting Screw back in Yoke and then attach Yoke back to Body.

Figure 8.3 Page 6

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STEP 9 DIAPHRAGM ASSEMBLY Insert the Pivot in the bottom of the Yoke (Fig. 9.1) Place the Spring Plate on top of the Pivot (Fig. 9.2)

Figure 9.1

Figure 9.2

Figure 9.3

Figure 9.4

Figure 9.5

Figure 9.6

Figure 9.7

Figure 9.8

Figure 9.9

Figure 9.10

Insert the Spring on top of the Spring Plate with the Spring plate on top (Fig. 9.3) Insert the Diaphragm Plate on top of the Spring (Fig. 9.4)

Use an adjustable wrench to hold the Upper Stem (Fig. 9.5) while tightening the Diaphragm Plate (Fig. 9.6)

Insert bolts in Bonnet (Fig. 9.7) and tighten them with an impact gun (Fig. 9.8)

Insert O-Ring on the Upper Adjusting Screw (Fig. 9.9) and tighten it on top of Bonnet (Fig. 9.10)

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STEP 10 BREATHER PLUG Insert Breather plug on Yoke (Fig. 10.1)

Figure 10.1

STEP 11 COUPLING BLOCK When you assemble the Coupling Block, make sure the bevels are in the same side of the block as show in (Fig.11.1) Place the threaded half Block on back side (Fig 11.2) Figure 11.1

Figure 11.2

Figure 11.3

Figure 11.4

Tighten the bolts in the Coupling Block with a socket (Fig. 11.3) Make sure the Travel Indicator tag shows the correct operation of the valve. (Fig. 11.4) In this case we are converting from Pressure Opening to Pressure Close

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL HPMV DISASSEMBLY

KIMRAY TOOLS Seat Pullers Figure A shows the Kimray’s Seat & Cage Removal Tool. The handles flange the disc to the body while pulling the seat or cage. Figure B shows a Kimray’s Seat Removal Tools able to remove the seat from body when the cage has been removed.

Figure A

Figure B

KIMRAY SEAT & CAGE REMOVAL TOOL

KIMRAY SEAT REMOVAL TOOL

PART #

LINE SIZE

PART #

LINE SIZE

3032

1"

615

1"

3033

2"

614

2"

STEP 1 AJUSTING SCREW Use a socket to remove the adjusting screw on top of the Bonnet (Figure 1.1 and 1.2)

Figure 1.1

Figure 1.2

Figure 2.1

Figure 2.2

STEP 2 BONNET Remove the bolts in the interface between the Bonnet and the Yoke (Fig. 2.1) Remove Breather Plug From Bonnet (Fig. 2.2)

Remove Bonnet from Yoke (Fig. 2.3)

Figure 2.3 www.kimray.com

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL HPMV DISSASEMBLY

STEP 3 SPRING Remove Pivot from top of the spring plate (Figure 3.1) Remove Spring Plate from top of the Spring (Figure 3.2)

Figure 3.1

Figure 3.2

Remove the spring from top Spring Plate (Fig. 3.3)

Figure 3.3

STEP 4 DIAPHRAGM PLATE BOLTED DIAPHRAGM NUT: Spin the Diaphragm plate in a counter clock wise direction loosing it from the Upper Stem while holding the Upper Stem with a small crescent wrench (Fig. 4.1). If the HPMV has screws holding the Diaphragm, use a screw driver to remove them (Fig. 4.2)

Figure 4.1

Figure 4.2

Figure 4.3

Figure 4.4

Figure 4.5

Figure 4.6

Remove the Diaphragm Nut from the Diaphragm Plate (Fig. 4.3) Remove the Diaphragm from the Diaphragm Plate (Fig. 4.4)

THREADED DIAPHRAGM NUT: Use a pair of piers to remove the Diaphragm Nut (Fig. 4.5) Remove the Diaphragm from the Diaphragm Plate (Fig. 4.6)

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STEP 5 TRAVEL INDICATOR Remove the bolts from the travel Indicator Block (Fig. 5.1) Remove the Block from stem (Fig. 5.2)

Figure 5.1

Figure 5.2

Figure 6.1

Figure 6.2

Figure 6.3

Figure 6.4

Figure 6.5

Figure 6.6

Figure 6.7

Figure 6.8

STEP 6 YOKE ASSEMBLY Use a wrench to remove the bolts from the Yoke base (Fig. 6.1) Slide out the Yoke from the Body (Fig. 6.2)

Flip the Yoke upside down, then take a socket and remove the Lower Adjusting Screw with an impact gun (Fig. 6.3 and 6.4)

Slide out the Upper Stem from the Lower Adjusting Screw (Fig. 6.5) Remove the outside O-Ring from the Lower Adjusting Screw (Fig. 6.6)

Remove O-Ring from the inside of the Lower Adjusting Screw (Fig. 6.7) Use a pair of snap ring pliers to remove the Snap Ring (Fig. 6.8)

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Remove the Retainer washer (Fig. 6.9)

Remove the Wiper from the Lower Adjusting Screw (Fig. 6.10)

Figure 6.9

Figure 6.10

Figure 7.1

Figure 7.2

Figure 7.3

Figure 7.4

Figure 7.5

Figure 7.6

Figure 7.7

Figure 7.8

STEP 7 STUFFING BOX ASSEMBLY Use an adjustable wrench to remove the stuffing Box from the Body (Fig. 7.1) Remove the Stuffing Box from the Body (Fig. 7.2)

Clamp the two flat sides of the Stuffing Box in vise and loosen seat with an adjustable wrench. (Fig. 7.3) Leave the Seat attached to cage. Insert a screw driver through cage and unscrew (Figure 7.4). Note: Leaving the seat attached prevents the cage from egg shaping.

Pull Stem and Cage out of Stuffing Box (Fig. 7.5), if it doesn’t come out then flip the Stuffing Box over and tap the Stem with a hammer and a small punch (Fig. 7.6)

Remove Cage and Stem from the Stuffing Box (Fig. 7.7) Remove the Spring (Fig. 7.8)

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Remove the Cage from the Ball and Stem (Fig. 7.9) Remove O-Ring from the Seat (Fig 7.10)

Figure 7.9

Figure 7.10

Figure 7.11

Figure 7.12

Figure 7.13

Figure 7.14

Figure 7.15

Figure 7.16

Remove O-Ring from Stuffing Box (Fig. 7.11) Remove Follower from the Stuffing Box (Fig. 7.12)

Remove the Packing Rings from the Stuffing Box (Fig. 7.13) Remove the Packing Sleeve from the Stuffing Box (Fig. 7.14)

Use a pair of snap ring pliers to remove the Snap Ring (Fig. 7.15) Remove the Retainer washer from the Stuffing Box (Fig. 7.16)

Remove the Wiper from the Stuffing Box (Fig. 7.17)


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SPECIAL CASES SEAT PULLERS Some times the Seat does not come out with Stuffing Box and Cage. We have a couple of options if this happens. First Option: If the Seat is the only part that stays stuck in Body: 1. Use the wire seat pullers and insert them in seat (Fig. 8.1). 2. Slide a wrench or small rod between the wire Seat Pullers 3. Tap up pulling the seat out (Fig. 8.2)

Figure 8.1

Figure 8.2

Second Option: If the Stuffing Box comes out by it self leaving seat, Ball & Stem and Cage stuck in Body. 1. 2. 3.

Thread Seat & Cage Removal Tool on to Cage (Fig. 8.3) Tighten flange down against Body Pull Case and Seat out of Body (Figure 8.4)

Figure 8.3

Figure 8.4

The other end of the tool is used in case just the Seat stays in Body.(Fig. 8.5) 1. Thread Seat & Cage Removal Tool on seat 2. Tighten flange against Body 3. Pull the seat out by turning the handle in a clock wise direction Figure 8.5

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SHOP MADE SEAT REMOVAL TOOL This seat removal tool can be made with the following parts: QTY

PART

DESCRIPTION

1

2889

Cage

1

2837

Cage

2

Stops

Disc 1 3/4"Ø x 3/4"

1

Rod

13/8"Ø x 22"

1

Handle

11 3/4 o.d. x 3/8 i.d. x 5 1/2" lg.

22" 3"

3/4"

2 1/2"

5 1/2" 1 3/4"

PART 2889

1 3/4" PART 2837

Figure 9.1

If Seat is stuck in Body (Fig. 9.2), use the appropriate cage size and thread on seat. (Fig. 9.3). Figure 9.2

Slide Handle forcefully upwards until you hit the upper stop (Fig. 9.4). The Handle impact will break loose the seat.

Figure 9.3

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Figure 9.4

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL HPMV INSPECTION of PARTS

MOST COMMONLY REPLACED PARTS • Seat • Stem & Ball • Diaphragm • O-Rings • Packing

OCCASIONALLY CHANGED PARTS • Body • Spring

BALL & STEM Check for scratches Replace: • If there are scratches present (Fig. 1.1)

Figure 1.1

SEAT Replace: • If the seat has indication of leakage (Fig 2.1)

Figure 2.1

BODY Replace: • If grooves are present on the seating surface (Fig.3.1)

Figure 3.1

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL HPMV ASSEMBLY

STEP 1 DIAPHRAGM ASSEMBLY CASE 1 BOLTED DIAPHRAGM NUT: Tighten Diaphragm Base Plate in Vice (Fig. 1.1) Insert Diaphragm on the Diaphragm Plate aligning holes with both parts (Fig. 1.2) Figure 1.1

Figure 1.2

Figure 1.3

Figure 1.4

Figure 1.5

Figure 1.6

Insert Diaphragm Plate in to Base Plate making sure holes are aligned (Fig. 1.3) Use gasket sealant material to dip each screw in before putting in hole. Tighten screws in a criss-cross pattern and then retighten very tight (Fig. 1.4)

CASE 2 THREADED DIAPHRAGM NUT: Tighten Diaphragm Plate in vice and insert Diaphragm on the Diaphragm Plate (Fig. 1.5) Grease the Diaphragm inside edge (Fig. 1.6)

Insert the Diaphragm Nut and use a pair of pliers to tighten (Fig. 1.7) Note: Make sure the Diaphragm does not wrinkle.

Figure 1.7

STEP 2 STUFFING BOX ASSEMBLY Insert Wiper in the Stuffing Box (Fig. 2.1) Insert the retainer with the sharp edge on top (Fig. 2.2)

Figure 2.1

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Figure 2.2

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Use a pair of snap ring pliers to insert the Snap Ring (Figure 2.3) Insert the packing rings on the Packing Sleeve (Fig. 2.4)

Figure 2.3

Figure 2.4

Figure 2.5

Figure 2.6

Figure 2.7

Figure 2.8

Figure 2.9

Figure 2.10

Figure 2.11

Figure 2.12

Grease the Packing before inserting it in the stuffing Box, with the large blue end of sleeve down (Fig. 2.5) Grease the Stuffing Box (Fig. 2.6)

Insert the Packing in the Stuffing Box (Fig. 2.7) Use a socket to push the Packing down (Fig. 2.8)

Insert Follower in the Stuffing Box (Fig. 2.9) Fill the Stuffing Box with grease (Fig. 2.10)

Insert O-Ring on Stuffing Box (Fig. 2.11) Insert Spring in the Stuffing Box (Fig. 2.12)

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Insert O-Ring on Seat (Fig. 2.13) Introduce the Stem in Cage (Fig. 2.14)

Figure 2.13

Figure 2.14

Figure 2.15

Figure 2.16

Figure 2.17

Figure 2.18

Figure 2.19

Figure 2.20

Figure 3.1

Figure 3.2

Thread the Seat in Cage (Fig. 2.15) Place the flat edges of stuffing box in vice (Fig. 2.16)

Insert Seat, Cage and Stem in the stuffing Box and tighten with a wrench (Fig. 2.17 and 2.18)

Tap the Stem until Ball seats (Fig. 2.19) Use a brush to grease O-Rings (Fig. 2.20)

STEP 3 BODY Flip the Body upside down and tighten Body on Stuffing Box Assembly (Fig. 3.1 and 3.2)

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BODY TESTING: Apply air pressure on the upstream side of the valve (Fig. 3.3) Test for leakage in the downstream side

Figure 3.3

STEP 4 LOWER ADJUSTING SCREW Insert O-Ring in the Lower Adjusting Screw (Fig. 4.1) Flip the Lower Adjusting Screw over and insert Wiper (Fig. 4.2)

Figure 4.1

Figure 4.2

Figure 4.3

Figure 4.4

Figure 4.5

Figure 4.6

Figure 4.7

Figure 4.8

Insert Retainer on top of Wiper making sure the sharp edge side is located on top (Fig. 4.3) Use a pair of snap ring pliers to insert the Snap Ring (Fig. 4.4)

Insert O-Ring on Lower Adjusting Screw and grease it (Fig. 4.5 and 4.6)

Insert Upper Stem in Lower Adjusting Screw, being careful not to share O-Ring (Fig. 4.7) Tighten Lower Adjusting Screw on the bottom part of Yoke (Fig. 4.8)

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STEP 5 DIAPHRAGM ASSEMBLY Place the Yoke on top of the Body (Fig. 5.1) Insert Bolts and tighten them with a wrench (Fig. 5.2)

Figure 5.1

Figure 5.2

Figure 5.3

Figure 5.4

Figure 5.5

Figure 5.6

Figure 5.7

Figure 5.8

Figure 5.9

Figure 5.10

Use a brush to grease the Upper Stem (Fig. 5.3)

Use an adjustable wrench to hold the stem while tightening the Diaphragm Plate (Fig. 5.4 and 5.5) Grease the Pivot surface of the Diaphragm Plate (Fig. 5.6)

Insert Spring Plate in the Pivot Sleeve (Fig. 5.7) Insert Spring on Diaphragm Plate (Fig. 5.8)

Insert Spring Plate on top of Spring (Fig. 5.9) Place the Bonnet on top of Yoke making sure the sure the Breather and the Supply holes are aligned (Fig. 5.10)

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Insert bolts on top of the Bonnet and tighten them with the impact gun (Fig. 5.11) Grease the Adjusting Screw (Fig. 5.12)

Figure 5.11

Figure 5.12

Figure 5.13

Figure 5.14

Figure 5.15

Figure 5.16

Figure 6.1

Figure 6.2

Figure 6.3

Figure 6.4

Place the Pivot on top of the Adjusting Screw and grease the top part of the Pivot (Fig. 5.13 and 5.14)

Screw the Adjusting Screw on top of Bonnet and tighten it with an adjustable wrench (Fig. 5.15 and 5.16)

STEP 6 BLOCK When you assemble the Block, make sure the bevels are in the same side of the block as show in (Fig. 6.1) Place the threaded Half Block on the back side (Fig. 6.2)

Tighten the bolts in the Block with a socket (Fig. 6.3) Make sure the Travel Indicator tag shows the correct operation of the valve either PO or PC (Fig. 6.4)

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL HPMV TESTING

EQUIPMENT & REQUIREMENTS SUPPLY PRESSURE: 100 psi SUPPLY CONNECTION: Device that will reduce your regulator end to any air supply connection. Fig. A shows an example of this device. It is important to have a valve in this device for testing purposes. Figure A

STEP 7 HPMV PO TESTING Apply air supply pressure (do not exceed 45 psi) on Yoke (Fig. 7.1) This will open the valve and will pressurize the bottom part of the Diaphragm. Spray soaped solution on the Lower Adjusting Screw to check for any leakage (Fig. 7.2)

Figure 7.1

Figure 7.2

Spray soaped solution on the Interface between the Bonnet and the Yoke. Check for leakage (Fig. 7.3)

Figure 7.3

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL PISTON BALANCED DISASSEMBLY

KIMRAY SEAT WRENCH W SERIES PART NUMBER

LINE SIZE

386SW

3" & 4" HPMVPB

Note: Seat Wrench W Series are mainly used for Treater Valves, but they can be used to assemble the Diaphragm Nut for 3” and 4” High Pressure Motor Valves. Figure A

UPPER CAGE PULLERS PART NUMBER

LINE SIZE

5296 5297 5298

2" HPMVPB 3" HPMVPB 4" HPMVPB Figure B

6” Piston Assembly Puller Use this tool to lift the Piston Assembly out of the Body by pulling it with a hoist. Note: This is a shop made tool using a Coupling Block, Upper Stem and a ring.

Figure C

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STEP 1 ADJUSTING SCREW Use a wrench to remove the Adjusting Screw on top of the Bonnet (Fig. 1.1)

Figure 1.1

STEP 2 BONNET Remove the bolts in the interface between the Bonnet and the Yoke (Fig. 2.1) Remove Breather Plug from Bonnet (Fig. 2.2)

Figure 2.1

Figure 2.2

Remove Bonnet from Yoke (Fig. 2.3)

Figure 2.3

STEP 3 SPRING Remove Pivot and the Spring Plate from top of the Spring (Fig. 3.1)

Remove the spring from top Spring Plate (Fig. 3.2) Figure 3.1

Figure 3.2

Figure 4.1

Figure 4.2

STEP 4 DIAPHRAGM PLATE Spin the Diaphragm plate in a counter clock wise direction loosening it from the Upper Stem while holding the Upper Stem with a small crescent wrench (Fig. 4.1). Remove the Diaphragm Nut from the Diaphragm Plate (Fig. 4.2)

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Remove the Diaphragm from the Diaphragm Plate (Fig. 4.3)

STEP 5 TRAVEL INDICATOR Remove the bolts from the Travel Indicator Block (Fig. 5.1) Remove the Coupling Block (Fig. 5.2)

STEP 6 YOKE ASSEMBLY Use a wrench to remove the bolts from Yoke (Fig. 6.1) Slide out the Yoke from Body (Fig. 6.2)

Flip Yoke upside down and remove the Upper Stem from the Lower Adjusting Screw (Fig. 6.3) Take a socket and remove the Lower Adjusting Screw with an impact gun (Fig. 6.4)

Remove the outside O-Ring from the Lower Adjusting Screw (Fig. 6.5) Remove O-Ring from the inside of the Lower Adjusting Screw (Fig. 6.6)

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Use a pair of snap ring pliers to remove the Snap Ring (Fig. 6.7) Remove the Retainer Washer (Fig. 6.8)

Figure 6.7

Figure 6.8

Remove the Wiper from the Lower Adjusting Screw (Fig. 6.9)

Figure 6.9

STEP 7 STUFFING BOX ASSEMBLY Use an adjustable wrench to remove the Stuffing Box from the Body (Fig. 7.1 and 7.2)

Figure 7.1

Figure 7.2

Figure 7.3

Figure 7.4

Figure 7.5

Figure 7.6

Remove Spring and Follower from Stuffing Box (Fig. 7.3) Remove the Packing Sleeve and the Packing Ring from the Stuffing Box (Fig. 7.4)

Use a pair of snap ring pliers to remove the Snap Ring (Fig. 7.5) Remove the Retainer Washer from the Stuffing Box (Fig. 7.6)

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Remove the Wiper from the Stuffing Box (Fig. 7.7)

Figure 7.7

STEP 8 UPPER HOUSING Use an impact gun to remove the bolts from the Upper Housing (Fig. 8.1) Break the Upper Housing loose by prying up with screw drivers (Fig. 8.2)

Figure 8.1

Figure 8.2

Remove the Upper Housing from the Body (Fig. 8.3).

Figure 8.3

STEP 9 PISTON ASSEMBLY Some times the Upper Cage will not break loose easy. If this is the case use an Upper Cage Puller. Start by removing the O-Ring from the Cage (Fig. 9.1) Slide Upper Cage Pullers in O-Ring groove on Cage and clamp with a water hose clamp (Fig. 9.2)

Figure 9.1

Figure 9.2

Alternately tighten screw until cage breaks loose from Body (Fig. 9.3)


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Remove the Piston Assembly from Body (Fig. 9.4) Slide up Upper Cage from the Piston Assembly (Fig. 9.5)

Figure 9.4

Figure 9.5

Figure 9.6

Figure 9.7

Figure 9.8

Figure 9.9

Figure 9.10

Figure 9.11

Remove the O-Ring and two Backups (Fig. 9.6) Remove the Lower Cage from Piston Assembly (Fig. 9.7)

Use a socket to remove the screw that holds the Ratio Plug (Fig. 9.8) Remove the Ratio Plug (Fig. 9.9)

Remove O-Rings from Piston Assembly (Fig. 9.10, 9.11 and 9.12)

Figure 9.12 Page 32

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STEP 10 SEAT Remove seat from Body (Fig. 10.1 & 10.2)

Figure 10.1

Figure 10.2

Remove O-Ring from Seat (Fig. 10.3)

Figure 10.3

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL PISTON BALANCED INSPECTION of PARTS

PISTON ROD Replace: • If piston rod is bent (Fig. 1.1)

Figure 1.1

PISTON Replace: • If the parts present corrosion in the outside surface (Fig. 2.1)

Figure 2.1

SEAT Replace: • In the presence of dings, nicks or corrosion (Fig. 3.1)

Figure 3.1

RATIO PLUG Replace: • In the presence of scratches, corrosion and wear (Fig. 4.1) Note: This is one of the most affected parts due to the severe impact of the particles that flow trough the valve. Figure 4.1

CAGE Replace: • If the Cage has lost its shape (Fig. 5.1) Note: If the valve was improperly disassembled, there is a high possibility to have a Cage out-of-round. Figure 5.1 www.kimray.com

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HIGH PRESSURE MOTOR VALVES REPAIR MANUAL PISTON BALANCED INSPECTION of PARTS

STUFFING BOX Replace: • In the presence of excessive corrosion and wear. (Fig. 6.1, 6.2 and 6.3) Note: Most of the times this part can be repair by cleaning and wire brushing the inside and outside threads.

Figure 6.2

Figure 6.1

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Figure 6.3

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL PISTON BALANCED ASSEMBLY

KIMRAY SEAT WRENCH W SERIES PART NUMBER

LINE SIZE

386SW

3" & 4" HPMVPB

Note: Seat Wrench W Series are mainly used for Treater Valves, but they can be used to assemble the Diaphragm Nut for 3" and 4" High Pressure Motor Valves. Figure A

STEP 1 SEAT Grease the seat surface inside the Body (Figure 1.1) Insert O-Ring on Seat and place it in Body (Fig. 1.2)

Figure 1.1

Figure 1.2

Figure 2.1

Figure 2.2

Figure 2.3

Figure 2.4

Figure 2.5

Figure 2.6

STEP 2 PISTON ASSEMBLY Insert O-Ring inside Piston Assembly (Fig. 2.1) Insert O-Ring in Ratio Plug (Fig. 2.2)

Insert O-Ring with the angled side on top (Fig. 2.3 and 2.4)

Insert Ratio Plug in the Piston Assembly (Fig. 2.5) Finger tighten the screw holding the Ratio Plug on Piston Assembly (Fig. 2.6)

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Use brass jaws to hold the Piston Assembly in vice (Fig. 2.7) Use a socket to tighten the Ratio Plug Screw (Fig. 2.8)

Figure 2.7

Figure 2.8

Figure 2.9

Figure 2.10

Figure 2.11

Figure 2.12

Figure 2.13

Figure 2.14

Figure 2.15

Figure 2.16

Insert Lower Cage on Piston Assembly (Fig. 2.9) Grease the Piston Assembly (Fig. 2.10)

Insert Backup on Piston Assembly (Fig. 2.11) Insert O-Ring on Piston Assembly (Fig. 2.12)

Insert Backup on Piston Assembly (Fig. 2.13) Grease O-Ring and Backups (Fig. 2.14)

Insert two O-Rings in the Upper Cage grooves (Fig. 2.15 and 2.16)

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Insert Piston Assembly Stem in to Upper Cage (Fig. 2.17). Press Upper Cage on to Piston Assembly. Grease O-Rings in Upper Cage (Fig. 2.18)

Figure 2.17

Figure 2.18

Figure 2.19

Figure 2.20

Figure 2.21

Figure 2.22

Figure 3.1

Figure 3.2

Figure 4.1

Figure 4.2

Spray Never Seez in the Piston Assembly (Fig. 2.19) Insert Piston Assembly in Body (Fig. 2.20)

Use a rubber hammer to press Piston Assembly in Body (Fig. 2.21) Use a rubber hammer to tap the Piston Assembly Rod pressing the Seat in place (Fig. 2.22)

STEP 3 UPPER HOUSING Insert Upper Housing on Body (Fig. 3.1). Make sure the Safety Relief Hole is facing tapped holes on Body. Insert bolts and tighten them in a crisscross pattern (Fig. 3.2)

STEP 4 STUFFING BOX Insert two wipers in Stuffing Box (Fig. 4.1) Insert Retainer Washer on top with the sharp edge side facing up (Fig. 4.2)

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Use a pair or snap ring pliers to insert the Snap Ring on top of the Retainer Washer (Fig. 4.3) Insert O-Ring on Stuffing Box (Fig. 4.4)

Figure 4.3

Figure 4.4

Figure 4.5

Figure 4.6

Figure 4.7

Figure 4.8

Figure 4.9

Figure 4.10

Figure 4.11

Figure 4.12

Grease the Stuffing Box Hole (Fig. 4.5) Insert Packing Rings and Packing Sleeve in Stuffing Box, with the large blue end of sleeve down (Fig. 4.6).

Insert Follower in Stuffing Box (Fig. 4.7) Insert Spring in Stuffing Box (Fig. 4.8)

Fill the Stuffing Box with grease (Fig. 4.9) Spray Never Seez on the Stuffing Box (Fig. 4.10)

Insert Stuffing Box in Upper Housing (Fig. 4.11) Tighten Stuffing Box with an adjustable wrench (Fig. 4.12)

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STEP 5 LOWER ADJUSTING SCREW Insert two Wipers in the Lower Adjusting Screw (Fig. 5.1)

Insert Retainer Washer with the sharp edge side facing up (Fig. 5.2) Figure 5.1

Figure 5.2

Figure 5.3

Figure 5.4

Figure 5.5

Figure 5.6

Figure 5.7

Figure 5.8

Figure 6.1

Figure 6.2

Use a pair of snap ring pliers to insert the Snap Ring on top of the Retainer Washer (Fig. 5.3) Insert O-Ring inside the Lower Adjusting Screw (Fig. 5.4)

Insert O-Ring around the Lower Adjusting Screw (Fig. 5.5) Grease O-Rings in Lower Adjusting Screw (Fig. 5.6)

Insert Upper Stem in Lower Adjusting Screw (Fig. 5.7) Note: Make sure you do not shear the ORing. Tighten Lower Adjusting Screw in Yoke (Fig. 5.8)

STEP 6 YOKE Insert Yoke on top of the Upper Housing (Fig. 6.1) Insert Bolts and tighten in a criss-cross pattern (Fig. 6.2)

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STEP 7 DIAPHRAGM ASSEMBLY Use a pair of brass jaws to hold the Diaphragm Plate in a vice (Fig. 7.1) Grease the Diaphragm Plate inside perimeter (Fig. 7.2)

Figure 7.1

Figure 7.2

Figure 7.3

Figure 7.4

Figure 7.5

Figure 7.6

Figure 7.7

Figure 7.8

Figure 7.9

Figure 7.10

Place Diaphragm on Diaphragm Plate (Fig. 7.3) Thread Diaphragm Nut on Diaphragm Plate (Fig. 7.4)

Use a 386SW Seat Wrench W Series to tighten the Diaphragm Nut (Fig. 7.5) Note: Make sure the Diaphragm does not wrinkle. Grease the top hole of the Diaphragm Plate (Fig. 7.6)

Insert Diaphragm Plate Assembly on top of Yoke (Fig. 7.7) Use an adjustable wrench to hold the Upper Stem while tightening the Diaphragm Plate (Fig. 7.8)

Grease the Sleeve on the Diaphragm Plate (Fig. 7.9) Insert the Spring Plate in Diaphragm Plate (Fig. 7.10)

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Insert Spring on Diaphragm Plate (Fig. 7.11) Insert the second Spring plate on top of Spring (Fig. 7.12)

Figure 7.11

Figure 7.12

Figure 7.13

Figure 7.14

Figure 7.15

Figure 7.16

Figure 7.17

Figure 7.18

Grease the top side of the Spring Plate (Fig.7.13) Insert Pivot on top of the Spring Plate (Fig. 7.14)

Place the Bonnet on top of Yoke (Fig. 7.15) Tighten the Breather Plug on top of the Bonnet (Fig. 7.16)

Insert bolts on the Bonnet and tighten in a criss-cross pattern (Fig. 7.17 and 7.18)

Tighten the Upper Adjusting Screw on top of Bonnet (Fig. 7.19)


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STEP 8 COUPLING BLOCK Make sure the bevels are aligned in the Coupling Block (Fig. 8.1) Use an impact gun to tighten the screws in the Coupling Block (Fig. 8.2)

Figure 8.1

Figure 8.2

Make sure the Travel Indicator tag shows the correct operation of the valve (Fig. 8.3)

Figure 8.3

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HIGH PRESSURE MOTOR VALVE REPAIR MANUAL NOTES

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Eng-002.3 Rev.3 High Pressure

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