Kimray PO Owner's manual

HIGH PRESSURE CONTROL VALVE
STEM GUIDED

All Rights Reserved.
All contents of this publication including illustrations are believed to be
reliable. And while efforts have been made to ensure their accuracy, they
are not to be construed as warranties for guarantees, express or implied,
regarding Kimray products or services described herein or their use or
application. All sales are governed by our terms and conditions, which are
available on request.
Kimray reserves the right to modify or improve the designs or specications
of such products at any time without prior notice.
©2015 Kimray Inc.

HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
3
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Model: PO, PC
Contents
A Before you start 4
A1 Scope 4
A2 Introduction 4
A3 Description 4
A4 Maintenance 4
A5 Changes and Updates 4
A6 Special Tools and Equipment 5
A7 Orientation 6
INSTALLATION
1 Installation 7
2 Start-up and Test 7
DISASSEMBLY
3 Adjusting Screw, Pivot, Breather Plug, Bonnet 8
4 Travel Indicator 9
5 Pivot, Spring Plate, Spring 9
6 Pivot Sleeve, Diaphragm Plate, Diaphragm Nut 10
7 Yoke Assembly 11
8 Packing Box 12
9 Removing Packing Box 13
10 Packing Box Assembly 14
INSPECTION
11 Inspection & Cleaning 15
ASSEMBLY
12 Cage Packing 16
13 Diaphragm Assembly 18
14 Internal Yoke Assembly 19
15 Pressure Closed 20
16 Travel Indicator 21
TESTING
17 High Pressure Control Valve Test 22

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
4
Model: PO, PC
WARNING:
DO NOT exceed the maximum pressure specied on the
nameplate. Under no circumstances should the regulator
supply pressure ever exceed the maximum psig.
A4 Maintenance
Maintenance should be performed on a regular basis.
Initial intervals of 12 months is recommended. The
maintenance interval may increase or decrease
depending on changing application environments. The
valve can be repaired without being removed from the
piping.
Related Publications
The following publications are applicable for the regulator
Number Type Title
See catalog section E1 for product pages.
Abbreviations / Acronyms
The abbreviations that follow are used in this manual.
Term Denition
PO Pressure Open
PC Pressure Closed
Commonly Replaced Parts
• Trim Set
• Diaphragm
• O-Ring
• Packing
Occasional Replacement Parts
• Body
• Spring
A5 Changes and Updates
NOTE:
To prevent galling or seizing at assembly level for straight
threads Kimray recommends using a nickel impregnated
paste. For other threads use a nickel impregnated PTFE
thread sealant tape.
A Before you start
CAUTION:
The instructions provided herein should be completely
reviewed and understood before operating or reparing this
equipment. All CAUTION and WARNING notes must be
strickly observed to prevent personal injury or equipment
damage.
A1 Scope
Do not install, operate, or maintain a control valve without
being fully trained and qualied with the Kimray installa-
tion operation and maintenance manual.
To avoid personal injury or property damage, it is
important to carefully read, understand, and follow all the
contents of this manual, including all safety CAUTION’s
and WARNING’s.
If you have any questions about this manual, contact
your Kimray applications support group before proceed-
ing.
A2 Introduction
This repair manual contains information for the PO, PC,
PC, High Pressure Control Valve.
A3 Description
The Kimray High Pressure Control Valve (HPCV) is
designed for use in liquid and gas control applications
which require modulating (throttling) or on/off service.
The HPCV has a single port Body and a pneumatic spring
actuator. This actuator is available in either pressure
open PO (normally closed), or pressure closing actuators.
Because of the high pressure range, a Packing Box
houses a non adjustable spring loaded teon sleeve
around the Stem with a Felt Wiper and Buna Back Ups for
leak free sealing.
CAUTION:
When ordered, the HPCV 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 pressure regulator to any other conditions without
rst contacting the Kimray Inc, sales ofce or a sales /
applications representative.
Kimray reserves the right to modify or improve the designs or specications of such products at any time without notice.

HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
SPECIAL TOOLS AND EQUIPMENT
A6
Tip:
Kimray recommends using the above
special tools and equipment for
disassembly, assembly and new part
replacements.
Kimray Seat & Cage Removal Tool
Part No. Line Size
3032 1 in.
3033 2 in.
Kimray Seat Removal Tool
Part No. Line Size
615 1 in.
614 2 in.

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
6
Model: PO, PC
See catalog section E1 for additional information
✴Recommended spare parts and stocked as repair kits
A7
ORIENTATION
Stem Guided Shown
16
15
14
13
11
12
10
19
20
18
9
8
7
6
5
2
1
17
4
3
16
15
14
13
11
12
10
19
20
18
9
8
7
6
5
2
1
17
4
3
Item Part No. / Description Qty
1 Adjusting Screw 1
2 Pivot 1
3 Breather Plug 1
4 Bonnet 1
5 Spring Plate 2
6 Spring 1
7 Diaphragm Plate 1
8 Diaphragm 1
9 Diaphragm Nut 1
10 Upper Stem 1
Item Part No. / Description Qty
11 Yoke 1
12 Lower Adjusting Screw 1
13 Packing Box 1
14 Lower Stem 1
15 Seat 1
16 Body 1
17 Screw 16
18 Screw 4
19 Travel Indicator Assembly 1
20 Nut 16
✴
✴

HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
1 Installation
Before installing the control valve, inspect it for shipment
damage and for foreign material that may have collected during
shipment. Inspect the openings in the valve and clean the pipe
lines to remove scale, chips and debris.
1. Install the valve with the arrow on the body pointing in the
direction of ow. The arrow indicates that the direction of ow
and will not necessarily prevent ow in the opposite direction.
The ow direction of the HPCV PB is up through
the valve. The stem guided trim is down through
the valve. If conditions indicate the possibility of
back word ow, you may wish to install check valves.
2. Install the valve using good piping practice. For anged
bodies use a suitable gasket between the body and the pipeline
anges. For threaded (NPT) bodies, use TFE Tape or pipe
thread sealant on external pipe threads.
3. Connect instrument gas to the actuator connection. The
maximum required instrument gas pressure is 30 psig (2 bar);
45 psig (3 bar) is permissible.
NOTE:
Always check fastener tightness prior to valve installation,
testing, and use, as fasteners have the potential to loosen
in transit. This is recommended to ensure your safety and
proper valve function.
*Kimray assembly torque method below*
Four Bolt
Four Bolt
1
1
2
2
3
3
4
4
Six Bolt
Six Bolt
1
1
2
2
3
3
4
4
5
5
6
6
Eight Bolt
Eight Bolt
1
1
2
2
3
3
4
4
5
5
8
8
6
6
7
7
Sixteen Bolt
Sixteen Bolt
1
1
2
2
9
9
14
14
5
5
16
16
8
8
11
11
4
4
13
13
10
10
6
6
15
15
7
7
12
12
3
3
CAUTION:
When ordered, the high pressure valve 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 valve to any other conditions without rst
contacting the Kimray Inc, sales ofce or a sales/applications
representative.
2 Start-up and Test
With the installation completed and appropriate relief and
check valves installed and set, slowly open the upstream and
downstream shutoff valves. In order to test the function of
the valve, allow only a small amount of upstream uid to ow
through the upstream shutoff valve. Check for proper valve
operation by cycling the actuator arm several times.
WARNING:
DO NOT exceed the maximum supply pressure specied on the
HPCV nameplate. Under no circumstances should the HPCV
supply pressure ever exceed the maximum psig.
Pressure Opening Valve
Remove the plastic stopper from the tapped hole in the
underside of the bonnet. Install a 1/4” or 3/8” tube tting (not
provided). The tubing must be installed from your source of
instrument gas. The tting at the top of the bonnet is a Breather
Plug.
Pressure Closing Valve
Remove the plastic stopper from the tapped hole in the top side
of the bonnet. Install a 1/4” or 3/8” tube tting (not provided).
The tubing must be installed from your source of instrument gas.
The tting in the lower half of the bonnet is a Breather Plug.
NOTE:
Never stand directly over or in front of a valve when the system
is pressurized. The valve could suddenly open, blowing debris
into the person’s face and eyes.
WARNING:
Before any service, be certain that the valve is fully isolated and
that all pressure upstream and downstream has been relieved.
Use bypass valves or fully shut off the process.
Be sure that any operating or instrument gas lines has been
disconnected. Never assume that a check valve is fully blocking
the downstream line. Never tighten any tting or the main
connections to the regulator while there is pressure on the line.
A leaking valve indicates that service is required. Failure to take
the valve out of service immediately may create a hazardous
condition.
Verify all pressure connections are tight before pressurizing the
system.
NOTE:
When a gasket seat is disturbed during disassembly a new
gasket should be installed during re-assembly to ensure proper
sealing.
Repair kits are available. contacting the Kimray Inc, sales ofce
or a sales/applications representative for the correct repair kit
number.

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
8
Model: PO, PC
DISASSEMBLY
Use a wrench to remove the Adjusting Screw on top of
the Bonnet. See Fig. 3-1
Remove Pivot from Adjusting Screw. See Fig. 3-2
NOTE:
Sometimes the Pivot will separate from the Adjusting
Screw and sit on top of the Spring Plate.
Remove the Breather Plug from Bonnet. See Fig. 3-3
Loosen the Bolts to remove the Bonnet. See Fig. 3-4
3 Adjusting Screw, Pivot, Breather Plug, Bonnet
Pivot
Adjusting
Screw
Breather
Plug
Fig. 3-1
Fig. 3-2
Fig. 3-3
Fig. 3-4

HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
DISASSEMBLY
5 Pivot, Spring Plate, Spring
NOTE:
Again sometimes the Pivot will separate from the
Adjusting Screw and sit on top of the Spring Plate.
Remove Pivot from top of Spring Plate.
Remove Spring Plate.
Remove the spring from the Pivot sleeve. See Fig. 5-1
4 Travel Indicator
Spring
Plate
Spring
Spring
Plate
Pivot
Fig. 5-1
Remove the Bolts from the Travel Indicator Block.
Remove the Block from the Stem.
See Fig. 4-1
Fig. 4-1

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
DISASSEMBLY
6 Pivot Sleeve, Diaphragm Plate, Diaphragm Nut
Use a small adjustable wrench to hold the Upper Stem
in place by the ats and spin the Diaphragm Plate in a
counter clock wise direction loosening it from the Upper
Stem. See Fig. 6-1
NOTE:
Peel the Diaphragm edge away from the Yoke,
rotate the Diaphragm Assembly off the Upper Stem inside
the Yoke See Fig. 6-1
Flip the Diaphragm Assembly over and remove the
Diaphragm Nut by using a hammer and punch.
See Fig. 6-2
Diaphragm
Assembly
Flats on
Upper Stem
Diaphragm
Nut
Fig. 6-2
Fig. 6-1
Diaphragm
Diaphragm Plate
Yoke

HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
DISASSEMBLY
✴ Recommended spare parts and stocked as repair kits
7 Yoke Assembly
Use a wrench to remove the Bolts from the Yoke base.
Slide Yoke up from the Upper Housing. See Fig. 7-1
Flip the Yoke upside down, then use a socket wrench to
remove the Lower Adjusting Screw. See Fig. 7-2
Slide out the Upper Stem from the Lower Adjusting Screw.
See Fig. 7-3
Remove O-Ring from the inside of the Lower Adjusting
Screw.
Use a pair of Snap Ring pliers to remove the Snap Ring.
See Fig. 7-3
Remove the Retainer Washer.
Remove the Wiper from the Lower Adjusting Screw.
See Fig. 7-3
Wrap the
Threads and
Pull Stem out
Lower
Adjusting
Screw
Fig. 7-3
Fig. 7-1
Fig. 7-2
Retainer
Washer
Wipers
Snap
Ring
Outside
O-Ring
Inside
O-Ring
Lower
Adjusting
Screw
✴
✴
✴
✴

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
DISASSEMBLY
8 Packing Box
Wrench up on the ats machined into the Packing Box
Body and remove by turning counter-clockwise.
Remove Packing Box from the Upper Housing.
See Fig. 8-1
CAUTION:
When removing Packing Box from Body, if pressure starts
to exit out of the safety relief hole than stop and check on
isolation.
NOTE:
Occasionally the Cage unscrews from
the Packing Box leaving the Cage, Seat
and Lower Stem in the Body or the Seat
will unscrew from Cage and remain in the
Body.
See Fig. 8-2 & Fig. 8-3
Seat
Fig. 8-3
Cage, Seat
and Lower
Stem
Fig. 8-2
Safety
Relief
Hole
Fig. 8-1
Use an adjustable
wrench on ats to
loosen. DO NOT
USE pipe wrench
on Body
Alternate Seat Removal

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Installation, Operation & Maintenance Guide
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Model: PO, PC
DISASSEMBLY
Fig. 9-1
9 Removing Packing Box
Flip the Packing Box up side down and clamp the two at
sides of the Packing Box in vise and loosen Seat with an
adjustable wrench.
Leave the Seat attached to Cage. Insert a screw driver or
small bar through the Cage and unscrew. See Fig. 9-1
NOTE:
Leaving the Seat attached will prevent the Cage from
damaging the Cage wall or egg shaping.
Pull Stem and Cage out of Packing Box.
If Stem and Cage doesn’t come out then ip the Packing
Box over and tap the Stem with a hammer and a small
punch. Remove Cage from the Ball Stem and Spring
from the Packing Box.

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
DISASSEMBLY
Item Part No. / Description Qty
1 Snap Ring 1
2 Retainer 1
3 Wiper 1
4 Packing Box 1
5 O-Ring 1
6 Packing Rings and Sleeve 1
10 Packing Box Assembly
Remove Snap Ring (Item 1).
Remove Retainer (Item 2).
Remove Wiper (Item 3).
Remove O-Ring.
Remove Packing Box and
Packing Ring (Item 6).
Remove Packing Follower (Item 7).
Remove Spring (Item 8).
Remove Cage (item 9).
NOTE:
Using a punch, tap the Packing Rings
and Sleeve through the bottom of the
Packing Box.
Check all parts for damages.
NOTE:
Apply all purpose grease the inside of the
Packing Box before inserting parts.
Insert new Felt Wiper (Item 3).
Insert new Felt Retainer (Item 2).
Insert new Snap Ring (Item 1).
Use all purpose grease on the outside of the
Packing Rings before inserting into the Packing
Box (Item 6).
Use a socket to push the Packing down.
Insert Packing Follower (Item 7).
Re-use Spring (Item 8).
Use a brush or a grease gun to ll the Packing
Box with all purpose grease.
Disassembly Assembly
Item Part No. / Description Qty
7 Follower 1
8 Spring 1
9 Cage 1
✴ Recommended spare parts and stocked as repair kits
9
7
8
6
5
4
3
2
1
✴
✴
✴
✴
Tip:
Use Kimray replacement parts only.
Fig. 10-1
✴
✴
✴
✴

HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
15
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Model: PO, PC
INSPECTION
Seat
Check for scoring or scratches on the inside diameter.
If the seal shows any indication of leakage.
See Fig. 11-2
Packing Box & Body
Replace the O-Ring.
Inspect the O.D. threads for nicks, burrs and ats.
Inspect the I.D. threads for nicks, burrs and ats.
A thread repair tool may be used for light
damage, but Packing Box will need to be
replaced for moderate to heavy damage.
See Fig. 11-3 & Fig. 11-4
Ball and Stem
Inspect the ball for pits and or grooves, and inspect
the Stem for extensive scoring or scratches. Check
for any bends on the Stem.
See Fig. 11-1
Inspect Seating area in Body
for any washouts or nicks
11 Inspection & Cleaning
Replace If the Packing Box shows excessive
corrosion and wear.
Remove O-Ring from Packing Box.
Remove Follower from the Packing Box.
Check Point
Verify the Packing-Assembly and Follower are
properly Seated in the Packing Box. Failure to
do so could lead to Packing-Sleeve damage
upon Stem installation. A socket is a handy and
safe tool to perform this action.
Fig. 11-1
Fig. 11-2
Fig. 11-3
Fig. 11-4

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
16
Model: PO, PC
ASSEMBLY
Apply all purpose grease on the outside of the Packing
Box. DO NOT apply grease on the outer threads.
NOTE:
To prevent galling or seizing use a nickel impregnated
PTFE thread sealant tape or equivalent.
Clean male and female threads throughly. Wrap the tape
around the male thread, making three complete wraps.
Keep the tape under tension as you are wrapping in the
direction of the thread so the tape molds itself into the root
of the thread. Make sure that the tape does not overlap
the end of the tting.
NOTE:
For poor quality or damaged threads that are hard to seal,
such as parallel threads or threads on ttings subject to
vibration, more than three wraps may be necessary.
Insert Packing Box into the Body.
Use an adjustable wrench on ats for tightening Packing
Box. DO NOT use pipe wrench on Body. DO NOT OVER
TIGHTEN.
Re-install the Cage on the Packing-box by applying
downward pressure (slightly compressing the Spring) in
order to start the threads. See Fig. 12-1
12 Cage, Packing
Fig. 12-1
Fig. 12-2 Fig. 12-3
Fig. 12-4
NOTE:
Hand tighten the Cage at this point in assembly. The
Cage will be fully tightened at Seat installation.
See Fig. 12-2
Insert the Stem in Cage and thread the Seat in Cage.
See Fig. 12-2 & Fig.12-3
Place the at edges of Packing Box in vise and tighten.
Tap the Stem until the ball seats.
Use a brush to grease O-Rings.
Flip the Body upside down and tighten the Body on
Packing Box Assembly.
See Fig. 12-4

HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
"V" Packing Box Assembly Option
1. Insert stem through lower end of cage, then through
spring, and then through follower.
2. Slide male packing expander (D) over stem with at
end toward follower.
3. Apply grease to upper end of stem.
4. Carefully install one black "V" ring (C) over end of stem
with open part of "V" going onto stem rst. The ring will
easily t over grooved portion of stem. To t ring onto
main portion of stem, lean it to one side and turn ring
while pressing it onto stem. See Fig.12-5
5. Install the second black "V" (C) ring followed by the
white "V" ring (D) in the same way you installed the rst
black ring.
6. Slide female packing expander (A) over stem with open
"V" groove going onto stem rst.
7. Apply grease to outside of packing rings, and push
assembly into stufng box.
8. Screw cage into stufng box.
9. Screw seat into cage.
See Fig. 12-6
The stufng box assembly can now be installed into the
valve.
NOTE:
Never remove stem from packing without rst removing
the cage from the stufng box. There must be no
compression force on the packing from the spring while
the stem is being removed or installed.
ASSEMBLY
Fig. 12-6
Fig. 12-5

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
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Model: PO, PC
ASSEMBLY
13 Diaphragm Assembly
Use a pair of brass jaws to hold the Diaphragm Plate in a
vice.
Place Diaphragm on Diaphragm Plate. See Fig. 13-1
Thread Diaphragm Nut on Diaphragm Plate.
NOTE:
Make sure the Diaphragm does not wrinkle.
Insert Diaphragm Assembly in the center of the Yoke. See
Fig. 13-2.
Place the Yoke on top of Body.
Insert Bolts and tighten with a wrench.
Use an adjustable wrench to hold the Upper Stem while
tightening the Diaphragm Plate. See Fig. 13-3
Use an
adjustable
wrench
here
Use all
purpose
grease on the
Diaphragm
Plate here
Diaphragm
Nut
Diaphragm
Use all purpose
grease in the hole of
the Diaphragm Plate
here
Fig. 13-1
Fig. 13-2
Fig. 13-3
Diaphragm
Assembly
Yoke

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Installation, Operation & Maintenance Guide
19
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Model: PO, PC
ASSEMBLY
14 Internal Yoke Assembly
Use a brush to grease the Upper Pivot point.
See Fig. 14-1
Slide the Spring Plate on the Pivot Sleeve.
See Fig. 14-2
Insert the Spring on the Sleeve.
Insert the second Spring Plate on top of the Stem.
Place Bonnet on top of internal assembly and insert
screws. See Fig. 14-3
NOTE:
Make sure you tighten the Bolts in a criss-cross pattern to
avoid any miss alignment. DO NOT OVER TIGHTEN. For
1in. and 2in. tighten Bolts from 25-30 ft/lbs torque.
See Fig. 14-3
Spring
Plate
Spring
Spring
Plate
Apply all purpose
grease to the base of
the Pivot Sleeve
Fig. 14-1
Fig. 14-2
Fig. 14-3
Pivot Sleeve

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HIGH PRESSURE CONTROL VALVE
Installation, Operation & Maintenance Guide
20
Model: PO, PC
ASSEMBLY
Fig. 15-1
NOTE:
For pressure closed, ip Diaphragm Assembly upside
down and place onto Yoke. See Fig. 15-1
Insert Bolts in Bonnet and tighten.
Insert Bolts in Bonnet and tighten. See Fig. 15-2
Insert O-Ring (not shown) on the Upper Adjusting Screw
and tighten it on top of Bonnet. See Fig. 15-3
Insert Breather Plug. See Fig. 15-4
NOTE:
Make sure you tighten the Bolts in a criss-cross pattern to
avoid any miss alignment. DO NOT OVER TIGHTEN. For
1in. and 2in. tighten Bolts from 25-30 ft/lbs torque. See
Fig. 15-2
Adjusting
Screw
Breather
Plug
15 Pressure Closed
Fig. 15-2
Fig. 15-3
Fig. 15-4
Diaphragm Assembly