Kimray 212 SMT PBT Operating instructions

PISTON BALANCED
THROTTLING
Repair Manual

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PISTON BALANCED THROTTLING REPAIR MANUAL
INDEX
Introduction .................................................................................................... 1
Elastomer Materials ....................................................................................... 2
Repair Kit Contents ........................................................................................ 3
Disassembly: Topworks Pressure Opens ..................................................... 5
Disassembly: Topworks Pressure Close ....................................................... 7
Disassembly: Piston & Body ......................................................................... 9
Cleaning & Inspection ................................................................................. 11
Assembly: Piston & Body ............................................................................ 13
Assembly: Topworks Pressure Opens ........................................................ 15
Assembly: Topworks Pressure Close ......................................................... 17
Testing ......................................................................................................... 19
NOTE: We reserve the right to modify or change, without prior
notice, any statement or information contained 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, Inc.

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PISTON BALANCED THROTTLING REPAIR MANUAL
INTRODUCTION
SCOPE
This repair manual contains information concerning the Piston Balanced Throttling Pressure Open/
Pressure Close low pressure motor valve. Included are detailed instructions regarding disassembly, repair,
assembly and testing.
DESCRIPTION
The PBT-PO/PC is a diaphragm operated motor valve designed to control or pressure in liquid or gas sys-
tems up to 400 psig with 15 to 30 psig pneumatic actuating signal. The piston balanced throttling motor valve
be used as oil or water dump valve, and for throttling service in back pressure or pressure reducing applica-
tions when installed with pressure pilots.
MAINTENANCE
Maintenance should be performed on a regular basis. Initial interval of 12 months is recommended. The
maintenance interval may increase or decrease depending on changing application environments.
WARNING
Before performing any service to regulator verify all system pressures are bled-off or pilot is properly iso-
lated and de-pressurized.
GENERAL SPECIFICATIONS
Working Pressures 125-300 Hydrostatic Test: ANSI B16.37
Body materials Grey Iron ASTM A48-94a Class 20
Ductile Iron ASTM A395 Class 65-45-12
Steel ASTM A216 WCB
Bonnet Materials Grey Iron ASTM A48-94a Class 20
Ductile Iron ASTM A395 Class 65-45-12
Steel ASTM A216 WCB
Body Types Thru
Connection Types Screw, Flange
Elastomers Buna-N (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!!!
ENG-002.13 Issued 6/20

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PISTON BALANCED THROTTLING REPAIR MANUAL
ELASTOMER MATERIALS
TEMPERATURE:
-10° to +350° F
-23° to +177° C
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, Sour Gas (C02), Propane, Gasoline,
Diesel, Fuel Oil Systems
DO NOT USE WITH:
Hot Water, Not preferred for wet H2S, Methyl Alcohol,
Amines, Sodium hydroxide solutions
TEMPERATURE:
-65° to +300° F
-54° to +148° C
APPLICATION:
Steam Flood
FLUID / GAS:
Steam, Water, Alcohol
DO NOT USE WITH:
Crude Oil & Gas, Diester Lubricants (Lube Oils)
TEMPERATURE:
-40° to +220° F
-40° to +104° C
APPLICATION:
High abrasion resistance Seats, Diaphragms
FLUID / GAS:
Crude Oil gas and Water, Sour Gas (C02), propane,
butane, fuel, mineral oil and grease
TEMPERATURE:
±0° to +300° F
-17° to +149° C
APPLICATION:
Production Heaters, Thermostats
FLUID / GAS:
Crude Oil & Gas at High Temperature
DO NOT USE WITH:
Alcohol, Glycols
TEMPERATURE:
+30° to +500° F
0° to +260° C
APPLICATION:
Crude Oil & Gas Production (High heat), Steam
Flood Production Chemicals (corrosion inhibitors) Amine
Sweetener Systems, Gasoline, Diesel, Fuel Oil Systems
FLUID / GAS:
Crude Oil & Gas Production, H2S, Steam, Petroleum
fluids, Sea Water
TEMPERATURE:
-15° to +300° F
-26° to +149° C
APPLICATION:
Crude Oil & Gas Production w/ H2S C02
FLUID / GAS:
Crude Oil & Gas H2S, C02, Sea Water
TEMPERATURE:
Buna-N:
-40° to +220° F
-40° to +105° C
Low-Temp:
-85° to +120° F
-65° to +49° C
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, Glycols, Hydraulic Oils, Resistance to crude
oil in the presence of hydrogen sulfide and amines, Diesel
fuel, fuel oils
DO NOT USE WITH:
Aromatic hydrocarbons, chlorinated hydrocarbons,
phosphate esters (hydraulic fluids)
TEMPERATURE:
-350° to +500° F
APPLICATION:
High heat, high chemical resistance, highly resistance
to gas permeation
AFLAS ® is a trade mark of Asahi Glass Co VITON ®is a trade mark of Dupont
ETHYLENE PROPYLENE
POLYURETHANE
GYLON
POLYACRYLATE
HSN (Highly Saturated Nitrile)
NITRILE

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PISTON BALANCED THROTTLING REPAIR MANUAL
REPAIR KIT CONTENTS
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 at right*
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

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PISTON BALANCED THROTTLING REPAIR MANUAL
NOTES

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PISTON BALANCED THROTTLING REPAIR MANUAL
DISASSEMBLY PRESSURE OPEN
STEP 1
Bonnet
Wrench loose the breather plug and set
aside (Fig. 1.0).
Using a back-up, wrench loose and
remove the nuts/bolts attaching the bon-
net to the yoke (Fig. 1.1).
Remove the bonnet and set a side
(Fig. 1.2).
Remove the spring and set aside
(Fig. 1.3).
STEP 2
Lower Housing
Wrench loose the bolts attaching the yoke
to the body (Fig. 2.0).
Remove the entire assembly from the
valve body (Fig. 2.1).
Using a back-up on the ratio plug nut,
wrench loose the nut holding the dia-
phragm plate in place (Fig. 2.2).
Remove the diaphragm plate (Fig. 2.3).
Remove the diaphragm and discard
(Fig. 2.4).
Remove the lower diaphragm plate
(Fig. 2.5).
Figure 1.0 Figure 1.1
Figure 1.2 Figure 1.3
Figure 2.0 Figure 2.1
Figure 2.2 Figure 2.3
Figure 2.4 Figure 2.5

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PISTON BALANCED THROTTLING REPAIR MANUAL
DISASSEMBLY PRESSURE OPEN
Remove the lower housing from the piston
assembly (Fig. 2.6).
Remove the gasket from the bottom of the
lower housing and discard (Fig. 2.7).
Figure 2.6 Figure 2.7

STEP 1
Bonnet
Remove the travel indicator, replace if
acrylic housing is opaque or cracked
(Fig. 1.0).
Inspect indicator stem and replace as
needed (Fig. 1.1).
Remove housing gasket and discard
(Fig. 1.2).
Remove the spring and set aside
(Fig. 1.3).
Wrench loose breather plug and set aside
(Fig. 1.4).
Wrench loose the nuts and bolts attach-
ing the bonnet to the lower housing and
remove (Fig. 1.5).
Remove the bonnet and set aside for
cleaning and inspection (Fig. 1.6).
Remove the diaphragm (Fig. 1.7).
Remove the diaphragm plate (Fig. 1.8).
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PISTON BALANCED THROTTLING REPAIR MANUAL
DISASSEMBLY PRESSURE CLOSE
Figure 1.0 Figure 1.1
Figure 1.2 Figure 1.3
Figure 1.4
Figure 1.5 Figure 1.6
Figure 1.7 Figure 1.8

Remove the diaphragm plate and set
aside for inspection and cleaning
(Fig. 1.9).
Remove the spring and set aside for
inspection and cleaning (Fig. 1.10).
STEP 2
LOWER HOUSING
Wrench loose the bolts that attach the
lower housing to the body (Fig. 2.0).
Remove bolts and set aside for inspection
and cleaning (Fig. 2.1).
Remove lower housing from the body
(Fig. 2.2)
Remove housing gasket and discard
(Fig. 2.3).
Remove piston assembly from the body
(Fig. 2.4)
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PISTON BALANCED THROTTLING REPAIR MANUAL
DISASSEMBLY PRESSURE OPEN
Figure 1.9 Figure 1.10
Figure 2.0 Figure 2.1
Figure 2.2 Figure 2.3
Figure 2.4

STEP 3
Piston Assembly
Removed the lower lockingnut using the
wrench flat on the stem as a back-up
(Fig. 3.0).
Remove the ratio plug (Fig. 3.1).
Remove the polyurethane seat and dis-
card (Fig. 3.2).
Remove the piston from the cylinder and
stem (Fig. 3.3).
Remove the seal retainer (Fig. 3.4).
Remove the first back-up and discard
(Fig. 3.5).
Remove the quad ring and discard
(Fig. 3.6).
Remove the second back-up and discard
(Fig. 3.7).
Remove the stem from the cylinder
(Fig. 3.8).
Remove the o-ring from the cylinder and
discard (Fig. 3.9).
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PISTON BALANCED THROTTLING REPAIR MANUAL
PISTON & BODY
Figure 3.0 Figure 3.1
Figure 3.2 Figure 3.3
Figure 3.4 Figure 3.5
Figure 3.6 Figure 3.7
Figure 3.8 Figure 3.9

Using a pick-like tool remove the inner
quad ring and discard (Fig. 3.10).
Remove the two spiral back-ups and dis-
card (Fig. 3.11).
STEP 4
Body
It is recomended to use the proper Kimray
seat removal tool at this point
(Fig. 4.0 & 4.1).
See inspection and cleaning section for
alternative to seat removal.
Remove the seat and set aside for clean-
ing and inspection (Fig. 4.2).
Remove the gasket from the seat and dis-
card (Fig. 4.3).
Removable Seat Tools
272SW 2"
273SW 3"
274SW 4"
275SW 6"
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PISTON BALANCED THROTTLING REPAIR MANUAL
PISTON & BODY
Figure 3.10 Figure 3.11
Figure 4.0 Figure 4.1
Figure 4.2 Figure 4.3

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PISTON BALANCED THROTTLING REPAIR MANUAL
CLEANING & INSPECTION
STEP 1
Cleaning
Diameter Wire Size Length Stem Dia.
1/4" .004" 3-1/2" 1/8"
3/4" .006" 3-1/2" 1/4"
1-1/4" .008" 3-1/2" 1/4"
It is important to inspect all thread surfaces
for pits, debris and at spots.
The listed wire brushes will allow you to
thoroughly clean virtually all threaded sur-
faces on Kimray products.
Often times the seat can-
not be removed and/or
replaced due to the length
of time in service. A seat
cleaning tool can be made
from a 3” ratio plug
(Fig. 1.1), a 2” ratio plug
(Fig. 1.2), and glue-on
sandpaper (Fig. 1.3). At-
tach the seat cleaning tool
to a speed wrench, make
at contact and spin the
speed wrench to dress the
seat, inspect the seat for
scratches and repeat the
process as needed.
In the process of cleaning the valve there are a few essential areas that must be addressed:
1. All thread surfaces
2. Ensure all gasket material is removed.
3. Exterior free of solvents, debris and fluids if the product is to be re-painted.
4. Interior free of solvents, debris and fluids that may damage elastomers and affect O-ring / gasket seals.
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Figure 1.1
Figure 1.2
Figure 1.3

STEP 2
Inspection
Inspect all internal and seating surfaces
for damage. Replace or repair as needed:
A. Seat surface
B. Cylinder
C. Piston
D. Ratio Plug
E. Stem - Emery cloth can be used
to repair light scratches.
F. Removable Seat
G. Housing gasket surface
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PISTON BALANCED THROTTLING REPAIR MANUAL
CLEANING & INSPECTION
Figure A Figure B
Figure C Figure D
Figure E Figure F
Figure G

STEP 1
Piston Assembly
Install the new o-ring onto the cylinder
(Fig. 1.0).
Install new quad ring into the machined
cylinder groove (Fig. 1.1).
Install the two new back-ups on either
side of the quad ring (Fig. 1.2 & 1.3).
Install the stem into the cylinder (Fig. 1.4).
Install the seal retainer onto the flat of the
stem (Fig. 1.5).
Install the new back-up onto the piston
(Fig. 1.6).
Follow with the new o-ring (Fig. 1.7).
Install the second back-up over the o-ring
(Fig. 1.8).
Install the seal retainer on the stem flat
(Fig. 1.9).
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PISTON BALANCED THROTTLING REPAIR MANUAL
ASSEMBLY PISTON & BODY
Figure 1.0 Figure 1.1
Figure 1.2 Figure 1.3
Figure 1.4 Figure 1.5
Figure 1.6 Figure 1.7
Figure 1.8 Figure 1.9

Install the partially assembled piston onto
the stem until at rest on the seal retainer
(Fig. 1.10).
Install the seat onto the piston assembly
(Fig. 1.11).
Install ration plug over the seat (Fig. 1.12).
Install the lock nut onto the stem
(Fig. 1.13).
Place a back-up on the stem wrench-flat
and tighten the lock nut (Fig. 1.14).
STEP 2
BODY
Install the new gasket onto the seat
(Fig. 2.0).
Thread the seat into the valve body and
tighten using a seat wrench (Fig. 2.1).
Install the piston assembly into the body
(Fig. 2.2).
Install new gasket onto piston assembly
(Fig. 2.3).
Note: It is reccomended to apply a
small amount grease to both sides of
the gasket.
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PISTON BALANCED THROTTLING REPAIR MANUAL
ASSEMBLY PISTON & BODY
Figure 1.10 Figure 1.11
Figure 1.12 Figure 1.13
Figure 1.14
Figure 2.0 Figure 2.1
Figure 2.2 Figure 2.3

STEP 1
LOWER HOUSING
Install the lower housing onto the body
(Fig. 1.0)
Reinstall the screws attaching the lower
housing to the body and wrench tight
(Fig. 1.1).
Install the lower diaphragm plate onto
stem (Fig. 1.2).
Install the diaphragm onto the lower plate
(Fig. 1.3).
Install the upper diaphragm plate onto the
diaphragm (Fig. 1.4).
Install spring onto the spring plate
(Fig. 1.5).
STEP 2
BONNET
Place the bonnet onto the lower housing
(Fig. 2.0).
Install the nuts and bolts attaching the
bonnet to the lower body (Fig. 2.1, 2.2).
Wrench the nuts and bolts tight (Fig. 2.3).
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PISTON BALANCED THROTTLING REPAIR MANUAL
ASSEMBLY PRESSURE OPEN
Figure 1.0 Figure 1.1
Figure 1.2 Figure 1.3
Figure 1.4 Figure 1.5
Figure 2.0 Figure 2.1
Figure 2.2 Figure 2.3

Install breather plug into bonnet and
wrench tight (Fig. 2.4).
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PISTON BALANCED THROTTLING REPAIR MANUAL
ASSEMBLY PRESSURE OPEN
Figure 2.4

STEP 1
LOWER HOUSING
Install the piston assembly into the body
(Fig. 1.0).
Reinstall the bolts that attache the lower
housing to the body and wrench tight
(Fig. 1.1).
Spring Compression Tool
2 inch MAPO #5534
3 inch MAPO #5535
4 inch MAPO #5535
STEP 2
BONNET
Install spring over the stem (Fig. 2.0).
Use the appropriate size spring tool to
compress the spring (Fig. 2.1).
Install the diaphragm plate and start it on
the threads (Fig. 2.2).
Apply a small amount thread lock into the
plate tap (Fig. 2.3).
Remove the spring compression tool
(Fig. 2.4).
Wrench tight the diaphragm plate
(Fig. 2.5).
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PISTON BALANCED THROTTLING REPAIR MANUAL
ASSEMBLY PRESSURE CLOSE
Figure 1.0 Figure 1.1
Figure 2.0 Figure 2.1
Figure 2.2 Figure 2.3
Figure 2.4 Figure 2.5

Install the diaphragm onto the plate with
the Kimray® facing up (Fig. 2.6).
Install the bonnet and the accompanying
nuts and bolts (Fig. 2.7).
Wrench tight the nuts and bolts (Fig. 2.8).
Install the breather plug (Fig. 2.9).
Install the new gasket onto the indicator
housing (Fig. 2.10).
Install the spring onto the indicator stem
(Fig. 2.11).
Install the indicator stem into the acrylic
housing (Fig. 2.12).
Install the travel indicator assembly into
the bonnet (Fig. 2.13).
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PISTON BALANCED THROTTLING REPAIR MANUAL
ASSEMBLY PRESSURE CLOSE
Figure 2.6 Figure 2.7
Figure 2.8 Figure 2.9
Figure 2.10 Figure 2.11
Figure 2.12 Figure 2.13