eng-002.3 rev.3 high pressure

7/31/2019 Eng-002.3 Rev.3 High Pressure

1/48High Pressure Motor Valves

Repair Manual


2/48www.kimray.com

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 priornotice, any statement or information contained herein. If exactdimensions or specifications are required by the customercertified prints will be furnished for a minimum charge uponrequest to KIMRAY, Inc.

Copyright 2006, KIMRAY, Inc.


3/48www.kimray.com Page 1

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 andtravel indicator. The actuators are reversible between pressure opening and pressure closing configurations.

The standard High Pressure Motor Valve employs a ball and cone seat configuration. The Piston BalancedHigh Pressure Motor Valve shuts off with a resilient seat.

OPERATIONThe Kimray High Pressure Motor Valves require no more than 30 psig to operate. The pneumatic pressure

drives a diaphragm against a 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 recom-

mended. Depending on the service conditions and the condition of the valve, the inspection interval may bedecreased or increased. The valve can be repaired without being removed from the piping.

WARNINGBefore 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 KIMRAYPARTS when doing repairs. Remember, parts made to less than Kimray specifications dont save you

money!!!

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


4/48www.kimray.comPage 2


ELASTOMERS

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) (Gaspermeability 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, Hydrocarbons

TEMPERATURE:

-25 to +500 F

-30 to +260 C

APPLICATION:

Crude Oil & Gas Production (High heat), Steam FloodProduction Chemicals (corrosion inhibitors) AmineSweetener Systems, Gasoline, Diesel, Fuel Oil Systems

FLUID / GAS:

Crude Oil & Gas Production, H2S, Steam, Petroleumfluids, 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, hydraulicpump seals

FLUID / GAS:

Crude Oil & Gas, Good to Poor in Sour Production (SeeHSN), Water, Glycols, Hydraulic Oils, Resistance to crudeoil in the presence of hydrogen sulfide and amines, Dieselfuel, 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 resistanceto 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




MATERIALS

Standard materials in the standard Kimray High Pressure Motor Valve include:

Exterior Parts:Bonnet Ductile Iron ASTM - A395

Body Cast Steel ASTM - A216 WCB

Interior Parts:

Stem 303 Stainless Steel

Cage Free Machining Steel AISI 12L14Stuffing Box Free Machining Steel AISI 12L14Seat Tool Steel AISI D2

Plug Carbide/303 Stainless

Elastomers:

Packing Nitrile/Teflon

O-Rings NitrileDiaphragm Nitrile

Standard materials in the Kimray Piston Balanced High Pressure Motor Valve include

Exterior Parts:

Bonnet: Ductile Iron ASTM - A395Body Cast Steel ASTM - A216 WCB

Interior Parts:

Upper Housing Steel AISI C1018

Stem 316 Stainless SteelCage 316 Stainless SteelStuffing Box Free Machining Steel AISI 12L14Seat Tool Steel AISI D2

Piston Tool Steel AISI D2

Elastomers:

Packing Nitrile/Teflon

O-Rings NitrileDiaphragm Nitrile

To get the long service you have come to expect from Kimray products, always use GENUINE KIMRAYPARTS when doing repairs. Remember, parts made to less than Kimray specifications dont save you

money!!!




NOTES




PRESSURE OPEN TO PRESSURE CLOSE CONVERSION

STEP 1

BLOCK DISSASEMBLY

Start from disassembling the TravelIndicator Block (Fig. 1.1)

STEP 2

BREATHER PLUG

Remove the breather plug from theBonnet (Fig. 2.1)

STEP 3

ADJUSTING SCREWRemove the Adjusting Screw from top of

Bonnet (Fig. 3.1)

STEP 4

PIVOTRemove Pivot from Adjusting Screw

(Fig. 4.1)

STEP 5BONNET

Remove the Bonnet by loosing the bolts

(Fig. 5.1 and 5.2)

Figure 1.1

Figure 2.1

Figure 3.1

Figure 4.1

Figure 5.1 Figure 5.2





STEP 6SPRING

Remove the Spring from the DiaphragmPlate (Fig. 6.1)

STEP 7DIAPHRAGM PLATE

Use an adjustable wrench to hold theUpper Stem (Fig. 7.1) while loosening the

Diaphragm Plate (Fig. 7.2)

Remove the Diaphragm Plate from the

Yoke (Fig. 7.3)

STEP 8

RETRIEVING O-RING

NOTE: THIS STEP SHOULD BE FOL-LOWED IF YOU DO NOT HAVE ANEXTRA 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)

Use a pick remove the O-Ring from the

Adjusting Screw (Fig. 8.3)

After the O-Ring has been removed, tight-en Adjusting Screw back in Yoke and then

attach Yoke back to Body.

Figure 6.1


Figure 7.3


Figure 8.3





STEP 9DIAPHRAGM 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)

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 theDiaphragm Plate (Fig. 9.6)

Insert bolts in Bonnet (Fig. 9.7) and tight-

en them with an impact gun (Fig. 9.8)

Insert O-Ring on the Upper Adjusting

Screw (Fig. 9.9) and tighten it on top ofBonnet (Fig. 9.10)







10/48

STEP 10BREATHER PLUG

Insert Breather plug on Yoke (Fig. 10.1)

STEP 11COUPLING 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 backside (Fig 11.2)

Tighten the bolts in the Coupling Blockwith a socket (Fig. 11.3)

Make sure the Travel Indicator tag showsthe correct operation of the valve.

(Fig. 11.4) In this case we are converting

from Pressure Opening to Pressure Close

Figure 10.1



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HPMV DISASSEMBLY

KIMRAY TOOLS

Seat PullersFigure A shows the Kimrays Seat & Cage

Removal Tool. The handles flange thedisc to the body while pulling the seat or

cage.

Figure B shows a Kimrays Seat Removal

Tools able to remove the seat from bodywhen the cage has been removed.

KIMRAY SEAT & CAGEREMOVAL TOOL

PART # LINE SIZE

3032 1"

3033 2"

KIMRAY SEATREMOVAL TOOL

PART # LINE SIZE

615 1"

614 2"

STEP 1

AJUSTING SCREW

Use a socket to remove the adjustingscrew on top of the Bonnet (Figure 1.1

and 1.2)

STEP 2

BONNET

Remove the bolts in the interface betweenthe Bonnet and the Yoke (Fig. 2.1)

Remove Breather Plug From Bonnet(Fig. 2.2)

Remove Bonnet from Yoke (Fig. 2.3)

Figure A Figure B



Figure 2.3




HPMV DISSASEMBLY

STEP 3SPRING

Remove Pivot from top of the spring plate(Figure 3.1)

Remove Spring Plate from top of the

Spring (Figure 3.2)

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

STEP 4

DIAPHRAGM PLATE

BOLTED DIAPHRAGM NUT:

Spin the Diaphragm plate in a counterclock wise direction loosing it from the

Upper Stem while holding the Upper Stemwith a small crescent wrench (Fig. 4.1).

If the HPMV has screws holding theDiaphragm, use a screw driver to remove

them (Fig. 4.2)

Remove the Diaphragm Nut from the

Diaphragm Plate (Fig. 4.3)

Remove the Diaphragm from theDiaphragm Plate (Fig. 4.4)

THREADED DIAPHRAGM NUT:Use a pair of piers to remove the

Diaphragm Nut (Fig. 4.5)



Figure 3.3







HPMV DISASSEMBLY

STEP 5TRAVEL INDICATOR

Remove the bolts from the travel IndicatorBlock (Fig. 5.1)

Remove the Block from stem (Fig. 5.2)

STEP 6YOKE ASSEMBLY

Use a wrench to remove the bolts fromthe Yoke base (Fig. 6.1)

Slide out the Yoke from the Body

(Fig. 6.2)

Flip the Yoke upside down, then take asocket and remove the Lower Adjusting

Screw with an impact gun(Fig. 6.3 and 6.4)

Slide out the Upper Stem from the Lower


Remove the outside O-Ring from theLower Adjusting Screw (Fig. 6.6)

Remove O-Ring from the inside of theLower Adjusting Screw (Fig. 6.7)

Use a pair of snap ring pliers to removethe Snap Ring (Fig. 6.8)









HPMV DISASSEMBLY

Remove the Retainer washer (Fig. 6.9)

Remove the Wiper from the Lower


STEP 7STUFFING BOX ASSEMBLY

Use an adjustable wrench to remove thestuffing Box from the Body (Fig. 7.1)

Remove the Stuffing Box from the Body

(Fig. 7.2)

Clamp the two flat sides of the StuffingBox 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 preventsthe cage from egg shaping.

Pull Stem and Cage out of Stuffing Box

(Fig. 7.5), if it doesnt come out then flipthe Stuffing Box over and tap the Stem

with a hammer and a small punch (Fig.7.6)

Remove Cage and Stem from the StuffingBox (Fig. 7.7)

Remove the Spring (Fig. 7.8)







15/48

Remove the Cage from the Ball and Stem(Fig. 7.9)

Remove O-Ring from the Seat (Fig 7.10)

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 theStuffing Box (Fig. 7.16)

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

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HPMV DISASSEMBLY





Figure 7.17


16/48

SPECIAL CASES

SEAT PULLERSSome times the Seat does not come out

with Stuffing Box and Cage. We have acouple 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 Pullers3. Tap up pulling the seat out

(Fig. 8.2)

Second Option:

If the Stuffing Box comes out by it selfleaving seat, Ball & Stem and Cage stuckin Body.

1. Thread Seat & Cage Removal Tool

on to Cage (Fig. 8.3)2. Tighten flange down against Body

3. Pull Case and Seat out of Body(Figure 8.4)

The other end of the tool is used in casejust the Seat stays in Body.(Fig. 8.5)

1. Thread Seat & Cage Removal Tool on

seat2. Tighten flange against Body3. Pull the seat out by turning the handle

in a clock wise direction



HPMV DISASSEMBLY

Figure 8.1

Figure 8.2


Figure 8.5




HPMV DISASSEMBLY

If Seat is stuck in Body (Fig. 9.2), use theappropriate cage size and thread on seat.

(Fig. 9.3).

Slide Handle forcefully upwards until youhit the upper stop (Fig. 9.4). The Handle

impact will break loose the seat.

SHOP MADE SEAT REMOVAL TOOL

This seat removal tool can be made with the fol-

lowing parts:

QTY PART DESCRIPTION

1 2889 Cage

1 2837 Cage

2 Stops Disc 1 3/4" x 3/4"

1 Rod 13/8" x 22"

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

Figure 9.2

Figure 9.1


22"

3" 2 1/2"

5 1/2"3/4" 1 3/4"1 3/4"

PART 2889 PART 2837


18/48


19/48

MOST COMMONLY REPLACED PARTS OCCASIONALLY CHANGED PARTS Seat Body

Stem & Ball Spring Diaphragm

O-Rings Packing

BALL & STEM

Check for scratchesReplace:

If there are scratches present(Fig. 1.1)

SEAT

Replace: If the seat has indication of leakage

(Fig 2.1)

BODY

Replace: If grooves are present on the seating

surface (Fig.3.1)



HPMV INSPECTION of PARTS

Figure 1.1

Figure 2.1

Figure 3.1




NOTES




HPMV ASSEMBLY

STEP 1

DIAPHRAGM ASSEMBLY

CASE 1BOLTED DIAPHRAGM NUT:

Tighten Diaphragm Base Plate in Vice(Fig. 1.1)

Insert Diaphragm on the Diaphragm Platealigning holes with both parts (Fig. 1.2)

Insert Diaphragm Plate in to Base Platemaking 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 thenretighten very tight (Fig. 1.4)

CASE 2THREADED 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 pairof pliers to tighten (Fig. 1.7)Note: Make sure the Diaphragm does not

wrinkle.

STEP 2STUFFING BOX ASSEMBLY

Insert Wiper in the Stuffing Box (Fig. 2.1)

Insert the retainer with the sharp edge on

top (Fig. 2.2)




Figure 1.7



22/48

Use a pair of snap ring pliers to insert theSnap Ring (Figure 2.3)

Insert the packing rings on the Packing

Sleeve (Fig. 2.4)

Grease the Packing before inserting it inthe 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)








HPMV ASSEMBLY




HPMV ASSEMBLY

Insert O-Ring on Seat (Fig. 2.13)

Introduce the Stem in Cage (Fig. 2.14)

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 stuffingBox 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

BODYFlip the Body upside down and tighten

Body on Stuffing Box Assembly(Fig. 3.1 and 3.2)







24/48

BODY TESTING:Apply air pressure on the upstream side

of the valve (Fig. 3.3)

Test for leakage in the downstream side

STEP 4LOWER ADJUSTING SCREW

Insert O-Ring in the Lower AdjustingScrew (Fig. 4.1)

Flip the Lower Adjusting Screw over and

insert Wiper (Fig. 4.2)

Insert Retainer on top of Wiper makingsure 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 AdjustingScrew, being careful not to share O-Ring

(Fig. 4.7)

Tighten Lower Adjusting Screw on the bot-

tom part of Yoke (Fig. 4.8)



HPMV ASSEMBLY

Figure 3.3








HPMV ASSEMBLY


Place the Yoke on top of the Body (Fig.5.1)

Insert Bolts and tighten them with a

wrench (Fig. 5.2)

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


stem while tightening the Diaphragm Plate(Fig. 5.4 and 5.5)

Grease the Pivot surface of theDiaphragm 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 Supplyholes are aligned (Fig. 5.10)









HPMV ASSEMBLY

Insert bolts on top of the Bonnet and tight-en them with the impact gun (Fig. 5.11)

Grease the Adjusting Screw (Fig. 5.12)

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 ofBonnet and tighten it with an adjustablewrench (Fig. 5.15 and 5.16)

STEP 6

BLOCK

When you assemble the Block, make surethe bevels are in the same side of theblock 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 showsthe correct operation of the valve either

PO or PC (Fig. 6.4)









HPMV TESTING

EQUIPMENT & REQUIREMENTS

SUPPLY PRESSURE: 100 psi

SUPPLY CONNECTION: Device that will reduce your regulator end to anyair supply connection.

Fig. A shows an example of this device. It is important to have a valve inthis device for testing purposes.

STEP 7HPMV PO TESTING

Apply air supply pressure (do not exceed45 psi) on Yoke (Fig. 7.1) This will open

the valve and will pressurize the bottompart of the Diaphragm.

Spray soaped solution on the LowerAdjusting Screw to check for any leakage

(Fig. 7.2)

Spray soaped solution on the Interfacebetween the Bonnet and the Yoke. Check

for leakage (Fig. 7.3)

Figure A


Figure 7.3




NOTES


29/48

Note: Seat Wrench W Series are mainly used for TreaterValves, but they can be used to assemble the Diaphragm

Nut for 3 and 4 High Pressure Motor Valves.

KIMRAY SEAT WRENCH W SERIESPART NUMBER LINE SIZE

386SW 3" & 4" HPMVPB

UPPER CAGE PULLERSPART NUMBER LINE SIZE

5296 2" HPMVPB5297 3" HPMVPB5298 4" HPMVPB

6 Piston Assembly Puller

Use this tool to lift the Piston Assembly out of the Body bypulling it with a hoist.

Note: This is a shop made tool using a Coupling Block,

Upper Stem and a ring.



PISTON BALANCED DISASSEMBLY

Figure A

Figure B

Figure C


30/48

STEP 1ADJUSTING SCREW

Use a wrench to remove the AdjustingScrew on top of the Bonnet (Fig. 1.1)

STEP 2BONNET

Remove the bolts in the interface betweenthe Bonnet and the Yoke (Fig. 2.1)

Remove Breather Plug from Bonnet

(Fig. 2.2)

Remove Bonnet from Yoke (Fig. 2.3)

STEP 3

SPRING

Remove Pivot and the Spring Plate fromtop of the Spring (Fig. 3.1)

Remove the spring from top Spring Plate

(Fig. 3.2)

STEP 4

DIAPHRAGM PLATESpin the Diaphragm plate in a counter

clock wise direction loosening it from theUpper Stem while holding the Upper Stem

with a small crescent wrench (Fig. 4.1).

Remove the Diaphragm Nut from theDiaphragm Plate (Fig. 4.2)




Figure 1.1


Figure 2.3








STEP 5TRAVEL INDICATOR

Remove the bolts from the TravelIndicator Block (Fig. 5.1)

Remove the Coupling Block (Fig. 5.2)

STEP 6

YOKE ASSEMBLY

Use a wrench to remove the bolts fromYoke (Fig. 6.1)

Slide out the Yoke from Body (Fig. 6.2)

Flip Yoke upside down and remove theUpper Stem from the Lower AdjustingScrew (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 theLower Adjusting Screw (Fig. 6.6)





Use a pair of snap ring pliers to removethe Snap Ring (Fig. 6.7)

Remove the Retainer Washer (Fig. 6.8)

Remove the Wiper from the LowerAdjusting Screw (Fig. 6.9)

STEP 7

STUFFING BOX ASSEMBLY

Use an adjustable wrench to remove theStuffing Box from the Body (Fig. 7.1 and

7.2)

Remove Spring and Follower from StuffingBox (Fig. 7.3)

Remove the Packing Sleeve and thePacking 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 theStuffing Box (Fig. 7.6)


Figure 6.9





33/48

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

STEP 8UPPER HOUSING

Use an impact gun to remove the boltsfrom the Upper Housing (Fig. 8.1)

Break the Upper Housing loose by prying

up with screw drivers (Fig. 8.2)

Remove the Upper Housing from the

Body (Fig. 8.3).

STEP 9

PISTON ASSEMBLY

Some times the Upper Cage will not breakloose easy. If this is the case use anUpper Cage Puller.

Start by removing the O-Ring from theCage (Fig. 9.1)

Slide Upper Cage Pullers in O-Ring

groove on Cage and clamp with a waterhose clamp (Fig. 9.2)

Alternately tighten screw until cage breaks

loose from Body (Fig. 9.3)




Figure 7.7


Figure 8.3


Figure 9.3


34/48

Remove the Piston Assembly from Body(Fig. 9.4)

Slide up Upper Cage from the Piston

Assembly (Fig. 9.5)

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 thatholds 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


35/48

STEP 10SEAT

Remove seat from Body (Fig. 10.1 & 10.2)

Remove O-Ring from Seat (Fig. 10.3)





Figure 10.3




NOTES




PISTON BALANCED INSPECTION of PARTS

PISTON ROD

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

PISTON

Replace: If the parts present corrosion in the

outside surface (Fig. 2.1)

SEAT

Replace: In the presence of dings, nicks or co-

rrosion (Fig. 3.1)

RATIO PLUG

Replace: In the presence of scratches, corro-

sion and wear (Fig. 4.1)

Note: This is one of the most affected

parts due to the severe impact of the par-ticles that flow trough the valve.

CAGE

Replace: If the Cage has lost its shape

(Fig. 5.1)

Note: If the valve was improperly disas-

sembled, there is a high possibility tohave a Cage out-of-round.

Figure 1.1

Figure 2.1

Figure 3.1

Figure 4.1

Figure 5.1


38/48

STUFFING BOX

Replace:

In the presence of excessive corro-sion and wear. (Fig. 6.1, 6.2 and 6.3)

Note: Most of the times this part can berepair by cleaning and wire brushing the

inside and outside threads.



PISTON BALANCED INSPECTION of PARTS

Figure 6.2





PISTON BALANCED ASSEMBLY

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)

STEP 2

PISTON ASSEMBLYInsert 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)

Note: Seat Wrench W Series are mainly used for TreaterValves, but they can be used to assemble the Diaphragm

Nut for 3" and 4" High Pressure Motor Valves.

KIMRAY SEAT WRENCH W SERIES

PART NUMBER LINE SIZE386SW 3" & 4" HPMVPB

Figure A









Use brass jaws to hold the PistonAssembly in vice (Fig. 2.7)

Use a socket to tighten the Ratio Plug

Screw (Fig. 2.8)

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 Cagegrooves (Fig. 2.15 and 2.16)










Insert Piston Assembly Stem in to UpperCage (Fig. 2.17). Press Upper Cage on to

Piston Assembly.

Grease O-Rings in Upper Cage (Fig. 2.18)

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

Insert Piston Assembly in Body (Fig. 2.20)

Use a rubber hammer to press PistonAssembly in Body (Fig. 2.21)

Use a rubber hammer to tap the PistonAssembly 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 facingtapped holes on Body.

Insert bolts and tighten them in a criss-

cross pattern (Fig. 3.2)

STEP 4

STUFFING BOXInsert 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 theSnap Ring on top of the Retainer Washer

(Fig. 4.3)

Insert O-Ring on Stuffing Box (Fig. 4.4)

Grease the Stuffing Box Hole (Fig. 4.5)

Insert Packing Rings and Packing Sleevein 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)













STEP 5LOWER ADJUSTING SCREW

Insert two Wipers in the Lower AdjustingScrew (Fig. 5.1)

Insert Retainer Washer with the sharpedge side facing up (Fig. 5.2)

Use a pair of snap ring pliers to insert theSnap Ring on top of the Retainer Washer

(Fig. 5.3)

Insert O-Ring inside the Lower AdjustingScrew (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 AdjustingScrew (Fig. 5.7)

Note: Make sure you do not shear the O-Ring.

Tighten Lower Adjusting Screw in Yoke(Fig. 5.8)

STEP 6

YOKEInsert Yoke on top of the Upper Housing

(Fig. 6.1)

Insert Bolts and tighten in a criss-crosspattern (Fig. 6.2)











Use a pair of brass jaws to hold theDiaphragm Plate in a vice (Fig. 7.1)

Grease the Diaphragm Plate inside

perimeter (Fig. 7.2)

Place Diaphragm on Diaphragm Plate(Fig. 7.3)

Thread Diaphragm Nut on Diaphragm

Plate (Fig. 7.4)

Use a 386SW Seat Wrench W Series totighten the Diaphragm Nut (Fig. 7.5)Note: Make sure the Diaphragm does not

wrinkle.

Grease the top hole of the DiaphragmPlate (Fig. 7.6)

Insert Diaphragm Plate Assembly on topof Yoke (Fig. 7.7)


Upper Stem while tightening theDiaphragm Plate (Fig. 7.8)

Grease the Sleeve on the Diaphragm

Plate (Fig. 7.9)

Insert the Spring Plate in Diaphragm Plate

(Fig. 7.10)










Insert Spring on Diaphragm Plate(Fig. 7.11)

Insert the second Spring plate on top of

Spring (Fig. 7.12)

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 theBonnet (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)





Figure 7.19





STEP 8COUPLING BLOCK

Make sure the bevels are aligned in theCoupling Block (Fig. 8.1)

Use an impact gun to tighten the screws

in the Coupling Block (Fig. 8.2)

Make sure the Travel Indicator tag showsthe correct operation of the valve

(Fig. 8.3)


Figure 8.3


47/48www.kimray.com

HIGH PRESSURE MOTOR VALVE REPAIR MANUAL

NOTES


48/48

eng-002.3 rev.3 high pressure

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