DIAPHRAGM BALANCED
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 specifications of such products at any time without prior notice. 2015 Kimray Inc.
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 1 Installation 7 2 Start-up and Test 7 DISASSEMBLY 3 Travel Indicator, Stem, Spring, Bonnet 8 4 Diaphragm, Diaphragm Plate, Spring 8 5 Lower Housing 8 6 Stem Assembly 9 7 Cage Assembly 10 INSPECTION 8 Inspection & Cleaning 11 ASSEMBLY 9 Body, Cage Assembly, Housing 12 10 Installing Diaphragm Plate 14 11 Diaphragm, Bonnet, Breather Plug, Travel Indicator 15 12 Serial Tag 15 TESTING 13 Flow Direction, Adjustment Screw, Check for Leakage 16 3
A Before you start CAUTION: The instructions provided herein should be completely reviewed and understood before operating or repairing 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 Low Pressure Balanced Valve without being fully trained and qualified with the Kimray installation 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 cautions and warnings. If you have any questions about this manual, contact your Kimray applications support group before proceeding. A2 Introduction This repair manual contains information for the DB, PO, PC, PB Low Pressure Balanced Valve. A3 Description The low pressure valve is designed for liquid systems up to 500 psig which require on/off service. The actuator is available in either pressure opening, (normally closed) or pressure closing (normally open) configurations. CAUTION: When ordered, the Low Pressure Balanced Valve configuration and construction materials were selected to meet specific pressure, temperature, pressure drop and fluid conditions. Since some Body / trim material combinations are limited in their pressure drop and temperature ranges, do not subject the Low Pressure Balanced Valve to any other conditions without first contacting the Kimray Inc, sales office or a sales / applications representative. WARNING: DO NOT exceed the maximum pressure specified on the nameplate. Under no circumstances should the Low Pressure Balanced Valve 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 E3 for product pages. Abbreviations / Acronyms The abbreviations that follow are used in this manual. Term Definition DB Diaphragm Balanced PO Pressure Open PC Pressure Closed PB Piston Balanced Commonly Replaced Parts Cage Seat Disc Ratio Plug Diaphragm O-Ring Occasional Replacement Parts Body Spring A5 Changes and Updates 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. 4
SPECIAL TOOLS AND EQUIPMENT Kimray Spring Compression Tools, Stem Guides, Stem Guide Tools Seat Wrenches and Spanner Wrenches Stem Guide 2 in. #1852 Stem Guide 3 in. #1853 Stem Guide 4 in. #1854 Stem Guide 6 in. #1855 Stem Guide Tool 2 in. #2463 Stem Guide Tool 3 in. & 4 in. #2464 Spring Compression Tool 2 in. #5534 Spanner Wrench 2 in. #1471SNW Seat Wrench-Hardened Seat 2 #706HTSW Spring Compression Tool 3 in. & 4 in. #5535 Spanner Wrench 3 in. & 4 in #1859SNW Spring Compression Tool 6 in. #6447 Tip: Kimray recommends using the above special tools and equipment for disassembly, Assembly and new part replacements. A6 Kimray reserves the right to modify or improve the special tools and equipment designs or specifications at anytime without notice. 5
ORIENTATION Diaphragm Balanced Pressure Open 1, 2 3 4 6 5 7 8 9 10 See Details on Page 9 11 12 13 14 15 16 See Details on Page 10 17 A7 Recommended spare parts and stocked as repair kits See catalog section E3 for product size and description. Item Description Qty 1 Travel Indicator 1 2 Gasket 1 3 Bonnet 1 4 Screws 8 5 Pull Ring Plug 1 6 Spring 1 Item Description Qty 7 Travel Indicator Stem 1 8 Diaphragm 1 9 Diaphragm Plate 1 10 Spring 1 11 Stem Guide Assembly 1 12 Housing 1 Item Description Qty 13 Nuts 8 14 Breather Plug 1 15 Screws 4 16 Cage Assembly 1 17 Body 1 6 Kimray reserves the right to modify or improve the designs or specifications of such products at anytime without notice.
1 Installation Before installing the Low Pressure Balanced 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. Verify all pressure connections are tight before pressurizing the system. Normally with actuator in vertical orientation. 1. Remove the Pull Ring Plug from the tapped hole and install a 1/4 or 3/8 tubing (fitting not provided). 2. Install the valve with the arrow on the Body pointing in the direction of flow. The arrow signifies that the device will operate properly in the direction of flow indicated and will not necessarily prevent flow in the opposite direction. See Fig. 1-1 If conditions indicate the possibility of backward flow you may wish to install check valves. 2 Start-up and Test 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 fitting 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. 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. See Section E3 of catalog or the packing slip enclosed with each valve for the correct repair kit numbers. 3. Install the valve using good piping practices. For flanged Bodies use a suitable Gasket between the Body and the pipeline flanges. For threaded (NPT) Bodies, use TFE tape or pipe thread sealant on external pipe threads. 4. The flanged valve Bodies are listed ANSI class 150RF. DO NOT install the valve in a system where the working pressure can exceed ANSI class ratings. 5. Connect instrument gas (usually from a Liquid Level Control Pilot) to the actuator connection. The minimum required instrument gas pressure is 10 psig (0.7 bar); up to 100 psig (6.7 bar) is permissible. Pull Ring Never stand directly in front or over a valve when the system is pressurized. The valve could suddenly open, blowing debris into the person s face and eyes. Fig. 1-1 7
DISAssembly 3 Travel Indicator, Indicator Stem, Spring, Bonnet Remove Travel Indicator and Gasket. See orientation on page 6. Wrench loose the Nuts and Bolts attaching the Bonnet to the Lower Housing and remove. Remove Spring and Travel Indicator Stem. 4 Diaphragm, Diaphragm Plate, Spring, Stem Guide Assembly Remove Diaphragm. See orientation on page 6. CAUTION: The Spring behind the Diaphragm Plate is Spring loaded so be careful when disassembling. Remove Diaphragm Plate. Remove Spring. 5 Lower Housing Wrench loose the Nuts and Bolts attaching the Lower Housing to the Body. See orientation on page 6. 8
6 Stem Assembly Disassembly DISAssembly Assembly Remove O-Ring (Item 2) around threads of Stem Guide. Remove Back Up (Item 3). Remove O-Ring (Item 4). Remove second Back Up (Item 3). See Fig. 6-1 Tip: Use Kimray replacement parts only. 1 2 At this point, apply all purpose grease to the threads of the Stem. Apply all purpose grease to O-Ring (Item 2) and place onto outer groove of the Cage Body. Verify that the O-Ring rests uniformly in the groove around the circumference of the Cage. See Fig. 6-1 & 6-2 3 4 Stem Guide Tool Fig. 6-1 Item Description Qty 1 Stem Guide 1 2 O-Ring 1 3 Spiral Back Ups 2 4 O-Ring 1 Fig. 6-2 Recommended spare parts and stocked as repair kits 9
7 Cage Assembly DisAssembly Remove Lock Nut (Item 12). DISAssembly 1 Assembly Insert Ratio Plug (Item 9) onto Stem. Remove Disc (Item 11). 2 Insert Seat (Item 10) onto Stem. Remove Seat (Item 10). 3 Insert Seat Disc (Item 11) onto Stem. Remove Ratio Plug (Item 9). Remove O-Ring (Item 5). Remove Stem Assembly (Item 1). Remove Diaphragm Nut (Item 2). Remove Stem (Item 8). Remove Gasket (Item 7). Remove Diaphragm (Item 3). Remove Plate (Item 4). Remove O-Ring (Item 5). See Fig. 7-1 5 7 4 6 8 At this point, apply all purpose grease to the threads of the Stem. Hand start the Lock Nut onto the Valve Stem making sure the slotted end of the Nut is up. Place Nut into vise and place wrench on flat area of Stem and tighten Assembly. Verify that the Seat is against the wall on the counter-bore of the Seat Disc but is not bulging out over the wall. Apply all purpose grease to the Stem. Be careful not to get any grease on the threads Apply all purpose grease to Gasket (Item 7) and place on bottom of Cage Body. Tip: Use Kimray replacement parts only. Item Description Qty 1 Stem Assembly 1 2 Diaphragm Nut 1 3 Diaphragm 1 4 Plate 1 5 O-Ring 1 6 Cage Body 1 7 Gasket 1 8 Stem 1 9 Ratio Plug 1 10 Seat 1 11 Disc 1 12 Lock Nut 1 9 11 Fig. 7-1 10 12 Slide Cage (Item 6) onto (Items 8, 9, 10, 11, 12) as a sub-assembly. Apply all purpose grease to O-Ring (Item 5) and place onto outer groove of the Cage Body. Verify that the O-Ring rests uniformly in the groove around the circumference of the Cage. Insert the Plate (Item 4) onto the Stem (Item 8) Place Diaphragm (Item 3) over Plate. Place Diaphragm Nut (Item 2) over Diaphragm. See Fig. 9-1 Thread Stem Assembly (Item 1) into Lower Stem (Item 8). See Fig. 7-1 Recommended spare parts and stocked as repair kits 10
8 Inspection & Cleaning INSPECTION It is important to clean the O-Ring groove. Any loose particles left in the groove could cause leakage. Repair: If Stem O-Ring groove surfaces shows light scratches. Cleaning: Use an air nozzle to blow debris from the O-Ring groove. See Fig. 8-1 Nicks or fragments of Gasket material can cause misalignment on the Body surface. This can be repaired by using a flat file. See Fig. 8-2 Fig. 8-1 Repair: If Cage groove surfaces for both O-Ring and Gasket shows light scratches. Cleaning: Use an air nozzle to blow debris from the O-Ring groove. Replace: If there are deep nicks that can not be removed or if the Cage Body shows signs of wear. Use "NO-GO" gauge to test Stem Guide. Repair: Observing Stem fit in Cage hole. Replace: If Cage hole gets worn or can cause misalignment. Check for nicks or wear Fig. 8-2 11
9 Body, Cage Assembly, Housing Assembly Use the right size Spanner Wrench and match the tool with two holes on top of Piston. See Fig. 9-1. Apply Loctite to threads of Valve Stem. Before installing the Cage Assembly into the Body, apply all purpose grease to both the O-Ring and Gasket area. See Fig. 9-2 Install the Cage Assembly into the valve Body and assure the hole in the Cage is aligned with the valve inlet during insertion. See Fig. 9-3 Place Stem Guide over the Stem thread. Tap on top of Cage with a rubber mallet while applying pressure to the opposite side. See Fig. 9-4 DO NOT use ball peen hammer for this operation. Fig. 9-3 Fig. 9-1 Apply grease to the Gasket area. Apply Grease on the O-Ring HERE Diaphragm edge must be near flush with the Body. Stem Guide Top of Cage Gasket Fig. 9-2 Fig. 9-4 12
Assembly Verify Housing is free of metal chips or other debris. Use Stem Guide tool to thread Stem Guide Assembly into Housing. See Fig. 9-5 Seat the Housing to the Valve Body. See Fig. 9-6 Oil to Inside Housing Remove Stem Guide Tighten the Bolts in a criss-cross pattern to avoid any miss alignment. For 2 in., 3 in. and 4 in. tighten Bolts from 25-30 ft/lbs torque. Housing Remove the Stem Guide after the Housing is installed. Pull the Stem all the way up and apply from 5/8 in. to 3/4 in. oil to the Housing. See Fig. 9-7 Install Spring into Housing. See Fig. 9-8 Fig. 9-7 Housing Housing Stem Guide Tool Body Fig. 9-5 Fig. 9-6 Fig. 9-8 13
10 Installing Diaphragm Plate Assembly Carefully compress the Spring with the Spring Compressor. See Fig. 10-1 Apply blue Loctite to the thread area of the Diaphragm Plate, install Diaphragm Plate with smooth side up. Use the palm of your hand to tighten the Plate onto the Stem. Relax the Spring pressure while assuring the Plate has started to remain in place. Make sure that the Spring stays under the Compressor Tool. Remove the Spring Compressor Tool. Spring Compressor Tool When tight, the top of Stem should be flush or slightly above plate Diaphragm Plate Fig. 10-1 14
11 Diaphragm, Bonnet, Breather Plug, Travel Indicator Assembly Assembly Place Diaphragm over the Diaphragm Plate flange down / cup up and center with the screw holes. See Fig. 11-1 Place Bonnet on the Housing and align the breather hole with the Housing breather hole. Place the screws in the Bonnet the Valve Body holes. Tighten the Bolts in a crisscross pattern to avoid any miss alignment. For 2 in., 3 in. and 4 in. tighten Bolts from 25-30 ft./lbs torque. Apply blue Loctite to the Breather Plug threads and install in the Upper Housing and tighten until it is seated. Install the Spring onto the Indicator Stem. Install the Indicator Stem and Spring into the Travel Indicator. Install the Travel Indicator Assembly and Gasket onto the Bonnet. Travel Indicator Indicator Stem Spring Gasket Bonnet 12 Serial Tag Lightly tap drive screws with small hammer. Leave tag slightly loose until remaining drive screws are in place. Then tap the screws tight against the tag. (not shown) Diaphragm Breather Plug Fig. 11-1 15
TESTING 13 Flow Direction, Adjusting Screw, Check For Leakage Flow Direction Make sure the air is flowing from upstream to downstream. Kimray valves have an arrow showing the direction of flow. Check for Leakage Apply shop air. Check if any leakage is coming out the downstream side. Spray soaped water on Housing, Breather Plug and plug. The identification of leakage will be noted if any bubble shows up. Valve Test Once no leakage is detected, apply supply gas of 40 psi for about 3 to 4 times to upper Bonnet to make sure the valve is opening and closing properly. Turn upstream pressure off of valve and let it set about 3 to 4 seconds than apply pressure to the upper Housing and relieve pressure inside valve. 16
Kimray is an ISO 9001- certified manufacturer. Kimray quality assurance process maintains strict controls of materials and the certification of parts used in the Kimray low pressure balanced valve. Please visit our website for up to date product data www.kimray.com Configuration of Back Pressure Valve is a trademark of Kimray, Inc.
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