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HIGH PRESSURE REGULATORS
Models HPMV
Instruction Manual: IME1HPMVREG
Supply gas
Regulator
Sense Line
Protector
30 HPG
Pilot
150 PG
Pilot
High Pressure Motor Valve
INTRODUCTION:
SCOPE:
SPECIFICATIONS:
This instruction manual includes installation, operation, and parts information for the Kimray Pilot operated High Pressure Regulators. Refer to
separate manuals for instructions covering actuators, controllers, maintenance, and accessories.
Normal Service:
Connection Size:
1” thru 8”
DN 25 thru DN 200
Only trained and qualified individuals should attempt to install, operate,
or maintain any Kimray products or accessories. The following instructions should be reviewed and completely understood before attempting
any installation, operation, or maintenance. If you have any concerns
or questions about these instructions, contact your Kimray sales office
before proceeding.
Body Style:
Through or Angle
Connection Type:
NPT, Flanged, or RTJ
Actuation:
Pressure Open or Pressure Closed
Control:
Upstream or Downstream
Features:
DESCRIPTION:
Temperature:
Kimray pilot operated high pressure regulators are used for liquids, natural gas, air, or other non-corrosive gas applications and include a High
Pressure Motor Valve, 12 SGR supply gas regulator, High pressure pilot,
and sense line protector were applicable. The High Pressure Regulator
will control set point at upstream or downstream of the valve depending
on configuration.
Range:
A name tag is attached to the upper bonnet housing on each Thermostat. The name tag lists the serial number, model number, and pressure
rating.
When servicing valves, always use only Kimray replacement parts. For
specific model numbers, part numbers, and repair kit numbers, refer to
the Kimray Catalog, Section H1, or to the packing slip which is enclosed
with each valve.
1
Liquid* or Gas
-20f to 200f
-29c to 93c
5 psig - 2500 psig
.34 bar - 172 bar
Options:
Pre-piped pilot supply
Filter drip pot
Reduced trim capacity
Trim material
Elastomer material
Quick exhaust slam-shut device
Electro-pneumatic control
Actuator spring ranges
Adjustable actuator
Non-freeze body
* Do not use in Liquid service with pulsations in pressure
HIGH PRESSURE REGULATORS
Models HPMV
AVAILABLE MODELS: Typical Configurations
Pressure Reducing Regulator with 30 hpg pilot
Control Pressure: 5 - 300 psig
Operating Pressure:
0 - 1000 psig
* 1000 psig with sense line protector
Pressure Reducing Regulator with PG pilot
Control Pressure:
75 - 2500 psig
Operating Pressure:
0 - 4000 psig
* 4000 psig with sense line protector
Back Pressure Regulator with 30 hpg pilot
Control Pressure: 5 - 300 psig
Operating Pressure:
0 - 1000 psig
* 1000 psig with sense line protector
Back Pressure Regulator with PG Pilot
Control Pressure:
75 - 2500 psig
Operating Pressure:
0 - 4000 psig
* 4000 psig with sense line protector
2
HIGH PRESSURE REGULATORS
Models HPMV
Hi-Lo Regulator with PG Pilots
Control Pressure:
75 - 2500 psig
Operating Pressure:
75 - 2500 psig
Hi-Lo Regulator with 30 HPG Pilots
Control Pressure:
10 - 300 psig
Operating Pressure:
10 - 1000 psig
* 1000 psig with sense line protector
Upstream Gap Control Regulator with PG
Pilots
Control Pressure:
75 - 2500 psig
Operating Pressure:
75 - 2500 psig
Downstream Gap Control Regulator with 30
HPG Pilots
Control Pressure:
10 - 300 psig
Operating Pressure:
10 - 1000 psig
* 1000 psig with sense line protector
3
HIGH PRESSURE REGULATORS
Models HPMV
Redundant Regulators with PG Pilots
Control Pressure: 75 - 2500 psig
Operating Pressure: 0 - 4000 psig
* 4000 psig with sense line protector
Worker Monitor Regulators with 30 HPG Pilots
Control Pressure: 5 - 300 psig
Operating Pressure:
0 - 1000 psig
* 1000 psig with sense line protector
4
HIGH PRESSURE REGULATORS
Models HPMV
INSTALLATION:
Body, Connections & Pressure Ratings
BEFORE INSTALLATION:
Size
1”
NPT
150 RF
300 RF
600 RF
900 RF
1500 RF
150 RTJ
300 RTJ
600 RTJ
1500 RTJ
4000 psig
285 psig
740 psig
1480 psig
2220 psig
3705 psig
285 psig
740 psig
1480 psig
3705 psig
96 bar
19 bar
51 bar
102 bar
153 bar
255 bar
19 bar
51 bar
102 bar
255 bar
NPT
150 RF
300 RF
600 RF
900 RF
1500 RF
150 RTJ
300 RTJ
600 RTJ
900 RTJ
1500 RTJ
4000 psig
285 psig
740 psig
1480 psig
2220 psig
3705 psig
285 psig
740 psig
1480 psig
2220 psig
3705 psig
96 bar
19 bar
51 bar
102 bar
153 bar
255 bar
19 bar
51 bar
102 bar
153 bar
255 bar
150 RF
300 RF
600 RF
600 RTJ
285 psig
740 psig
1480 psig
1480 psig
19 bar
51 bar
102 bar
102 bar
4”
150 RF
300 RF
600 RF
285 psig
740 psig
1480 psig
19 bar
51 bar
102 bar
6”
150 RF
300 RF
600 RF
285 psig
740 psig
1480 psig
19 bar
51 bar
102 bar
300 RF
600 RF
740 psig
1480 psig
51 bar
102 bar
2”
3”
8”
Be sure you fully understand the application, operation, and connection of
the device before installing.
WARNING:
Only trained personnel should install or service a control valve. Control valves and other control devices should be installed, operated,
and maintained in accordance with international codes and regulations, manufacturer’s instructions, and proven best practices.
Personal injury, equipment damage, property damage, leakage, or
bursting of pressure-containing parts may result if the valve is overpressured or installed where service conditions could exceed the limits given in the SPECIFICATIONS section.
Overpressure protection should also be provided if the valve inlet
pressure may exceed the safe working pressure of the equipment
downstream.
To avoid injury or damage, install pressure-relieving or pressure limiting devices to prevent service conditions from exceeding those limits.
Consult the appropriate code, regulations, or standards.
Consideration should be given to the potential risk of injury or property damage due to escaping fluid. To avoid such risks, install the
regulator in a safe location.
1. Inspect the openings in the valve for foreign material and clean the pipe
lines to remove scale, chips, and debris.
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.
The flow direction of the HPMV 1” and 2” with ball and cone trim is DOWN
through the valve. If conditions indicate the possibility of backward
flow you may wish to install check valves.
The flow direction of the HPMV PB 2” thru 8” is UP through the valve. If
conditions indicate the possibility of backward flow you may wish to
install check valves.
A person should never stand directly over or in front of a valve when
the system is pressurized. Never look directly into a valve in a pressurized system. The valve could suddenly open, blowing gas, dirt,
metal particles, or other debris into the person’s face and eyes.
Construction Materials:
Item
Standard
Optional
Body
A216-WCB
316SS6 Stainless
Cage
AISI 12-L14
316SS6 Stainless
Stem
303 Stainless
316SS6 Stainless
Plug
Chrome alloy
316SS6 Stainless
Seat
D-2 Steel
316SS6 Stainless
Stuffing Box
AISI 12-L14
316SS6 Stainless
Bonnet
ASTM-A395
Kimray’s HPMV regulators are self contained and no external connections
are required unless an outside source of supply gas is required.
Diaphragm
Nitrile/Nylon
Viton
O-rings
Nitrile
Packing
PTFE
4. If an outside source of supply gas is required, connect supply gas to the
drip pot with 1/4” connection or directly to pilot supply input if regulated. The
maximum required instrument gas pressure is 45 psig (3bar).
3. Install the valve using good piping practice. 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.
The flange bodies are rated ANSI class. Do not install the valve in a system
where the working pressure can exceed ANSI class rating.
5
HIGH PRESSURE REGULATORS
Models HPMV
START UP:
4. If a supply gas regulator is being used set to 35 psig at this time.
BACK PRESSURE REGULATOR:
5. Adjust pilot until desired control pressure is achieved. Tighten
adjustment bolt to increase downstream set point or loosen
adjustment bolt to decrease downstream set point.
In a Back Pressure Regulator the sense line is connected upstream,
and the valve is typically operated in a pressure closed (fail open)
mode. The Back Pressure Regulator is fully self-contained with both
supply and sense lines being connected to the valve. An instrument
gas regulator is installed to cut the upstream pressure to the recommended pressure for the actuator (30 -35 psig). The drip pot is added
to collect any liquid that might be in the upstream gas.
6. Once desired set point is achieved tighten lock nut on pilot adjust
ment knob to lock pilot.
7. Check for any leaks around pilot or valve area at this time and cor rect if necessary.
1. Make sure all block and vent valves are closed.
HI-LO REGULATOR:
2. Back out the pilot adjusting screw.
In a Hi-Lo Regulator the sense line is connected downstream and and
the vale is typically operated in a pressure open ( fail closed ) mode.
The Hi-Lo Regulator is fully self-contained with both supply and sense
lines being connected to the valve. An instrument gas regulator is
installed to cut the upstream pressure to the recommended pressure
for the actuator (30 - 35 psig). The drip pot is added to collect any liquid
that might be in the upstream gas.
3. Carefully open the following valves in this order:
a. Pilot supply and control line valves, if applicable.
b. Upstream block valve.
c. Downstream block valve.
The function of the Hi-Lo Regulator is to allow medium to flow through
the valve within pilots controlled range. As long as the mediums pressure is between the regulators Hi set point and Low set point the valve
will be open, if pressure falls or climbs outside this range the Regulator
will close and a manual reset will be required.
4. If a supply gas regulator is being used set to 35 psig at this time.
5. Adjust pilot until desired control pressure is achieved. Tighten
adjustment bolt to increase upstream set point and loosen
adjustment bolt to decrease upstream set point.
1. Make sure all block and vent valves are closed.
6. Once desired set point is achieved tighten lock nut on pilot adjust ment knob to lock pilot.
2. Back out the pilot adjusting screw.
7. Check for any leaks around pilot or valve area at this time and cor rect if necessary.
3. Carefully open the following valves in this order:
a. Pilot supply and control line valves, if applicable.
PRESSURE REDUCING REGULATOR:
b. Upstream block valve.
c. Downstream block valve.
In a Pressure Reducing Regulator the sense line is connected downstream, and the valve is typically operated in a pressure open (fail
closed) mode. The Pressure Reducing Regulator is fully self-contained
with both supply and sense lines being connected to the valve. An
instrument gas regulator is installed to cut the upstream pressure to
the recommended pressure for the actuator (30 -35 psig). The drip pot
is added to collect any liquid that might be in the upstream gas.
4. If a supply gas regulator is being used set to 35 psig at this time.
1. Make sure all block and vent valves are closed.
6. Adjust Low setpoint (direct acting) to desired set point or shut off
pressure. This can be determined by closing upstream block valve
and observing upstream pressure when valve is closed. The manual
reset will need to be reset everytime the low set point is reached.
5. Adjust Hi set point pilot (indirect acting) to desired set point or shut
off pressure by turning adjustment screw in. This can be determined
by closing downstream block valve and observing downstream
pressure when valve is closed. The manual reset will need to be
reset everytime high set point is reached.
2. Back out the pilot adjusting screw.
3. Carefully open the following valves in this order:
a. Pilot supply and control line valves, if applicable.
7. Once both Hi and Low set points have been achieved, tighten lock
nut on pilot adjustment knob to lock pilot.
b. Upstream block valve.
8. Open upstream and downstream block valves to begin flow.
C. Downstream block valve.
9. Check for any leaks around pilot or valve area at this time and
correct if necessary.
6
HIGH PRESSURE REGULATORS
Models HPMV
Downstream Gap Controller will monitor downstream pressure and
close the valve when downstream pressure reaches Hi set point, the
valve will remain closed until downstream reaches low pilot set point.
At low set point the regulator will open and remain open until downstream pressure reaches Hi level set point and will close again.
GAP CONTROL REGULATOR:
In a Gap Control Regulator the sense line is connected to either upstream or downstream of the valve depending on desired control. The
Gap Control Regulator typically uses a pressure open ( fail closed )
valve configuration. The Gap Control Regulator is fully self-contained
with both supply and sense lines being connected to the valve. An
instrument gas regulator is installed to cut the upstream pressure to the
recommended pressure for the actuator (30 - 35 psig). The drip pot is
added to collect any liquid that might be in the upstream gas.
1. Make sure all block and vent valves are closed.
2. Back out the pilot adjusting screw.
3. Carefully open the following valves in this order:
The function of the Gap Control Regulator is to allow medium to flow
through the valve within pilots control range. The Gap Control Regulator will control upstream or downstream range.
Upstream Gap Controller will monitor upstream pressure and open
the valve when pressure reaches Hi set point, the valve will remain
open until low set point is achieved and will then close. The regulator
will remain closed until high set point is sensed by pilot and valve will
open again.
3. Carefully open the following valves in this order:
b. Upstream block valve.
c. Downstream block valve.
b. Upstream block valve.
c. Downstream block valve.
5. Adjust HI set point pilot to desired set point or closed pressure by
turning adjustment screw in to increase pressure. High set point can
be reached by shutting downstream block valve and and adjusting
Hi
pilots adjustment screw in until valve closes. It may be required to
repeat this several times until set point is achieved.
2. Back out the pilot adjusting screw.
a. Pilot supply and control line valves, if applicable.
a. Pilot supply and control line valves, if applicable.
4. If a supply gas regulator is being used set to 35 psig at this time.
1. Make sure all block and vent valves are closed.
6. Adjust Low set point pilot to desired set point or open pressure by
turning adjustment screw in to increase low set point. Low set point
can be reached by shutting downstream block valve and monitor pressure when valve open. It may be required to repeat this several
times until set point is achieved.
7. Once both Hi and Low set points have been achieved, tighten lock
nut on pilot adjustment knob to lock pilot.
4. If a supply gas regulator is being used set to 35 psig at this time.
5. Adjust HI set point pilot to desired set point or open pressure by
turning adjustment screw in to increase pressure. High set point can
be reached by shutting downstream block valve and and adjusting Hi
pilots adjustment screw in until valve opens. It may be required to
repeat this several times until set point is achieved.
8. Open upstream and downstream block valves to begin flow.
9. Check for any leaks around pilot or valve area at this time and
correct if necessary.
6. Adjust Low set point pilot to desired set point or closed pressure by
turning adjustment screw in to increase low set point. Low set point
can be reached by shutting upstream block valve and monitoring pressure when valve closes. It may be required to repeat this
several times until set point is achieved.
7. Once both Hi and Low set points have been achieved, tighten lock
nut on pilot adjustment knob to lock pilot.
8. Open upstream and downstream block valves to begin flow.
9. Check for any leaks around pilot or valve area at this time and
correct if necessary.
7
HIGH PRESSURE REGULATORS
Models HPMV
REDUNDANT REGULATOR:
WORKER MONITOR REGULATOR:
In a Redundant Regulator the sense line is connected downstream,
and the valves are typically operated in a pressure open (fail closed)
mode. The Redundant Regulator is fully self-contained with both supply and sense lines being connected to the valve. An instrument gas
regulator is installed to cut the upstream pressure to the recommended
pressure for the actuator (30 -35 psig). The drip pot is added to collect
any liquid that might be in the upstream gas.
In a Worker Monitor Regulator the sense line is connected downstream,
and the valves are typically operated in a pressure open (fail closed)
mode. The Redundant Regulator is fully self-contained with both supply and sense lines being connected to the valve. An instrument gas
regulator is installed to cut the upstream pressure to the recommended
pressure for the actuator (30 -35 psig). The drip pot is added to collect
any liquid that might be in the upstream gas.
Redundant Regulators are two pressure reducing regulators that share
the same sense point, while operating independently from one another.
In case of a pilot failure set point will always remain constant.
Worker Monitor Regulators are designed to control a downstream
pressure. The first regulator in line is designed to monitor the second
regulator and in case of a failure the first regulator will take over and
control will never be lost. Both regulators can be set at the same pressure, because a pressure sensing pilot is connected to sense the line
pressure between regulators. It is set at a slightly higher pressure to
avoid interaction with the primary regulator.
1. Make sure all block and vent valves are closed.
2. Back out the pilot adjusting screw.
3. Block sense line on regulators sense line, a ball valve works
well for this.
1. Make sure all block and vent valves are closed.
2. Back out the pilot adjusting screw.
4. Carefully open the following valves in this order:
a. Pilot supply and control line valves, if applicable.
3. Block sense line on regulators sense line, a ball valve works
well for this.
b. Upstream block valve.
4. Carefully open the following valves in this order:
C. Downstream block valve.
a. Pilot supply and control line valves, if applicable.
5. If a supply gas regulator is being used set to 35 psig at this time.
b. Upstream block valve.
6. Open sense line ball valve of first regulator.
C. Downstream block valve.
6. Adjust pilot of first regulator until desired control pressure is achieved. Tighten adjustment bolt to increase downstream set point and loosen adjustment bolt to decrease downstream set point.
5. If a supply gas regulator is being used set to 35 psig at this time.
6. Turn the adjusting screw on the Monitor Pilot clockwise all the way
down.
7. Once desired set point is achieved tighten lock nut on pilot adjust ment knob to lock pilot.
7. Turn the adjusting screw on the Standby Regulator Pilot clockwise
two turns after you feel it engage the spring. The Standby Regula
tor valve should open. The gauge on the Standby Regulator Pilot
should read ‘0’, and the gauge on the Monitor Pilot should read
downstream pressure.
8. Open ball valve to sense line of second regulator and close ball
valve on sense line of first regulator.
9. Adjust pilot of second regulator until desired control pressure is achieved. Tighten adjustment bolt to increase downstream set point and loosen adjustment bolt to decrease downstream set point.
8. Begin turning the the adjusting screw on the Primary Regulator Pilot
clockwise. The Primary Regulator should begin to open. Continue
turning the adjusting screw until the desired downstream pressure
setting is reached. The Primary Regulator is now set. Set the lock
nut on the adjusting screw.
10. Once desired set point is achieved tighten lock nut on pilot adjust ment knob to lock pilot.
11. Open ball valve on first regulator.
9. Turn the adjusting screw on the Monitor Pilot counterclockwise. At
some point the gauge on the Standby Regulator Pilot will begin
to show pressure. Turn the adjusting screw at least one more full
turn counter clockwise. This will keep the Monitor Pilot from
interfering with further setup.
12. Check for any leaks around pilot or valve area at this time and cor rect if necessary.
10. Close the small block valve on the sense line of the Primary
Regulator Pilot, and open the bleed valve. The Primary Regulator
should fully open, the gauge on the Primary Regulator Pilot should
read ‘0’.
8
HIGH PRESSURE REGULATORS
Models HPMV
TROUBLESHOOTING:
11. The Standby Regulator should now be controlling
downstream pressure. Position the adjusting screw
on the Standby Regulator Pilot until the desired
downstream pressure setting is reached. The Standby Regulator is now set. Set the lock nut on adjusting
screw.
Regulator is not stable
Oversized trim.
Improper piping, regulators
require a minimum of 10 times
pipe O.D. Upstream and Downstream of valve.
Move sense line, turbulance
through body causing false
reading.
12. Slowly turn the adjusting screw on the Monitor Pilot
clockwise. At some point the gauge on the Standby
Regulator Pilot will begin to indicate loss in pressure.
At this point turn the adjusting screw on the Monitor
Pilot 1/2 turn counter clockwise. The Monitor Pilot is
set. Shut the bleed valve on the Primary Regulator
Pilot, open the block valve.
Regulator will not open
Check for clogged control line.
Make sure control line and
supply line are properly
connected.
Make sure supply gas is turned
on.
13. To restore control to the Primary Regulator turn the
adjusting screw on the Monitor Pilot 1/2 turn clockwise. Pressure indicated on the gauge of the Standby
Regulator Pilot should drop to ‘0’. The Standby Regulator should fully open, and the Primary Regulator
should move into control. After control by the Primary
Regulator is verified, turn the adjusting screw on the
Monitor Pilot 1/2 turn counter clockwise to restore its
setting. Set the lock nut on the adjusting screw. The
entire unit is now set.
Check actuator diaphragm for
damage
Regulator will not close
Check pilot control line, clogged
or broken.
Check pilot vent plug for restriction.
Check actuator diaphragm for
damage
* When the Primary Regulator is in control (normal conditions) the
gauge on the Standby Regulator will read ‘0’.
No adjustment in Regulator
Check pilot sense area for
damaged diaphragm or bellow
assembly
Check for broken spring in pilot
bonnet
Check actuator diaphragm for
damage
Make sure regulator is operating
in control range of pilot.
Check supply gas pressure,
requires 30-35 psig
9