HIGH PRESSURE REGULATORS

Models HPMV
Instruction Manual: IME1HPMVREG

Sense Line Supply gas

Protector Regulator

150 PG
30 HPG Pilot
Pilot High Pressure Motor Valve
INTRODUCTION:

SCOPE: SPECIFICATIONS:

This instruction manual includes installation, operation, and parts infor-

mation for the Kimray Pilot operated High Pressure Regulators. Refer to
Normal Service: Liquid* or Gas
separate manuals for instructions covering actuators, controllers, main- Features:
tenance, and accessories. Connection Size: 1” thru 8”
DN 25 thru DN 200

Only trained and qualified individuals should attempt to install, operate, Body Style: Through or Angle
or maintain any Kimray products or accessories. The following instruc-
tions should be reviewed and completely understood before attempting Connection Type: NPT, Flanged, or RTJ
any installation, operation, or maintenance. If you have any concerns
or questions about these instructions, contact your Kimray sales office Actuation: Pressure Open or Pressure Closed
before proceeding.
Control: Upstream or Downstream
DESCRIPTION:
Temperature: -20f to 200f
-29c to 93c
Kimray pilot operated high pressure regulators are used for liquids, natu-
ral gas, air, or other non-corrosive gas applications and include a High
Pressure Motor Valve, 12 SGR supply gas regulator, High pressure pilot, Range: 5 psig - 2500 psig
and sense line protector were applicable. The High Pressure Regulator .34 bar - 172 bar
will control set point at upstream or downstream of the valve depending
on configuration. Options: Pre-piped pilot supply
Filter drip pot
A name tag is attached to the upper bonnet housing on each Thermo- Reduced trim capacity
stat. The name tag lists the serial number, model number, and pressure Trim material
rating. Elastomer material
Quick exhaust slam-shut device
When servicing valves, always use only Kimray replacement parts. For Electro-pneumatic control
specific model numbers, part numbers, and repair kit numbers, refer to Actuator spring ranges
the Kimray Catalog, Section H1, or to the packing slip which is enclosed Adjustable actuator
with each valve. Non-freeze body

* Do not use in Liquid service with pulsations in pressure
1

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
Back Pressure Regulator with 30 hpg pilot
Control Pressure: 5 - 300 psig
Operating Pressure: 0 - 1000 psig
* 1000 psig with sense line protector
2
HIGH PRESSURE REGULATORS
Models HPMV
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 PG Pilot
Control Pressure: 75 - 2500 psig
Operating Pressure: 0 - 4000 psig
* 4000 psig with sense line protector

Hi-Lo Regulator with PG Pilots
Control Pressure: 75 - 2500 psig
Operating Pressure: 75 - 2500 psig
Upstream Gap Control Regulator with PG
Pilots
Control Pressure: 75 - 2500 psig
Operating Pressure: 75 - 2500 psig
3
HIGH PRESSURE REGULATORS
Models HPMV
Hi-Lo Regulator with 30 HPG Pilots
Control Pressure: 10 - 300 psig
Operating Pressure: 10 - 1000 psig
* 1000 psig with sense line protector
Downstream Gap Control Regulator with 30
HPG Pilots
Control Pressure: 10 - 300 psig
Operating Pressure: 10 - 1000 psig
* 1000 psig with sense line protector
 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

Body, Connections & Pressure Ratings INSTALLATION:

BEFORE INSTALLATION:
Size
Be sure you fully understand the application, operation, and connection of
1” NPT 4000 psig 96 bar the device before installing.
150 RF 285 psig 19 bar
300 RF 740 psig 51 bar WARNING:
600 RF 1480 psig 102 bar
900 RF 2220 psig 153 bar Only trained personnel should install or service a control valve. Con-
1500 RF 3705 psig 255 bar trol valves and other control devices should be installed, operated,
150 RTJ 285 psig 19 bar and maintained in accordance with international codes and regula-
300 RTJ 740 psig 51 bar tions, manufacturer’s instructions, and proven best practices.
600 RTJ 1480 psig 102 bar
1500 RTJ 3705 psig 255 bar Personal injury, equipment damage, property damage, leakage, or
bursting of pressure-containing parts may result if the valve is over-
2” NPT 4000 psig 96 bar pressured or installed where service conditions could exceed the lim-
150 RF 285 psig 19 bar its given in the SPECIFICATIONS section.
300 RF 740 psig 51 bar
600 RF 1480 psig 102 bar Overpressure protection should also be provided if the valve inlet
900 RF 2220 psig 153 bar pressure may exceed the safe working pressure of the equipment
1500 RF 3705 psig 255 bar downstream.
150 RTJ 285 psig 19 bar
300 RTJ 740 psig 51 bar To avoid injury or damage, install pressure-relieving or pressure limit-
600 RTJ 1480 psig 102 bar ing devices to prevent service conditions from exceeding those limits.
900 RTJ 2220 psig 153 bar Consult the appropriate code, regulations, or standards.
1500 RTJ 3705 psig 255 bar
Consideration should be given to the potential risk of injury or prop-
3” 150 RF 285 psig 19 bar erty damage due to escaping fluid. To avoid such risks, install the
300 RF 740 psig 51 bar regulator in a safe location.
600 RF 1480 psig 102 bar
600 RTJ 1480 psig 102 bar 1. Inspect the openings in the valve for foreign material and clean the pipe
lines to remove scale, chips, and debris.
4” 150 RF 285 psig 19 bar
300 RF 740 psig 51 bar 2. Install the valve with the arrow on the body pointing in the direction of
600 RF 1480 psig 102 bar flow. The arrow signifies that the device will operate properly in the direc-
tion of flow indicated and will not necessarily prevent flow in the opposite
direction.
6” 150 RF 285 psig 19 bar
300 RF 740 psig 51 bar
The flow direction of the HPMV 1” and 2” with ball and cone trim is DOWN
600 RF 1480 psig 102 bar
through the valve. If conditions indicate the possibility of backward
flow you may wish to install check valves.
8” 300 RF 740 psig 51 bar
600 RF 1480 psig 102 bar 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 pres-
Construction Materials: surized system. The valve could suddenly open, blowing gas, dirt,
metal particles, or other debris into the person’s face and eyes.
Item Standard Optional
3. Install the valve using good piping practice. For flanged bodies use a suit-
Body A216-WCB 316SS6 Stainless able gasket between the body and the pipeline flanges. For threaded (NPT)
Cage AISI 12-L14 316SS6 Stainless bodies, use TFE tape or pipe thread sealant on external pipe threads.
Stem 303 Stainless 316SS6 Stainless
The flange bodies are rated ANSI class. Do not install the valve in a system
Plug Chrome alloy 316SS6 Stainless where the working pressure can exceed ANSI class rating.
Seat D-2 Steel 316SS6 Stainless
Stuffing Box AISI 12-L14 316SS6 Stainless Kimray’s HPMV regulators are self contained and no external connections
are required unless an outside source of supply gas is required.
Bonnet ASTM-A395
Diaphragm Nitrile/Nylon Viton 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
O-rings Nitrile
maximum required instrument gas pressure is 45 psig (3bar).
Packing PTFE

5

START UP:
BACK PRESSURE REGULATOR:
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 recom-
mended 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:
a. Pilot supply and control line valves, if applicable.
b. Upstream block valve.
c. Downstream block valve.
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.
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.
PRESSURE REDUCING REGULATOR:
In a Pressure Reducing Regulator the sense line is connected down-
stream, 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.
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:
a. Pilot supply and control line valves, if applicable.
b. Upstream block valve.
C. Downstream block valve.
6
HIGH PRESSURE REGULATORS
Models HPMV
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 or loosen
adjustment bolt to decrease upstream set point.
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.
HI-LO REGULATOR:
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.
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 pres-
sure 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.
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:
a. Pilot supply and control line valves, if applicable.
b. Upstream block valve.
c. Downstream block valve.
4. If a supply gas regulator is being used set to 35 psig at this time.
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.
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.
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.
 HIGH PRESSURE REGULATORS
Models HPMV

GAP CONTROL REGULATOR: 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.
In a Gap Control Regulator the sense line is connected to either up-
At low set point the regulator will open and remain open until down-
stream or downstream of the valve depending on desired control. The
stream pressure reaches Hi level set point and will close again.
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
1. Make sure all block and vent valves are closed.
instrument gas regulator is installed to cut the upstream pressure to the
recommended pressure for the actuator (30 - 35 psig). The drip pot is
2. Back out the pilot adjusting screw.
added to collect any liquid that might be in the upstream gas.
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 Regula-
a. Pilot supply and control line valves, if applicable.
tor will control upstream or downstream range.
b. Upstream block valve.
Upstream Gap Controller will monitor upstream pressure and open
the valve when pressure reaches Hi set point, the valve will remain
c. Downstream block valve.
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
4. If a supply gas regulator is being used set to 35 psig at this time.
open again.
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
1. Make sure all block and vent valves are closed.
be reached by shutting downstream block valve and and adjusting
Hi
2. Back out the pilot adjusting screw.
pilots adjustment screw in until valve closes. It may be required to
repeat this several times until set point is achieved.
3. Carefully open the following valves in this order:
6. Adjust Low set point pilot to desired set point or open pressure by
a. Pilot supply and control line valves, if applicable.
turning adjustment screw in to increase low set point. Low set point
can be reached by shutting downstream block valve and monitor
b. Upstream block valve.
pressure when valve open. It may be required to repeat this several
times until set point is achieved.
c. Downstream block valve.
7. Once both Hi and Low set points have been achieved, tighten lock
4. If a supply gas regulator is being used set to 35 psig at this time.
nut on pilot adjustment knob to lock pilot.
5. Adjust HI set point pilot to desired set point or open pressure by
8. Open upstream and downstream block valves to begin flow.
turning adjustment screw in to increase pressure. High set point can
be reached by shutting downstream block valve and and adjusting Hi
9. Check for any leaks around pilot or valve area at this time and
pilots adjustment screw in until valve opens. It may be required to
correct if necessary.
repeat this several times until set point is achieved.

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

REDUNDANT 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 sup-
ply 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.
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.
4. 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.
5. If a supply gas regulator is being used set to 35 psig at this time.
6. Open sense line ball valve of first regulator.
6. Adjust pilot of first regulator until desired control pressure is 5. If a supply gas regulator is being used set to 35 psig at this time.
achieved. Tighten adjustment bolt to increase downstream set point
and loosen adjustment bolt to decrease downstream set point.
7. Once desired set point is achieved tighten lock nut on pilot adjust
ment knob to lock pilot.
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 8. Begin turning the the adjusting screw on the Primary Regulator Pilot
and loosen adjustment bolt to decrease downstream set point.
10. Once desired set point is achieved tighten lock nut on pilot adjust setting is reached. The Primary Regulator is now set. Set the lock
ment knob to lock pilot.
11. Open ball valve on first regulator.
12. Check for any leaks around pilot or valve area at this time and cor turn counter clockwise. This will keep the Monitor Pilot from
rect if necessary.
8
HIGH PRESSURE REGULATORS
Models HPMV
WORKER MONITOR REGULATOR:
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 sup-
ply 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.
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 pres-
sure, 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.
4. 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.
6. Turn the adjusting screw on the Monitor Pilot clockwise all the way
down.
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.
clockwise. The Primary Regulator should begin to open. Continue
turning the adjusting screw until the desired downstream pressure
nut on the adjusting screw.
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
interfering with further setup.
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’.
 HIGH PRESSURE REGULATORS
Models HPMV

TROUBLESHOOTING:

11. The Standby Regulator should now be controlling Regulator is not stable Oversized trim.
downstream pressure. Position the adjusting screw
Improper piping, regulators
on the Standby Regulator Pilot until the desired
require a minimum of 10 times
downstream pressure setting is reached. The Stand-
pipe O.D. Upstream and Down-
by Regulator is now set. Set the lock nut on adjusting
stream of valve.
screw.
Move sense line, turbulance
12. Slowly turn the adjusting screw on the Monitor Pilot through body causing false
clockwise. At some point the gauge on the Standby reading.
Regulator Pilot will begin to indicate loss in pressure. Regulator will not open Check for clogged control line.
At this point turn the adjusting screw on the Monitor
Pilot 1/2 turn counter clockwise. The Monitor Pilot is Make sure control line and
set. Shut the bleed valve on the Primary Regulator supply line are properly
Pilot, open the block valve.
connected.
13. To restore control to the Primary Regulator turn the Make sure supply gas is turned
adjusting screw on the Monitor Pilot 1/2 turn clock- on.
wise. Pressure indicated on the gauge of the Standby Check actuator diaphragm for
Regulator Pilot should drop to ‘0’. The Standby Reg- damage
ulator should fully open, and the Primary Regulator
should move into control. After control by the Primary Regulator will not close Check pilot control line, clogged
Regulator is verified, turn the adjusting screw on the or broken.
Monitor Pilot 1/2 turn counter clockwise to restore its Check pilot vent plug for restric-
setting. Set the lock nut on the adjusting screw. The tion.
entire unit is now set.
Check actuator diaphragm for
* When the Primary Regulator is in control (normal conditions) the damage
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