In this guide we’ll walk you through everything there is to know about high pressure control valves.
From the basics of how it works to step-by-step repairs and troubleshooting, you’ll gain a solid foundation of knowledge on how to operate and maintain Kimray’s high pressure control valves.
Use the table of contents to skip to different sections of the learning path.
One effective way to repair your control valve is to replace the valve trim.
Replacing valve trim is a simple and cost-effective option when compared to replacing an entire valve. There are two primary reasons to change your valve trim:
Fortunately, replacing the trim in your valve is a simple process. In this example, we'll change out the valve trim on a 2" High Pressure Control Valve.
When removing the stuffing box, you may hear a hissing noise. This is coming from the communication hole in the trim, which is alerting you there is still pressure in the valve body. If you hear this noise, you have a leak somewhere upstream of the valve. You need to STOP WORK IMMEDIATELY to locate and fix the leak in order to depressurize the valve.
This whole piece should come out as one assembly. If it doesn’t, you can use Kimray's Seat Removal Tool. This tool threads directly onto the seat for easy removal.
Now that you’ve changed the trim size of your control valve it’s ready to handle your new flow conditions.
In this article and video, we show how to repair and rebuild a 2" Stem Guided High Pressure Control Valve, as well as how to easily change or convert the actuator fail position from fail open to fail close.
This Kimray control valve disassembly and assembly uses a Kimray repair kit.
Before beginning, consult your company's safety guidelines and requirements. Follow all regulations and wear all necessary PPE.
If the seat separates from the cage inside the valve body, use a Kimray Seat Removal Tool. Another problem could be that the cage comes unthreaded from the stuffing box and stays in the valve body. Flip the Kimray Seat Removal Tool over, thread it onto the cage and remove it all in one piece.
The diaphragm needs to be inspected for any abnormal wear like punctures or swelling. If it is damaged, you will need to order a replacement because it is not included in the repair kit. It’s also good to inspect the part of the diaphragm under the diaphragm nut. However, to remove this or to replace the diaphragm, you will need the Kimray Diaphragm Nut Removal Tool.
At this point, you're ready to reassemble the valve.
If you have any questions about any of this process or the custom Kimray tools used, reach out to your local Kimray store or authorized distributor.
In this video, we’ll show you how to repair a 2" Cage Guided High Pressure Control Valve, as well as how to easily change the actuator failure position.
For this job, you will need the following tools, equipment, and chemicals. There are also a couple of commonly replaced parts like the diaphragm and trim set pieces that are not in the repair kit.
All-purpose Grease
Blue Loctite/Thread locker #242
Primer
Oil
Brake Parts Cleaner
Anti-seize (for stainless steel stuffing boxes only)
Nitrile gloves are highly recommended when working with and handling greases and chemicals to prevent skin irritation. 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 have been disconnected.
Use caution—if pressure starts to exit from the weep hole, stop immediately and check if the valve is isolated from pressure.
The plug assembly includes the cage and piston assembly inside of it.
Before assembling the valve, you need to inspect a few of the key components that are often affected due to the severe impact of particles that flow through the valve. If any of these parts are damaged, you will need to order a replacement.
If there are multiple components that are worn and will need to be replaced, you may consider ordering a complete plug assembly. This will save you time and money, making the repair much easier. Complete plug assemblies are listed on the tech specs page. See our video about trim set options for more details.
In all models except the 2” line size, you will need to align the holes in the piston and ratio plug.
Now you have the option to assemble for fail open (pressure close) or fail close (pressure open) operation.
You can now remove the supply pressure, and your repair is complete
That completes our repair. If you have any questions about this process or the custom Kimray tools used, contact your local Kimray store or authorized distributor.
A High Pressure Control Valve is a versatile solution that features field-reversible topworks for easy field conversions.
Do you need to reverse the function from fail open to fail close for a different application?
For example, maybe you have been using the valve as a suction controller on the inlet of a compressor. In this case you had it set to fail open.
Now you want to use it for back pressure service, to hold pressure on a three-phase separator—in which case you would want the valve set up to fail open.
That’s how to convert the topworks on a High Pressure Control Valve for a different application.
Download a Printable PDF of this Tutorial
To speak with an expert about converting your control valve's fail position, contact your local Kimray store or authorized distributor.
Oil and gas producers use high pressure control valve packages to regulate natural gas flow at their well site.
In a Back Pressure application, High Pressure Control Valve Packages are set up to hold upstream pressure "back" on production vessels and release it downstream when a set point is reached.
This is opposed to a Pressure Reducing application, where the package is set up to reduce the gas pressure, but also allow it to flow through at a consistent, pre-determined flow rate.
To use it in a back pressure application, you'll need to add a handful of complementary components.
If you order the package from us, we'll help you spec it out and then deliver it fully assembled and ready to install.
If you purchase these parts individually, however, you can watch the video above, where Kyle shows you how to assemble a high pressure regulator package for back pressure.
Note: Before you get started, you'll want to put on your appropriate PPE and be sure to follow all of your company's safety requirements.
The components of a High Pressure Back Pressure Package include:
Depending on how you choose to arrange the components, the number of elbow and straight connectors will vary, but we've listed the minimum below:
Finally, to put the package together, you’ll need the following tools:
If you assemble these packages regularly, you will already have a standard for how to arrange your assembly—whether all of the parts on one side or if it’s more symmetrical.
Knowing this in advance makes it easier to attach the tubing connecters and nipples to the parts before adding them each to the valve.
The way Kyle builds this package in the video will have the components closer together, facing the front of the valve and on the upstream side. We use less tubing this way and avoid creating areas where someone may try to use to lift. From our experience, this arrangement is typically most successful.
Back pressure valves need to be fail open (pressure close). All of our Kimray valves come standard as fail close, so if you’re building a back pressure package yourself, you’ll need to flip the top works before you begin.
Note: For this package, you may be using a 30 HPG pilot instead of a high pressure pilot. For this configuration, the assembly will be the same, but the tubing lengths and angles will look different.
The Electric Valve Controller package is a compact, easy-to-use solution for oil and gas automation, including remote monitoring and control of your production.
In this video and article, we'll show you have to assemble an Electric Valve Controller package. This placement of components will provide the smallest footprint and the most efficient use of tubing.
Before you get started, you’ll want to put on your appropriate PPE and be sure to follow all your company’s safety requirements.
If monitoring upstream pressure:
If doing electrical hookup:
First, we’ll install the fittings into each component, then mount them to the valve body.
For all tubing connections, apply primer and Loctite. For all non-pressurized, threaded connections (nipple from I/P to YEP & YEP to transducer connections), use thread tape.
With the fittings attached, now we’ll mount the components to the valve.
To monitor upstream pressure (for back pressure), remove the tubing to the downstream (2). Instead connect the upstream tubing (1) to the transducer by adding a ¼" nipple and T-connector to the transducer. Then tube the T-connector to the drip pot.
