When you purchase a high pressure control valve for a back pressure application, you
need several other components to make that valve fully functional. Typically, when you
order from us, we’ll help you spec in your package and it’ll be delivered fully assembled
and ready to install. However, if you purchase these parts individually, you’ll want to
know what they do and how to assemble the package.
I’m Kyle, and today, I’ll be showing you how to assemble HPCV packages for back pressure
regulation. 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 control valve package include:
The valve
A Sense line protector to block out the sensed pressure to a device when it exceeds the adjustable limit.
A drip pot to knock out any liquid in your supply gas.
A supply gas regulator to provide supply pressure to the pilot.
And a pilot which is responsible for telling the valve what to do.
Along with these parts, you’ll also need the following:
Depending on how you choose to arrange the components, the number of elbow and straight
connectors will vary, but you’ll need at least eight, ¼” x 3/8” tubing connectors
Two, ¼” nipples
One, high pressure, ¼” T-connector
Approximately 5 feet of 3/8” tubing
And Loctite
Finally, to put the package together, you’ll need the following tools:
A vise
Tubing benders
Tubing cutters
A ½" wrench
A 5/8” wrench
A 11/16” wrench
A 9/16” wrench (for bonnet bolts)
Channel locks
And a crescent wrench
Someone who assembles these packages regularly will already have a standard for how to arrange
their 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 that I’ll be building this package will have the components closer together,
facing the front of the valve and on the upstream side. We’ll be using 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.
The first step is to thread the needle valve into the bottom of the drip pot.
Then connect the supply gas regulator to the drip pot with a ¼” nipple and Loctite.
Now, mount the valve body in a vise.
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. See our video if you need help
with that process.
Remove a bolt from the bonnet on the upstream side and attach the drip pot and supply gas
regulator on the valve.
Now we’ll install the pilot to the front of the valve by removing two bonnet bolts,
and attaching the bracket included on the pilot.
Next, install a nipple into the outlet of the sense line protector with Loctite.
Connect that into the sensing port of the pilot.
Attach the ¼” T into the sense line protector inlet.
Install one tubing connector into the T, and another into the upstream side of the valve body.
Bend, cut and install the tubing from the upstream of the valve to the T.
Install a tubing connector on the T, and another on the drip pot inlet.
Connect these together with tubing.
Attach tubing connectors to the outlet of the supply gas regulator and the supply side of the pilot.
The supply gas regulator cuts down the supply gas to the required 30PSI of the pilot. This
is preset, so you won’t have to adjust it.
Now install the tubing.
Attach tubing connectors to both the output of the pilot and the top of the valve bonnet.
Cut, bend and install the tubing.
Finish by installing a pressure gauge on the supply gas regulator.
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.