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Model FC Operation and Maintenance Booklet

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Model FC Operation and Maintenance Booklet

pValveworks USA Operation and Maintenance Booklet Model FC BOOKLET APPROVED BY MODEL FC 3000, 5000, 10000, amp; 15000 W.P. FLOATING SLAB GATE VALVES 1 13/16” -2 1/16” -2 9/16” -3 1/16” - 4 1/16” Valveworks USA Model FC Operation and Maintenance Booklet 1 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA INTRODUCTION In appreciation to you for purchasing our product, we have prepared this booklet to assist you in the assembly, installation, operation and maintenance of the Valveworks USA API 6A Model FC Gate Valve. We encourage you to follow recommendations in this booklet to attain the best possible service from our product, which is designed and proven to offer the service one can expect of a quality product. If you need to contact a representative for more specific ination pertaining to a special problem, you should contact VALVEWORKS USA 1841 BARTON DRIVE SHREVEPORT, LOUISIANA USA 71107 PHONE 318-425-0266 FAX 318-425-0934 TOLL FREE 888-425-0266 EMAIL SALESVALVEWORKSUSA.COM WEBSITE WWW.VALVEWORKSUSA.COM CONTENTS APPLICATIONS.2 TEMPERATURE RATING .3 TRIM CHART.4 ORDERING INATION.5 OPERATION.6 PERIODIC MAINTENANCE7 MAINTENANCE TOOLS.7 STEM BEARING LUBRICATION.8 STEM PACKING.9 TROUBLESHOOTING11 ASSEMBLY INSTRUCTIONS12 1.1. BODY SUB-ASSEMBLY .12 1.2. BONNET SUB-ASSEMBLY .22 1.3. FINAL ASSEMBLY.30 ASSEMBLY DRAWING38 BILL OF MATERIALS39 PHYSICAL DIMENSIONS40 TEST PROCEDURE.41 HYDROSTATIC BODY TEST 44 HYDROSTATIC SEAT TEST .45 VISUAL INSPECTION 48 FIELD HOOK UP INSTRUCTIONS50 Valveworks USA Model FC Operation and Maintenance Booklet 2 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA APPLICATIONS The Valveworks USA Model FC valves in this booklet can be applied to the following sizes and working pressures. Size inches Working Pressures PSI 1 13/16 nbsp;10000 15000 2 1/16 5000 10000 15000 2 9/16 5000 10000 15000 3 1/8 3000 5000 nbsp;3 1/16 nbsp;10000 15000 4 1/16 3000 5000 10000 nbsp;The Model FC valves covered in this booklet are suitable for perance requirement levels 1 and 2, PR1 and PR2 respectively. Valveworks USA Model FC Operation and Maintenance Booklet 3 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA TEMPERATURE RATING Operating range C F Temperature classification min. max. min. max. K -60 82 -75 180 L -46 82 -50 180 P -29 82 -20 180 R Room Temperature Room temperature S -18 66 0 150 T -18 82 180 U -18 121 0 250 V 2 121 35 250 Note For special applications involving other sizes and pressure ratings, temperatures, materials, etc., please contact Valveworks USA 1841 Barton Dr. Shreveport, LA 71107 Phone 888-425-0266 Fax 318-425-0934 Valveworks USA Model FC Operation and Maintenance Booklet 4 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA TRIM CHART Minimum material requirements Material class Body, bonnet, end and outlet connections Pressure-controlling parts, stems and mandrel hangers AA - General service Carbon or low-alloy steel Carbon or low-alloy steel BB - General service Carbon or low-alloy steel Stainless steel CC - General service Stainless steel Stainless steel DD - Sour service a Carbon or low-alloy steel b Carbon or low-alloy steel b EE - Sour service a Carbon or low-alloy steel b Stainless steel b FF - Sour service a Stainless steel b Stainless steel b HH - Sour service a CRAs b CRAs b a As defined by NACE MR 0175. b In compliance with NACE MR 0175. Valveworks USA Model FC Operation and Maintenance Booklet 5 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA ORDERING INATION The following ination should be provided with any request for quote or order placement of Valveworks USA Model FC gate valves Model of Valve Size of Valve Pressure Rating maximum API 6A Requirements PR-PSL API 14D Requirements Class of Service Temperature Rating API 6A Material API 6A Any Special Test Requirements Any Special Material Requirements Any Special Coating or Protection Requirements Other Specifications and/or Certifications Valveworks USA Model FC Operation and Maintenance Booklet 6 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA OPERATION The Valveworks USA Model FC gate valves are handwheel operated valves. The gate of the MODEL FC Valve is a one piece slab gate that uses two floating seats to generate a highly reliable seal. The slab gate eliminates the chance of trapping pressure within the body cavity which can cause pressure locking. 1. Fully open the valve before installing or shipping. The sealing area of the gates, in the full open position, is protected by the body and is less likely to be damaged. nbsp;2. Do not remove the molybdenum disulfide coating from internal parts. This coating serves as a lubricant and corrosion inhibitor. 3. To hydrostatically test the valve body to full API test pressure, the valve must be in a partially open position. When testing the valve in the closed position seat test do not exceed the working pressure stamped on the valve identification plate. 4. During storage always leave the valve in the fully opened or fully closed position. This will tightly wedge the gate against the seats and prevent damage to the sealing area of both the gate and seats. nbsp;5. Always remove the valve from service before work is pered on the stem bearings. 6. When lubricating the body do not exceed the maximum API working pressure stamped on the identification plate. nbsp;7. The valve should be fully closed or fully opened during lubrication of the body or seats. nbsp;8. Seat lubrication pressures should not exceed the maximum allowable API test pressure. nbsp;This of operation will prevent damage to the sealing surfaces of the gate and seats, and will increase the life of the valve. Valveworks USA Model FC Operation and Maintenance Booklet 7 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA PERIODIC MAINTENANCE The Model FC gate valves are non-lubricated valves, in that they do not require the injection of lubricants or sealants to effectively seal. However, to prevent corrosion and excessive wear a normal amount of lubrication is recommended to extend the life and serviceability of the valve. Maintenance Tools To per normal maintenance and lubrication, the following tools are recommended 1 Grease gun with adapter and coupling Fig. 1. 2 Safety pressure releasing tool Fig. 2. Valveworks USA Model FC Operation and Maintenance Booklet 8 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Valveworks USA API Gate Valves, 2000 PSI W.P. to 10,000 PSI W.P. are supplied with 1/2“ NPT body fitting connections. Body fittings on 15,000 PSI W.P. valves are 1/ 1/8“ 12 UN Threads. Stem Bearing Lubrication Valveworks USA API valves are equipped with alemite hydraulic type 1/8“ NPT bonnet grease fittings. Stem bearing lubrication is accomplished through this fitting using a standard type grease gun. nbsp;Any good grade No. 3 grease is recommended for this lubrication. Stem bearings normally do not require great amounts of grease. nbsp;If over-lubrication should occur, the excess grease will flow around the stem to the atmosphere. nbsp;Valveworks USA Model FC Operation and Maintenance Booklet 9 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA CAUTION If bearings should need to be changed, the valve must be removed from service. CAUTION During pressurized valve body lubrication, pressure applied to the valve body with the grease gun must not exceed the maximum working pressure of the valve being lubricated. Stem Packing Most products contain a certain amount of water, line scale, sediment and other foreign matter which tend to accumulate in the valve body. A regular draining program will increase the life of a valve against damage caused by nbsp;1 Water freezing in the body cavity, causing damage to the body. nbsp;2 An accumulation of foreign matter in the lower part of the body, which could prevent the valve from fully closing, resulting in a throttling action which may cause inefficient sealing. 3 Foreign matter trapped in the body may become lodged between the sealing surfaces of the gate and seats, resulting in scored or damaged sealed. nbsp;4 Venting a Model FC valve is a positive of checking the sealing ability of the gate and seats. If the body vents down to zero pressure with the valve in fully closed position, this is definite indication that sealing surfaces are in good condition. Procedure to Vent or Drain 1. Place the valve gate in a fully opened or fully closed position. 2. Remove the safety cap from either body grease fitting and attach the pressure release tool. CAUTION Remove the safety cap slowly to allow the ball check to sufficiently seal, to avoid uncontrolled venting. Should the ball check fail to seal properly, pressure will continue to blow through the safety cap orifices. You should then retighten the safety cap screw and vent through the other body grease fitting. Once the body pressure is bled to zero you should then attempt to repair the leaking ball check. 3. Screw the stem of the releasing tool into the fitting forcing the ball check off its seat. The valve will vent and drain once the ball check is unseated. nbsp;A program of regular draining and body venting is the most positive way to prevent problems caused by foreign matter in the valve. However, if a regular draining program cannot be followed, it is recommended that valves be drained after the following operations Valveworks USA Model FC Operation and Maintenance Booklet 10 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA 1 After a well has come in and has been cleaned up. 2 After a mudding operation. 3 After a cementing operation. 4 Anytime the valve seems hard to operate by hand and will not fully open or close by the required number of handwheel turns. 5 When the valve is hard to operate from the fully open or fully closed position because it is “pressure locked“ or “Iced-up“. “Pressure locked“ is a condition that may exist with any dual seat expanding type gate valve when body pressure greatly exceeds line pressure. It occurs only in fully closed position and is a positive indication that sealing surfaces are in good condition. “Iced-up“ is a condition caused by a restriction in the flow or a differential in the pressure of gas flow at high pressure, which produces extremely low temperatures. These restrictions or differentials in pressure may be caused by throttling through a valve, by leakage of a closed valve or by Leakage through the stem packing. Valves in service on gas containing hydrates or in fresh water service, exposed to low external temperatures may also “iced-up“. In this case it is advisable to inject alcohol or glycol into the valve body through the drain fitting to combat these conditions. The same procedures are used for injecting alcohol or glycol as are used for valve body lubrication. Do not operate the valve immediately after injecting as these fluids should be retained in the body to per the Antifreeze effect. nbsp;IDENTIFICATION PLATE Identification plates are attached to all Valveworks USA API Production Gate Valves and they are located on the bonnet of each valve and warrants that all products are manufactured to design and quality control specifications of industry standards. The ination listed on the identification plate should be referred to when ordering replacement parts. Valveworks USA Model FC Operation and Maintenance Booklet 11 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA TROUBLESHOOTING Problem Cause Solution Leakage when closed Seats Disconnect from service and replace the seats Leakage when open thru body/bonnet connection Bonnet Seal Ring Disconnect from service and replace the bonnet seal ring Leakage when partially open thru top of bonnet Packing Disconnect from service and replace the packing Leakage at flange Flange Seal Ring Disconnect from service and replace the flange seal ring For extra assistance with these or any other problems, please contact Valveworks USA 1841 Barton Dr. Shreveport, LA 71107 Phone 888-425-0266 Fax 318-425-0934 Valveworks USA Model FC Operation and Maintenance Booklet 12 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA ASSEMBLY INSTRUCTIONS 1.1. Body Sub-Assembly All of the FC body assembly parts. Grease the seal ring side of the body bushing with red Bentone grease. Valveworks USA Model FC Operation and Maintenance Booklet 13 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Insert the greased seal ring side of the body bushing into the body as shown above. Grease and insert the other body bushing. The two should appear as shown above. Valveworks USA Model FC Operation and Maintenance Booklet 14 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Insert the each seat into a retainer plate with the seal ring showing. Grease the seal ring side of the seat and retainer plate. Valveworks USA Model FC Operation and Maintenance Booklet 15 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Insert the greased seal ring side of the retainer plate into the body and onto a body bushing. Insert the other body bushing into the body with the greased seal ring side in contact with the other body bushing. Valveworks USA Model FC Operation and Maintenance Booklet 16 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Insert the gate into the body between the retainer plates. The gate when completely inserted into the valve body. Valveworks USA Model FC Operation and Maintenance Booklet 17 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Insert one of the gate guides as shown. Then, insert the remaining gate guide. Valveworks USA Model FC Operation and Maintenance Booklet 18 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Slide the gate guides completely into the body as shown. Insert the bonnet seal ring into the bonnet seal ring groove. Valveworks USA Model FC Operation and Maintenance Booklet 19 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA The bonnet seal ring should rest in the groove as shown. Apply anti-seize compound to the threads in the bonnet stud holes. Valveworks USA Model FC Operation and Maintenance Booklet 20 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Screw in the studs by hand. All of the studs after being screwed in by hand. nbsp;Valveworks USA Model FC Operation and Maintenance Booklet 21 Proprietary Booklet Do not reproduce without explicit permission of Valveworks USA Using a stud tightening bolt and a torque wrench, tighten the studs into the body. The/p

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