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Model FM4 (Handwheel Operated) Service and Operation Manual

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Model FM4 (Handwheel Operated) Service and Operation Manual

pWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 1 WWW.VALVEWORKSUSA.COM SALESVWUSA.US MODEL FM4 HANDWHEEL OPERATED SERVICE AND OPERATION MANUAL PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION.WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 2 MODEL FM4 SERVICE AND OPERATION MANUAL INTRODUCTION In appreciation to our customer for purchasing our product, we have prepared this Operation Manual to assist you in the Operation, Maintenance, Assembly and Installation of the Valveworks USA API 6A Model FM4 Gate Valve. We encourage following the 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. To contact a representative for more specific information pertaining to a special problem 1650 SWAN LAKE ROAD BOSSIER CITY, LA USA 71111 PHONE 318-425-0266 FAX 318-425-0934 TOLL FREE 888-425-0266 EMAIL SALESVWUSA.US WEBSITE WWW.VALVEWORKSUSA.COM QUALITY Valveworks USA management and employees are committed to continually improve the effectiveness of our quality management system to produce a quality assured product which meets or exceeds our customer’s expectations and requirements. SAFETY Caution must be taken as to the surrounding area and its potential dangers of projectiles. Pressure kills Even a loose, stand alone valve may contain trapped pressure which will turn any component into a projectile missile when disassembled, causing injury or death. Never stand over a component or in its path of release during assembly. Always operate the valves from the open to close position slowly releasing trapped pressure. Always remove fittings first, taking extreme caution to their potential danger as a projectile. If the valve is frozen and can not be operated, take extreme caution to the disassembly of the components. Caution should be taken when handling components during disassembly and assembly, as most components are heavy, greasy, hard to handle and have edges which can cause injury. Always be cautious of how the valve is positioned and standing. Be sure the valve is secured in position so there is no possible chance of tipping over. Never apply test pressure above the manufacturers rated working pressure. The shell test pressure above the working pressure has already been tested by the manufacturer and is not required after the initial assembly test of the valve. The manufacturer has already verified the quality of the valve shell body components and will void the warranty from the manufacturer if the valve is pressure tested above the rated working pressure indicated for the valve. Always wear steel toes shoes, hard hat, eye and ear protection while performing repairs.WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 3 MODEL FM4 SERVICE AND OPERATION MANUAL TABLE OF CONTENTS APPLICATIONS 4 TEMPERATURE RATING 4 TRIM CHART 4 ORDERING INFORMATION 5 OPERATION 5 ASSEMBLY DRAWING 6,8 BILL OF MATERIALS 7,9 DIS-ASSEMBLING THE VALVE 11-12 DIS-ASSEMBLING THE BONNET SUB-ASSEMBLY 13-14 PERIODIC MAINTENANCE 14-15 INSTALLING INJECTION PACKING 16 PROCEDURE TO VENT OR DRAIN 17 TROUBLESHOOTING 18 MAINTENANCE INTERVALS 18 TEST PROCEDURE 19 HYDROSTATIC BODY TEST 20 HYDROSTATIC SEAT TEST 21 VISUAL INSPECTION 22 FIELD HOOK-UP INSTRUCTIONS 22WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 4 MODEL FM4 SERVICE AND OPERATION MANUAL APPLICATIONS Valveworks USA FM4 gate valve unit can be applied to the following sizes and working pressures. APPLICATION OPTIONS AVAILABLE GATE VALVE SIZE 5-1/8”, 7-1/16” MAXIMUM ALLOWABLE WORKING PRESSURE MAWP 2M, 3M, 5M TEMPERATURE RANGE -60C TO 121C -75F TO 250F TEMPERATURE RATING TEMPERATURE CLASSIFICATION OPERATING RANGE C F K -60 82 -75 180 L -46 82 -50 180 N -46 60 -50 140 P -29 82 -20 180 S -18 60 0 140 T -18 82 0 180 U -18 121 0 250 V 2 121 35 250 TRIM CHART MATERIAL CLASS MINIMUM MATERIAL REQUIREMENTS 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 MR0175. b In compliance with NACE MR0175. As shown by API-6A. For specific details consult Valveworks USA.WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 5 MODEL FM4 SERVICE AND OPERATION MANUAL ORDERING INFORMATION The following information should be provided with any request for quote or order placement of Valveworks USA FM4 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 OPERATION Valveworks USA Model FM-4 Expanding Gate and FM-4 Slab Gate valves are generally hand wheel operated. The expanding gate of the MODEL FM-4 Valve consists of two pieces major and minor acting one against the other by means of a dual wedge expanding when the valve is either fully closed or fully opened. The expansion effect of the wedge against the seats, through the parallel faces of the gate, provides a strong and positive seal against pulsations and vibrations created by flow conditions. The MODEL FM-4 slab gate 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. 2. Do not remove the molybdenum disulfide coating from internal parts. This coating serves as a lubricantand 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 fully opened or fully closed position. This will tightly wedge the gate and segment against the seats and prevent damage to the sealing area of both the gate and seats. 5. When lubricating the body do not exceed the maximum API working pressure stamped on the identification plate. 6. The valve should be fully closed or fully opened during lubrication of the body or seats. 7. Seat lubrication pressures should not exceed the maximum allowable API test pressure. The expanding gate design of our Model FM4 valves provides a tight mechanical positive seal; however to properly effect this seal, the valve must be fully opened or fully closed in order to wedge the gate and segment against the seats. Do not back off the hand wheel. 8. This method of operation will prevent damage to the sealing surfaces of the gate and seats, and will increase the life of the valve. WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 6 MODEL FM4 SERVICE AND OPERATION MANUAL MODEL FM4 - EXPANDING GATE 7-1/16” 3M HANDWHEEL OPERATED WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 7 MODEL FM4 - BILL OF MATERIALS ITEM DESCRIPTION QTY 1 UPPER BONNET 1 2 LOWER BONNET 1 3 GATE ASSEMBLY 1 4 GATE GUIDE 2 5 STUD W/ NUT 32 6 PACKING RETAINER BUSHING 1 7 BONNET SEAL RING, UPPER 1 8 BONNET SEAL RING, LOWER 1 9 BEARING HOUSING 1 10 STEM 1 11 ALEMITE FITTING 1 12 PACKING INJECTION FITTING 1 13 BODY GREASE FITTING 2 14 PACKING 1 15 BEARINGS 2 16 HANDWHEEL 1 17 O-RING 1 18 HANDWHEEL NUT 1 19 BODY 1 20 SEAT 2 21 O-RING 2 MODEL FM4 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 8 MODEL FM4 SERVICE AND OPERATION MANUAL MODEL FM4 - SLAB GATE 7-1/16” 3M HANDWHEEL OPERATED WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 9 MODEL FM4 - BILL OF MATERIALS ITEM DESCRIPTION QTY 1 UPPER BONNET 1 2 LOWER BONNET 1 3 GATE, SLAB 1 4 LIFT NUT 1 5 GATE GUIDE 2 6 STUD W/ NUT 32 7 PACKING RETAINER BUSHING 1 8 BONNET SEAL RING, UPPER 1 9 BONNET SEAL RING, LOWER 1 10 BEARING HOUSING 1 11 STEM 1 12 ALEMITE FITTING 1 13 PACKING INJECTION FITTING 1 14 BODY GREASE FITTING 2 15 PACKING 1 16 BEARINGS 2 17 HANDWHEEL 1 18 O-RING 1 19 HANDWHEEL NUT 1 20 BODY 1 21 SEAT 2 22 O-RING 2 MODEL FM4 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 10 MODEL FM4 SERVICE AND OPERATION MANUAL “X” MATERIAL TYPE “Y” COATING 1 4130 0 NONE; PHOSPHATE, MOLY, STANDARD PAINT/COATING, POWDER COAT 1A 4140 1B 1040 1C 1018 1D 1020 1E SA285-C 1 NITRIDE QPQ-PHOSPHATE; EXCEPTION - FC BODY BUSHING - DO NOT NITRIDE 1F 1026 2 410SS FORGED 2A S42400 3 174SS 3A NITRONIC 50 2 HARDFACE-STELLITE 6 SPRAY any good grade 3, 4, or 5 grease is recommended for body lubrication. Caution is to be taken so as not to use soluble grease near the product flowing through the valve. Approximately one pound of grease per inch of nominal valve bore size is sufficient to provide adequate lubrication. Place the valve in the fully opened or fully closed position before lubricating the valve. 2. Install the grease gun fitting with gauge on either of the grease fittings. 1. Remove the safety caps from both safety ball check fittings. 3. Install the pressure release tool on the other grease fitting. The pressure release tool must be able to contain pressure by sealing off the grease fitting. A 1/2” NPT 10,000 psi W.P. needle valve may be attached to the outlet of the pressure release tool as a safety measure, in case the ball check does not hold the pressure. Open 1/2” needle valve, rotate handle of pressure release tool clockwise until main stem makes contact with the ball check. If the body pressure does not bleed down completely, the volume of the pressure released can be controlled with the pressure release tool. Continue injecting grease into the body through the other grease fitting. After lubrication, reinstall the two safety caps and operate the valve several times and return to desired position. 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./p

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