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Model FM1 Gate Valve Service and Operation Manual

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Model FM1 Gate Valve 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 FM1 GATE VALVE 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 FM1 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 FM1 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 specifi c 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 CUSTOMERSERVICEVWUSA.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 fi ttings fi rst, 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 verifi ed 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 FM1 SERVICE AND OPERATION MANUAL TABLE OF CONTENTS APPLICATIONS 4 TEMPERATURE RATING 4 TRIM CHART 4 ORDERING INFORMATION 5 OPERATION 5 ASSEMBLY DRAWING 6-7 BOM 8-9 DISASSEMBLING THE VALVE 10-12 BACKSEATING PROCEDURE 13-14 PERIODIC MAINTENANCE 14-17 TROUBLESHOOTING 18 MAINTENANCE INTERVALS 18 TEST PROCEDURE 19 HYDROSTATIC SEAT TEST 20 STUDDED OUTLET INSTALLATION/TESTING 21 VISUAL INSPECTION 22 FIELD HOOK UP INSTRUCTIONS 22 LIMITED PRODUCT WARRANTY 23-24 TECHNICAL DATA 25WWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 4 MODEL FM1 SERVICE AND OPERATION MANUAL APPLICATIONS Valveworks USA FM1 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 10M, 15M, 20M TEMPERATURE RANGE -60C TO 121C -75F TO 250F The fl anged outlet gate valve is rated for 10,000 psi and 15,000 psi working pressure and the studded outlet gate valve of this product line is rated for 10,000 psi, 15,000 psi, and 20,000 psi. 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 defi ned by NACE MR0175. b In compliance with NACE MR0175. As shown by API-6A. For specifi c details consult Valveworks USA. MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 5 ORDERING INFORMATION The following information should be provided with any request for quote or order placement of Valveworks USA FM1 Gate Valves nbsp;API 6A Requirements PR-PSL nbsp;Temperature Rating API 6A nbsp;Material API 6A nbsp;Any Special Test Requirements nbsp;Any Special Material Requirements nbsp;Any Special Coating or Protection Requirements nbsp;Other Specifi cations and/or Certifi cations OPERATION The Valveworks USA Model FM1 gate valves are Ball Screw operated valves. The gate of the MODEL FM1 Valve is a one piece slab gate that uses two fl oating 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. nbsp;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;To hydrostatically test the valve body to working 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 identifi cation plate. nbsp;During storage always leave the valve in the fully opened position. This will prevent damage to the sealing area of both the gate and seats. nbsp;Always remove the valve from service before work is performed on the stem bearings. nbsp;When lubricating the body do not exceed the maximum API working pressure stamped on the identifi cation plate. nbsp;The valve should be fully closed or fully opened during lubrication of the body cavity. Lubrication pressures should not exceed the maximum allowable API test pressure. This method of operation will prevent damage to the sealing surfaces of the gate and seats, and will increase the life of the valve. MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 6 MODEL FM1 - STUDDED X STUDDED BODY HANDWHEEL OPERATED OPERATION BI-DIRECTIONAL - SLAB GATE TO OPEN AND CLOSE BACKOFF HANDWHEEL 1/4 TURN GATE SHOWN IN OPEN POSITION MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 7 MODEL FM1 SERVICE AND OPERATION MANUAL MODEL FM1 - FLANGED X FLANGED BODY HANDWHEEL OPERATED OPERATION BI-DIRECTIONAL - SLAB GATE TO OPEN AND CLOSE BACKOFF HANDWHEEL 1/4 TURN GATE SHOWN IN OPEN POSITIONWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 8 MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 9 PART NUMBER BREAKDOWN 29 A - FM1 - B C X Y “A” BODY TYPE “B” MAWP “C” BORE SIZE 0 FLANGED 7 10,000 PSI 5 5-1/8” 8 STUDDED 8 15,000 PSI 7 7-1/16” 9 FLANGED X STUDDED 9 20,000 PSI “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 1F 1026 2 410SS FORGED 2A S42400 3 174SS 3A NITRONIC 50 2 HARDFACE-STELLITE 6 SPRAY amp; FUSE 4 316SS 4A 316/304SS 4B 304SS 3 HARDFACE - TUNGSTEN CARBIDE 5 BRONZE 6 INCONEL 718 6A INCONEL 725 4 HARDFACE - COLMONOY 5 6B INCONEL X750 7 MONEL 5 ELECTROLIS NICKEL 8 A487-4D 8A A487-4C 6 WELD ON HARDFACE 8B CA15 8C CF8M 7 ZINC PLATE 8D CF3M 8 XYLAN COATING 8E CA6NM 9 4130 INCONEL 625 CLAD 9 STELLITE 6 9A PLASTIC 9A 4130SS-316-RING GROOVE 9B STELLITE 3 The last two digits in the part no’s vary with “X” Material Type and “Y” Coating. The table below gives the different available material types and coatings. Please refer to the valve tag to know the material type and coating on the valve parts. MODEL FM1 SERVICE AND OPERATION MANUAL MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 10 DISASSEMBLING THE VALVE 1. Horizontal Orientation Unscrew and remove the Handwheel Nut with a crescent wrench. 2. Remove the Handwheel. 3. Unscrew and remove Cover Plate Screws with an allen wrench. 4. Remove the Cover Plate. Note Use a wire brush to clean paint off the stem adapter. 5. Unscrew and remove Set Screws on the Ball Screw Housing. 7. Rotate handwheel clockwise while unscrewing the Ball Screw Housing counter-clockwise. 6. Replace the Handwheel. 8. Rotate the handwheel counter- clockwise to back up the Ball Screw Housing enough to access the Spirolox Retainer Ring. 9. Remove the Handwheel. MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 11 10. Remove the Retainer Ring with a screwdriver. 11. Remove the Ball Screw Housing. 12. Remove the Roll Pin to disengage the Ball Screw. 13. Remove the Ball Screw Assembly. 17. Remove the Upper Bonnet. 18. This gives access to the Bonnet Seal Ring, Gate, and Seats. 15. Vertical Orientation Unscrew and remove the Packing Retainer Locknut and Packing Retainer with an expanding wrench. 14. Remove the Bearing Sleeve and Retainer Ring. 16. Unscrew and remove the Bonnet Nuts using a torque wrench. MODEL FM1 SERVICE AND OPERATION MANUAL MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 12 20. Remove the Gate Guides. 19. Remove the Gate and Stem Assembly. 21. Remove the Seats. 26. If required, the Lower Bonnet may be removed. Follow the same steps used to remove the Upper Bonnet. 24. Repeat steps 22 and 23 for the Balancing Stem. 22. Remove Gate Nut Set Screws us- ing an allen wrench. 23. Unscrew and remove the Gate Nut and Operating Stem. 25. Unscrew and remove Set Screw located on the Stem Protector with an allen wrench. 26. Unscrew and remove the Stem Protector. MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 13 2. Remove the Lower Stem Protector. 1. Remove the Backseat Gland. 3. Operate the valve to the fully open position and hold. The balance stem should be mostly into the lower bonnet. 5. Have a second operator turn the hand wheel forcing the backseat to engage and hold. Do not apply excessive force to the hand wheel. No “cheater pipes” are needed. 4. Install the backseat engagement tool and thread on the cap until it bottoms out. Do not over tighten the cap. 6. While the second operator holds the backseat engaged, thread the supplied bolt into the cap. BACKSEATING PROCEDURE - OPERATING STEM 7. Using a wrench to tighten the bolt down to lock the stem/backseat into position. Do not over tighten the bolt. Approximately 50 ft*lbf Note Use fi ne sand paper to remove any burrs left on the balance stem. Additionally, injecting grease into the grease port helps pushing the packing out of the bonnet. 9. Use a bleeder style fi tting to relieve pressure below the packing. Be cautious of well gases ieH 2 S It is up to the operator to know what is in their wells. MODEL FM1 SERVICE AND OPERATION MANUAL MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 14 2. Carefully insert the FM Series Backseat Tool about 1 inch. Be sure the supplied nut is threaded under the hand wheel as shown. 1. Remove the Backseat Gland. 3. Move the valve to the closed position and ensure the backseat is tightly held engaged. Bottom View Shown 5. While holding both hand wheels tight, tighten the lock nut down to hold everything engaged. 4. While one operator holds the backseat engaged, have another operator thread in the backseat tool and tighten the backseat tool hand wheel. Do not over tighten the tool. 6. The backseat is now engaged. Use a bleeder style fi tting to relieve the pressure. Note All warnings of the operating stem backseating procedure apply here as well. BACKSEATING PROCEDURE - BALANCE STEM PERIODIC MAINTENANCE The Model FM1 gate valves are non-lubricated valves and 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. Valveworks USA API Gate Valves at 15,000 PSI W.P. are supplied with 9/16” 17-4SS autoclave fi tting connections. MODEL FM1 SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 15 MAINTENANCE TOOLS To perform normal maintenance and lubrication, the following tools are recommended Grease pump with adapter and coupling Safety pressure releasing tool VALVE BODY LUBRICATION Valve body lubrication reduces operating friction and prevents the accumulation of water, lime scale, sediment, and other foriegn matter. It is recommended that the valve is greased on a regular basis and the body cavity be at least 3/4 full of grease. Recommended Lubricant Valveworks USA OEM Grease Part 400-0002 2. Remove the safety cap from the bonnet grease fi tting. 1. Partially open the valve. 3. Install the grease hose fi tting with gauge to the bonnet grease fi tting. 4. Inject lubricant into the body as required. CAUTION During pressurized valve body lubrication, pressure applied to the valve body with the grease gun must not exceed maximum working pressure of the valve being lubricated. 5. If there is no fl ow through the valve, open and close the valve/p

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