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Model FC Gate Valve Service and Operation Manual

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Model FC 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 FC 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 FC 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 FC 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 ination 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 pering repairs. MODEL FC SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 3 TABLE OF CONTENTS APPLICATIONS 4 TEMPERATURE RATING 4 TRIM CHART 4 ORDERING INATION 5 OPERATION 5 ASSEMBLY DRAWING / BOM 6-8 DISASSEMBLING THE BODY 9 DISASSEMBLING THE BONNET SUB-ASSEMBLY 10 PERIODIC MAINTENANCE 11-12 PROCEDURE TO VENT OR DRAIN 12-13 TROUBLESHOOTING 13 MAINTENANCE INTERVALS 13 TEST PROCEDURE 14 HYDROSTATIC SEAT TEST 15 VISUAL INSPECTION 16 FIELD HOOK UP INSTRUCTIONS 16 REPLACING BROKEN SHEAR PIN 17 BACK SEATING PROCEDURE 18 MODEL FC SERVICE AND OPERATION MANUAL MODEL FC SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 4 APPLICATIONS Valveworks USA Model FC gate valves can be applied to the following sizes and working pressures. APPLICATION OPTIONS AVAILABLE GATE VALVE SIZE 1-13/16, 2-1/16, 2-9/16, 3-1/8, 3-1/16, 4-1/16 MAXIMUM ALLOWABLE WORKING PRESSURE MAWP 3M, 5M, 10M, 15M TEMPERATURE RANGE -18C TO 180C 0F TO 350F The Model FC Gate Valves covered in this manual are suitable for perance requirement levels 1 and 2, PR1 and PR2 respectively. 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 X -18 180 0 350 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. MODEL FC SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 5 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 OPERATION Valveworks USA Model FC gate valves are hand wheel operated HWO 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. Below are some steps which have to be followed at all times 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. 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 identification plate. 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. The stem bearings can be replaced while the valve is in service. Safety precautions must be taken before work is conducted. A minimum of two safety barriers must be used. When lubricating the body do not exceed the maximum API working pressure stamped on the identification plate. The valve should be fully opened or fully closed during lubrication of the body or seats. Seat lubrication pressures should not exceed the maximum allowable working pressure of the valve. Cycling the valve during the greasing operation will help displace the old grease with the new. This of operation will prevent damage to the sealing surfaces of the gate and seats, and will increase the life of the valve. MODEL FC SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 6 MODEL FC - SLAB GATE 2-1/16” 10M HANDWHEEL OPERATED MODEL FC SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 7 MODEL FC - BILL OF MATERIALS ITEM DESCRIPTION QTY 1 BODY 1 2 BONNET 1 3 BONNET SEAL RING 1 4 BODY GREASE FITTING 1 5 STUDS AND BOLTS 8 6 BODY BUSHING SEAL 2 7 SEAT 2 8 BODY BUSHING 2 9 SEAT SEAL 2 10 GATE GUIDE 2 11 GATE SLAB 1 12 TORRINTION BEARINGS 2 13 PACKING GLAND 1 14 BEARING CAP 1 15 STEM ADAPTER 1 16 STEM ADAPTER 0-RING 1 17 STEM 1 18 SHEAR PIN 1 19 GREASE ALEMITE FITTING 2 20 HANDWHEEL 1 21 BEARING CAP O-RING 1 22 HANDWHEEL BOLT 1 23 HANDWHEEL NUT 1 24 RETAINING PLATE 2 25 OPTI-SEAL 1 25 BACK-UP RING 2 MODEL FC SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 8 PART NUMBER BREAKDOWN 290 - A B X Y “A” MAWP “B” BORE SIZE 5 5,000 PSI 1 1-13/16” 7 10,000 PSI 2 2-1/16” 8 15,000 PSI 3 3-1/8” 5M 3-1/16” 10M,15M 4 4-1/16” “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 resulting in a throttling action that 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. VENTING OR DRAINING A VALVE MODEL FC SERVICE AND OPERATION MANUALWWW.VALVEWORKSUSA.COM SALESVWUSA.US PROPRIETARY BOOKLET OF VALVEWORKS USA. DO NOT REPRODUCE WITHOUT EXPLICIT PERMISSION. Page 13 A regulatory scheduled greasing program 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 After a well has come in and has been cleaned up. After a mudding operation. After a cementing operation. Anytime the valve seems hard to operate by hand and will not fully open or close by the required number of hand wheel turns. When the valve is hard to operate from the fully open or fully closed position because it is “pressure locked” or “Iced-up”. “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. This happens by leakage of a closed valve or leakage through the stem packing. Valves in service on gas containing hydrates or in fresh water service, which are exposed to low external temperatures can also get “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. TROUBLESHOOTING PROBLEM CAUSE SOLUTION Handwheel backoff allows the gate to float Handwheel Grease valve body and cycle valve open to closed. If leak is still present, then remove the valve from service. Leakage when closed Seats Disconnect from service and check for the condition of the seats. Leakage between body and bonnet Bonnet Seal Ring Disconnect from service and replace the bonnet seal ring. Leakage observed from the bearing cap Packing Disconnect from service and replace the packing. Leakage at flange Flange Seal Ring Disconnect from service and replace the flange seal ring. Handwheel spins freely Broken Shear Pin Replace broken shear pin as explained below. MAINTENANCE INTERVALS PROCEDURE RECOMMENDED INTERVAL Vent or Drain See Page 12 Cycle Open to Close Semi-Annually Disconnect and Test Annually MODEL FC SERVICE AND OPERATION MANUAL/p

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