Operating & Maintenance Manual - FMC Technologies

Operating & Maintenance Manual 

Weco ® Model ULT Plug Valves

Doc No: OMM50000121 

Rev: A Page 1 of 18 

OPERATING AND MAINTENANCE MANUAL, WECO MODEL ULT 

PLUG VALVES 

Rev ECN No. Date Reviewed By Approved By Status 

A 5014824 16-DEC-2005 Douglas, Don Soltau, James RELEASED 

Summary: 

Operating, maintenance and storage instructions – WECO ® Model ULT Plug Valves 

Subject to contractual terms and conditions to the contrary, this document and all the information contained herein are the confidential and exclusive 

property of FMC Technologies, and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by FMC.

Table of Contents 



Section Title Page 

1.0 SAFETY INSTRUCTIONS ............................................................5 

2.0 OPERATING INSTRUCTIONS .....................................................5 

3.0 MAINTENANCE INSTRUCTIONS ................................................6 

3.1 REQUIRED TOOLS ......................................................................7 

3.2 DISASSEMBLY .............................................................................7 

3.3 ASSEMBLY...................................................................................8 

3.4 KITS AVAILABLE ..........................................................................9 

4.0 STORAGE INSTRUCTIONS.........................................................9 

5.0 APPENDIX – Assembly/Disassembly Graphics......................10 

6.0 TROUBLE SHOOTING GUIDE...................................................15 



List of Figures 



Figures Page 

Figure 1: Plug Valve Assembly*.......................................................................................6 

Figure 2: Install/Remove the Body Cap .........................................................................10 

Figure 3: Remove the Plug ............................................................................................10 

Figure 4: Install/Remove the Side Segments .................................................................11 

Figure 5: Install/Remove the Seal Segments .................................................................11 

Figure 6: Install/Remove the Wave Springs...................................................................12 

Figure 7: Seal Segment Inspection................................................................................12 

Figure 8: Position of Stem .............................................................................................13 

Figure 9: Align Milled Slot of Plug with Dimples .............................................................13 

Figure 10: Install Wave Springs .....................................................................................14 



WARNINGS 



FMC cannot anticipate all of the situations a user may encounter while installing and 

using FMC products. Therefore, the user of FMC products MUST know and follow all 

applicable industry specifications on the safe installation and use of these products. 

Refer to the FMC product catalogues, product brochures and installation, operating 

and maintenance manuals for additional product safety information or contact FMC at 

800-772-8582. 

WARNING: Failure to follow these warnings could result in serious injury or death! 

1. Do not mix or assemble components, parts or end 

connections with different pressure ratings. Mismatched 

parts may fail under pressure. 

2. Do not use or substitute non-FMC components or parts in 

FMC products and assemblies. 

3. Do not strike, tighten or loosen pressurized components or 

connections. 

4. Do not exceed the rated working pressure or temperature 

rating of the product. 

5. Complete and proper make-up of components and 

connections is required to attain rated working pressure. 

6. Do not use severely worn, eroded or corroded products. 

Contact FMC for more information on how to identify the 

limits of erosion and corrosion. 

7. Follow safe practices when using products in overhead 

applications. Products not properly secured could fall. 

8. Select only appropriate product and materials for the 

intended service: 

9. Do not expose standard service products to sour gas fluids. 

(Refer to NACE MR0175). Do not interchange sour gas 

with standard service components. 



10. Use appropriate safety precautions when working with 

ferrous products in below freezing temperatures. Freezing 

temperatures lower the impact strength of ferrous materials. 

11. Follow manufacturers instructions and Material Safety Data 

Sheet directions when using solvents 

12. Make certain that personnel and facilities are protected 

from residual hazardous fluids before disassembly of any 

product. 

13. If any leakage is detected from FMC products, remove 

them from service immediately to prevent potential damage 

and personal injury. 

1.0 SAFETY INSTRUCTIONS 



The applications of FMC products are in working environments where general 

personnel safety procedures and policies MUST be followed. Always use appropriate 

protective equipment in high pressure, extreme temperature or severe service 

applications. 

2.0 OPERATING INSTRUCTIONS 

WECO ® Model ULT plug valves are primarily used as isolation valves. The ULT plug 

valve is bi-directional; it can isolate flow from either direction. 

1. Prior to use, the valve should be inspected for proper 

operation. The valve should be free of contamination and 

the valve should actuate from open to close position freely. 

WARNING: 

Never look into the valve bore while the valve is in a flowline. Pressure 

and fluids could escape from the valve causing bodily injury. 

2. The valve should be thoroughly flushed with clean fresh 

water after each use and the bore of the valve should be 

sprayed with a light oil or comparable corrosion inhibitor. 

3. While the valve is in the open position, use the grease 

inserts located on both sides of the valve to pump CLIMAX 

plug valve grease into the valve until the grease is flushed 

out into the bore of the valve. 



4. To prevent leakage, malfunctions resulting from internal 

wear or seal degradation, the user must establish a 

preventative maintenance and inspection program. This 

program must include: 

1. Inspection of parts to detect loss of wall thickness that 

may result in decreased pressure capacity. 

2. Routine replacement of seals and inspection for proper 

operation. 

3.0 MAINTENANCE INSTRUCTIONS 

Figure 1: Plug Valve Assembly* 



* Note: Side segments, wave springs and grease plugs are not visible in this view. 



3.1 REQUIRED TOOLS 



Spanner wrench, sledge hammer, screw driver, adjustable wrench, solvent/rags, 

rubber mallet, grease, grease gun, Climax No. 1500, Anti-seize or equivalent, 400 grit 

or finer 3M WETORDRY Tri-M-Ite paper, and personal safety equipment. For the 4” 

ULT plug valve an optional FMC plug installation tool can be used. 

3.2 DISASSEMBLY 

1. Before getting started, bleed all pressure from the line. 

WARNING: 

Loosening the end connections or disassembly of the valve under 

pressure could result in the loss of pipe support, uncontrolled 

movement of the pipe section, valve components, or fluid spillage which 

may cause equipment damage and/or severe injury to operating 

personnel. 

2. If the bottom of the valve is not accessible, you will have to remove the valve from 

the line. You will need at least 2X the height of the valve as clearance on the 

bottom to service. 

3. Prior to assembly, cycle the valve to open to release any fluids that may be 

retained in the body. Leave the valve in the full open position. 

4. Remove the grease fittings using the adjustable wrench. 

5. If the valve is removed from the line, place the assembly on one side on a secure 

surface. Attach the spanner wrench to the body cap (see figure 2). Using the 

sledgehammer to drive the spanner wrench, loosen the body cap from the valve 

body taking special care not to damage the threads and o-ring seal groove. 

6. Place the valve assembly with the valve cavity facing up (see figure 3). Using a 

bar-type puller, remove the plug utilizing the tapped hole on the bottom of plug 

while reacting against the valve body. Pull the plug out of the valve cavity taking 

care not to damage the plug as this is a metal-to-metal sealing surface. An 

optional FMC plug removal tool can be used (4” valve only). 

7. Remove the side segments (see Figure 4) and then the seal segments (see 

Figure 5). If necessary, carefully pry the side segments away from the body using 

a screwdriver (Be careful not to scratch the valve cavity). 

8. Remove the booster springs from each seal segments (see figure 6). 

Note: Do not remove the plug by pushing on the stem. If the stem is 

removed, a separate procedure is required to re-install the stem and 

stem seals to prevent leakage. 

9. Remove and properly discard the old grease on the parts and inside the valve 

cavity. 



3.3 ASSEMBLY 



WARNING: Always use solvents in accordance with Material Safety Data Sheet. 

1. Check/verify parts against bill of materials; clean all parts and inspect for nicks, 

burrs or excessive wear. 

2. If the work is being performed with the valve out of line, position the body so that 

the assembly can be performed with the valve cavity facing upward. Preferably, 

the valve is to be placed on a table modified to allow the passage of the stem 

through the table top. 

3. Install the inner and outer s-seals onto the seal segments. Make sure that 

orientation is correct (after installation a single “o-ring bump” should face outward 

in each s-seal). Apply a thin film of Lubriplate to the outside diameter surfaces of 

the seal segments. Using your index finger remove the excess Lubriplate 

between the two s-seals. If too much Lubriplate is in between the s-seals, 

difficulty in the installation of the plug could occur later. Apply a liberal amount of 

plug valve grease to the ID of the seal segments. Insure that the ramp angle is 

covered. Carefully install the two seal segments into the valve cavity while 

aligning the locator pin holes with the locator pins in the valve cavity (see Figure 

5). 

4. Inspect the lead-in chamfer of the seal segments; this area should be free of 

nicks, chips and sharp edges (see figure 7). Apply a liberal amount of Lubriplate 

to the lead-in chamfer of the seal segments. 

5. Apply a liberal amount of plug valve grease to the side segments and install them 

into the valve cavity. It may be necessary to push the seals segments outward 

when installing the side segments (see figure 4). 

6. Check plug for nicks, scratches and sharp edges on the lead-in chamfer. Apply a 

liberal amount of grease to the OD of the plug and Lubriplate to the lead-in 

chamfer. Verify the stem is in the open position (The position of the tang of the 

stem should be perpendicular (vertical) to the fluid bore of the valve; see figure 8). 

Align the milled slot of the plug with the dimples of the seal segments (see figure 

9). Using an arbor press gently press the plug in. Verify that the plug has seated 

correctly by looking in the bore; the bore of the plug should be inline with the bore 

of the body. An optional FMC plug installation tool can be used (4” valve only). 

7. Drive all four booster springs in the slots formed by the outer diameter of the seal 

segments and the valve cavity using a hammer and a brass punch (see figure 

10). It is important that the brass punch is used in driving the last inch of the 

booster springs into the assembly to prevent scoring the valve cavity sealing area. 

8. Install the back-up rings and o-rings onto the body cap. Verify that the orientation 

is correct using the assembly drawing in figure 1. Apply anti-seize to the threads 





of the body cap and Lubriplate to the seals. Install the body cap on the assembly 

(see figure 2). 

3.4 KITS AVAILABLE 

There are two types of kits available for servicing the WECO ® Model ULT Plug Valve. 

• Repair Kit w/ Plug: This is the most commonly needed kit and consists of the 

parts recommended for rebuilding the valve. This kit includes the plug. 

• Repair Kit w/o Plug: This is the most commonly needed kit and consists of the 

parts recommended for rebuilding the valve. This kit includes the plug. 

Table 1: WECO ® Model ULT Plug Valve Kits – Standard Service & Sour Service 

Standard 

Kit w/ Plug 

Standard 

Kit w/o 

Plug 

Sour Gas 

Kit 

3” ULT100 3” ULT150 

3-1/16” 

ULT150 

3” ULT200 4” ULT100 4” ULT150 


property of FMC Technologies, and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by FMC. 

4-1/16” 

ULT150 

N/a 3265500 P528304 P519446 P518243 3268180 P531289 

N/a P510214 n/a n/a P519505 n/a n/a 

3266024 n/a n/a P525393 n/a n/a n/a 

4.0 STORAGE INSTRUCTIONS 

When not in use, the valve should be stored in an area that protects it from sun, rain, 

sand, and other debris. Before storing the valve, ensure that the operating fluids 

have been removed by flushing with water. After cleaning, fully drain all fluids from 

the valve and spray the valve with a water displacing lubricant such as a Teflon / oil 

mix. Spray inside both flow bores as far into the valve as possible. Also spray the 

threads of the union ends. With the valve in the open position, use the grease inserts 

to grease the valve until the grease is flushed out into the bore of the valve. During 

long-term storage keep the valve dry and painted to prevent corrosion.

5.0 APPENDIX – Assembly/Disassembly Graphics 

Figure 2: Install/Remove the Body Cap 

Figure 3: Remove the Plug 





Figure 4: Install/Remove the Side Segments 

Figure 5: Install/Remove the Seal Segments 





Figure 6: Install/Remove the Wave Springs 

Figure 7: Seal Segment Inspection 





Figure 8: Position of Stem 

Figure 9: Align Milled Slot of Plug with Dimples 





Figure 10: Install Wave Springs 





6.0 TROUBLE SHOOTING GUIDE 

Figure 11. Leak path diagram 

WARNING: Always remove pressure from line before Trouble Shooting. 



Problem Possible Cause Recommended Repair 

Leak at body cap. 

Figure 11, leak path 

“A”. 

Damage body cap o-ring. Incorrect 

installation of backup ring 

Dents and deep scratches in the 

body cavity or body cap seal area. 

Remove body cap. Replace body cap o-ring and 

backup ring. Verify the backup ring is installed with 

concave side toward the o-ring. The o-ring should be 

located in the groove furthest from the threads. Fully 

grease and pressure test the valve to full working 

pressure prior to returning to service. 

Disassemble valve. Inspect body cavity for scratches, 

dents or corrosion in the body cap sealing area. 

Repair minor scratches and corrosion with 400 grit 

WETORDRY. Deep dents or gouges may require the 

body to be replaced. Fully grease and pressure test 

the valve to full working pressure prior to returning to 

service. 






Leaking between seal 

segment and body. 


“B”. 

Leak between seal 

segment and plug. 


“C” 

Contamination or foreign debris 

between the seal segment and body. 

Damaged or aged seal segment face 

seal. 

Damaged seal segment seal area 

due to scratches, corrosion, or 

erosion. 

Damaged body seal segment sealing 

surface due to scratches, corrosion, 

or erosion. 

Contamination or foreign debris 

between the seal segment and plug. 

Damaged seal segment due to 

scratched, corrosion or erosion. 

Damaged plug sealing surface due 

to scratches, corrosion, erosion, 

chipped or damaged plating. 

Cycle opened and closed several valve times. Fully 

grease valve and cycle several more times. 

Dissemble valve. Replace seal segment face seal. 

Full grease and pressure test the valve to full working 


Disassemble valve. Inspect seal segments for 

scratches, dents or corrosion in the body cap sealing 

area. Repair minor scratches and corrosion with 400 

grit WETORDRY. Deep dents or gouges may require 

the seal segments to be replaced. Fully grease and 

pressure test the valve to full working pressure prior to 

returning to service. 

Disassemble valve. Inspect body to seal segment for 




the body to be replaced. Fully grease and pressure 

test the valve to full working pressure prior to returning 

to service. 

Cycle opened and closed several valve times. Fully 

grease valve and cycle several more times. 

Disassemble valve. Inspect seal segments for 




the seal segments to be replaced. Fully grease and 



Disassemble valve. Inspect plug for scratches, dents 

or corrosion in the sealing area. Repair minor 

scratches and corrosion with 400 grit WETORDRY. 

Deep dents or gouges may require the plug to be 

replaced. Fully grease and pressure test the valve to 

full working pressure prior to returning to service. 



Problem 

Leak between valve 

body and 

operator/actuator. 


“D” 



Possible Cause Recommended Repair 

Hydraulic oil from the hydraulic 

operator (if applicable). 

Damaged stem or stem adapter orings 

or back-ups. 

Damaged or contaminated stem to 

stem adapter seal surfaces. 

Damaged or contaminated body to 

stem adapter seal surfaces. 

Check hydraulic inlet and outlet fitting for leaks. 

Remove operator/actuator and test for leaks. Replace 

actuator if leakage is found. Fully grease and pressure 

test the valve to full working pressure prior to returning 

to service. 

Disassemble operator/actuator. Disassemble valve. 

Inspect the stem and stem adapter o-rings and backups 

for damage. Replace any damages o-ring and 

back-ups. Fully grease and pressure test the valve to 



Inspect the stem to stem adapter for scratches, dents 

or corrosion. Repair minor scratches and corrosion 

with 400 grit WETORDRY. Deep dents or gouges may 

require the stem or stem adapter to be replaced. Fully 




Inspect the stem adapter seal area for scratches, dents 

or corrosion. Repair minor scratches and corrosion 

with 400 grit WETORDRY. Deep dents or gouges may 

require the body to be replaced. Fully grease and 








Leak at grease fitting. 


“E”. 

Loose grease fitting. Tighten the grease fitting. Fully grease and pressure 

test the valve to full working pressure prior to 

Damaged or contaminated grease 

fitting. 

Damaged or contaminated grease 

fitting threads. 

Damaged body grease fitting 

threads. 


Remove grease fitting and replace with a new 

grease fitting using Teflon tape on threads. Fully 



Remove grease fitting. Clean and inspect the 

threads. If the threads are intact , replace the Teflon 

tape on the grease fittings and install in the body. If 

the threads are damaged, replace the grease fitting 

with a new grease fitting using Teflon tape on the 

threads. Fully grease and pressure test the valve to 


Remove the grease fitting. Clean and inspect body 

threads. If the threads are intact, replace the Teflon 

tape on the grease fitting and install in the body. If 

threads are damaged replace the body. Fully 





FMC Technologies, Inc 

1803 Gears Road 

Houston, Texas 77067 

Tel 281.260.2121 

Fax 281.260.2122 

Manufacturing 

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Stephenville, Texas 76401 

Tel 1.800.772.8582 (U.S.) 

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