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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

Doc No: OMM50000121

Rev: A Page 2 of 18

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

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.


List of Figures

Doc No: OMM50000121

Rev: A Page 3 of 18

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

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.


WARNINGS

Doc No: OMM50000121

Rev: A Page 4 of 18

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.

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.


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

Doc No: OMM50000121

Rev: A Page 5 of 18

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.

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.


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*

Doc No: OMM50000121

Rev: A Page 6 of 18

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

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.


3.1 REQUIRED TOOLS

Doc No: OMM50000121

Rev: A Page 7 of 18

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.

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.


3.3 ASSEMBLY

Doc No: OMM50000121

Rev: A Page 8 of 18

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

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.


Doc No: OMM50000121

Rev: A Page 9 of 18

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

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.

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

Doc No: OMM50000121

Rev: A Page 10 of 18

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.


Figure 4: Install/Remove the Side Segments

Figure 5: Install/Remove the Seal Segments

Doc No: OMM50000121

Rev: A Page 11 of 18

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.


Figure 6: Install/Remove the Wave Springs

Figure 7: Seal Segment Inspection

Doc No: OMM50000121

Rev: A Page 12 of 18

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.


Figure 8: Position of Stem

Figure 9: Align Milled Slot of Plug with Dimples

Doc No: OMM50000121

Rev: A Page 13 of 18

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.


Figure 10: Install Wave Springs

Doc No: OMM50000121

Rev: A Page 14 of 18

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.


6.0 TROUBLE SHOOTING GUIDE

Figure 11. Leak path diagram

WARNING: Always remove pressure from line before Trouble Shooting.

Doc No: OMM50000121

Rev: A Page 15 of 18

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.

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.


Doc No: OMM50000121

Rev: A Page 16 of 18

Problem Possible Cause Recommended Repair

Leaking between seal

segment and body.

Figure 11, leak path

“B”.

Leak between seal

segment and plug.

Figure 11, leak path

“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

pressure prior to returning to service.

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

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.

Cycle opened and closed several valve times. Fully

grease valve and cycle several more times.

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 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.

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.


Problem

Leak between valve

body and

operator/actuator.

Figure 11, leak path

“D”

Doc No: OMM50000121

Rev: A Page 17 of 18

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

full working pressure prior to returning to service.

Disassemble operator/actuator. Disassemble valve.

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

grease and pressure test the valve to full working

pressure prior to returning to service.

Disassemble operator/actuator. Disassemble valve.

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

pressure test the valve to full working pressure prior to

returning to service.

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.


Doc No: OMM50000121

Rev: A Page 18 of 18

Problem Possible Cause Recommended Repair

Leak at grease fitting.

Figure 11, leak path

“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.

returning to service.

Remove grease fitting and replace with a new

grease fitting using Teflon tape on threads. Fully

grease and pressure test the valve to full working

pressure prior to returning to service.

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

full working pressure prior to returning to service.

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

grease and pressure test the valve to full working

pressure prior to returning to service.

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.


FMC Technologies, Inc

1803 Gears Road

Houston, Texas 77067

Tel 281.260.2121

Fax 281.260.2122

Manufacturing

2825 West Washington

Stephenville, Texas 76401

Tel 1.800.772.8582 (U.S.)

Tel 254.968.2181

Fax 254.968.5709

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Tel (44) 1224.898.555

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Tel (65) 6.316.1908

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Tel 405.787.6301

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