1
User’s Manual
E Type Gate Valve(with fail safe actuator)
This document contains proprietary and confidential information which belongs to National Oilwell Varco. Reproduction, in whole or part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco. This document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned.
National Oilwell Varco 7th Avenue Team Valley Trading Estate Gateshead Tyne and Wear NE11 0JW Phone +44191 4820022 Fax +44191 4878835
Document Number M49
Rev. 5
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7th Avenue, Team Valley Trading Estate Gateshead, Tyne and Wear NE11 0JW, England
Phone 44 0 191 4820022 Fax 44 0 191 4878835
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Table of Contents
General Information Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal Training .......................... Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . General System Safety Practices . . . . . . . . . . . . . . . . . Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . .
Parts Location
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Page 3 Page 3 Page 3 Page 3 Page 3 Page 3 Page 3
Page 4
Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 5-9
Proximity Switches & Observation window. . . .
Page 9
Gate and Seat Replacement . . . . . . . . . . . . . . . . . . .
Page 10
Stem Seal Replacement . . . . . . . . . . . . . . . . . . . . . . .
Page 10
Dismantling for Complete Rebuild . . . . . . . . . . . . . .
Page 11
Inspection
................................
Page 12
Maintenance
................................
Page 12
Spares, Special Tools and Lubricants . . . . . . . .
Page 12
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General Information Illustrations Illustrations (figures) provide a graphical representation of equipment components or screen snapshots for use in identifying parts or establishing nomenclature, and may or may not be drawn to scale. For component information specific to your assembly, see the technical drawings included with your NOV Mission Products documentation.
Personal Training –
To avoid injury to personnel or equipment damage, carefully observe requirements outlined
in this section.
All personnel performing installation, operations, repair or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation and maintenance to ensure their safety. Personnel should wear protective gear during installation, maintenance and certain operations. Contact NOV Mission Products if you require for more information about equipment operation and maintenance training.
Recommended Tools Service operations may require the use of tools designed specifically for the purpose described. NOV Mission Products recommends that only these tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when following service procedures or using tools not specifically recommended by NOV Mission Products.
General System Safety Practices –
Read and follow the guidelines below before installing equipment
or performing maintenance to avoid endangering exposed persons or damaging equipment.
Isolate energy sources before beginning work. Avoid performing maintenance or repairs while equipment is in operation. Wear proper protective equipment during equipment installation, maintenance or repair.
Replacing Components Verify that all components (such as cables, hoses, etc.) are tagged and labelled during
assembly and disassembly of equipment to ensure correct instalment. Replace failed or damaged components with NOV Mission certified parts. Failure to do so could result in equipment damage or injury to personnel.
Routine Maintenance –
Failure to conduct routine maintenance could result in equipment damage or injury to
personnel.
Equipment must be maintained on a routine basis. See the service manual for maintenance recommendations.
Proper Use of Equipment NOV Mission Products equipment is designed for specific functions and applications, and should be used only for its intended purpose. www.nov.com/mission
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Parts Location 20 17 16 19 15
14 11
18
9A
12
7 9 2 11
10
5
13
4
6
3 8
1
1. 2. 3. 4. 5. 6. 7. 8. 9. 9A 10. 11.
Body Bonnet Seat Gate Stem Seat Seal Nut Stud Stem Seal Back Up Ring Grease Nipple Stem Guide Ring
12. Packing Gland 13. Bonnet Seal 14. ‘O’ Ring 15. ‘O’ Ring 16. Support Plate 17. Shim Adaptor 18. ‘O’ Ring 19. Hex Bolt 20. C Clamp 21. Lower Retaining Ring 22. Housing 23. Lower Retaining Ring
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24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
Return Spring Upper Retaining Plate Stem Locator Hydraulic Plug ‘O’ Ring Translating Cylinder Hydraulic Seal Guide Ring Inner Hydraulic Cylinder ‘O’ Ring Set Screw Upper Retaining Ring
36. Bleed Plug (safety head) 37. Stem Protector 38. Excluder Seal 39. Guide Ring 40. Stem Seals 41. Indicator Stem 42. Socket Set Screw
5
Valve Assembly
13 5 4
3 6 6 3
1 8
Note – The valve assembly may be an integral part of a composite valve assembly. 1. Before commencing the assembly ensure every part is thoroughly clean. Screw threads should be coated with anti-seize compound, hydraulic oil may be used to assist the assembly of seals and hydraulic components. 2. Assemble the Seat Seals (6) to the Seats (3). Place the Seats into the seat pockets in the valve Body (1) 3. Slide the Tee section of the Stem (5) into the Tee slot of the Gate (4) and install the Gate down into the Body between the Seats. Body filler Grease may be applied to both Gate faces and the Tee slot to provide initial lubrication. 4. Screw Studs (8) into the Body if they have been removed. 5. Apply light grease to the Bonnet Seal (13) and place onto the Body. 6. Place ‘O’ring (14) onto the Bonnet (2) to cover the small leak detection hole. Place ‘O’ring (15) into the groove at the back of the threaded section. If it has been removed replace Grease fitting (10) www.nov.com/mission
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17 18 16 15
9A 9
14
7 12 11 2 10
11
7. Install a Stem Guide Ring (11) into the Bonnet (2), then lower the Bonnet carefully over the Stem and down on to the Body. Secure with Nuts (7) 8. Install a Stem Guide Ring (11) and ‘O’ring (18) into the Packing Gland (12) 9. Place a Stem Seal (9) followed by Back-up ring (9A) down over the Stem and into the Bonnet, the open end of the seal containing the springs facing down towards the direction of pressure. Push the Seal and Back-up ring down into the Bonnet by installing the Packing Gland (12). 10. Screw the Support Plate (16) down onto the Bonnet, tighten down on to the shoulder of the bonnet by placing a bolt into one of the radial holes and striking with a soft hammer. Lock into position with Shim Adapter (17).
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Basic Hydraulic FS Actuator
35
36 33
34 32
31
22 30
25 21
29
20
24 28 27 23
26 20 19
32 25
11. Place ‘O’ring (33) and Seal (30) onto the Inner 29 Hydraulic Cylinder (32). See Fig 1 for correct 31 Fig 1 orientation of the Seal. 30 Cylinder Assembly 28 12. Place ‘O’ring (28) into the Hydraulic Plug (27), if it 26 27 has been removed insert the Stem Locator (26). Screw the Hydraulic Plug into the Hydraulic Cylinder (29). 13. Install the Inner Hydraulic Cylinder (32) into the Translating Cylinder (29) until the Seal just enters into the Bore. Place the Guide Ring (31) onto the Inner Hydraulic Cylinder and slide fully home. www.nov.com/mission
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14. Place the Cylinder assembly into the Housing (22), install Retaining Ring (35). Invert the housing so that the cylinder assembly comes into contact with the retaining ring (35). 15. Place the Upper Retaining Plate (25), Spring (24) and Lower Retaining Plate (23) into the Housing. See Fig 1 for correct orientation of the Upper Retaining Plate. Compress the Spring and retain in position with Locking Ring (21) Secure the cylinder assembly in position with 4 off Set Screws (34). (Continue after step 16 page 10)
Hydraulic FS Actuator c/w Rising Stem Position Indicator
37 38 35
39 40 40
34
33 36 25 22 32
31
24
21 30 23 20 29 28 20
41
19
27
26
42
11. Place ‘O’ring (33) and Seal (30) onto the Inner Hydraulic Cylinder (32). Install Stem Seals (40), Guide Ring (39) and Excluder Seal (38) into the inner Hydraulic Cylinder (32). Note items (40) and (38) are 2 piece seals see Fig 2 for correct orientation. 12. Place ‘O’ring (28) into the hydraulic Plug (27). Screw the Indicator Stem (41) into the Hydraulic Plug (27) until it bottoms out, rotate the Indicator Stem back out from the Hydraulic Plug until the slot at the base of the stem aligns with the tapped hole through the boss of the Hydraulic Plug. Secure the Stem to the Plug by screwing the Socket Set www.nov.com/mission
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Screw (42) into position. If it has been removed insert the Stem Locator (26), screw the hydraulic plug (27) into the Translating Cylinder (29). 13. Install the Inner Hydraulic Cylinder (32) into the Translating Cylinder (29) until the Seal just enters into the Bore. Place the Guide Ring (31) onto the Inner Hydraulic Cylinder and slide fully home ensuring the Indicator Stem (41) enters smoothly through the upper bore of the Cylinder through the seals. Clean hydraulic oil can be applied to the surfaces to aid assembly. Screw stem protector (37) into position.
Hydraulic FS Actuator c/w Rising Stem Position Indicator 14. Place the Cylinder assembly into the Housing (22), install Retaining Ring (35). Invert the housing so that the cylinder assembly comes into contact with the retaining ring (35). 15. Place the Upper Retaining Plate (25), Spring (24) and Lower Retaining Plate (23) into the Housing. See Fig 2 for correct orientation of the Upper Retaining Plate. Compress the Spring and retain in position with Locking Ring (21) Secure the cylinder assembly in position with 4 off Set Screws (34). (Continue after step 16 page 10)
38 39
37
40 40 32
25 41 29
31
Fig 2 Cylinder Assembly
30 28
42
27 26
Proximity Switches / Observation Window
Plate or Observation Window Proximity Switches
Fig 3
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Actuators will typically be supplied with either a cover plate or an observation window on the outside of the cylinder housing. This plate or window can be removed to facilitate the fitting of proximity switches. (see fig 3 opposite) Details of electrical connections to these proximity switches will be supplied separately from this publication and will depend on type supplied and any other additional requirements such as terminal boxes that may have been provided at the time of purchase.
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Typical set up procedure for these switches would be: • With no hydraulic pressure on the actuator screw the upper switch in until it touches the upper retaining plate, retract one full turn then lock into place with the lock nut. Apply pressure to the actuator so that the cylinder is fully extended, screw the lower switch in until it touches the upper retaining plate, retract one full turn then lock into place with the lock nut 16. Fill the Hydraulic Cylinder with oil evacuating all air. Replace Safety Head (36) if fitted and attach the Actuator to the Hydraulic System. Pressurise to extend the piston until the Tee slot of the Hydraulic Plug (27) is just below the Lower Retaining Plate (23). Do Not Over Extend The Piston. 17. Slide the Tee slot locate on the Hydraulic Plug (27) over the end of the Valve Stem (5). The Stem Locator (26) should hold the assembly in position. 18. Release pressure slowly to locate the Housing (22) on to the Support Plate (16). Secure with ‘C’ clamp (20) and 6 off Hex Bolts (19).
Gate and Seat Replacement The valve Gate and Seats may be replaced without dismantling the upper hydraulic components as follows: 1. If the valve is still in the flowline ensure all pressure has been released and isolate the valve to be maintained by locking / chaining valves upstream and downstream of the subject valve label them “CAUTION - DO NOT OPERATE” Check that all line pressure has been dissipated by using a stinger (part no. 17538) on the grease fitting (10). 2. Detach any hoses or piping connected to the hydraulic cylinder. 3. Unscrew the Nuts (7) from the Studs (8). Lift the bonnet cylinder assembly clear of the Body (1). Caution - ensure the Gate does not damage the top seal face as it is withdrawn from the Body. 4. Pressurise the cylinder to approximately 150 psi to extend the Gate (4) and Stem (5) from the Bonnet. Slide the Gate off the Stem. 5. Remove the Seats (3) from the Body (1) and remove the Seals (6) from the Seats. 6. Remove the Bonnet Seal (13). Rebuilding of the Valve from this stage is as follows: 1. Ensure all parts to be used for the assembly are thoroughly clean and that all old body filler grease has been removed from the valve. 2. Insert Seals (6) into Seats (3) and place into Seat Pockets in the Body (1) 3. Place a Bonnet Seal (13) onto the Body. 4. The Cylinder will need to be pressurised to approximately 150 psi to extend the Stem (5) out of the Body. Slide the Tee slot of the Gate (4) on to the Stem (5). Depressurise the Cylinder so that the Gate and Stem retract into the Bonnet. 7. Carefully lower the Bonnet Cylinder assembly down onto the Body ensuring the Gate enters smoothly between the Seats. Replace Nuts (7) to Studs (8) 8. Reconnect hydraulic hoses or piping. Grease the valve through Grease fitting (10).
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Stem Seal Replacement With The Valve Under Pressure 1. Close the Valve by venting all hydraulic pressure from the Cylinder. Ensure the Valve has Back Seated by applying a stinger part No. 17538 to the grease fitting (10), ALL LINE PRESSURE SHOULD HAVE DISSIPATED. 2. Remove Hex. Bolts (19) and ‘C’ Clamp (20). 3. Pressurise the Cylinder to approximately 150 psi to raise the cylinder from the Support Plate (16). Push the Cylinder Assembly in the direction of the Hydraulic Plug Tee Slot and lift from the Valve. Unscrew Shim Adapter (17) and Support Plate (16) 4. Check the integrity of the Back Seat by reapplying the Stinger to the Grease Fitting (10), there should no pressure at this port. Unscrew the Packing Gland (12) and retrieve the Seal (9) and Back-up Ring (9A). This operation may be assisted by pumping grease into the seal pocket through the Grease fitting (10). Rebuild of the valve from this stage is as follows: 1. Remove all traces of grease from the seal pocket and inspect the surfaces for damage. 2. Place the Seal (9) followed by Back-up Ring (9A) down over the Stem with the open end containing the spring facing down. Install the Packing Gland (12) down over the Stem and screw fully home into the Bonnet. Note - it will be necessary to apply the stinger to the Grease fitting (28) during this stage to prevent a hydraulic lock. 3. Replace the Support Plate (16) and lock in place with Shim Adapter (17). 4. Pressurise to extend the piston until the Tee slot of the Hydraulic Plug (27) is just below the Lower Retaining Plate (23) Slide the Tee slot of the Hydraulic Plug (27) on to the Stem (5), the Stem Locator (26) should assist in holding the assembly Central. Depressurise the Cylinder slowly so that the assembly retracts onto the Bonnet. 5. Replace C Clamp (20) and 6 off Hex. Bolts (19).
Dismantling For Complete Re Build 1. If the valve is still in the flowline ensure all pressure has been released and isolate the valve to be maintained by locking / chaining valves upstream and downstream of the subject valve label them “CAUTION - DO NOT OPERATE” Check that all line pressure has been dissipated by using a stinger (part no. 17538) on the grease fitting (10). 2. Remove Hex. Bolts (19) and ‘C’ Clamp (20). 3. Pressurise the Cylinder to approximately 150 psi to raise the cylinder from the Support Plate (16). Observe the direction of the Tee slot connection between the Stem (5) and the Hydraulic Plug (27). Push the Cylinder Assembly in this direction and lift from the Valve. Unscrew Shim Adapter (17) and Support Plate (16). 4. Unscrew Packing Gland (12), remove ‘O’rings (18), (15) ,14) and Stem Guide Ring (11). 5. 5. Unscrew Nuts (7) from the Studs (8) and lift the Bonnet (2) from the Body (1). Retrieve Back-up Ring (9A), Seal (9), lower Stem Guide Ring (11) and Grease Fitting (10). 6. Remove the Gate (4) and Stem (5) from the Body (1) then remove the Gate from the Stem. 7. Extract the Seats (3) from the Body and remove Seals (6).
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Cylinder Disassembly: 8. Remove any hydraulic hoses to the Cylinder and Safety Head (36) if fitted. Drain hydraulic oil from the Cylinder. 9. Compress the Spring (24) using tool part No. A30255. Remove the Lower Retaining Ring (21) and the compression tool. 10. Remove Lower Retaining Plate (23), Spring (24) and Upper Retaining Plate (25). 11. Remove Upper Retaining Ring (35) and slide the Cylinder Assembly out of the Housing (22). Remove ‘O’ring (33) 12. Slide the Translating Cylinder (29) from the Inner Cylinder (32). Remove Seal (30) and Cylinder Guide Ring (31) 13. Unscrew Hydraulic Plug (27) from the Cylinder (29) and remove ‘O’ring (28). 14. On actuators supplied with rising stem position indicators (page 5 and 6) remove additional components in the following sequence :- Socket Set Screw (42), Stem (41), Stem protector (37), Seals (40), Guide Ring (39) and Excluder Seal (38). Note - items (40) and (38) are two part seals.
Inspection . Visually Inspect: • All sealing surfaces for damage • Screw threads for wear or galling
IF IN DOUBT REPLACE
• Gate and Seat surfaces for wear or damage Complete seal replacement is recommended
Maintenance Maintenance intervals will depend very much upon the service conditions and frequency of operation. However, the following should be observed as a minimum: 1. As a minimum, every 2 months or 20-50 cycles, re-inject barrier grease into the valve cavity via the Grease Nipple. 2. If the hydraulic system is continuously flushed/cleaned during operation then fluid replacement is not normally necessary, otherwise replace fluid every two months.
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Spares, Special Tools and Lubricants NOV Mission Products UK offers a world-wide back-up service for all its products. In the first instance contact your local NOV Mission Products Stockist or Agent. If you are in any doubt whatsoever, do not hesitate to contact our head office in Gateshead, UK. We are only a fax, email or a phone call away and we would be pleased to give any assistance we can. Contact details for NOV Mission Products UK can be found below. When ordering spare parts it is important that the component is correctly described. The documentation supplied with each valve includes a Data Sheet that will give the description and part numbers of the components of the valve you have in your possession. If you quote this description and part number you can be sure of being supplied with the correct item. If no documentation is at hand, quote valve model number and serial number from the nameplate or flange, followed by item number and description given on the parts location illustrated.
Body Cavity - Barrier Grease -
Temperature -20oF to +350oF (API Class P-X) 17537 (40lb Tin) Temperature -75oF to +250oF (API Class K and L to U) 24104 (40lb Tin)
Pressure Retaining Threads -
Liquid ‘O’ring - Ref. 20627 (1lb Tin) 20628 (10lb Tin)
Thread Lubrication -
45368
Hydraulic Oil -
Hydraulic mineral oil (Tellus T32 or equivalent) suitable for the operating conditions to be encountered.
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